Global Cement Newsletter

Issue: GCW360 / 04 July 2018

Headlines


Congratulations are due to Bamburi Cement this week after the completion of a new production line at its Nairobi grinding plant. The new US$40m line will add 0.9Mt/yr of cement production capacity to the unit, bringing its total to 2.4Mt/yr when it is commissioned towards the end of 2018. Together with the subsidiary of LafargeHolcim’s integrated plant at Mombasa the company will have a production capacity of 3.2Mt/yr.

Graph 1: Cement production and consumption in Kenya 1999 - 2017. Source: Kenya National Bureau of Statistics.

Graph 1: Cement production and consumption in Kenya 1999 - 2017. Source: Kenya National Bureau of Statistics.

As Graph 1 shows above it is an interesting time to open new production capacity in the country. Both production and consumption fell for the first time since 2000 in 2017. Production fell by 8.2% year-on-year to 6.2Mt in 2017 from 6.7Mt in 2016 and consumption fell by a similar amount. The change was blamed on reduced demand for building materials in the construction sector occurring at the same time as a fall in the value of building plans approved in 2017. The country also suffered political uncertainty as its general election in August 2017 was subsequently annulled and repeated in October 2017.

With Global Cement Directory 2018 data giving Kenya a cement production capacity of 5.2Mt/yr from five producers and at least four grinding plants with a capacity of 4.6Mt/yr it looks like the country is in an overcapacity phase. The question for producers like Bamburi Cement is whether 2017 is just a temporary blip or not. After all, as per usual for many African countries, the demographic pressure for development to happen and per capita cement consumption to grow seems ineveitable.

Bamburi Cement is not alone in betting on growth. Also this week the Kenya Port Authority recevied four hoppers from the UK’s Samson for the Port of Mombasa. The hoppers will be used to import clinker, coal and gypsum at the site. Earlier in February 2018, National Cement opened a 1.2Mt/yr integrated plant in Kajiado County. On the larger scale Nigeria’s Dangote Cement has been preparing to open two cement plants, near Nairobi and Mombasa respetively. However, these project were reported delayed to 2021 in its annual report for 2016 around the time the company faced problems at home due to a local financial recession.

Meanwhile local producers have faced pressure so far in 2018. Bamburi Cement reported a 6% fall in turnover to US$357m in 2017 that it blamed on the weather, the elections and lower construction activity. Other producers have had a harder time of it with the East African Portland Cement (EAPC) reportedly having to rely on a land sale to remain solvent in April 2018. ARM Cement has also been forced to sell assets to remain operational. Its loss for 2017 more than doubled to US$55m. Amid the problems the UK-government investor CDC Group, which holds a 41% stake in the company, replaced board members of the company in a likely bid to shore up the situation.

It’s into this kind of situation that Bamburi Cement has opened its new plant. On the plus side though it is a grinding plant so it should be able to maximise the company’s use of clinker from either within the country or from imports from other LafargeHolcim operations elsewhere. In its press release for the new unit the company pinned its hopes on anticipated growth in domestic housing and infrastructure projects, backed by government schemes for affordable housing and roads. With the rating agency Moody’s having issued a report this week about the relative reslilence of the Kenyan economy despite recent shocks such as last year’s elections, Bamburi Cement may yet have the last laugh.


Switzerland: LafargeHolcim has appointed Miljan Gutovic as the Head of Region Middle East Africa and a member of its executive committee of LafargeHolcim. He succeeds Saâd Sebbar, who has left the company.

Gutovic, aged 39 years, is an Australian national with over 13 years of experience in the building materials sector. He joined LafargeHolcim in 2018 as head of marketing and Innovation after working for Sika. At Sika he worked as an Area Manager for the Middle East as well as General Manager for Australia. He holds a Bachelor's degree in Civil Engineering and a PhD in Engineering from the University of Technology in Sydney.


India: Dalmia Cement (Bharat) has appointed Ujjwal Batria as its chief operating officer. Batria will be in charge of leading the company's sales, marketing, logistics, manufacturing, logistics, manufacturing and technical services departments, according to the Economic Times newspaper. He holds 33 years of industry experience with roles such as the chief executive officer (CEO) for Nuvoco Vistas (formerly Lafarge India) and positions at the cement divisions of Tata Steel and Century Textiles & Industries.


