Global Cement Newsletter

Issue: GCW554 / 27 April 2022

Headlines


Cement shortages were being reported in the US media last week in Alabama and South Carolina. The owner of a ready-mixed concrete supplier in South Carolina was blaming it on labour and supply shortages. Dan Crosby, the president of Metrocon, told Fox News that his business could only take on 60% of the work it could normally cope with due to the issue despite demand for construction growing in the state. Meanwhile, the Alabama Concrete Industries Association said that its home state saw a 14% increase in the demand for concrete in 2021 but that a cement shortage might cause delays to projects. The association also pointed the blame at labour and supply issues. It pointed out that high demand for concrete during the winter prevented inventory being built up and then the annual cement plant maintenance breaks in the spring added to the problems. Once contractors actually secured supplies of cement they then faced further delays due to a nationwide truck driver shortage!

Graph 1: Annual rolling cement shipments in the South of the US. Source: USGS. 

Graph 1: Annual rolling cement shipments in the South of the US. Source: USGS.

Data from the United States Geological Survey (USGS) doesn’t especially shed light on the situation in Alabama and South Carolina. Alabama was the fifth largest cement producing state in the country in January 2022 but this is unsurprising as it’s the state with the fifth largest cement production capacity. Rolling annual data on Portland and blended cement shipments by origin show the effects of the coronavirus outbreak in the south from the start of 2020 to January 2022. Shipments took a dive in 2020 and then mostly recovered in 2021. However, Alabama, Kentucky and Tennessee saw shipments rise from 7.1Mt pre-pandemic to 7.6Mt in January 2022. South Carolina’s shipments grew from 3Mt to 3.2Mt. Regionally, the North East had a similar pattern although, unlike the South, shipments have surpassed those at the start of 2020. The Midwest and West were different with a general upwards trend over the two years, although the West softened slightly from mid-2021 onwards. Overall the US as a whole has seen its shipments grow throughout this period.

Ed Sullivan from the Portland Cement Association (PCA) told the May 2022 issue of Global Cement Magazine that the US cement sector did well in 2021 with a 4.1% year-on-year rise in sales to 104Mt. However, he flagged up supply chain problems that actually slowed growth, led by a lack of staff.

The other point along these lines that Sullivan made was that imports of cement might not necessarily be able to compensate for domestic supply issues due to global demand for shipping post-coronavirus. USGS data placed imports to the US at 13.7Mt in 2019 compared to 16.3Mt in 2021. Notably, Cemex restarted one production line in 2021 at its CPN cement plant in Sonora State in Mexico to export cement to the west of the US. In March 2022 it added that it was going to restart another line at the plant also. It’s not alone though as GCC reported in January 2022 that a line at one of its plants in Chihuahua, Mexico, was exporting cement to Texas. Sullivan reckoned that January 2022 was ‘weak’ but that it was followed by an ‘extremely strong’ February 2022. The first quarter results from Holcim and CRH seem to back this up with the former describing the period as ‘outstanding’ and the region leading its sales and earnings growth rate globally. CRH reported strong demand in central and southern regions.

As the US economy restarted following the peak of the early coronavirus waves in 2020, various supply chain issues have manifested. Staff shortages are one issue and this can also worsen other logistic problems. The south seems particularly vulnerable to all of this as it is both the country’s largest cement market and because demand has held up. In January 2022 research by the International Monetary Fund (IMF) identified several reasons for staff shortages in the US and the UK. These included increased inactivity among older workers, the so called ‘She-cession’ (where female employment has overly reduced due to coronavirus trends) and shifting worker preferences amid strong labour demand.

Staff shortages are expected to sort themselves out throughout 2022 but favourable forecast demand for cement in the US is balanced by inflationary pressure. Persistent low staffing levels could further add to inflation growth. The US cement sector may be doing well at the moment but even success carries risks.

Global Cement’s Robert McCaffrey will be giving a keynote presentation at the IEEE-PCA Cement Conference in Las Vegas on Tuesday 3 May 2022. The May 2022 issue of Global Cement Magazine, including interviews with PCA chief executive officer Mike Ireland and chief economist Ed Sullivan, is available to download now.


India: ACC has appointed Rashmi Khandelwal as its company secretary. She succeeds Rajiv Choubey who will remain with ACC as chief legal officer.

