Global Cement Newsletter

Issue: GCW478 / 21 October 2020

Headlines


Ed Sullivan was present to tell Global Cement Live viewers about the Portland Cement Association’s (PCA) autumn forecast last week. The PCA expects US cement consumption to drop by 1.5% year-on-year on 2020. This is a weighted average of its three projections, which cover a gradual recovery from coronavirus-related economic disruption, a less controlled scenario and one where wide-spread vaccination has a positive effect in the second half of 2021. The first scenario is the PCA Market Intelligence’s most likely one but only the fast vaccination scenario predicts a return to growth in 2021. This is wide but understandable deviation from the PCA’s autumn forecast in 2019 that expected moderate growth albeit a slowly weakening economy. Almost nobody seriously expected 2020 to turn out like it has. Follow the link at the bottom of this article to view the presentation in full.

Graph 1: Portland & Blended Cement shipments by US region in 2019 and 2020. Source: United States Geological Survey (USGS).

Graph 1: Portland & Blended Cement shipments by US region in 2019 and 2020. Source: United States Geological Survey (USGS).

We’ll now take a general look at the US cement industry so far in 2020 to compliment Sullivan’s economic overview. Up until 2020 cement consumption, production and imports had been growing steadily since the financial crash in 2008. Using August 2020 data the PCA says this is changing. Graph 1 above shows a general reverse of the position in the autumn of 2019 [LINK] with declines in the South and North-East and growth in the West and Midwest. Imports alongside this have continued to build. Overall, national cement shipments increased by 2.2% year-on-year to just under 50Mt in January to July 2020 from 48.9Mt in the same period in 2019. This was driven by growth of 10.8% in the Midwest. Missouri is the standout in the region, behind only Texas and California nationally as the third biggest cement shipping state so far in 2020.
From the corporate side, LafargeHolcim, the US’ biggest cement producer, described North America as having, “…the most resilience of all regions despite Covid-19 restrictions in some areas.” It reported an overall fall in cement volumes of 1.4% year-on-year to 8.9Mt in the first half of 2020. However, it didn’t go into specifics for the US. Cemex’s experience seemed to be doing better with an 8% rise in cement volumes supported by the infrastructure and residential sectors. HeidelbergCement went further and described the impact of coronavirus on the US economy as ‘significant.’ It reported a decrease in cement deliveries at its North American plants of 4.9%, to 7.1Mt. Both Buzzi Unicem and CRH reported cement sales growth of 4 – 5%, with CRH noting that, “strong volume trends in West supported by growth in our downstream businesses drove performance.”

Perusing the industry news reveals a slew of environmental stories. So far in 2020, Holcim US said it was going to run a carbon capture and storage (CCS) study at its Portland cement plant in Colorado, Alamo Cement signed a deal to build a solar farm, Grupo Cementos de Chihuahua’s (GCC) Rapid City plant in South Dakota announced plans for a wind farm, CalPortland launched a sustainable product line with a lower clinker factor, LafargeHolcim launched its ECOPact low-carbon concrete range, LafargeHolcim US also said it was adopting new environmental product declarations and Holcim US opened a solar power plant at its Hagerstown cement plant. There have been a few upgrade stories, like the new line being built at National Cement’s Ragland plant in Alabama or Lhoist’s new lime kiln projects, but Lehigh Hanson said it was suspending work on the upgrade to its Mitchell plant in Indiana in April 2020.

At this point all eyes are on the US Presidential election scheduled to run on 3 November 2020. Donald Trump’s long promised but never delivered infrastructure still hasn’t arrived although blame could be apportioned to both sides of the local political divide for this. The PCA believes that both presidential candidates will probably see it through although the Republicans’ interpretation might well involve more cement! In the interest of balance though, it also expects the Democrats to focus on low-income housing construction. At this stage it seems more likely that the early arrival of a coronavirus vaccine will have more impact on the cement industry in the short to medium term than the results of the election.

View Ed Sullivan’s presentation at Global Cement Live


India: Dalmia Bharat’s chief financial officer Jayesh Doshi has submitted his resignation to the board of the company. Hi departure will become effective after 31 October 2020.


India: UltraTech Cement’s consolidated net sales grew by 8% year-on-year to US$1.39bn in the second quarter of its financial year to 30 September 2020 from US$1.29bn in the same period in 2019. Its profit after tax more than doubled to US$167m from US$78.5m. The group attributed its progress to, “strong quarterly performance on the back of operational efficiencies and its ability to serve all India markets.”

It added that it had focused on health and safety and ‘efficient working conditions’ as it had gradually resumed operations following coronavirus-related lockdown restrictions. Overall, the group’s revenue from operations fell by 14% year-on-year to US$2.44bn in the first half of its financial year from US$2.85bn in the same period in 2019.


