Global Cement Newsletter

Issue: GCW493 / 17 February 2021

Headlines


One news story to note recently has been Cemex’s decision to recommission a kiln in Mexico to address cement shortages in the southwest US. In early February 2021 the Mexico-based producer said it was spending US$15m to restart a 1Mt/yr kiln at its CPN cement plant in Hermosillo, Sonora. The unit is over 250km from the US border but Cemex said it was making the investment to cope with cement shortages and project delays in California, Arizona and Nevada. At present it supplies over 3Mt/yr to California, Arizona, and Nevada from its integrated plant in Victorville, California and via sea-borne imports. Efficiency improvements at Victorville and other unspecified supply chain changes are also planned.

Cemex isn’t the only company with an eye on the south-west US. Around the same time Japan-based Taiheiyo Cement concluded its deal with Semen Indonesia to buy a 15% stake in its subsidiary Solusi Bangun Indonesia (SBI) for around US$220m. It’s a long way from Arizona but the related statement mentioned plans to make SBI’s integrated Tuban plant in East Java more export focused, with the construction of a new jetty and silos. It intends to export 0.5Mt/yr of cement to Taiheiyo Cement’s business in the US. Its local subsidiary, CalPortland, runs two integrated plants in California and one in Arizona.

Chart 1: Annual change in US cement consumption by state, December 2019 – November 2020. Source: PCA & USGS.

Chart 1: Annual change in US cement consumption by state, December 2019 – November 2020. Source: PCA & USGS.

In its recent winter forecasts the Portland Cement Association (PCA) reported that the Mountain region of the US recorded the highest growth in cement consumption in 2020, at 10%, due to underlying economic fundamentals and favourable demographic trends. Data from the United States Geological Survey (USGS) supports Cemex’s view too. Ordinary Portland Cement and blended cement shipments rose by 21% year-on-year to 2.74Mt in Arizona and New Mexico in the first 11 months of 2020 from 2.28Mt in the same period in 2019. This doesn’t quite tally in California where shipments fell slightly, by 0.8%, to 9.42Mt. However, it reported 12% growth to 2.38Mt in the first quarter of 2020, suggesting that the market could return sharply once the coronavirus epidemic is better under control. Overall, shipments in the US grew by 1.03% to 82.3Mt in the first 11 months of 2020, driven by growth in central regions. The PCA expects national cement consumption to grow by about 1% in 2021 with a ‘robust’ recovery driven by residential housing but slowed by uncertain coronavirus vaccination supplies and general market volatility.

In a world with too much clinker production capacity, it stands out to see two established producers so visibly chasing market share in a mature market. Rather than building new plants, both Cemex and Taiheiyo Cement are using or reviving existing production lines in other countries, and building import strategies as well as optimising their existing facilities in the regions. With the western building material multinationals now often looking to focus on ‘safe’ markets in Europe or North America the fight to grow market share in these regions is likely to become more intense. It also complicates decisions about when or if an existing plant should be mothballed or shut. After all, Cemex’s old production line in Hermosillo is about to become very useful indeed.


Honduras/Panama: Cementos Argos has appointed Gustavo Adolfo Uribe as its manager in Panama and Central America. He has been succeeded by Luis Eduardo Tovar as the manager in Honduras.

Uribe studied civil engineering at the School of Engineering of Antioquia (EIA) and followed this with graduate training in economics at the University of Los Andes in Colombia and business at the École Supérieure des Sciences Economiques et Commerciales (ESSEC). He has worked for Argos for over 15 years in a variety of management roles, including being the general director for the business in Honduras.

Tovar studied business at the University of Lincoln in the UK. He has also worked for Argos for over 15 years in various managerial and strategic roles.


Kenya: East African Portland Cement (EAPCC) has appointed Daniel Kiprono as its acting managing director. He succeeds Stephen Nthei, who was appointed to the temporary post in mid-2019. No reason for his departure has been disclosed. Nthei replaced Simon Peter Ole Nkeri, who was reportedly relieved of the role, in mid-2019. Kiprono has worked at EAPCC for over 20 years in a variety of roles.


Kazakhstan: Kazakhstan’s cement production increased to 10.8Mt in 2020. Kazakhstan Newsline has reported that 2020 is the first year in which domestic cement production has exceeded 10Mt. Capacity utilisation across the nation’s 16.5Mt/yr of installed cement capacity was 66%.

