Global Cement Newsletter

Issue: GCW399 / 10 April 2019

Headlines


More movement in Italy this week with Buzzi Unicem’s purchase of three cement plants from HeidelbergCement. Buzzi acquired the Testi integrated cement plant at Greve and the Borgo San Dalmazzo and Arquata Scrivia grinding plants in Piedmont. No value for the transaction was disclosed but HeidelbergCement trumpeted that it was ‘well on our way’ to reach its target of Euro1.5bn of disposals by the end of 2020. This follows last week’s purchase of Cemitaly's Spoleto cement plant in Perugia by Colacem. Cemitaly, in case readers don’t know, is another of HeidelbergCement’s Italian subsidiaries.

Upon completion of these deals, Buzzi Unicem will own 10 integrated plants and five grinding plants in Italy. It continues the company’s consolidation drive in Italy from mid-2017 when it bought Cementizillo and two of its integrated plants for the knock down price of up to Euro125m.

The two other leading cement producers are now Germany’s HeidelbergCement with its local subsidiaries (led by Italcementi) and Colacem. HeidelbergCement has 10 integrated plants and 10 grinding plant. Colacem has seven integrated plants and one grinding plant. All three companies have integrated production capacities of around 9 – 14Mt/yr. Since 2012 the market has shifted from six major producers to three. Sacci, Cementir and Cemenzillo have left the field following acquisitions by their competitors. Italcementi was taken over by HeidelbergCement in 2016.

 Graph 1: Cement production in Italy, 2006 – 2017. Source: Italian Cement Association (AITEC).

Graph 1: Cement production in Italy, 2006 – 2017. Source: Italian Cement Association (AITEC).

Data from the Italian Cement Association (AITEC) shows that the impetus for this consolidation trend was the reduction in Italian cement production to 19.3Mt in 2017 from a high of 47.9Mt in 2006. Despite this though the country still has a total production capacity of 37.7Mt/yr, according to Global Cement Directory 2019 data, giving it an utilisation rate of just over 50%. Production picked up again in the north and central regions of Italy in 2017 but this was insufficient to counter declines in the south and Italy’s islands. Exports have held steady in this time at around 2 – 3Mt/yr but this represents a doubling share of production from 5% in 2006 to 10% in 2017. Production has been steadily dwindling year-on-year since 2006 but domestic consumption rallied a little to 18.7Mt in 2017.

The Italian government instituted its ‘Industry 4.0’ policy in early 2017 to boost competitiveness. This included modest growth forecasts of 1%. International Monetary Fund (IMF) data shows that the country managed gross domestic product (GDP) growth of 0.9% in 2018. Yet, Buzzi Unicem reported like-for-like net sales contraction of 0.9% in 2018. HeidelbergCement was more circumspect in its reporting on Italy for 2018 but it did describe a ‘moderate’ increase in sales volumes of cement excluding its acquisitions.

With the IMF diagnosing the Italian economy as ‘weak’ and cutting its growth forecast to 0.1% in 2019 the prospects aren’t looking encouraging for the cement sector. AITEC data placed cement consumption at 309t/capita in 2017. This is on the low side for Western European standards suggesting that, although more consolidation could be coming, the market may also be down too. Its not great news for cement producers but the Italian market is edging ever closer to recovery.


Russia: Eurocement has appointed Andrey Solovyov as the director general of its 2.6Mt/yr Peterburgtsement plant. Soloviev, a graduate of the Moscow Mining Institute, holds experience working for other cement companies. He previously ran Eurocement’s Sengileevskiy cement plant in Ulyanovsk. He has been suceeded at this site by Ildus Sagitov, a graduate of the Belgorod State Technological University.


UK: EvoQuip has appointed Barry O’Hare as its International Sales Director. He holds experience in the crushing and screening industry, having worked in a number of positions for Powerscreen and Terex MPS over the past 11 years, most recently as a Powerscreen Regional Sales Manager. In the new role O’Hare will be responsible for leading the strategic and operational sales activities for EvoQuip in all markets excluding North America, as well as a range of sales supporting responsibilities, including the development and management of territory sales.


