Displaying items by tag: Holcim

The key trends to note from the financial results of cement producers in 2022 released so far are that sales revenues are up, sales volumes of cement are mostly down and earnings have mostly dropped too. Readers are not going to be surprised that 2022 was a tough year for business as the raw materials and services inflation coming out of the coronavirus period was heightened by energy cost spikes caused by the Russian invasion of Ukraine. Producers put their prices up in response to deliver often record high annual revenues.

Graph 1: Sales revenue from selected cement producers in 2021 and 2022. Source: Company reports. Note: Figures calculated for UltraTech Cement.

What sticks out by looking at the sales volumes of cement figures in Graph 2 (below) is that Holcim’s cement sales volumes were about the same as Heidelberg Materials’ were in 2022, at around 120Mt. Remember, Holcim’s cement sales volumes were 200Mt in 2021 and 256Mt in 2015 at the time of the merger with Lafarge. Large divestments have followed with the sale to Adani Group of Holcim’s India-based companies in 2022 being one of the biggest. UltraTech Cement, meanwhile, has been steadily increasing its India-based cement production capacity.

Graph 2: Cement sales volumes from selected cement producers in 2021 and 2022. Source: Company reports. Note: Figures calculated for UltraTech Cement.

By company, Holcim’s diversification and regionalisation strategy appears to be paying off well. Reducing its exposure to the cement market is giving it a strong story to tell as it grows its light building materials division, frames this as a success in sustainability and moves out of developing markets. How well this will work if and when it ends the divestment and investment stage remains to be seen. One point to highlight is that its operating profit fell by 18% year-on-year on a like-for-like basis to US$3.43bn in 2022. As well as contending with high costs in 2022, a subsidiary connected to the group was fined US$778m by the US Department of Justice in late 2022.

Heidelberg Materials’ approach to the current economic conditions in 2022 seems to have been to keep its head down and push on for decarbonisation rather than diversifying its business. So it followed the ‘sales up, costs up but earnings down’ pattern of a few of the other cement companies covered here. Although, that said, it did diversify its name to ‘Materials’ from ‘Cement’ in September 2022.

Cemex experienced the same problems as the other companies for most of 2022 but conditions started to improve in the fourth quarter in most of its territories. In particular, it reported that earnings started to grow in Mexico towards the end of 2022 despite falling sales volumes of cement. It attributed this to its pricing strategy. Of note this week, the Mexican government is preparing to support higher levels of imports of cement into the country due to a shortage in the southeast of the country.

Buzzi Unicem, meanwhile, noticed a faster slowdown in cement deliveries in its key markets in Italy, the US and Eastern Europe in the last quarter of 2022 from a general trend that could also be seen earlier in the year. In its largest market, the US, it reported that investment in residential construction slowed. This was further affected by the growing cost of building materials and the rate of inflation, although increasing spending on infrastructure helped to keep domestic consumption stable. A favourable currency exchange rate between the US and the Euro also helped the company to report provisional earnings growth. Vicat’s US businesses in the US and Brazil helped cushion the group somewhat with a large rise in sales revenue. However, earnings in the US were hit by the costs related to the start up of the new kiln at the Ragland plant in Alabama, as well as general energy cost inflation. Its business in France fought against inflation with ‘significant’ price rises delivering a high increase in sales revenue but this was insufficient to prevent earnings from dropping.

The non-European based cement producers present a different picture. Despite the high energy costs, UltraTech Cement managed to increase its revenue and sales volumes of cement in 2022. Its net profit fell though year-on-year in the nine months to 31 December 2022. The company is targeting a cement production capacity of 159Mt/yr by around the 2025 financial year with the aim of becoming the largest cement producing company in the world outside of China. Dangote Cement managed to raise its prices at home in Nigeria to fight off inflation and hold revenue and earnings up. This was harder internationally though with supply chain disruption, high commodity prices, high freight rates and a plant shutdown in Congo blamed for holding earnings back.

Inflation and the energy markets will be clear concerns in 2023. If energy prices for industry stabilise globally then there is more of a chance for business as usual as markets cope better with higher costs. The continued dilemma for multinational cement companies remains whether to decarbonise through diversification or investment in new processes, and how far to go along either path. Meanwhile, the large regional producers are starting to show themselves outside of China, as UltraTech Cement’s growth trajectory testifies. One test for these companies is balancing the risk of expansion versus potential tighter local environmental regulations. The environmental rules of export markets are also a factor to consider here with the head of AdBri calling this week for an Australian equivalent to the European Union’s border adjustment mechanism to block so-called ‘dirty’ imports.

