Displaying items by tag: US

US: Eagle Materials raised its sales in the first nine months of 2024, by under 1%, to US$1.79bn. Its profit also grew by under 1%, to US$569m. However, sales by its Heavy Materials Sector, which includes its cement, concrete and aggregates businesses, declined by 4% to US$352m. Cement revenue for the quarter was also down by 4% to US$295m, reflecting lower cement sales volume and increase in cement maintenance costs due to the planned outages at the company’s Oklahoma and Texas cement plants during the quarter. Cement sales volumes decreased by 7% to 1.7Mt.

President and CEO Michael Haack praised the company’s overall growth in the face of ‘ongoing adverse weather’ in the Midwest and Great Plains markets, which reportedly affected sales volume of the company’s cement business. He said “While the path to lower interest rates and improved home-buying affordability is less certain today, we remain optimistic about our businesses and our ability to execute on the opportunities in front of us. On the cement side, spending from the Infrastructure Investment and Jobs Act is still in the beginning phases, which should support multiple years of strong cement demand.”

Northern-Ireland based cement producer Cemcor said this week that it has completed trials of a calcined clay cement product called CalcinX. The company started its trials in 2023 and it has been supported by Queen’s University Belfast and funding from Innovate UK. Work with commercial partners has involved precast concrete paving manufacturer Tobermore producing paviours made from 50% CalcinX as a CEM II replacement and Moore Concrete has also manufactured precast units using 50% CalcinX as a CEM I replacement. So far over 3000t of CalcinX has been produced in a number of industrial-scale trials.

David Millar, the managing director of Cemcor, mentioned his company’s plans for calcined clay in June 2022 when he was interviewed by Global Cement Magazine. The company that became Cemcor bought the Cookstown cement plant and a few other assets from Holcim at the start of 2022. It then changed its name to Cemcor in November 2022. At the time of the interview the company was looking to “...develop new value-added products, including low-CO₂ options. This will allow us to use the same amount of clinker to produce more cement.” Millar couldn’t give away too many details at the time, however calcined clay was cited specifically. It was also noted that the company had the right material in its quarry and that it was already working with partners on it.

Amongst all the other decarbonisation options available for cement plants, a slow trickle of calcined clay projects keep being announced. In January 2025, for example, thyssenkrupp Polysius said it had secured a front-end engineering design contract from Circlua for the construction of the world’s largest activated clay plant in Brazil. This project in Para state will have a capacity of 3000t/day, will use renewable energy sources and will “improve the CO₂ footprint in cement production.” CBMI Construction also officially launched a flash calcination clay project in Tangshan, Hebei province in China. In December 2024, Vicat signed an agreement with the US Department of Energy (DOE) Office of Clean Energy Demonstrations to develop the Lebec Net Zero (LNZ) project at its Lebec cement plant in California. This includes plans to produce calcined clay-based cement. Earlier in the autumn of 2024 Portugal-based Cimpor said it was preparing to convert a kiln at its Souselas plant to produce calcined clays, AVIC International Beijing and KHD said that they had secured a deal to build a 900t/day clay calcination plant for Ciments de l'Afrique (CIMAF) in Burkina Faso, and Holcim Česko said it was going to construct a calcined clay processing line at the Čížkovice cement plant in the Czech Republic.

One news story that stuck out in the autumn was the progress of a collaboration between Aumund and Holcim towards developing an electric linear calcination conveyor (eLCC). The two companies started work on the project in 2020 intending to look at the electrical calcination of clay using an Aumund pan conveyor. Initial tests of the eLCC reportedly demonstrated efficient thermal activation of clay through a combination of radiant heat and material circulation. The eLCC system is fully enclosed, insulated, has a compact design and can operate using electrical-powered renewable sources. The first industrial plant utilising this technology is scheduled for construction in 2025. Calcined clay technology and products by other industrial suppliers are available. The work by Aumund and its competitors show they are watching this market closely.

OneStone Consulting’s Joe Harder has found that only 14 clay calcination plants were operational worldwide in 2023 with a production capacity of just under 3.5Mt/yr. These are based in Latin America, Europe and Africa. In an article previewing a market report in the February 2025 issue of Global Cement Magazine, Harder predicts that by 2035 there will be 79 clay calcination plants with a capacity of just under 21Mt/yr. A steady growth of over 20 new plants annually is also expected subsequently from 2035 to 2050 as cement producers seek cost-effective ways to reduce their clinker factor. He identified installation costs, a lack of knowledge about clay-based cements, trouble obtaining mining rights and policy issues amongst other issues as holding back the use of clay calcination.

