Interaction

INSWAREB Develops
No-Aggregate Concrete (NAC)

W
ith sustainability being the buzz-
word in the construction indus-
try, a lot of research is being
carried on by various research and aca-
demic institutions across India on com-
ing out with innovative construction mate-
rials and solutions. The Institute of Solid
Waste Research & Ecological Balance
(INSWAREB), Vishakhapatnam has been
doing path breaking research on utiliza-
tion of industrial by-products for develop-
ment of sustainable construction prod-
ucts. INSWAREB had been in news ear-
lier for developing FaL-G, a cementitious
product, using fly ash as the principal
input. The research outfit is in news again,
now for developing No- Aggregate Con-
crete (NAC), which is also christened as
'Nano Concrete'. In an exclusive interview
with Editor-in-Chief, K.P. Pradeep, on the
sidelines of the International Conference
& Seminar on Challenges in Precast Con-
struction for Buildings and Infrastructure
Projects, held at GVP College of Engi-
neering, Vishakhapatnam, the Founder-
Directors of INSWAREB, Dr.Bhanumathidas,
and N.Kalidas spoke in detail about their
latest invention. Here are excerpts from
the interview.
N.Kalidas Dr.Bhanumathidas
inspire confidence among the populace
for the use of FaL-G bricks and blocks.
As part of our further research for opti-
mizing FaL-G we developed various
mixes using 4th generation admixtures.
The result we saw was a mix showing up
absolute workability, compaction, and
cohesiveness, all at 0.15 WCF (factor of
water/cementitious material) with grade
strengths of 55 MPa to 70 MPa. When we
took a closer look at the specimens after
strength test, the matrix resembled closely
to that of ceramic, with absolute pore-
refinement. Absence of coarse aggre-
gate had taken out the scope for transi-
tion zone, which is known for creating a
weak bond between coarse aggregate
and cement paste. This caught our imag-
ination. We thought that using such mate-
rial as structural media would address
the issues of durability in a single go and
that too in a holistic manner.
We lost no time and immediately con-
ducted some basic engineering studies
applicable to concrete, patented and de-
clared the invention of No-Aggregate
Concrete (NAC). In convention to our
practice of taking the lab work to field with-
out delay, we cast a dome of 10.5 ft dia
with NAC over FaL-G mansion that was
due for face-lift at that time.
Tell us about the science at work behind
the low WCF of NAC at 0.15, and at the
same time its ability to allow a flowing mix?
As emphasized by us at many a
forum, FaL-G is the 'Ayurveda' of cement -
concrete formulation. More the attrition
greater is the potency. The edge runner
serves this basic principle by tapping the
holistic performance of fly ash. There
upon the special admixture used by us
does the wonder. The role of anhydrite
too cannot be ignored. All this collectively
account for the high workability at the
least WCF.

You had already broken fresh ground

with FaL-G technology. And now you
have come out with NAC. What made
you conceive this total paradigm shift in
concrete?
To put it in a nutshell, the urge to use
complementary cement materials pres-
ent in industrial wastes and thereby give
thrust to conserving natural resources. As
you are aware, we had developed the FaL-G
technology in 1989. We had introduced
FaL-G as a cementitious material made
by ingredients from industrial by-products.
To prove its efficacy we did cast a
2000 sq.ft of slab way back in 1991 for our
house consisting of 15-18 ft long beams,
making couple of them as tie beams too
(Please refer to the photos attached).
This helped us to demonstrate the poten-
tial of FaL-G as structural cement and FaL-G Mansion ground floor slab (1991) cast with FaL-G in lime route without using even a gram of cement