The next set of financial results from the cement sector in 2022 to look out for will be those from the large China-based cement producers. Once these are released we will examine them in more detail.

Switzerland: The board of directors of Holcim intends to propose Jan Jenisch as the group’s chair at its annual general meeting in May 2023. The move follows current chair Beat Hess’ decision not to stand for re-election. Hess was elected to Holcim’s board of directors in 2010 and became its chair in 2016. Jenisch has been the chief executive officer (CEO) of Holcim since 2017 and a member of the board of directors since 2021. He was previously the CEO of Sika from 2012.

Switzerland: Holcim recorded sales of US$31.2bn during 2022, up by 8.8% year-on-year from US$28.7bn in 2021. Its recurring earnings before interest and taxation (EBIT) were US$5.08bn, up by 3% from US$4.93bn. The group's cement business recorded sales of US$17.5bn, up by 14% on a like-for-like basis. Its EBIT grew to US$3.53bn, up by 1% on a like-for-like basis.

In its Asia Pacific region, Holcim faced high cost inflation in India and reduced demand in China, but reported 'good performance' in Australia. In Europe, the group's cement volumes were ‘softer’ but 'strong pricing' offset cost inflation. It recorded 'strong profitable growth' in Latin America and 'over-proportional recurring EBIT growth' in Middle East - Africa and North America.

Chief executive officer Jan Jenisch said “As we enter 2023, we are continuing our fast pace. We’ve already made seven acquisitions in the first two months of the year, including Duro-Last, a roofing systems leader in the most attractive North American market. We also acquired German roofing leader FDT to expand our commercial roofing presence in Europe, as well as a range of bolt-ons across Europe and the US. I look forward to another year of continued profitable growth and fast-paced transformation, to become the global leader in innovative and sustainable building solutions.”

Spain: Holcim España has appointed José María Gómez as the director of its Jerez cement plant near Cadiz. Gómez previously worked as the Head of Production at the Montcada i Reixac cement plant near Barcelona. He holds over 15 years of experience with the company, including in Malaysia. He is a graduate in environmental sciences from the University of Castilla-La Mancha.

Algeria: Lafarge Algeria has appointed Redouane Djazairi as a plant manager. He has worked for the subsidiary of Holcim for nearly 20 years in a variety of quality control and performance roles. Most recently he held the position of Production Manager. The cement producer operates two integrated plants in the country, at M'Sila and Oggaz respectively.

US: Holcim subsidiary Geocycle has signed a multi-year contract with Louisville Gas and Electric and Kentucky Utilities to market fly ash produced by the power generation companies. Geocycle and Holcim will use to up to around 225,000t/yr of fly ash to produce blended cement products.

Sophie Wu, Head of Geocycle North America, said “In line with Geocycle’s commitment and passion for recycling and achieving a net zero future, we are honoured to partner with Louisville Gas and Electric and Kentucky Utilities to develop creative and efficient solutions that contribute to the circular economy.” She added, “Together we’ll be able develop blended cementitious materials, reduce CO₂ levels and further encourage carbon neutral construction.”

South/Central America: Holcim Latinoamérica says that it expects to use 18% renewable power across its operations in February 2023, compared to 8% throughout 2022. The regional unit of Holcim says that it will increase its share of renewable power to 25% by the end of 2023. It is committed to a target of 60% renewables by 2030. Holcim Latinoamérica's operations span Argentina, Colombia, Costa Rica, Ecuador, El Salvador, Nicaragua and Mexico.

Earlier in February 2023, Holcim Nicaragua commenced construction of a 3.38MW solar power plant in Nagarote, León Department. The producer said that the solar power plant's contribution to the national grid will cover 40% of its consumption in its cement operations there.

Holcim's Latin America regional head Oliver Osswald said “Our world is in constant change from population growth, urbanisation and the climate challenge. That is why, at Holcim, we are determined to put our best foot forward to accelerate low carbon circular construction."

Switzerland: CDP, a non-profit organisation that helps industrial players improve their environmental performance, has recognised Holcim's sustainability achievements with an award for a double ‘A’ ranking in climate and water management. The double ‘A’ award, a first for any cement producer, was handed over at the 2023 CDP Europe Awards in Paris, France, on 16 February 2023.