HeidelbergCement’s 0.8Mt/yr Caspi Cement plant exceeded its rated capacity by 10%. Kazakhcement’s 1.0Mt/yr Shar cement plant and ACIG’s 0.5Mt/yr Khantau cement plant both produced no cement in 2020. Gezhouba-Shiyeli Cement’s Shiyeli cement plant stood idle for several months in early 2020 when management and engineering staff became stranded in China due to the coronavirus outbreak.

Kazakhstan Association of Cement and Concrete Producers executive director Erbol Akymbaev said, “The production capacities of Kazakhstani factories exceed the needs of the domestic market by 41%: domestic consumption in 2020 amounted to just over 9Mt. Access to neighbouring markets is complicated by the fact that states protect their own producers. For example, in Russia, according to GOST, additional certification of imported products is required." He added that the cement industries of the two main cement exporters to Kazakhstan – Iran and Russia – are unregulated in terms of CO2 emissions. Kazakhstan’s commitment to a reduction in its emissions of 15% by 2030 gives it a competitiveness disadvantage.


Colombia: The Regional Autonomous Corporation of Antioquia (CorAntioquia) approved the modification of the environmental license of Cemex Colombia’s upcoming 1.0Mt/yr Cementera del Magdelena Medio integrated cement plant in Maceo, Antioquia. The modification will allow for the production of up to 1.5Mt/yr of cement annually. It will additionally enable the company to extract up to 990,000t/yr of limestone and clay. The producer called the authorisation an ‘important step’ towards the plant’s completion.

Cemex Colombia and Peru president Alejandro Ramírez said, "The modification of the environmental licence is a milestone that allows us to resume work to make this project a reality, through which it is expected that we will offer our materials for infrastructure and housing works in the country more efficiently."


Cameroon: Atlantic Group is planning to build a 1Mt/yr integrated cement plant in the Port of Kribi. Business in Cameroon has reported that the company has received all necessary permissions for the project. The group’s only asset in Cameroon is the 48,000t/yr Atlantic Cocoa plant in the Port of Kribi, commissioned in 2020. Parent company Ivory Coast-based Atlantic Group recently inaugurated the 1.5Mt/yr Société Ciment Côte d'Ivoire (SCCI) near Abidjan in Ivory Coast.

Kribi’s five existing cement plants have a total production capacity of 5.8Mt/yr.


Egypt: Misr Beni Suef Cement has ended a contract with Arab Swiss Engineering Company (ASEC). In April 2019 the companies signed a contract for ASEC to provide technical management at the producer’s plant. Reuters News has reported that the cement company will now undertake the operation of its production lines.


China: The Anti-Monopoly Bureau of the State Administration for Market Regulation has fined eight cement companies US$35m for price fixing. Caixin reports that seven companies in Shandong province formed Zibo United Cement Enterprise Management in 2017 to manage their arrangement through invoicing, sales, setting prices and coordinating operating regions. The extent of the anti-competitive behaviour between the companies extended to organising a price management committee to manage the arrangement by monitoring sales and even fining members in breach of its self-declared rules. As well as Zibo United, the other companies in the cartel were Shandong Baoshan Technology, Shandong Donghua Cement, Shandong Shanlü Environmental New Material, Zibo Luzhong Cement, Shandong Chongzheng Special Cement, Zibo Shanshui Cement and Linqu Shanshui Cement.


US: Martin Marietta’s total revenue remained stable at US$4.73bn in 2020. Its adjusted earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 11% year-on-year to US$1.39bn from US$1.25bn in 2019. Cement shipments rose by 11.7% year-on-year to 1.1Mt in fourth-quarter of 2020 due to strong demand in Texas.

“As we move forward, we believe underlying demand fundamentals will reset, establishing 2021 as the year during which the nation regains its economic footing,” said Ward Nye, the chairman and chief executive officer (CEO) of Martin Marietta. He added, “We anticipate single-family housing growth, expanded infrastructure investment and notable heavy industrial projects of scale will support the company’s near-term shipment levels. We expect these demand drivers, combined with the ancillary construction necessary for housing community buildouts and the potential increased infrastructure investment from a comprehensive Federal surface transportation package, should provide for multi-year growth in product demand,”


Cameroon: Cimenteries du Cameroun (CIMENCAM) has signed an agreement with YUP Cameroon to accept online payments via YUP’s mobile phone-based banking system. Orders can be made via on CIMENCAM’s online portal. YUP allows its customers to access financial services without a bank account. The system started in Ivory Coast and Senegal in 2017 and is now present in Burkina Faso, Cameroon, Guinea, Ghana and Madagascar.


