Displaying items by tag: concrete

UK: Hanson has said that it is supplying 2000m3 of concrete to the Harwell Science Campus, Oxfordshire for use in the construction of the Vaccine Manufacture and Innovation Centre (VMIC), the first facility of its kind in the UK. Due to the on-going coronavirus outbreak, the centre will be finished ahead of schedule in mid-2021. Hanson UK West regional general manager James Moorhouse said, “We are working flat out to manage the accelerated requirements of the construction programme.”

Argentina: Loma Negra’s sales of cement, masonry and lime fell by 26% year-on-year to 1.13Mt in first quarter of 2020. The decline was driven by the coronavirus lockdown in Argentina, where the subsidiary of Brazil’s InterCement has most of its sales. Concrete and aggregate sales volumes declined also. The company’s new revenue dropped by 29.6% to US$115m and its adjusted earnings before interest, taxation, depreciation and amortisation (EBITDA) fell by 17.9% to US$38.6m. However, the company’s accountant adjustment for use in so-called ‘hyperinflationary economies’ made a negative impact on these figures. With this adjustment removed both revenue and earnings reportedly rose in the first quarter.

“By the end of the first quarter the coronavirus broke out, bringing additional challenges to the already adverse background,” said Sergio Faifman, Loma Negra’s chief executive officer (CEO). He added that cement demand in Argentina nationally contracted by around 29% year-on-year in the first quarter of 2020.

The cement producer temporarily suspended its production facilities and its L´Amalí Expansion project in late March 2020 due to the government lockdown. Production and dispatches of cement were restarted in early April 2020 following the implementation of new sanitation protocols. The company has now resumed working on its upgrade project at L´Amalí.

India: The impact of the coronavirus pandemic was visible in the financial performance of ACC, one of LafargeHolcim’s major Indian subsidiaries, during the three months to 31 March 2020. For the quarter, the company’s consolidated net profit fell by 6.6% on a year-on-year basis to US$42.1m, while net sales declined by 11% to US$448m on the back of a steep fall in volumes, which came to 6.6Mt, 12% lower year-on-year. ACC’s ready mix concrete (RMC) volumes remained stable at 930,000t.

The pandemic mainly impacted sales volumes in March 2020, whereas January and February 2020 saw healthy growth in both cement and RMC sales. ACC said that this was due to a focus on premium products, increase in value-added solutions in its ready mix business, cost reductions on the manufacturing side and logistics-derived savings. Input cost of raw materials were lower on account of material source mix optimisation and supply chain efficiencies. Consequently, the company’s earnings before interest, tax, depreciation and amortisation (EBITDA) for the first quarter increased by 10% year-on-year to US$76.4m.

Sridhar Balakrishnan, ACC’s managing director and chief executive officer (CEO), said, “We believe that with a high probability of a normal monsoon season, growth in the rural economy will revive and stay strong. We expect cement demand to increase in the medium term once the pandemic subsides and business operations commence”.

US: Eagle Materials has sold its Western Aggregates and Mathews Ready Mix subsidiaries for a combined value of US$93.5m. Eagle’s President and chief executive officer (CEO), Michael Haack said that the transaction represented the sale of non-core assets on the heavy-side of the company that do not provide essential support to its primary cement plant network.

Australia: A paper published in the journal Resources, Conservation and Recycling has reported that concrete made with treated slag is 8% stronger than standard slag concrete and 17% stronger than concrete made with conventional aggregates. A Royal Melbourne Institute of Technology (RMIT) team produced treated slag concrete using slag that had absorbed phosphate, magnesium, iron, calcium, silica and aluminium during use in wastewater treatment. Researcher Biplob Pramanik said, “The things that we want to remove from water are actually beneficial to concrete.” Pramanik said that the findings have promising implications for the water and concrete sectors within the circular economy.

Italy: Italcementi’s integrated Calusco plant near Bergamo has been awarded a Responsible Sourcing Scheme (RSS) certificate for its concrete and related supply chain operations. The certification looks at the entire production process from transportation to recycling raw materials. It is the first cement plant in the Italian subsidiary of HeidelbergCement to obtain the certification.

Italcementi suspended operation at its plants in March 2020 due to the coronavirus outbreak due to government decree.

