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AAC production in cement plant

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Cement companies can manufacture AAC blocks and can compete with stand alone AAC units in the country.
The raw materials required for AAC production are readily available in any cement manufacturing plant. The process does not require installation of a steam boiler or a power plant and can utilise the waste-heat from the clinker cooler exhaust gases for steam curing of aerated concrete. The method also earns carbon credits not only for the green product being made, but also for waste-heat utilisation. Although, there are more than 35 standalone AAC manufacturing units in India, very limited attempts have been made to manufacture AAC by the cement plants. One reason behind this is the lack of awareness about the new technologies that were developed recently in this field. DS Venkatesh elaborates on the technology offered by Cemeng for AAC production in a cement plant.

What is AAC
AAC is lightweight autoclaved aerated concrete, which is completely cured, inert and stable form of calcium silicate hydrate. It is a structural material, approximately one quarter in weight of the conventional concrete. It is composed of minute cells/air pockets, which give the material its lightweight and high thermal insulation characteristics. It is available as blocks and as pre-cast reinforced units for building floors, roofs, walls and lintels.

Raw material
Raw materials for AAC vary with the manufacturer and the location. The kinds of materials that could be used are detailed in the ASTM C1386 specifications. They include some, or all, of the following: fine silica sand; Class F fly ash; hydraulic cements; calcined lime; gypsum; expansive agents such as finely ground aluminium powder or paste; and water.

AAC is produced by mixing quartz sand and/or pulverised fly ash (PFA), lime, cement, gypsum/anhydrite, water and aluminium and is hardened by steam-curing in autoclaves. The silica is obtained from silica sand, fly ash (PFA), crushed silica rock and/or stone. It is possible to obtain silica as a by-product coming from other processes such as foundry sand or burgee from glass grinding; although, it can be used only if the levels of alkali or other impurities are not too high. The calcium is obtained from quick lime, hydrated lime and cement. Gypsum acts as a catalyst and enhances the properties of AAC. Careful regulation of the amount of aluminium powder gives accurate control over the density of the final product.

Cement with the least per cent of clinker would be the cheapest and suitable, e.g., Portland limestone cement. If milling of siliceous material is required, Cemeng suggests grinding of a composite mix of siliceous materials together with cement clinker, lime and gypsum/anhydrous. The ground material can be stored in a single bin. It also eliminates the need for multiple handling of individual constituents and weigh batchers. Cemeng employs a PSRG mill function in open circuit to produce the desired fineness of the composite mix.

Process flow
Cemeng has simplified the process flow to minimise the number of equipment and material handling requirements in mini AAC plants. The process gets rid of ?wet cutting? the green cake as it is possible only if the plant is involved in exclusive production of smaller blocks. Other AAC products with or without reinforcement certainly require ?dry milling? of cured cakes for profiling. Cemeng moulds for AAC are wheel-mounted units with a base plate and sliding sidewalls. There is no need for rotation or dismantling and re-assembling of side plates. Loaded moulds are transferred directly into the autoclaves for steam curing. Cemeng autoclaves generate the required steam in the autoclave itself. Separate boiler is not required. For mini AAC plants, Cemeng suggests after-cutting/milling of cured blocks for economic benefits.

The important unit operations involved in AAC production are gravimetric proportioning and mixing of constituents with water to form the slurry. This is followed with secondary mixing with expansive agents, pouring the slurry into casting moulds and then allowing sufficient time for initial hydration. Once the material is hydrated it gains enough strength to support its own weight and can undergo de-moulding/cutting. The cakes are then transferred into autoclave for high pressure steam curing. Once cooled, the autoclaved blocks are ready for after-cutting/milling as per the required profile. The AAC cost depends mainly on the cost of mineral binders and the expansive agents used. The cost of silica can vary from location to location.

Cement plant and Cemeng mini AAC production line
Cemeng mini AAC production line can be installed in an existing cement plant. Cement plants are already processing and handling both siliceous and mineral binder constituents, except for lime and sand. Also, ground raw meal, preheater ESP dust, pre-calcined meal from bottom most stage of preheater can partially or wholly replace lime. Sand may be replaced by ground slag and cinder. Clinker dust from cooler ESP and gypsum can replace cement. Besides, clinker cooler exhaust air may be effectively utilised for production of steam required for autoclaving, thus eliminating the need for a separate boiler set up.