Saudi Arabia: Yanbu Cement has started a two months modernisation project on Line 4 at its integrated Yanbu plant. The company said that dispatches would not be affected by the stoppage due to sufficient clinker stocks. Line 5, which represents 60% of the company's total capacity at the plant, will continue production at full capacity.

The cement producer reported that its sales fell by 4% year-on-year to US$251m in 2020 from US$260m in 2019. Its net profit after zakat and tax grew by 9% to US$74.9m from US$68.7m.


Saudi Arabia: Yamama Cement’s sales rose by 10% year-on-year to US$235m in 2020 from US$214m in 2019. Its net profit after zakat and tax grew by 42% to US$96.9m from US$68.3m.


US: Cemex USA has acquired Beck Readymix Concrete. The ready-mix producer operates three concrete plants in San Antonio, Texas and an additional portable plant.

Texas Regional President Scott Ducoff said, “Texas is experiencing explosive growth and Cemex has repeatedly shown it is ready to make moves to help fuel it. By acquiring these facilities, Cemex will be able to deliver our high-quality products that many Texans are already familiar with to satisfy the high demand of customers of one of the state’s most dynamic markets. We welcome our new employees and look forward to a smooth transition for them.”


US: Terminal Ready-Mix has announced its acquisition of assets from ready-mix concrete and building materials producer Huron Cement. Ohio Newstime has reported that the companies completed the deal in February 2021.


France: Vicat recorded full-year consolidated sales of Euro2.81bn in 2020, up by 2% year-on-year from Euro2.74bn in 2019. Earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 6% to Euro557m from Euro526m. Consolidated net income rose by 8% to Euro172m from Euro160m.

The group said that organic sales were ‘strong,’ rising in all regions except in France, by 6% in total. It attributed the decline to a near-total shutdown due to the coronavirus outbreak in mid-March 2020, which lifted incrementally throughout the first half of the year. Vicat France’s cement business recovered ‘robustly’ in the second half of 2020, resulting in an operational sales increase of 3% for the year. Full stoppages of activity lasted for 33 days in India and for 30 days in Italy. Despite these challenges, business growth, cost-cutting and lower energy costs drove earnings growth, with ‘very sharp improvements’ recorded in the Americas and in Asia. Additionally, the ramp-up of a new grinding plant in Mali and production performance improvements in Senegal supported a ‘significant’ earnings increase in Africa.

Chair and chief executive officerGuy Sidos said, “Thanks to our employees’ tremendous efforts and commitment, the Vicat group strengthened its position amid the unprecedented current pandemic situation. Our resilience and flexibility allowed us to make organisational changes in order to reconcile our competing imperatives of keeping everyone safe and healthy, unlocking savings and making rapid adjustments, such as relocating our Paris head office to L’Isle d’Abeau in the Auvergne-Rhône-Alpes region. Likewise, we made improvements to Vicat’s governance and stepped up our environmental and digital transformation programmes. Given the strength of our cash generation, we were able to resume key productivity investment programmes for the future. Despite the adversity we faced, our teams across all our various regions successfully delivered higher production efficiency levels and met market demand cost-effectively, paving the way for a solid increase in the Vicat group’s results.”

In 2021, the group plans to expand cement production and invest in new cement terminals in India and to continue with the upgrade of its Ragland cement plant in the US. It also says that it will ramp up projects aimed at meeting its carbon footprint reduction targets. The group expects its earnings to rise at constant scope and exchange rates over the full year.


Turkmenistan: Full-year cement production reached 1.9Mt in 2020. The Trend News Agency has reported that industrial production, construction work and services grew by 8% year-on-year during the period. The nation exceeded its reinforced concrete building construction plan for the year by 4%.

In January 2021, cement production increased by 29% year-on-year.


Dominican Republic/Philippines: Cemex says that it will commission two new energy saving installations at cement plants in the Dominican Republic and the Philippines in 2021. In the Dominican Republic, a new 41MW solar power plant will partly supply the company’s cement operations in the country. In the Philippines, it will commission a 4.5MW waste heat recovery (WHR) plant at its APO cement plant.


India: LafargeHolcim subsidiary ACC has launched its ECOPact range of reduced-CO2 concrete products in Hyderabad and Mumbai. A full nationwide rollout will follow in February and March 2021.

Managing director Sridhar Balakrishnan said, "The innovative manufacturing process of the ECOPact range reduces CO2 emissions by up to 100% and further enhances our sustainable products offerings for the construction industry.”


UK: Cemex UK has announced the launch of Viabase, an engineered asphalt concrete. The company says that the product is especially suited to use in residential housing estate roads, where it will be exposed to construction traffic before being surfaced after houses are built. The launch supports the UK government’s drive to increase house building to 300,000units/yr.

