Global Cement Newsletter

Issue: GCW516 / 28 July 2021

Headlines


Holcim has started to unify its low carbon cement product range this week with the launch of its ECOPlanet label globally. The products are already available in Germany, Romania, Canada, Switzerland, Spain, France and Italy. The plan is to extend this to 15 countries by the end of 2021 and then to double its ‘market presence’ by the end of 2022.

The headline news is that the range will include what Holcim says is the world’s first cement product with 20% recycled construction and demolition waste. This appears to be an improvement on the group’s Susteno cement products that use fine fractions from concrete and demolition waste. This product is currently sold in Switzerland where it is advertised as saving 10% of CO2 emissions compared to a standard cement product. Both Holcim and HeidelbergCement already sell concrete products that use the coarse waste from building demolition. Other than this, Holcim says that the range will also include cements that contain calcined clay. In June 2021 subsidiary Lafarge France announced that it would produce a cement product under the ECOPlanet banner using kaolin clay with its proprietary ProximA Tech process at its integrated La Malle cement plant in Bouc-Bel-Air.

We will have to wait and see how far Holcim goes in standardisng the range between different countries. Yet, judging from what the countries that are already selling ECOPlanet are doing, it looks like it will be a variety of blended cements. At present, for example, Holcim Germany offers four products in the ECOPlanet range. These are all slag cements, with three having effective CO2 reductions of up to 70% and the fourth, ECOPlanet Zero, reaching 100% through a carbon offsetting scheme in conjunction with MoorFutures. Holcim Italy also launched a product in the range called ECOPlanet Prime using calcined clay in June 2021.

Incidentally, LafargeHolcim US announced a research project this week with the US Army about using demolition waste. It’s going to start working with the US Army Corps of Engineers’ Engineer Research and Development Center and Geocycle to look at how construction and demolition materials from military installations can be used for energy recovery and mineral recycling. Group resources at Geocycle’s Holly Hill Research Center in South Carolina, US and Holcim’s Global Innovation Center in Lyon, France will be used in the scheme.

Other low carbon cement products are available of course. Holcim is far from alone in launching low CO2 cement and concrete products. Yet the use of worldwide brand names is different. Cemex is doing something similar with the global rollout of its Vertua concrete products. It first launched Vertua in France in 2018 before going global in 2020. Holcim started to launch ECOPact Concrete in 2019. Now, Holcim has gone further by doing the same thing with cement. Given how localised cement and concrete products are, it will be instructive to see how global branding for low carbon cementitious products helps these companies. For instance, who is the target audience? It could be eco-minded self-build customers or project specifiers or government departments or industry lobbyists. Or perhaps it is simply another marketing channel to reinforce the sector’s sustainable offerings.

The other point worth considering is when will the multinational cement producers start selling sustainable cements and concretes in less rich parts of the world? While Holcim was playing with blended cements and marketing this week, Dangote Cement said that it was ready to start commissioning its new 6Mt/yr integrated plant at Okpella, Edo State in Nigeria. Another 5Mt/yr plant is also on the way in the country from Madugu Cement. It has just signed a contract for China-based Sinoma International Engineering Company to build it. When Holcim and the other cement companies start selling low carbon cements in places like Nigeria then the rise of these products will be complete.

For more information on low CO2 cement production read our feature in the February 2021 issue of Global Cement Magazine


Russia: Sibirsky Cement has appointed Dmitry Kireev as the managing director of the Krasnoyarsk cement plant and Vladimir Afanasin as the managing director of the Angarskcement plant.

Kireev worked at Sibirsky Cement’s Topkinsky cement plant from 2001 until 2013, eventually becoming the director for equipment maintenance and repair. He was then appointed as the managing director of TimlyuiCement before becoming the head of the Angarskcement plant in 2016. He is a graduate of the Belgorod Technological Institute of Building Materials and the Kuzbass State Technical University. He also holds a Master of Business Administration (MBA) degree from the Moscow International Higher School of Business (MIRBIS).

Afanasin became the deputy chief engineer at the Topkinsky cement plant in 2007. He later worked at Krasnoyarsk cement plant until 2011 as the chief engineer, technical director and the production director. In 2011, he became the head of Angarskcement and then managed the Krasnoyarsk cement plant from 2016. Afanasin is a graduate of the Belgorod Technological Institute of Building Materials and holds an MBA from MIRBIS.