AAC production capacity, on a thumb rule basis, can be considered as twenty cubic meter per day for every 100 tpd production capacity of the clinkerisation unit. This is based on steam production using gases only from the from clinker cooler exhaust.

Manufacturing process
To make AAC, sand is ground to the required fineness in a ball mill and is stored along with other raw materials. The raw materials are then batched by weight and are delivered to the mixer. Measured amounts of water and expansive agent is added to the mixer to prepare a cementitious slurry.

Preparation of slurry
Slurry preparation is a batch process. When AAC is being made from dry constituents, Cemeng employs separate weighbin augur dosers for each constituent the Cemeng weighbin augur doser, which uses a combination of weight and volumetric filling. A vertical auger looks like a corkscrew. The auger rotates in the hopper filled with lose powder. As it turns, it drives the powder through the bottom of the hopper into a narrow tube, where the powder is drawn down by a turning screw. The auger runs through the narrow tube, creating a tight fit. As the screw turns, it pulls the prescribed amount of powder down the tube. The agitator keeps the feed flowing to the centre of the auger. You can control the amount of powder delivered by setting the number of revolution made by the auger.

The augur screw discharges into a tubular disc conveyor for conveying and transferring directly into the AAC mixer. Subsequently, aluminium paste is added, secondary mixing is carried out and the final slurry is discharged into the AAC moulds.

Casting in moulds
Steel moulds are prepared to receive fresh AAC. If reinforced AAC panels are to be produced, steel reinforcing cages are secured within the moulds. After mixing, the slurry is poured into the moulds. The expansive agent creates small, finely dispersed voids in the fresh mixture, which increases the volume by about 50 per cent within three hours. The moulding of AAC in the mould box, holding for initial strength and de-moulding prior to autoclaving is an important step in reducing the material handling. Conventionally, the base of the moulds-box and three sides are welded together with only one side plate of mountable type. This calls for mould rotation to load the green mould on to the mountable side plate.

Cemeng moulds for AAC are trolley-mounted units with a base plate and sliding sidewalls. During casting, the sidewalls are slided inwards to form a box holding the slurry. The sidewalls keep space all around the green cake for the passage of steam. No rotation or dismantling of the side plates and reassembling are required. After curing in autoclaves, the cake is picked up by a grab and is transferred to the trolley.

Cemeng also offers ?FlexiMold? wherein rectangular shaped pre-stitched permeable cloth bags with open top are held at the base of the trolley. The flexibag is filled half with slurry and the top half is left empty to allow for expansion. As the green cake attains strength, it attains the shape of the flexibag. The telescopic brackets are then lowered. The bracket is held in its lowest position when the trolley is moved into the autoclave. The green cake along with FlexiMold is left undisturbed. After curing, the trolley is moved out and the cured cake in the moulding bag is lifted and transferred to storage. FlexiMold serves as a protective cover for cured block and it is also disposable. The size of the green cake can be set as required and several green cakes can be mounted on a single trolley.

Autoclaving
Autoclaving is steam curing at high temperature and pressure. It is required to achieve the desired structural properties and dimensional stability. The chemical reactions that produce the final calcium silicate hydrate structure happen in the autoclave. The process takes about eight to 12 hours under pressure of about 174 psi (12 bar) and a temperature of about 360?F (180?C), depending on the grade of material produced. Preferably, two autoclaves are used with the casting and precuring section in between. The mixing station is located near the discharge end of the autoclave. The thermic fluid reservoir is located at the feed end of the autoclave. This permits the precuring shed to store the cast moulds for the required duration. The waste heat from grate cooler exhaust is utilised for the heating the thermic fluid in a simple heat exchanger. It is estimated that at least 350-400 kg/hr of steam could be generated per 100 tpd production capacity of clinkerisation unit. To initiate the curing cycle, the thermic fluid, heated to 205?C, is passed through the coils in the reservoir at the bottom of each autoclave to generate steam. The hot steam pressure rises up to 1.75Mpa.

