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One unusual thing about coverage of cement in the media is the way that discussions often centre precisely on its absence – that is, on alternatives to cement. These alternatives boast unique chemistries and performance characteristics, but are all produced without Portland cement clinker. They are generally called ‘alternative cements,’ perhaps because ‘cement-free cement’ does not have such a commercially viable ring to it. This contradictory tendency reached a new high in the past week, with developments in alternative cement across Asia, Europe, the Middle East and North America. Together, they hint at a more diverse future for the ‘cement’ industry than the one we know today.

Asia

In Indonesia, Suvo Strategic Minerals has concluded tests with Makassar State University of a novel nickel-slag-based cement. Huadi Nickel-Alloy Indonesia supplied raw materials, and tests showed a seven-day compressive strength of 37.5MPa. Suvo Strategic Minerals says that a partnership with Huadi Nickel-Alloy Indonesia for commercial production is a likely next step.

Europe

Cement producer Mannok and minerals company Boliden partnered with the South Eastern Applied Materials (SEAM) research centre in Ireland to launch a project to develop supplementary cementitious materials (SCMs) from shale on 7 October 2024. The project will additionally investigate CO₂-curing of cement paste backfill for use in mines. Irish state-owned global commerce agency Enterprise Ireland has contributed €700,000 in funding.

UK-based SCM developer Karbonite expects to launch trial production of its olivine-based SCM with a concrete company in 2025. The start-up launched Karbonite Group Holding BV, with offices in the Netherlands, to facilitate this new phase. Karbonite’s SCM is activated at 750 – 850°C and sequesters CO₂ in the activation process, resulting in over 56% lower CO₂ emissions than ordinary Portland cement (OPC). Managing director Rajeev Sood told Global Cement that talks are already underway for subsequent expansions into the UAE and India.

Back in the UK, contractor John Sisk & Son has received €597,000 from national innovation agency Innovate UK. John Sisk & Son is testing fellow Ireland-based company Ecocem’s <25% clinker cement technology in concrete for use in its on-going construction of the Wembley Park mixed development in London.

At the same time, Innovate UK granted a further €3.23m to other companies for concrete decarbonisation. Recipients included a calcined clay being developed by Cemcor, an SCM being developed from electric arc furnace byproducts by Cocoon, a geopolymer cement technology being developed by EFC Green Concrete Technology UK and an initiative to develop alternative cement from recycled concrete fines at the Materials Processing Institute in Middlesbrough. Also included was the Skanska Costain Strabag joint venture, which is working on the London stretch of the upcoming HS2 railway. The joint venture, along with partners including cement producer Tarmac and construction chemicals company Sika UK, will test low-kaolinite London clay as a raw material with which to produce calcined clay as a cement substitute in concrete structures in HS2’s rail tunnels.

Middle East

Talks are underway between UK-based calcined clay producer Next Generation SCM and City Cement subsidiary Nizak Mining Company over the possible launch of a joint venture in Riyadh, Saudi Arabia. The joint venture would build a 350,000t/yr reduced-CO₂ concrete plant, which would use alternative cement based on Next Generation SCM’s calcined clay.

North America

Texas-based SCM developer Solidia Technologies recently patented its carbonatable calcium silicate-based alternative cement, which sequesters CO₂ as it cures.

Meanwhile, C-Crete Technologies made its first commercial pour of its granite-based cement-free concrete in New York, US. C-Crete Technologies says that the product offers cost and performance parity with conventional cement, with net zero CO₂ emissions. Its raw material is globally more abundant than the limestone used as a raw material for clinker. Other abundantly available feedstocks successfully deployed within C-Crete Technologies’ repertoire include basalt and zeolite.

Across New York State, in Binghamton, KLAW Industries has succeeded in replacing 20% of concrete’s cement content with its powdered glass-based SCM, Pantheon. KLAW Industries has delivered samples to local municipalities and the New York State Department of Transportation. Its success expands the discussion of possible circular cement ingredients from the industrial sphere into post-consumer resources.

In Calgary, Canada, a novel SCM has drawn attention from one of the major cement incumbents: Germany-based Heidelberg Materials. It invested in local construction and demolition materials (CDM)-based SCM developer EnviCore on 9 October 2024. The companies plan to build a pilot plant at an existing Heidelberg Materials CDM recycling centre.

