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Barrage of Plenty!

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The 1,447-m Sundilla Barrage of the Kaleshwaram Lift Irrigation Scheme, built at a cost of Rs 17.50 billion, will help store 228 million cu m of water.

The massive Kaleshwaram Lift Irrigation Scheme (KLIS), among the world’s largest irrigation projects, comprises three barrages"Medigadda, Annaram and Sundilla"on the Godavari Riverin the Karimnagar district of Telangana.In the third and final instalment of our series on the scheme, we showcase the construction of Sundilla Barrage(recently named Parvathi Barrage), which has a storage capacity of 228 million cu m’ts construction was awarded toNavayuga Engineering Company.

The components
Broadly, the components of the barrage include cut-off walls for prevention of percolation of water under the foundation, bottom open foundation to support the piers, piers for fixing the gates, main radial gates for storing and letting out water, stop-log gates for the repair of main gates, bridge over the piers for inspection and maintenance, guide bunds to guide theflow into the barrage and side retaining structure, among others. The total length of SundillaBarrage is 1,447m. "This length is divided into seven blocks separated by expansion joints, which are spanned by PVC water stoppers," says Dr Ir PV Chandramohan, Chief Technical Officer, Navayuga Engineering Company. "One of these blocks has 10 vents of 15×11.50 m each while the other six blocks have varying numbers of vents of 15×10.50 m each."

A bridge spanning the piers has been provided for access and inspection. This is designed for two-lane traffic. "The bridge was constructed with precast girders," highlights Dr Chandramohan."The deck was partially precast and partially in-situ. six blocks have varying numbers of ventsStorage of water at the high flood level will result in flooding of the banks on the upstream side. So, flood banks have been provided for a length of 8.2 km on the upstream side. Besides, to contain the flow at high velocities, guide bunds have been provided on both banks, downstream."

Unique features
One unique feature of Sundilla Barrage is its secant pile cut-off walls. As Dr Chandramohan explains, secant walls are formed by overlapping bored concrete piles.These walls are provided under the foundation to increase the percolation path of water under the structure. As water is retained on the upstream at a high level and there is hardly any water on the downstream, there is differential hydrostatic head acting. This is a driving force for percolation of water. The secant pile cut-off walls that go into the ground for considerable depth will offer resistance to the percolation of water that undermines the soil from underneath. This is critical for the safety of the barrage.

The crest level of the barrage is +119.5; high flood level is +132.13. "This means there will be 13.63m of water above the crest at highest flood level," adds Dr Chandramohan. "The usual pond level is +130. The barrage facilitates a discharge of 57,000 cum per second. The scour depth was computed to be 19.43m. Level of scoured bed at the upstream side is +112.67. On the downstream side, this level is +107.813. At the level of +114.65, the base pressure exerted by the superstructure of the barrage is computed to be 300kPa."At Sundilla, for the secant wall, reinforced piles are of 30 MPastrength concrete, while plain concrete piles are of 20MPa strength.

Materials in demand
Notably, the total concrete consumption for this barrage was about 1,060,000 cu m with a steel component of 53,000tonne. Further, structural steel for the radial gates consumed a massive 16,000 tonne and for the stop-log gates, 1,386 tonne. The huge Sundilla Barrage structure is 1,447-mlong. The raft foundation is 3-mthick and 89-mwide. There are 80 piers extending to the full width of the raft, i.e. 89m. The piers are 4-mthick to resist the hydrostatic pressure passed on from the radial gates. Dr Chandramohan further elaborates:"The radial gates span the vents. Skin plates of the radial gates curve in a circular shape to resist water pressure effectively. These plates are in turn supported on radial steel frames. The radial frames converge at the centre of a fictitious circle.

The trunnion of the gate is located at this point. The entire force on the radial gate is concentrated on these trunnions. In general, this could be called the kingpin of the gate. Tremendous amount of force will be passed on to this point. Long large diameter steel rods are embedded in the pier concrete to anchor this force. A salient feature of this anchoring is that any kind of passive resistance will yield in the face of this massive force and will result in movements, though minute. This would result in the misfit of the gate with the concrete surfaces. So, an active anchorage has been provided. The technique is to apply a pre-stress on the anchorage at the time of erection. This will keep the gate surfaces pressed against pier concrete" The radial gates were fabricated and erected by Becum Engineering Company, Hyderabad.