After-cutting/milling of cured AAC Blocks
Steam cured AAC blocks can be transported directly to the marketing yards. After-cutting can be carried out by the stockists or at the construction site itself. Existing granite/stone cutting and polishing units at different cities in the marketing zone can be used to saw the AAC blocks to the required size/dimensions. It is always possible to saw cut the large size AAC blocks to the required size at the construction site. Any broken pieces could be used as lightweight filler, thus nothing is wasted.

Conclusion
Every cement plant has to take green initiatives to safeguard sustainability. Using waste-heat for steam generation is highly cost effective and adds to the profits of AAC production. Besides, the plant will also be a captive consumer of cement. Every cement plant can produce AAC at considerably lower cost and can compete with standalone AAC units. AAC products can save time, labour, cement and sand during construction.

References
Eco-Care Building products: www.primeaac.com
Raw material formulae: Dearye Brick machine
Silica, calcium joined in premium products, by Sandy Herod Pit and Quarry Dec 1987 Pg.72 – 74
Brick manufacture in a Cement Plant by DS Venkatesh, Cemtec Engineering, Secunderabad. Indian Cement Review May 1989, Pages ICR-19 to ICR-25 Green Concrete by Yuvraj Patil, Flycrete. Indian Cement Review, May 2014 ?Let us employ PSRG Milling Technology? by DS Venkatesh, Indian Cement Industry Desk Book, March 2014. www.victoryenergy.com

DS Venkatesh,
Freelance Industrial Consultant
Email: dsvenkatesh40@gmail.com
Former CEO and Director of Cemtec Engineering at Secunderabad, DS Venkatesh is currently working as a freelance industrial consultant. He started as a Design Engineer at ACC and later had a long stint at Holtec-India holding several responsible positions. He has been one of the lead consultants to many rotary based mini cement plants and expansions.

DS Venkatesh has provided technical know-how, design and manufacturing drawings for cement production machinery to many Indian machinery manufacturers. Re-engineering and retrofitting of plant/machinery for enhanced productivity is his forte. His work has helped in enhancement of PSRG milling technology applied in media grinding.

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Economy & Market

The Road Ahead Begins Here

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The future of India’s roads took centrestage at RAHSTA Expo 2026, where policymakers, contractors and industry leaders came together under one roof. The event blended thought leadership, technology showcase and industry recognition into a single powerful platform.

India’s roads and highways community gathered in full strength at the Jio World Convention Centre, Mumbai, for the 16th edition of the RAHSTA Expo (Roads and Highways Sustainable Technologies & Advancement). Over two action-packed days, the event brought together policymakers, contractors, consultants, developers, equipment manufacturers, material suppliers, technology providers and investors to deliberate on the future of India’s ,infrastructure while showcasing the latest innovations driving the sector.

The event culminated in the prestigious RAHSTA Awards, where Shri. Ajay Tamta, Union Minister of State for Road Transport & Highways, felicitated organisations and professionals for their outstanding contributions to road construction, engineering, safety, sustainability and technology. With leading contractors, senior government officials, industry veterans and technology providers under one roof, the event reaffirmed RAHSTA’s position as one of India’s most influential platforms for the roads, highways, bridges and tunnels ecosystem.

Organised by FIRST Construction Council in association with ASAPP Info Global Group, RAHSTA has steadily evolved beyond an exhibition into a platform where policy, technology, engineering and business converge to address the opportunities and challenges shaping India’s next generation of transport infrastructure.

Beyond expansion, towards value

The conference opened with a thought-provoking address by Pratap Padode, Founder and Editor-in-Chief, Construction World, who observed that India’s highways sector has reached an important inflection point. Introducing this year’s theme – ‘From Expansion to Value: The Next Phase of India’s Highways’ – he noted that while the country has successfully expanded its road network over the past two decades, the industry’s priorities are now shifting towards building infrastructure that delivers greater lifecycle value, durability, safety and operational efficiency. With funding pressures, asset monetisation and evolving project models changing the sector’s dynamics, he said the focus must now move beyond kilometres constructed to the quality and long-term performance of every asset.

