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UltraTech Cement approved a US$1.5bn capacity expansion plan this week. The initiative intends to add 21.9Mt/yr in production capacity by setting up four new cement plants, four upgrades and four new terminals. It will also add 39MW in waste heat recovery (WHR) units and alternative fuels feeding and handling investments. Commercial production at the new sites is scheduled to start from the 2026 financial year onwards.

The company is India’s largest cement producer by production capacity and the third biggest globally outside of China. Yet it is still growing as this latest announcement shows. Kumar Mangalam Birla, the chair of parent company Aditya Birla Group, revealed the ambition earlier this year, that UltraTech Cement wants to reach a production capacity of 200Mt/yr in the near future. This is likely to be ordinary Portland cement (OPC) capacity from both integrated and grinding plants. It reported a figure of 132Mt/yr in its annual report for the 2023 financial year. This latest capacity investment is its third in recent years. In December 2020 it announced investment of just below US$560m to add 12.8Mt/yr of capacity with commissioning by around the end of the 2023 financial year. It later confirmed that most of this had been completed on schedule. Then another US$1.55bn investment was ordered in June 2022 to add 22.6Mt/yr. This tranche of new plants and terminals is planned to be completed by the end of the 2025 financial year.

Graph 1: UltraTech Cement’s OPC production capacity and utilisation rate, 2017 - 2023 financial years. Source: Company annual reports.

The graph above shows how the company’s capacity has grown since 2017. This is the year in which it acquired 21Mt/yr of capacity from Jaiprakash Associates for US$2.5bn. These plants then show up in the capacity figure for 2018. The next big bump to capacity arrived in 2019 when UltraTech Cement was able to complete its purchase of Century Textiles & Industries, adding another 15Mt/yr of capacity. Since then though it has mainly been newly built plants or upgrades. It is also worth noting the capacity utilisation figures the company has reported. There has generally been an upward trend since 2017 with a dip during the Covid-19 pandemic years in 2020 and 2021. This has also been happening despite adding more capacity through both acquisitions and building new plants. The other point to note is that the cement company is mostly a wholly India-based one. It has presences in the UAE, Bahrain and Sri Lanka but these are small compared to the operations back home. In the 2023 financial year, 23 of its 24 integrated plants were domestic, 25 out of 29 grinding plants were and seven out of eight terminals were too.

UltraTech Cement’s current nearest rival, Adani Group, appeared on the scene in 2022 when it bought Holcim’s subsidiaries in India. The timing may have been coincidental but, after Holcim agreed to sell to Adani Group in May 2022, UltraTech Cement announced its US$1.55bn capacity drive in June 2022. A year later in June 2023 Adani Group targeted a capacity of 140Mt/yr by 2028. To give an idea of the market both of these companies are competing in, Ratings Agency ICRA’s last forecast in September 2024 predicted that cement volumes would grow by 9 - 10% in the 2024 financial year. Capacity expansion by all cement producers was expected to be driven by “steady demand for housing and increased government investments in infrastructure.”

UltraTech Cement may be the fastest expanding cement company in the world at the moment. India certainly needs the cement as its population overtook China’s in April 2023. The Aditya Birla Group company is not taking any chances with its competitors by maintaining its lead in capacity. One risk it may want to watch out for though is India’s nascent Carbon Credit Trading Scheme. Some form of carbon trading for the petrochemicals, steel, cement and paper sectors looks set to start in the second half of the 2020s. However, any such scheme is likely to favour incumbent manufacturers with newer plants. With the country’s net zero target set at 2070, UltraTech Cement has plenty of room to manoeuvre.

UK: The World Cement Association (WCA) has appointed Wei Rushan as its president. He succeeds founding president Song Zhiping in the post.

Wei has been the president and executive director of CNBM since late 2022, having had a range of senior roles within CNBM Group over the last 15 years. He obtained a doctoral degree in political economy from the School of Economics of Renmin University of China in 2007. Wei also serves as president of China Building Materials Engineering Construction Association.

Saudi Arabia: The board of directors of Umm Al-Qura Cement Company has appointed Mohamed Fadl Kamel Al-Hawi as its interim chief executive officer. Previous company head Majid Tarik Gharbawi resigned in August 2023 with effect from mid-October 2023.