Maintaining dry conditions
This barrageis a structure where water will always be retained on the upstream side. In this condition, any maintenance or repair of the main radial gates cannot be carried out. To facilitate this kind of necessary maintenance, dry conditions are required.To create these, a stop-log gate is provided on the upstream side of each radial gate, at a distance of 3.5m.

"The stop-log gate spans between the piers-15m-and extends to 10.8m from the sill,"adds Dr Chandramohan. "They are made of steel joists and provided with PVC water seals. They are made in pieces of 2-m height for ease of handling. These pieces are lifted and lowered by a gantry crane provided at the top. They are lowered into position through grooves in the pier. These gates will be acted upon by hydrostatic pressure from the upstream side. This force presses the rubber seals on to the grooves and ensures water tightness. There will be no water on the downstream side of the stop-log gates and the radial gates will be in dry condition for repairs.

According to safety regulations, stop-log gate sets will be provided for 10 per cent of the vents."At Sundilla, there are 74 vents; so, eight sets of stop-log gates have been fabricated. These were fabricated by Ardee Engineering Company.

Built at a cost of Rs 17.50 billion, the Sundilla Barrage projectimbues a promise of hope and a greener tomorrow for people in this water-scarce region.

– SERAPHINA D’SOUZA

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Economy & Market

RAHSTA Roundtable Sets Agenda for Smarter, Safer Highways

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Roundtable discussions focus on innovation for safer highways.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the RAHSTA Roundtable brought together stakeholders from across the highways and infrastructure ecosystem to shape the agenda for the 16th RAHSTA 2026, scheduled for 8–9 July 2026 at the Jio Convention Centre, Mumbai. The session focused on key industry themes including road construction, technology, safety and long-term sustainability.

Opening the discussion, Pratap Padode, Founder, FIRST Construction Council, said the roundtable marked the beginning of a broader consultative process leading up to the July event. The aim, he noted, is to bring together industry stakeholders to refine the agenda for discussions on the future of roads, bridges, tunnels and allied infrastructure.

Padode noted that while central road project awards have slowed in recent years, states are increasingly driving the next phase of infrastructure growth. Maharashtra, with its long-term road development plans and agencies such as MSRDC and MSIDC, is expected to play a significant role in this expansion.

RAHSTA Expo 2026 as a specialised platform dedicated to road infrastructure, covering highways, tunnels, bridges and flyovers along with construction technologies, safety systems and maintenance solutions. He also highlighted the growing importance of rural connectivity and said the organisers are engaging with government bodies to highlight rural road development initiatives.

Tanveer Padode, CIO, ASAPP Info Group, presented insights from IMPACCT, the group’s infrastructure intelligence platform. He pointed to a strong project pipeline despite slower highway awards earlier in the year, noting that states such as Maharashtra, Odisha and Arunachal Pradesh are emerging as key drivers of new projects. The data also revealed that only a small group of contractors participates in large-value infrastructure bids.

Lt Gen Rajeev Chaudhary, former Director General, Border Roads Organisation and Chairman of the RAHSTA Expo Committee, emphasised the need for stronger collaboration across the ecosystem, including policymakers, contractors, technology providers and financiers. He also called for addressing systemic issues within the sector and encouraged greater participation of women in infrastructure leadership.

The discussion also explored the evolving economics of road development. Phani Prasad Mandalaparthy, Associate Director, CRISIL Intelligence, noted that the slowdown in project awards reflects a shift towards higher-value logistics corridors rather than simple road widening projects. However, private participation through BOT and TOT models remains limited.

From the contractors’ perspective, Sudhir Hoshing, Whole-Time Director, Ceigall, said companies are becoming more selective in bidding, favouring projects with clearer payment mechanisms and efficient processes. While NHAI continues to offer greater operational clarity, states such as Uttar Pradesh and Bihar were cited as relatively supportive environments for project execution.

Durability and sustainability also emerged as key themes. Himanshu Agarwal, COO – Road & Infrastructure, Zydex Group India, highlighted the need to prioritise lifecycle performance and resilient pavements, while participants discussed the potential of alternative materials such as plastic waste, steel slag and industrial by-products in road construction.

Dr LR Manjunatha, Vice President, JSW Cement, emphasised that India has abundant fly ash, slag and other industrial materials that can improve durability and sustainability if integrated into specifications and policy frameworks.

Technology and equipment challenges were also discussed. Dr Lakshmana Rao Mantri, Dy General Manager, Afcons Infrastructure, highlighted the shortage of tunnel boring machines (TBMs), which is delaying several underground infrastructure projects. Participants agreed that developing domestic TBM manufacturing capabilities will be critical for future infrastructure expansion.

