Nonunions and segmental bone defects associated with infection are challenging problems faced by the orthopaedic surgeon. Antibiotic cement-coated (ACC) interlocking nails, prepared in the operating theatre using nails and materials generally available, can be used to treat these conditions. Two different types of moulds can be used (reusable or disposable).

Materials and Methods: The infected nonunion/segmental bone defect was treated by débridement followed by ACC nailing in 52 patients (12 female, 40 male, age range 16–86 years). Other procedures for deformity correction, bone defect etc were carried out simultaneously as indicated. Infected nonunion was seen in 34 patients, 1 was an acute fracture after external fixator. Segmental defect in the bone of 1 to 30 cm was seen in 17 patients. Anatomical sites included Femur (13), Tibia (11), Knee (12) and ankle (16).

Results: Limb salvage was achieved in 96% and amputation in 2 patients. Bony union was achieved in 41 of 49 patients (84%). In 3 patients (15%), control of infection was achieved with stable nonunion (1 patient) and stable nonunion with cement spacer (2 patients). Control of infection was achieved in 85%. Single procedure achieved this goal in 73%. Cement nail de-bonding occurred during removal in 9 patients and during insertion in 1 patient. The average follow-up was 16 months (1 to 60 m).

Conclusion: Dual goals of control of infection as well as stability to promote union can be achieved using this technique. Although useful for all infected nonunions, this technique is particularly useful for patients who are not ideal candidates for external fixators or those who do not want an external fixator.