Kenya/South Africa: Kenya’s ARM Cement is fighting moves by minority investors in South Africa’s Mafeking Cement to buy it out for a nominal sum. ARM Cement is attempting to sell its 70% stake in the company for around US$3m as part of its administration process, according to the Business Daily newspaper. Mafeking Cement owns limestone reserves in north-west South Africa and ARM Cement originally took a stake in the company to raise investment and eventually build a cement plant.

However, the minority investors have invoked parts of the shareholders’ agreement and filed a court application in South Africa that, if successful, would allow them buy out ARM Cement’s stake for a nominal price less than US$1. ARM Cement’s administrators PricewaterhouseCoopers have taken steps to counter the move.


Benin: Aliko Dangote, the chairman of Nigeria’s Dangote Cement, raised the issue his company has with exporting cement to Benin. He said this company could not export cement to Benin despite its Ibese plant in Nigeria being under 30km from the border, according to the Vanguard newspaper. He alleged that the country was importing ‘more expensive’ cement from China instead.

Dangote made the comments in an interview with Mo Ibrahim at the 2019 Ibrahim Governance Weekend in Abidjan, Ivory Coast. He also said that he looked forward to the Continental Free Trade Area (CFTA) making trade easier in the region.


Bolivia: SEDEM, the government’s business development agency, has refuted accusations that a new cement plant being built in Caracollo, Oruro does not have enough water or raw materials. Patricia Ballivián, the general manager of SEDEM, presented reports from PricewaterhouseCoopers and C & C Ingeniería y Procesos defending the supplies to the unit. The reports were released in response to accusations by a local politician that the project had been poorly planned.

The reports revealed that the Empresa Publica Productiva Cementos de Bolivia’s (ECEBOL) plant will recycle the industrial portion of its water supply. It will have a supply of 4l/s and a 3.5Ml reservoir. It also has limestone, gypsum and clay reserves sufficient for the production of 100Mt of cement. These are expected to last the plant 60 years.


Indonesia: Indocement is aiming for 4% growth in sales year-on-year to around US$1.12bn in 2019 due to sluggish cement consumption. This compares to 5% growth in revenue in 2018. The subsidiary of Germany’s HeidelbergCement expects demand to increase in the second half of 2019 following elections, according to the Jakarta Post newspaper. It predicts that cement consumption will be driven by government infrastructure projects and the construction of residential projects and buildings. It plans to spend up to US$70m towards setting up a quarry in West Java and completing new cement terminals.

The cement producer is also preparing to increase its thermal substitution rate with alternative fuels like refuse-derived fuel (RDF). This follows a 50% rise in production costs due to coal in 2018. In September 2018 to agreed to buy 500t of RDF from the West Java government.


US: The Portland Cement Association (PCA) has announced the winners of the 2019 Energy and Environment (E&E) Awards. The awards recognised environmental and community relations projects that were completed in 2018 and were presented at the 3rd Annual Cement and Concrete Fly-In.

The CalPortland Mojave cement plant in California won the Energy Efficiency award for the installation of a new classifier system for its vertical roller mill that increased energy efficiency by reducing fan power requirements. The plant also installed a control system for the finish mill that will maximise performance and help reduce wear on equipment. The classifier installation reduced the finish mill energy intensity by 1.5 to 2.0kWh/t, and the control system reduced energy intensity by 13%. In 2018 22% of the electricity consumed by the plant came from on-site renewable wind energy generation. CalPortland has implemented significant energy efficiency measures and its energy management program has been recognised by the Environmental Protection Agency Energy Star program as the Energy Star Partner of the Year for 15 years in a row.

Roanoke Cement Company and Titan America’s Troutville plant in Virginia won the Environmental Performance award for being the first cement manufacturing plant in the US to receive ISO 50001 certification for energy management of all aspects of energy procurement, design and use. The plant reduced its total electrical consumption by 10% and fossil fuels use by more than 12%. The plant has also implemented an alternative fuels program as part of its certification for the True Zero Waste Program, administered by Green Business Certification and has received silver status achieving a 96% rate of waste divergence from landfills.

Lehigh Hanson’s Permanente cement plant at Cupertino in California won the Innovation award for the installation of a water treatment system reducing concentrations of metals, including selenium, to meet permit limits. Lehigh Hanson developed a treatment system that combined ultrafiltration and reverse osmosis (UF/RO) technology in conjunction with biological treatment technology to remove metals, including selenium and dissolved solids. This ensured applicable effluent limits were met while optimising treatment capacity and efficiency. This treatment system is the first of its kind in the cement industry ensuring that effluent limits are met while, at the same time, limiting the quantity of waste needed to be managed.

