Technology
Barrage of praise!
Published
5 years agoon
By
admin
Built at a cost of Rs 27.32 billion in 24 months, the Annaram Barrage of the KLIS project made use of secant piling in the cut-off foundation for the first time in the world in barrage construction.
It’s a part two of our series on the Kaleshwaram Lift Irrigation Scheme (KLIS), among the world’s largest irrigation projects. In this edition, we showcase the construction of Annaram Barrage, constructed by Afcons Infrastructure. This barrage, combined with the Medigadda and Sundilla barrages constitute the ambitious KLIS. Almost 2,000 million cu ft (tmc) of water per day will be moved upriver through gravity canals from Medigadda barrage to Annaram barrage, from where it will be pumped further back to Sundilla barrage. From there, the water will be diverted to Yellampalli reservoir and then distributed to nearby districts.
"We entered the dam and barrage segment in 2017 with the Annaram barrage project, which is part of this mammoth water preservation project," says K Subramanian, Executive Vice-Chairman, Afcons Infrastructure. "Despite entering a new segment, Afcons has achieved several national benchmarks in concrete pumping in the irrigation and hydropower sector. Kudos to the entire team for bringing in the laurels!"
"Being part of such an amazing and extraordinary engineering marvel is an honour. Annaram was the first of the three barrages to be completed substantially before time," adds Sekhar Das, Project Manager, Annaram Barrage Project, Afcons Infrastructure. "The early delivery makes Afcons’s maiden venture into the irrigation segment extra special. With a capacity of 10.87 tmc, Annaram is the second-largest barrage in the entire KLIS." Annaram Barrage was built at a cost of Rs 27.32 billion in a timeframe of 24 months.
Civil scope
Here’s a look at the civil structure specifications of this barrage:
Dimensions: Length – 1,270 m; Width – 100 m
No. of piers: 72. Dimensions (each): Length – 100 m; Thickness – 4 m; Height – 24 m
Launching apron: Upstream – 71 m; Downstream – 116.4 m.
The scope of work included:
Construction of the barrage for a length of 1,270 m with 66 vents of 15 m along with energy dissipation arrangement and abutments, wing and return/flank wall, etc
All mechanical works related to the barrage radial gates of size 15 m +13 m (12 in total) for under sluice bay and for other bays of size 15 m + 12 m (54 in total)
Road bridge with clear carriageway of 7.50 m
Earth bunds in right and left side to connect the road
Construction of guide bunds of both the sides of barrage
Laying of CC block size of 1,500 x 1,500 x 900 mm with loose stone protection in both streams and along with water side of guide bunds.
Laying of stone pitching in upstream and downstream of barrage and launching apron with stones in water side of guide bunds
Design flood discharge – 65,000 cusecs.
Quantifying right
Materials such as cement,reinforcement steel, aggregate, structural steel and rock boulders have been used in the construction of this barrage.
Highlights include:
1,200,000 cu m of concreting done for the entire project
55,000 mt of reinforcement steel used
80 lakh cu m of earthwork moved
1,500 tonne of cement consumed on average per day
200 mt of steel used on average per day
About 6,000 cu m concrete poured on average per day
More than 1 lakh cu m concreting per month achieved for four consecutive months.
Fully equipped
As this project had a short deadline, Afcons sourced additional equipment and resources from time to time to complete work efficiently. "The initial change of scope and halt of work for over 45 days during floods meant extra resources were the key to getting this barrage completed in just 24 months," shares Das. He goes on to elaborate upon the equipment used in the construction of the barrage: 11 piling rigs; 120 dumper trucks; 60 excavators; 11 boring rigs; seven boom placers; four concrete pumps; 36 transit mixers; seven batching plants; two crusher plants with a capacity of 250 tph; vibro hammer for sheet piling; crawler cranes; pick-n-carry cranes; trailers; and dewatering pumps.
Further, Doka formwork was used in the construction of the piers, where 3-m height lift could be achieved in one go. Rolla deck sheets were used in place of precast panels for the road bridge, saving nearly two months" time for casting of panels, erection and material handling. "Moreover, the project progress was monitored in Primavera and financial status tracked on SAP to keep the project on track in all aspects," says Das. "All periodic reports were made as per formats prepared after discussion with all department heads. We also tracked daily progress through CCTV cameras, site visits and focused WhatsApp groups."
Innovation in execution
Conquering challenges
Effective planning and strong teamwork were definitely factors that helped the team overcome various difficulties during execution. As Das shares, "The approach to the site location was poor initially; so mobilisation was a major challenge. But with the help of the authorities and correct permissions, mobilisation could begin smoothly. For timely land acquisition, we conducted numerous meetings with the villagers and explained the benefits of the barrage and KLIS. It helped a great deal to expedite land acquisition. Local support was critical in timely completion."
Das shares other major challenges involved in constructing this barrage and how the team effectively overcame them:
Approach roads: There were no appropriate roadways to transport materials to the site. Many roads and approach paths were created before the project began to cater to this remote location.
