Concrete

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

Published

12 years ago

July 31, 2014

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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

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

15 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.