Economy & Market
Demand Drivers
Published
9 years agoon
By
admin
The cement industry is expected to benefit from the country’s huge potential for development in the infrastructure and construction sectors, says NITIN MADKAIKAR.
India is the second largest producer of cement globally and the industry has been a vital part of its economic development, providing employment opportunities to more than a million people, directly or indirectly. Since its deregulation in 1982, the Indian cement industry has grown at a tremendous pace, attracting huge investments, both from domestic as well as foreign investors. The sector is expected to largely benefit from the country’s huge potential for development in the infrastructure and construction sectors. Some of the recent major initiatives like development of 98 Smart Cities will provide a major boost to cement demand.
Industry Structure
The Indian cement industry is dominated by a few companies. The top 20 cement companies account for almost 75 per cent of the total cement production of the country. A total of 188 large cement plants together account for 97 per cent of the total installed capacity in the country, with 365 small plants accounting for the rest. Of these large cement plants, 77 are located in Andhra Pradesh, Rajasthan and Tamil Nadu.
On the back of growing demand, due to increased construction and infrastructural activi-ties, the cement industry has attracted huge inve-stments and developments in recent years.
Construction Market
India’s construction business stands over at Rs 30,000 billion, and has been slowly expanding over the years. With value addition of over Rs 10,500 billion, its share in total GDP rose from 5.6 per cent in 1990-91 to over 7.7 per cent in 2016-17. This has given a major advantage to the cement industry, which is poised to expand with increased attention of the government promoting large infrastructure projects.
However, the growth of construction activity has slowed down significantly in recent years. The last highest yearly growth of 10.8 per cent was recorded in 2011-12, but thereafter it has not even touched 5 per cent until now. In 2016-17, it is estimated to have increased 3.1 per cent, slightly faster than the 2.8 per cent clocked in 2015-16. Going ahead, it appears that the growth will remain under 5 per cent, thus truncating demand for construction materials, including cement.
However, the growth will largely depend on the government’s initiative in developing infrastructure and the process of boosting the housing sector.
In construction, cement is the second-largest component, although its value accounts for only 12 per cent of total input cost of construction, whereas steel takes away nearly half the cost of inputs. Over Rs 2,000 billion worth of cement is consumed to construct a variety of structures. Within this premise, dwelling construction account for 30 per cent of all construction activity, while another 40 per cent is accounted for by non-residential buildings construction.
Roads and bridges, major infrastructure components, account for just 6 per cent of constru-ction. What remains is other structures and land improvement activity. Thus, housing and commer-cial construction is the major economic activity and it is largely dependent on cement and steel.
Cement production volume in 2016-17 has seen a year-on-year decline for the first time in 15 years, as the demonetisation exercise reduced demand. The industry, with an estimated capacity of around 420 million tonnes, saw production fall 0.7 per cent during the year. However, with no authentic data available on cement consumption or demand in the public domain, estimating actual production figures is a difficult exercise.
Cement demand has a close linkage with eco-nomic growth and government spends. Demand for housing is driven by income growth while infrastructure development largely depends on government expenditure, both state and Central.
In the recent past, demand for cement has remained poor as economic growth slowed down to less than 6 per cent between 2012-13 and 2016-17 from an average of 9 per cent between 2005-06 and 2010-11. During that period, cement demand had expanded by 8.5 per cent per annum, which has come down to around 4 per vcent per annum over the past five years.
Considering that the economy may grow at 8.50-9 per cent over the next five years, the statistical relation between cement demand and economic growth predicts that demand for the commodity may grow at the rate of 4 per cent per annum over the next five years.
The housing sector will be biggest demand driver for cement, which now accounts for about 45 per cent of total cement consumption. The other major consumers will include infrastructure (17 per cent), commercial construction (11 per cent) and the rest will be made up by industrial construction. Rural housing (40 per cent) and urban housing (25 per cent) will be the major demand drivers for the cement industry.