Cement and concrete products with sustainability credentials have increased in recent years as societies start to demand decarbonisation. In spite of the recent drop in the European Union (EU) Emissions Trading Scheme (ETS) price, there has been a trend in recent years in the construction industry towards offerings with better environmental credentials. Indeed, this week’s position paper from Cembureau on a carbon border mechanism concerns directly the growth of these kinds of products within Europe. Typically, the higher profile projects have been slag cement or concrete implementations such as Hanson’s use of its Regen cement substitute in a London sewer project or David Ball Group’s Cemfree concrete in a road project also in the UK. In this short review we’ll take a selective look at a few of the so-called low carbon cement and concrete products currently available.

Table 1: Some examples of methods to reduce embodied CO₂ in cement and concrete. Note - the product examples are selective. In some cases many other products are available.

Looking at cement first, the easiest way for many producers to bring a lower carbon product to market has been to promote cements made using secondary cementitious materials (SCM) such as granulated blast furnace slag or fly ash. These types of cements have a long history, typically in specialist applications and/or in relation to ease of supply. For example, cement producers in eastern India often manufacture slag cements owing to the number of local steel plants. However, cement producers have more recently started to publicise their environmental credentials as they reduce the clinker factor of the final product. Alongside this though, in Europe especially, a number of so-called low carbon cement producers have appeared on the scene such as EcoCem and Hoffman Green Technologies. These newer producers tend to offer SCM cement products or other low carbon ones built around a grinding model. It is likely that their businesses have benefitted from tightening EU environmental legislation. How far cement producers can pivot to SCM cement products is contentious given that slag and fly ash are finite byproducts of other industries that are also under pressure to decarbonise. Although it should be noted that other SCMs such as pozzolans exist.

As will be seen below a few of the methods to reduce embodied CO₂ in cement and concrete can be used in both materials. SCMs are no exception and hold a long history in concrete usage. As mentioned above David Ball Group sells Cemfree a concrete product that contains no cement. Harsco Environmental, a minerals management company, invested US$3m into Carbicrete, a technology start-up working on a cement-free concrete, in late 2019.

Limestone calcined clay cements are the next set of products that are starting to make an appearance through the work of the Swiss-government backed LC3 project, more commercial offerings like FutureCem from Cementir and H-EVA from Hoffman Green Technologies and today’s announcement about ThyssenKrupp’s plans to fit the Kribi cement plant in Cameroon with its Polysius activated clay system. They too, like SCM cements, reduce the clinker factor of the cement. The downside is that, as in the name, the clay element needs to be calcined requiring capital investment, although LC3 make a strong case in their literature about how fast these costs can be recouped in a variety of scenarios.

Calcium silicate cements offer reduced process emissions by decreasing the lime content of the clinker lowering the amount of CO₂ released and bringing down the temperature required in the kiln to make the clinker. Solidia offers its calcium silicate cement as part of a two-part system with a CO₂ cured concrete. In the US LafargeHolcim used Solidia’s product in a commercial project in mid-2019 at a New Jersey paver and block plant. Solidia’s second core technology is using CO₂ to cure concrete and reducing water usage. They are not alone here as Canada’s CarbonCure Technologies uses CO₂ in a similar way with their technology. In their case they focus more on CO₂ mineralisation. In Germany, Schwenk Zement backed the Celitement project, which developed a hydraulic calcium hydro silicate based product that does not use CO₂ curing. Celitement has since become part of Schwenk Zement.

Solidia isn’t the only company looking at two complementary technologies along the cement-concrete production chain. A number of companies are looking at recycling concrete and demolition waste. Generally this splits into coarse waste that is used as an aggregate substitute in concrete and fine waste that is used to make cement. LafargeHolcim has Evopact for the coarse waste and Susteno for the fine. HeidelbergCement has EcoCrete for the coarse and is researching the use of fines. Closing the loop for heavy building material producers definitely seems like the way to go at the moment and this view is reinforced by the involvement of the two largest multinational producers.

Of the rest of the other low carbon cement methods detailed in table 1 these cover other non-Ordinary Portland Cement (OPC) such as geopolymer and calcium sulphoaluminate cements. The former are a type of alkali activated binder and generally lack common standards. The latter are similar to slag cements in that they are established specialist products with lower CO₂ emissions than OPC.

