Global Cement News

Pakistan: Cement exports from Pakistan fell by 36% year-on-year to 467,000t in September 2015, as the import duty by South Africa took a heavy toll on its exports.

"Around 45 – 50% of total cement exports were destined for South Africa before the duty was imposed," said Sheikh Adeel, Senior Manager of Sales and Marketing at Maple Leaf Cement. South Africa has imposed duty as high as 77% on Pakistan's cements. Adeel said that the drop in exports has adversely affected exporters in Punjab. The transportation cost from Punjab to Karachi Port also rose by US$20/t.

Another industry official said that the industry is not utilising its production capacity. "There is enough idle capacity. The government should step in to support the industry to export surplus volumes, otherwise cement exports will continue to decline in the coming months," said Shahzad Ahmed, a spokesman of the All Pakistan Cement Manufacturers Association (APCMA). "We expect the government to announce export incentives for the cement industry."

In September 2014, cement exports stood at 730,000t, according to APCMA data. Total cement dispatches were recorded at 2.95Mt in September 2015 compared to 3.15Mt in September 2014, showing a cut of 6.34%. The industry data showed that cement dispatches to domestic markets were 2.48Mt in September 2015 compared to 2.42Mt in September 2014, up by 2.6%.

The local industry has been demanding that the government curb cement imports from Iran, which they said is eating into local share. "The industry expects the government to take effective steps to stop the penetration of Iranian cement in Pakistani markets through massive under invoicing and/or mis-declaration," said Ahmed. He added that the mills in the south suffered more than those operating in northern part of the country.

In the south, domestic cement dispatches declined to 399,581t in September 2015 from 431,133t in September 2014. Domestic consumption in the north, however, rose to 2.08Mt in September 2015 from 1.99Mt in September 2014. Ahmed said that domestic dispatches in the north were nominally higher than the 2.02Mt of consumption in September 2015. "This shows that the pace of construction in the north has not been hit as badly as in the south," he said. The export decline was almost the same both in north and south. Cement exports from the north declined to 306,564t in September 2015 from 480,025t in September 2014. Exports from the south dipped to 160,698t in September 2015 from 249,906t in September 2014.

Brazil/Turkey: Votorantim Cimentos has announced investment plans of up to US$158m to expand its business in Turkey. As well as tripling the output of its cement plant in Sivas, Votorantim may set up or acquire a new plant to tap the growth potential of Turkey's construction sector, according to company officials.

"The investment in our Sivas plant will boost production capacity to 1.8Mt/yr, up from its current level of 600,000t/yr. Following the upgrade, the Sivas plant will account for 42% of Votorantim's cement production capacity in Turkey," said Sefik Tuzun, Votorantim Turkey's CEO. "Votorantim sees the potential of Turkey's construction sector and this investment shows our commitment to reinforcing our presence in Turkey. Sivas' expansion will bring a crucial dynamism and competitiveness to the company in the Turkish cement market."

The capacity upgrade will be completed by April 2017. The construction works for the extension will create employment for 700 people. Votorantim Turkey is active in cement production as well as concrete and aggregate businesses in the country, accounting for a share of about 29% of Votorantim Cimentos' total production capacity, excluding China.

Turkey: Global Cement Magazine is exhibiting at the 13th TCMB International Technical Seminar and Exhibition at the Gloria Golf Resort Hotel in Antalya, Turkey on 7-10 October 2015. Around 510 delegates looking to learn about the latest technical innovations and new products and services will visit the event, which is sponsored by ABB Group.

Picture: Fatzunnahar Ngopil of Fosroc, Asia, visits the Global Cement stand to talk with Paul Brown, Commercial Director of Global Cement.

We report on development from Japan this week with the creation of a low-alkali cement for use at nuclear waste sites. Professor Katsuyoshi Kondo, Joining and Welding Research Institute at Osaka University, and Nippon Steel & Sumikin Cement Co have prepared a process that mixes silica dioxide extracted from rice chaff with cement.

As press reports explain, the team has developed technology to extract highly purified silica with numerous holes measuring 5 – 7nm in diameter by washing rice chaff with organic acid and burning it. The surface area of the silica extracted from rice chaff is 50,000 - 90,000 times larger than that contained in existing cements, enhancing the reaction between silica and calcium hydroxide and thus lowering the alkaline level.

The stated application for this new research is for underground nuclear waste disposal sites. At these locations extremely high durability is required for long periods of time, potentially for tens of thousands of years.

Normally the concern with alkali-silica reactivity is between alkali in the cement and a sensitive aggregate over a shorter time period. Under high moisture and high alkali content the resulting concrete can crack leading to reduced-performance. However, the issue with nuclear waste storage is that it has to be stored underground and for long periods of time. This means that the cement can potentially react with groundwater producing calcium hydroxide making the groundwater alkaline. This can then react with aggregates in the clay and bedrock at the storage site. Clearly this is undesirable for a long-term storage site of hazardous materials.

In the wake of the Fukushima disaster, this kind of development will be of high interest in Japan. It will also have applications around the world wherever radioactive waste sites are built.

One example of the demanding construction conditions facing builders in these environments is the original sarcophagus used to encase the Chernobyl Nuclear Power Plant reactor in 1986. Building it used more than 7,000t of steel and 410,000m³ of concrete. Erected in a hurry under horrendous conditions, the container was never sealed properly and the structure was only given a design lifespan of 20 to 30 years. Currently a replacement, New Safe Confinement, is being built at a projected cost of Euro2bn for completion in 2017. The structure will be up to 100m tall and 165m long with a lifetime of at least 100 years.

One of the issues raised in the documentary film 'Into Eternity' is what exactly should one daub on the entrance to a long-term waste dump? Given that the Onkalo spent nuclear fuel repository in Finland is planning to stay sealed for 100,000 years, how should its planners communicate to people, who potentially rediscover it in the future, that they should stay away? One suggestion quoted here is to put Edvard Munch's The Scream on the door. However, we have difficulty today in reading and interpreting Ancient Egyptian writing and art from 5000 years ago. What this means for any of our descendants unlucky enough to stumble upon a buried nuclear waste site is anyone's guess. At the very least though using a low-alkali cement that will last as long as possible is a good start.

South Africa: Cement producer PPC has been named as the new naming sponsor for the Newlands Cricket Ground in Cape Town, Western Province. "We want to cement this relationship," said PPC chief executive Darryll Castle on 6 October 2015 at the stadium.

Although an obvious play on words, Castle could not contain his excitement as it was made official that the ground will now be known as 'PPC Newlands.' "We're exceptionally proud to be creating a new moment in history for these two champion brands and are looking forward to adding real value to the sport, the community and, ultimately, the country through this new legacy partnership with the Western Province Cricket Association," he added.

The first international action at the PPC Newlands stadium will see South Africa take on England in the New Year's Test against England in January 2016.