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Concrete

Fly ash: The New Cement

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If the merits of fly ash are so well established and if it is available at about one fifth the cost of cement, then why are we consuming only about 38 per cent of the fly ash available in the country? ICR interacts with leaders in construction world to understand the benefits and finer points of using fly ash.

As much as 60 per cent of power in India is generated by burning coal. And looking at the vast reserves of coal available, it will continue to be the primary source of power in the country.

But coal-fired power stations make more than just power. In a way they are also making cement called "Fly Ash." You could also call a power station, a cement factory, having steam as its by-product. Unfortunately, rather than being seen as a resource, fly ash has been considered as industrial waste. Till about a decade ago it was being disposed of in ash ponds. The cement consumer industry still sees fly ash as a pollutant, which it is using for blending in cement/concrete and contributing to the betterment of environment while improving the strength of the construction material.

Fly ash is neither free nor is it cheap. At least not the good quality fly ash. Good quality fly ash is produced by passing the fly ash generated at the power stations through electrostatic precipitators. Here fly ash is screened and classified. Only 15-20 per cent of the fly ash screened is retained back and is considered as a superior quality material. The process, and the low yield of high quality fly ash, adds to cost.

Merits of fly ash are well known in the industry and it is being used as a partial cement replacement (on average 30 per cent) in structural concrete. Thus, today fly ash has become the fourth ingredient in concrete, next to cement, aggregate and water. Despite this realisation though, fly ash is still under utilised in the construction sector. One of the prime reasons is the lack of properly detailed standards pertaining to use of fly ash. Though there are various Indian Standards published by the Bureau of Indian Standards (BIS) that specify the use of fly ash as part replacement of cement in concrete, in actual practice the guidelines are still in nascent stage. During mid seventies and early eighties, the quality of fly ash was not that good due to high content of unburnt carbon and negligible awareness. The eighties ushered in the era of super thermal power stations. Equipped with high-efficiency boilers and coal mills, the quality of fly ash produced in these power stations was good. These improvements, however, were not communicated adequately. The doubts regarding using fly ash in cement probably have lingered too long, and even today it is not odd to find engineers hesitant to use fly ash in their mix. Besides, fly ash being a high volume low value product, transportation adds severe restrictions to its reach and use. It is not economically viable to use fly ash beyond a radius of 100 km from the point of production.

Considering the tremendous growth required in the power sector for the development of Indian economy, it is expected that ash generation will reach 225 million tonnes by 2017. The quality of fly ash produced in India is superior due to low sulphur and unburnt carbon content. Growth in infrastructure will create huge cement demand. And if encouraged properly, fly ash can provide for at least 30 per cent of this demand. Using fly ash is economical too. Shailesh Puranik, Managing Director, Puranik Builders, puts it in numbers stating that, "Fly ash reduces 20 per cent of cement cost in a project. Today fly ash costs about Rs 50 to Rs 60 per bag, while cement on an average is sold at Rs 250-300 per bag. Fly ash reduces the construction cost by about Rs 10-15 per sq.ft. On top of that projects based on fly ash utilisation receive green credits that could be traded." That leaves us with no reason not to use fly ash when available.

Today utilisation of fly ash is limited mainly due to lack of required information to actual users like State/Central Governments, construction departments, builders, developers, etc. There is a need to communicate these benefits to todays nation builders. In a series of interviews that follow, we look at the benefits of using fly ash and the parameters to examine while picking up the right product.

Benefits of using fly ash

  • Reduced permeability of the structure to water and aggressive chemicals
  • Reduction in the amount of water needed for mixing
  • Consumes fly ash, which is other wise dumped in fly ash ponds leading to pollution
  • Serves as a substitute to cement which is about five times costlier than fly ash.

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.

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