Global Cement Newsletter

Issue: GCW632 / 01 November 2023

Headlines


UltraTech Cement approved a US$1.5bn capacity expansion plan this week. The initiative intends to add 21.9Mt/yr in production capacity by setting up four new cement plants, four upgrades and four new terminals. It will also add 39MW in waste heat recovery (WHR) units and alternative fuels feeding and handling investments. Commercial production at the new sites is scheduled to start from the 2026 financial year onwards.

The company is India’s largest cement producer by production capacity and the third biggest globally outside of China. Yet it is still growing as this latest announcement shows. Kumar Mangalam Birla, the chair of parent company Aditya Birla Group, revealed the ambition earlier this year, that UltraTech Cement wants to reach a production capacity of 200Mt/yr in the near future. This is likely to be ordinary Portland cement (OPC) capacity from both integrated and grinding plants. It reported a figure of 132Mt/yr in its annual report for the 2023 financial year. This latest capacity investment is its third in recent years. In December 2020 it announced investment of just below US$560m to add 12.8Mt/yr of capacity with commissioning by around the end of the 2023 financial year. It later confirmed that most of this had been completed on schedule. Then another US$1.55bn investment was ordered in June 2022 to add 22.6Mt/yr. This tranche of new plants and terminals is planned to be completed by the end of the 2025 financial year.

Graph 1: UltraTech Cement’s OPC production capacity and utilisation rate, 2017 - 2023 financial years. Source: Company annual reports. 

Graph 1: UltraTech Cement’s OPC production capacity and utilisation rate, 2017 - 2023 financial years. Source: Company annual reports.

The graph above shows how the company’s capacity has grown since 2017. This is the year in which it acquired 21Mt/yr of capacity from Jaiprakash Associates for US$2.5bn. These plants then show up in the capacity figure for 2018. The next big bump to capacity arrived in 2019 when UltraTech Cement was able to complete its purchase of Century Textiles & Industries, adding another 15Mt/yr of capacity. Since then though it has mainly been newly built plants or upgrades. It is also worth noting the capacity utilisation figures the company has reported. There has generally been an upward trend since 2017 with a dip during the Covid-19 pandemic years in 2020 and 2021. This has also been happening despite adding more capacity through both acquisitions and building new plants. The other point to note is that the cement company is mostly a wholly India-based one. It has presences in the UAE, Bahrain and Sri Lanka but these are small compared to the operations back home. In the 2023 financial year, 23 of its 24 integrated plants were domestic, 25 out of 29 grinding plants were and seven out of eight terminals were too.

UltraTech Cement’s current nearest rival, Adani Group, appeared on the scene in 2022 when it bought Holcim’s subsidiaries in India. The timing may have been coincidental but, after Holcim agreed to sell to Adani Group in May 2022, UltraTech Cement announced its US$1.55bn capacity drive in June 2022. A year later in June 2023 Adani Group targeted a capacity of 140Mt/yr by 2028. To give an idea of the market both of these companies are competing in, Ratings Agency ICRA’s last forecast in September 2024 predicted that cement volumes would grow by 9 - 10% in the 2024 financial year. Capacity expansion by all cement producers was expected to be driven by “steady demand for housing and increased government investments in infrastructure.”

UltraTech Cement may be the fastest expanding cement company in the world at the moment. India certainly needs the cement as its population overtook China’s in April 2023. The Aditya Birla Group company is not taking any chances with its competitors by maintaining its lead in capacity. One risk it may want to watch out for though is India’s nascent Carbon Credit Trading Scheme. Some form of carbon trading for the petrochemicals, steel, cement and paper sectors looks set to start in the second half of the 2020s. However, any such scheme is likely to favour incumbent manufacturers with newer plants. With the country’s net zero target set at 2070, UltraTech Cement has plenty of room to manoeuvre.


UK: The World Cement Association (WCA) has appointed Wei Rushan as its president. He succeeds founding president Song Zhiping in the post.

Wei has been the president and executive director of CNBM since late 2022, having had a range of senior roles within CNBM Group over the last 15 years. He obtained a doctoral degree in political economy from the School of Economics of Renmin University of China in 2007. Wei also serves as president of China Building Materials Engineering Construction Association.