UAE: Raysut Cement has appointed Afzaal Qadri as the Plant Manager of its subsidiary Pioneer Cement Industries. Afzaal will report to Raysut’s chief executive officer (CEO) Joey Ghose. Qadri, aged 49 years, holds over 30 years of experience of the Cement Industry. He started his career in the cement industry in 1987 and has worked in various engineering and operational roles in the US, Saudi Arabia, UAE and Pakistan. Most recently he worked by HeidelbergCement in the US.


US: Ametek Brookfield has appointed Vicki Case as Global Marketing Director. She has spent the past 12 years working at Sealed Air in Saddle Brook, New Jersey. Most recently she worked as the VP Marketing, Global e-Commerce & Fulfillment Solutions for the company. Case is a graduate of the University of Michigan with a Bachelor of Science degree in Chemical Engineering.


Botswana: The Ministry of Investment, Trade and Industry plans to restrict imports of cement following the introduction of new legislation. It will require 70% of cement to be sourced from local producers with only 30% allowed to be imported, according to the Weekend Post newspaper. The Control of Goods, Prices and Other Charges Act was announced in April 2018. An import permit scheme is scheduled to start in September 2018. The new regulations are intended to regulate trade with South Africa better.


Nigeria: Dangote Cement has opened a terminal at Owerri in Imo State. The unit was officially inaugurated by the governor of the state, Chief Rochas Okorocha with the president of Dangote Group, Alhaji Aliko Dangote, also in attendance, according to the This Day newspaper. In a speech Dangote said that the state was one of the ‘major’ markets domestically for the company.


Argentina: Cement consumption rose by 7% year-on-year to 5.85Mt in the first half of 2018 from 5.49Mt in the same period in 2017. Data from the Asociación de Fabricantes de Cemento Portland (AFCP) also showed that despatches rose by 7% to 5.86Mt from 5.49Mt. However, both consumption and despatches for May and June 2018 fell.


US: Welding Alloys has released information about a project to rebuild a FCB Horomill at Buzzi Unicem’s Maryneal cement plant in Texas in early 2018. The engineering company’s Mexican subsidiary Welding Alloys Panamericana has experience of rebuilding these types of mills and it collaborated with the group’s American wing, Welding Alloys USA, on the project.


France/Italy: Chryso has signed an agreement to buy certain assets of Italy’s Ruredil, including its cement additives, concrete admixtures and technical mortars business divisions, but excluding the Rurmec brand. The cost of the acquisition has not been revealed. The transaction is expected to complete over the summer of 2018 subject to the satisfaction or waiver of customary conditions precedent.

“The combination of our operating businesses in Italy will provide a wider range of products to our customers, as well as improve our geographic coverage, enabling us to serve a greater number of building companies and cement and concrete manufacturers across Italy and abroad. The businesses will have strong offerings to answer the new technical challenges of the building industry,” said Thierry Bernard, president and chief executive officer of Chryso.

In Italy, Chryso operates as Chryso Italia, which was established in 1997. Its customers in the region include cement manufacturers, concrete producers and building companies. Ruredil is an Italian company, established in the 1950s. It manufactures chemicals and structural reinforcement systems, and owns well-recognised brands in the construction industry such as Ruredil and Levocell.


US: CRH has completed the sale of cement and ready-mix assets to Grupo Cementos de Chihuahua (GCC) following its acquisition of Ash Grove Cement. Ireland's biggest company sold the Trident cement plant in Montana to GCC for US$107.5m.

The move comes less than a month after CRH received regulatory approval from the US Federal Trade Commission to acquire cement manufacturer Ash Grove Cement for US$3.5bn in a deal first announced in September 2017.

As part of the transaction with GCC, CRH acquired most of the ready-mix plants and transportation assets belonging to GCC in Oklahoma and northwest Arkansas for US$118.5m. GCC will continue to own and operate four ready-mix plants in the Fort Smith, Arkansas area and own an office building in Tulsa, Oklahoma, which it will lease to CRH.
The purchase and sale amounts have been paid in full but are subject to final inventory valuation adjustments, which are expected to be completed within 90 days.


Peru: Domestic cement sales climbed by 8.25% in Peru in May 2018. They had grown by 8.17% in April 2018, according to figures released by the National Institute of Statistics.


