Investigation of Cementitious Material Oozing through Dams and Its Implications on Structural Health

Abstract

Concrete and masonry dams subjected to prolonged seepage undergo progressive physicochemical deterioration through calcium leaching, wherein calcium hydroxide (Ca(OH)?) dissolvesand migrates with seepage water, compromising cement paste integrity. This study investigates cementitious material collected from seepage-affected drainage galleries of two major Maharashtra dams—Upper Wardha Dam (Amravati) and Hatnur Dam (Jalgaon)—through systematic chemical analysis per IS 4032:1985. Seven parameterswere determined: Loss onIgnition(LOI), SiO?, R?O?, CaO, MgO, SO?, andInsolubleResidue(IR). The CBIP methodology was applied to estimate cement loss per tonne of leached material.Results confirm significant CaO depletion (36–44% vs. 60–67% in fresh OPC) and extremely elevated LOI (>30%), confirming calcium leaching as the dominant deterioration mechanism. Estimated cementlossis 0.63t/t for UpperWardhaDamand0.67t/tfor HatnurDam.Bothdamsareclassifiedat moderatedeterioration,requiring periodic monitoring rather than immediate structural intervention.

Introduction

This study investigates the chemical deterioration of dam concrete caused by seepage and calcium leaching in two major Indian dams—Upper Wardha Dam (Amravati) and Hatnur Dam (Jalgaon). Dams play a vital role in irrigation, water supply, hydropower generation, and flood control, but prolonged exposure to water pressure and seepage can gradually weaken their structures. The research focuses on analyzing cementitious material oozing from drainage galleries to assess the extent of deterioration and estimate cement loss.

The study was motivated by the observation that cementitious deposits and efflorescence on dam surfaces indicate active transport of dissolved cement compounds through seepage paths. Such deterioration can compromise long-term structural integrity if not monitored. A literature review highlighted that calcium leaching increases porosity and permeability, reduces concrete strength, and accelerates deterioration. Previous studies have also emphasized the importance of seepage control, grouting, and structural health monitoring (SHM) to manage these issues.

Samples of cementitious sludge were collected from various locations within both dams and analyzed according to IS 4032:1985 and CBIP Miscellaneous Report No. 10 guidelines. Seven chemical parameters were examined: Loss on Ignition (LOI), Silicon Dioxide (SiO?), Metal Oxides (R?O?), Calcium Oxide (CaO), Magnesium Oxide (MgO), Sulphate (SO?), and Insoluble Residue (IR). Cement loss was estimated using CaO content and stoichiometric conversion to calcium hydroxide.

The results showed significant signs of calcium leaching in both dams. Average CaO content was 38.90% for Upper Wardha and 41.03% for Hatnur, much lower than the 60–67% range found in fresh cement. High LOI values (31–39%) indicated advanced carbonation and ageing, while elevated IR values (3–10%) suggested removal of cement paste due to seepage. Cement loss estimates were approximately 0.63 tonnes per tonne of leached material for Upper Wardha and 0.67 tonnes per tonne for Hatnur.

Comparative analysis revealed that Upper Wardha Dam is experiencing moderate to active deterioration, characterized by higher insoluble residue and stronger evidence of cement paste removal, while Hatnur Dam is in an early to moderate stage of deterioration. No significant sulphate attack or magnesium-related deterioration was observed, indicating that the primary degradation mechanism is calcium leaching rather than chemical attack.

The study concludes that both dams are undergoing progressive but manageable deterioration. It recommends preventive measures such as using low water-cement ratio concrete, supplementary cementitious materials (fly ash, GGBS, silica fume), upstream surface treatments, and pressure grouting in seepage zones. Regular monitoring of CaO, LOI, and IR, periodic chemical testing, seepage discharge measurements, and long-term deterioration tracking programs are also recommended. Future work should include microstructural analysis, numerical seepage modeling, and IoT-based monitoring systems to improve dam health assessment and maintenance planning.

Conclusion

Thispaperpresentedasystematicchemicalinvestigationof cementitiousmaterialoozingfromtwomajorMaharashtradams. Key conclusions are: 1) Both dams exhibit calcium leaching as the primary deteriorationmechanism,confirmedbyCaOdepletion, elevated LOI, and increased insoluble residue. 2) Estimated cement loss is 0.63t/t (Upper Wardha Dam) and 3) 0.67t/t (HatnurDam) perthe CBIPmethodology. 4) UpperWardhaDam:ModeratetoActiveDeterioration. Hatnur Dam: Early to Moderate Deterioration. 5) Noevidenceofseveresulphateormagnesiumattackat either dam. 6) Chemical ageing (LOI >30%) is significant at both dams, reflectinglong-termcarbonationofhydratedcementphases. 7) Periodic chemical monitoring every 2–3 years is recommended;immediatestructuralinterventionisnot warranted. 8) Thequantitative,data-drivenmonitoringapproachparallels precision sensor-based infrastructure management philosophies [1,2].

References

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Copyright

Copyright © 2026 D. D. Parkhe, P. D. Nemade, Sangale Vrushali Manik, Deshmukh Rutuja Bharat, Deshmukh Sakshi Dattatray. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.