Global Cement Newsletter

Issue: GCW371 / 19 September 2018

Headlines


Nigerian financial analysts Cordros Securities concluded this week that the merger of some of Lafarge’s Sub-Saharan African businesses had reduced earnings at Lafarge Africa. The report is interesting because it explicitly points out a situation where the consolidation of some of Lafarge’s various companies have failed in the wake of the formation of LafargeHolcim.

Cordros Securities’ criticism is that Nigeria’s Lafarge WAPCO performed better in 2013 alone before it became part of Lafarge Africa, with a higher standalone earnings before interest, taxation, depreciation and amortisation (EBITDA) margin. Lafarge Africa formed in 2014, a year before the LafargeHolcim merger was completed, through the consolidation of Lafarge South Africa, United Cement Company of Nigeria, Ashakacem and Atlas Cement into Lafarge WAPCO. Since the formation of Lafarge Africa, Cordros maintains that its earnings per share have consistently fallen, its share price has dropped, its debt has risen, its margins have decreased and its sales volumes of cement have also withered.

Cordros mainly focuses on the Nigerian parts of Lafarge Africa’s business, given its interest in that market and the fact that about three quarters of the company is based in the country. It blames the current situation on growing operating costs since the merger, skyrocketing financing costs for debts and efficiency issues. In Nigeria, Lafarge Africa has had to cope with disruptions to gas supplies. Nigeria’s Dangote Cement had similar problems domestically in 2017 with falling cement sales volumes in a market reeling from an economic recession but Cordros reckoned that Dangote is picking up market share in the South West due to an ‘aggressive retail penetration’ strategy. Finally, Lafarge Africa faced a US$9m impairment in 2017 due to its abandoned pre-heater upgrade project at AshakaCem. The project has been suspended since 2009 due to security concerns in the North-East region. The plant faced an attack by the Boko Haram militant group in 2014 and the group has seemed reluctant to invest further in the site subsequently.

Cordros’ final word on the matter is that with the Nigerian cement market performing slower than it has previously, the local market has become a battleground between the established players of Dangote Cement, BUA Group and Lafarge Africa. What little the report does have on South Africa covers problems with old and inefficient hardware, labour disputes, low prices due to weak demand, high competition and a negative product mix.

Lafarge Africa itself presents a more mixed picture, with market growth picking up in Nigeria following end of the recession but continued market problems in South Africa. Overall, its reported sales grew by 4.8% to US$448m in the first half of 2018 but its EBITDA fell by 25% to US$76.4m. Overall cement sales volumes were reported as up by 5.4% to 2.6Mt in the first half but volumes were still falling in South Africa in the second quarter.

Part of the backdrop to all of this is the intention of Lafarge Africa to cut its debt. In May 2018 its chairman Mobolaji Balogun said that the company wanted to cut its debts by 2020 before continuing with its expansion programme. Part of this process will include a new rights issue later in 2018 to allow shareholders to buy stock at a discount.

It must have made sense, on paper at least, to merge the Lafarge subsidiaries in the two largest economies in Sub-Saharan Africa. Once the merger had settled in, with synergies generating extra revenue, the group could have considered adding extra territories such as Kenya. However, it’s not turned out like that. Two recessions in Nigeria and South Africa respectively, old equipment, debt and serious competition from locally owned producers have piled on the pressure instead. From a stockholder perspective, Cordros is not impressed by the performance of Lafarge Africa. The wider question is: what else did Lafarge and Holcim get wrong when they joined to form LafargeHolcim?


Sweden: Cementa has appointed Jenny Larsson as the district manager for its south region. She succeeds Lars-Åke Andersson, who has held the role for 20 years. Andersson will retire in the spring of 2019 and the pair will work together until this time.


UK: Cemex is planning to restart commercial production on the second kiln at its South Ferriby cement plant in November 2018. The company says that this investment highlights its confidence in the long-term potential of the UK building materials market.

The kiln has a capacity of 1000t/day and was originally installed in 1973. Since then the cement producer has conducted upgrade work on the production line to comply with environmental legislation and to install new electrical infrastructure, a control system and instrumentation. The second kiln was previously the first Cemex line in the world to achieve a 100% alternative fuel substitution rate in 2011. Once fully operational both kilns at the plant will give it a production capacity of 0.7Mt/yr.


