Displaying items by tag: concrete

Mexico: Cemex has reviewed its global sustainability and financial performance during 2022 in its Integrated Report 2022. During the year, the group reduced its specific CO₂ emissions by 9% from 2020 levels and by 30% from 1990 levels. It achieved a target of US$1bn-worth of investment in strategic projects over a period begun in 2020. Projects included the execution of water optimisation plans at 20% of Cemex sites in high-water stress areas. Cemex co-processed 27Mt of waste as alternative fuel (AF) in its global cement production - 67 times greater than its own non-recyclable waste footprint - and achieved an AF substitution rate of 35%. Meanwhile, the group also reduced its cement's clinker factor to 74%. Its Vertua reduced-CO₂ concrete range accounted for 33% of its concrete sales. During the year, Cemex launched the world's first net zero, fully electric heavy concrete mixer truck.

In 2022, Cemex recorded sales of US$15.6bn, down by 12% year-on-year, and reduced its debt to US$408m.

Canada: The city administration of Langford in British Columbia plans to enact regulations requiring all public and private projects to use reduced-CO₂ concrete. It plans to support the rules with parallel measures affecting the design of buildings.

Victoria News has reported that the city authorities previously mandated reduced-CO₂ cement for all projects in June 2022, but subsequently relaxed the regulations after only one company – Butler Concrete and Aggregates – completed the transition. Butler Concrete and Aggregates produces its reduced-CO₂ concrete using slag cement supplied by Lafarge Canada.

Peru: Cementos Pacasmayo’s revenue rose by 1.7% year-on-year in the fourth quarter of 2022, mainly on the back of higher bagged cement sales prices, although inflation affected raw material and energy costs. However, its sales volume of cement, ready-mix concrete and pre-cast elements fell by 7.7% partly due to high sales in the comparable quarter of 2021, although road blockages as part of political disruption in December 2022 also reduced sales. Its net profit for the quarter was US$10.1m, a 24.6% rise.

Across the whole of 2022, the company’s revenues were up by 9.2% year-on-year, while sales of cement, concrete and pre-cast elements rose by 5.3%. Consolidated earnings before interest, tax, depreciation and amortisation (EBITDA) rose by 8.8% to US$128m, mainly due to performances in the first nine months of the year. It made a net profit of US$45.8m, an increase of 15.4%.

UK: Cambridge Electric Cement (CEC) has launched the two-year trial of its Cement 2 Zero project, aimed at scaling up production of its net zero-CO₂, demolition waste-based alternative cement. It aims to produce 20t of the material for use in a low-impact construction project. CEC’s method, developed at the University of Cambridge, is based on the conversion of demolition waste into a slag-forming material within a steel furnace.

Developer Julian Allwood said “By combining steel and cement recycling in a single process powered by renewable electricity, we could supplement the global supply of the basic construction materials to support the infrastructure of a zero emissions world and to enable economic development where it is most needed.”

Cemex launched a new waste management division called Regenera this week. Cemex describes Regenera as a “business that provides circularity solutions, including reception, management, recycling, and coprocessing of waste.” The Mexico-based company has a long and leading history with sourcing and using alternative fuels in the cement sector and the new organisation looks set to utilise this experience. What is notable though is how the business is targeting three waste streams: municipal and industrial; industrial by-products; and construction, demolition and excavation waste (CDEW). Bringing the three waste streams together in this way appears to be novel for the heavy building materials sector, particularly the inclusion of CDEW, which we will explore further here.

CDEW is split into fractions, just like the municipal and solid waste streams that end up as alternative fuels at cement plants, but the biggest fractions are generally concrete, followed by bricks. The recycled concrete is then typically used as an aggregate, either in new concrete production or in areas like road construction and earthworks. The use of recycled aggregates (RA) made from CDEW goes back to at least the 1930s in its current form although ‘reusing’ materials from structures such as castles and churches goes back far further. Recycling and reusing CDEW gained a boost in 2020 when the European Union (EU) set a 70% recovery target. However, within the EU the CDEW recycling rates vary considerably and that 2020 target includes the use of CDEW in backfill applications.

In its launch statement for Regenera, Cemex noted that it operates a dock in Paris, where it receives a variety of materials, including construction debris, excavated material and inert soil. These materials are sorted, processed and then transformed into recycled aggregates or organic material used to restore quarries. Cemex then promptly followed up the official launch of Regenera on 30 January 2023 with the acquisition of a majority stake in Shtang Recycle, an Israel-based CDEW recycling company. It added that Shtang Recycle is preparing to build a recycling plant with a production capacity of 0.6Mt/yr of CDEW waste materials. The output from the plant will be used as raw materials for aggregate production.

The focus on CDEW recycling was flagged up at Cemex’s investor event in November 2022. It said that it was targeting a recycling rate of 14Mt/yr of construction and demolition waste by 2030. Other managed waste stream goals included doubling the amount of municipal and industrial waste it manages, to achieve a 50% to fossil fuel substitution rate, and increasing its usage of alternative raw materials and by-products by 30%, thereby eliminating 13Mt/yr of extracted materials.