Khandelwal is a qualified company secretary with 13 years of professional experience. Previous roles include working for YES Bank and the legal company Mis Yaish Associates. She has also co-written two books about the government’s Companies Act 2013.


India: Adani Group has reportedly entered an advanced stage of discussions with Holcim over its possible acquisition of the latter's Indian cement operations. The Times of India newspaper has reported that Holcim subsidiaries Ambuja Cements and ACC together have a cement production capacity of 64Mt/yr. The value of their assets has a market cap of US$15.7bn.


Mexico: GCC recorded consolidated sales of US$207m in the first quarter of 2022, up by 16% year-on-year from first-quarter 2021 levels. US sales growth of 21% contributed to the increase, driven by regional cement volumes growth of 10%. The group's cement volumes in its native Mexico rose by 12%. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) in the quarter reached US$54.5m, up by 10% year-on-year. Following the results, the company plans to reactivate its on-going share buyback programme.

Chief executive officer (CEO) Enrique Escalante said "GCC is off to an excellent start this year. We are pleased with the results delivered during this quarter and of the way we are overcoming a high inflation environment amid global challenges. One of our top priorities is being extremely vigilant in offsetting cost pressures as we capitalise on market opportunities and focus our efforts in maximising production and terminal outputs. Market trends and full-year backlogs are encouraging for 2022; therefore, we expect to end the year in line with our high-single to double-digit EBITDA growth guidance."


Spain: Cementos Molins recorded first-quarter consolidated sales of Euro274m in 2022, up by 23% year-on-year from first-quarter 2021 levels. The group's net profit for the period fell by 34% year-on-year to Euro22m. It attributed this to material, power and transport costs inflation. During the quarter, Cementos Molins acquired Hanson Hispania's Catalonian ready-mix concrete and aggregates operations. It says that its 0.8x debt-to-earnings before interest, taxation, depreciation and amortisation (EBITDA) ratio positions it well to continue with the execution of its Strategic Plan 2020-2023.

Chief executive officer (CEO) Julio Rodríguez said “The year 2022 has an uncertain and highly complex global environment, in which the war in Ukraine and its global effects are added to the previously existing problems of costs inflation and supply chain disruptions. Despite this complex environment, we expect to continue in 2022 the path of solid results achieved in previous years."


Uzbekistan: Orient Group has entered talks with foreign banks to obtain loans and raise funds. BNE IntelleNewshas reported that the company's earnings before interest, taxation, depreciation and amortisation (EBITDA) is 3x its debt.

Head of corporate finance Davron Ozgurer said “Now we are well diversified, but we plan to exit some of the businesses and sectors but we are also considering getting into some new businesses. The main change will be that now we are an operational company – we make and sell things – but the plan is to transform into more of a financial holding. But that will take time.” Regarding future fundraising, Ozgurer said “Nothing is decided yet. We are just looking at options, but we could issue a bond, or maybe take a syndicated loan. Eventually, an initial public offering (IPO) could be possible.”


India: Police in Mumbai, Maharashtra, have opened a case against a Gujarat-based cement producer on charges of cheating, forgery and criminal conspiracy. The Times of India newspaper has reported that the accused company borrowed US$27m in 2017 and early 2018, purportedly for the purchase of four clinker carrier ships and the construction of jetties at two sites in Gujarat. However, the producer had mortgaged all four ships, pledging over 20% of its shares. From the funds, it reportedly paid itself for the construction of the jetties, and used US$17.35 to repay outstanding bank loans.


Dominican Republic: Mexico-based Cemex has reopened the second production line at its integrated San Pedro Macoris plant. The decision will add 0.5Mt/yr to the plant’s production capacity bringing its total to 2.5Mt/yr. The decision has been made to support customers in the Caribbean market. Other recent investment in the country by Cemex include new packaging machines, palletisers, hydro combustion, new trucks and tanks.

Jesús González, the president of Cemex South, Central America and the Caribbean said “The reactivation of the production line is a clear example of our commitment to the sustainable development of the Dominican Republic. This investment contributes to the revitalisation of the national economy, promotes exports, reduces the need for imports and supports employment and a more sustainable environment in the country."