US: Fortera has appointed Eric Olsen to its board of directors. Olsen is the former chief executive officer (CEO) of LafargeHolcim.

He started his career in the field of mergers and acquisitions at Deloitte & Touche, Banque Paribas and was one of the managing partners of Trinity Associates for six years. He studied business at the University of Colorado and holds a Master of Business Administration (MBA) from HEC international business school in Paris. He joined Lafarge Group in 1999 and was a member of its executive committee from 2007 until its merger with Holcim in 2015 to form LafargeHolcim. He then worked as the CEO of LafargeHolcim until April 2017 when he resigned following a review into a conduct of a cement plant in Syria. Legal charges of financing a terrorist organisation were dropped by French authorities in 2019.

Fortera is a materials technology company that has developed a recarbonation process that uses captured CO2 and mineralises it into a secondary cementitious material. In March 2021 it signed a collaboration agreement with Lehigh Hanson to build a carbon capture and storage (CCS) system at the producer’s 0.8Mt/yr integrated Redding Cement plant in California.


Germany: Bosch Rexroth has appointed Holger von Hebel as its chief financial officer (CFO) and the Director of Industrial Relations with effect from 1 October 2021. He will retain his position as head of the Mobile Hydraulics business unit. Von Hebel succeeds Markus Forschner, who will join the board of management of Robert Bosch as CFO and chief performance officer in 2022.

Von Hebel studied industrial engineering in Berlin and Karlsruhe. He joined the Bosch Group in 1990 as a trainee. After serving in a range of management positions in Germany and other countries, he became the commercial director of Switzerland-based Bosch subsidiary SIG Pack International in 2004. In 2005, von Hebel was given additional responsibility for finances, controlling and IT at the former Packaging Technology division of Bosch. Afterward, he became chairman of the divisional board of management of Bosch Solar Energy. Von Hebel has worked in a variety of areas at Bosch Rexroth since 2013 when he became the commercial director of the former Industrial Applications business unit. He has been the managing director of the Mobile Hydraulics division since 2017.

Bosch Rexroth supplies drive and control technologies to a variety of industries including the cement sector.


France: Vicat’s consolidated sales rose by 19.6% year-on-year to Euro1.56bn in the first half of 2021 from US$1.30bn in the same period in 2020. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) increased by 41% to Euro300m from Euro213m. Sales and earnings rose in all territories on an adjusted basis as markets recovered from a poor second quarter in 2020 due to the coronavirus pandemic, particularly in India and France.

“Focused on its carbon footprint reduction targets, the group has accelerated the commercialisation of its low-carbon product lines, adapted to the global climate challenge,” said Guy Sidos, the group’s chairman and chief executive officer. The company added that the upgrade of its Ragland cement plant in the US is on track for expected commissioning in the first half of 2022 and that it is ramping up a new mill in Mali.


Mexico: GCC’s sales rose by 9.7% year-on-year to US$466m in the first half of 2021 from US$424m in the same period in 2020. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) increased by 15.3% to US$147m from US$127m. Cement sales volumes grew by 3.2% and 11.5% in the US and Mexico respectively. Concrete sales volumes fell by 21.1% in the US but grew by 22.8% in Mexico.

“Cement demand is stronger than pre-pandemic levels and construction activity is expected to remain robust throughout the year. Every kiln at GCC is up and running,” said Enrique Escalante, GCC’s chief executive officer.


India: Dalmia Bharat’s first-quarter consolidated income net sales were US$348m in the 2022 financial year, up by 36% year-on-year from US$256m in the first quarter of the 2021 financial year. The group’s cement sales totalled 4.89Mt, up by 33% from 3.66Mt. Profit after tax increased by 45% to US$37.2m from US$25.7m.

Managing director Puneet Dalmia said “Despite the challenges posed by the second wave of Covid-19, our business has once again shown resilience and successfully delivered an all-round performance. We are very excited about the opportunities that we see in the marketplace, and our consistent performance over the past quarters gives us immense confidence as we embark on an aggressive growth journey over the next decade.” He added “Our vision is to build an institution based on the principles of growth, profitability, sustainability and respect, and also to be able to participate meaningfully in our country’s growth story. We are committed to delivering industry-leading returns to our stakeholders through our sustainable business model and a robust governance mechanism.”