Magali Anderson, Holcim’s Chief Sustainability and Innovation Officer, said "This award is a testament to the progress that our teams around the world are making to build a net-zero future, while protecting and restoring precious freshwater resources. 2022 marks the third consecutive year that our climate actions have put us on CDP's A List, and our first ‘A’ ranking for our work on water security. I am confident we will keep the momentum going in years to come."

Germany: Holcim has signed an agreement to acquire FDT Flachdach Technologie (FDT), a leading manufacturer of thermoplastic roofs. FDT has a presence in European markets, with net sales of Euro50m in 2022. Holcim says that, as a technology and sustainability leader in its sector, FDT will complement Holcim’s integrated roofing product range and strengthen the geographical footprint of the business.

With this acquisition, Holcim roofing systems will exceed US$4bn in net sales ahead of schedule. Chief executive officer Jan Jenisch said “By acquiring FDT we are further expanding our Solutions & Products business to become a global leader in roofing systems. Due to its leadership in technology and sustainability, as well as its strong customer relationships, FDT will be a cornerstone of our continued expansion into the most attractive European roofing markets. I am excited to further grow and strengthen FDT’s business and welcome all 180 employees to the Holcim family.”

Congratulations to Lafarge France for launching the first calcined clay cement unit in Europe. The subsidiary of Holcim says that the unit, based at the integrated Saint-Pierre-la-Cour cement plant, is the first of its kind on the continent. It is using the company’s proprietary proximA Tech technology and will produce up to 500,000t/yr of cement in its ECOPlanet range. The operation is also powered with biomass alternative fuels and uses a waste recovery system to further drive down overall CO₂ emissions. Once production ramps-up the producer expects that 30% of cement from the Saint-Pierre-la-Cour plant will be from the ECOPlanet range by 2024.

The investment at Saint-Pierre-la-Cour was Euro40m. Holcim is also producing calcined clay cement at its La Malle plant in France. It received an investment of Euro6m in 2022 to produce low-carbon cements. Together, both plants are aiming to produce over 2Mt/yr of calcined clay cement by 2024. As is usual for these kinds of projects, the French government partly funded the clay calcination unit at Saint-Pierre-la-Cour as part of the ‘France Relance’ scheme investing in large-scale decarbonisation and energy efficiency initiatives.

Calcined clay cements in Europe aren’t exactly new, but Holcim’s new unit in France does appear to be the first full-scale line located at a cement plant. Research by OneStone Consulting, for example, reckons that the first flash activated clay unit expressly set up to supply the cement sector was commissioned in 1995 in Toulouse, France. More recently, Hoffmann Green Cement inaugurated its 50,000t/yr pilot plant at Bournezeau in France in 2018. This site produces cements made from flash calcined clay and blast furnace slag, although it is unclear how demand for the different products varies. A new 0.25Mt/yr plant in the Vendée department was scheduled for commissioning in the second half of 2022. Another 0.25Mt/yr plant in Dunkirk is expected to be commissioned in the second half of 2024.

Cementir Group launched its calcined clay cement product FUTURECEM in Denmark in 2021 with production via a pilot plant. It then extended this to the Benelux and French cement markets in 2022. As part of its industrial plan for 2021 - 2023 it was planning to build a clay calcination unit to support the growth of FutureCem. FLSmidth revealed in June 2021 that it had won a contract to build a 400t/day clay calcination unit for Vicat’s Xeuilley integrated cement plant. The deal was worth around Euro27m and commissioning is scheduled for 2023.

Firstly, it is interesting to see a focus on France for some of the projects above. The presence of Lafarge’s technical centre in Lyon may explain the interest for that company. However, Hoffmann Green Cement and Vicat are also active in the field. It is worth noting that France also holds a busy secondary cementitious material market with standalone operators including Ecocem, Cem’In’Eu and Hoffmann Green Cement. Secondly, despite the early start, clay calcination for cement is currently more active outside of Europe. In Africa, for example, there is at least one live full production line and a number of other projects on the way. Various other pilots and projects are also happening elsewhere around the world, often in conjunction with the limestone calcined clay cement (LC3) initiative. Where calcined clay cement production in Europe goes from here is uncertain at present as it is one solution among many for lower carbon cement products in the future. Yet, the projects that have made it so far to the commercial scale will be watched closely by the companies that have invested in them - and their competitors.