The industry is bullish over demand on account of the government’s focus on infrastructure and housing. The Union Budget for 2017-18 has raised the allocation for roads from Rs 5,798 billion in 2016-17 to Rs 6,490 billion in 2017-18, with a stress on laying 2,000 km of coastal roads.
According to estimates, cement comprises 30 per cent of the cost of laying a road and the budgetary allocation may translate into a Rs 1,947-billion business opportunity for the industry. For the transportation sector alone, Rs24,139 billion has been allotted for 2017-18.
Although demand for cement will not be significant, increase in volumes and prices will be pertinent for a cement industry as volume will satisfy increasing demand and prices will rise to help manage rising costs.
To boost cement demand, the government has been approving various investment schemes (see Box-1) as fast as possible.
A Macro View
ACC believes that the prospects for economic growth have become buoyant with the rural economy benefiting from a good monsoon after two successive rain-deficient years. However, the Goods and Services Tax and the demonetisation scheme which aimed to usher in greater tran-sparency in financial transactions and a transition towards a cashless economy, over the short term, has squeezed liquidity and consumption across the economy, notably in the construction sector.
The outlook for 2017 is bright, as liquidity in the economy has moved towards normalisation, with expectations for early revival and growth in overall consumption across several sectors including construction and building materials. The Union Budget with thrust on the rural sector, infrastructure development and housing will boost the overall investment climate. If 2017-18 experiences a normal monsoon, GDP growth is likely to rebound during the year. Better liquidity and improved tax collections will enhance the government’s ability to spend on infrastructure and other development projects, leading to faster growth.
ACC foresees that the industry will continue to be dogged by the challenge of excess capacity leading to intense competition. If the government is successful in increasing its investment expen-diture on large infrastructure and other develo-pment projects as announced in the Budget, it will further energise construction activity. Any cut in interest rates on housing loans will boost investment in the housing sector. Together, these developments will provide the much-needed fillip to demand for cement and concrete in the coming year.
According to Gujarat Ambuja Cement, despite several challenges, the economy has immense potential, which will power economic growth. The securitisation of real estate – Real Estate Inve-stment Trusts and Infrastructure Investment Trusts – is likely to foster greater economic activity, along with a more efficient and transparent market.
For demand growth, the government has provided incentives for rural development and also allowed 100 per cent FDI in the construction of development and industrial parks. Overall, cement demand growth is expected to rise in 2017-18 on account of higher government spending on various initiatives as announced in the Budget along with incentives for affordable housing by providing it with ‘Infrastructure Status’. This will boost demand for cement by a positive multiplier.
Sensitive Outlook
Housing demand is not expected to see a significant turnaround in the short term. However, much would depend on higher-than-expected demand or significant progress by the government on schemes such as ‘Housing for All’ or Smart Cities. If they are well implemented, it could result in good demand for cement in the near future. A below-than expected pick up in construction and infrastructure projects could affect demand for cement and the credit profile of cement companies. This may play a negative role for cement demand.
The cement industry has now become intensely competitive, with the foray of new entrants and existing players expanding inorganically. This could potentially impact market share and margins.
With the new Mines and Minerals (Development & Regulation) Amendment Act 2015, the earlier policy of deemed renewal has been discontinued and all the mining leases will be allotted through an auction. This has made it difficult for cement companies to retain or acquire existing leases. Forest and wildlife clearances are now a prerequisite and land acquisition is becoming more challenging and expensive.