Dewatering: As the barrage location was right on the riverbed, the entire area was filled with water. Dewatering arrangements were made using a multistage well-point dewatering system, which helped speed up the process.
River diversion: To start construction activities, the whole length of the river was diverted using separate bunds. The bunds were constructed upstream for temporary diversion and connected to the total length of the barrage.
Procurement: Procurement was a major challenge. Owing to the remoteness of the site location, even for small materials, one would have to travel at least 300 km. Hence, planning and procurement played a critical role in avoiding delays.
Change of barrage location: At the outset of the project, there was a big change in plan. The location of the barrage was shifted, increasing its length by 151 m. A new geological survey was done at the new site once again. This resulted in extra work of more than 4,000 piles and 20 per cent increase over the estimated quantities of concreting and steel. And while there was increase in work quantity, the survey also threw up another major challenge. The ground at the new site had differentiated strata with layers of sand, soil, gravel and, at times, hard rock. Thus secant piling was used in the cut-off foundation.
Safety first
Afcons established and maintained strong health, safety and environment protocols for this project. Consistent mobilisation of resources (machinery, formwork, manpower) in time was ensured for timely completion. The result: a clean safety record of 8.2 million safe man-hours!
SERAPHINA D’SOUZA
Project details
Location: Annaram, Telangana
Features/specifications: Construction of barrage for a length of 1,270 m with 66 vents of 15 m along with energy dissipation arrangement and abutments, wing and return/flank wall
Total cost: Rs 27.32 billion
Contractor: AFCONS-VIJETA-PES (JV). Afcons Infrastructure. Website:
www.afcons.com; Vijeta. Website: www.vijeta.in; PES. Website: www.peseng.net
Architect/planner: Central Design Organisation (CDO), Government of Telangana.
Cement/concrete: In-house production. Material was procured from many vendors.
You may like
Concrete
We consistently push the boundaries of technology
Published
1 month agoon
April 18, 2025By
admin
Swapnil Jadhav, Director, SIDSA Environmental, discusses transforming waste into valuable resources through cutting-edge technology and innovative process solutions.
SIDSA Environmental brings decades of experience and expertise to the important niche of waste treatment and process technologies. As a global leader that is at the forefront of sustainable waste management, the company excels in recycling, waste-to-energy solutions and alternative fuel production. In this conversation, Swapnil Jadhav, Director, SIDSA Environmental, shares insights into their advanced shredding technology, its role in RDF production for the cement industry and emerging trends in waste-to-energy solutions.
Can you give us an overview of SIDSA Environmental’s role in waste treatment and process technologies?
SIDSA is a leading innovator in the field of waste treatment and process technologies, dedicated to delivering sustainable solutions that address the growing challenges of waste management.
SIDSA is a more than 52-year-old organisation with worldwide presence and has successfully realised over 1100 projects.
Our expertise is in the engineering and development of cutting-edge systems that enable the conversion of waste materials into valuable resources. This includes recycling technologies, waste-to-energy (W2E) systems, and advanced methods for producing alternative fuels such as refuse derived fuel (RDF). The organisation prioritises environmental stewardship by integrating energy-efficient processes and technologies, supporting industrial sectors—including the cement industry—in reducing their carbon footprint. Through our comprehensive approach, we aim to promote a circular economy where waste is no longer a burden but a resource to be harnessed.
How does SIDSA Environmental’s shredding technology contribute to the cement industry, especially in the production of RDF?
SIDSA’s shredding technology is pivotal in transforming diverse waste streams into high-quality RDF. Cement kilns require fuel with specific calorific values and uniform composition to ensure efficient combustion and operational stability, and this is where our shredding systems excel. In India, we are segment leaders with more than 30 projects including over 50 equipment of varied capacity successfully realised. Some of the solutions were supplied as complete turnkey plants for high capacity AFR processing. Our esteemed client list comprises reputed cement manufacturers and chemical industries. Our technology processes various types of waste—such as plastics, textiles and industrial residues—breaking them down into consistent particles suitable for energy recovery.
Key features include:
- High efficiency: Ensures optimal throughput for large volumes of waste.
- Adaptability: Handles mixed and heterogeneous waste streams, including contaminated or complex materials.
- Reliability: Reduces the likelihood of operational disruptions in RDF production. By standardising RDF properties, our shredding technology enables cement plants to achieve greater energy efficiency while adhering to environmental regulations.
What are the key benefits of using alternative fuels like RDF in cement kilns?
The adoption of RDF and other alternative fuels offers significant advantages across environmental, economic and social dimensions:
- Environmental benefits: Cement kilns using RDF emit fewer greenhouse gases compared to those reliant on fossil fuels like coal or petroleum coke. RDF also helps mitigate the issue of overflowing landfills by diverting waste toward energy recovery.
