Global Cement Newsletter

Issue: GCW430 / 06 November 2019

Headlines


Semen Indonesia’s third quarter results this week give us a reason to look at one of the world’s largest cement producing countries, Indonesia. As the local market leader, Semen Indonesia’s financial results have been positive so far in 2019 following its acquisition of Holcim Indonesia at the start of the year. Analysts at Fitch noted that gross margins for Semen Indonesia and its rival Indocement grew in the first half of 2019 as coal prices fell and cement sales prices rose.

Sales volumes, however tell a story of local production overcapacity and a move to exports. Domestic sales volumes fell by 2.05% year-on-year to 48.8Mt in the first nine months of 2019. Cement and clinker exports nearly compensated for this by rising by 15.4% to 4.8Mt. This is brisk growth but slower than the explosion of exports in 2018. Semen Indonesia’s local sales from its company before the acquisition fell faster than the national rate at 4.9% to 18.7Mt. The new sales from Solusi Bangun, the new name for Holcim Indonesia, partially alleviated this. It’s been a similar story for HeidelbergCement’s Indocement. Its sales revenue and income have risen so far in 2019. At the mid-year mark its sales volumes fell by 2.3% year-on-year to 29.4Mt.

Graph 1: Indonesian cement sales, January – September 2019. Source: Semen Indonesia. 

Graph 1: Indonesian cement sales, January – September 2019. Source: Semen Indonesia.

Geographically, Indonesia Cement Association (ASI) data shows that over half of the country’s sales volumes (56%) were in Java in the first half of 2018. This was followed by Sumatra (22%), Sulawesi (8%), Kalimantan (also known as Indonesian Borneo, 6%), Bali-Nusa Tenggara (6%) and Maluku-Papua (2%). By cement type the market is dominated by bagged cement sales. It constituted 74% of sales in September 2019. The main producers have been keen to point out growth in bulk sales as its share has increased over the last decade.

Graph 2: Indonesian cement sales by type, 2010 – 2019. Source: Semen Indonesia/Indonesia Cement Association. 

Graph 2: Indonesian cement sales by type, 2010 – 2019. Source: Semen Indonesia/Indonesia Cement Association.

Previously the main story from the Indonesian market has been one of overcapacity and this has continued. It had a utilisation rate of 70% in 2018 from production volumes of 75.1Mt and a capacity of 110Mt, according to ASI data. This was likely to have been a major consideration in LafargeHolcim’s decision to leave the country and South-East Asia (see GCW379) with no end in sight to the situation in the short to medium term. At the end of 2018 it felt like consolidation was in progress following this sale and the reported sale of Semen Panasia. So far though this has been all and perhaps the upturn in the second quarter might buy the producers more time.

As mentioned at the start, another aspect of the Indonesian market deserving comment is that it is one of the first countries with a large cement sector where a Chinese company has made a significant entry. Conch Cement Indonesia, a subsidiary of China’s Anhui Conch, became the third largest producer following the acquisition of Holcim Indonesia. Semen Indonesia and Indocement control 70% of local installed capacity across both integrated and grinding plants with 51Mt/yr and 25.5Mt/yr respectively.

Conch Cement Indonesia is the next biggest with 8.7Mt from three integrated plants and a grinding unit. It’s in a tranche of three smaller producers locally, along with Semen Merah Putih and Semen Bosowa. Fitch also picked up on this in a research report on the cement sector published in August 2019. It pointed out that, although Holcim Indonesia and Indocement had gained pricing power through their leading market share, this is being eroded by local producers owned by Chinese companies.

Depending on how you look at it, Indonesia has the ‘fortune’ to be only the second largest producer in South-East Asia, after Vietnam. China, the world’s largest producer, is not too far away either. As can be seen above this can be a mixed blessing for local producers as the market changes. Overcapacity abounds, a major multinational has moved out, a local firm has consolidated the market as a result and Chinese influence grows steadily. Indonesia could well be an example of things to come for other markets.