Concrete Push
Here are a few initiatives taken by the government in the recent past to boost cement demand:
- Assigning ‘infrastructure status’ to affor-dable housing projects and facilitating higher investments and better credit facilities, with an aim to provide ‘Housing for All’ by 2022. The cement industry stands to gain from the grant of infra-structure status to affordable housing;
- Interest rate rebate of 3 per cent for Rs 12 lakh housing loans will boost demand for real estate in Tier-II and Tier-III cities;
- The Finance Minister has announced that the National Housing Bank will refinance individual housing loans of around Rs 2,000 billion ($3 billion) in 2017-18. The minister has also set a target of completing 10 million houses by 2019;
- Increased allocation to rural low-cost housing under the Pradhan Mantri Awaas Yojana- Gramin scheme to Rs 2,300 billion ($3.45 billion) from Rs 1,600 billion ($2.4 billion) in FY17. This will directly drive a 2 per cent increase in cement demand;
- With the Parliament clearing the amendments to the Mines and Minerals Development and Regulation (MMDR) Act, it has enabled companies to transfer captive mine leases, similar to mines won through auctions. This will lead to more mergers and acquisitions among cement companies;
- The government’s plans to revive state-run cement factories across India will give a boost to road and realty projects by bringing down construction costs;
- A 15 per cent increase in capital outlay on infrastructure projects will create cement demand in roads, railway projects, irrigation and port projects;
- Higher allocation to MNEGRA will boost rural income and have a catalytic effect on rural consumption. This is expected to help the cement industry, as it will lead to increased and sustained levels of cement consumption.
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SEEPEX introduces BN pumps with Smart Joint Access (SJA) to improve efficiency, reliability, and inspection speed in demanding rock blasting operations.
Designed for abrasive and chemical media, the solution supports precise dosing, reduced downtime, and enhanced operational safety.
SEEPEX has introduced BN pumps with Smart Joint Access (SJA), engineered for the reliable and precise transfer of abrasive, corrosive, and chemical media in mining and construction. Designed for rock blasting, the pump features a large inspection opening for quick joint checks, a compact footprint for mobile or skid-mounted installations, and flexible drive and material options for consistent performance and uptime.

“Operators can inspect joints quickly and rely on precise pumping of shear-sensitive and abrasive emulsions,” said Magalie Levray, Global Business Development Manager Mining at SEEPEX. “This is particularly critical in rock blasting, where every borehole counts for productivity.” Industry Context
Rock blasting is essential for extracting hard rock and shaping safe excavation profiles in mining and construction. Accurate and consistent loading of explosive emulsions ensures controlled fragmentation, protects personnel, and maximizes productivity. Even minor deviations in pumping can cause delays or reduce product quality. BN pumps with SJA support routine maintenance and pre-operation checks by allowing fast verification of joint integrity, enabling more efficient operations.
Always Inspection Ready
Smart Joint Access is designed for inspection-friendly operations. The large inspection opening in the suction housing provides direct access to both joints, enabling rapid pre-operation checks while maintaining high operational reliability. Technicians can assess joint condition quickly, supporting continuous, reliable operation.
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Applications – Optimized for Rock Blasting
BN pumps with SJA are designed for mining, tunneling, quarrying, civil works, dam construction, and other sectors requiring precise handling of abrasive or chemical media. They provide robust performance while enabling fast, reliable inspection and maintenance.With SJA, operators can quickly access both joints without disassembly, ensuring emulsions are transferred accurately and consistently. This reduces downtime, preserves product integrity, and supports uniform dosing across multiple bore holes.
With the Smart Joint Access inspection opening, operators can quickly access and assess the condition of both joints without disassembly, enabling immediate verification of pump readiness prior to blast hole loading. This allows operators to confirm that emulsions are transferred accurately and consistently, protecting personnel, minimizing product degradation, and maintaining uniform dosing across multiple bore holes.
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A leading explosives provider implemented BN pumps with SJA in open pit and underground operations. By replacing legacy pumps, inspection cycles were significantly shortened, allowing crews to complete pre-operation checks and return mobile units to productive work faster. Direct joint access through SJA enabled immediate verification, consistent emulsion dosing, and reduced downtime caused by joint-related deviations.
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Concrete
Digital process control is transforming grinding
Published
3 weeks agoon
February 20, 2026By
admin
Satish Maheshwari, Chief Manufacturing Officer, Shree Cement, delves into how digital intelligence is transforming cement grinding into a predictive, stable, and energy-efficient operation.