214 The Masterbuilder - May 2013 · www.masterbuilder.co.in


Can you throw some light on 'Transition
Zone' and its implications in concrete?
'Transition zone' is the interface bet-
ween coarse aggregate and cement paste.
Generally concrete does fail at transition
zone, when subjected to stress, because
of adverse effects caused by differential
thermal stresses and weak crystallogra-
phy at this zone. When OPC is used bel-
ching out high surplus lime at early ages,
such surplus lime gets dissolved in water
tending to settle at transition zone. In high
performance concretes aggregate size is
rationalized in order to minimise differen-
tial stresses at transition zone, upon which
the strengths are attributable to the strength
of cement matrix associated with sand.
How does NAC address the issues asso-
ciated with Transition Zone?
First of all there is no scope for transi-
tion zone in NAC, since coarse aggregate
is avoided. Even the inert fly ash particles
develop cohesive bond with cement
matrix making the ultimate NAC-matrix
close to monolithic. This is manifested in
NAC's high strength (55-70 MPa) and low
permeability at 27 coulombs.
In a given material and matrix, smaller
the particles higher the bond. A lot of
energy is required to snap such a bond.
Nano science works on this premise, and
Nano Concrete performs very much
Tie-beam in ground floor slab of FaL-G Mansion (1991) without using cement
within this framework. Micro and sub-
micron particles of fly ash that develop
adhesive bond at early age attain cohe-
sive bond with progress of age due to
reaction of lime and other mineralogical
hydrates on surface of particles. This is
manifested in Nano Concrete developing
115 MPa strength in over a year as
against 55 MPa at 28-day. Such quantum
jump in strength is uncommon in cement
-concrete, whatever maybe the tech-
nique of preparation.
How do you respond to certain sections
of the construction industry fraternity who
are concerned about shrinkage in NAC?
As an innovative material, NAC should
address all facets of concrete behaviour
with data back up and we are very much
working on them. But based on basic
behaviours we give priority to some issues
and, shrinkage studies are in our least
priority list because at 0.15 to 0.18 WCF,
concrete has hardly any scope for shrink-
age.
Secondly shrinkage in concrete mani-
fests in many ways viz., plastic shrinkage,
drying shrinkage, thermal shrinkage and
autogenous shrinkage. So one should be
clear in mind as to which shrinkage they
are referring to. NAC has very nominal
room to any of these shrinkages because
of its material characteristics associated
www.masterbuilder.co.in · The Masterbuilder - May 2013
Interaction
with low WCF and moderate cement
input. For example, when studied for dry-
ing shrinkage, NAC has shown up 0.05%
as against permissible limit of 0.15% vide
IS 4031 (Part 10)-1988 and IS 1727-1967.
Data is casually sought by a section
of faculty based on application similarity
unmindful of variation in material science.
We recall such experience with FaL-G
bricks during the early days of its inven-
tion. It is customary to seek data on 'alter-
nate wetting and drying' for clay bricks
that reflect soundness of sintering and
strength. This data was sought at many
fora for FaL-G bricks, whilst ignoring the
fact that FaL-G is a hydraulic product that
gains strength at every wetting through
hydration-chemistry.
Has there been a similar technology
developed anywhere else in the world?
While applying for patent, our global
search gave no clue of such development.
We have also communicated to some of
our friends of CANMET/ACI in different
countries. No such development was
reported by any of them.
A recent development at Massachu-
setts Institute of Technology (MIT), USA,
shows their explorative attempts, seeking
to identify alternate materials to cement
that can give packing effect with equal
efficiency. But, no mention has been made
by MIT about any such identification of
alternate. Though fly ash is a known com-
plement to cement, its packing effect as
achieved in NAC is derived out of process
manoeuvre rather than any simple input.
You have taken a decision to execute
structures for schools and temples offer-
ing concrete-materials, mixers, and super-
visory services without any cost. Explain
the philosophy behind this decision.
Having established basic engineer-
ing data, we have a great urge to put this
concrete in field for first hand site experi-
ence. Therefore, we are prepared to absorb
the cost of concrete (exclusive cement)
for model structures. Serving temples
and schools additionally satiates our pas-
sion for spiritualism and education.
Do you feel that your studies on material
science are sufficient to scale up the
product for structural application?
Yes. Any concrete material needs to
possess certain engineering properties,
215
 Interaction
Cast in-situ slab done with Nano Concrete or No-Aggregate Concrete (NAC)
abided by codal provisions. As long as
these parameters are met, such materi-
als are amenable for structural applica-
tion. Concern for durability and perfor-
mance criteria fall in the purview of mate-
rial science over which we are confident
of our studies, thanks to Prof. P.K. Mehta
who has channelized our insight on con-
crete.
How do you respond to the criticism that
you are going ahead with executing
structures without completing structural
engineering studies?
We do very much realise the impor-
tance of structural engineering studies. It
is because of this realisation, we have
signed with GVP-SIRC for joint research
with focus of studies on structural engi-
neering dimensions. In order to facilitate
structural studies with enlarged scope,
we have even funded for a loading frame
costing ` 5.50 lakhs which is due for com-
missioning at GVPCE by next month.
Structures are subjected to nominal
dynamic loads up to 2 to 3 floors that can
be designed based on basic engineering
data of concrete. Structural engineering
studies are more essential for massive
utility projects and high rise buildings,
more so when attempted to harmonise/
rationalise quantities of concrete and
216 The Masterbuilder - May 2013 · www.masterbuilder.co.in
steel. Coming to the issue of our urge to
demonstrate structures in this approach,
we recall our experience with casting FaL-
G concrete slab in 1991 in lime route, with-
out using even a gram of cement. Critics
had their own doubts then too.
The structural engineering design for
FaL-G Mansion was provided by Late
Prof .Krishnamacharyulu, Ex. Principal of
Civil Engg. Department, Andhra Univer-
sity, who was an accredited structural
engineer of his times. We had put a rider
that he should not specify steel in any
member extra than the conventional
design. While receiving the drawings, we
checked with him whether he had con-
fined to specifying steel absolutely to that
of conventional concrete. He affirmed
again and again. We then asked him, “Sir,
as material scientists we have our confi-
dence to make such request. But how
could you develop confidence in conced-
ing to our request for not increasing struc-
tural steel”. He just smiled and replied,
“You have thoroughly convinced me
through XRD studies that the mineralogy
in FaL-G is akin to that of OPC. The engi-
neering studies conducted in our labs (he
was then head of Civil, GITAM Engineer-
ing College) have proved that FaL-G con-
crete is at par to M25 concrete by 45-60
days of age. Then, of course, safety fac-
tor is invoked which is invariably associ-
ated even with conservative designs.
This is how I quantified steel parallel to
that of RCC structure with control con-
crete.” Thus, you see empirical judge-
ments sometimes help to progress fast.
In fact for the above structure we have
used LT ash containing about 5% unburnt
carbon that was expected to prove hos-
tile to concrete right from water demand
till durability. However the sound and pro-
gressive chemistry of FaL-G seemed to
supersede the impact of high unburnt
carbon, if the safe condition of the struc-
ture is any testimony.
Now the ground floor slab of FaL-G
Mansion is 23 years old, to which we
added 2 more floors in 1994, again using
FaL-G concrete (in cement route). NAC is
nothing but extension of FaL-G with better
engineering properties.
So there are structural engineering
testimonies and superior engineering
properties that have strengthened our
hands to go ahead with structures.
What are the constraints in practicing
this technology?
There are a good number of con-
straints.
Firstly, the WCF to admixture dose is
very critical. During some portion of the
studies, we were encountering top 10-15
mm layer of cast element as incohesive
and soft for violating this harmony. It took
almost six months for us to identify the
flash point to avoid such mishap.
Secondly, mixing time, with respect to
specific duration to tap the workability. If
one is in urgency and keeps adding
water, the mix attains more fluidity caus-
ing plastic shrinkage on the surface of
cast element and there upon strengths
would be diluted.
Thirdly, brittleness due to ultra high
strengths. A well prepared NAC has the
ability to attain 35 MPa strength at 3-day;
52 MPa at 7-day and over 80 MPa by 28-
day. Though brittleness is not uncommon
to high strength concretes, NAC with its
ceramic-like matrix appear to behave dis-
tinctly different against cement concrete,
more so as RCC member. This aspect
gives thrust for structural engineering
research to identify the limitations or bene-
fits of this wonder-product, keeping in
view its application for high rise buildings,
bridges and high profile structures.
 Interaction