China: Huang Ting has ceased to be the chief financial officer (CFO) of China Resources Cement. He will remain as the company’s vice president and has been reassigned as chief procurement officer.

Duan Wanli, the general manager of finance department of the company will take on the duties of the CFO role on a temporary basis. She joined the finance department of the China Resources Cement in 2014. She holds a Master’s degree in accounting from the Macquarie University in Australia and is a member of CPA Australia.


Germany/UK: Pietro de Michieli, the managing director at Aumund Fördertechnik, has taken over the chair for Equipment Design and Infrastructure at the Port Equipment Manufacturers Association (PEMA) in the UK. In February 2019 he became the Vice Chairman of the Safety and Environment Committee at PEMA.

“I’m delighted to chair PEMA’s Equipment Design and Infrastructure Committee. I have an excellent contact network of people across a number of segments, so I offer an open window to different sectors. I have most experience in bulk handling – one of the sectors where PEMA is now attracting members. This is vital if we are to advance PEMA’s work on building the mutual exchange of information and learning best practice from across different sectors,” said de Michieli.


UK: Hanson has appointed Rick Green as the managing director of its Leicestershire-based asphalt and quarrying business MQP (Midland Quarry Products). He moves from his role as managing director of Hanson Contracting to replace Dave Bagshaw, who has retired after 39 years in the industry. Green has also been chair of the Asphalt Industry Alliance (AIA) since 2017. The AIA was established in 2000 and is a partnership between the Mineral Products Association (MPA) and Eurobitume UK.

MQP consists of three quarries and 10 asphalt plants located across the Midlands. It was operated as a joint venture with Tarmac until 2013, when Hanson wholly acquired the company.


India: JK Cement is awaiting environmental clearance to commence construction of a 2.0Mt/yr grinding plant at Aligarh in Uttar Pradesh. The project has been valued at US$37.5m. Domex has reported that FLSmidth is in the process supplying machinery to the facility, for which civil work has been completed. Its 2.0Mt/yr Ordinary Portland and Portland Pozzolana Cement production capacity will bring JK Cement’s installed capacity to 12.9Mt/yr. It already grinds 3.0Mt/yr of clinker at its Mudhol grinding plant near Bagalkot in Karnataka.


France: Vicat has sold Euro2.06bn-worth of cement in the nine months to 30 September 2019, up by 5.7% year-on-year from Euro1.95bn in the corresponding period of 2018. Its cement section’s sales lagged behind concrete and aggregates, with a rise of 4.5% to Euro991m from Euro948m in the nine months to 30 September 2018. “The Group’s strategy of raising prices is paying off in almost all operating regions, while energy costs fell,” said Vicat Group Chairman and CEO Guy Sidos. He expects exchange rate gains to pay dividends in the final quarter, notably in Turkey.


UK: A fire broke out at Cemex’s 1.8Mt/yr integrated Rugby plant at 02:00 on 6 November 2019. BBC News has reported that operations were unaffected and none of the plant’s 180 employees injured by the fire, which was caused by a mechanical malfunction in a machine belt conveying raw materials. The fire spread over three floors of the plant’s preheater tower.


Thailand: Siam Cement Group (SCG) has announced its involvement in the establishment of an innovation hub at the National Science and Development Agency in Pathum Thai. The Bangkok Post has reported that the development will cost US$14.3m. SCG’s partner for the project is the Chinese Academy of Sciences, a 100-site, 70,000-member body established under the Chinese Government’s Belt and Road foreign investment Initiative. When operational, it will market new products, initially consisting of petrochemicals, energy storage and batteries and smart cities.

High-value-added products and services made up 39% of SCG’s total sales in 2018 of US$15.7bn (US$6.11). It spent US$0.15bn on research and innovation over the period, around 1.0% of total revenue.


Nigeria: Abia Cement, Russian-based Drobmash and Energomotor and Czech-based PSP Engineering signed a memorandum of understanding for construction of a 2.0Mt/yr integrated cement plant in Abia province at the first Russia-Africa Summit on 2 November 2019. The latter companies will supply equipment to the development, while Abia cement will receive an export loan from Russia’s Roseximbank.