Saudi Arabia: The board of directors of Umm Al-Qura Cement Company has appointed Mohamed Fadl Kamel Al-Hawi as its interim chief executive officer. Previous company head Majid Tarik Gharbawi resigned in August 2023 with effect from mid-October 2023.

Mohammad Al-Hawi holds a bachelor’s degree in mechanical engineering from King Fahd University of Petroleum and Minerals. His cement industry experience spans over 30 years, including his role as plant manager of the Umm Al-Qura Cement Company plant.


UK: James Thorne has been appointed as the joint-head of the Mineral Products Qualifications Council (MPQC) and The Institute of Quarrying (IQ) with effect from December 2023. He has been the chief executive officer (CEO) of IQ since 2017. He takes over the new joint-position following the retirement of the MPQC‘s current CEO Viv Russell.

The appointment of a joint-head of both organisations marks a long-standing collaboration between the two membership organisations. The MPQC and the IQ signed a memorandum of understanding in 2022 to work together to increase the value of membership services within the mineral products sector and further develop partnerships with other sectors, industries, and government bodies. This also supports the strategy to develop the National Stone Centre as an international centre of excellence for the mineral products industry.

Established in 1983, the MPQC is a 'not for profit' membership organisation whose purpose is to fulfil the extractive sector's need for a safe, competent and sustainable workforce through the setting and maintaining of standards and qualifications, ensuring quality training and assessment.

The IQ is the professional membership body for quarrying, and the related mineral products extractive and processing industries, with a worldwide membership of more than 5500 individuals.


India: Nuvoco Vistas sold 4.5Mt of cement during the second quarter of its 2024 financial year (FY2024), up by 1.2% year-on-year. Its revenues grew by 7% to US$309m, while its earnings before interest, taxation, depreciation and amortisation (EBITDA) grew by 73% to US$40.4m. The producer achieved specific CO2 emissions of 462kg/t and an alternate fuel (AF) substitution rate of 14%. During the quarter, it completed debottlenecking projects at the Risda, Chhattisgarh, and Nimbol, Rajasthan, cement plants. The company said that these raised its clinker capacity by 2000t/day. It also secured a new patent, for its fibre reinforced cement composition, and introduced its Concreto UNO and Duraguard F2F premium cements on the Jharkhand market.

Managing director Jayakumar Krishnaswamy said “Our value over volume strategy has positively contributed to the company’s performance. Our trade share has increased from 72% in the second quarter of the 2023 financial year (FY2023) to 74% in the second quarter of FY2024. In addition, the results also demonstrate our commitment to managing the dynamic cost environment through an optimised power and fuel mix, between conventional and clean energy sources.” He added “The expansion at the Haryana cement plant is expected to be completed in FY2024, which will enable us cater to strong demand in the Northern India region.”


Nigeria: Lafarge Africa raised its consolidated sales by 7.1% year-on-year to US$367m throughout the first nine months of 2023. Over the same period, the company’s cost of sales rose by 4.4% to US$179m. Its net profit was US$49.9m, down by 13% year-on-year.


Philippines: Cemex Philippines’ sales were US$238m during the first nine months of 2023, down by 15% year-on-year. The Philippine Daily Inquirer newspaper has reported that the company recorded increased costs during the period, although its electricity costs dropped. It implemented cost efficiency measures, but failed to reduce its net loss, which rose by 47% to US$66.5m from US$45.4m.

President and chief executive officer Luis Franco said "In this year of transition for our company, we remain dedicated to finding opportunities to improve our overall efficiency and profitability by proactively managing the variables we can control. I am pleased with the initial progress we have made in the implementation of our efficiency programme and its results in optimising our operations, streamlining processes, increasing supply chain efficiency and improving our energy mix."


Saudi Arabia: Yanbu Cement’s sales were US$156m during the first nine months of 2023, down by 21% year-on-year. Its net profit also dropped in the period, by 35% to US$27.1m.


Mexico: Cemex has refinanced a syndicated credit agreement worth US$3bn. Dow Jones Institutional News has reported that the refinanced agreement includes a US$1bn, five-year term loan and US$2bn five-year revolving credit facility.

