Displaying items by tag: Buzzi Unicem USA

Ecocem announced this week that it has achieved certification in the US for its ACT low-carbon cement technology. This follows CRH’s agreement to buy US-based Eco Material Technologies, a supplier of supplementary cementitious materials (SCM), which was revealed in late July 2025. These moves and others mark a flurry of activity by various companies in the US SCM sector in recent months.

Donal O’Riain, the founder and managing director of Ireland-based Ecocem, underlined the importance of certification in North America when he said that “The US is one of the largest cement markets in the world, and this certification will support integration into existing supply chains and offers a pathway for the sector to rapidly decarbonise.” The country imported just under a fifth, 19Mt, of its Portland and blended cement in 2024 according to the United States Geological Survey (USGS).

Ecocem started out as a manufacturer of cements made using ground granulated blast furnace slag (GGBS), a SCM, in the early 2000s. Its ACT technology was formally announced in 2022. It is described as a process that can make cements using “available fillers like limestone and local SCMs.” It is currently scheduled for a commercial launch in 2026, starting in France. In the US it is planning to build a terminal and mill at the Port of Los Angeles in California. This follows a previous attempt to build a slag grinding plant, also in California, in the 2010s.

CRH, another cement company with strong links to Ireland incidentally, said on 29 July 2025 that it had agreed to acquire Eco Material for US$2.1bn. The latter operates a network of fly ash, pozzolan, synthetic gypsum and green cement operations. It partners with electricity generators to process about 7Mt/yr of fly ash and 3Mt/yr of synthetic gypsum and other materials. As CRH’s CEO Jim Mintern put it, “this transaction secures the long-term supply of critical materials for future growth and puts CRH at the forefront of the transition to next generation cement and concrete.” The deal is expected to close by the end of 2025. In separate comments to analysts Mintern added that he expects the market for SCMs to double in the US by 2050.

Other players have also been busy in recent months. Amrize, for example, noted in its financial results for the second quarter of 2025 that it had broken ground on a new fly ash beneficiation facility in Virginia in the reporting period. Last week, Graymont and Fortera signed an agreement to produce Fortera’s ReAct low-carbon cement product by using Graymont’s existing lime production operations. Fortera runs a plant in Redding, California that takes captured CO₂ from the adjacent CalPortland cement plant and uses it to manufacture its own proprietary SCM. Back in April 2025 Buzzi Unicem said that it had partnered with Queens Carbon to produce a novel cement and SCM. The start-up was intending to build a 2000t/yr demonstration plant at Buzzi Unicem’s cement plant in Stockertown, Pennsylvania.

The backdrop to all of this attention on SCMs in the US are the cost of cement and sustainability. Using more SCMs reduces clinker usage in cement and it can reduce the cost. At the same time reducing the amount of clinker used decreases the amount of CO₂ emissions. So, for example, Ecocem says that its ACT technology can reduce CO₂ emissions by up to 70% compared to conventional cement.

A report by Mckinsey on SCMs in the autumn of 2024 reckoned that growth in the cement market in North America was expected to be ‘robust’ in the next 15 years to 2050. However, the sector faces material, particularly clinker, and labour shortages. Enter SCMs! It went on to assert that much of the available stocks of GGBS and fly ash in the country are effectively used. Yet, traditional industrial SCMs such as GGBS, fly ash and limestone are anticipated to be available for longer than in Europe as industries such as steel manufacture and electricity generation will take longer to decarbonise. Hence companies such as Ecocem are preparing to import them, ones like CRH are cornering existing stocks and others such as Fortera and Queens Carbon are working on creating their own ‘virgin’ sources. At the same time the American Cement Association has been promoting the use of Portland Limestone Cement in the country.

All this helps to explain the interest in SCMs in the US right now. It’s a busy moment.