India: Tamil Nadu Cement has constructed a second 1.0Mt/yr production line at its 0.7Mt/yr Ariyalur cement plant, bringing its total capacity to 1.7Mt/yr. Projects Today has reported that Tamil Nadu Cement, which also operates a 0.4Mt/yr integrated cement plant in Alangulam, will employ 250 at the second line, the development of which will cost US$115m. In the 12 months to 31 March 2019, Tamil Nadu Cement sold 74% of cement produced at its plants (0.4Mt) to the Rural Development Agency and other government departments at lower than market rate.


Jordan: 21.8% state-owned Jordan Cement, 50.3% subsidiary of LafargeHolcim, has laid off 200 of its 550 employees after incurring losses of US$87m in the nine months to 30 September 2019. Reuters has reported that the company, whose 2018 losses were US$48.9m, up by 4.0% year-on-year from US$47.0m in 2017, made the sackings ‘to ensure its continuity,’ according to Jordan Cement CEO Samaan Samaan. The company has operated a single line at its 2.0Mt/yr integrated Rashadiyah cement plant since the closure of its 2.0Mt/yr Fuhais plant in 2013. The country’s 9Mt/yr-capacity cement sector serves a domestic demand of 4Mt/yr.


USA: Cemex USA’s 0.9Mt/yr integrated Clinchfield cement plant has received a Sentinels of Safety Award from the National Mining Association, National Institute of Occupational Safety and Health, US Department of the Interior Office of Surface Mining, Reclamation and Enforcement and Bureau of Land Management for safety and environmental stewardship at its associated quarry. PR Newswire has reported that the plant and quarry operated for a total of 200,000 hours in 2018 without any employee sustaining a lost-time injury (LTI). Cemex USA president Jaime Muguiro said “Our Clinchfield operations serve as a strong example of what we can accomplish with safety as a number one priority.”


Germany: Siemens has announced what it calls a ‘plant lifetime-increasing’ Simotics HV M slipring motor for mills, crushers, conveyors or fans. The 4.5MW motor fills the gap in Siemens’ slipring range with powers between 0.5MW and 8.2MW. The product uses Global Vacuum Impregnation Technology to increase reliability, giving maximum plant reliability. Siemens Large Drives Applications CEO Hermann Kleinod said “The motors can be easily integrated using 3D-model data.”


Indonesia: Semen Indonesia has reported revenues of US$2.00bn in the nine months to 30 September 2019, up by 31% from US$1.53bn in the corresponding period of 2018. The Group’s acquisition of Holcim Indonesia in February 2019 expanded its domestic cement production capacity to 39.4Mt/yr, which it says has bolstered its competetiveness against importers in a crowded domestic market.

The company recorded US$91.7m in profit over the period, down by 38% year-on-year from US$148m as its foreign sections failed to grow.


Ireland: CRH has concluded a deal with an unspecified party for the sale of CRH Europe Distribution for Euro1.64bn. The Financial Times reported in July 2019 that private equity funds managed by American-based Blackstone would buy the company’s European distribution division. CRH will reportedly use the proceeds of sale for future acquisitions including its own share buyback programme.


Pakistan: The All Pakistan Cement Manufacturers’ Association has released figures showing a total cement output of 4.98Mt in October 2019, up by 9.2% from 4.56Mt in October 2018. Business Recorder recorded that this is a national record for monthly despatches; the second month of growth following year-on-year falls in July and August 2019. Exports continued to rise, to 0.79Mt, up by 28% from 0.62Mt in October 2018.


UK: The Mayor of London visited Mexican-based Cemex’s Stepney readymix concrete plant to launch a road safety initiative along with Transport for London (TfL) and London Councils. The initiative consists of a ratings scheme of up to five stars for in-cabin vision for heavy goods vehicles (HGVs), with a ban on zero-star vehicles inside of Greater London. The regulation comes into effect in November 2020, before which time HGV operators may install a ‘Safe System’ consisting of sensors and noise alerts, in order to apply for a Safety Permit to keep their vehicles on the roads.


