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Last week the US General Services Administration (GSA) announced that it was investing US$2bn on over 150 construction projects that use low-embodied carbon (LEC) materials. The funding is intended to support the use of US-manufactured low carbon asphalt, concrete, glass and steel as part of the Inflation Reduction Act. For readers who don’t know, the GSA manages federal government property and provides contracting options for government agencies. As part of this new message, it will spend US$767m on LEC concrete on federal government buildings projects following a pilot that started in May 2023. The full list of the projects can be found here.

This is relevant because the US-based ready-mixed concrete (RMX) market has been valued roughly at around US$60bn/yr. One estimate of how much the US federal government spent on concrete was around US$5bn in 2018. So the government buys a significant minority of RMX in the country, and if it starts specifying LEC products, this will affect the industry. And, at present at least, a key ingredient of all that concrete is cement.

This isn’t the first time that legislators in the US have specified LEC concrete. In 2019 Marin County in California introduced what it said was the world’s first building code that attempted to minimise carbon emissions from concrete production. It did this by setting maximum ordinary Portland cement (OPC) and embodied carbon levels and offering several ways suppliers can achieve this, including increasing the use of supplementary cementitious materials (SCM), using admixtures, optimising concrete mixtures and so on. Unlike the GSA’s approach in November 2023 though, this applies to all plain and reinforced concrete installed in the area, not just a portion of procured concrete via a government agency. Other similar regional schemes in the US include limits on embodied carbon levels in RMX in Denver, Colorado, and a reduction in the cement used in RMX in Berkeley, California. Environmental services company Tangible compiled a wider list of embodied carbon building codes in North America that can be viewed here. This grouping also includes the use of building intensity policies, whole building life cycle assessments (LCA), environmental product declarations (EPD), demolition and deconstruction directives, tax incentives and building reuse plans.

Government-backed procurement codes promoting or requiring the use of LEC building materials for infrastructure projects have been around for a while in various places. The general trend has been to start with measurement via tools such as LCAs and EPDs, move on to government procurement and then start setting embodied carbon limits for buildings. In the US the GSA’s latest pronouncement follows on from the Federal Buy Clean Initiative and from when California introduced its Buy Clean California Act in 2017. Outside of the US similar programmes have been introduced in countries including Canada, Germany, the Netherlands, Sweden and the UK. On the corporate side members of the World Economic Forum’s First Movers’ Coalition have committed to purchasing or specifying volumes of LEC cement and/or concrete by 2030. Examples of whole countries actually setting embodied carbon emissions limits for non-government buildings are rarer, but some are emerging. Both France and Sweden, for example, introduced laws in 2022 that start by analysing life-cycle emissions of buildings and will move on to setting embodied carbon limits in the late 2020s. Denmark, Finland and New Zealand are also in the process of introducing similar schemes. The next big move could be in the EU, where legislators are considering embodied carbon limits for building materials as part of its ongoing revisions to its Energy Performance of Buildings Directive or the Construction Products Regulation legislations. Lobbying, debate and arguing remains ongoing at present.

To finish, Ireland-based Ecocem spent a period in the 2010s attempting to build a slag cement grinding plant at Vallejo, Solano County, in the San Francisco Bay Area of California. The project met with considerable local opposition on environmental grounds and was eventually refused planning permission. The irony is that slag cement is one of those SCM-style cements that Marin County, also in the San Francisco Bay Area, started encouraging the use of just a few years later. Ecocem held its inaugural science symposium in Paris this week. A number of scientists who attended the event called for existing low carbon technologies to be adopted by the cement and concrete sectors as fast as possible. One such approach is to lower the clinker factor in cement through the use of products that Ecocem and other companies sell. A point to consider is, if Marin County’s code or the GSA’s recent procurement directive came earlier, then that slag plant in Vallejo might have been built. Encouraging the use of LEC building materials by governments looks set to proliferate but it may not be a straightforward process. Clear and consistent policies will be key.

UK: The World Cement Association (WCA) has appointed Wei Rushan as its president. He succeeds founding president Song Zhiping in the post.

Wei has been the president and executive director of CNBM since late 2022, having had a range of senior roles within CNBM Group over the last 15 years. He obtained a doctoral degree in political economy from the School of Economics of Renmin University of China in 2007. Wei also serves as president of China Building Materials Engineering Construction Association.

UK: James Thorne has been appointed as the joint-head of the Mineral Products Qualifications Council (MPQC) and The Institute of Quarrying (IQ) with effect from December 2023. He has been the chief executive officer (CEO) of IQ since 2017. He takes over the new joint-position following the retirement of the MPQC‘s current CEO Viv Russell.