Buzzi Unicem USA’s Greencastle cement plant in Indiana won the Land Stewardship award for opening a 4km smooth packed stone trail in conjunction with the not-for-profit People Pathways organisation as Phase 2 of the Putnam Nature Trail. Buzzi Unicem USA staff and People Pathways used heavy equipment for rough clearing and grading of the overgrown former railroad bed and improved and expanded the physical trail. These areas were then landscaped with trees, native prairie vegetation plugs, interpretive signage, benches, birdhouses and other features. Additional nature trail enhancements include placement of wildlife monitoring cameras along the trail, installation of nesting boxes and interpretive signage, and maintenance of the recently completed restoration of native flora installed in 2017 and 2018.

Cemex’s Lyons cement plant in Colorado won the Outreach award for volunteering work by its staff at the Rocky Mountain National Park in Boulder, Colorado, performing campground improvement activities at Glacier Basin Campground by moving rocks and fallen timber and clearing existing fire pits of ash deposits. The plant then introduced a new community outreach initiative by hosting a Manufacturing Day event, providing local students tours of the quarry and plant to increase youth interest in pursuing a vocation in skilled trades. Additionally, the plant teamed up with the Celestial Seasonings B Strong Ride for cancer care and research for an event aimed at increasing safety awareness while fundraising for two local organizations and their efforts to fight cancer.


Mexico: Holcim Mexico has won an award from the National Chamber of Cement (CANACEM) for reporting no accidents at its cement plants in 2018. The award was presented at CANACEM‘s XXXVI National Congress of Occupational Health and Safety in Chihuahua.


Ivory Coast: Dangote Cement is building a 3Mt/yr cement plant with two production lines from an investment of around US$260m in the Ivory Coast. In an audience with Souleymane Diarrassouba, Minister of Commerce, Industry and Promotion of SMEs, the company said that the project is 70% complete, according to the Agence Ivoirienne de Presse. The new plant will create 800 jobs. It is scheduled to start production in early 2020.


Brazil: Investors have started legal action over in Cimento Tupi’s defaulted debts and attempts to merge with its parent company Cimento Santo Estevão. The cement producer defaulted in mid-2018 on payments to foreign investors that hold around US$30m in it, according to the Valor Econômico newspaper. It also stopped paying interest on the debts in 2015.

Other creditors are also working to stop Cimento Tupi’s plans to merge with Cimento Santo Estevão because it would raise the company’s debts rather than cut costs. A court in Rio de Janerio rejected one case although others are on-going elsewhere. Separately, the Agricultural Bank of China is also challenging the cement producer over arrears in a loan worth US$18m.

Cimento Tupi operates one integrated plant at Pedra do Sino in Minas Gerais and a grinding plant in Modi das Cruzes in São Paulo. It has a combined cement production capacity of 2.5Mt/yr but it has been producing half of this since around 2015. Its operating revenue remained stable at US$43m for the first nine months of 2018. However, its loss more than trippled year-on-year to US$76m.


Trinidad & Tobago: Trinidad Cement has asked the Caribbean Court of Justice (CCJ) to make its competitor Rock Hard Cement pay more than a 5% tariff on imports. It follows a ruling by the council of trade ministers in the Caribbean Community (CARICOM) in March 2019 that agreed to a classification of Rock Hard Cement’s products in Trinidad leading to duties of up to 5%, according to the Nation newspaper. The case has been referred to the CCJ for final arbitration in June 2019.


China: Sinoma International Engineering has won a prize in the National Quality Engineering Awards organised by the China Construction Enterprise Management Association for its work on the Biskria Cement plant in Algeria. Sinoma supplied a second production line for the plant. It was commissioned in 2018.


Serbia: Elektroprivreda Srbije, a government-owned power company, has completed a Euro14m terminal on the River Danube for its Kostolac B coal-fired power plant. The unit will be use to transport 105,000t/yr of synthetic gypsum and 157,000/yr of fly ash. It will also process limestone. The terminal was built as part of the first phase of a credit arrangement between Serbia and China.