Czech Republic: Lafarge Cement’s sales in Czechia increased by almost 7% to Euro38.2m in 2017 but its profit dropped by 25% to Euro5.9m, according to spokeswoman Milena Hucanova.

Czech construction registered only moderate growth in 2017, which was reflected in the company's sales. Operating profit was comparable with the level from 2016.
"The company's net profit was mainly as a consequence of changes in the volume and appraisal of inventories, higher consumption of carbon credits and the firming up of the Koruna / Euro (exchange) rate after the Czech National Bank’s interventions," said CFO Jan Mencl.

Investments by the company in 2018 are planned to amount to Euro3.8m. Hucanova said that half of this had already been spent on the conversion of an electrostatic precipitator to a baghouse at the company’s Čížkovice plant.


Kenya: Bamburi Cement has completed construction of a new US$40m production line at its grinding plant in Nairobi. The new unit will allow the company to start manufacturing two new high strength products that were previously only produced at its Mombasa plant, according to the Kenya Broadcasting Association. The new line increases the plant’s cement production capacity by 0.9Mt/yr to 2.4Mt/yr.


Sudan: Musa Mohamed Karama, the Minister of Industry, says that government is keen to remove all obstacles facing the cement industry including a block on exports. The announcement follows a meeting with Mohamed Abdullah, the UAE-based chairman of Berber Cement Company, according to the Sudan News Agency. The country’s cement production capacity exceeds its domestic consumption.


Colombia: Édgar Ramírez Martínez, the former vice president of planning for Cemex, will be detained in prison as part of an ongoing investigation into alleged irregularities in the acquisition of land at Maceo in Antioquia for the construction of a cement plant. The prosecutor’s court has also issued a detention ticket for Camilo González Téllez, former vice president of planning for Cemex Colombia, who is currently in the US, according to Noticias Financieras. Eugenio Correa Díaz, the former representative of CI Calizas y Minerales, which sold the property to the cement producer, will also be detained.

The former employees of Cemex allegedly paid over US$13m to Correa, despite being aware of the fact that the property was in the process of being expropriated over unpaid taxes.


Colombia: Cemex Colombia, LG and the mayor of Ibague say that they have started technical economic and legal studies studies to support building a solar plant near Ibague in Tolima. The unit will supply energy to the Caracolito cement plant and lighting systems in the nearby city, according to Valora Analitik. The solar plant will be located on a 56-hecatre site owned by the Mayor’s Office on the Doima - Buenos Aires highway.


India: The Supreme Court has ordered the National Company Law Appellate Tribunal (NCLAT) to adjudicate upon all issues relating to the Binani Cement insolvency case, including whether Ultratech Cement’s bid for the company is eligible. The case will be heard by the appeals tribunal from mid-July 2018, according to the Mint newspaper. The NCLAT is the body that processes appeals from the National Company Law Tribunal, a legal body that adjudicates disputes between companies.

UltraTech Cement made a direct bid of US$1.12bn for the bankrupt Binani Cement following an auction in March 2018 that was originally won by Dalmia Bharat. Dalmia Bharat has disputed UltraTech Cement’s offer and the two companies have conducted legal campaigns to reinforce their respective claims.


France/Syria: Lafarge SA, a subsidiary of LafargeHolcim, has been placed under judicial investigation over its actions in Syria between 2011 and 2014. It has been accused of complicity in crimes against humanity and financing terrorism, according to the Agence France Presse.

LafargeHolcim said that would appeal against the charges. It admitted that the system of supervision of its Syrian subsidiary did not allow the company to identify wrongdoing. However, it blamed this on “…an unprecedented violation of internal regulations and compliance rules by a small group of individuals who have left the group.”

“We truly regret what has happened in the Syria subsidiary and after learning about it took immediate and firm actions. None of the individuals put under investigation is today with the company,” said the chairman of the board of LafargeHolcim, Beat Hess.

Non-government organisation (NGO) Sherpa, one of the plaintiffs in the case, said it was the first time that a parent company anywhere in the world had been charged with complicity in crimes against humanity. A panel of three judges in Paris has ordered Lafarge to pay over Euro30m as a security deposit ahead of the trial. Eight former executives, including ex-chief executive officer (CEO) Bruno Lafont, have already been charged in connection to the investigation.