Cemex’s chief financial officer Maher Al-Haffar said "We now have a flatter debt maturity profile, with no significant maturities in any year."


Algeria: Holcim Algeria successfully commissioned a new 18,000t/day clinker loader at the Port of Djendjen in late October 2023. The cost of the equipment was Euro3m. APS News has reported that port authorities have ordered two further such machines from China.


Austria: RHI Magnesita says that its sales volumes declined quarter-on-quarter during the third quarter of 2023, with its refractories plants operating at 70% capacity. The company noted ‘under-absorption’ of fixed costs. However it succeeded in maintaining constant earnings before interest, taxation and amortisation (EBITA) levels in line with the second quarter of the year. As such, RHI Magnesita revised its adjusted EBITA guidance for full-year 2023 to Euro380m from Euro360m. It said that its order book visibility is at ‘normal’ levels, with limited signs of a recovery in demand volumes in 2024, as global construction activity continues to be weak.

Chief executive officer Stefan Borgas said “I am pleased by the strong execution demonstrated by RHI Magnesita during difficult conditions for our key end markets. We are currently benefitting from the strategic investments we have made in reducing our cost base and rationalising our production network, together with improved planning and careful management of our assets through this period of weaker demand. Pricing discipline has helped to maintain EBITA margins at over 11%, offsetting the impact of lower production on our fixed cost base. We have also been able to progress our mergers and acquisitions strategy, with six acquisitions completed in the first nine months of 2023 and a total of nine in the past 24 months.


India: Larsen & Toubro recorded sales of US$6.12bn during the third quarter of 2023, up by 19% year-on-year. Its infrastructure projects segment contributed sales worth US$3.36bn, 55% of the total, with an increase in order inflow of 72%. Larsen & Toubro’s net profit grew by 45% year-on-year during the quarter, to US$387m.


US: Solidia Technologies has commenced production of its mineralised CO2-based supplementary cementitious material (SCM) at a pilot line at its headquarters in San Antonio, Texas. The pilot line increases the company’s production capacity of the SCM by a factor of 25.

Solidia Technologies senior director of strategy and business development Pradeep Ghosh said "With the dramatic increase in production capacity that the new pilot line brings, we are now shipping significant quantities of Solidia SCM to ready-mix concrete producers, transport agencies and contractors to qualify and trial our material."


Spain: Cementos Molins reported sales worth Euro1.08bn during the first nine months of 2023, up by 13% year-on-year from those recorded in the corresponding period of 2022. Meanwhile, the company’s earnings before interest, taxation, depreciation and amortisation (EBITDA) rose by 33%, to Euro278m. Its net profit grew by 38% to Euro124m. The producer succeeded in reducing its debt by 76% to Euro34m, compared to Euro1.42bn at the beginning of the year.

Cementos Molins chief executive officer Julio Rodríguez said "Despite the increasing challenges in the global environment, the results for the first nine months of 2023 showcase the strength of our integrated business model, which comprises products and solutions. We are also making significant progress in implementing our sustainability strategy. I extend my personal gratitude to our dedicated and committed team of more than 6200 employees, whose efforts have enabled our growth across our diverse business segments and in most geographical regions.”


France: Lafarge France has ignited the new kiln at its Martres-Tolosane cement plant following a Euro120m upgrade. Local press has reported that the upgrade replaced the plant’s existing kilns and preheater tower with entirely new equipment. The new kiln has tripled the plant’s capacity, to 2.1Mt/yr from 0.7Mt/yr. Meanwhile, the new preheater tower will help to reduce the plant’s electricity consumption by over 20%. As a result of the upgrade, the Martres-Tolosane plant can now support an alternative fuels (AF) substitution rate of 60%, compared to 20% beforehand. Lafarge France aims to carry out further work to reach 85% AF substitution at the plant by 2027. Other planned projects include the installation of a carbon capture system.

Lafarge France chief executive officer François Petry said “We are going to create a research and innovation centre here dedicated to the capture of CO2, with the ambition of ultimately making the Martres-Tolosane plant net zero carbon.”