Dr Brijesh Dixit, Managing Director, Maharashtra State Infrastructure Development Corporation (MSIDC), reminded delegates that successful infrastructure delivery is ultimately a collective effort. Emphasising on collaboration between government, industry and engineering professionals, he remarked, “There is no loser in a winning team, and there is no winner in a losing team,” urging stakeholders to work together to deliver projects with quality, financial sustainability and technological excellence.

Delivering the keynote address, Bidur Kant Jha, Director, New Technologies for Highway Development, Ministry of Road Transport & Highways (MoRTH), outlined the Government’s long-term vision for India’s highway network. Highlighting the country’s 6.26 million km roads network, he spoke about the growing adoption of digital planning tools such as BIM and GIS, bridge health monitoring systems and Integrated Smart Transport Corridors under the Vision 2047 roadmap. He emphasised that while India remains open to global innovations, every new technology must be adapted to Indian conditions before large-scale deployment.

Addressing the gathering during the awards ceremony, Tamta underlined the increasing role of specialised equipment and modern construction technologies in executing complex infrastructure projects across diverse terrains. Referring to challenging tunnel projects in Uttarakhand, he noted how advanced machinery has transformed execution capabilities, while also acknowledging the rapid evolution of Indian contractors into globally competitive infrastructure companies. Recognising excellence through industry awards, he said, motivates organisations to continually raise performance standards and embrace innovation.

Meanwhile, Dr Sanjay Mukherjee, IAS, Metropolitan Commissioner, MMRDA, highlighted that infrastructure development must increasingly focus on integrated urban mobility. Reflecting on Mumbai’s engineering journey – from its historic underground utility network to the Coastal Road and other transformative projects – he underlined that future infrastructure planning must seamlessly integrate roads, metro systems and public transport to create efficient, multimodal cities.

Uttar Pradesh takes centrestage

One of the highlights of the second day was Uttar Pradesh’s comprehensive presentation on its infrastructure-led industrial transformation.

Srihari Pratap Shahi, IAS, Additional CEO, Uttar Pradesh Expressways Industrial Development Authority (UPEIDA), demonstrated how the state’s expanding expressway network is evolving into a catalyst for industrial development through integrated manufacturing and logistics clusters. Expressways, he noted, are no longer merely transport corridors but engines of economic competitiveness.

Building on this narrative, Deeksha Jain, IAS, Additional Chief Executive Officer, Uttar Pradesh State Industrial Development Authority (UPSIDA), showcased the state’s rapidly expanding industrial ecosystem supported by extensive expressway connectivity, dedicated freight corridors, airports, industrial townships and investor-friendly policies. She highlighted Uttar Pradesh’s strong manufacturing growth, expanding industrial land bank, plug-and-play infrastructure and increasing use of digital governance to facilitate investments.

Further underlining the significance of the platform, Deepak Kumar, IAS, Infrastructure & Industrial Development Commissioner, Government of Uttar Pradesh, remarked, “RAHSTA provides an excellent platform for states to showcase our infrastructure progress and investment ecosystem. Uttar Pradesh has transformed significantly over the past decade, backed by more than 34 investor-friendly industrial policies, and platforms like RAHSTA help communicate these developments to industry stakeholders from across the country.”

Ideas that shaped the industry conversation

The two-day conference featured seven panel discussions, each examining a critical dimension of India’s evolving roads and highways sector.

The opening discussion on ‘Financing Roads & Highways in a Capital-Constrained Era’ brought together experts from Cube Highways, NIIF, SBI Capital Markets, Centrum Capital and Bandhan Infra Fund, who examined how the financing landscape is changing. Discussions revolved around asset monetisation, InvITs, institutional investments and new funding structures, with panellists agreeing that better project preparation, transparent governance and predictable returns will be crucial for attracting long-term capital into infrastructure.

Attention then shifted to execution realities during the panel on ‘Contractors’ Perspective: Execution Realities, Risks & the Quality Imperative.’ Representatives from GHV Infra Projects, PNC Infratech, NCC and Maccaferri candidly discussed the challenges of delivering projects amid contractual complexities, land acquisition delays, rising costs and tight timelines. While execution pressures remain significant, the discussion reinforced that better collaboration across the project value chain is essential for achieving both speed and quality.