With these limitations how do you pro-
pose to go ahead with dissemination of
your technology?
We have no intention to release this
technology to site mix applications, at
least to begin with. NAC makes good
sense for precast elements because:
- Accuracy of inputs is possible due to
dosing mechanisms governed by
instrumentation techniques.
- Butter-like mix of NAC facilitates cast-
ing with absolute finish associated
with detailing of mould profiles, if any,
making it amenable for ornamental
concrete too.
- Density of NAC is around 1800-1900
kg/cu.m; almost 20-25% reduction
over that of control concrete.
- High early strengths of NAC, which
can also be augmented within 36
hours through accelerated curing,
prove conducive for handling precast
elements for immediate despatch to
market bringing down the inventory
costs.
- As the construction market is gearing
up to produce and use precast ele-
ments, we believe that NAC is the
timely boon to precast industry.
However, in view of importance on
structural engineering studies, we wish to
sign as many agreements as possible
with IITs and engineering colleges for joint
research on NAC. During our visit to
Manipal Institute of Technology in the
month of April a dialogue was opened
and we hope to sign an agreement within
next one month. We welcome other col-
leges having good laboratory for such
joint research. In addition to awarding
best research on NAC, we want to pro-
vide instruments for further research to
accomplished institutions engaged in the
research of NAC.
Concluding Remarks by Editor in Chief,
K.P.Pradeep
“Concrete as we know today is vastly
different from say what it was about three
decades ago. It is still not a finished prod-
uct and would invariably keep changing
in the future. INSWAREB has been doing
pioneering work in developing sustain-
able construction technologies and their
efforts which led to the invention of NAC
needs to be lauded. The need of the hour
is for the industry and the academic world
to join hands with INSWAREB's founder-
directors, Dr.Bhanumathidas and N.Kalidas,
and help in further research on NAC in
order to make it a commercially viable
proposition“

