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Sika Technology for Dam Refurbishment

Sika Products
Sachin Chugh
National Manager

Sika Products Were Used For The Renovation Works Following Approval By The Central Water And Power Research Station (cwprs) In Pune

Mandira dam was conceived and constructed by Hirakud Project Authority during the years 1957–59. The dam was built across Sankh River, a tributary of Brahmani River. The dam is located at a distance of 32 km from Rourkela, and the Rourkela Steel Plant (RSP) is about 24km downstream of it. It has a 426.72 m zoned embankment and releases a regulated supply of water of 100 cusecs through an 8 x 8 foot outlet sluice. It also has a weir (low dam) built across Brahmani river near Rourkela to pump out water from the pond to the plant area.

RSP presently controlled by the Steel Authority of India (SAIL), produces a wide variety of special purpose steels, and has many firsts to its credit. In fact, it was the first plant in Asia to adopt the energy-efficient LD steelmaking process. Diverse RSP products are used in a variety of industrial applications, including the manufacture of LPG cylinders, automobiles, and railway wagon chassis, silicon steels for the power sector, high quality pipes for the oil and gas sector, tin plates for the packaging industry and specialty steels for the defense sector among others.

To cater for the water needs of this mammoth plant Mandira dam was built.

Over the past half century, the dam had suffered severe structural damage due to natural wear and tear, requiring intensive repair and retrofitting. Under closer scrutiny, it was found that the dam’s aprons, spillway, blocks and buckets had been acutely damaged. There were instances of massive pitting erosion and also cavity formation. While ensuring that operations continued running smoothly at RSP, renovation work on the dam began immediately as a matter of utmost priority.



Sika products were used for the renovation works following approval by the Central Water and Power Research Station (CWPRS) in Pune, a renowned research institute under the Indian government’s Ministry of Water Resources. The products were subjected to a number of quality tests at the site, such as pot life, compressive strength, bond strength, shrinkage strength, abrasion test, and tensile strength.

The massive cavities created in the spillways were filled up using SikaTop®-122. It was lined with Sikadur®-31 primer and Sikadur®-41 up to 5 mm. Finally, two layers of PU coating Sikagard® PU (UR) were applied to obtain a smooth surface. Next in line was the treatment for the cavities occurring in the chute, baffle block and weir walls. The walls and blocks were jacketed up to 75 mm using SikaRep® Microcrete-2 and further lined with Sikadur®-31 mortar primer and Sikadur®-41 mortar up to 5 mm. Here as well, two final coats of PU coating Sikagard®-PU (UR) were applied to achieve a smooth surface.

The basin area had already been repaired with new concrete. However, to enhance the life of the concrete many times over, it was lined with Sikadur®-31 along with two final layers of Sikagard® epoxy coating. The cracks and voids found all over the dam were treated with surface injection using low viscosity injection epoxy resin, i.e. Sikadur®-52, whereas the construction and expansion joints were repaired employing the Sikadur – Combiflex® SG Tape System.

The Mandira dam is now completely restored to its former glory, preparing the way for RSP to reach new highs. And no wonder that RSP, which came on stream in the 1960s with an installed capacity of only 1 million tonnes per year, is now expected to increase to an enormous 10.8 MTPA by 2025.

For further details
Sika India Pvt. Ltd.
601 A, Infinity Tower, Off Link Road,
Malad (West), Mumbai – 400 064
Ph: +91 22 4038 4038, Fax: +91 22 4038 4039
Email: info.india@in.sika.com
Web: http://ind.sika.com


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