Day 2 opened with a technically rich discussion on ‘Designing Roads for Sustainability, Durability & Climate Resilience’. Experts from CSIR-CRRI, IIT Bombay, IIT Madras, Zydex Group and SRMB Steel explored advanced pavement technologies, recycled materials, climate-resilient designs and scientific construction practices that can significantly improve durability while lowering lifecycle costs. Sustainability, they agreed, must become an integral part of road design rather than an afterthought.

The subsequent session on ‘Bridges & Tunnels: Complex Engineering, Safety & Future Readiness’ highlighted the growing complexity of India’s infrastructure projects. Panellists discussed advances in structural engineering, digital monitoring, risk management and safety practices that are enabling the successful delivery of increasingly ambitious bridge and tunnel projects across the country.

Technology remained a recurring theme during the discussion on ‘Technology as a Risk-Mitigation Tool for Developers & Investors’. Experts explained how AI, BIM, drones, predictive analytics, digital twins and intelligent monitoring systems are helping improve project planning, minimise execution risks, strengthen quality assurance and enhance asset management throughout the infrastructure lifecycle.

The construction equipment panel brought together leading industry experts to examine how technology, sustainability and digitalisation are redefining construction equipment in an era of rising cost pressures. Discussions centred on enhancing productivity, reducing lifecycle costs and preparing the industry for India’s infrastructure ambitions leading up to 2047.

The conference concluded with an engaging CXO Forum on ‘Rebuilding Confidence in India’s Roads & Highways Sector’, where senior industry leaders emphasised that stronger governance, better project preparation, digitalisation, transparent contracting and closer public-private collaboration will be essential to sustain India’s infrastructure growth over the coming decades.

Technology and recognition under one roof

Beyond the conference halls, RAHSTA Expo reflected the technological transformation underway across India’s road infrastructure ecosystem. Leading equipment manufacturers, technology companies and material suppliers showcased advanced construction equipment, intelligent digital platforms, pavement technologies, structural materials and productivity-enhancing solutions designed to improve project efficiency and asset performance. The exhibition created valuable opportunities for contractors, consultants, government agencies and project developers to evaluate new technologies while interacting directly with solution providers.

The event also served as a celebration of excellence through the RAHSTA Awards 2026, which recognised outstanding achievements across road construction, contracting, materials, equipment, technology, safety, sustainability and infrastructure development. Presented by Minister Tamta, the awards honoured organisations that are setting new benchmarks for quality, innovation and execution across India’s roads sector.

RAHSTA Expo 2026 also received extensive support from across the infrastructure ecosystem. Alongside leading corporate sponsors, the event was backed by industry bodies including the Builders Association of India (BAI), Construction Equipment Rental Association (CERA), Consulting Engineers Association of India (CEAI), International Road Federation (IRF), CSIR-CRRI, CILT India, All India Transporters Welfare Association, Hydraulic Trailer Owners Association (HTOA), Gujarat Contractors Association, Bitumen Forum, Fluid Power Society of India, Indian Institute of Material Management, Ministry of Ports, Shipping and Waterways, Gati Shakti Vishwavidyalaya and Mumbai First, reflecting the industry’s collective commitment to advancing India’s road infrastructure.

As the curtains came down on the two-day event, one message resonated throughout the conference: India’s highways story is entering a new chapter. While expansion will continue, the future will increasingly be defined by smarter planning, stronger partnerships, digital transformation, sustainable engineering and long-term value creation. By bringing together the entire infrastructure value chain on a single platform, RAHSTA Expo 2026 once again demonstrated why it has become one of the country’s most influential forums for shaping the future of roads, highways, bridges and tunnels.

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Economy & Market

Fornnax Names Lukas Baur as Authorised Service Partner to Bolster EU Operations

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Strapline: Fornnax Technology has appointed NOBA Maschinenservice’s Lukas Baur as its authorised service partner for the European Union, strengthening its commitment to delivering fast, reliable, and localised after-sales support across the region.

Fornnax Technology, a leading manufacturer of industrial shredding solutions, has announced the appointment of Mr. Lukas Baur of NOBA Maschinenservice as its authorised service partner for the European Union. The partnership, formalised under the authorisation of Fornnax CEO Mr. Jignesh Kundaria, reinforces the company’s commitment to providing dependable, localised service support to its expanding customer base across Europe.