Nigeria: Over a nine-month period to 30 September 2019 in which Dangote Cement increased its volumes by 1.1% to 18.0Mt from 17.8Mt in the corresponding period of 2018, earnings before interest, taxes, depreciation and amortisation (EBITDA) for Africa’s largest cement producer fell by 1.6% year-on-year to US$0.84bn from US$0.85bn. Group CEO Joe Makoju noted a year-on-year 0.6% increase in Nigerian volumes to 10.8Mt from 1.07Mt, as well growth in Tanzania and good sales in Senegal, as helping to offset ‘economic and operating challenges in key territories such as Ethiopia and South Africa.’

Dangote identified its Seven Sustainability Pillars for management as enabling it to realise its commitment to increasing value for all stakeholders. This may have contributed to its ranking second in Sub-Saharan Africa in Forbes’ Global 2000 World’s Best Employers.


Colombia: Empresa Colombiana de Cementos (EcoCementos), a 50-50 joint venture between Colombian multinational Organizacion Corona and Spanish-based Cementos Molins, has announced the start of production at its new 1.5Mt/yr integrated cement plant at Sonson, Antioquia province. The plant, which was constructed with an investment of US$380m, mines limestone from its own quarry and will produce Alion brand cement for the Colombian market. The unit is increases Cementos Molins’ first in Columbia. It already produces and trades cement via its subsidiaries in Argentina, Bolivia and Uruguay.


Cameroon: The Chinese-based Afcham China National Consortium Material Company has signed a memorandum with the Kribi Industrial Cement Plant Company (CmIKri) for the construction of an integrated cement plant with a capacity of over 0.5Mt/yr, and the possibility of an extension to 1.5Mt/yr, in the port of Kribi. The installation, spanning 30ha, will include shipping facilities and an 18,000t clinker silo, and cost US$60m.


Spain: Cementos Molins’ nine-month income rose by 8.0% year-on-year to Euro594m from Euro550m in the corresponding period of 2018. Its earnings before interest, taxes, depreciation and amortisation (EBITDA) rose by 6.3%. Its South American subsidiaries’ sales and EBITDA outstripped those in other regions. The company’s consolidated net profit for the period rose by 9.7% to Euro70.2m from Euro64.0m in 2018.


Nigeria: Obu Cement and Cement Company of Northern Nigeria (CCNN), both subsidiaries of BUA Group, are set to merge. Abdul Samad Rabiu, founder and executive chairman of BUA Group, said that the merger ‘marks the culmination of the first phase of the BUA mid-term strategic plan,’ which aims at deepening the domestic cement market and enhancing industry growth.

Rabiu stated that the completion of the 3Mt/yr integrated Sokota Kalambaina II cement plant and a 48MW power station, construction of which began in 2018, has been scheduled for the second half of 2020. In addition to its four existing plants, this will bring the group’s total integrated cement production capacity to 11Mt/yr.


Russia: 577 Gornozavodskcement employees became unemployed in the six months to 30 June 2019. 87 resigned, 195 retired and 295 left by agreement with the company. This follows South Ural Mining and Processing’s takeover of the struggling cement producer in December 2018. Kommersant has reported that the liquidation of auxiliary departments is a part of unit optimisation which extends to the company’s facilities, with the site of a planned dry line at its 2.2Mt/yr (wet) integrated Perm cement plant being used for parking. Wages have reportedly risen for the remaining three quarters of the Gornozavodskcement’s original staff.


Nigeria: Dangote Cement has extended its services agreement with US-based General Electric to the implementation of asset performance management (APM) digital products at its 12.5Mt/yr integrated Obajana cement plant and 12Mt/yr integrated Ibese cement plant, with the aim of unplanned downtime reduction. Dangote operations director Ravi Sood said that “Operational performance is crucial to a plant’s overall productivity, directly affecting end products. The introduction of GE’s latest digital solutions will improve efficiency and enable us to become more self-sufficient in power generation.”