UK: The Global Cement and Concrete Association (GCCA) has expanded its membership to 36 companies with its number of affiliates organisations rising to 15. The new members include Corporacion Moctezuma in Mexico, Unión Andina de Cementos (UNACEM) in Peru, JSW Cement in India and West China Cement in China.

The new affiliates include Oficemen (the Spanish Cement Association), the Cement Manufacturers Association of India, the Japan Cement Association, the National Ready Mixed Concrete Association in the US, the European Concrete Platform and the Federacion Iboamericana del Hormigon Premezclado (FIHP) which covers Latin America and the Iberian Peninsula

“The continuing and rapid growth of the association’s membership is very encouraging. With a strong work program now underway it’s important that our authoritative voice represents the growing list of cement and concrete manufacturers committed to our principles of enhancing industry sustainability efforts and driving innovation.” said GCCA chief executive officer (CEO) Benjamin Sporton.

The GCCA was launched in 2018. It aims to represent at least 50% of global cement production capacity.


Germany: Ali Emir Adıgüzel has resigned as the chief executive officer (CEO) of HeidelbergCement trading subsidiary HC Trading. He will be succeeded by Hakan Gurdal, a member of HeidelbergCement’s management board.

In a statement on LinkedIn Adıgüzelthanked HeidelbergCement’s chairman Bernd Scheifele for his support over the last 15 years. He added that it was, normal to have differences of opinion regarding the performance evaluation, strategy and future steps in companies.

Born in Turkey, the 58-year old Adıgüzel graduated from Harvard Business School in the US and the Boğaziçi University Business Administration Department in Turkey. He started his career working in Saudi Arabia and has been the general manager of HC Trading since 1996. He became Trade Chairman for the Mediterranean, Middle East and International regions, which include Turkey in 2004 and was appointed CEO in 2016.


Italy: Buzzi Unicem has purchased the Testi integrated cement plant at Greve and the Borgo San Dalmazzo and Arquata Scrivia grinding plants in Piedmont from HeidelbergCement’s subsidiaries. The enforceable agreement is expected to be completed by the end of July 2019. No value for the deal has been disclosed. Buzzi Unicem said it was making the acquisitions as part of its plan to strengthen its position in the national market.


Germany: Holcim Deutschland’s Kollenbach cement plant in Beckum has commissioned a Zeppelin Cat 6030 FS hydraulic excavator. The machine is 15m long, 7.5m high and it has an engine power of 1500HP. It will mine at least 470t/hr of limestone from the plant’s quarry. The excavator was purchased due to the height and thickness of the marl layers in the deposit. Material from the quarry will then be transported 2.5km by truck to a stationary primary crusher before use at the cement plant.


Syria: Russian companies have met with representatives of the Syrian Ministry of Industry to discuss restoring and upgrading the Al Arabiya cement plant in Aleppo. During the visit to Syria representatives of the company also held talks about building a new cement plant, Muslimiya, according to the Prime News Agency. Negotiations were also held about renovating a steel plant in Hama province.


Togo: HeidelbergCement is considering investments of up to Euro25m in its local subsidiaries including Cimtogo, Scantogo and Granutogo. Local director general of the company Eric Goulignac outlined the plans, including building and installing a new mill at Cimtogo’s cement grinding plant in Lomé and a photvoltaic (PV) solar energy plant, according to the All Africa news agency. The projects will be considered by the board of HeidelbergCement in the summer before a final decision is made.


Uganda: Hima Cement has agreed to return land it acquired in the Mwello Parish of Tororo District to the local residents due to mistakes made by its land agent. The company’s agent, Optima Mining and Minerals, allegedly purchased land from residents who did not hold the necessary paperwork, according to the Daily Monitor newspaper. The agent then intended to apply for a lease on the land from Tororo District Land Board.

Dunstan Ndyaguma, Optima’s managing director, was advised by the commission to obtain a lawyer to learn about the land tenure system in the district. He was also described as a ‘dangerous’ man because he had manipulated local residents in his dealings with them.

Hima Cement, a subsidiary of LafargeHolcim, wants to build a US$250m new cement plant in the area. It has warned that the project may be moved to Kenya instead due to the difficulties in obtaining land.