Strengthening Service Through Proven Expertise

With over two decades of experience in servicing, maintaining, and overhauling industrial shredders, Mr. Baur brings extensive technical expertise to the partnership. His capabilities span welding, hardfacing, shaft and knife rebuilding, complex assembly, hydraulics, and complete electrical engineering services, delivered in collaboration with a trusted partner company based in Halle/Saale.

Operating from Worbis, Germany, Mr. Baur is strategically positioned to provide emergency support across the European Union within 24 hours, covering an operational radius of approximately 1,000 kilometres.

Supporting this capability is a well-equipped service infrastructure comprising 12 Mercedes Sprinter service vans, a team of 24 skilled technicians, specialised bearing-change tools, a fully equipped hydraulic workshop, and a 1,000-square-metre facility with a five-ton crane track. Together, these resources position his team to manage the complete spectrum of Fornnax’s European service requirements efficiently and reliably.

Partnership Driven by Industry Insight

Having spent years servicing Eldan, Lindner, and Vecoplan shredders across the European recycling industry, Mr. Baur’s decision to collaborate with Fornnax is rooted in his understanding of market needs and customer expectations. His experience has provided valuable insight into what recycling plant operators require—not only from their machinery but also from the service teams supporting them.

According to Mr. Baur, Fornnax’s reputation for robust machine construction, superior wear protection, and maintenance-friendly design made the partnership a natural fit.

The collaboration comes at a time when Europe’s tyre recycling industry is facing mounting challenges, including rising cost pressures, shrinking margins, delayed investments, and a shortage of skilled labour. Mr. Baur believes these conditions reinforce the need for technically strong service partners capable of delivering rapid, dependable support.

Commenting on the partnership, he said, “Fornnax, with its exceptional price-performance ratio and superior quality, has the potential to become a market leader in Europe. We would like to be their service partner in this journey.”

Comprehensive Support Across the Equipment Lifecycle

As Fornnax’s authorised service partner, Mr. Baur will oversee the complete lifecycle support of the company’s equipment throughout the European Union. His responsibilities will include installation, commissioning, preventive maintenance, emergency repairs, and spare parts support across mechanical, hydraulic, and electrical systems.

Looking ahead, he also plans to develop a centralised spare parts distribution hub for European customers, particularly if Fornnax establishes a warehouse facility in Worbis to facilitate faster deliveries. To further strengthen service coverage, Mr. Baur intends to expand operations by adding two to three additional service teams and vehicles each year, progressively increasing capacity across the continent.

A Shared Commitment to Customer Excellence

Highlighting the strategic importance of the partnership, Mr. Jignesh Kundaria, Director and CEO of Fornnax, said:

“We strongly believe that by continuously improving our service quality and customer satisfaction index, we can build long-term relationships with our customers. Higher customer satisfaction leads to greater trust, which significantly increases repeat orders and ultimately drives sustained growth in our sales revenue.”

This customer-first philosophy underpins Fornnax’s strategy of building a dedicated European service partner network instead of relying solely on remote support. With Mr. Baur joining this network, customers across the European Union will benefit from faster response times, expert technical assistance, and dedicated on-ground support from a partner with extensive experience in high-throughput shredding operations.

Mr. Baur’s appointment also reflects Fornnax’s broader ambition to establish itself as the preferred shredding solutions provider for the European recycling industry, marking another important milestone in the company’s international growth strategy.

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Concrete

Nuvoco Vistas launches Limla cement plant, expands Gujarat footprint

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Nuvoco Vistas opens a 2 MMTPA grinding unit at Limla, entering Gujarat and advancing its target of 35 MMTPA capacity by FY 2028.

Surat (Gujarat)

Nuvoco Vistas Corporation Ltd, a part of Nirma Group and one of India’s leading building materials company, has inaugurated the Limla Cement Plant in Surat (Gujarat), one of Vadraj Cement Limited’s (VCL) principal manufacturing facilities. The commissioning represents a key milestone in Nuvoco’s acquisition and restoration of VCL, while supporting the company’s expansion across the Western Indian cement market.