Conclusion

Alternative cement developers are still finding the words to talk about their products. They may be more than ‘supplementary’ up to the point of entirely supplanting 100% of clinker. Product webpages offer ‘hydraulic binder,’ ‘pozzolan’ and even ‘cement.’ As alternative ‘cements’ are developed, they build on the work of pioneers like Joseph Aspdin and Louis Vicat. Start-ups and their backers are now reaching commercial offerings, on a similar-but-different footing to cement itself. None of these novel materials positions itself as the sole, last-minute ‘super sub’ in the construction sector’s confrontation with climate change. Rather, they are a package of solutions which can combine into a net zero-emissions heavy building materials offering, hopefully before 2050.

Related to this is the need for ‘technology neutral’ standards, as championed this week by the Alliance for Low-Carbon Cement and Concrete (ALCCC), along with 23 other European industry associations, civil society organisations and think tanks. The term may sound new, but the concept is critical to the eventual uptake of alternative cements: standards, the ALCCC says, should be purely performance-based. They ought not attempt to define what technology, for example cement clinker, makes a suitable building material. According to the ALCCC, Europe’s building materials standards are not technology neutral, but instead ‘gatekeep’ market access, to the benefit of conventional cement and the exclusion of ‘proven and scalable low-carbon products.’

At the same time, cement itself is changing. Market research from USD Analytics showed an anticipated 5% composite annual growth rate in blended cement sales between 2024 and 2032, more than doubling throughout the period from US$253bn to US$369bn. If you can’t beat it, blend with it!

For a further discussion of alternative cement and binders in Europe, see Global Cement’s interview with ALCCC co-ordinator Joren Verschaeve in the forthcoming November issue of Global Cement Magazine on 17 October 2024.

US: CRH subsidiary Oldcastle APG has acquired France-based Saint-Gobain's fence, railing and decking business in the US. The business consists of two production locations, in Buffalo, New York, and Orem, Utah. Together, the sites employ 210 people. The business generated US$65.6m in sales in 2022.

Saint-Gobain said that the divestment serves to advance its profile optimisation strategy under its Grow & Impact plan.

US: Holcim US has joined the New York Value of Distributed Energy Resources (VDER) program as part of its plans to enter Purchase Power Agreements (PPA) so that it can use more renewable energy sources. The scheme is intended to help support its investment in on-site renewable energy generation.

Atl Martinez, the Vice President of Procurement at Holcim North America, said “Holcim US is focused on driving significant progress to meet our Green Growth Strategy goals, so we consistently evaluate our environmental impact and opportunities to incorporate more sustainable solutions into our operations.” He added, “Through the New York VDER program, we support not only our ongoing investment in on-site generation but also community solar projects that help drive greener outcomes for all.”

The company will host three separate solar arrays on Holcim's non-mineable aggregate sites. These sites, operating in conjunction with various other offsite arrays within the Holcim VDER agreement, are expected to generate more than 80GWh/yr of energy. Energy generated from these sites will effectively power seven aggregate and cement sites through renewable energy credits.

Other work by Holcim US towards net zero includes its participation in the Northeast Regional Clean Hydrogen Hub program. The company has also expanded its renewable portfolio to include a 40MW battery storage system and 78MW of solar arrays in Ohio, Maryland and Arkansas. In late 2022, it entered into its first virtual power purchase agreement (VPPA) with the Electric Reliability Council of Texas (ERCOT).

US: Lehigh Hanson is preparing to start cutting jobs at the Glens Falls cement plant in New York from April 2023. The majority of the employees at the site will be laid off in April 2023 with some staff to be retained until later until 2023, according to the Times Union newspaper. It was previously reported in November 2022 that the subsidiary of Germany-based Heidelberg Materials was planning to close the plant in a phased manner in 2023. Production from the Glens Falls site will be covered in the future by the company’s new Mitchell plant in Indiana.

US: Lehigh Hanson has announced the upcoming permanent closure of its Glens Falls cement plant in northeastern New York. Times Union News has reported that the producer has extended an offer of financial and job-hunting support to the plant's 85 employees. A phased closure will commence in 2023. The company said that 'changes to the competitive landscape within the context of a global cement industry' partly informed its decision, in addition to the 'small, aging and inefficient' condition of operations at the plant. Lehigh Hanson's Mitchell, Indiana, cement plant will cover the plant's market in future.