China: Tianrui Cement has entered into a clinker supply deal with Ruiping Shilong. It will buy clinker from Ruiping Shilong from 1 April 2019 until 31 December 2021. The price and quantity will be set following negotiations, although a cap of around US$74m/yr has been set. Tianrui Cement’s chairman and his wife hold a significant minority share in Ruiping Shilonga.


Azerbaijan: Holcim Azerbaijan has launched Unkial, a cement product offering water resistant properties in the concrete it makes. The product is being targeted for general usage, according to the Turan Information Agency. Production of the new product will meet local demand.


Pakistan: Cement despatches fell by 9% year-on-year to 34.6Mt in the nine months to the end of March 2019 from 34.8Mt in the same period to March 2018. Data from the All Pakistan Cement Manufacturers Association (APCMA) shows that despatches and exports fell in both the north of the country but that despatches fell and exports rose in the south. Exports more than doubled in the south to 3.14Mt. This was due to a reported start in seabourne clinker sales in the 2018 – 2019 year. Otherwise, overall cement exports to Afghanistan and India declined.


Uganda: Nicolas George, the managing director of Hima Cement, has warned that a US$250m new cement plant project may be relocated to Kenya due to difficulties in obtaining land in Uganda. He made the comments to the Commission of Inquiry into Land Matters following complaints by local residents about the land purchase process, according to the Daily Monitor newspaper. The cement producer is trying to buy mineral rights in the Mwello Parish in Tororo District. Previously, it attempted to build a plant in Moroto.

George also alleged that the subsidiary of LafargeHolcim had repeatedly run up against ‘speculators with exploration licences’ with links to the Directorate of Geological Survey and Mines. He asked the government to cancel such licences within two years if the owners lacked the in financial resources to develop them.


Algeria: GICA Group’s Hadjar Soud cement plant has made its first 37,000t clinker shipment to the Ivory Coast via the Port of Annaba. It is part of a 0.2Mt/yr consignment planned for 2019 from the unit, according to the Algeria Press Service. Overall, GICA intends to export 1.5Mt of clinker to African countries in 2019.


Chile: Cbb, formerly known as Cementos Bío Bío, has inaugurated a new 0.2Mt/yr cement grinding plant at Arica. The unit had an investment of US$20m, according to the Diario Financiero newspaper. It is the company’s fifth plant in the country. As part of Cbb’s expansion strategy to target Peru, the new plant may double its production capacity in the future. The cement producer is also planning to build a US$20m plant at the Port of Matarani near Arequipa in Peru for a scheduled commission date in 2020.


Colombia: Cementos Argos is switching its trucks in Medellín to electric-powered vehicles. The new trucks will be powered by 600v batteries and be capable of carrying 4t of cement, according to the La Republic newspaper. The cement producer is planning to expand the electric-powered trucks to other cities subsequently.


Germany/China: Baltrader Capital has ordered the construction of two cement carriers from China’s Fujian Southeast Shipbuilding, who will deliver the new vessels from end of 2020. The ships will be intended for the European shortsea trade. Following the completion of the order, the Baltrader fleet will comprise 12 cement carriers with pneumatic self-discharging systems.

Each of the sister vessels, CemCoaster and CemClipper, measures 98m in length, 15.6m in width and carries 4650t at 6m draft. They will be equipped with a MaK main engine, allowing a future conversion into dual fuel operation. The ships will then be optionally run on liquid natural gas (LNG) or on marine gasoil.

The ships have been planned and designed in Germany by SDC Ship Design & Consult in cooperation with the project engineering department of the BRISE-Group. Dutch producer Van Aalst Marine & Offshore will supply the automatic self-discharging system, powered alternatively by the main engine’s shaft generator or the auxiliary generators. It can be used for the transportation of loose cement, ground granulated blast-furnace slag and fly-ash. It will have a loading capacity of 500t/hr and unloading capacity of 250t/hr. Additionally, these iceclass 1B ships are equipped with a ballast water treatment system (BWTS).


UK: Aggregate Industries, a subsidiary of LafargeHolcim, has obtained PAS 2080 verification, a new Carbon Management in Infrastructure specification. PAS 2080 is the world’s first specification for managing whole-life carbon in infrastructure. Developed by the Construction Leadership Council’s Green Construction Board with the British Standards Institute (BSI), it provides a framework and guidance for measuring and managing carbon across the whole value chain.