Europe regional asphalt, paving and building products director Carl Platt said, “With Viabase, we are pleased to offer a way to ensure the longevity of housing development roads, which standard materials struggle to provide if the surface course is not placed soon after. Viabase provides a highly durable, low maintenance surface which will meet the challenges presented by heavy duty vehicles and prevent long-term problems in the overall pavement construction.”

The company will produce Viabase at all its UK asphalt plants, where it will be available for delivery to customers or collection.


US: HeidelbergCement subsidiary Lehigh Cement has resumed work on an expansion at its 0.8Mt/yr Mitchell, Indiana cement plant with the execution of initial project plans and the delivery of materials to the site. Local media has reported that the upgrade will cost US$600m and create 1000 construction jobs over a four year project timeline.

Mitchell cement plant manager Tracy Crowther said, “We are currently receiving parts and over the summer this will continue to get busier. Much of the equipment will come in through a port near Louisville and will be hauled by truck up here. There will be some large equipment that will be moved in.”

On April 2020 it was reported that Lehigh Cement had suspended work on a 2.0Mt/yr expansion of the Mitchell plant to 2.8Mt/yr, on which it had broken ground in October 2019. The scheduled completion date moved to late 2023 from September 2022.


China: Germany-based supplier IKN says that its customer Jidong Group has started up a 6200t/day-capacity cooler at its Lincheng cement plant in Hebei province. The supplier also said that installation of another cooler for the cement producer for a new production line was underway and scheduled for completion later in 2021.Jidong Group completes IKN cooler installation


Chile: The protest organisation Frente de Defensa de Islay has launched a challenge against the legality of Cbb’s planned 200,000Mt/yr Arequipa grinding plant in the Port of Matarani. The La República newspaper has reported that the organisation says that the plans would violate Islay district’s urban zoning law due to the risk of contamination.

The producer plans to complete the US$20m plant in mid-2021. It acquired the project from Inversiones Primax in 2019.


Nigeria: Dangote Cement has donated a total of 10 auto rickshaws to cement plant and limestone mine host communities in Akpata, Iwaa, Obajana and Owo. The Nigerian Tribune newspaper has reported that the aim of the donations is to support business and community transportation. Deputy general manager Ademola Adeyemi said that these fall under the company’s corporate social responsibility.


Mexico: Cemex recorded consolidated cement volumes of 63.8Mt in 2020, up by 2% year-on-year from 62.7Mt in 2019. Ready mixed concrete sales volumes fell by 6% to 47.0Mm3 from 50.1Mm3. Its net sales fell by 1% to US$13.0bn from US$13.1bn although the group has reported a slight rise on a like-for-like basis. Operating earnings before interest, taxation, depreciation and amortisation (EBITDA) rose to US$2.46bn, up by 3% from US$2.38bn. However, sales and earnings picked up significantly in the fourth quarter of 2020.

Fernando A González, the chief executive officer (CEO) of Cemex said, “2020 was one of the most challenging years we have faced but it also was a remarkable year that tested the strengths of Cemex and several of our recent strategic initiatives. I am proud of our performance, the organisation, and how we responded to the sudden arrival of Covid-19 in 2020.”

Cement volumes rose by 6% in Mexico and by 8% in the US, but fell by 1% in Europe, Middle East, Asia and Africa and by 8% in South and Central America and the Caribbean. Prices fell in all regions except Europe, where they rose by 3%, and the US, where they remained level. Annual like-for-like sales and gross profit increases were noted in Mexico, the US and Middle East and Africa.

The group concluded the sales of its 75% stake of US-based Kosmos Cement for US$499m in March 2020 and of ready-mix assets in the UK for US$230m in August 2020.


India: JSW Cement has hired US-based Yalochat to supply software for transactions with trade customers. It says it is among the first Indian cement companies to introduce conversational commerce services to this marketing segment. The software promises to increase the company’s ease of doing business by integrating customer service into transactions via the WhatsApp messaging platform. The producer says that this will help differentiate it as it transitions to 25Mt/yr of production capacity by 2023 from 14Mt/yr.

Managing director Parth Jindal said, "Digital technology is shaping the long-term sustainable growth strategy of all JSW Group businesses. We are in a unique position to deliver integrated home-building solutions to Indian consumers. Our digital transformation will ensure the ease of doing business to our customers through continued improvements in the overall brand experience combined with efficient operations for well-synchronised and timely deliveries."