UK: The planning department of East Lothian Council in Scotland has granted planning permission to an upgrade of Tarmac’s Dunbar cement plant. The work will include building a new cement grinding mill, a new cement storage silo and a rail loading facility. The work will also include a shed, belt conveyors pneumatic pipelines and associated works.

In its supporting statement the company said that the new cement mill was necessary to produce new grades of cement required for modern construction and the cement market. The proposed mill will replace two existing mills on the site and is intended to be more energy efficient and quieter than the existing mills. It added that the plant would benefits from rail sidings on both the south and north side of the East Coast Mainline railway line. At present trains are fed only on the south side using adjacent silos where train capacity is already fully used. Additional products are exported by road.


Ukraine: Ukrcement, the Ukrainian cement association, has found in a study that over 80% of cement with the wrong labelling was counterfeit. The research was conducted on 50 cement bags for the consumer market, according to Interfax. 82% of cement proved to be counterfeit, over 50% of the samples were below the declared weight and 56% had weaker strength and did not comply with the В.2.7-46 -2010 national standard for minimum compressive strength.

The association said that the risks of using counterfeit cement vary from loss of time and revenue in smaller projects to a direct threat to human life in larger projects such as high-rise buildings. Local regulations require that cement bags include five items: the name of the producer, the conventional designation of cement, the designation of the normative document, the net weight and a conformity mark.


South Korea: Ssangyong Cement has launched what it says is the world’s largest waste heat recovery unit at its Donghae plant in Gangwon. The 43.5MWh unit had a budget of US$889m and was originally planned to 2016, according to the
Maeil Business Newspaper. 11 boilers plus turbines and cooling towers have been installed on six cement kilns at the site. The new system will also work in conjunction with an energy storage system (ESS) that was installed in April 2017.


Republic of Congo: Cement producers have expressed concerns about government plans to increase Value Added Tax (VAT) on cement to 18% from 5%. Cement prices are expected to rise as manufacturers pass the extra cost on to consumers, according to the Central African Information Agency. An industry source quoted by the agency said that local cement plants are doing badly due to a capacity utilisation rate of 10 – 20%. The country has five cement plants with a production capacity of 3.2Mt/yr but cement consumption was only 0.7Mt in 2017.


Kenya: The Mombasa county government has ordered the closure of a clinker storage plant run by Corrugated Sheets due to the accusation that is has emitted large amounts of dust. Stephen Wambua, the head of the National Environment Management Authority (Nema) in Mombasa said that operations at the Mikindani-based unit had been stopped and would not resume until it was in full compliance with environmental regulations, according to the Business Daily newspaper. The closure followed complaints by local residents.

Wambua said that imported clinker via the Port of Mombasa is stored in a number of premises locally. Dust is emitted during loading and offloading of consignments. Nema is also investigating claims that other companies are storing ‘toxic’ materials in the Jomvu area. In August 2018 the Kenya Star newspaper linked the Corrugated Sheets site to widespread respiratory illness in the local neighbourhood, including some suspected fatalities since clinker storage started in 2010.


Nigeria: Dangote Cement has formally launched BlocMaster Cement product in Kano. The new cement product is described as ‘extra strong’ and targeted at block moulders, according to the Vanguard newspaper. At the official launch event Joe Makoju, the group managing director of Dangote Cement, said the new brand had followed ‘years’ of research and that it had been tested and approved by builders in the country.


Pakistan: Maple Leaf Cement’s profits have fallen due to mounting costs of goods. Its profit after taxation fell by 4% year-on-year to US$37m in the year to 30 June 2018 from US$39m in the same period in 2017. Despite this its sales rose by 7.5% to US$208m from US$194m. The cement producer added that it had approved a US$8.1m loan to its holding company Kohinoor Textile Mills to meet ‘working capital requirements.’


Vietnam: Tan Thang Cement has ordered additional integrated digital automation and electrical equipment from Switzerland’s ABB for a new 2Mt/yr plant it is building in Nghe An province. The order is a follow- up order to the initial automation and electrical systems delivery from ABB for this site, which is currently under construction.

The follow-up order includes a 110kV AIS Substation (Air Insulated Substation), with a SCADA (Supervisory Control and Data Acquisition) system based on ABB Ability System 800xA for Power Control, as well as telecommunications, and High Voltage primary and secondary equipment to support the electrical infrastructure. ABB will also deliver power transformers, distribution transformers, an Intelligent Motor Control Centre, Auxiliary Control Centre, Emergency Diesel Generator, DC power supply, various field devices and related commissioning services.

