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We use computerised batching plants to ensure proper blending of fly ash with concrete

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Mayur Shah, Managing Director, Marathon Group

Availability of good quality fly ash is not an issue. And the methods for testing it are well established as well. Construction leaders have now realised the merits of blending fly ash, and some, like the Marathon Group, are using fly ash in all their projects. The challenge however, is to blend it perfectly, says Mayur Shah, in an interaction with ICR. Excerpts from the interview.

How often, and how much of fly ash do you blend in cement?
We have used fly ash blended concrete in all our projects. We have been replacing cement with 28 per cent of fly ash in our blends. We produce high performance concrete using fly ash, GGBS, etc. Apart from blended concrete, we are using fly ash bricks too for construction. These bricks have better density and strength as compared to the conventional ones.

What encourages you to use fly ash in such significant quantities?
We at Marathon believe that our buildings should last for 75 years without any deterioration despite adverse weathering conditions. We also aim to reduce the cost of building repairs. In order to gain maximum benefits, we use high quality materials for in the construction process. Fly ash is one such material used by us.

How does fly ash contribute to concrete strength?
Fly ash is rich in silica. After primary cement hydration reaction, free lime available in concrete reacts with silica of fly ash and forms calcium silicate hydrate gel, which further adds to the strength of concrete as well as reduces porosity. This is called secondary reaction and it continues for at least a year. It increases durability of the structure over time. As (part of) cement content in the mix is substituted by fly ash, the heat of hydration gets reduced, which in turn eliminates the cracks in concrete.

Can you name some of your noteworthy projects where fly ash was used in significant quantity?
We have successfully completed many projects in which fly ash has been used:

  • Residential tower Marathon Era – 36 storeys in South Mumbai
  • Commercial Tower Marathon Futurex – 25 storeys in South Mumbai
  • Residential Tower Monte Vista – 33 storeys in Mulund, Mumbai
  • Residential Complex Marathon Nagari at Badlapur – winner of Best Low Cost Housing Apartments, at the CREDAI Real Estate Awards in 2012.

How do you ensure quality of your fly ash-cement blend?
Manual blending of fly ash is prone to errors. It is not possible to get desired quality of concrete consistently unless there is strict supervision on the site. So we use computerised batching plants at our sites to ensure proper blending of fly ash with concrete. There is no need for human intervention in the production of concrete. This eliminates any possible blending errors and helps us make good quality concrete consistently.

How do you assess the quality of fly ash?
Fly ash is broadly classified as Grade I or Grade II. As per IS 3812-2003, when silicon dioxide (SiO2), aluminium oxide (Al2O3) and Iron (Fe2O3) quantiles are more than 70 per cent it is classified as Grade I. We have been using the Grade I fly ash, which has at the most 5 per cent loss on ignition. Also, retention on 45 micron must be less than 34 per cent (by wet sieving method) as per IS: 3812 (Pt-I)-2013. We have also been using fly ash having 20 per cent retention on 45 micron sieve. We conduct sieve analysis test on site to ensure that the material retention on 45 micron sieve is in desired range.

What about the availability of good quality fly ash in the country?
Fly ash is generated as a by-product while burning coal at power plants. We are sourcing it from Dahanu and Nashik power plants. This raw fly ash is graded on the basis of its silica, alumina and iron content. We are not facing any issues in sourcing good quality 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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