The current expectation is that calcined clay usage in the cement industry will be a minority option. Yet the size of global cement production can make a production share of, say, 3 - 8% a viable option for both cement manufacturers and equipment suppliers. The adoption of new cement products and standards can also take a long time and this clouds predictions of how far clay can go in the cement industry. At this point in the calcined clay story it is time to keep track of the new projects being set up.

Joe Harder will present a talk entitled ‘Calcined clay market trends by 2035’ at the Global FutureCem Conference taking place in Istanbul in early February 2025

US: Titan Cement has announced that its subsidiary, Titan America, has launched its initial public offering (IPO) of 24 million common shares, comprising 9 million new shares to be issued and 15 million existing shares to be sold. The IPO is expected to price between US$15-18 per share.

Following completion, Titan Cement will retain 160,362,465 shares, representing 87% ownership of Titan America.

US: The US Department of Energy's (DOE) Office of Fossil Energy and Carbon Management has selected Cemex's Knoxville cement plant in Tennessee as the site for a carbon capture, removal and conversion test centre. The project is part of a US$101m initiative shared among five projects that aim to decarbonise cement plants and power facilities.

Cemex, in collaboration with the University of Illinois Urbana-Champaign (UIUC) and a coalition of US cement producers, will develop the conceptual design, business, technical and managerial frameworks for the test centre under Phase 1. Phase 2 will involve constructing and operating the centre to evaluate advanced carbon management systems.

Jaime Muguiro, president of Cemex US, said “While we are making steady progress, the cement industry has the opportunity to accelerate the pace of our decarbonisation even more. I am excited that our Knoxville cement plant has been selected as the host site for the carbon capture test centre. Through collaboration and continuous innovation with the University of Illinois and industry peers, Cemex is committed to advancing decarbonisation solutions.”

Holcim revealed the board members for its proposed North America business this week. Former group CEO Jan Jenisch was confirmed as the designated chair and CEO. He will be joined by nine directors chosen from sectors including construction, manufacturing, industrial operations and financial services. Notably, current Holcim director Jürg Oleas will be joining Jenisch at the new company. He previously worked as the head of GEA Group and had senior stints at ABB and the Alstom Group.

The group’s decision to split its business in North America from that in the rest of the world has been presented as a piece of financial engineering designed to increase earnings, margins and increase the value of the business. Markets in the US and Europe have diverged in recent years, with the former growing and the latter slowing in comparison. Splitting the business should, in theory, allow both companies to grow at their own pace. However, the spin-off company in North America will remain linked to Europe as it will be listed at both the New York Stock Exchange and the SIX Swiss Exchange. The latter is for the benefit of European investors. The separation is expected by the end of the first half 2025, subject to shareholder and customary approvals.

Naturally, other companies are also chasing growth in North America. Titan Cement announced this week that its US-based subsidiary, Titan America, has filed a registration statement with the Securities and Exchange Commission as part of a proposed initial public offering (IPO). Yet, the company said that the offering is subject to market conditions. As such it couldn’t say when it might happen, how big it might be or much else. Back in May 2024 the group said it was going to list Titan America in the US to “...facilitate the group’s and Titan America’s future growth and unlock new opportunities.” The IPO was intended to be of a minority stake without creating any large-scale tax issues. At this time the transaction was planned to be completed in early 2025.

Titan’s sales share in North America has remained similar from 2018 to 2023 at around 55%. Holcim’s, by comparison, grew to 39% in 2023 from 22% in 2018. This is due to big acquisitions in the US such as Firestone Building Products in 2021 as it built up its lightweight building materials segment. The size of the two companies’ operations in North America are also different. Holcim reported net sales in the region of over US$11bn in 2023. Titan reported net sales of just under US$1.5bn.

