Concrete

Fly ash: The New Cement

Published

12 years ago

July 31, 2014

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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

JK Lakshmi Cement Begins Rs 110 Billion Assam Plant Project

The 2.5 MTPA integrated cement plant is expected to be completed by FY2029.

Published

16 hours ago

October 31, 2026

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JK Lakshmi Cement has recently laid the foundation stone for Project Kamakshi, its first integrated cement manufacturing facility in Assam, marking its entry into Northeast India. The groundbreaking ceremony was held at Umrangso village in Dima Hasao district in the presence of Assam Chief Minister Himanta Biswa Sarma.

The project involves an investment of Rs 110 billion, including the mining lease, and will have an annual cement production capacity of 2.5 million tonnes, supported by a 1 million tonne clinkerisation unit. Scheduled for completion by FY2029, the facility is expected to generate employment for over 2,000 people while catering primarily to the growing Northeast market.

The integrated plant will feature dedicated railway sidings to facilitate efficient transportation of raw materials and finished cement, strengthening supply chain reliability and regional distribution.

Vinita Singhania, Chairperson and Managing Director, JK Lakshmi Cement, said, “”Project Kamakshi is the start of a long-term relationship with Assam and the wider North East. This is a region that is building fast, and it deserves quality cement made close to home. With this plant, we want to bring scale, jobs, and dependable supply to the region. At JK Lakshmi Cement, we believe that building a stronger India goes beyond infrastructure. It is also about growing together with the communities we serve.””

The investment aligns with the company’s strategy to expand into high-growth markets beyond its established presence in Northern, Western and Eastern India. The project is also expected to support regional economic development and infrastructure growth.

JK Lakshmi Cement aims to pursue its expansion plans while working towards its long-term target of achieving net-zero emissions by 2047.

Concrete

JK Lakshmi Cement to Expand EV Fleet to 120 Vehicles by March 2027

JK Lakshmi Cement has deployed more than 70 EVs across its logistics network.

Published

2 days ago

October 30, 2026

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JK Lakshmi Cement has deployed more than 70 electric vehicles (EVs) across its logistics network and plans to increase the fleet to 120 vehicles by March 2027. The expansion is part of its decarbonisation strategy, which aims to reduce transport-related emissions and improve operational efficiency.

The company has achieved nearly 100 per cent EV-based clinker dispatches from its Sirohi plant in Rajasthan to the Kalol Grinding Unit in Gujarat. The transition marks an increased use of electric mobility for long-haul cement transportation and is intended to lower the environmental impact of logistics operations.

The existing fleet operates on routes connecting the Sirohi plant with the Kalol Grinding Unit, Palanpur Unit and Surat Grinding Unit. JK Lakshmi Cement is working with electric vehicle logistics providers SwitchLabs and Billion E to support fleet deployment and manage transportation requirements across these routes.

The company expects the planned expansion to increase the use of electric mobility throughout its logistics network for moving cement and clinker. Chairperson and Managing Director Vinita Singhania said the programme reflected the integration of sustainable practices with the company’s focus on long-term business efficiency, while describing the Sirohi–Kalol transition as an important step in its wider decarbonisation strategy.

The EV programme forms part of JK Lakshmi Cement’s green logistics and sustainability roadmap, alongside initiatives to improve efficiency and reduce emissions across its value chain. The company has set a long-term target of achieving net-zero emissions by 2047. It is part of the JK Organisation and operates integrated cement plants in Rajasthan and Chhattisgarh, along with grinding units in Gujarat, Haryana and Odisha. The company has an annual turnover of more than Rs. 60 bn, combined cement capacity of approximately 18 mn t per annum and a target to raise capacity to 30 mn t by 2030. Its portfolio includes ready-mix concrete, gypsum plaster, wall putty, primer, adhesives and fly ash blocks.

Concrete

Martin Engineering Appoints Ashwini Khunte as India General Manager

Published

2 days ago

October 30, 2026

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Martin Engineering names Ashwini Khunte India General Manager to strengthen operations and drive growth across key bulk material handling sectors.

Pune

Martin Engineering, a global provider of bulk material handling solutions, has appointed Ashwini Khunte as General Manager of its India business, strengthening its leadership as the company expands its presence across the country’s cement, mining, steel, power and infrastructure sectors.

Khunte brings more than a decade of experience with Martin Engineering, having joined its Indian operations in 2013 as a Design Engineer, shortly after the company established its presence in the country in 2012.

A mechanical engineer by qualification, she spent her initial five years developing bulk material handling solutions in collaboration with the company’s operations team. During this period, she gained extensive experience addressing operational challenges in the steel, cement and coal industries. She subsequently moved into project engineering, managing major engineering, procurement and construction (EPC) and original equipment manufacturer (OEM) projects from initial enquiry to commissioning. Her responsibilities later expanded to overseeing Martin Engineering’s conveyor product portfolio in India, involving customer engagement, technical presentations and site visits across heavy industries.

In 2024, Khunte was promoted to Head of Sales & Marketing for the company’s Europe, Middle East, Africa and India (EMEAI) region. The position broadened her international market exposure and strengthened her strategic and commercial leadership capabilities.

Commenting on her appointment, Ashwini Khunte, General Manager, Martin Engineering India, said: “India represents a tremendous opportunity for Martin Engineering. The country’s continued investment in cement, mining, steel, power and infrastructure is creating increasing demand for safer, cleaner and more productive bulk material handling, and that’s exactly what we do. My priority will be to build on the strong foundations already established in India, while continuing to develop our people, strengthen customer relationships and bring practical solutions to the challenges faced by our industry.”

Robert Whetstone, Area Vice President – EMEAI, Martin Engineering, highlighted Khunte’s technical expertise, market understanding and leadership experience.

“Ashwini brings an exceptional combination of technical understanding, customer knowledge and commercial leadership. She has grown as Martin Engineering has grown, and has consistently demonstrated outstanding capability to transform her expertise into practical solutions. Her knowledge of the Indian market, together with her international experience, makes her ideally suited to lead our India business through its next stage of growth for years to come.”

Since establishing its Indian business in 2012, Martin Engineering has expanded its local workforce, manufacturing capabilities and dealership network. The company supplies conveyor products, transfer point solutions, material flow aids, training and technical support to bulk material handling industries. Khunte’s appointment positions the company to further strengthen customer relationships and expand its solutions portfolio in India’s growing industrial and infrastructure markets.