Cemex is not alone in targeting the CDEW waste sector. Holcim’s recent work in the area goes back to at least 2016 when a recycling unit near its Retznei cement plant in Austria started processing 130,000t/yr of CDEW. It announced in December 2022 that it was setting up a similar recycling centre, also in Austria, at its Mannersdorf cement plant. In October 2022 Holcim acquired Wiltshire Heavy Building Materials in the UK. This company recycles 150,000t/yr of construction and demolition waste into aggregates and concrete. Holcim linked the acquisition to its Strategy 25 target of recycling 10Mt/yr of construction and demolition waste by 2025.

Activity by other cement companies includes the commissioning of a construction waste recycling plant at Gennevilliers in France by CRH-subsidiary Eqiom in April 2022. It was aiming for a target of 50,000t in 2022. In November 2022 Heidelberg Materials agreed to acquire RWG Holding based in Berlin, Germany. Then, in December 2022, it announced a deal to buy Mick George Group in the UK. Both proposed acquisitions are subject to competition authority approval. Heidelberg Materials’ current target is to offer circular alternatives for half of its concrete products by 2030.

The moves by the bigger cement companies into the CDEW sector follow sustainable thinking and the waste hierarchy. Yet the big prize here is to gain a route to dispose of some of their CO₂ emissions through recarbonation and this has been flagged up in several net-zero roadmaps for the cement sector such as those by Cembureau and the Global Cement and Concrete Association (GCCA). Holcim has been involved in the FastCarb project in France, running a pilot at its Val d’Azergues cement plant in 2021. Heidelberg Materials has been testing its own process with so-called recycled concrete paste. The development now appears to be that utilising CDEW has entered the sustainability strategies for some of the big cement-concrete-aggregate producers, targets have been set and acquisitions are happening.

For more information on Heidelberg Materials research into concrete recycling read the January 2023 issue of Global Cement Magazine

Switzerland: Cemsuisse, the Swiss cement association, recorded full-year national cement deliveries of 4.15Mt/yr throughout 2022. The figure represents a 0.7% year-on-year decline from 4.18Mt/yr throughout 2021. During 2022, ready-mix concrete batching plants received 73% of deliveries, while building sites received 20%. 37% of cement travelled to its destination by rail.

Cemsuisse said that energy uncertainty and rising inflation impacted on deliveries during the fourth quarter of the year.

Australia: First Graphene has partnered with Suvo Strategic Minerals to develop graphene-enhanced metakaolin for use in cement and concrete production. Metakaolin is a pozzolanic material derived from kaolinite clay. The partners believe that the technology has commercial potential to improve concrete performance and reduce CO₂ emissions.

Italy: Holcim announced its acquisition of Nicem, Italy's ground calcium carbonate market leader. The group said that it plans to use Nicem's ground calcium carbonate as raw material in production of its ECOPact and ECOPlanet reduced-CO₂ cement and concrete range.

Holcim's Europe regional head Miljan Gutovic said “Nicem complements our existing operations perfectly and allows us to further leverage our expertise in green formulation, opening a new source of alternative materials to decarbonise our ready-mix concrete. I look forward to welcoming the employees of Nicem to the Holcim family, whose valuable expertise will help us accelerate green growth.”

UK: Germany-based Heidelberg Materials has signed a deal for the acquisition of Mick George Group, the leading concrete recycling company in the East Midlands and East of England. Mick George Group’s 40 sites span bulk excavation, earthmoving and demolition services and demolition waste removal and management, as well as ready-mix concrete and aggregates distribution.

Heidelberg Materials Western and Southern Europe director Jon Morrish said “With the acquisition of Mick George, we are clearly moving towards establishing a truly circular materials and services offer in our UK business. I warmly welcome all 1000 Mick George employees to Heidelberg Materials and look forward to further developing the business together.”

Heidelberg Materials aims to offer circular alternatives for half of its products by 2050.

New Zealand: The Global Cement and Concrete Association has welcomed Fletcher Building’s concrete division as its first member from Oceania. Scoop News has reported that the concrete’s division’s business spans the entire concrete value chain, including 26 limestone and aggregates quarries and 80 ready-mix concrete batching plants. Its cement subsidiary Golden Bay Cement operates the 0.9Mt/yr Portland cement plant in Whangārei, New Zealand.

Fletcher Building concrete division CEO Nick Traber said "Fletcher Building firmly believes we can play a significant part in a carbon zero and circular future. Our Golden Bay EcoSure cement is one of the lowest-carbon cements in the world already, with 13 - 22% less embodied carbon than imported products. We believe having access to the global research and knowledge from the GCCA will help us improve this further and continue to lead Australasia in best practice decarbonisation of the built environment."