“We can help designers at Early Contractor Involvement (ECI) stage to design lower carbon solutions. Our management systems (ISO 14001 and 50001) ensure consistent and reliable data collection, allowing our Carbon Managers to report embodied CO2 to other members of the value chain. Baseline data made available to the value chain allows carbon targets to be set at design phase and for performance to be monitored against these targets during project delivery. This will result in infrastructure with lower embodied carbon,” said Paul McCaffrey, Sustainable Products Manager at Aggregate Industries.


Indonesia: Exports drove Semen Indonesia’s cement sales volume growth in 2018. Its local sales volumes of cement grew by 1.2% year-on-year in 2018 to 27.4Mt from 27.1Mt in 2017 but exports increased by 68% to 3.16Mt from 1.87Mt. Sales volumes at its Thanh Long Cement subsidiary in Vietnam grew by 7.9% to 2.57Mt from 2.39Mt due to a sharp increase in exports. The group’s revenue rose by 10% to US$2.17bn from US$1.96bn. Its net profit nearly doubled to US$218m from US$117m.

Semen Indonesia completed its acquisition of Holcim Indonesia for US$1.75bn in February 2019. Prior to the purchase it had a cement production capacity of 38.2Mt/yr and Holcim Indonesia had a capacity of 14.8Mt/yr.


Brazil: Votorantim Cimentos’ revenue rose by 15% year-on-year to US$3.26bn in 2018 from US$2.82bn in 2017. Its sales volumes of cement increased slightly to 30.9Mt from 30.6Mt. Its adjusted earnings before interest, taxation, depreciation and amortisation (EBITDA) grew by 51% to US$677m from US$477m. Despite a 1.2% drop in cement demand in Brazil, the group managed to raise its revenue. The cement producer said that its revenue growth in 2018 was affected by markets in Brazil and the US and positive currency depreciation effects.


Latvia: Cemex Latvia will be renamed as Schwenk Latvija following its acquisition by Germany’s Schwenk in February 2019. In Sweden Cemex’s operations will be renamed to Schwenk Sverige, in Norway to Schwenk Norge and in Finland to Schwenk Suomi, according to the Latvian News Agency.

The Euro340m deal included one 1.7Mt/yr integrated cement plant in Broceni, Latvia, as well as four aggregates quarries, two cement quarries, six ready-mix concrete plants, one marine terminal and one land distribution terminal in that country. The assets divested also include Cemex’s approximate 38% indirect interest in a 1.8Mt/yr cement plant in Akmene in Lithuania. In addition, the exports business to Estonia is also included as part of the divestment.


Spain: Endesa sold 0.3Mt of fly-ash from its Carboneras power plant in Almeria to cement companies in the UK and North America in 2018. The energy company also sold fly-ash to the nearby LafargeHolcim Carboneras cement plant, according to La Voz de Almería newspaper. The company has also sold 30,00t of slag and 60,000t of gypsum from its limestone plant.


Japan: Sumitomo Osaka Cement has completed a new cement silo at its Kochi plant. The upgrade is part of a long-term plan to focus on exports to Southeast Asia. The cement producer intends to establish an overseas business presence outside of Japan.


Cameroon: Cimencam has inaugurated its 0.5Mt/yr Nomayos cement grinding plant. The company also launched a new logo, according to the Ecofin Agency. The new unit will manufacture the company’s MultiX CEM II 32.5 R Ordinary Portland Cement (OPC) and its Sublime white cement products.

The subsidiary of LafargeHolcim is planning to regain lost market share in the country since Dangote Cement started operating locally. It is planning to build a new kiln at its Figuil integrated plant in Garoua, which is due for commissioning in 2020.


The Gambia: Bai Lamin Jobe, the Minister of Trade, says that the country has a cement capacity utilisation rate of 23%. Local producers have a capacity of 1.9Mt/yr but national demand is only around 0.4Mt, according to the Foroyaa newspaper. He added that the country imported 0.39Mt in 2018 in answers to members of the National Assembly.

It was also revealed that Jah Multi Industries is building new silos at its import terminal. Jah Cement is also planning to upgrade its terminal into a grinding plant. Construction work started in 2018 and it is expected to be completed by late 2019.