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Barrage of praise!

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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.

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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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Economy & Market

CTS Roundtable Charts Tech-Led Roadmap for Construction

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CTS Roundtable Maps Technology Roadmap for Construction

Ahead of the Construction Technology Show (Con Tech Show) 2026, industry leaders, technology innovators and academia came together in Mumbai to deliberate on how digitalisation, automation and industrialised construction can reshape the sector. The discussion made one thing clear: construction can no longer afford to treat technology as optional.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the CTS Roundtable served as a precursor to the Construction Technology Show 2026, scheduled for 19–20 August 2026 at NESCO, Mumbai.

A platform to move from discussion to deployment

Opening the session, Pratap Padode, Founder and Editor-in-Chief, ASAPP Info Global Group, said construction technology has long remained close to his heart, especially given the sector’s traditionally slow pace of technology adoption. He noted that over the years, the Construction Technology Summit had steadily built interest, and the next step was now to expand it into a larger, more meaningful platform that could bring together technology providers, users, startups and innovators under one roof.

Padode said the vision for CTS is not limited to software alone. The platform aims to embrace all forms of technology that can improve construction efficiency, quality and execution—from digital tools and project management systems to lean construction, off-site fabrication and startup-led innovation. He also highlighted plans to deepen startup participation and create space for young companies to showcase emerging construction solutions.

Industry at a turning point

Moderating the roundtable, Naushad Panjwani, Chairman, Mandarus Partners, set the context by pointing out that the global construction industry, despite being a multi-trillion-dollar sector, continues to lag in productivity. He noted that while manufacturing has consistently improved efficiency, construction has remained slow to modernise.

Referring to both global and Indian trends, Panjwani underlined that the industry is now at a decisive moment. India, he said, is entering a major build cycle, and delivering the next phase of infrastructure and real estate growth through traditional methods alone is no longer viable. The goal of the roundtable, therefore, was not to debate technology in isolation, but to identify the most critical conversations that would bridge the gap between innovation and implementation.

His central message was clear: CTS 2026 must be shaped around themes that make CEOs, CIOs and CTOs feel they cannot afford to miss the event.

From BIM to AI, data to governance

A major theme that emerged through the discussion was the need for better data, better visibility and better decision-making. Dr Venkata Santosh Kumar of IIT Bombay echoed this, saying that the underlying data infrastructure itself needs attention. Construction projects, particularly remote ones, often face issues around connectivity, data collection and data use. Without this foundation, more advanced technologies cannot deliver their full value.

Chandra Vasireddy, CEO & Co-founder, Inncircles, expanded the discussion to governance, arguing that technology must help connect the many moving parts of a construction business. For him, the real value of digital transformation lies in creating better governance, clearer visibility and stronger business outcomes.

Tejas Vara of Inncircles stressed the importance of timely site data for leadership teams, especially in large and remote projects where decisions on materials, machinery and manpower often get delayed because information does not reach headquarters in time.

The role of AI also featured prominently. Rushabh Mamania, Partner and CBO, Roadvision said that while AI and machine learning are now common terms, vision intelligence and language intelligence have still not deeply penetrated the construction sector. He emphasised that startups in India are building relevant AI-led solutions and are already attracting international interest, showing that innovation need not be imported—it can be built locally and scaled globally.

Industrialised construction gains ground

The roundtable also placed strong emphasis on industrialised construction methods. Kalyan Vaidyanathan, CTO – Construction & R&D, Tvasta, called for greater focus on off-site fabrication and the broader industrialisation of construction. Bhargav Jog, General Manager, Dextra, highlighted precast technology and alternative sustainable materials as areas with immediate relevance.

Several participants agreed that modular, precast and pre-engineered approaches are no longer niche ideas. They are increasingly becoming practical responses to the sector’s challenges around labour shortage, timelines, quality control and predictability.

Anup Mathew, Sr VP & Business Head, Godrej, argued that the industry needs a fully integrated approach—from design and procurement to execution and asset management. Unless these are connected, technology adoption will remain fragmented and sub-optimal. He pointed to pre-engineered and modular systems as examples of how industrial thinking can compress timelines, improve quality and reduce dependence on difficult on-site conditions.

Adoption remains the biggest hurdle

While there was broad agreement on the promise of technology, the discussion repeatedly returned to one fundamental challenge: adoption.

Abhishek Kumar, COO, LivSYT, observed that the market is crowded with solutions, but many buyers still struggle to evaluate which technology suits which use case. According to him, the industry needs clearer frameworks to help users select, compare and adopt solutions, rather than expecting a single platform to solve every problem.

Dr Tenepalli JaiSai, Associate Professor, School of Construction(SoC), NICMAR University, noted that isolated technologies will not solve the productivity problem by themselves. What is required is an integrated Construction 4.0 approach, where digital, physical and cyber-physical systems work together rather than in silos.

That concern around silos was reinforced by Subodh Dixit, former Director, Shapoorji Pallonji, who said the issue is not just that technologies are disconnected, but that stakeholders are as well. Clients, consultants, contractors and partners often operate with different priorities. Unless these silos are broken, technology will struggle to percolate across the full project value chain.

Harleen Oberoi, Project Management, Tata Realty shared a practical perspective from the client side, saying that successful BIM implementation requires investment across the ecosystem, not just within one organisation. Trade partners, vendors and other stakeholders must also be trained and aligned if the technology is to deliver its intended results.

