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One unusual thing about coverage of cement in the media is the way that discussions often centre precisely on its absence – that is, on alternatives to cement. These alternatives boast unique chemistries and performance characteristics, but are all produced without Portland cement clinker. They are generally called ‘alternative cements,’ perhaps because ‘cement-free cement’ does not have such a commercially viable ring to it. This contradictory tendency reached a new high in the past week, with developments in alternative cement across Asia, Europe, the Middle East and North America. Together, they hint at a more diverse future for the ‘cement’ industry than the one we know today.

Asia

In Indonesia, Suvo Strategic Minerals has concluded tests with Makassar State University of a novel nickel-slag-based cement. Huadi Nickel-Alloy Indonesia supplied raw materials, and tests showed a seven-day compressive strength of 37.5MPa. Suvo Strategic Minerals says that a partnership with Huadi Nickel-Alloy Indonesia for commercial production is a likely next step.

Europe

Cement producer Mannok and minerals company Boliden partnered with the South Eastern Applied Materials (SEAM) research centre in Ireland to launch a project to develop supplementary cementitious materials (SCMs) from shale on 7 October 2024. The project will additionally investigate CO₂-curing of cement paste backfill for use in mines. Irish state-owned global commerce agency Enterprise Ireland has contributed €700,000 in funding.

UK-based SCM developer Karbonite expects to launch trial production of its olivine-based SCM with a concrete company in 2025. The start-up launched Karbonite Group Holding BV, with offices in the Netherlands, to facilitate this new phase. Karbonite’s SCM is activated at 750 – 850°C and sequesters CO₂ in the activation process, resulting in over 56% lower CO₂ emissions than ordinary Portland cement (OPC). Managing director Rajeev Sood told Global Cement that talks are already underway for subsequent expansions into the UAE and India.

Back in the UK, contractor John Sisk & Son has received €597,000 from national innovation agency Innovate UK. John Sisk & Son is testing fellow Ireland-based company Ecocem’s <25% clinker cement technology in concrete for use in its on-going construction of the Wembley Park mixed development in London.

At the same time, Innovate UK granted a further €3.23m to other companies for concrete decarbonisation. Recipients included a calcined clay being developed by Cemcor, an SCM being developed from electric arc furnace byproducts by Cocoon, a geopolymer cement technology being developed by EFC Green Concrete Technology UK and an initiative to develop alternative cement from recycled concrete fines at the Materials Processing Institute in Middlesbrough. Also included was the Skanska Costain Strabag joint venture, which is working on the London stretch of the upcoming HS2 railway. The joint venture, along with partners including cement producer Tarmac and construction chemicals company Sika UK, will test low-kaolinite London clay as a raw material with which to produce calcined clay as a cement substitute in concrete structures in HS2’s rail tunnels.

Middle East

Talks are underway between UK-based calcined clay producer Next Generation SCM and City Cement subsidiary Nizak Mining Company over the possible launch of a joint venture in Riyadh, Saudi Arabia. The joint venture would build a 350,000t/yr reduced-CO₂ concrete plant, which would use alternative cement based on Next Generation SCM’s calcined clay.

North America

Texas-based SCM developer Solidia Technologies recently patented its carbonatable calcium silicate-based alternative cement, which sequesters CO₂ as it cures.

Meanwhile, C-Crete Technologies made its first commercial pour of its granite-based cement-free concrete in New York, US. C-Crete Technologies says that the product offers cost and performance parity with conventional cement, with net zero CO₂ emissions. Its raw material is globally more abundant than the limestone used as a raw material for clinker. Other abundantly available feedstocks successfully deployed within C-Crete Technologies’ repertoire include basalt and zeolite.

Across New York State, in Binghamton, KLAW Industries has succeeded in replacing 20% of concrete’s cement content with its powdered glass-based SCM, Pantheon. KLAW Industries has delivered samples to local municipalities and the New York State Department of Transportation. Its success expands the discussion of possible circular cement ingredients from the industrial sphere into post-consumer resources.

In Calgary, Canada, a novel SCM has drawn attention from one of the major cement incumbents: Germany-based Heidelberg Materials. It invested in local construction and demolition materials (CDM)-based SCM developer EnviCore on 9 October 2024. The companies plan to build a pilot plant at an existing Heidelberg Materials CDM recycling centre.

Conclusion

Alternative cement developers are still finding the words to talk about their products. They may be more than ‘supplementary’ up to the point of entirely supplanting 100% of clinker. Product webpages offer ‘hydraulic binder,’ ‘pozzolan’ and even ‘cement.’ As alternative ‘cements’ are developed, they build on the work of pioneers like Joseph Aspdin and Louis Vicat. Start-ups and their backers are now reaching commercial offerings, on a similar-but-different footing to cement itself. None of these novel materials positions itself as the sole, last-minute ‘super sub’ in the construction sector’s confrontation with climate change. Rather, they are a package of solutions which can combine into a net zero-emissions heavy building materials offering, hopefully before 2050.

