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Modular Concrete Curing: A green alternative to curing process

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The traditional process of curing concrete is cumbersome, requires extensive labour work and leads to significant quantities of water loss. Ambuja has introduced a waterless curing technique in India that is economical and environment friendly.

Any cement concrete product or structure has to go through a curing process when the product or structure gains strength. The process of curing is done mainly with water. The chemical action between cement and water helps in hardening of concrete.

Curing must be done for a certain period of time so that concrete achieves its potential strength. It is very important to do curing properly as it crucial for the strength and durability of the concrete product or structure. The amount of time curing is to be done depends on the purpose of the concrete product or structure, temperature and humidity of the atmosphere.

Traditional curing process

Traditionally, curing is done by pouring or spraying water on concrete or mortar surfaces for an adequate period of time. Water has to be continuously replenished as and when it evaporates due to high temperature and low humidity. If the water dries out the strength of the concrete structure or surface will be impacted.

On flat surfaces such as pavements, roads, sidewalks and floor slabs curing is done by ponding water on the exposed top surface. This is done by making small bunds a few hours after the concrete work is over.

Typically, masons and labourers build bunds with cement and sand on flat concrete surfaces. Water is then poured on the surface and retained for a few days. On surfaces that cannot hold water, labourers spray water several times during the day for several days.

History and description of the technology

Ambuja Cements has come up with an alternative to combat difficulties in managing the traditional method of curing, the Ambuja Modular Curing Solution (AMCS). AMCS entails the use of a plastic sheet to prevent water losses due to evaporation, protects against strong winds, low humidity and high ambient temperatures.

How it can be used/ installed

Surfaces, which are concreted or cemented, are covered by plastic sheets primarily to prevent loss of humidity. All that the contractor has to do is to inform the service providers at Ambuja. The site engineer from Ambuja visits the premises where concrete is being poured and makes necessary arrangement at the site to cover the laid concrete. Once concrete is poured the cover is laid on top. The polymer covering comes in standard sizes that can be joined end to end to make a larger sheet. The joint is strong and water tight and does not let water or moisture to seep out. It is a quick and hassle free process.

Advantages for the construction industry

The biggest benefit is saving of water. About 12,000 litres of water required for curing 100 square metres of slab surface could be saved on an average. In India, many places are extremely hot and arid. Water availability is a serious issue. Under these circumstances curing process is not always done well. Also, labourers are required to build bunds on cemented surface or spray water several times during the day. Many a times the slab may have dry patches due to inappropriate/insufficient water application on the surface. AMCS is a service that helps reduce water usage and lower labour and other costs.

Its availability in India

At present AMCS is a service and is being expanded through its channel partners. The response to AMCS has been quite encouraging as curing is done effectively without hassles, water or labour. For Ambuja Cements, AMCS is yet another initiative towards sustainability.

Concrete

Lokesh Lays Stone For Rs 31 Billion Cement Unit In Kadapa

Line-2 expansion to make Kadapa a major cement hub

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Andhra Pradesh Education and IT Minister Nara Lokesh on Wednesday laid the foundation stone for the Line-2 expansion of Dalmia Bharat Cement at Chinnakomerla village in Mylavaram Mandal in Kadapa district. The project carries an investment of Rs 31 billion (bn) and is slated for completion by the third quarter of the financial year 2028. The expansion is intended to boost industrial growth and employment generation across the Rayalaseema region.

Once commissioned, the Kadapa facility will become Dalmia Bharat’s largest integrated cement manufacturing ecosystem in southern India, creating over 1,000 direct and indirect jobs and opening new business avenues for regional micro, small and medium enterprises and transport operators. Lokesh said the expansion signalled growing corporate confidence in the state and reflected the practical ease of doing business that secured repeat investment.

He placed the project within the government’s wider economic targets and recalled the Yuvagalam padayatra commitment to generate two million (mn) jobs within five years, noting that the state would cultivate talent while industry created opportunities. Lokesh highlighted Andhra Pradesh’s competitive pursuit of major manufacturing accounts, mentioning past successes and a personal initiative to engage global investors when persuading them to anchor expansion in the state.