India: Ramco Cements recorded standalone net sales of US$166m in the first quarter of the 2022 financial year, up by 17% year-on-year from US$141m in the corresponding quarter of the 2021 financial year. Its earnings before interest, taxation depreciation and amortisation (EBITDA) rose by 37% to US$49.7m from US$36.3m. The company’s net profit growth for the quarter was 54%, taking this to US$22.7m from US$14.8m.

Chief executive officer Aahvan Dharmakrishnan said “With lot of uncertainties and commodity prices going up without corrections, we were able to control the cost reasonably well and performed well.”


India: Ramco Cements plans to invest US$64m in a modernisation and capacity expansion of its Ramasay Raja Nagar cement plant in Tamil Nadu. The Hindu newspaper has reported that the project involves building a new 3000t/day clinker line to replace a 1450t/day line. This will increase the plant’s overall capacity by 32% to 1.44Mt/yr from 1.09Mt/yr. The company has placed equipment orders for the project and plans to commissions the upgrade in December 2022. It expects to receive environmental clearance for the work in September 2021.


Philippines: Japan-based Taiheiyo Cement has underwritten a US$250m capital increase for its subsidiary Taiheiyo Cement Philippines. Nikkei Business Trends News has reported that the company has scheduled six payments between July 2021 and January 2024. The funding will increase Taiheiyo Cement Philippines’ total capital to US$291m.


Algeria: Ahmed Zeghdar, the Minister of Industry, says that he will help reduce the difficulties that Groupe des Ciments d'Algérie (GICA) faces with its exports. During a meeting with the management of GICA the minister said that the government would assist with logistical problems linked to sea and land transport, according to the Expression newspaper. He also urged the company to increase its exports due to high domestic cement production capacity. GICA produced over 11Mt of cement in 2020 and this is expected to rise to nearly 17Mt in 2021. Its exports reached a value of nearly US$600m in 2020 and are forecast to reach US$1bn in 2021.


Paraguay: Industria Nacional del Cemento (INC) says that it will not increase its cement prices despite the high cost of petcoke. The state-owned producer reports that both increasing international prices for the fuel and logistical challenges, such as varying river water levels, have raised overall prices. It added that stopping production would cause negative impacts to both the construction sector and the local economy.


Australia: James Hardie Industries has published its 2021 Sustainability Report, entitled Building Sustainable Communities. The report outlines the group’s sustainable future, commitments and progress to date in four key areas, namely Communities, Environment, Innovation and Zero Harm. The framework uses measurable goals, such as a 40% greenhouse gas reduction between 2019 and 2030, a 5% increase in gender diversity in management positions between 2020 and 2024 and an increase in the proportion of revenues covered by environmental product declarations to 80% from 26% in the 2021 financial year. Formalised in the 2021 financial year, the sustainability strategy is integrated with James Hardie’s global strategy for value creation and operational performance.

Chief executive officer Jack Truong said “Our commitment to building better, more sustainable communities starts by building better homes, with the homebuilding materials of the future.” He added “Our commitment to a sustainable future extends to our James Hardie community, the local communities in which we operate and across the largest shared community of all, our global ecosystem. At James Hardie, we are transforming the way the world builds by offering better, safer and more sustainable products.”


Belgium: Magotteaux says that its production plants at Vaux-sous-Chèvremont and Trooz near Liege were ‘severely hit’ by flooding in mid-July 2021. The industrial equipment and services supplier is currently assessing the extent of the damage but production is expected to be affected. It reported that all of its staff were safe following the incident.


Germany: Flexco Europe has launched the T-Type secondary belt cleaner. The supplier says that the cleaner is able to remove moist, sticky, dry or abrasive residues from belts, even without a precleaner. It is equipped with tungsten carbide blades which rotate by up to 15°, to provide ‘perfect’ adaptation to the belt surface. Cleaning blades with C-Tips are provided for mechanical connectors. Segmented polyurethane (PUR) vibration dampers ensure even wear, while thin carbide blades achieve very good performance in combination with the robust tensioning system. The blades also have an offset for streak-free cleaning. The new secondary cleaner is available for belt widths of 400mm - 1600 mm and for belt speed of op to 4m/s. Little space is required for installation, so it can fit neatly into almost all conveyor belt structures.


Nigeria: Madugu Cement plant to build a 5Mt/yr cement plant at Kembu in Gombe state. The producer has awarded an engineering, procurement and construction (EPC) contract for the project to China-based Sinoma International Engineering Company. Construction will consist of two phases, each of which will establish a production line of 2.5Mt/yr capacity. The Nigerian Tribune newspaper has reported that, when commissioned, the plant will be the second in Gombe state. The state has extensive gypsum reserves and a surplus of coal and hydroelectric power.