India: Dalmia Bharat subsidiary Dalmia Cement has inaugurated a new school building that it has built in Barunia, Odisha. The Orissa Diary newspaper has reported that the work was part of a US$7690 project which also included the refurbishment of two existing classrooms.

Projects executive directorRamawatar Sharma said, "The access to quality education is a basic human right. As a company, we have always believed in providing opportunities to the best of our capacity and helped in laying the foundation for a better life for everyone. We are optimistic that with the renovation of the school infrastructure, the students will feel motivated to attend classes and continue working towards building a better future for them."


Belarus: Belarusian Cement Company subsidiary Krasnoselskstroimaterialy has reported total costs savings across its operations of Euro1.34m in 2020. Belarus: Daily News has reported that the company undertook several and diverse measures to achieve the reduction.

The company said, "We have replaced imported bottom ash mix with high-aluminium clay from our own deposit.” It added, “The coal content of the fuel mix rose to 85%. We have also optimised the use of raw materials in the production of cinder blocks. This has helped to reduce the cost of their production by means of decreasing the usage rates for cement, lime and thermal energy."


UK: SigmaRoc has launched Greenbloc, a cement-free concrete block. The product reduces emissions by 77% compared to concrete blocks produced with Ordinary Portland Cement (OPC), corresponding to a reduction of 1.1kg/block.

Chief executive officer Max Vermorken said, "Our Greenbloc range and brand is the brainchild of our innovation and technical teams. It addresses a key challenge in the building products industry - the embodied CO2 in one of the most widely used building materials: the concrete block. Greenbloc is only the start of a range of sustainable alternatives to our product offering as we invest, improve, integrate and innovate."


US: France-based Vicat subsidiary National Cement Company of Alabama has completed the installation of a new 5000t/day clinker line at its Ragland, Alabama cement plant. The line has a raw meal capacity of 13,000t.

Vicat engineering senior vice president Jean-Claude Brocheton congratulated the installation team on the ‘major step’ and on completing the work ahead of schedule.


Australia: James Hardie recorded net sales of US$2.10bn in the first nine months of its 2021 financial year, up by 9% year-on-year from US$1.93bn in the first nine months of its 2020 financial year. Adjusted earnings before interest and taxation rose by 25% to US$456m from US$366m. Sales and earnings increased in all three regions in which the company operates. In Australia and New Zealand, it reduced costs by consolidating fibre cement production at its two Australian plants.

Chief executive officer Jack Truong said, “I am pleased with these record results, underpinned by excellent execution of our business transformation that we began in 2019, combined with increasing demand for our premium-quality James Hardie brand products and solutions. The transformation we undertook to unlock capacity and increase efficiency in our global manufacturing network through lean initiatives and to better integrate our supply chain with our customers continues to deliver consistent market share gains and the ability to serve our customers seamlessly around the world. We are firmly on track with our investments in growth to broaden our portfolio with industry-leading innovations that enhance aesthetic value for homeowners. Our transformation initiatives will enable us to expand our market opportunity and allow us to continue to deliver strong performance.”


Saudi Arabia: Saudi White Cement has rebranded as Riyadh Cement Company. Mubasher News has reported that the company previously received regulatory approval for the change to the commercial register. It had used both names in parallel prior to the change.


UK: HeidelbergCement subsidiary Hanson has installed a solar and wind-powered hydrogen generation demonstration unit at its Port Talbot Regen ground granulated blast furnace slag (GGBFS) plant in Port Talbot in Neath Port Talbot. The company says that the project is part of a collaboration with Swansea University’s Energy Safety Research Institute under the European Research and Development Fund’s Reducing Industrial Carbon Emissions initiative. The hydrogen generated by the installation will replace natural gas in the GGBFS plant’s burners.

Head of sustainability Marian Garfield said, “It is estimated that cement is the source of just under 2% of UK CO2 emissions. With demand for cement and cement replacement products predicted to increase by 25% by 2030, researchers and industry are working hard to reduce the level of CO2 emissions associated with production. As a leading manufacturer, we take our responsibility very seriously. In the UK we have already achieved a 30% reduction in CO2 emissions since 1990 across the business and have set an ambitious new target of a 50% reduction by 2030 from the same baseline. We are constantly looking to improve energy efficiency and carbon reduction at our cement and Regen GGBFS plants, so we are delighted to be involved with this innovative research project.”


India: Denmark-based Hasle has supplied a Hasle D59A coating-resistant castable to Asian Cement for use on the inlet chamber and riser duct at its cement plant. The supplier supervised installation. It said that the castable will reduce the required lining materials of the equipment, resulting in savings.