Germany: Robecco says that it took over the inerting business from Yara on 1 September 2020. The acquisition is intended to support customers and their future needs. The company says that combination of Yara’s inerting systems and robecco’s monitoring and control technology is a ‘unique tailor-made solution’ to maximise safety in preventive explosion protection.

With over 25 years’ experience, Robecco has become a specialist in preventive explosion protection and can provide complete packages of equipment for monitoring, control and CO2 / N2 inerting systems from a single source and one interface according to the relevant international and European norms and rules. The company holds long-established business relationships with customers worldwide providing preventive explosion protection solutions and automation services for the integration of explosion protection solutions into customers’ systems.


Nepal: The Investment Board Nepal has granted approval to Samrat Cement and Dang Cement for cement production at their upcoming integrated cement plants. New Business Age has reported that Samrat Cement will begin production at its 1.3Mt/yr cement plant in Dang Region in December 2020, and plans to increase the plant’s capacity to 1.6Mt/yr after a total investment of US$132m. Dang Cement’s 2.0Mt/yr cement plant, also in Dang region, is due for commissioning in late 2023 at a total investment cost of US$277m.

Samrat Cement Chair Mukunda Timilsina said, “We have brought modern machineries with German technology and skilled manpower is coming from India for this purpose.” He added that the plant will directly employ 500 local people and supply cement throughout western Nepal.


Pakistan: The Sindh Environmental Protection Agency (SEPA) has arranged hearings on 21 October 2020 over alleged environmental protection regulation violations by Dewan Cement and Lucky Cement at their respective Kamilpur and Karachi cement plants in the province. The provincial agency, “has expedited its monitoring activities throughout the province to manage different types of pollution at their source.”


Uzbekistan: Cement sales volumes has decreased by 29% to 5000t/day from 7000t/day at the Akhangarancement cement plant in Toshkent and by 55% to 5000t/day from 11,000t/day at the Almalyk Mining and Metallurgical Combine cement plant in Jizzakh. Uzbekistan Newsline has reported the cause of the decline as the breakdown of two kilns at the plants. This has led to a decrease in domestic cement production to 37,000t/day and sales to 35,000t/day, resulting in a slight price increase. Prices had previously been falling due to the effects of the post-coronavirus lockdown economic recovery.


Mexico: Jaime Rocha Font, the president of the National Cement Chamber (CANACEM), says that cement sales fell by 2% year-on-year in the first half of 2020 due to low demand from construction companies and the private sector. He added that sales fell by 6.3% year-on-year in the second quarter of 2020, according the El Financiero newspaper. Annual sales were 43Mt in 2018 and 40Mt in 2019.


Canada: Lafarge Canada, Geocycle Canada and Rio Tinto are working together to reuse waste from the aluminium smelting process to make cement. The three companies have developed a new product called Alextra, made from used potlining, as part of the aluminium electrolysis process that would otherwise go to landfill. Lafarge Canada plans to produce on average 1Mt/yr of cement at its plant in Bath, Ontario, using Alextra as an alternative to raw materials such as alumina and silica. The companies will also explore options to further expand the supply of Alextra from Rio Tinto’s Potlining Treatment Plant in Saguenay-Lac-St Jean to Lafarge Canada's network of cement plants.

"This partnership shows how Rio Tinto is innovating to find new ways to reuse waste, generating value from our operations and reducing their environmental footprint,” said Rio Tinto Aluminium manager valorisation and marketing Stéphane Poirier. “We have worked closely with Lafarge Canada and Geocycle Canada over the past two years to develop a product that meets their needs and look forward to building on this partnership,”


Tanzania: The Ministry of Industry and Trade said it is working to connect natural gas supplies to the local cement industry to help reduce operation costs and ultimately reduce the cost of cement to consumers. "The government is looking for the best way to ensure that gas is easily available, especially for existing (cement) industries in the Coastal Zone," said Minister for Industry and Trade Innocent Bashungwa.

The minister has also held a joint meeting with Minister of State in the Prime Minister's Office (Investment) Angellah Kairuki and nine cement manufacturers, according to the Tanzania Daily News newspaper. The meeting covered issues such as poor roads, energy supplies and taxation.

In 2018 the government set cement prices both locally and for import.


Nigeria: LafargeHolcim subsidiary Lafarge Africa says that it has signed an agreement with the Cross River State government to build a 38km concrete road connecting its local cement plant to the wider network. Chief executive officer (CEO) Khaled El Dokani said the project was a major contribution of Lafarge to the state at large with the purpose of making the roads safer for the citizens. The road is intended to divert trucks away from a nearby city centre once it is completed.


