Global Cement News

Congratulations are due to the National Cement Company of Alabama and Vicat for the inauguration of the new production line at the Ragland cement plant in Alabama. The event took place on 21 July 2022.

The US$300m project was originally announced in late 2019. It then took two years to build with construction starting in January 2020. Key features include a raw vertical grinding mill, a new roller mill, a five stage preheater tower, an automatic clay storage system, a 78m tall homogenisation silo, an alternative fuels storage area for tyre-derived fuel, sawdust and wood chips, a laboratory and a new control room. The new kiln was previously reported to have a clinker production capacity of 5000t/day and it will add up to 2Mt/yr of cement production capacity to the plant. ThyssenKrupp signed up as the principal equipment supplier in 2019 and H&M was the main contractor. The production line is expected to reduce energy consumption by one third. Further change is scheduled with a switch to production of Portland limestone cement (PLC) from Ordinary Portland cement (OPC) by the start of 2023.

Vicat has repeatedly noted its affection for the plant as it was the first cement plant the group purchased outside of France, back in 1974. Indeed, Vicat’s group chair and chief executive officer Guy Sidos personally managed the Ragland plant in 2001. However, rather more prosaic reasons may also have been behind the decision to expand Ragland. According to United States Geological Survey (USGS) data, Alabama, Kentucky and Tennessee’s cement shipments grew by nearly 5% year-on-year to 7.1Mt in 2019 from 6.8Mt in 2018. Shipments are up by 3% year-on-year to 2.5Mt in the first four months of 2022 and the three states were the fifth largest region in the US for cement shipments in April 2022. A shortage of cement was also reported in Alabama in April 2022.

The other big US-based cement plant expansion is Lehigh Hanson’s US$600m upgrade to its Mitchell plant in Indiana. It also celebrated a milestone this week with a ‘topping out’ ceremony to mark the placement of the final section of steel for the stack. Another recent achievement here was the completion of a 169,000t storage dome supplied by Dome Technologies. The supplier says that the 67m diameter and 48m tall dome is the second largest clinker storage facility in Europe and North America, after one it previous built in Romania in 2008.

The Mitchell K4 project was announced in mid-2018 and then ground breaking began in late 2019. However, the start of the coronavirus pandemic delayed construction in early 2020 before it restarted in September 2020. The revised commissioning date was then moved back about half a year to early 2023. The key part of this project is that it will replace the plant’s three current kilns with just one. The new production line will increase the site’s production capacity, reduce energy usage and decrease CO₂ emissions per tonne of cement. It was reported by local press back in 2018 that the project would increase the plant’s cement production capacity to 2.8Mt/yr. The project has been linked to supplier KHD with CCC Group as the contractor.

It’s fascinating to see two major new upgrades to cement plants emerging in a mature market like the US and during an unprecedented event like the emergence of coronavirus. No doubt compelling tales will emerge of how both teams coped with managing nine-figure capital expansion projects as a global public health emergency unfolded. The US market has been on a roll in recent years, despite all the uncertainty in the world, and so far it doesn’t seem to be slowing down. With luck both of the projects feature above have timed their opening right.

Pakistan: Dewan Cement has appointed Ishtiaq Ahmed as its chief executive officer (CEO). He succeeds Malik Bilal Omar in the position. Ishtiaq Ahmed was previously appointed as the company’s chair in 2018. Waseem-ul-Haque Ansari has also been appointed as a director in place of the departing CEO.

Switzerland: Holcim increased its consolidated sales by 17% year-on-year to US$15.3bn in the first half of 2022 from US$13.1bn in the first half of 2021. Its recurring earnings before interest and taxation (EBIT) were US$2.26bn, up by 9.6% from US$2.06bn. Cement sales volumes fell by 3.7% to 95.3Mt from 99Mt, and decreased in all regions except North America, where they rose by 9.6% to 10Mt. Meanwhile, the sharpest drop was in Holcim’s home region of Europe, where cement sales fell by 9.5% to 20.1Mt from 22.2Mt. Group operating profit rose by 15% to US$2.15bn from US$1.86bn, while its net debt rose by 7.5% to US$13.9bn from US$12.9bn.

Holcim called market conditions “volatile,” but forecast net sales growth of 10% year-on-year on in 2022, upgraded from 8%. It also expects to end the year with accelerated progress towards its 2025 sustainability targets, positive growth in its recurring EBIT and a free cash flow above US$3.12bn.

Chief executive officer Jan Jenisch said “Our record results, from net sales to recurring EBIT and earnings per share, are setting solid foundations to deliver our Strategy 2025 - Accelerating Green Growth.”

Thailand: Siam Cement Group (SCG) recorded sales of US$8.29bn in the first half of 2022, up by 19% year-on-year from US$6.95bn in the first half of 2021. Cement and building materials revenues were US$2.82bn, 34% of total sales, up by 12% from US$2.52bn in the first half of 2021. The group’s earnings before interest, taxation, depreciation and amortisation (EBITDA) dropped by 24% to US$1.15bn from US$1.51bn.

SCG recorded domestic declines in demand for cement and ready-mix concrete of 5% and 7% respectively in the first half of 2022. Cement demand also fell by 10% in Cambodia and by 2% in Myanmar, but rose by 5% in Indonesia and by 1% in Vietnam. In Thailand, SCG expects cement demand to “improve” in the third quarter of 2022, but noted the possible mitigating impact of rising inflation.

UK: Breedon Group recorded sales of Euro798m in the first half of 2022, up by 12% year-on-year from Euro714m in the first half of 2021. Its earnings before interest and taxation (EBIT) increased by 22% to Euro77.9m from Euro63.9m, while its profit after tax increased by 29% to Euro70.7m from Euro54.9m.

The group said “We are optimistic for the remainder of 2022. Our customers’ order books are healthy, the mechanism for passing through cost increases has traction and enquiry levels are encouraging. We therefore expect to deliver underlying EBIT at the top end of the range of consensus expectations.”

Chief executive officer Rob Wood said “We enjoyed a strong start to 2022. Our teams are focused on getting pricing right, our end market exposure is supportive and that has produced excellent results, advancing our margins and returns towards our medium term targets. We completed two in-fill transactions during July 2022, with further mergers and acquisitions activity in the pipeline, and we have continued to progress on a broad range of sustainability initiatives, including a commitment to the Science Based Targets Initiative.”