US: Queens Carbon has secured US$10m in seed funding to scale up production of its novel cement and supplementary cementitious materials (SCMs). The start-up will build a 2000t/yr demonstration plant at strategic partner Buzzi Unicem USA's Stockertown, Pennsylvania, cement plant. The plant will demonstrate Queens Carbon’s low-energy Q-Reactor technology, which employs novel hydrothermal chemistry, with the help of steam and pressure, to combine standard cement feedstocks into carbon-neutral hydraulic cement and SCMs. The company’s flagship product, Q-SCM, is capable of replacing up to 50% of cement in concrete mixes. Queens Carbon says that it will now also begin preparations for its first full-scale commercial plant.

Buzzi Unicem USA was among investors in the seed funding round, led by Climate technologies investor Clean Energy Ventures, with participation from fellow venture capital firm Plug and Play.

Queens Carbon CEO Daniel Kopp said "With support from Clean Energy Ventures, Buzzi Unicem USA and the US Department of Energy, we're building next-generation technology and assembling the creative talent needed to drive industry revenues to move cement innovation forward and significantly reduce CO₂ emissions from cement production, all without a green premium."

Luigi Buzzi, Chief Technology Officer at Italy-based Buzzi, said "We know that achieving our goal of net-zero carbon emissions by 2050 demands forward-thinking solutions to enhance both our operations and our environmental performance.”

US: Buzzi Unicem has blamed a late tax payment in Pennsylvania on an accounting error. The cement company made the US$18m payment five months late, in May 2024, according to the Express Times newspaper.  The issue was highlighted by a lien filed in December 2023 in Northampton county civil court. Stockertown cement plant manager Rad Slavov clarified that the payment was timely but misallocated. He said "The company is financially strong and able to meet its obligations.”

US: A research team from Lehigh University has won a three-year, US$2m grant from the Department of Energy's industrial efficiency and decarbonisation office for a project on concrete decarbonisation. The team, including Carlos Romero, director of Lehigh's Energy Research Centre, aims to develop a sustainable concrete binder using calcined clay, reducing emissions associated with Ordinary Portland Cement production. The project collaborates with Buzzi Unicem USA and focuses on processing and testing calcined clay to mimic the properties of conventional cement.

Lehigh's team will explore various low-grade calcined clays, supplied by Buzzi, testing their compressive strength and durability. The goal is to halve the CO₂ emissions of traditional concrete mixes.

Chair of the Department of Civil and Environmental Engineering Shamim Pakzad said "I am excited about the expansion of the research portfolio of CEE departments into this area of greener cement, which opens many opportunities for future research and implementation in industry."

US: Buzzi Unicem USA is among industrial partners collaborating with Electrified Thermal Solutions in the development of its Joule Hive Thermal Battery for industrial heat decarbonisation. The partners plan to launch a commercial-scale pilot of the battery in San Antonio, Texas, in association with the Southwest Research Institute. The project is supported by US$171m in funding from the US Department of Energy. The battery delivers heat of up to 1800°C from energy from renewable sources.

Buzzi Unicem USA president and chief executive officer Massimo Toso said “Cement production is known as a hard to abate industrial sector in large part because of the high temperatures required. Electrified Thermal Solutions’ Joule Hive Thermal Battery is the first industrial heat decarbonisation solution we have identified that could potentially enable us to cost-effectively and completely eliminate the use of fossil fuels in our heating processes and achieve our corporate decarbonisation goals.”

Electrified Thermal Solutions chief executive officer Daniel Stack said “We believe the breadth and depth of involvement from our industrial partners like Buzzi Unicem USA was critical to demonstrate to the Department of Energy just how valuable the Joule Hive Thermal Battery will be for industrial decarbonisation, and we are grateful for their partnership.” Stack added “Southwest Research Institute’s engineering support and world-class industrial demonstration facilities signalled to the Department of Energy that our technology will be developed, built, operated, tested and evaluated to the highest standards.”

US: The Portland Cement Association (PCA) has elected Massimo Toso as its next chair. He is the current president and chief executive officer (CEO) of Buzzi Unicem USA and has worked as the vice chair of the association. He succeeds Filiberto Ruiz, president and CEO of Votorantim Cimentos North America, in the post.