China: China National Building Materials has submitted a letter of intent of cooperation to its subsidiary Sinoma International Engineering, in which it proposes the sale of several engineering businesses to the latter. ET Net News has reported that the assets in question are under negotiation, but may include Beijing Triumph Building Materials, Nanjing Triumph International Engineering and Sinoma Mining Construction.


India: LafargeHolcim subsidiary ACC’s profit in the first nine months of 2020 was US$130m, down by 13% year-on-year from US$149m in the corresponding period of 2019. Sales also dropped, by 17% to US$1.31bn from US$1.58bn. Cement sales totalled US$1.24bn from US$1.45bn. An 18% decline in expenses to US$1.14m from US$1.39m failed to offset the effects of a price drop in the first half of 2020 due to decreased demand.


India: BK Birla Group subsidiary Mangalam Cement has launched Mangalam ProMaxX, a premium fly ash Portland pozzolana cement (PPC) that it says boasts “high one-day strength and also high 28-day ultimate strength.” The company says that the new cement is “an environmentally-friendly alternative with all the performance abilities of Mangalam Cement’s Birla Uttam cement.”


India: JK Cement has increased the capacity of its Katni wall putty plant in Madhya Pradesh to 700,000t/yr from 400,000t/yr. Projects Today News has reported that the putty consists mainly of JK Cement white cement. The company now has a wall putty production capacity of 1.2Mt/yr.


Kenya: Nairobi Business Ventures has shared plans for the establishment of a 1.0Mt/yr-capacity integrated cement plant following its 84% acquisition by UAE-based Delta International Holdings. Arab Finance News has reported that the former footwear producer is in the process of selecting a location for its upcoming plant and securing a source of clinker imports for the plant’s preliminary grinding-only phase.

Delta International Holdings is the owner of real estate company Delta Holdings Kenya, Shreeji Chemicals Kenya and Shreeji Glass Uganda.


Egypt: South Valley Cement’s first-half sales were US$12.5m in 2020, down by 21% year-on-year from US$15.9m in the first half of 2019. Arab Finance News has reported that the company’s net loss fell by 31% to US$4.45m from US$6.43m. South Valley Cement was last profitable in 2018, when it recorded a full-year net profit of US$0.65m.


Oman: Oman Cement recorded a profit of US$7.27m in the first nine months 2020, up by 3.7% year-on-year from US$7.01m. Reuters News has reported that revenues rose by 4.3% to US$10.4m from US$9.95m.


Egypt: The Financial Regulatory Authority (FRA) has approved HeidelbergCement and Simon France subsidiary Suez Cement’s mandatory tender offer (MTO) for acquisition of a 100% stake in Egyptian Tourah Portland Cement for US$32.7m. Daily News Egypt has reported that the FRA also approved a change to Suez Cement’s ownership, with HeidelbergCement France acquiring a 33% stake in the company.


Morocco: France-based Chryso has announced its acquisition of a majority stake in construction chemicals producer APTEX. The local producer operates an application laboratory and plant in Casablanca, Anfa-Settat Region. President and director general Mohamed Benlyamani said, “We are delighted to partner with an international structure offering significant means of development and a strong culture of innovation.”

Chryso chief executive officer (CEO) Thierry Bernard said, “By acquiring a majority stake in APTEX, we sustain our long-term relationship with our Moroccan customers and strengthen our local roots in Morocco. We will thus accelerate the deployment of new technologies and support producers in the development of high-performance, environmentally friendly building materials.”


US: The Portland Cement Association (PCA) has forecasted a fourth-quarter cement demand decline of 1.5% year-on-year in 2020, slowing to 0.9% throughout 2021. It said that all three of its post-coronavirus economic recovery scenarios involved a decline until mid-2021, primarily due to “weak construction sectors specifically within retail, hotel and office” non-residential markets, though in the best-case scenario a vaccine could prompt a recovery in these sectors, reducing total demand decline to 0.1% in the second half of 2021. A worst-case ‘W-shaped’ scenario would result from state governments implementing second lockdowns.

Senior vice president and chief economist Ed Sullivan said, “We think that the gradual sustained recovery – the 'U' – has the largest likelihood, followed by the 'vaccine' scenario. The growth-interrupted 'W' scenario is the least likely. He said that in each case federal spending in the fourth quarter of 2020 and the first quarter of 2021 would be essential “in preventing a deep and prolonged downturn in economic recovery,” as it did in the second and third quarters of 2020.