Mohammad Al-Hawi holds a bachelor’s degree in mechanical engineering from King Fahd University of Petroleum and Minerals. His cement industry experience spans over 30 years, including his role as plant manager of the Umm Al-Qura Cement Company plant.

UK: James Thorne has been appointed as the joint-head of the Mineral Products Qualifications Council (MPQC) and The Institute of Quarrying (IQ) with effect from December 2023. He has been the chief executive officer (CEO) of IQ since 2017. He takes over the new joint-position following the retirement of the MPQC‘s current CEO Viv Russell.

The appointment of a joint-head of both organisations marks a long-standing collaboration between the two membership organisations. The MPQC and the IQ signed a memorandum of understanding in 2022 to work together to increase the value of membership services within the mineral products sector and further develop partnerships with other sectors, industries, and government bodies. This also supports the strategy to develop the National Stone Centre as an international centre of excellence for the mineral products industry.

Established in 1983, the MPQC is a 'not for profit' membership organisation whose purpose is to fulfil the extractive sector's need for a safe, competent and sustainable workforce through the setting and maintaining of standards and qualifications, ensuring quality training and assessment.

The IQ is the professional membership body for quarrying, and the related mineral products extractive and processing industries, with a worldwide membership of more than 5500 individuals.

India: Nuvoco Vistas sold 4.5Mt of cement during the second quarter of its 2024 financial year (FY2024), up by 1.2% year-on-year. Its revenues grew by 7% to US$309m, while its earnings before interest, taxation, depreciation and amortisation (EBITDA) grew by 73% to US$40.4m. The producer achieved specific CO₂ emissions of 462kg/t and an alternate fuel (AF) substitution rate of 14%. During the quarter, it completed debottlenecking projects at the Risda, Chhattisgarh, and Nimbol, Rajasthan, cement plants. The company said that these raised its clinker capacity by 2000t/day. It also secured a new patent, for its fibre reinforced cement composition, and introduced its Concreto UNO and Duraguard F2F premium cements on the Jharkhand market.

Managing director Jayakumar Krishnaswamy said “Our value over volume strategy has positively contributed to the company’s performance. Our trade share has increased from 72% in the second quarter of the 2023 financial year (FY2023) to 74% in the second quarter of FY2024. In addition, the results also demonstrate our commitment to managing the dynamic cost environment through an optimised power and fuel mix, between conventional and clean energy sources.” He added “The expansion at the Haryana cement plant is expected to be completed in FY2024, which will enable us cater to strong demand in the Northern India region.”

Nigeria: Lafarge Africa raised its consolidated sales by 7.1% year-on-year to US$367m throughout the first nine months of 2023. Over the same period, the company’s cost of sales rose by 4.4% to US$179m. Its net profit was US$49.9m, down by 13% year-on-year.

Philippines: Cemex Philippines’ sales were US$238m during the first nine months of 2023, down by 15% year-on-year. The Philippine Daily Inquirer newspaper has reported that the company recorded increased costs during the period, although its electricity costs dropped. It implemented cost efficiency measures, but failed to reduce its net loss, which rose by 47% to US$66.5m from US$45.4m.

President and chief executive officer Luis Franco said "In this year of transition for our company, we remain dedicated to finding opportunities to improve our overall efficiency and profitability by proactively managing the variables we can control. I am pleased with the initial progress we have made in the implementation of our efficiency programme and its results in optimising our operations, streamlining processes, increasing supply chain efficiency and improving our energy mix."

Saudi Arabia: Yanbu Cement’s sales were US$156m during the first nine months of 2023, down by 21% year-on-year. Its net profit also dropped in the period, by 35% to US$27.1m.

Mexico: Cemex has refinanced a syndicated credit agreement worth US$3bn. Dow Jones Institutional News has reported that the refinanced agreement includes a US$1bn, five-year term loan and US$2bn five-year revolving credit facility.

Cemex’s chief financial officer Maher Al-Haffar said "We now have a flatter debt maturity profile, with no significant maturities in any year."

Algeria: Holcim Algeria successfully commissioned a new 18,000t/day clinker loader at the Port of Djendjen in late October 2023. The cost of the equipment was Euro3m. APS News has reported that port authorities have ordered two further such machines from China.