The plant will leverage Kadapa’s abundant limestone reserves to scale production and sustainability. Clinker capacity is planned to rise from two point five million tonnes per annum (mn tpa) to six point one mn tpa, while overall cement output will increase from three point six mn tpa to nine point six mn tpa. The unit is designed to operate on over eighty per cent renewable energy and deploy waste heat recovery, zero liquid discharge, water recycling and advanced AI systems to optimise efficiency. Industries Minister TG Bharat, BC Welfare Minister S. Savitha and Jammalamadugu MLA C. Adinarayana Reddy attended the ceremony.

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Concrete

Cement Prices to Stay Flat in Q2 FY27 as Costs Squeeze Margins

HDFC Securities warns monsoon slowdown and higher fuel costs

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HDFC Securities has said the cement industry is unlikely to register a sequential increase in prices in Q2 FY27 as monsoon-related demand moderation coincides with rising fuel and packaging costs that will squeeze margins. The brokerage observed that price gains remained modest, with increases of two to three per cent quarter-on-quarter across regions, and noted subdued offtake in May with improvement in June as a delayed monsoon supported construction activity. The brokerage added that modest pricing gains so far have been insufficient to offset the input cost escalation.

The report stated that input cost pressures intensified in Q1 FY27 owing to the West Asia conflict, which pushed up coal and pet coke prices and is expected to keep fuel costs elevated, with a likely peak in Q2 FY27. It assessed that total variable costs, including packing, could rise by around Rs 150 per t quarter-on-quarter and that lower offtake and seasonal operating deleverage could further raise operating expenditure by about Rs 50 per t quarter-on-quarter.

Overall, cement prices were estimated to remain flat in Q2 FY27 as monsoon-led demand weakness offsets limited upside in realisation, and rising fuel costs alongside seasonal deleverage were expected to compress industry margins by over Rs 100 per t quarter-on-quarter to below Rs 880 per t. The brokerage indicated that the combined impact of energy inflation and higher packing expenditure would be the principal drivers of margin contraction in the near term. HDFC Securities projected a recovery in margins in H2 FY27 should the West Asia turmoil subside and energy and packing costs cool off.

The brokerage expressed optimism on long-term demand fundamentals and said improving realisation together with an anticipated cost cool-off should support a margin rebound from H2 FY27 onward, underpinning favourable industry prospects over the medium term. Its outlook rests on monsoon normalisation and a decline in imported fuel prices in the second half of the fiscal year.

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Concrete

Dalmia Bharat Begins Rs 31 Bn Green Cement Unit in Kadapa

New Andhra Pradesh plant to add 9.6 MTPA cement capacity by FY28

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Dalmia Bharat Limited recently laid the foundation stone for its second manufacturing unit at Kadapa in Andhra Pradesh. The company will invest Rs 31 billion in developing the next-generation integrated cement manufacturing facility.
The foundation-laying ceremony was attended by Nara Lokesh, Andhra Pradesh Minister for Information Technology, Electronics and Communications, Real-Time Governance and Human Resources Development, along with Puneet Dalmia, Managing Director and Chief Executive Officer, Dalmia Bharat, senior government officials and company representatives.
Scheduled to be commissioned by the third quarter of FY28, the Kadapa unit will become Dalmia Bharat’s largest integrated manufacturing facility in southern India. It will have a clinker production capacity of 6.1 million tonnes per annum and a cement manufacturing capacity of 9.6 million tonnes per annum.
The facility is designed to produce what the company describes as one of the world’s greenest cements. It is also expected to generate approximately 1,000 direct and indirect employment opportunities while supporting local MSMEs, transporters, contractors and service providers.
Lokesh said the investment reflected Dalmia Bharat’s confidence in Andhra Pradesh and aligned with the state’s objective of promoting sustainable industrialisation, job creation and technology-led economic growth.
Puneet Dalmia said the project represented the company’s long-term vision of developing low-carbon cement manufacturing assets. He added that the facility would establish new benchmarks in operational efficiency and sustainability while supporting India’s infrastructure and environmental goals.
Dalmia Bharat will also expand its regional community development programmes in education, healthcare, skill development and welfare through its DIKSHa and Gram Parivartan initiatives.
The company currently has an installed cement manufacturing capacity of 54.7 million tonnes across 19 manufacturing units in 12 states. It is also the first cement company globally to commit to the RE100, EP100 and EV100 initiatives.

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