ABB’s initial delivery included ABB Ability System 800xA DCS (Distributed Control System) to integrate control, electrical and communication systems for optimal visibility into all processes for stable production and efficient use of raw materials and energy. It also included ABB Ability Knowledge Manager and Expert Optimizer software, as well as basic communication and electrical system infrastructure and equipment.

The project is scheduled to be commissioned in late 2019.


US/China: The Office of the US Trade Representative has started implementing a 10% tariff on mineral and other products from China, including cement, following a consultation period. Mineral products affected by the proposed tariffs of interest to the cement industry include limestone flux, quicklime, slaked lime, gypsum, anhydrite, clinkers of Portland, aluminous, slag, supersulphate and similar hydraulic cements, white Portland cement, Portland cement, aluminous cement, slag cement, refractory cements, additives for cement, cement based building materials and more.

The latest tariff list follows an earlier decision by the US government to tax imports from China worth US$34bn that came into force in early July 2018.


Germany: Environmental data from the German Cement Works Association (VDZ) show that average nitrogen dioxide emissions (NO2) from cement production dropped below 300mg/Nm³ in 2017. The value has more than halved since 2000. Other data from the ‘Environmental Data of the German Cement Industry 2017’ report shows that fossil fuels usage by the cement industry fell to 35% in 2017 compared to 45.6% in 2008.

"By consistently promoting the development of clinker-efficient cements, German cement manufacturers are noticeably reducing the carbon footprint as compared to traditional Portland cements," said VDZ President Christian Knell.

Knell also warned that the costs of carbon capture technologies should not be allowed to jeopardise the competitiveness of domestic cement manufacturers and give rise to ‘undesirable’ carbon leakage effects. The industry is currently researching methods to further reduce CO2 emissions such as carbon capture, storage and utilisation techniques, but it is dependent on external financing.

18 German cement manufacturers with a total of 46 cement plants are members of the VDZ. The local industry employs around 8000 people.


Kazakhstan: Steppe Cement’s sales revenue rose by 22% year-on-year to US$32.8m in the first half of 2018 from US$26.8m in the same period in 2017. The cement producer said that the local market grew by 5% and that it had increased its market share to 15.5% from 14.5%. Its sales volumes grew by 14% to 0.74Mt from 0.65Mt. It reported that its selling expense increased as sales in the south and exports grew ‘significantly.’

The company noted that the local market is expected to be 9Mt in 2018, a figure similar to 2017. Construction was reported ‘strong’ in the west and south of the country. Imports in the country have increased by 30% so far in 2018 to 0.34Mt. Exports increased to 0.92Mt from 0.45Mt due to demand from Uzbekistan.


Philippines: San Miguel Northern Cement has ordered two mills from Germany’s Loesche for a new 5000t/day production line at its Sison plant in Pangasinan. The scope of supply includes two complete grinding plants: a type LM 56.4 mill for cement raw material and a type LM 35.3 D for sub-bituminous coal.

Loesche will supply a majority of the electro-technical components for the line and the automation systems including its LM Master product. It will be responsible for the plant engineering and the supply of filters and blowers. The new line will use also A-Tec’s Hurriclon technology for de-dusting the raw mills.

Delivery of the order is scheduled for the start of 2019.


Finland: Metso is celebrating its 150th anniversary with a photo exhibition illustrating how the company has taken part in shaping and building the modern world. Interim chief executive officer (CEO) and chief financial officer (CFO) Eeva Sipilä will open the event on 18 September 2018 at Sanoma House in Helsinki. The exhibition will be open to the public until the end of September 2018.

The company was first established in 1868 when Erik Jan Hammarberg set up the Sunds Bruk ironworks in Sweden. As the business developed its products and services widened and its ownership changed. In 1991, the operations become part of Rauma-Repola. Rauma then merged with Valmet in 1999 to form Metso. At present the company operates in more than 50 countries and over 12,000 staff. It serves the mining, aggregates, recycling and process industries.

A central part of the company’s focus includes aggregates and minerals processing. Key parts of Metso’s development in this area include the creation of the Nordberg Manufacturing Company in 1886 by Bruno Nordberg, a Finnish migrant who settled in Michigan in the US and produced some of the first crushing equipment for mines. In 1928, Nordberg acquired Symons cone crusher technology. Bergeaud & Bruno was established in France in 1895 to manufacture crushing equipment, and in Tampere, Finland, Lokomo produced its first jaw crushers at the beginning of the 1920s. Each of these companies and their products continue to the present day as products offered by Metso.