China: China National Building Material (CNBM) says that its subsidiary Gansu Qilianshan Cement has issued shares. Reuters has reported that CNBM stated the reason for the issuance is ‘asset acquisition’ as part of the group’s on-going restructuring.


Philippines: Holcim Philippines has appointed I Squared Capital subsidiary Berde Renewables to build, maintain and operate two rooftop solar power plants, at its Bulacan and La Union cement plants, respectively. The solar power plants will have a combined capacity of 7.8GWh/yr and reduce Holcim Philippines’ CO2 emissions by 5500t/yr. The Business Mirror newspaper has reported that the projects advance the producer’s aim to reduce its energy-related CO2 emissions by 65% between 2018 and 2030.

Holcim Philippines president and CEO Horia Adrian noted the 20% reduction in overall CO¬2 emissions that the company has already achieved up to 2022 and said “This project further strengthens our ability to support Holcim's net zero direction and the country's nationally determined contributions.”


India: JK Cement has advanced its diversification into the energy sector with four new acquisitions. The Free Press Journal has reported that the cement producer has signed agreements to acquire stakes in CleanMax Matahari, Fourth Partner Energy, Nay Energy and Renewable Energy V.


Vietnam: The government recorded growth of 0.3% year-on-year in exports of cement and clinker from Vietnam during the first 10 months of 2023. They ended the period at a cumulative 26.2Mt, compared to 25.9Mt a year earlier. Việt Nam News has reported that the value of exports fell by 2.4%, to US$1.13bn.


Uzbekistan: The State Statistics Committee has reported that cement plants produced 9.2Mt of cement during the first nine months of 2023, up by 5.9% year-on-year from the corresponding period of 2022. The Uzbek Building Materials Producers’ Association says that the new 1.4Mt/yr Karakalpak cement plant will further add to full-year production volumes in 2023 when it comes online later in the year.


Qatar: The board of directors of Qatar National Cement has approved the proposed sale of the company’s Cement Plant No. 1 in Umm Bab, Al-Shahaniya Municipality. Reuters has reported the plant’s buyer as Arab International Metal Trading.


India: UltraTech Cement announced planned new capital expenditure (CAPEX) investments worth US$1.56bn to grow its production capacity, beginning in the 2026 financial year (1 April 2025 – 31 March 2026). The Telegraph newspaper has reported that the growth will expand UltraTech Cement’s capacity by 13% to 187Mt. 33.8Mt-worth of this (18%) will be in its native West India, 40.4Mt-worth (22%) in East India, 36.2Mt-worth (19%) in North India, 35.7Mt-worth (19%) in Central India and 35.5Mt-worth (19%) in Central India, with the remainder situated overseas. The new capacity consists of four new production facilities and four upgrades to existing facilities, supported by four new cement terminals. The producer says that it will come online in a phased manner, up to an unspecified end date.

Kumar Mangalam Birla, chair of parent company Aditya Birla, said "Over the past seven years, UltraTech has strategically invested over US$6bn to support India's rapidly changing infrastructure landscape. Our fresh commitment of US$1.56bn underscores our deep-rooted belief in India's economic potential. With each investment, we have not only expanded our footprint, but also empowered India in meeting its need for housing, roads and other vital infrastructure."


US: Holcim US will invest US$100m in an expansion to raise its Ste. Genevieve cement plant’s capacity by 15% to 4.6Mt/yr. The expansion will involve the installation of a fifth vertical roller mill (VRM) for cement grinding and a new mineral component addition system, alongside a rail-loadout expansion. The producer says that the expanded plant will have lower net CO2 emissions than before. Construction is set to commence in 2024.

Toufic Tabbara, head of Holcim’s North America region, said “With an emphasis on achieving the highest levels of environmental performance and operational efficiency, Ste. Genevieve has been the leader in US cement manufacturing since it was built in 2009. This investment will ensure we maintain that leadership in supporting the sustainable growth of our nation’s infrastructure and residential construction while accelerating net carbon reduction across the built environment.”


China: Tangshan Jidong Cement recorded US$3.05bn in sales during the first nine months of 2023, down by 18% year-on-year from US$3.74bn during the first nine months of 2022. Its nine-month net loss was US$44m, against a profit of US$223m one year previously.