The appointment of a joint-head of both organisations marks a long-standing collaboration between the two membership organisations. The MPQC and the IQ signed a memorandum of understanding in 2022 to work together to increase the value of membership services within the mineral products sector and further develop partnerships with other sectors, industries, and government bodies. This also supports the strategy to develop the National Stone Centre as an international centre of excellence for the mineral products industry.

Established in 1983, the MPQC is a 'not for profit' membership organisation whose purpose is to fulfil the extractive sector's need for a safe, competent and sustainable workforce through the setting and maintaining of standards and qualifications, ensuring quality training and assessment.

The IQ is the professional membership body for quarrying, and the related mineral products extractive and processing industries, with a worldwide membership of more than 5500 individuals.

Cementos Molins has been celebrating the first anniversary this week of its alternative raw materials unit at its Sant Vicenç dels Horts plant near Barcelona. It has processed 75,000t of waste since September 2022 when the site started up. More is yet to come as the unit has a production capacity of up to 200,000t/yr. The facility receives waste in coarse, granular, powder and sludge formats. Waste from concrete plants is crushed and screened to produce recycled aggregate. Industrial and construction waste is dosed and homogenised to produce alternative raw materials for cement production.

Global Cement Weekly has covered construction and demolition waste (CDW) a couple of times already so far in 2023. A number of cement producers are investing in the sector - including Holcim, Heidelberg Materials, CRH, Cemex – by developing technology, buying up other companies, setting up internal CDW divisions and so on. Holcim and Heidelberg Materials have been the more obviously active participants over the past six months based on media coverage. In September 2023 Holcim France commissioned the Saint-Laurent-de-Mûre alternative raw materials plant and Holcim Group invested in Neustark, a company promoting technology to sequester CO₂ in CDW. In August 2023 Lafarge Canada also completed the first stage of a pilot project to use CDW in cement production at its St. Constant plant in Quebec. Heidelberg Materials meanwhile announced in October 2023 that a forthcoming upgrade to its Górażdże cement plant in Poland would include a new CDW recycling unit and in September 2023 it launched a CDW division for its subsidiary Hanson UK.

Previously we have described how the European Union (EU) has set recovery targets for CDW. However, McKinsey & Company published research in March 2023 setting out the economic case for cement and concrete companies looking at CDW. It estimated that “an increased adoption of circular technologies could be linked to the emergence of new financial net-value pools worth up to roughly Euro110bn by 2050.” It is not a certainty and there is risk involved, but adopting circular practices is one way to reduce this risk. It then went on to predict that recirculating materials and minerals could generate nearly Euro80bn/yr in earnings before interest, taxation, depreciation and amortisation (EBITDA) for the cement and concrete sectors by 2050. The biggest portion of this could come from using CDW in various ways such as a clinker replacement or as an aggregate in concrete production, or the use of unhydrated cement ‘fines.’ Capturing and using CO₂ and increasing alternative fuels (AF) substitution rates would have a financial impact but not to the same scale.

Graph 1: CO₂ abatement cost via circular technologies for cement and concrete sectors. Source: McKinsey & Company.

Graph 1 above puts all of the McKinsey circular technology suggestions in one place with the prediction that all of these methods could reduce CO₂ emissions from cement and concrete production by 80% in 2050 based on an estimated demand of 4Bnt/yr. The first main point they made was that technologies using CO₂, such as curing ready-mix or precast concrete, can create positive economic value at carbon prices of approximately Euro80/t of CO₂. Readers should note that the EU emissions Trading Scheme CO₂ price has generally been above Euro80t/yr since the start of 2022. The second point to note is that using CDW could potentially save money by offering CO₂ abatement at a negative cost through avoiding landfill gate fees and reducing the amount of raw materials required. This is dependent though on government regulation on CO₂ prices, landfill costs and so on.

Cement producers have been clearly aware of the potential of CDW for a while now, based on the actions described above and elsewhere, and they are jockeying for advantage. These companies are familiar with the economic rationale for AF and secondary cementitious materials (SCM) in different countries and locations. CDW usage is similar but with, in McKinsey’s view, existing CO₂ prices, landfill costs, and regulatory frameworks all playing a part in the calculations. Graph 1 is a prediction but it is also another way of showing the path of least resistance to decarbonisation. It is cheaper to start with AF, SCMs and CDW rather than barrelling straight into carbon capture. The beauty here is that cement and concrete sold, say, 50 years ago is now heading back to the producers in the form of CDW and it still has value.