An Open Letter to Engineering Colleges for Joint Research

on No-Aggregate Concrete (Nano Concrete)

D r. Bhanumathidas and N Kalidas have developed No-Aggregate Concrete

(NAC) technology, ie., a concrete without using sand or stone. They have also
named it as Nano Concrete due to the nature of inputs with sub-micron particles
and matrix of hardened concrete containing nano pores as against micro pores in
conventional concrete. They predict over 1000-years of service life to nano con-
crete due to absolute packing and impermeability resulting in as low as 27 cou-
lombs of permeability vide RCPT test, as against 2000 to 4000 coulombs for con-
ventional concrete. In order to study the concrete in field application, the inventors
have cast in 2010 a dome of 10.5 ft dia over their living house, FaL-G Mansion at
Visakhapatnam.
Please visit the link to see the casting activity of the dome:
http://youtu.be/ 1MRPRFgpr1E
In order to gain firsthand experience in field and study the applicational intricacies
of NAC, inventors have cast a slab of 1200 sft on 8th April to a temple in AP. Please
view the pictorial description of casting this slab @
https://plus.google.com/photos/114174959184859555609/albums?banner=pwa&gpsrc
=pwrd1#photos/114174959184859555609/albums/5865661036706260481/586878
9669094142834
For any innovative structural material such as NAC, it is necessary to address all
the engineering parameters, more so in structural engineering point of view. This
concrete develops phenomenal strengths 35 MPa at 3-day, 51 MPa at 7-day, 70
MPa at 28-day and over 100 MPa at 1-year. Thus, it is brittle as much as any other
high strength concrete, but maintaining compression to tensile strength ratio at
10:1 to 10:0.9. Pending the structural studies, it is viewed that high early strengths
of NAC may prove as a boon or post an issue for critical structures with high order
of dynamic loads.
Hence the inventors would like to initiate as many research projects as possible on
structural aspects, involving as many IITs and Engineering colleges as possible.
How to progress on joint research:
Colleges with good structural lab only would be selected as partner institute, who
have to sign agreement of joint research with the Inventors. The Agreement saliently
contains the clauses in the following lines:
Partner Institute would:
- Get thorough knowledge from Inventors on the material science behind the
invention of NAC.
- Get training on the preparation of NAC from the Inventors.
- Get required quantity of chemical admixture from Inventors free of cost to the
extent of R & D studies.
- Get the typical mixer (edge runner) from inventors on returnable basis, which will
be with the institute for 3-5 years.
- Enjoy absolute freedom in practicing this technology for various studies.
- Enjoy freedom to publish any number of technical papers based on the research
conducted.
- Enjoy freedom to construct as many structures as they desire with NAC within
their institutional boundaries/areas.
- Get automatically enrolled to the Award for 'Best Structural Engineering
Research on Nano Concrete', instituted by the Inventors with a total award
amount of ` one million. The first award period is 2013 to 2016, over three years.
However, Partner Institute should:
- Commit to uphold the IP rights of the Inventors on the subject for which patent
has already been applied.
- Sign an agreement with Inventors committing to use the information only for
research but not for commercial purpose.
- Acknowledge the role of inventors in all the technical papers prepared on the
subject.
Interested colleges are requested to write to: N Kalidas, Executive Director,
Eco Carbon Pvt. Ltd., at nkalidas@co2credits.biz or bhanukali@vsnl.com

218 The Masterbuilder - May 2013 · www.masterbuilder.co.in