Beyond buzzwords

A notable takeaway from the session was that the industry is moving past the phase of treating technology as a buzzword. Participants repeatedly stressed that the real question is not whether technology should be used, but where it creates measurable value and how that value can be scaled.

The conversation also expanded beyond mainstream themes to include repairs and rehabilitation, construction and demolition waste, sustainability, circular economy, green sourcing, carbon measurement, design interoperability, generative design, robotics, and the role of horticulture and greener built environments.

Setting the agenda for CTS 2026

By the close of the session, the roundtable had surfaced a strong set of themes for the upcoming show: BIM and digital twins, AI and data platforms, industrialised construction, startup innovation, governance-led technology adoption, robotics, sustainable materials, and integrated project delivery.

More importantly, the session established CTS 2026 as more than an exhibition. It is shaping up to be a serious industry platform where users, technology providers, researchers and policymakers can collectively define the future of construction.

As Padode noted in his closing remarks, the conversation will continue through further consultations and possibly webinars in the run-up to the show. If the roundtable is any indication, CTS 2026 will aim not merely to showcase technology, but to push the industry towards meaningful adoption at scale.

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Concrete

Human Factor in Grinding Optimisation

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Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, discusses the role of skilled operators as the decisive link between advanced additives, digital control and world-class mill performance.

The industry always tries to reduce the number of operators in the Centre Control Room. (CCR) Though the concept was succeeded to certain extent, still we need a skilled person in the CCR.
In an era where artificial intelligence (AI) grinding aids, performance enhancers, and digital optimisation tools are becoming increasingly sophisticated, it’s tempting to believe that chemistry alone can solve the challenges of mill efficiency. Yet plants that consistently outperform their peers share one common trait: highly skilled operators who understand the mill as a living system, not just a machine.
Additives can improve flowability, reduce agglomeration, and enhance separator efficiency, but they cannot replace the nuanced judgement that comes from experience. Grinding is a dynamic process influenced by raw material variability, moisture, liner wear, ball charge distribution, ventilation, and separator loading. No additive can fully compensate for poor control of these fundamentals.

Operators see what additives cannot
When I joined the cement industry in 1981, not much modernisation was available then. Mostly the equipment was run from the local panel. Once I was visiting the cement mills section. The cement mills were water sprayed over the shell to reduce the temperature to avoid the gypsum disintegration.
The operator stopped the feeding for one of the mills. When I asked the reason, he replied that mill was getting jammed, and he added that he could understand the mill condition by its sound. I also learned that and it was useful throughout my career. In another plant I saw the ‘Electronic Ear,’ which checked the sound of the mill and the signal was looped with feed control!
Whatever modernisation we achieve, it is from the human factor that the development starts.
Additives respond to conditions; operators interpret them.
A skilled operator can detect subtle shifts, like a change in mill sound, a slight variation in circulating load, or a drift in separator cut point. It’s long before instrumentation flags a problem. These micro-observations often prevent major efficiency losses.
Additives work best when the process is stable
I would like to share one real time incident. The mill was running on auto mode looped with the mill outlet bucket elevator kilowatt. (KW)There was a decrease in the KW, and the mill feed was increased by the auto control (PID). After a while, the operator stopped both the feed and the mill. He asked the local operator to check the airslide between mill outlet and the elevator. They found the airslide was jammed and no material flow to the elevator!
The operator deduced the abnormality by his experience by seeing the conditions and the rate of increase of the feed by the auto control.
It’s always the human factor that adds value to the optimisation.

Grinding aids are multipliers,
not magicians.
They deliver maximum benefit only when:
• Mill ventilation is correct
• Ball charge is balanced
• Feed moisture is controlled
• Separator speed and loading are improved
• Blaine targets are realistic
Without these fundamentals, even advanced additives may become costly investments. The operator is responsible for ensuring process stability, whether using a ball mill or a vertical mill. After ensuring the system is stable, the operator observes it briefly before transitioning to automatic control. If there is any anomaly in the system the operator at once takes control of the system, stabilises and bring back to auto control.

Skilled operators adapt in real time
It will be interesting to note that the operators who operate from local panel start to operate from DCS also. They have the experience and the ability to adapt the changes. Operator checks each parameter deeply. Any meagre change in the parameters is also visible to him.
Raw materials change. Weather changes. Wear patterns change.
A skilled operator adjusts:
• Feed rate
• Water injection
• Separator speed
• Grinding pressure (in VRMs)
• Mill load distribution.
These adjustments require intuition built from years of experience, something no additive can replicate.

Human insight prevents over reliance on additives
Plants sometimes increase additive dosage to mask deeper issues like:
• Poor clinker quality
• Inadequate drying capacity
• Incorrect ball gradation
• High residue due to worn separator internals.


A knowledgeable operator finds root causes instead of chasing temporary chemical fixes.
The real optimisation sweet spot is reached when:
• Operators understand how additives interact with their specific mill.
• Additive suppliers collaborate with plant teams.
• Process data is interpreted by humans who know the mill’s behaviour.
This constructive collaboration consistently delivers:
• Lower kWh/t
• Higher throughput
• Better product consistency
• Optimum standard deviation.

Advanced additives are powerful tools, but they are not substitutes for human ability. Grinding optimisation is ultimately a human driven discipline, where skilled operators make the difference between average performance and world class efficiency. Additives enhance the process but operators
control it.

About the author:
Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, is a seasoned cement process consultant with 43+ years of global experience in plant operations, process optimisation, refractory management, safety systems and training multicultural teams across international cement plants.

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