Nigeria: Dangote Cement says that its new 6Mt/yr cement plant at Okpella in Edo state is ready to enter cement production. The Daily Independent newspaper has reported that group invested US$1bn in the plant. China-based Sinoma International Engineering Company supplied engineering, procurement and construction (EPC) services. When commissioned, the plant will employ 6000 people, according to the owner.

Dangote Cement is in the process of establishing a further 6Mt/yr cement plant at Itori in Ogun state. The launch of both plants will give the producer an active cement capacity of 41.3Mt/yr. The company says that its aim is to increase the uptake of cement in Nigeria. It said, “We still need to do more to make the cement get to the poorest of the poor.”


World: Switzerland-based Holcim has launched its ECOPlanet reduced-CO2 cement range in six European markets and Canada. The range offers at least 30% lower emissions than Ordinary Portland Cement (OPC). It includes one cement produced using recycled construction and demolition waste.

Chief executive officer Jan Jenisch said “Driving the circular economy, our ECOPlanet range includes the world’s first cement with 20% recycled construction and demolition waste inside, advancing our net zero vision in a nature-positive way. With the world’s population rising and rapid urbanisation, solutions like ECOPlanet are critical to enable greener cities and smarter infrastructure, building more with less.”

The group plans to introduce the range to 15 countries by 2022 and double its market presence in 2023.


US: Cemex USA’s Victorville cement plant in California has won the Portland Cement Association (PCA)’s Chairman’s Safety Performance Award 2021 in the Large category. The award recognises top safety performance. The Victorville cement plant previously won the award in 2019 and 2020. Cemex USA says that the plant recorded zero incidents in 2020. Earlier in 2021, it surpassed four years without a lost time injury to any employee or contractor.

President Jaime Muguiro said “Safety is our top priority, and Victorville cement plant is demonstrating that Zero4Life is possible. We are proud of the continued commitment of our team, and their achievement is a great example of what can happen when everyone is dedicated to safety and works together to look out for one another.”


France: Cemex France has supplied 40,000m3 to the site of the now completed Paris Duo Towers in Paris, Île-de-France. The company also provided construction waste removal services through its multimodal transport network. The producer said that the strong commitment of its technical teams ensured the success of the operation. It said that excellent communication between its various departments and the concrete production teams enabled ‘smooth and consistent’ concrete deliveries.


India: Ambuja Cement recorded sales of US$930m in the first half of 2021, up by 41% year-on-year from US$659m in the same period in 2020. Cement sales volumes grew by 36% to 13.5Mt from 9.95Mt. Its profit after tax was US$186m, up by 63% from US$114m.

“This performance resulted from strong growth in sales of premium products and successful execution of efficiency improvement programs which has partly been impacted by rising energy and raw material costs. Synergies under the master supply agreement have significantly benefited both Ambuja and ACC as we leverage our national footprint,” said Neeraj Akhoury, the chief executive officer of Holcim in India and the managing director of Ambuja Cement.

The company also announced that its board has approved a 1.5Mt/yr expansion project at its Ropar grinding plant in Punjab.


Australia: AdBri has awarded a gas sales agreement with Senex Energy to supply up to 11PJ of natural gas to support its manufacturing operations in the south of the country to 2030. Supply will start in January 2023. The long-term, contract sets prices ‘in line with current market levels.’ Adbri chief executive officer Nick Miller said that he was ‘pleased to execute this long-term agreement,’ which gives certainty to both parties moving forward.

Adbri committed to net-zero carbon emissions by 2050 in late May 2021.


Kazakhstan: The Ministry of Industry and Infrastructural Development has lifted a ban on imports of Portland cement, alumina cement, hydraulic cement and clinker into the country. A three-month ban on such imports began in late April 2021, according to the Trend News Agency. Imported cement must conform to new quality standards introduced by the ministry’s Technical Regulation and Metrology Committee in July 2021.


Bangladesh: LafargeHolcim Bangladesh has unveiled new branding for its Holcim Strong Structure cement product. The subsidiary of Switzerland-based Holcim presented launching the new packaging to distributors and retailers at a virtual event.