The future of concrete pavements was another area of discussion. Dr V Ramachandra, President, Indian Concrete Institute, stressed that the debate should focus on lifecycle performance rather than material choice alone, noting that evolving design standards are improving the feasibility of concrete roads.

Prof Dharamveer Singh of IIT Bombay added that while India has made significant progress in infrastructure development, stronger capacity building and better execution practices are essential to ensure consistent road quality.

The discussion also touched upon technology adoption in the sector. Rushabh Mamania, Partner & CBO, Roadvision, highlighted the growing role of AI in road infrastructure, noting that AI-driven monitoring systems are already being deployed across large stretches of national highways.

Overall, the roundtable underscored that the future of highway infrastructure will depend not only on the pace of construction but also on durability, safety, technology integration and sustainable materials. The discussions offered valuable insights that will help shape the agenda for RAHSTA 2026 and guide future collaboration within the industry.

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Concrete

Turning Downtime into Actionable Intelligence

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Stoppage Insights instantly identifies root causes and maps their full operational impact.

In cement, mining and minerals processing operations, every unplanned stoppage equals lost production and reduced profitability. Yet identifying what caused a stoppage remains frustratingly complex. A single motor failure can trigger cascading interlocks and alarm floods, burying the root cause under layers of secondary events. Operators and maintenance teams waste valuable time tracing event chains when they should be solving problems. Until now.
Our latest innovation to our ECS Process Control Solution(1) eliminates this complexity. Stoppage Insights, available with the combined updates to our ECS/ControlCenter™ (ECS) software and ACESYS programming library, transforms stoppage events into clear, actionable intelligence. The system automatically identifies the root cause of every stoppage – whether triggered by alarms, interlocks, or operator actions – and maps all affected equipment. Operators can click any stopped motor’s faceplate to view what caused the shutdown instantly. The Stoppage UI provides a complete record of all stoppages with drill-down capabilities, replacing manual investigation with immediate answers.

Understanding root cause in Stoppage Insights
In Stoppage Insights, ‘root cause’ refers to the first alarm, interlock, or operator action detected by the control system. While this may not reveal the underlying mechanical, electrical or process failure that a maintenance team may later discover, it provides an actionable starting point for rapid troubleshooting and response. And this is where Stoppage Insights steps ahead of traditional first-out alarm systems (ISA 18.2). In this older type of system, the first alarm is identified in a group. This is useful, but limited, as it doesn’t show the complete cascade of events, distinguish between operator-initiated and alarm-triggered stoppages, or map downstream impacts. In contrast, Stoppage Insights provides complete transparency:

  • Comprehensive capture: Records both regular operator stops and alarm-triggered shutdowns.
  • Complete impact visibility: Maps all affected equipment automatically.
  • Contextual clarity: Eliminates manual tracing through alarm floods, saving critical response time.


David Campain, Global Product Manager for Process Control Systems, says, “Stoppage Insights takes fault analysis to the next level. Operators and maintenance engineers no longer need to trace complex event chains. They see the root cause clearly and can respond quickly.”

Driving results
1.Driving results for operations teams
Stoppage Insights maximises clarity to minimise downtime, enabling operators to:
• Rapidly identify root causes to shorten recovery time.
• View initiating events and all affected units in one intuitive interface.
• Access complete records of both planned and unplanned stoppages

  1. Driving results for maintenance and reliability teams
    Stoppage Insights helps prioritise work based on evidence, not guesswork:
    • Access structured stoppage data for reliability programmes.
    • Replace manual logging with automated, exportable records for CMMS, ERP or MES.(2)
    • Identify recurring issues and target preventive maintenance effectively.

  2. A future-proof and cybersecure foundation
    Our Stoppage Insights feature is built on the latest (version 9) update to our ACESYS advanced programming library. This industry-leading solution lies at the heart of the ECS process control system. Its structured approach enables fast engineering and consistent control logic across hardware platforms from Siemens, Schneider, Rockwell, and others.
    In addition to powering Stoppage Insights, ACESYS v9 positions the ECS system for open, interoperable architectures and future-proof automation. The same structured data used by Stoppage Insights supports AI-driven process control, providing the foundation for machine learning models and advanced analytics.
    The latest releases also respond to the growing risk of cyberattacks on industrial operational technology (OT) infrastructure, delivering robust cybersecurity. The latest ECS software update (version 9.2) is certified to IEC 62443-4-1 international cybersecurity standards, protecting your process operations and reducing system vulnerability.

