Displaying items by tag: concrete

Heidelberg Materials inaugurated a plant near Katowice in Poland this week for separating and sorting demolition concrete. This gives us the chance to catch up with the state of construction and demolition waste (CDW) for the cement and concrete sectors and consider the differences between the strategies of the multinational heavy building materials companies in Europe and the US.

The new CDW recycling unit has a capacity of up to 100t/hr. Heidelberg Materials says that it is the “first company in the industry to introduce high-quality, selective concrete separation at this scale.” The company is using its proprietary ReConcrete process to sort out fractions from the CDW including sand, gravel and, finest of all, recycled concrete paste (RCP). That last one is particularly valuable because it can either be used as an alternative raw material for clinker production by replacing limestone or as a secondary cementitious material. Heidelberg Materials is also promoting the potential use of RCP as a carbon sink over the lifetime of a concrete structure via ‘enforced carbonation.’ The RCP is exposed to raw exhaust gases from cement production allowing it to both mineralise CO₂ and act as a clinker substitute. To further explore this option Heidelberg Materials is building an industrial pilot at its Górażdże plant to test the concept with construction expected by the end of 2024.

Both Holcim and Heidelberg Materials have been visibly busy buying up more aggregate recycling companies over the last nine months since Global Cement Weekly last reported on CDW. Holcim acquired Germany-based Mendiger Basalt in January 2024, Switzerland-based Cand-Landi Group and UK-based Land Recovery in June 2024, and Belgium-based Mark Desmedt in July 2024. It also said at the start of the year that it aimed to conclude 15 - 20 new acquisitions in 2024 with a focus on CDW companies in Belgium, France, Germany and the UK. Heidelberg Materials bought UK-based B&A Group in May 2024 and US-based Highway Materials and Aaron Materials in July 2024. Holcim has set itself a target of recycling 12Mt/yr of CDW by 2030 by using its ECOCycle technology. It reported 8.4Mt/yr in 2023 and hopes to reach 10Mt/yr in 2024.

Some of the recycling companies mentioned above are based in the US but the pace of CDW acquisitions have generally been faster in Europe. In the US, meanwhile, the heavy building materials producers have tended to buy more general aggregates companies. Heidelberg Materials announced on 30 July 2024 that it was buying Albany-based Carver Sand & Gravel. This followed the companies mentioned above and Texas-based Victory Rock, also in July 2024. Holcim said in its first half-year results for 2024 that it had ‘executed’ a bolt-on acquisition in the US that would strengthen its aggregate and ready-mixed concrete business. Cemex also revealed a joint-venture agreement with sand and gravel supplier Couch Aggregates and marine bulk product distributor Premier Holdings in July 2024. It said that the move was part of its “ongoing strategy to accelerate growth in the US and expand its aggregates business.” A big recent deal in the sector was the merger of the US-based operations of Summit Materials and Cementos Argos that completed in January 2024. Although at the time we concentrated on the cement-side of the transaction, it also gave the organisation just under 5Bnt of aggregate reserves.

It may be a stretch to call what’s going on here a trend. Yet the large heavy building materials companies do appear to be acting differently in the US and Europe with regards to aggregate companies and CDW recyclers. The main drivers here are the strength of the US market and the stricter environmental legislation in Europe. Higher population density in Europe compared to the US may also be playing a part in the differences in speed of adoption between the two markets. The ongoing Holcim spinoff demonstrates the differences between the two market regions in bold terms. In short, the company has decided to split itself in two in order to meet the different needs of each market. As for CDW, the trickle of acquisitions keep coming and momentum is steadily building.

Singapore: Malaysia-based YTL Corporation has concluded a conditional sale and purchase agreement for an 81% stake in NSL for US$169m. YTL Cement will launch a mandatory unconditional cash offer for all outstanding shares in NSL after completing the acquisition. NSL manufactures precast concrete components and operates an environmental services division.

UK: The Materials Processing Institute has launched the next phase of the EconoMISER programme with a €5m investment to develop sustainable technologies. The institute aims to advance research in alloy development, furnace modelling and decarbonisation of cement and concrete.

The institute will establish a new cement and concrete research centre and invest in technologies such as predictive artificial intelligence for alloy development. This initiative is part of the UK's effort to decarbonise critical sectors like cement through the EconoMISER programme, supported by UK Research and Innovation.

Canada: Hyperion Global Energy has fired up its pilot Tandem Carbon Recycling System at Lafarge Canada’s Bath cement plant in Ontario. The system mineralises captured CO₂ to produce mineral components for alternative building materials. It has a capture capacity of 1000t/yr. The partners will test the Tandem Carbon Recycling System in producing Lafarge Canada’s 30 – 90% reduced CO₂ ECOPact concrete.