- Economic savings: Alternative fuels are often more cost-effective than traditional energy sources, allowing cement plants to reduce operational expenses.
- Sustainability and resource efficiency: RDF facilitates the circular economy by repurposing waste materials into energy, conserving finite natural resources.
- Operational flexibility: Cement kilns designed to use RDF can seamlessly switch between different fuel types, enhancing adaptability to market conditions.
What innovations have been introduced in waste-to-energy (W2E) and recycling solutions?
SIDSA’s machinery is meticulously engineered to handle the complex requirements of processing hazardous and bulky waste.
This includes:
- Robust construction: Our equipment is designed to manage heavy loads and challenging waste streams, such as industrial debris, tires and large furniture.
- Advanced safety features: Intelligent sensors and automated controls ensure safe operation when dealing with potentially harmful materials, such as chemical waste.
- Compliance with standards: Machinery is built to adhere to international environmental and safety regulations, guaranteeing reliability under stringent conditions.
- Modular design: Allows for customisation and scalability to meet the unique needs of various waste management facilities.
How does your organisation customised solutions help cement plants improve sustainability and efficiency?
We consistently push the boundaries of technology to enhance waste management outcomes.
General innovations and new product development focus on:
- Energy-efficient shredders: These machines consume less power while maintaining high throughput, contributing to lower operational costs.
- AI-powered sorting systems: Utilise advanced algorithms to automate waste classification, increasing material recovery rates and minimising errors.
- Advanced gasification technologies: Convert waste into syngas (a clean energy source) while minimising emissions and residue.
- Closed-loop recycling solutions: Enable the extraction and repurposing of materials from waste streams, maximising resource use while reducing environmental impact.
What future trends do you foresee in waste management and alternative fuel usage in the cement sector?
Looking ahead, several trends are likely to shape the future of waste management and alternative fuels in the cement industry:
- AI integration: AI-driven technologies will enhance waste sorting and optimise RDF production, enabling greater efficiency.
- Bio-based fuels: Increased use of biofuels derived from organic waste as a renewable and low-carbon energy source.
- Collaborative approaches: Strengthened partnerships between governments, private industries and technology providers will facilitate large-scale implementation of sustainable practices.
- Circular economy expansion: The cement sector will increasingly adopt closed-loop systems, reducing waste and maximising resource reuse.
- Regulatory evolution: More stringent environmental laws and incentives for using alternative fuels will accelerate the transition toward sustainable energy solutions.
(Communication by the management of the company)
Concrete
FORNNAX Technology lays foundation for a 23-acre facility in Gujarat
Published
3 months agoon
March 17, 2025By
admin
FORNNAX Technology, a leading manufacturer of recycling equipment in India, has marked a major milestone with the Groundbreaking (Bhoomi Pujan) ceremony for its expansive 23-acre manufacturing facility in Gujarat. Specialising in high-capacity shredders and granulators, FORNNAX is strategically positioning itself as a global leader in the recycling industry. The new plant aims to produce 250 machinery units annually by 2030, making it one of the largest manufacturing facilities in the world.
The foundation stone for this ambitious project was laid by Jignesh Kundaria, CEO and Director, alongside Kaushik Kundaria, Director. The ceremony was attended by key leadership members and company staff, signifying a new chapter for FORNNAX as it meets the growing demand for reliable recycling solutions. Speaking on the occasion, Jignesh Kundaria stated, “This marks a historic moment for the recycling sector. Our high-quality equipment will address various waste categories, including tyre, municipal solid waste (msw), cables, e-waste, aluminium, and ferrous metals. this facility will strengthen our global presence while contributing to India’s Net Zero emissions goal by 2070.”
FORNNAX is actively expanding its footprint in critical markets such as Australia, Europe and the GCC, forging stronger sales and service partnerships. The facility will house an advanced Production Department to ensure seamless manufacturing.
Concrete
Decarbonisation is a focus for our R&D effort
Published
4 months agoon
February 12, 2025By
admin
Dyanesh Wanjale, Managing Director, Gebr. Pfeiffer discusses the need to innovate grinding technologies to make the manufacturing process more efficient and less fuel consuming.
Gebr. Pfeiffer stands at the forefront of grinding technology, delivering energy-efficient and customised solutions for cement manufacturers worldwide. From pioneering vertical roller mills to integrating AI-driven optimisation, the company is committed to enhancing efficiency and sustainability. In this interview, we explore how their cutting-edge technology is shaping the future of cement production.
Can you tell us about the grinding technology your company offers and its role in the cement industry?
