Displaying items by tag: Standards
Shree Cement Ras facility earns NABL accreditation
21 October 2024India: Shree Cement's Ras quality control laboratory in Rajasthan has been recognised by the National Accreditation Board for Testing and Calibration Laboratories (NABL), affirming its compliance with the ISO/IEC 17025:2017 standards. Managing Director Neeraj Akhoury said that the accreditation acknowledges the company's commitment to providing premium, sustainable building materials. The laboratory's role in ensuring standardisation across all product testing is important for maintaining production quality at the plant.
New developments in alternative cement
16 October 2024One 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!
Pakistani cement producers challenge quality control fees
14 October 2024Pakistan: The Senate Standing Committee on Science and Technology heard on 10 October 2024 that some cement producers have obtained stay orders from courts against the Pakistan Standards and Quality Control Authority over unpaid marking fees. The marking fees equate to 0.1% of cement’s ex-factory price, and go towards ensuring that cement conforms to standards. Pakistan Today News has reported that only two producers have regularly paid the fee, with combined defaults valued at US$18m across the entire industry. A delegation from Saudi Arabia reportedly queried authorities about the lack of clear labelling.
Science and Technology Committee chair Kamil Ali Agha reportedly said "No one knows what quality of cement is being produced by local manufacturers.”
Tanzania: The Tanzania Revenue Authority (TRA) has introduced a new digital verification application named Hakiki Stempu, aimed at helping consumers verify the quality of cement products and combat the sale of counterfeit and substandard cement.
Ndositwe Haonga, TRA Director for Internal Affairs, explained that Hakiki Stempu allows the public to check whether the product they are about to purchase is genuine or not by scanning the product to check if it has the right tax stamp. The app also serves as a tool for ensuring that products meet necessary standards and offer value for money.
Ban ‘green’ cement!
05 June 2024The Indonesian government emphasised its intention this week to use ‘green’ cement in the construction of its new capital city Nusantara in Borneo. However, this begs the question: what exactly is ‘green’ cement?
In this case, Mohammad Zainal Fatah, the secretary general of the Ministry of Public Works and Public Housing, told state media that his department was “seeking to encourage the supply of domestic-industry-based material resources and construction equipment, which can support sustainable infrastructure development principles." The ministry is working with state-owned cement producers such as Semen Indonesia (SIG) to ensure the provision of sustainable cement and related products. SIG was selected as a supplier for the project in late 2022 and, as of February 2024, has reportedly provided 400,000t of cement from its plants at Balikpapan and Samarinda.
This is admirable stuff. However, the timing of the announcement is curious given that both the head and deputy head of the Nusantara Capital City Authority resigned this week forcing the government to reassure investors that the project was still on. Cue some swift discussion about ‘green’ cement! Previously it was hoped that the first phase of the US$34bn project could be inaugurated on the country’s independence day in August 2024 with civil servants scheduled to start relocating to the site in the autumn.
SIG sells a number of ‘green’ blended cement products and some of these have received Green Label Cement certification from the Green Product Council Indonesia. The group says that these products have contributed up to a 38% drop in CO2 emissions compared to Ordinary Portland Cement (OPC). This compares to the group’s clinker factor reduction rate of 69% and its Scope 1 emissions intensity reduction of 17% to 585kg/CO2/t of cement in 2023 compared to 2010 levels.
Along similar lines, the Alliance for Low-Carbon Cement & Concrete (ALCCC) in Belgium also announced this week that it had released a new policy roadmap aimed at achieving net zero emissions by 2040. Amongst its recommendations were a focus on the standards for cement and concrete to promote low-carbon products and encouragement to create lead markets to develop demand for them.
Crucially, the ALCCC uses low-carbon cement in place of ‘green’ cement and this makes its definition clearer. ‘Green’ cement is a marketing term intended to associate cement with environmentalism. Yet there is no accepted definition describing how these products are more sustainable than, say, OPC. For example, a so-called ‘green’ cement could use 100% clinker manufactured with no CO2 emissions-abatement, but it might be sustainable in other ways such as saving water. For the purposes of this article we’ll assume that ‘green’ cement means a low-carbon one. To further add to the confusion, ‘green’ concrete can be made using OPC in various ways but that’s beyond the scope of this piece. Clearly the world could do with some universal definitions.
US-based research and consulting company Global Efficiency Intelligence came to the same conclusion when it published its ‘What are Green Cement and Concrete?’ report in December 2023. It decided that - despite there being plenty of standards, protocols, and initiatives - there is no general agreement on the definition of ‘green’ cement or concrete. Its emissions intensity for cement summary table can be viewed below. It demonstrates the massive range of emissions intensity between the various standards. It is worth noting here that the description the Indonesian government may have been using for ‘green’ cement could already meet SIG’s Scope 1 emissions intensity reduction for its cement in 2023 depending on the standard being used.
Standard / Initiative / Policy Name | Emissions intensity target (t/CO2 per tonne cement) |
Climate Bonds Initiative | 0.437 & 0.58 |
IEA and IDDI | 0.04 – 0.125 |
First Movers Coalition | 0.184 |
U.S. General Services Administration IRA Requirement | 0.751 |
New York (USA) Buy Clean | 0.411 |
Table 1: Emissions intensity definition for cement as stated by standards, protocols, initiatives, and policies with stated numerical quantity targets. Source: Global Efficiency Intelligence.