Chief executive officer Rajesh Surana said, "LafargeHolcim Bangladesh always emphasises innovation and customer satisfaction. As a part of this, we are unveiling the new look of our Holcim Strong Structure bag. The new look of the bag is really attractive and reflects our stronger brand image and product differentiation. We are committed to providing the best product, for our customers to build their dream homes.”


India: The government of Uttar Pradesh plans to build over 10,000km of new roads in rural areas. The state is presently engaged in the construction of 6500km of road, consisting of 800 separate roads and five bridges. The Times of India newspaper has reported that the latest proposals await the approval of the national government. Some of the roads will be rebuilt using full depth reclamation with cement and other additives.


India: UltraTech Cement’s sales rose by 54% year-on-year to US$1.59bn in the first quarter to the end of June 2021 from US$1.03bn in the same period in 2020. Its net profit more than doubled to US$228m from US$107m. The group’s cement sales volumes grew by 47% to 21.53Mt.


UK: Breedon Group recorded first-half sales of Euro701m in 2021, up by 79% year-on-year from Euro391 in the first half of 2020. The group’s profit for the period was Euro27.8m, compared to a Euro16.1m loss in the first half of 2020. Its cement sales rose by 47% to Euro140m from Euro95.0m. Cement and ready-mixed concrete sales volumes increased by 50% to 1.2Mt and 70% to 1.7Mm3 respectively.

Chief executive officer Rob Wood said “Breedon delivered a strong trading result in the first half of 2021, building on the recovery in demand which started in the second half of last year. This resilient performance reflects the commitment and efforts of all our colleagues, who have each demonstrated the highest levels of enthusiasm, professionalism and flexibility in working safely across the business despite the challenges of the past fifteen months.” He added “Our first-half performance, current trading conditions and improved visibility for the remainder of the year combine to give us greater confidence in the outlook for 2021 and we now expect underlying earnings before interest and taxation for 2021 to be at the top end of market expectations.”


Mozambique: Adil Cement, África Cement Factory, Maputo Cement, National Cement, Limak Cement Factory, Royal Cement and Suneira Cement Fonte have written a letter to the Ministry of Industry and Commerce complaining about ‘unfair’ pricing by Dugongo Cement. They allege that the pricing of their Chinese-backed rival breaks local competition law and has caused harm to their businesses, according to Moçambique Media Online. The price of cement has reportedly dropped by as much as 70% since Dugongo Cement’s new plant opened in May 2021.


Canada/US: Schaeffler has launched Optime, a condition monitoring system, on the Canada and US markets. The supplier says that the system consists of wireless vibrator sensors, a cellular gateway and a dedicated data collection app. The captured information is then processed and analysed by Schaeffler’s proprietary software and models. This can then be used to improve cement producers’ awareness of possible damage to components such as fans, motors and pumps.

Americas regional manager for condition monitoring and Industry 4.0 service solutions Frank Mignano said “With Optime, comprehensive and automated condition monitoring is now a cost-effective proposition for reliability personnel and facility operators.”


Iraq: Joint security forces have repelled militants from the Kubiasa cement plant in Al-Anbar province. Iraqi News has reported that 18 fighters from the Islamic State of Iraq and Syria (ISIS) were killed in the operation. The security forces also detonated four car bombs at the site.


Italy: Taiwan-based Taiwan Cement has successfully acquired a 60% stake in battery and hydrogen power systems supplier Engie EPS for Euro132m. The building materials producer is attempting to become a global supplier in the sector.


US: Hanson Aggregates has purchased 577ha of land near Buckeye, Arizona. The Phoenix Business Journal newspaper has reported that the company will use the land to produce ready-mix concrete and rock products and. Martin Marietta Materials agreed to acquire Germany-based HeidelbergCement’s US West regional business, which included Hanson Aggregates, in May 2021 for US$2.3bn.


Germany: HeidelbergCement has signed the Science-Based Targets Initiative’s (SBTi) Business Ambition for 1.5°C commitment and joined the United Nations (UN) Framework Convention on Climate Change Race to Zero campaign. The former entails a commitment to limiting global warming to 1.5°C and achieving net zero carbon emissions by 2050. Race to Zero membership entails a positive commitment to beginning the transition to a decarbonised economy before the UN Climate Change Conference of the Parties in November 2021.

Chair Dominik von Achten said “As one of the world's leading building materials producers, we are continuously increasing our efforts in the global fight against climate change. We are working on all levels to reach climate neutrality – within our operations as well as through associations and initiatives such as the Race To Zero campaign. Every effort brings us closer to our goal.”