Nigeria: Dangote Cement recorded sales of US$1.9bn during the first nine months of 2023, up by 29% year-on-year from nine-month 2022 levels. The group’s sales volumes of cement and clinker both dropped. The Premium Times newspaper has reported that Dangote Cement’s costs rose by 33%, primarily due to increased spending on electricity and fuel. Nonetheless, its profit after tax grew by 30%, to US$351m.


India: The Supreme Court will hear the case against Adani Group over its alleged financial misrepresentation and stock manipulation on 24 November 2023, 24 days after the previous deferred date of 30 October 2023. BusinessWorld News has reported that the National Financial Reporting Authority (NFRA) is currently ‘scrutinising’ the group's auditors, S.R. Batliboi, while the Securities and Exchange Board of India (SEBI) is investigating British Virgin Islands-based investment fund Gulf Asia Trade & Investment for possible violations of share ownership regulations in connection with the Adani Group.

Adani Group says that it has committed no wrongdoing.


India: Andhra Cements has commenced work to dispose of grinding mills from its Visakha grinding plant in Andhra Pradesh’s Visakhapatnam District, Reuters has reported. The plant previously had a capacity of 600,000t/yr.

Sagar Cements concluded a deal to acquire Andhra Cements in January 2023.


Switzerland: Holcim has reported growing sales and earnings on an organic basis in first nine months of 2023. In real terms its sales declined by 10% year-on-year to US$22.7bn during the first nine months of 2023 from US$25.2bn in the first nine months of 2022. Its recurring earnings before interest and taxation (EBIT) fell by 2.2% to US$4.05bn from US$4.14bn. However, sales and recurring EBIT grew by 6.2% and 14% respectively on an organic basis. The group divested businesses in India, Brazil and Russia in 2022.

Cement sales were US$11.5bn (51% of group sales), down by 20% from US$14.4bn (57% of group sales). These sales rose by 12% on an organic basis. Throughout the period, ECOPlanet low-carbon cement accounted for 19% of the company’s cement sales. It also recycled 17% more construction and demolition waste year-on-year. Group CO2 emissions per net sales fell by 43% between 2020 and 2023.

Chair and chief executive officer Jan Jenisch said “I thank all members of the Holcim family for delivering profitable growth in the third quarter of 2023 despite challenging economic conditions, marked by softer demand in some markets and foreign exchange headwinds.” He added “The third quarter of 2023 results confirm Holcim’s strong earnings profile, with broad-based growth drivers delivering another increase in profitability. This performance gives us the confidence to upgrade our 2023 guidance to an industry-leading recurring EBIT margin of above 17% for the year.” The group also upgraded its outlook for full year organic sales growth to above 6% and for organic EBIT growth to above 10%.


Thailand: Siam Cement Group’s sales dropped by 12% year-on-year to US$3.47bn during the first nine months of 2023. The group’s net profit remained level year-on-year, at US$67.4m.


India: ACC recorded sales of US$1.16bn during the first half of its 2024 financial year that started in April 2023. This represents a year-on-year rise of 14% from US$1.02bn in the first half of the previous financial year. Cement sales grew by 15%, to US$1.08bn, 94% of total sales. The company’s raw materials costs rose by 16% to US$185m, while its power and fuel costs fell by 24% to US$241m, failing to offset a 5% rise in overall costs, to US$1.06bn. As such, ACC reported a profit after tax of US$102m, up by a factor of six from nine-month 2023 financial year levels.


US: Eagle Materials sold 4.14Mt of cement during the first half of its 2024 financial year, from 1 April 2023, a slight increase from the volume sold in the same period in its 2023 financial year. It reported sales revenue from its wholly owned cement business of US$614m, up by 15% year-on-year and corresponding to 50% of total group sales. Overall, group revenue rose by 4.9% to US$1.22bn.

