Nanospan’s Spanocrete®: nano-admixture for concrete

About Spanocrete

Nanospan’s Spanocrete, a Greenpro-certified, award- winning, groundbreaking nano-admixture for concrete, actualizes the concept of “durability meets sustainability”. This product simplifies the production of durable concrete, making it cost-effective and highly reliable. Spanocrete offers durable concrete that can be considered waterproof, crack-proof, corrosion-proof, and boasts high early strength along with a 130-150% 28-day compressive and tensile strength.

In an era where climate resilience is paramount, durable concrete is essential for every construction project. Spanocrete has demonstrated its versatility with a variety of projects nationwide. Here, we delve into the construction of a high-rise with a rooftop garden and a 500-meter jogging track by a reputed Hyderabad builder in collaboration with Nanospan. This project spans 6.9 acres, with blocks of 13 floors each, covering a total 77,745 sq ft of terrace area.

The Challenges

Incorporating terrace gardens in urban high-rise buildings presents unique structural challenges. These spaces must withstand environmental pressures while preserving the building's integrity. Key concerns include preventing water seepage that can cause mold, weakened concrete, and safety hazards. Addressing these challenges requires a blend of architectural innovation and material science to balance structural soundness with aesthetic appeal. This task involves understanding specific stresses imposed by terrace gardens, including additional weight, moisture exposure, and root penetration, which can impact the building's longevity and safety.

The Prerequisites

Effective terrace gardens necessitate a structurally sound and environmentally adaptable concrete base. This involves resistance to temperature fluctuations, support for soil and vegetation weight, and a watertight nature to prevent leaks. Traditional construction methods often lack longevity and reliability, typically involving complex chemical treatments and various materials. Meeting these demanding requirements calls for exploring new materials and construction techniques, ensuring that the terrace gardens are not only structurally sound but also enduring.

The Spanocrete Solution

Spanocrete® by Nanospan provides an ideal solution to these complex challenges in high-rise construction. As a graphene-based concrete admixture, it significantly enhances the concrete's structural properties. For high-stress applications like terrace gardens, Spanocrete® incorporates inbuilt waterproofing, crack-proof, corrosion-proof properties, and improves concrete's overall strength, durability, and resilience in the concrete – all of which are critical requirements for terrace gardens in high-rise buildings.

Advantages of Spanocrete®

Using Spanocrete® in construction projects has led to substantial improvements in building terrace quality and process efficiency. Its unique properties minimize the need for traditional construction methods, leading to a streamlined and cost-effective building process. This results in cost savings during construction and long-term maintenance, offering a practical solution for builders and developers.

The reduction in the need for multiple construction materials such as secondary reinforcement admixtures and the process overheads thereof, simplifies the construction workflow and enhances the final structure's quality. Spanocrete®'s efficiency in improving concrete performance reduces the complexity and duration of construction projects, offering a more efficient approach without compromising quality.

Benefits Realized with Spanocrete®

The qualification process involved testing the Spanocrete-enhanced concrete at a 3rd party NABL certified center, recommended by the client. In addition to enhanced durability there were also material cost savings. For example, the total cementitious content (cement and fly ash combination) was 415 kg/m3 as per the mix design. 15% of the cement quantity was replaced with fly ash. Then there was the elimination of PP fibers and other admixtures, savings on labor, water consumption due to 100% early strength, and 20% water reduction. The combined impact of Spanocrete led to a reduction in CO2 emissions by more than 25%. In other words, net carbon emissions were reduced without affecting concrete performance.

Spanocrete® : Offering a New Approach to Construction

Spanocrete® has redefined high-rise construction, meeting the demands of durability and sustainability in modern urban development. Spanocrete® exemplifies the potential of innovative materials in transforming the construction industry, leading to the development of resilient and high-quality urban structures.

Currently, Spanocrete is being used in more than 25,000 cubic meters of concrete nationwide, with a variety of mix designs from M20 to M120, UHPC, SCC, recycled concrete, and 3D printed concrete, in a range of projects like buildings, roads, tunnels, precast, paver blocks, and flyash bricks. It is also suited for coastal constructions, and for cold/hot concreting.

About Nanospan

Nanospan, established in 2016, is the name behind many innovative, disruptive, and decarbonizing graphene nanomaterial technologies. The company holds its own IP and manufacturing facility for high surface areas, and for cost-effective bulk manufacturing of graphene required for its composites. Its portfolio of nano-engineered graphene composites for construction includes Spanocrete® for Concrete and SpanOil™ for AAC panels.