Part of the problem here is that there is a language gap between the simple definition of a cement that is less CO2 emissions-intensive than OPC and the technical definitions used in the specifications and standards. Simply describing a cement product as ‘green’ can potentially cover anything that is slightly better than OPC down to a bona-fide net-zero product. Added to this is pressure from the manufacturers of new and existing cement products that use less or no OPC for regulators to move to performance-based standards to replace existing prescriptive standards, because it makes it easier for their products to be used. For more on this issue see Global Cement Weekly #606. Cement associations such as Cembureau and the Global Cement and Concrete Association (GCCA) have also called in their respective net zero roadmaps for changes to the standards system to promote low-carbon cement and concrete products.
The answer to what is ‘green’ cement is whatever the promoters want it to be. So, it might be helpful if the use of the word ‘green’ were banned in connection to any marketing activity related to cement products. Everyone could then adopt some kind of universal grading system using simpler language. One approach might be to copy the colour-coding scheme used by hydrogen to describe how it is made. One could use yellow for limestone blends, silver for slag, orange for clay, black for OPC made with carbon capture and so on… but not green! Another route might be to mandate the use of the carbon labels that some cement producers have used for at least a decade. Or something like the alphabet energy rating system used in the UK and EU for electrical appliances could be used. It’s too much to hope for a global system but simpler systems in the main markets would make it much easier to determine what exactly is ‘green’ cement.
Cement firms shift to lighter bags for worker health
04 April 2024Mexico: Members of the National Cement Chamber (Canacem) are set to reduce cement bag weights from 50kg to 25kg to comply with NOM-036, according to El Financiero, which aims to prevent and control musculoskeletal and ergonomic diseases in construction workers. The shift affects companies such as Cemex, Cementos Moctezuma, GCC, Cemento Cruz Azul, Cementos Fortaleza and Holcim.
The standard came into effect on 31 March 2024, but Cementos Moctezuma has already started transitioning to 25kg bags. José Barroso, CEO of Cementos Moctezuma, said "Since 2023, Cementos Moctezuma began the transition from 50kg to 25kg bags in all of its packaged product family.” He added "In Mexico, musculoskeletal disorders represent almost half of the occupational injuries, so we are already implementing changes in our plants to operate according to the new standard.”
Furno Materials secures US$6.5m in seed funding
20 March 2024US: Furno Materials completed an oversubscribed US$6.5m seed funding round on 13 March 2023. Subsequently, the start-up unveiled plans for its Furno Brick carbon-neutral modular cement plant, which can use a variety of gaseous fuels. The plant scales on demand, drastically reducing the barrier to entry for local or small-scale cement production.
Furno CEO Gurinder Nagra said “At Furno, we have the ability to produce ordinary Portland cement now, to adapt to a range of gas-based fuels and materials innovations as they emerge and to meet demand where it exists, while still abiding by a shifting regulatory landscape. Our mission is to go the distance by innovating at the heart of cement production and operating as a complement to other technological developments in the cement space. Our cement far exceeds ASTM International standards, a bare-minimum quality threshold. While most companies tout meeting these standards and stop there, we have continued to refine our process and are on target to surpass the even higher commercial requirements set by significantly-sized customers eager for our solution.”
EU: The European Commission has introduced a Draft Guidance document regarding the Free Allocation Regulation (FAR), now expanded to include ‘alternative hydraulic binders’ within the cement clinker benchmark. To qualify for allocation under this benchmark, these binders must meet three specific criteria: they must be used in cement production, not be included in any other benchmark under the European Union's Emissions Trading Scheme (ETS), and must not be by-products of waste or other production processes.
The European Cement Association (CEMBUREAU) has expressed concerns regarding these criteria. Namely, that the proposed changes suggest a shift from a clinker to a cement-based benchmark approach, making current methodologies and regulations inconsistent and impractical, especially as cement production often occurs outside ETS-covered sites. CEMBUREAU also states that some materials like pozzolana and calcined clay, requiring activation by lime or grey cement clinker, do not fit the hydraulic binder definition. Lastly, the association suggests that only materials covered by the standard EN 197-1 should be considered as alternative hydraulic binders, implying that the current definition in the FAR is overly broad and potentially problematic.
Portland Cement Association to join with other industry associations against new particulates standard
04 March 2024US: The Portland Cement Association (PCA)’s Environment and Energy Committee met in Tampa, Florida, to discuss the formation of a new coalition with other industry bodies under the leadership of the US Chamber of Commerce. The PCA said the coalition will take legal action against the US government, following the Environmental Protection Association (EPA)'s introduction of new, lower particulates emissions standards. The association says that the revised standards may lead to layoffs and lower cement and concrete production.
Other items on the agenda for the committee’s biannual meeting include permitting and regulatory reform for carbon capture, utilisation and storage and alternative fuels for cement production.
Ghana tightens cement standards
12 February 2024Ghana: The Ghana Standards Authority has enacted new quality standards for cement products. BNN Breaking News Ghana has reported that the new standards are intended to uphold safety for users of concrete buildings. This will reportedly be accompanied by increased enforcement against substandard products, including the roll-out of a new licensing system.