Denmark: FLSmidth has formed a partnership called ECoClay to develop and commercialise the technology needed to electrify the calcination of clay used in cement production. The partners include the Danish Technological Institute, US-based industrial heating specialist Rondo Energy, France-based Vicat, Colombia-based Cementos Argos and the Technical University of Denmark. The project is partly funded by the Energy Technology Development and Demonstration Program (EUDP) under the Danish Energy Agency.

The use of calcined clay in cement production allows cement producers to replace up to 30% of limestone-based clinker, resulting in up to 40% lower CO₂/t in cement produced. By electrifying the process, ideally powered by renewable sources, the ECoClay partnership expects to further reduce emissions by 10% at more uniform conditions that allow processing of a broader range of raw clays.

Based on the shared research and tests on high-temperature electric heat generation, storage solutions and renewable grid integration, the ECoClay partnership will build a pilot plant at FLSmidth’s research and development centre in Denmark. The consortium will seek to demonstrate how the ECoClay process is superior to the conventional combustion processes, has a smaller physical footprint on site and significantly lower emissions of air pollutants. According to the project plan, the ECoClay partners expect to be able to commence construction of the first full-scale electric clay calcination installation by the end of 2025.


Russia: Eurocement has started an initiative to reduce its reliance on spare parts purchased from outside of the country. The programme is designed to start a phased transition to in-house production of components. One of the first examples of the scheme has been the development and installation of a clutch for a mill at the Sengileevsky cement plant.

The cement producer hopes to source at least 90% of the parts it requires domestically. At present it says that around 30% of the equipment used in the local cement sector is imported. The estimated economic effect will be around Euro14m.

The company has also announced an unscheduled indexation of staff wages to over 7000 workers at 16 cement plants. Indexing of wages is typically used to compensate for inflation. Other measures have also included food support. Vyacheslav Shmatov, the general director of Eurocement, said ““We have decided to increase our support measures for our employees during this difficult time in order to strengthen our work teams. Eurocement is, first of all, people, so the company will continue to take care of its employees.”

International economic sanctions were implemented upon Russia by European and North American countries in response to its invasion of Ukraine in February 2022.


Czech Republic: Cement Hranice’s sales rose by 13% year-on-year to US$89m in 2021. Its cement sales rose most sharply in its domestic Czech market, especially in the second half of 2021. As a result, the company increased its net profit for the year by 4% year-on-year to US$25.6m.

Czech News Agency Business News has reported that the company said "The past year was marked by increased demand for cement. Especially at the end of the year, we were forced to reduce our clinker and cement stocks to the lowest possible level, but we still had to slightly reduce deliveries to our customers."


Mexico: Cemex has reported its successful completion of laboratory tests aimed at converting CO2 emitted by cement kilns into carbon nanomaterials. The producer said that it was able to turn 50% of available carbon in a flue gas stream into nanomaterials. Possible industrial uses for carbon nanomaterials include in building materials, biomedicines, electronics and agriculture. Cemex says that its next step will be to scale the technology for a cement plant pilot study.

CEO Fernando Gonzalez said “This breakthrough technology is significant for Cemex, not only because it offers the potential to commercialise carbon emissions, but because it demonstrates the value of our Smart Innovation platform. The path to carbon neutrality will be built with innovation, and we remain committed to being at the forefront in developing new circular technologies and processes.”


Cameroon: The government has enacted a ban on the export of cement, along with other commodities including oil and grain, from East Region. The Journal du Cameroun newspaper has reported that the impacts of the Russian invasion of Ukraine have exacerbated a difficult supply situation of the basic commodities in the region, dating to the beginning of the Covid-19 outbreak in the country in March 2020.

The East Region borders the Central African Republic and Congo. It has no cement plants of its own.


India: The Directorate General of Mines Safety (DGMS) has named Ambuja Cements’ Rabriyawas cement plant as winner of its National Safety Award (Mines). Its winning initiatives include its Behaviour Based Safety training programme and Reward & Recognition employee engagement programme. Ambuja Cements said that the award confirms that Ambuja's Zero Harm policy has borne fruit.


India: An explosion at a cement plant in Gujarat’s Rajkot district has killed three workers. The Times of India newspaper has reported that police have detained two engineers on suspicion of criminal negligence.