President and chief executive officer Michael Haack said "Market conditions for our construction materials remained resilient during the quarter, even as the Federal Reserve continued to raise interest rates and tighten money supply to contain inflation. Several factors helped offset the higher rates and supported demand for cement, including limited housing supply, strong homebuyer demand, increasing infrastructure awards and significant investment in domestic manufacturing facilities. As demand remained strong and our operations remained nearly sold-out, we implemented a second round of cement price increases in early July across half our markets, and announced the next round of price increases for early January 2024.” Haack added “We expect that our portfolio of businesses will remain well-positioned for the second half of fiscal 2024."


Vietnam: Cement producers received 811,000t of boiler slag and fly ash from the Vinh Tan 1 coal-fired power plant in Binh Thuan during the first nine months of 2023. This corresponds to 74% of the volume of the by-products generated at the plant during the period. Việt Nam News has reported that the nearby Vinh Tan 4 coal-fired power plant also ‘almost entirely’ avoided waste in the same way. The Vinh Tan 1 coal-fired power plant ended the period with 4.3Mt of ash and slag in stockpiles, while the neighbouring Vinh Tan 2 Thermal Power Plant had 7Mt.

The provincial government of Binh Thuan Province has lobbied the Ministry of Construction to review and adjust current requirements around HDPE liner use, water quality testing and radiation safety in order to facilitate the use of boiler slag and fly ash in cement and other construction products.


Mexico: Cemex’s sales were US$13.2bn during the first nine months of 2023, up by 13% year-on-year from US$11.7bn in the first nine months of 2022. The group’s operating earnings before interest, taxation, depreciation and amortisation (EBITDA) were US$2.6bn, up by 27% from US$2.1bn. This came in spite of a 7% year-on-year decline in its cement volumes, to 39.1Mt from 41.8Mt. Volumes rose by 3% in Mexico, but fell by 13% in the US, 4% in South, Central America and the Caribbean and 10% in Europe, Middle East, Asia and Africa.

Cemex chief executive officer Fernando González said “2023 is proving to be an exceptional year for our company, and I am especially encouraged by our recovery of EBITDA margins to 2021 levels, a key strategic priority. The success of our pricing strategy, contribution of growth investments and our fast-growing Urbanisation Solutions business, as well as decelerating cost inflation, are contributing to profitability in a very meaningful way.” He continued “We are making significant progress on our decarbonization roadmap, reducing Scope 1 and Scope 2 carbon emissions by 12% and 11%, respectively, since 2020. Prior to the introduction of our Future in Action programme in 2020, a reduction of this magnitude would have taken almost 15 years.”


China: Xinjiang Tianshan Cement, a subsidiary of China National Building Material (CNBM), recorded sales of US$3.68bn during the third quarter of 2023. This corresponds to a 19% year-on-year rise compared to third-quarter 2022 levels. Reuters has reported that Xinjiang Tianshan Cement’s net loss was US$12.4m, while in the corresponding quarter of 2022 it recorded a profit of US$78.3m.


Peru: Cementos Pacasmayo’s sales fell by 9.1% year-on-year to US$371m during the first nine months of 2023. Its earnings before interest, taxation, depreciation and amortisation (EBITDA) fell less sharply, by 2.9% to US$93.6m. The producer stated that lower costs partially offset the drop in sales. Its net income was US$34.4m, down by 3.6%.


Spain: Switzerland-based Holcim has concluded a deal to acquire Élite Cementos from Grupo Simetría and other shareholders. Élite Cementos operates a grinding plant at the Port of Castellón in Castellón de la Plana, Valencia. Holcim said that its acquisition of the business will unite the latter’s local brand recognition with its own experience and vision of sustainable growth.

The group said “With this agreement, Holcim expands its geographical presence, responding to the increasingly demanding and specialised needs of the sector. The Élite Cementos team joins the Holcim family to continue together an era of growth and transformation of the construction sector.”


US: Solidia Technologies has appointed climate consultancy 3Degrees to manage the measurement, verification and sale of carbon credits for CO2 emissions reductions generated using Solidia Technologies products. Users of the products can deploy the credits against their Scope 3 emissions from cement and concrete, as well as to compensate for other greenhouse gas emissions.

Solidia Technologies chief executive officer Russell Hill said "By partnering with 3Degrees to issue carbon credits, Solidia is providing a mechanism for the marketplace to invest in technologies that will accelerate and enable global carbon emissions reduction.”