India: UltraTech Cement has commissioned a 1.75Mt/yr grinding unit at its Manawar plant in Dhar District, Madhya Pradesh. The main part of the 2.5Mt/yr integrated plant was commissioned in April 2018. A 13MW waste heat recovery unit is also being built at the site.


China: The city of Wuhu has suspended cement production for local producers for six days. Anhui Conch, South Cement and Leida Cement have all been affected, according to Hexun. Local production is expected to drop by 0.5Mt/yr.


Colombia: Cemex Colombia plans to grow its additives production to 9.7ML in 2018. The building materials producer says it is the only local manufacturer of producing aggregate, cement and additives, according to the La Republica newspaper. It produces additives to enhance the properties of cement and concrete. It also supplies additives to other companies with around 11% aimed at third parties in Latin America.


Switzerland: 2016 data published by the Cement Sustainability Initiative (CSI) from its Getting the Numbers Right (GNR) report shows no change in CO2 emissions in recent years. Gross specific CO2 emissions from cementitious products rose slightly from 2014 and net specific emissions have remained the same. However, the data shows considerable improvement since a baseline in 1990 with both metrics falling by over 15%.

Other notable figures from the latest report include an 11% year-on-year drop in clinker volumes to 606Mt in 2016 from 680Mt in 2015 and a 12% fall in cementitious volumes to 818Mt from 916Mt. Kiln fuel use, specific electricity use and the percentage of clinker in cement all rose slightly. However, the percentage of alternative fuels used increased to 16.7% from 15.9%.

The GNR report presents information on energy efficiency and CO2 emissions from the worldwide cement industry. Participants use the CSI CO2 and Energy Accounting and Reporting Standard for the Cement Industry to provide information and 80% of the data provided is independently assured. The report uses information from 849 cement manufacturing plants around the world, both integrated and cement grinding units, representing 19% of global cement production.


Kenya: Samson, a subsidiary of Aumund Group, has delivered four hoppers with ATEX certification to the Port of Mombasa operated by the Kenya Port Authority. The new equipment will be used to import clinker, coal and gypsum to the site. Peak rates of 700t/hr per hopper are expected to considerably improve the import capabilities of the port.

The hoppers are decked with inlet grills with suction capacity, a reverse-jet cleaning system, air compressors, a flex-flap filtration system creating a pressure differential between the inner and outer hopper areas and dust filters on three sides of the hopper. The hoppers are mobile with powered travel and crabbing functionality which lets them be positioned alongside a vessel for unloading and which will allow them to be manoeuvred off the quay and freeing up space when not required. Samson says that these are the first ecological hoppers to be provided with ATEX certification.

This equipment was sourced to fulfil the aims of TradeMark East Africa - Kenya Port Authority Port Resilient Infrastructure Programme to improve port facilities whilst minimising the environmental impact of port operations.


India: Shree Cement has commissioned the cement grinding mill at its Kodla cement plant in Karnataka. The mill has a cement production capacity of 3Mt/yr. The new integrated plant was proposed in early 2017 with a clinker production capacity of 2.8Mt/yr. It had an investment of US$260m and was scheduled to be completed by the end of 2018.


Philippines: Global Ferronickel is considering building a cement plant to take advantage of the government’s rapid infrastructure development programs.
Company president Dante Bravo said that its Cagdianao mine showed potential for limestone, according to the Philippine Star newspaper. The mining company is considering options to maximize the investment from its reserves.


Vietnam: Cement exports rose by 50% year-on-year to over 15Mt in the first half of 2018. Estimates from the Construction Materials Department of the Ministry of Construction shows that the country consumed 51.4Mt of cement, an increase of 25%, according to the Viet Nam News newspaper. Cement inventory was 3.1Mt or equivalent to 14 - 15 days of production. High local consumption has been attributed to good weather and growing exports have been attributed to a halt in cement production in a number of cities in China.


Nigeria: The Cement Company of Northern Nigeria (CCNN) plans to merge with Kalambaina Cement, a subsidiary of BUA Cement. CCNN operates a 0.5Mt/yr plant at Sokoto and Kalambaina Cement runs a 1.5Mt/yr plant, also in Sokoto state, according to the This Day newspaper. The merger is intended to improve CCNN’s competitiveness locally and take advantage of the newly-built Kalambaina Cement plant.