Nigeria: Financial analysts Cordros Securities have blamed falling earnings at Lafarge Africa on the merger of its Nigerian businesses with Lafarge South Africa. In a research report the analysts found that the merger increased operating costs and reduced shareholder value, according to the Vanguard newspaper. Lafarge WAPCO’s earnings per share, earnings before interest, taxation, depreciation and amortisation (EBITDA) and profit before tax have all fallen since 2013. It also found that operating costs had increased ‘significantly’ following the merger, debt had risen and that earnings had also been hit by efficiency issues.

Lafarge announced plants to merge its businesses in Nigeria and South Africa in 2014. The move saw the consolidation of Lafarge South Africa, United Cement Company of Nigeria, Ashakacem and Atlas Cement to Lafarge WAPCO. It was subsequently renamed Lafarge Africa.


Taiwan/Turkey: Taiwan Cement and Turkey’s Sanko Holding have signed a memorandum of understanding and a confidentiality clause about the company’s plan to invest in Sanko’s cement business. Taiwan Cement said it would continue talks with the Turkish business group about a strategic partnership and would make details public once the parties sign a definitive contract, according to the Taipei Times newspaper. The cooperation agreement was first announced in June 2018.


India: Bharathi Cement has launched its BharathiUltraFast product for the market in Karnataka. The OPC 53 cement product promises faster pre-casting work, even in humid conditions, high early strength and a low heat of hydration to minimise crack formation.

The cement producer is a subsidiary of Vicat. The French company acquired a 51% stake in Bharathi Cement in 2010. It also owns Kalburgi Cement, formerly known as Vicat Sagar Cement. Bharathi Cement operates a 5Mt/yr integrated plant at Nallalingayapalli in Kadapa district of Andhra Pradesh and Kalburgi Cement runs a 2.75Mt/yr plant at Chatrasala in Kalaburagi district of Karnataka. Both plants market their products under the brand name ‘Bharathi Cement.’


Pakistan: Thatta Cement’s standalone sales fell by 22% US$23.1m in the financial year to 30 June 2018 from US$29.7m in the same period in 2017. Its gross profit fell by 35% to US$6.1m from US$9.4m. Its profit for the year fell by 39% to US$2.9m from US$4.7m.


Zimbabwe: Lafarge Zimbabwe says that it is able to supply the market with cement following a shortage. In a statement the subsidiary of LafargeHolcim said that the recent surge in demand was ‘temporary’ and that, overall, the situation was a ‘positive signal of economic growth,’ according to the Chronicle newspaper. It said that the situation might be attributable to a rise in mortgage finance as well as improved disposable income following a successful tobacco and maize farming season on the back of the Command Agriculture Programme.

Cement prices have reportedly risen by over 50% due to the shortage. Producers have blamed her situation on technical problems following maintenance works at their plants. They have also ruled out any further increases in prices. Despite the cement shortage they have warned against trading cement on the black market.


Chad: Morocco’s Ciments de l’Afrique (CIMAF) has launched commercial operations at its new 0.5Mt/yr grinding plant at Lamadji. CIMAF regional director Hatim Kahttabi said that the production capcity of the unit is expandable to 1Mt/yr, according to Alwihda. The project had an investment of Euro35m and it has created 200 jobs.


Tanzania: The State Mining Corporation (Stamico) has assured cement producers that it holds sufficient coal supplies. It said that 18,600t/month of coal is being produced every month at its mine at Kabuko in Songwe, according to the Citizen newspaper. It intends to increase production to 45,000t/month when demand is ‘high’ and then to later raise production to 60,000t/month when it fixes infrastructure bottlenecks.

In August 2018 cement producers reported that they faced coal shortages. Subsequently, cement prices rose.


Cyprus: Vassiliko Cement has presented a new low hydration heat cement product, Portland Pozzolana Cement CEM II/A-P 42,5N-LH, to local clients. The new product will be launched in early October 2018. It will be targeted at larger construction projects, such as footing or dams, where the company says it will prevent the formation of micro-cracks in concrete.


Spain: FYM-HeidelbergCement has reached a record two years without an accident at its Malaga cement plant. The milestone also includes no accidents for subcontractors working at the site. The company has operated a ‘Zero Accident’ program since 2000 that has focused on improving the safety culture for all staff.