Mexico: 18 people have been injured after representatives of Cemento Cruz Azul and police took control of the integrated 2.2Mt/yr Oaxaca plant in Lagunas. The La Jornada newspaper has reported that Cruz Azul’s directors José Antonio Marín and Víctor Manuel Velázquez entered the plant accompanied by security personnel in fulfilment of a court order before fighting broke out with cooperativist members of the organisation. Police arrested five members of the group, allegedly linked to a criminal organisation, while the Cruz Azul representatives successfully retook control of the plant.

Cooperativists restricted access to the plant in August 2020. The board of directors of Cruz Azul also asserted legal control of its Cementos y Concretos Nacionales (CYCNA) subsidiary cement plants in Puebla and Aguascalientes in September 2020.


North America: Germany-based Schenck Process has awarded a contract for the supply of “fitting connectors, spigots and bulk bag loaders to one of its North American plants” to original equipment manufacturing (OEM) company BFM Global. It says it will integrate BFM Global products in pneumatic conveying, dust collection, weighing and feeding systems produced at the plant, all of which it sells to the cement industry.

Americas regional president Jay Brown said, “Entering this partnership with BFM Global aligns with our strategy of providing industry recognised parts and system components to our customer base. Working with a company that understands the challenges of bulk material handling strengthens our solutions capabilities. We look forward to what this partnership will bring to Schenck Process and the customers we serve.”


Germany: Schmersal has presented the prototype of the HDS switchgear wireless data transmitter for use with extended conveyor systems. The company says that it developed the products, prototypes of which are still undergoing laboratory tests, in partnership with customer-specific hardware developer Aconno. It says, “The switchgear unites a range of functions into a single platform, making it suitable for an extremely wide range of applications. Typical application areas include emergency-stop shutdown, belt misalignment monitoring in the transport of bulky materials, end position monitoring in steel making and level monitoring in material silos.”


Canada: Screen suppliers to the cement industry Haver & Boecker Niagara and Major have jointly presented an online seminar aimed to “give operations the tools to maximize production, improve performance and increase revenues” through a discussion of “best practices, insights and real-world examples.”

Major president Bernard Betts said, “Major and Haver & Boecker Niagara are leaders in the screening industry, so joining forces gives us the ability to provide customers with a one-stop shop for improvements in every aspect of screening. This webinar complements our customer service efforts to support mineral processing operations. We are dedicated to helping producers improve efficiency and performance.”


Mexico: Holcim Mexico says that it supplied a record 70,000m3 of concrete to the Dos Bocas oil refinery in September 2020, bringing the total volume supplied since major infrastructure work began at the site in March 2020 to 300,000m3. El Norte News has reported that the company is supplying the project from three sites with a total capacity of 4000m3/day: the Paraíso, Refinería and Dos Bocas concrete plants. Holcim Mexico noted that, of the 215 employees involved in the project, 50% are women.

Chief executive officer (CEO) Jaime Hill Tinoco said, “Dos Bocas is one of the most important infrastructure works in the history of LafargeHolcim and Holcim Mexico.” Upon completion in late 2022, the company expects to have delivered 2.14Mm3 of concrete to the project.


India: Dalmia Cement has imported 3830t of fly ash from a National Thermal Power Corporation (NTPC) power plant in Uttar Pradesh for use at its 0.8Mt/yr-capacity integrated Calcom cement plant in Assam. United News of India has reported that the supplementary cementitious material (SCM) travelled over 1000km.

62.9GW-total capacity NTPC produces 65Mt/yr of fly ash, some of which is used by ACC at its cement plants in Uttar Pradesh, Madhya Pradesh and Punjab.


Australia/Indonesia: Semen Indonesia subsidiary Semen Padang says that it has dispatched a 25,000t batch of cement for Australia. Bisnis News Sumatra has reported that company is targeting total shipments of 1.58Mt to the country in 2020.

Senior manager of export sales Fifit Abriyanto said, “We are building connections with new customers. We already exported 35,000t of clinker to Bangladesh in September 2020.”


Argentina: The Instituto del Cemento Portland Argentino (ICPA) has announced that a series of ten talks, entitled Vision 2030 – a Decade of Action, will take place in late October 2020. It says that the presentations, “will provide a space for reflection on 10 key topics on the 2030 Sustainable Development Goals agenda.” 

The event is also a celebration of ICPA’s 80th anniversary.


Pakistan: The Institute of Chartered Accountants of Pakistan (ICAP) and the Institute of Cost and Management Accountants of Pakistan (ICMAP) have named Maple Leaf Cement the winner of Best Corporate Report Award Cement 2020 for its company coverage.

ICAP and ICMAP said, “The objective of corporate reporting is to be easily understood by all the stakeholders as well as showing utmost transparency. Considering these golden rules, Maple Leaf Cement, which has always accepted corporate accountability being its primary goal, is the best in category.”

Lucky Cement won runner up for the award.