Zimbabwe: UK-based Associated International Cement Limited (ACIL) has reportedly rejected an offer for its 76% stake in Lafarge Zimbabwe. Lafarge Zimbabwe company secretary Faithful Sithole said that the parent company is still assessing offers received for the stake. The NewZimbabwe newspaper has reported that the declined offer may have come from China-based Huaxin Cement.


India: Bharathi Cement plans to build a US$17m automated terminal and packaging plant at Coimbatore, Tamil Nadu. United News of India has reported that the facility will package the company’s bagged and bulk cement and supply the South West Tamil Nadu and Kerala markets.

On 23 April 2022, the subsidiary of France-based Vicat despatched its first rake of cement aboard custom-built tank and box container cars to Coimbatore from its Kadapa, Andhra Pradesh, cement plant. Vicat’s India CEO Anoop Kumar Saxena said that the first-of-its method of bulk cement transportation will reduce the company’s logistics costs and carbon emission and increase the service level for customers.


US: Holcim US has become the first cement producer member of the Great Plains Institute’s Carbon Capture Coalition. The coalition’s 78 participating members and 23 observer organisations collaborate to build federal policy support for economy-wide, commercial-scale deployment of carbon capture and related technologies. Holcim US is currently assessing the viability of commercial-scale carbon capture, with two studies underway, at its Portland cement plant in Colorado and its Ste. Genevieve cement plant in Missouri.

Region head North America Toufic Tabbara said “Being at the forefront of developing low carbon solutions requires continuous innovative thinking and partnerships. Our efforts are most effective when we can align and join forces with other companies and organisations across industries who share this same commitment. We are proud to be part of an organisation that is similarly focused toward more efficient, innovative and sustainable practices.”


China: Gansu Qilianshan Cement plans to restructure its business. The group says that, should it proceed with its proposed restructuring, it will issue shares. Reuters News has reported that the restructuring may constitute a material asset restructuring.


Jamaica: Caribbean Cement says that its Rockfort cement plant in Kingston has surpassed 1000 days without a health and safety incident among employees and contractors. Health and safety coordinator Andre Haynes said that the achievement demonstrates that parent company Cemex’s Zero4Life zero-incident policy is possible.

Haynes said “As a company, we have invested heavily in the people aspect, with training geared towards improved safety and culture, and capital expenditure to improve the overall safety of the plant.” He said that the Rockfort cement plant will advance to its next safety milestone by keeping its focus on ‘closing all unsafe conditions’ and developing employees as health and safety champions.


Switzerland: Holcim recorded net sales of US$6.75bn in the first quarter of 2022, up by 20% year-on-year from US$5.62bn in the first quarter of 2021. The group’s recurring earnings before interest, taxation, depreciation and amortisation (EBIT) rose by 16% to US$643m from US$553m. The company has upgraded its outlook 2022 to a forecast of full-year net sales growth of at least 10%.

CEO Jan Jenisch said “I am very encouraged by the record start of the year, setting a solid foundation to our Strategy 2025 – Accelerating Green Growth.”

The first quarter of 2022 brought four new bolt-on acquisitions in addition to the group’s conclusion of its US$1.35bn Malarkey Roofing Products acquisition. The company says that it remains actively engaged in supporting humanitarian efforts in Ukraine.

Holcim has also published its industry-first Climate Report 2022. The report details the company’s progress towards achieving its sustainability targets under the four pillars of its Strategy 2025 – Accelerating Green Growth. Under the Accelerating Growth pillar, Holcim reached a total of 15 markets with its ECOPlanet reduced-CO2 cement range. Under Expanding Solutions & Products, it reduced the proportion of cement sales in its consolidated sales to 57% in 2021 from 60% in 2020. Its other pillars are Leading in Innovation and Sustainability and Delivering Superior Performance. In 2021, the company used 6.6Mt of recycled construction and demolition waste in its products, against a 2050 target of 10Mt.

Chief sustainability and innovation officer Magali Anderson said “On our net-zero journey, we are walking the talk at Holcim, taking clear science-driven action to win the race for climate.”