With concrete when trying to make a low carbon product the first choice is whether to choose a low-carbon cement as the binder or even not to use cement at all in the case of Regen or Cemfree. From here the next step is to simply use less cement in a concrete mixture. There are a number of ways to do this from optimising aggregate gradation, following performance specifications more closely, using strength tests like maturity methods and generally adhering to quality control protocols better to deliver more consistency. Read the Mineral Production Association (MPA) publication Specifying Sustainable Concrete for more detail on this. Using concrete admixtures can also help make concrete more sustainable by improving quality and performance at construction sites through the use of plasticisers and accelerators, by decreasing embodied carbon through the use of water reducers and by improving the whole life performance of concretes. The use of locally-sourced aggregates is also worth noting here since it can reduce associated transport CO₂ emissions.

More novel methods of reducing embodied CO₂ emissions in concrete include the use of geopolymer concrete in the case of Zeobond Group’s E-Crete or adding graphene as Concrene does. Like geopolymer cements, geopolymer concretes are relatively new and lack common standards. Products like Concrene, meanwhile, remain currently at the startup level. Finally, if all else fails, offsetting the CO₂ released by a cement or concrete product is always an option. This is what Cemex has done with its Vertua Ultra Zero product. The first 70% reduction in embodied CO₂ is gained through the use of geopolymer cement. Then the remaining 30% reduction is achieved through a carbon offsetting scheme via a carbon neutral certification verified by the Carbon Trust.

As can be seen, a variety of methods exist for cement and concrete producers to reduce the embodied CO₂ of their products and call them ‘low-carbon.’ For the moment most remain in the ‘novelty section’ but as legislators promote and specifiers look for sustainable construction they continue to become more mainstream. What has been interesting to note from this short study is that some companies are looking at multiple solutions along the production and supply chain whilst others are concentrating on single ones. The companies looking at multiple methods range from the biggest building material producers like LafargeHolcim and HeidelbergCement to smaller newer ones like Solidia and Hoffman Green Technologies. Also of note is that many of these products have existed already in various forms for a long time like SCM cements and concretes or the many ways concretes can be made more sustainable through much simpler ways such as changing aggregate sourcing or working more efficiently. In many cases once markets receive sufficient stimulus it seems likely that low carbon cement and concrete products will proliferate.

Global Cement is researching a market report on low carbon cement and concrete. If readers have any comments to make please contact us at This email address is being protected from spambots. You need JavaScript enabled to view it.

Germany: Schwenk Zement’s 1.2Mt/yr Karlstadt cement plant in Bavaria, 1.0Mt/yr Allmendingen and Mergelstetten cement plants in Baden Württemberg and 0.86Mt/yr Bernburg cement plant in Saxony-Anhalt have all achieved the Concrete Sustainability Council (CSC)’s gold certification, enabling the use of their cements in concrete for CSC certified sustainable buildings. Schwenk building consultancy head Werner Rothenbacher said, “Schwenk is committed to sustainable cement production at all locations. More works will follow soon.” In addition to its cement plants, Schwenk operates numerous ready-mix concrete production facilities in Germany.

In 2019 20% of German new-builds were CSC certified.

El Salvador: Switzerland-based LafargeHolcim subsidiary Holcim El Salvador has announced a planned investment of US$7.5m to establish six concrete plants in 2020, which will bring its total to 18 plants. Esmerk Latin American News has reported that the investment also covers ‘new trucks and other machinery.’ Holcim El Salvador also announced its intention ‘in the long term’ to resume operations at its 1.6Mt/yr Maya cement plant, mothballed in 2008, at an estimated cost of US$20m. It is currently investigating the possibility of installing a US$5m solar power plant at its 1.7Mt/yr El Ronco cement plant.

In 2019 Holcim El Salvador produced 1.2Mt of cement and 710,000m³ of concrete.

US: Oldcastle APG, a subsidiary of CRH, has acquired dry mix manufacturer US MIX. The purchase adds to APG's dry mix manufacturing footprint and expands its network of facilities to the Denver, Colorado market. In addition, the acquisition provides APG with materials science expertise and adds another brand, US SPEC, to its existing dry mix product portfolio of Sakrete and Amerimix. No value for the acquisition has been disclosed.

US MIX primarily operates out of a manufacturing facility in Denver, with a secondary specialty bagging location in Fontana, California. Founded in 1968, US MIX has been privately owned by the Peterson family for over 50 years. Its products include bagged concretes, mortars and specialty cement mixes, in addition to liquid repair products.

US MIX currently operates as a Sakrete and Amerimix licensee and offers a variety of specialty products under the well-known US SPEC brand. US SPEC products are professionally engineered concrete and masonry repair products used in a variety of applications, formulated and tested in laboratory conditions under ASTM testing methods and specifications.