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MIO coating for concrete structures is required when both pollution and humidity levels are high

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Professor Anand Khanna, Chairman, Society For Surface Protective Coatings India (SSPC) and Surface Engineering and Coating Consultant (SECC), is a specialist in high temperature corrosion, high temperature coatings, organic coatings and surface modifications.

Professor Anand Khanna, Chairman, Society For Surface Protective Coatings India (SSPC) and Surface Engineering and Coating Consultant (SECC), is a specialist in high temperature corrosion, high temperature coatings, organic coatings and surface modifications. In this interview, he elaborates on the use of Micaceous Iron Oxide (MIO) coating for anti-carbonisation of concrete structures.

What inspired you to start your research?

Material analysis is one of the most important components for establishing a new industry or creating or fabricating a new structure. The life of the component depends upon the material. Today there are so many steel super alloys used in sophisticated structures. Firstly, if material selection is not done properly, the life of the structure cannot be calculated.

Secondly, given that the most pressing issue is corrosion, material stability is very important. given that the most important problem is corrosion. As the environment is polluted, steel gets corroded. When steel or other materials are used for construction, they need to be properly protected. Surface engineering is taking care of the surface of the material to give suitable protection and that makes this an important subject in any kind of material.

Thirdly, all kinds of studies, even failure analysis, start with surface analysis, so it is important to understand the reason for deterioration of the material.

What is the kind of paint testing done in your lab and how does it help the construction industry?

Paint coating is one part of surface engineering. The Indian market is worth Rs 70,000 crores while the global market is $1.8 billion. Paint analysis is required because there are three categories of companies in paint manufacturing – high class MNC, middle level and low level companies.

When paint is used for large projects such as refineries, it needs test certification from a laboratory, preferably under the government. Ours is a private lab under the name of surface engineering and coating consultant, which is accredited with NABL. This certification ensures the lab’s credibility with equipment that are as per the international standards.

Tell us about the anti-carbonisation testing and coating developed or tested at your lab.

Calcium oxide is the main component of concrete. When concrete comes in contact with CO2 in the environment, it gets absorbed by the concrete and part of calcium oxide turns into calcium carbonate. That starts some kind of deterioration of concrete. When it reaches the steel concrete interface, the pH falls and some kind of steel corrosion occurs, leading to formation of iron carbonate. As the pollution is increasing, the problem is also increasing, which means when you make concrete structures, we have two solutions. One is to modify the concrete by adding construction chemicals that reduce the intake of carbon dioxide or apply a suitable coating on the concrete surface as a finishing product. Most of the coatings are acrylic based, which have a tendency to stop carbon dioxide diffusion.

Paint companies give us samples for testing. We create a free film of paint in an aluminium cup in which the paint is kept with a solution of potassium chloride. This mixture is kept in high pressure equipment and CO2 is passed through it. When it is passed under pressure, it diffuses through the coating and carbonate is formed. As it forms, its weight increases. We measure the weight increase in time to get 2-3 values to understand the diffusion coefficient of CO2 through the coating. Based on this, the decarbonisation of coating is determined.

Tell us more about use of anti- carbonising coating in the current infrastructure of the country?

To take the example of Mumbai, which has high levels of moisture and CO2 in the air, concrete structures such as flyovers and bridges tend to deteriorate fast. When a Micaceous Iron Oxide (MIO) Epoxy based coating , which is light bluish coating, is applied, it doesn’t allow CO2 to enter into the concrete. In places like Delhi where pollution levels are high but moisture levels are not, the situation is not so dangerous. Moisture in the air along with airborne chlorides spur the carbonation process. Since airborne chlorides have suspended salt and gaseous content, they can affect corrosion significantly (given that salt is corrosive).

Therefore, anti-carbonation is important. For instance, the Mumbai Metro construction is not using MIO coating, and the structure has started leaking. I had written to Mumbai Metropolitan Region Development Authority (MMRDA) explaining to them how the life of the structure will be affected in the absence of this coating but they are yet to take heed of my warnings. The black concrete structures that are a common sight in our country indicate how porous the structures have become and how fast chloride can diffuse now.

Is the MIO Epoxy coating used widely? What are its key components?

It is not required for all structures in all kinds of environments. MIO Epoxy coating for concrete structures is required when both pollution and humidity levels are high. The damage due to CO2 in humidity less than 50 per cent is just one micron damage per year compared to 20 micron damage per year if the humidity is 90 per cent. Delhi has high levels of pollution, yet it’s metro structures are robust as there is no humidity in the environment. Coastal towns like Mumbai and Chennai need to use MIO Epoxy coating on their concrete structures. This coating comes with additives that block CO2 movement.

What is the impact of anti-carbonising coating on the environment as compared to normal coating?

If you put anti-carbonation coating it will enhance the life of the structure, normal coating will not be able to protect the concrete and the damage will be faster. Coating is not harmful to the environment; it helps in sustaining the life of the concrete structure. Architectural coatings can be modified with additives to ensure durability of concrete.

How are these coatings priced?

Normal coating is Rs 250-350 per litre. By adding additives to make the coating an anti-carbonation one adds Rs 10-20 to the per litre cost.

What technological innovations can be seen and expected in the upcoming year?

One of the biggest innovations occurring is functional coating. It refers to the use of coating as per the function of the structure. Such a coating can be modified and is customisable. Nano technology is another innovation in the offing, wherein very small additions are made to enhance the structure to a great extent. The next innovation is smart coatings, which means, the coatings which are self cleaning, self healing, anti-microbial, anti-fungal and conductive coating.

Kanika Mathur

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Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.

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