Middle East/North Africa: The World Cement Association (WCA) has called on its members in the Middle East and North African cement sectors to take new actions towards industry decarbonisation. UAE-based consultant and WCA member A3 & Co has said that companies in the region have the potential to cut their carbon footprints by up to 30% with no new capital expenditure required. The Middle East and North Africa accounted for 15% of global cement production in 2021. In the region, only the UAE and Saudi Arabia have committed to national net zero carbon targets, for 2050 and 2060 respectively.

WCA CEO Ian Riley said “There has been a lot of discussion in Europe and North America about decarbonisation roadmaps for the cement industry and good work has been done to start on this journey. However, 90% of the world’s cement is produced and used in developing countries; to impact overall industry emissions we must include these stakeholders. Cement companies in the Middle East have some low hanging fruit to take advantage of, which will lower costs at the same time as reducing CO2 emissions. At WCA we have a number of programmes that can help them realise this opportunity."


Colombia: Cementos Argos says that 368,000 people directly benefited from its social investment programmes in Colombia in 2021. During the year, the company invested US$4.56m in projects including its Hogares Saludables home improvement programme and its Via Forte road infrastructure programme. The Via Forte programme has laid 600km of road since 2017, while the Hogares Saludables programme aims to assist and improve over 10,000 homes by 2027.


Serbia: The impacts of Russia’s invasion of Ukraine mean that the Serbian cement industry’s operations are ‘endangered’ and will likely fail to meet steady market demand in the coming months. Serbian Cement Industry Association director Dejana Milinkovic said that the industry relied on Russia and Ukraine for 50% of its coal supply in 2021.

In 2021, the industry produced 2.6Mt of cement, up by 10% year-on-year, operating close to 100% capacity utilisation.


Bangladesh: Shun Shing Group subsidiary Seven Circle says that it has successfully migrated its on-premises, business-critical, finance and manufacturing systems to Oracle’s Cloud Infrastructure digital services platform. The Bangladesh Monitor newspaper has reported that the company made the transition in order to lower its costs, increase its operational agility and improve productivity. It has since experienced a 30% drop in capital expenditure and almost doubled its uptime as a result. Seven Circle also deployed cloud disaster recovery capabilities for its workloads on the new platform. This can allow the company to serve its customers in a timely manner and reinvest the savings to drive innovation.

Shun Shing Group human resources and digitalisation head Anika Ali Chowdhury said “Running our back-office operations quickly and reliably, 24/7, is critical for success. It helps us to ensure we are sourcing the best raw materials, making the right production investments, and delivering quality products with reliable and fast delivery. This allows us to earn the highest level of customer trust.”


US: Concrete companies have reported an on-going shortage of cement as a contributor to increased costs in the construction industry. Local press has reported that the shortage is the result of high demand, most notably from commercial projects. A lack of cement truck drivers has reportedly exacerbated the supply situation.

North Carolina-based ready-mix concrete producer Metrocon president Dan Crosby said that his company’s facilities are currently operating at 60% capacity due to the shortage.


Canada: Carbon Upcycling Technologies has secured US$6.15m in financing from a group of companies led by Clean Energy Ventures, Cemex Ventures, Amplify Capital and Oxy Low Carbon Ventures (OLCV). The investment round includes participation from Zero Carbon Partners, Purpose ESG, Clean Energy Venture Group, Fund for Sustainability and Energy, Prithvi Ventures, Bryan Trudel, and Mark and Faye McGregor. Carbon Upcycling intends to use the funding to grow its team and build its second commercial-scale facility in North America, with a production capacity of over 200t/day of its cement and concrete additive. Carbon Upcycling sequesters CO2 in secondary cementitious materials such as fly ash, which are then used in cement or concrete production.


US: Conveyor Components has announced the launch of its SBR belt cleaner, a smaller version of its original brush-style belt cleaner. The cleaner uses an electric motor to drive a helical shaped, open face brush. Its hanger rail mounting allows for field customisable mounting on most conveyors. The supplier says that the product efficiently removes fines and carry-back material without clogging or loading.


Namibia: Immigration authorities have deported eight illegal Whale Rock Cement workers back to China. The Namibia Press Agency has reported that a court sentenced the Chinese nationals to deportation and fined them US$403 each.

Whale Rock Cement has reportedly launched its own legal action against vigilante workers’ rights group Namibia Economic Freedom Fighters (NEFF), which uncovered the illegal practices, for trespassing.