Ireland-based CRH moved its stock market listings to the US earlier than both Holcim and Titan. It completed the transition of its primary listing to the New York Stock Exchange in mid-2023, although it too retains a listing in Europe, at the London Stock Exchange in its case. Yet analysts have started to wonder whether the company might spin-off its businesses outside the US. As reported by the Irish Times, Bank of America analysts reckon that the non-US parts of the company now represent only 16% of the US$82bn concern. For sanity’s sake this is still a US$10bn-plus sized company! Although other commentators did wonder why CRH might have bought assets in Australia in 2024 if it was seriously considering making changes on this scale anytime soon.

Despite all this attention on the US and North America by some of the multinational cement producers, it is worth remembering that markets change over time. Europe may not look so hot right now but it is unlikely to stay like this. The head of Heidelberg Materials, for example, said in early 2024 that his company wasn’t planning a split in the US because it was focusing on decarbonisation. This may prove prescient in the longer term if Europe sticks to its sustainability goals. FInally, the US isn’t the only place where cement companies are attempting to build their value in growth markets. It was also reported this week that JSW Cement had obtained approval from the Securities and Exchange Board of India to proceed with its IPO.

US: Oakland, California-based cleantech startup Brimstone has received a US Department of Energy grant worth up to US$189m to establish a plant with a capacity of 80,000t/yr of ‘green’ cement and 20,000t/yr of smelter-grade alumina, according to the San Francisco Business Times. The grant will be paid out in instalments and requires matching funds from new investments, loans and other sources.

The US$378m facility, which is still in the site selection phase, will be located near an existing quarry in order to mine calcium silicate rocks.

CEO Cody Finke said “We’re exclusively looking at brownfield sites. The goal is to build our own plant while utilising existing quarries to ensure a sustainable and economically viable operation.”

Brimstone plans to begin pilot operations in 2025 and aims to have the plant fully operational by the end of the decade. The company is currently testing its decarbonised cement with potential customers from its Oakland research and development facility.

US: The Department of Energy’s (DOE) Office of Fossil Energy and Carbon Management has announced US$101m in funding for five projects to establish carbon capture, removal, and conversion test centres for cement plants and power facilities. The test centres aim to cost-effectively research and evaluate technologies to capture and convert CO₂ into products from utility and industrial sources, or by removing CO₂ from the atmosphere. The initiative aims to reduce CO₂ emissions, promote sustainable technologies and create job opportunities.

Notable projects include the University of Illinois in Urbana, which plans to design a test centre to evaluate carbon management technologies for the cement industry, and Holcim US, which intends to establish a Cement Carbon Management Innovation Centre at its Hagerstown facility in Maryland.

Brad Crabtree, assistant secretary for Fossil Energy and Carbon Management, said “Carbon management technologies such as carbon capture can significantly reduce emissions from fossil energy use and key industrial processes, like cement production. By investing in test centres, we are helping reduce barriers to commercial-scale deployment of carbon capture, conversion and removal technologies that will ultimately help reduce pollution and create jobs.”

US/France: Hoffmann Green Cement Technologies has extended its licensing agreement with Hoffmann Green USA, signed in July 2024, to cover 25 states in the eastern United States. This has triggered an additional entry fee of €8m, following the €2m already received. The agreement grants industrial and technological transfer rights and exclusivity in the expanded territory. It includes fixed and variable royalties based on sales of Hoffmann Green cements. Hoffmann Green USA may also sub-license units in these territories, with discussions currently underway with potential sub-licensees.

US: Titan America, the US subsidiary of Titan Cement, has filed a registration statement for its proposed initial public offering (IPO) with the Securities and Exchange Commission. The company plans to list shares on the New York Stock Exchange (NYSE), including both primary and secondary sales, aiming to raise up to an estimated US$500m, subject to market conditions.

Switzerland/US: Holcim is progressing towards the planned listing of its North American business and has designated its future board members. The board will comprise 10 members and will become effective following the execution of the spin-off, expected in the first half of 2025, subject to shareholder and customary approvals.

Jan Jenisch, current chair of Holcim and its former CEO from 2017 to 2024, has been designated chair and CEO of the new business. Jenisch will remain Holcim’s chair until the Annual General Meeting on 14 May 2025.

The Board will include nine independent directors: Theresa Drew, Nicholas Gangestad, Dwight Gibson, Holli Ladhani, Michael McKelvy, Jürg Oleas, Robert Rivkin, Katja Roth Pellanda, and Cristina Wilbur.