Vadraj Cement Limited is a subsidiary of Nuvoco Vistas Corporation Limited and has installed cement capacity of 6 MMTPA across its assets. The Limla inauguration therefore represents the first operational step in the acquired platform’s wider revival, while the Kutch facilities provide clinker supply, mineral security and coastal logistics support for the western business.

Nuvoco completed its acquisition of Vadraj Cement Limited, then under the Corporate Insolvency Resolution Process, after paying a consideration of Rs 1,800 crore in June 2025. VCL’s asset portfolio comprises a clinker unit at Kutch and a grinding unit at Limla in Surat. It also includes high-quality captive limestone reserves and a captive jetty at Kutch, supporting more efficient logistics. Following the takeover, Nuvoco began an extensive programme of restoration, refurbishment and expansion at both locations, leading to the commissioning of the Limla plant.

The Limla Cement Plant is expected to support a phased increase in sales volumes across Gujarat. It will also help Nuvoco supply neighbouring markets in Western Maharashtra and release cement capacity from its northern plants, which can consequently be redirected towards markets in North India. The plant will manufacture a full portfolio comprising Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. It will additionally produce the complete Nuvoco Duraguard range, including the premium Nuvoco Duraguard Microfibre product. The acquisition is also expected to generate operational synergies with Nuvoco’s existing plants at Nimbol and Chittorgarh in Rajasthan, improving logistics optimisation and market reach across important regional markets.

The grinding unit at the Limla Cement Plant was completed ahead of schedule, with 2 MMTPA of capacity now inaugurated to expand Nuvoco’s operating scale and customer reach. After Vadraj Cement’s assets become fully operational, plants in North and West India are expected to account for nearly 40 per cent of Nuvoco’s total cement capacity. This will broaden the company’s manufacturing network, strengthen access to high-growth markets and support its plan to increase consolidated cement capacity to 35 MMTPA by FY 2028, reinforcing its longer-term growth strategy.

Commenting on the development, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said: “The inauguration of the Limla Grinding Unit in Surat is an important milestone in Nuvoco’s growth journey and demonstrates our commitment to disciplined, value-accretive expansion. Gujarat is strategically significant for Nuvoco, with substantial opportunities arising from infrastructure investment, industrial growth, rapid urbanisation and continuing demand from the housing and construction sectors. The facility strengthens our regional footprint, improves operational flexibility and increases our ability to serve customers across northern and western markets with greater reliability and efficiency.”

He added: “Through the Vadraj acquisition, we have refurbished and restarted a strategically important asset, returning it to operations in record time through strong execution and collaboration between teams. The achievement demonstrates our ability to create value from acquired assets, fulfil our commitments and retain the confidence of stakeholders. It also highlights the strength of our project delivery capabilities and our continued focus on building sustainable, profitable growth over the long term.”

Nuvoco Vistas Corporation Limited is a building materials company whose vision is to build a safer, smarter and more sustainable world. It is among the leading players in East India and has a significant presence across North and West India. Nuvoco began operations in 2014 with a greenfield cement plant at Nimbol, Rajasthan. It later acquired Lafarge India Limited, which had entered India in 1999, followed by Emami Cement Limited in 2020 and Vadraj Cement Limited in April 2025. The company has also announced an expansion in eastern India through a new grinding mill at the Arasmeta Cement Plant, supported by several debottlenecking programmes involving equipment upgrades, process improvements and internal capacity initiatives. These developments place Nuvoco on track to achieve total cement capacity of approximately 35 MMTPA. The company reported total income of Rs 11,362 crore in FY 2025-26, reflecting its continuing growth trajectory.

Nuvoco operates a diversified portfolio across three segments: Cement, Ready-Mix Concrete and Modern Building Materials. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem, covering Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. Its pan-India RMX business provides value-added products under Concreto for performance concrete, Artiste for decorative concrete, InstaMix for ready-to-use bagged concrete, X-Con covering M20 to M60 grades, and Ecodure for specialised green concrete. Nuvoco has supplied materials to projects including the Mumbai-Ahmedabad Bullet Train, Birsa Munda Hockey Stadium in Rourkela, Aquatic Gallery at Science City in Ahmedabad, and metro railway projects in Delhi, Jaipur, Noida and Mumbai.

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