UK: Cemex UK says that it has collected 130,000t of by-pass dust (BPD) from its Rugby cement plant in Warwickshire since 2015. The producer supplies the BPD to the agriculture sector, where it can replace traditional fertilisers and lime due to its high lime and potassium content. Additionally, Cemex UK has sponsored research into this and other circular economic uses of BPD, including an on-going study which claimed the Carbon Journey Award at the Eco Innovation North West Awards 2023.

Cemex’s Europe regional head of sustainability Paul Fletcher said “We are very proud of our partnership with Silverwoods and the considerable positive impact their innovation and expertise has had on our ability to reuse BPD for other applications. We believe it leads the way in our industry and presents real potential to be adapted elsewhere across our operations. Not only does it benefit the environment by reducing the amount of materials that need to be disposed of, but it generates a product that has a value for farmers and helps cut the use of traditional materials.” He added “This partnership demonstrates that to deliver true circularity, more industrial by-products, including those from different sectors of the economy, need to be used as secondary resources, rather than primarily be seen as waste. If this is to be achieved, a new perspective is needed to boost circular economy practices, with regulations and permitting supporting this proactively.”

UK: Fernando Gonzalez has been appointed as the president of the Global Cement and Concrete Association (GCCA). He has been the association’s vice-president since 2018 and succeeds outgoing president Jan Jenisch.

Gonzalez has called for industry and governments around the world to establish a "robust regulatory framework" that can further accelerate the cement and concrete sector's decarbonisation efforts. He said "It is a great honour to be president of the GCCA - cement and concrete are the world's essential building materials. As an industry, we've gone beyond the commitment phase to taking decisive action today to reduce our CO₂ emissions."

Gonzalez is the chief executive officer (CEO) of Cemex. He has worked for the company since 1998. On the operational side, he has led various regions of Cemex, including Europe, Asia and South Central America and the Caribbean, and has held corporate positions in strategy, planning, business development and human resources. He was appointed Executive Vice President of Planning and Development in 2009, chief financial officer in 2011, and has been the company's CEO since 2014.

UK: First Graphene and Breedon Group have entered into a development and commercialisation agreement. Together, the companies aim to enhance Breedon Cement’s CEM II Portland limestone cement (PLC) through the use of First Graphene’s graphene enhanced grinding aids and cement admixtures. Breedon will provide increased access to cement production lines in order to optimise the understanding of the processing environment and operating conditions.

Breedon Group’s Hope cement plant in Derbyshire previously conducted a 24-hour graphene-enhanced cement production trial on 28 June 2023.

UK: Holcim subsidiary Aggregate Industries has installed Driver Status Monitoring Systems supplied by Spillard Vehicle Safety Systems in the cabins of its Cauldon cement plant truck fleet. The systems use cameras and AI software to detect signs of tiredness, as well as mobile phone use, lane deviation, not wearing a seatbelt and smoking. In the case of tiredness, this triggers an alarm which continues to sound until the vehicle comes to a stop.

Cement supply chain manager Matt Owen said “Health and safety is a massive priority for us as a company and the industry, so anything that can serve to continuously improve our approach to it is very welcome. Driver fatigue is always a potential issue across any business involved in transport and fleet, so we’re delighted to be utilising the latest technology with our partners to ensure that everyone gets safely home from work.”

EU/UK: EUROSLAG says that the use of ground granulated blast furnace slag (GGBFS) in cement production in the EU and UK between 2000 and 2022 has generated a cumulative reduction in CO₂ emissions of 408Mt. GGBFS replaced 716Mt-worth of raw materials over the period.

EUROSLAG Chair Thomas Reiche said "Resource conservation through secondary raw materials, especially in the construction sector, and lower emissions of climate-damaging CO₂, are of outstanding ecological and economic importance. The use of ferrous slags makes an important contribution to this. EUROSLAG is working multilaterally to master the enormous challenges in the coming years, above all the transformation of the steel industry, through research and adjustments to national and European regulations.”

UK: The Cement 2 Zero project has successfully concluded its first trial melt of recovered cement paste in an electric arc furnace at the Materials Processing Institute’s Teesside campus. The project uses the paste as flux for electric steel recycling. Cambridge Electric Cement (CEC) has demonstrated that the ‘slag’ from this process can be ground into fine clinker that, when mixed with gypsum and supplementary cementitious materials (SCMs), produces net zero CO₂ cement. The Cement 2 Zero project to produce CEC’s cement at an industrial scale launched in March 2023, with US$7.85m in funding from UK Research and Innovation. Tarmac will grind the clinker from the project’s trial melts for testing in order to obtain certification and specification as a usable cement product.