Dam Gate Failure Triggers ₹51 Crore Replacement of All 33 Gates at Tungabhadra
The Tungabhadra reservoir in Karnataka has completed the installation of 33 new crest gates, replacing the entire spillway system after one gate was washed away in August 2024. The ₹51 crore project, officially inaugurated on June 25, marks the end of a crisis that began with a late-night failure and led to a comprehensive safety overhaul.
The reservoir, an inter-State irrigation project serving Karnataka, Andhra Pradesh, and Telangana, was built between 1945 and 1955. The original gates had been in use for nearly 69 years. On August 10, 2024, at around 10.50 p.m., Spillway Gate No. 19 broke loose from its groove when the reservoir was nearly full. The sudden release of water raised immediate fears about the safety of the ageing structure and the potential loss of irrigation water for thousands of farmers.
Engineers led by hydro-mechanical expert N. Kannaiah Naidu chose to install a temporary stop-log gate within seven days, instead of draining the reservoir. This allowed retention of 71.35 tmcft of water, ensuring irrigation supply for the 2024 kharif and rabi crops. The stop-log arrangement bought time for a full inspection of all gates, which revealed widespread deterioration. Based on technical committee recommendations, the Tungabhadra Board decided to replace all 33 crest gates rather than restore just the damaged one.
The replacement work was awarded to Hardware Tools & Machinery Projects Private Limited in April 2025. The operation involved dismantling old gates, installing new ones, and replacing lifting chains and bevel gear units within a narrow timeline. All 33 new gates are now operational, strengthening the structural safety and reliability of the reservoir.
The incident has reshaped safety planning for ageing dams in India, highlighting the need for periodic health assessments and proactive replacement of critical components.