Related to this is the need for ‘technology neutral’ standards, as championed this week by the Alliance for Low-Carbon Cement and Concrete (ALCCC), along with 23 other European industry associations, civil society organisations and think tanks. The term may sound new, but the concept is critical to the eventual uptake of alternative cements: standards, the ALCCC says, should be purely performance-based. They ought not attempt to define what technology, for example cement clinker, makes a suitable building material. According to the ALCCC, Europe’s building materials standards are not technology neutral, but instead ‘gatekeep’ market access, to the benefit of conventional cement and the exclusion of ‘proven and scalable low-carbon products.’

At the same time, cement itself is changing. Market research from USD Analytics showed an anticipated 5% composite annual growth rate in blended cement sales between 2024 and 2032, more than doubling throughout the period from US$253bn to US$369bn. If you can’t beat it, blend with it!

For a further discussion of alternative cement and binders in Europe, see Global Cement’s interview with ALCCC co-ordinator Joren Verschaeve in the forthcoming November issue of Global Cement Magazine on 17 October 2024.

Pakistan: Lucky Cement has announced its reappointment of Muhammad Sohail Tabba to the role of chair of its board. The appointment will be effective through to 2027. Tabba has served in the role since 1993. He currently holds other executive positions in the textiles and energy sectors, at Gadoon Textile Mills, Lucky Textile Mills and Yunus Energy.

Meanwhile, Muhammad Ali Tabba will also continue to occupy the position of CEO through to 2027. He was first appointed to the role in 2005.

Saudi Arabia: Al Jouf Cement Company’s board of directors has accepted the resignation of Suleiman Abdulaziz Al-Zaben as chair of its audit committee. Al-Zaben had been serving as committee member from outside the board.

In July 2024, Al Jouf Cement Company took legal action against unnamed former board members, following an investigation into possible ‘administrative irregularities’ by an independent auditor launched in December 2023.

Zimbabwe: Huaxin Cement has invested US$15m in a new manufacturing plant in Zimbabwe, according to Bulawayo 24 News. The company has set up a subsidiary Huaxin Zimbabwe, to oversee operations. Huaxin Zimbabwe director Clemence Gomba said that the initial capacity will be 300,000t/yr, potentially increasing to 1Mt/yr if lime reserves are accessed, adding that he wanted “Zimbabweans to get cement at their doorsteps.” The plant will serve both local and export markets. Huaxin plans to employ five Chinese nationals and 200 local people.

Company CEO Mr Chen said “We started construction of the site last month [September 2024] and we hope to finish by the end of November 2024. In December 2024, we will start the production of cement. The plant will start with a production capacity of 25,000t/month of cement, we will mainly be manufacturing 32.5 and 42.5 cement. We hope to satisfy the local market so that we can reduce our imports. We hope to find some limestone reserves so that we will not be importing any clinker.”

Industry and Commerce Minister Mangaliso Ndlovu toured the site, saying that Zimbabwe is experiencing a surge in imports mainly from Zambia and South Africa, a reflection that local production is ‘not satisfying’ the market.

Portugal: Cimpor has signed a 10-year extendable contract with Vodafone Portugal for private ‘pure’ 5G network installations at its plants, starting with the Alhandra plant and soon expanding to Souselas and Loulé. This network will aim to improve data management and operational efficiencies across Cimpor's cement business and eventual expansion to other sectors. Technology partners include Germany-based SAP and Sweden-based Ericsson.

Cimpor's chief technology officer Berkan Fidan said that the company felt the need to make this investment because the cement industry is data-intensive, and the collection of available data is a challenge due to the physical and operational conditions at the plants.

This partnership makes it possible to obtain precise quality reviews of the cement manufactured at the plants without having to wait 28 days. It also gives total visibility of the plant, making emission forecasts and maintenance easier. The deal involves around 10,000 sensors in 19 plants globally, 50 antennas, drones to measure stock levels and thermal cameras with real-time monitoring capabilities. The long-term strategy with Vodafone also involves the use of smart glasses with video streaming functionalities inside the plants. Fidan explained that the plants have some connectivity challenges, which is why the company is investing heavily in the mobile network.