Monica Manolas has been elected as vice chair. She is the first woman in the 21st century to be elected to the position and she currently works as the president of Ash Grove East. Jorge Wagner, CEO of Votorantim Cimentos North America, was also elected to the PCA Board of Directors.

US: Buzzi Unicem USA’s Maryneal cement plant in Texas hit a production record of 1.03Mt of clinker and 1.18Mt of cement in 2022. The figures were more than 4% over the year’s budgeted figures. The plant says it achieved the result through consistent communication and a positive culture. Managers at the unit also shared updated production figures at daily meetings, kept all employees actively engaged and created an encouraging atmosphere. The plant has set new goals for 2023.

Antonio Corea Cruz, Operations Manager at the plant, said, “We’ve implemented strategies to keep reliable assets which allow the team members to work on continuous improvement. This affects the efficiency and productivity of all aspects of the plant.”

US: The Portland Cement Association (PCA) has announced the winners of its 2023 Safety Innovation and Chairman's Safety Performance Awards.

The Safety Innovation Award Program recognises companies that have developed innovative practices, projects and programs that improve safety at cement plants in the US. Entries are judged in five areas: innovation, ease of use and ease of construction, effectiveness and risk prevention. The recipients were:

• Distribution: Continental Cement, Continental Port Allen Terminal, Chesterfield, Missouri
• Quarry: CalPortland Company, CalPortland Oro Grande Plant, Oro Grande, California
• Pyroprocessing: GCC of America, GCC Tijeras Plant, Tijeras, New Mexio
• General Facility: Mitsubishi Cement Corporation, Mitsubishi Cushenbury Plant, Lucerne Valley, California

The Chairman’s Safety Performance Awards are given to member cement plants that did not have a reportable injury or illness during the year. Fifteen plants achieved this in 2023, which represented more than 10% of all active cement facilities in the US and its territories. The recipients were:

• Argos USA, Atlanta, Georgia
• Argos USA, Newberry, Florida
• Argos Puerto Rico Corp, Dorado, Puerto Rico
• Ash Grove Cement Company (CRH), Durkee, Oregon
• Ash Grove Cement Company (CRH), Midlothian, Texas
• Buzzi Unicem USA, Chattanooga, Tennessee
• Buzzi Unicem USA, Maryneal, Texas
• CalPortland Company, Rillito, Arizona
• GCC of America, Odessa, Texas
• Heidelberg Materials, Bellingham, Washington
• Martin Marietta Materials, New Braunfels, Texas
• Martin Marietta Materials, Midlothian, Texas
• Martin Marietta Materials, Tehachapi, California
• National Cement Company of California, Kern, California
• St Marys Cement (Votorantim), Detroit, Michigan

US: Buzzi Unicem USA has challenged penalties worth US$62,500 and denied that it failed in its duty to protect an employee who died after falling into the Mississippi River while working on a barge at the Natchez terminal in Mississippi in February 2023. The Occupational Safety and Health Administration (OSHA) cited multiple alleged safety violations by the Buzzi subsidiary in a report published in mid-August 2023.

Buzzi Unicem USA said “The company strongly contends that it did not violate the regulations set forth in the citations regarding personal floatation devices and guardrails, and therefore timely filed notice with OSHA that it is contesting the alleged violations contained in these citations (as well as certain aspects of the other citations).” It continued “The company objects to any characterisation by OSHA that the citations are a final determination that the company violated any OSHA regulation or caused the death of our valued employee.”

US: The Occupational Safety and Health Administration (OSHA) of the US Department of Labor has found that Buzzi Unicem USA failed in its duty to implement safe practices, after a 50-year-old employee died at work in February 2023. The victim was working on a Mississippi River barge belonging to Buzzi Unicem USA subsidiary River Cement Sales when he fell overboard, leading to his death. OSHA concluded that Buzzi Unicem USA had committed multiple serious safety violations. Those connected to the tragedy in February 2023 included failures to ensure that workers wore personal floatation devices and to install guardrails. The administration said that the failures ‘cost a worker his life.’ Safety inspectors proposed a fine of US$62,500 for the breaches.