Lehigh Hanson Northeast regional president Alex Car said "We are committed to continuing to supply our customers in the New England region. We have the available capacity to meet the current and future needs of our customers, even after the Glens Falls plant halts production." Car added "We are thankful for the dedication and efforts of our Glens Falls workforce over the years and we will work to minimise the impacts to our employees and the community as much as possible."

US: Holcim US’ Lafarge Ravena cement plant in New York State has launched a celebration of six decades’ successes on the occasion of the 60th anniversary of the plant’s groundbreaking ceremony. 1000 people attended the ceremony on 19 May 1961, where New York Governor Nelson Rockefeller broke ground on the then Atlantic Cement Company’s new US$64m facility.

Addressing the crowd, Rockefeller said “The enormous production capacity of this plant will undoubtedly draw many large and small companies to the environs, and, as a result, employment will rise considerably.”

Today, the Lafarge Ravena cement plant directly employs 160 local people.

US: A lawsuit raised by the US Equal Employment Opportunity Commission (EEOC) against CCC Group alleges that black construction workers were subject to racial discrimination and harassment during the construction company’s work on an upgrade at the Lafarge Ravena cement plant in 2016. The EEOC says that the workers were the target of racial language, were threatened and made to carry out more dangerous and physically taxing tasks. It added that it only took legal action after first attempting to reach a pre-litigation settlement through the agency’s conciliation process.

CCC Group says it investigated the claims from one former employee in 2017 about ‘inappropriate comments’ after it was reported to the EEOC. However, it says that the complaint was never reported internally and that the EEOC refused to share information about the allegations. Subsequently, it was unable to determine what happened. The construction company only became aware of the other allegations when the EEOC filed its lawsuit in June 2020. CCC Group said, “We take all such allegations very seriously and continue to thoroughly investigate these claims. Regardless, CCC Group will continue its commitment to ensure that any such conduct is not tolerated or allowed to occur in our workplaces.”

800 workers were involved in the upgrade to the plant in New York State, which brought it to its present integrated capacity of 2Mt/yr.

This story was updated on 16 June 2020 following comment from CCC Group

Canada: McInnis Cement has closed a US$380m refinancing deal. US$230m will be provided by an increase McInnis Cement’s senior loan from a syndicate of 11 Canadian and international banks and the remaining US$150m comes in the form of a loan by the Caisse de dépôt et placement du Québec (CDPQ) and Beaudier. This refinancing also makes it possible to repay a bridge loan granted by BlackRock in 2016.

The cement producer also provided details on various projects it is undertaking. Two new cement silos will be built at the company’s integrated cement plant at Port-Daniel–Gascons. Nearly 200 workers will be mobilized on the site during the peak construction period of the two silos, during the autumn of 2019.

Its Bronx Terminal in New York, US has doubled its loading capacity for customers. A second truck-loading lane is now fully operational. A new 40,000t warehouse is currently under construction at its Providence Terminal in Rhode Island, US bringing the total storage capacity to 75,000t. A new truck-loading lane will also be added and commissioned in time for the 2020 spring construction season. McInnis Cement has also confirmed the charter of the NACC New Yorker, a 24,000t self-unloading vessel, in conjunction with Nova Marina Carriers. It will join other vessels in its fleet including the NACC Quebec (14,000t), the Cielo di Gaspesie (35,000t) and the Resolute unloading barge.

US: Brazil’s Votorantim Cimentos has acquied United Materials, a producer of aggregates, concrete and building materials, for an undisclosed amount. The purchase was conducted by its subsidiary Votorantim Cimentos North America. United Materials operates four ready-mix concrete plants, one aggregate quarry and two building materials units in the western part of New York state. It has around 140 employees.

US: Lafarge North America, a subsidiary of LafargeHolcim, has officially opened the upgrade to its Ravena cement plant in New York. The upgrade work took three years at a reported cost of US$300m.

“By modernising the plant, we have transformed it into an efficient, competitive and state-of-the-art facility that will allow us to meet the growing needs of our customers and remain a strong partner to the community for the foreseeable future,” said John Stull, chief executive officer (CEO) US Cement, LafargeHolcim. He added that the plant has supplied cement for high profile projects, including the Tappan Zee bridge reconstruction and One World Trade Center Memorial.

Upgrade work focused on building a new clinker production line to modernise the previously wet process plant. Following the work the plant now has a clinker production capacity of 2Mt/yr with improved emissions levels and higher operational performance.