Canada: Sustainable materials startup EnviCore has raised US$3m in its seed funding round led by CSN Inova Ventures (the corporate venture capital arm of Brazil’s Companhia Siderúrgica Nacional), Heidelberg Materials and others. The funding will scale up Envicore’s production of low-carbon supplementary cementitious materials (SCMs), like mining tailings, slag, shale and glass. The company’s technology reportedly reduces the carbon footprint of cement production by up to 30%, using recycled mineral feedstock, with the SCMs replacing up to 35% of Portland cement in concrete. Proceeds will expand EnviCore's production capacity and support new business development, operations and research and development efforts. Heidelberg Materials, together with EnviCore, will conduct a feasibility study for a pilot SCM production facility close to one of Heidelberg Materials’ recycling hubs.

CEO and co-founder Shahrukh Shamim said "This investment marks a pivotal moment in our journey to commercialise a game-changing technology in the cement industry. The support from CSN, Heidelberg Materials and other investors will allow us to scale up quickly and meet the growing demand for greener building solutions."

India: Cement demand in India is projected to increase by 7 - 8% to approximately 475Mt in the 2025 financial year, down from a compound annual growth rate of about 11% between financial year (FY) 2022 and FY 2024, according to a report by CRISIL Ratings. The company analysed 18 cement producers, which account for over 85% of domestic sales volume. The forecast follows a 3% growth in demand during the first half of FY 2024, affected by an extended heatwave and a labour shortage during the general elections, the Financial Express has reported.

Director of research at CRISIL Market Intelligence and Analytics, Sehul Bhatt, said "Cement demand is expected to rebound in the second half of the 2024 financial year, as construction activity gathers pace across infrastructure and housing segments post-monsoon. Healthy monsoon, improved labour availability after the festive season, and an increase in government spending on infrastructure and housing should drive demand up 9 – 11% in the second half of the year, taking the annual growth tally to 7 – 8%."

Philippines: Holcim Philippines and Universal Robina Corporation (URC) have entered a tripartite agreement with the local government of Obando, Bulacan, to provide incentives for workers at the town's material recovery facility, based on the volume of refuse diverted. The material recovery facility in Obando has collected and sorted 785t of plastic waste for co-processing. Since 2021, URC and Holcim's waste management unit Geocycle has been processing plastic from URC's operations for co-processing. The plastics are converted into alternative fuels used to power the kiln at Holcim’s plant in Misamis Oriental.

Irwin Lee, URC president and CEO, said "This new agreement, with Obando as a key partner, aims to further drive community-based ‘waste’ diversion efforts. We hope to replicate it in other towns and cities to amplify the impact of what we set out to do three years ago."

US: Researchers at UCLA's Institute for Carbon Management have developed a new method called ZeroCAL that could eliminate ‘nearly all’ of the carbon dioxide emissions from the process of cement production, according to the UCLA Newsroom. The team created a process using limestone and a water-based solution containing ethylenediaminetetraacetic acid. Through membrane nanofiltration and an electrochemical process, they produced calcium hydroxide.

To meet ZeroCAL’s water demand, the team suggests focusing on cement plants near coasts or rivers. The researchers are reportedly working with Ultratech Cement to build a demonstration plant that will produce ‘several’ tonnes of lime per day using the ZeroCAL process. Currently, the process requires more energy than traditional lime production methods, but ongoing research aims to reduce its energy consumption.

Gaurav Sant, director of the Institute and professor at UCLA Samueli School of Engineering, said “The ZeroCAL approach offers an elegant solution to eliminate carbon dioxide emissions associated with the process of cement production. First, it addresses the carbon emissions resulting from limestone’s decomposition while providing clean hydrogen and oxygen to heat the cement kiln. Second, it enables onsite decarbonisation while making use of existing kilns and limestone feedstocks without having to build separate carbon capture and storage facilities.”

Bolivia: Bolivia recorded a 2.7% year-on-year increase in cement production and sales in August 2024. According to the National Statistics Institute, production reached 2.6Mt from January - August 2024, up from 2.53Mt in the same period in 2023. Santa Cruz produced 699,062t of cement, followed by La Paz with 679,317t, Chuquisaca with 510,841t, Cochabamba with 384,329t, Oruro with 214,660t and Tarija with 150,068t.

Marcelo Morales, general manager of Itacamba Cemento, noted a year-on-year increase of 3% in domestic demand, with 2.6Mt of cement consumed as of August 2024, saying that the growth was positive ‘considering the current economic situation’.

General manager of the Bolivian Institute of Cement and Concrete, Marcelo Alfaro, also mentioned that Santa Cruz, La Paz and Cochabamba collectively account for about 70% of cement sales in Bolivia, according to La Razón newspaper. The cement industry's installed capacity reportedly stands at 10Mt/yr and the country is facing challenges exporting cement, as neighbouring countries already produce their own.