Lafarge Canada’s Eastern Canada regional president and CEO of David Redfern said "Our collaboration with Hyperion marks an exciting milestone in our decarbonisation journey and the advancement of our circular construction technologies. We look forward to advancing our net zero strategy by leveraging carbon utilisation technology like Hyperion's, enabling us to further reduce CO₂ emissions from our operations while at the same time producing innovative and sustainable building solutions."

Hyperion CEO Heather Ward said "Working together with an innovative partner like Lafarge on this exciting pilot project allows us to apply our proprietary carbon recycling technology to large-scale industries, and make an immediate, measurable reduction on carbon emissions. At the same time, we are advancing our vision to offer a scalable and affordable decarbonisation solution for industry, and a market-driven profit incentive on the cost of carbon removal."

Russia: Belarusian Cement has concluded a deal with the Moscow regional government to build a logistics facility in the region at Naro-Fominsk. Prime Press News has reported that the facility will cost US$22.5m. It will be equipped with ready-mix concrete, precast concrete and dry mix plants, as well as a rail terminal, storage areas and loading zones for despatches by road.

Director General Alexander Dovgalo said "This investment will not only bolster our logistics capabilities but also enhance our service quality for Russian partners and extend our market reach within Russia and the CIS member states."

Belgium: The Alliance for Low-Carbon Cement & Concrete (ALCCC) has marked its first anniversary with a new policy roadmap aimed at achieving net zero emissions by 2040. Initiated in May 2023, the alliance brings together environmental NGOs and industry stakeholders to transform the cement and concrete sectors. The ALCCC has grown significantly, now comprising 25 members.

Senior programme manager Joren Verschaeve from ECOS, the coordinator of ALCCC, said "Our members show that the technologies needed to make low-carbon cement and concrete the norm already exist. This uniquely positions our Alliance to raise the alarm when policies and standards lead to unfair competition instead of a greener future – and the latter is perfectly achievable if policymakers implement our roadmap."

US: Sublime Systems has announced the first-ever commercial application of its low-carbon Sublime Cement product at WS Development’s One Boston Wharf building in Massachusetts. The concrete placement is located in the Paseo indoor public space at the office building. The floor will be marked with educational materials explaining the significance of decarbonised cement in combating global climate change.

Leah Ellis, the CEO and Co-Founder of Sublime Systems, said “Buildings are monuments to the values of the people who build them, and the One Boston Wharf project represents WS Development’s leadership in ushering in our post-carbon future.” She continued “They are creating not only the building but the world where people want to be. We are honoured to have Sublime Cement featured so prominently here and are confident this pioneering place will inspire infrastructure owners everywhere to embrace low-embodied-carbon materials as a powerful tool for achieving our global net-zero goals.”

Global: The Global Cement and Concrete Association (GCCA) has announced new collaborations between global cement manufacturers and technology start-ups, focusing on the development of low carbon concrete. Four start-ups—EnviCore in Canada, Queens Carbon and Chement, both in the US and NeoCrete in New Zealand—were part of the 2023 GCCA Innovandi Open Challenge and have now partnered with cement manufacturers. These partnerships aim to reduce the carbon footprint of concrete.

The startups will receive access to industry plants, labs and networks to fast-track their technologies. They will also demonstrate their progress on 6th June 2024 in Bangkok, Thailand, during the GCCA's CEO and Leaders Conference. The association continues its efforts under the 2050 Net Zero Concrete Roadmap, with 29 new start-ups shortlisted this year to work on carbon capture, utilisation and storage (CCUS) technology.

China: Poor performance by CNBM’s Basic Building Materials division dragged down the group’s sales in 2023 despite positive performance by the group’s Engineering Technical Services and New Materials segments. Its revenue fell by 10% year-on-year to US$29.1bn in 2023 from US$32.3bn in 2022. Its profit after tax dropped by 33% to US$1.44bn from US$2.13bn. Sales volumes of cement and clinker decreased by 3% to 309Mt from 317Mt. Sales volumes of commercial concrete fell by 5% to 80.8Mm³ from 84.7Mm³.

Revenue for the Basic Building Materials division fell by 19% to US$16.4bn. The company blamed this on a fall in the price of cement, concrete and aggregates although an increase in sales volume of aggregates was noted. The group said that in 2023, the cement industry was characterised by ‘insufficient demand, weakening expectations and weakening off-peak season characteristics,’ coupled with and aggravating surplus and high costs.

China: Huaxin Cement grew its revenue and profit in 2023 by growing its concrete market domestically and increasing its international business. Its revenue rose by 11% year-on-year to US$4.67bn in 2023 from US$4.21bn in 2022. However its operating revenue from cement and clinker declined. The group’s net profit increased by 2% to US$382m from US$373m. Its cement sales volumes grew by 2% to 76.8Mt from 75.3Mt. Concrete sales volumes mounted by 66% to 27.3Mm³.

The share of its international business grew by 16% in 2023 from 13% in 2022. Notable acquisitions in 2023 included the purchases of Oman Cement and InterCement’s assets in Sub-Saharan Africa.