What’s available now and what’s coming next?
The ECS/ControlCenter 9.2 and ACESYS 9 updates, featuring Stoppage Insights, are available now for:

  • Greenfield projects.
  • ECS system upgrades.
  • Brownfield replacement of competitor systems.
    Stoppage Insights will also soon integrate with our ECS/UptimeGo downtime analysis software. Stoppage records, including root cause identification and affected equipment, will flow seamlessly into UptimeGo for advanced analytics, trending and long-term reliability reporting. This integration creates a complete ecosystem for managing and improving plant uptime.

(1) The ECS Process Control Solution for cement, mining and minerals processing combines proven control strategies with modern automation architecture to optimise plant performance, reduce downtime and support operational excellence.
(2) CMMS refers to computerised maintenance management systems; ERP, to enterprise resource planning; and MES to manufacturing execution systems.

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Economy & Market

FORNNAX Appoints Dieter Jerschl as Sales Partner for Central Europe

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FORNNAX TECHNOLOGY has appointed industry veteran Dieter Jerschl as its new sales partner in Germany to strengthen its presence across Central Europe. The partnership aims to accelerate the adoption of FORNNAX’s high-capacity, sustainable recycling solutions while building long-term regional capabilities.

FORNNAX TECHNOLOGY, one of the leading advanced recycling equipment manufacturers, has announced the appointment of a new sales partner in Germany as part of its strategic expansion into Central Europe. The company has entered into a collaborative agreement with Mr. Dieter Jerschl, a seasoned industry professional with over 20 years of experience in the shredding and recycling sector, to represent and promote FORNNAX’s solutions across key European markets.

Mr. Jerschl brings extensive expertise from his work with renowned companies such as BHS, Eldan, Vecoplan, and others. Over the course of his career, he has successfully led the deployment of both single machines and complete turnkey installations for a wide range of applications, including tyre recycling, cable recycling, municipal solid waste, e-waste, and industrial waste processing.

Speaking about the partnership, Mr. Jerschl said,
“I’ve known FORNNAX for over a decade and have followed their growth closely. What attracted me to this collaboration is their state-of-the-art & high-capacity technology, it is powerful, sustainable, and economically viable. There is great potential to introduce FORNNAX’s innovative systems to more markets across Europe, and I am excited to be part of that journey.”

The partnership will primarily focus on Central Europe, including Germany, Austria, and neighbouring countries, with the flexibility to extend the geographical scope based on project requirements and mutual agreement. The collaboration is structured to evolve over time, with performance-driven expansion and ongoing strategic discussions with FORNNAX’s management. The immediate priority is to build a strong project pipeline and enhance FORNNAX’s brand presence across the region.

FORNNAX’s portfolio of high-performance shredding and pre-processing solutions is well aligned with Europe’s growing demand for sustainable and efficient waste treatment technologies. By partnering with Mr. Jerschl—who brings deep market insight and established industry relationships—FORNNAX aims to accelerate adoption of its solutions and participate in upcoming recycling projects across the region.

As part of the partnership, Mr. Jerschl will also deliver value-added services, including equipment installation, maintenance, and spare parts support through a dedicated technical team. This local service capability is expected to ensure faster project execution, minimise downtime, and enhance overall customer experience.

Commenting on the long-term vision, Mr. Jerschl added,
“We are committed to increasing market awareness and establishing new reference projects across the region. My goal is not only to generate business but to lay the foundation for long-term growth. Ideally, we aim to establish a dedicated FORNNAX legal entity or operational site in Germany over the next five to ten years.”

For FORNNAX, this partnership aligns closely with its global strategy of expanding into key markets through strong regional representation. The company believes that local partnerships are critical for navigating complex market dynamics and delivering solutions tailored to region-specific waste management challenges.

“We see tremendous potential in the Central European market,” said Mr. Jignesh Kundaria, Director and CEO of FORNNAX.
“Partnering with someone as experienced and well-established as Mr. Jerschl gives us a strong foothold and allows us to better serve our customers. This marks a major milestone in our efforts to promote reliable, efficient and future-ready recycling solutions globally,” he added.

This collaboration further strengthens FORNNAX’s commitment to environmental stewardship, innovation, and sustainable waste management, supporting the transition toward a greener and more circular future.

 

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