From collapse to comeback: Karnataka’s Tungabhadra dam gets a new lease of life
Almost two years after Gate No. 19 was washed away, the historic Tungabhadra Dam near Hosapete was restored, replacing all 33 ridge gates. It is scheduled to be officially opened by the end of the month. | Photo credit: File photo
When Crest Gate No. 19 of the Tungabhadra Dam near Hosapete was washed away late on August 10, 2024, it created panic among millions of farmers dependent on the reservoir for irrigation.
Considered the lifeline of north Karnataka and parts of Andhra Pradesh and Telangana, the massive reservoir was then filled with 105,788 tmcft of water at a Full Reservoir Level (FRL) of 1,633 feet. Within minutes of the chain link breaking, nearly 35,000 pieces of water began gushing uncontrollably through the damaged bay. Engineers scrambled to open the remaining gates to relieve pressure on the structure, even as concerns grew downstream.
What began as a terrifying engineering emergency soon evolved into one of the largest dam restoration exercises undertaken in recent years. The crisis prompted intense technical efforts, political attention, farmer anxiety, and interstate coordination. Almost two years later, it culminated in the replacement of all 33 ridge gates. The old ones operated through an overhead bridge mechanism involving chains, gears, motors and counterweights. For almost seven decades, the gates functioned without major reconstructions.
When the gates gave way in 2024, experts from Hyderabad, Chennai and Bengaluru got to work along with engineers from JSW Steel and local manufacturing companies. Hydromechanics expert N. Kannaiah Naidu emerged as a key figure in the operation, preparing designs and engineering drawings for the temporary stop-log arrangement. The operation itself was extremely risky as the engineers had to work amidst strong currents and fluctuating discharge conditions.
Against all odds, the engineers succeeded. On August 17, 2024, just seven days after the disaster, the team successfully installed a temporary barrier consisting of five massive steel elements. It prevented further catastrophic water losses.
Experts who inspected the dam after the incident recommended a comprehensive replacement of all 33 ridge gates, taking into account their age and long years of operation without major repairs. Based on the recommendations of the technical committee, the Tungabhadra Board has decided to replace all the 33 spillway gates. The Tungabhadra board later commissioned the replacement of Hardware Tools & Machinery Projects Pvt. based in Ahmedabad. Ltd.
Extensive replacement work gained momentum in late 2025 and involved dismantling the old gates and fitting new ones in a narrow working window.
The disassembly and assembly of all 33 gates was completed in 123 days, between 24 December 2025 and 25 April 2026. Trial runs of the newly installed gates were also successfully completed, and the remaining finishing works are in the final stages.
The project also included the replacement of 68 lifting chains and 100 bevel gears. Although a detailed examination found the existing chains to be structurally sound, the then Deputy Chief Minister DK Shivakumar (now Chief Minister-designate) said during his visit to the dam on 3 May 2026 that the government had decided to replace all the chains as a precautionary measure. External quality control agencies from Hyderabad were entrusted with testing and monitoring the work. The total cost of replacing all 33 spillway gates along with chain links and quality checks was around ₹51 crore.
The successful replacement of all 33 ridge gates has now become a crisis recovery story, with tireless efforts by engineers and laborers racing against time to save one of the most important irrigation projects in South India.
As the renovated gates prepare for their formal dedication, the Tungabhadra Dam is not just restored, it’s restored. Engineers associated with the project believe that the comprehensive replacement of all 33 ridge gates has strengthened the dam’s structural safety and extended its life by another 50 years.
The government plans to hold a big public meeting soon to invite farmers from the command area, especially Koppal, Raichur and Ballari, to dedicate the restored dam to the nation.
Published – 16 May 2026 18:58 IST