We are pioneers in grinding technology, with our company being based in Germany and having a rich history of over 160 years, a milestone we will celebrate in 2024. We are widely recognised as one of the most efficient grinding technology suppliers globally. Our MBR mills are designed with energy efficiency at their core, and for the past five years, we have been focused on continuous improvements in power consumption and reducing the CO2 footprint. Innovation is an ongoing process for us, as we strive to enhance efficiency while supporting the cement industry’s sustainability goals. Our technology plays a critical role in helping manufacturers reduce their environmental impact while improving productivity.
The use of alternative fuels and raw materials (AFR) is an ever-evolving area in cement production. How does your technology adapt to these changes?
Our vertical roller mills are specifically designed to adapt to the use of alternative fuels and raw materials. These mills are energy-efficient, which is a key advantage when working with AFR since alternative fuels often generate less energy. By consuming less power, our technology helps bridge this gap effectively. Our solutions ensure that the use of AFR does not compromise the operational efficiency or productivity of cement plants. This adaptability positions our technology as a vital asset in the industry’s journey toward sustainability.
What are some of the challenges your company faces, both in the Indian and global cement industries?
One of the major challenges we face is the demand for expedited deliveries. While customers often take time to decide on placing orders, once the decision is made, they expect quick deliveries. However, our industry deals with heavy and highly customised machinery that cannot be produced off the shelf. Each piece of equipment is made-to-order based on the client’s unique requirements, which inherently requires time for manufacturing.
Another significant challenge comes from competition with Chinese suppliers. While the Indian cement industry traditionally favoured our technology over Chinese alternatives, a few customers have started exploring Chinese vertical roller mills. This is concerning because our German technology offers unmatched quality and longevity. For example, our mills are designed to last over 30 years, providing a long-term solution for customers. In contrast, Chinese equipment often does not offer the same durability or reliability. Despite the cost pressures, we firmly believe that our technology provides superior value in the long run.
You mentioned that your machinery is made-to-order. Can you elaborate on how you customise equipment to meet the specific requirements of different cement plants?
Absolutely. Every piece of machinery we produce is tailored to the specific needs of the customer. While we have standard mill sizes to cater to different capacity requirements, the components and configurations are customised based on the client’s operational parameters and budget. This process ensures that our solutions deliver optimal performance and cost efficiency. Since these are heavy and expensive items, maintaining an inventory of pre-made equipment is neither practical nor economical. By adopting a made-to-order approach, we ensure that our customers receive machinery that precisely meets their needs.
The cement industry is focusing not only on increasing production but also on decarbonising operations. How does your company contribute to this dual objective, and how do you see this evolving in the future?
Decarbonisation is a key focus for our research and development efforts. We are continuously working on innovative solutions to reduce CO2 emissions and improve overall sustainability. For example, we have significantly reduced water consumption in our processes, which was previously used extensively for stabilisation. Additionally, we are leveraging artificial intelligence to optimise mill operations. AI enables us to monitor the process in real-time, analyse feedback, and make adjustments to achieve optimal results within the given parameters.
Our commitment to innovation ensures that we are not only helping the industry decarbonise but also making operations more efficient. As the cement industry moves toward stricter sustainability goals, we are confident that our technology will play a pivotal role in achieving them.
Can you provide more details about the use of digitalisation and artificial intelligence in your processes? How does this improve your operations and benefit your customers?
Digitalisation and AI are integral to our operations, enabling us to offer advanced monitoring and optimisation solutions. We have developed three distinct models that allow customers to monitor mill performance through their computer systems. Additionally, our technology enables real-time feedback from our German headquarters to the customer. This feedback highlights any inefficiencies, such as when a parameter is outside the optimal range,
and provides actionable recommendations to address them.
By continuously monitoring every parameter in real time, our AI-driven systems ensure that mills operate at peak efficiency. This not only enhances production but also minimises downtime. I am proud to say that our mills have the lowest shutdown rates compared to other manufacturers. This reliability, combined with the insights provided by our digital solutions, ensures that customers achieve consistent and efficient operations. It’s a game-changer for reducing costs and enhancing overall productivity.

Cement demand to rise 7% in FY26

India Sets Up First Carbon Capture Testbeds for Cement Industry

JK Lakshmi Adopts EVs to Cut Emissions in Logistics

Holcim UK drives sustainable construction

Cemex invests in AI optimisation through OPTIMITIVE

Cement demand to rise 7% in FY26

India Sets Up First Carbon Capture Testbeds for Cement Industry

JK Lakshmi Adopts EVs to Cut Emissions in Logistics

Holcim UK drives sustainable construction