Grinding sits at the heart of cement manufacturing, accounting for the largest share of electrical energy consumption. In this interview, Satish Maheshwari, Chief Manufacturing Officer, Shree Cement, explains how advanced grinding technologies, data-driven optimisation and process intelligence are transforming mill performance, reducing power consumption and supporting the industry’s decarbonisation goals.
How has the grinding process evolved in Indian cement plants to meet rising efficiency and sustainability expectations?
Over the past decade, Indian cement plants have seen a clear evolution in grinding technology, moving from conventional open-circuit ball mills to high-efficiency closed-circuit systems, Roller Press–Ball Mill combinations and Vertical Roller Mills (VRMs). This shift has been supported by advances in separator design, improved wear-resistant materials, and the growing use of digital process automation. As a result, grinding units today operate as highly controlled manufacturing systems where real-time data, process intelligence and efficient separation work together to deliver stable and predictable performance.
From a sustainability perspective, these developments directly reduce specific power consumption, improve equipment reliability and lower the carbon footprint per tonne of cement produced.
How critical is grinding optimisation in reducing specific power consumption across ball mills and VRMs?
Grinding is the largest consumer of electrical energy in a cement plant, which makes optimisation one of the most effective levers for improving energy efficiency. In ball mill systems, optimisation through correct media selection, charge design, diaphragm configuration, ventilation management and separator tuning can typically deliver power savings of 5 per cent to 8 per cent. In VRMs, fine-tuning airflow balance, grinding pressure, nozzle ring settings, and circulating load can unlock energy reductions in the range of 8 per cent to 12 per cent. Across both systems, sustained operation under stable conditions is critical. Consistency in mill loading and operating parameters improves quality control, reduces wear, and enables long-term energy efficiency, making stability a key operational KPI.
What challenges arise in maintaining consistent cement quality when using alternative raw materials and blended compositions?
The increased use of alternative raw materials and supplementary cementitious materials (SCM) introduces variability in chemistry, moisture, hardness, and loss on ignition. This variability makes it more challenging to maintain consistent fineness, particle size distribution, throughput and downstream performance parameters such as setting time, strength development and workability.
As clinker substitution levels rise, grinding precision becomes increasingly important. Even small improvements in consistency enable higher SCM utilisation without compromising cement performance.
Addressing these challenges requires stronger feed homogenisation, real-time quality monitoring and dynamic adjustment of grinding parameters so that output quality remains stable despite changing input characteristics.
How is digital process control changing the way grinding performance is optimised?
Digital process control is transforming grinding from an operator-dependent activity into a predictive, model-driven operation. Technologies such as online particle size and residue analysers, AI-based optimisation platforms, digital twins for VRMs and Roller Press systems, and advanced process control solutions are redefining how performance is managed.
At the same time, workforce roles are evolving. Operators are increasingly focused on interpreting data trends through digital dashboards and responding proactively rather than relying on manual interventions. Together, these tools improve mill stability, enable faster response to disturbances, maintain consistent fineness, and reduce specific energy consumption while minimising manual effort.
How do you see grinding technologies supporting the industry’s low-clinker and decarbonisation goals?
Modern grinding technologies are central to the industry’s decarbonisation efforts. They enable higher incorporation of SCMs such as fly ash, slag, and limestone, improve particle fineness and reactivity, and reduce overall power consumption. Efficient grinding makes it possible to maintain consistent cement quality at lower clinker factors. Every improvement in energy intensity and particle engineering directly contributes to lower CO2 emissions.
As India moves toward low-carbon construction, precision grinding will remain a foundational capability for delivering sustainable, high-performance cement aligned with national and global climate objectives.
How much potential does grinding optimisation hold for immediate energy
and cost savings?
The potential for near-term savings is substantial. Without major capital investment, most plants can achieve 5 per cent to 15 per cent power reduction through measures such as improving separator efficiency, optimising ventilation, refining media grading, and fine-tuning operating parameters.
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Concrete
Refractory demands in our kiln have changed
Published
3 weeks agoon
February 20, 2026By
admin
Radha Singh, Senior Manager (P&Q), Shree Digvijay Cement, points out why performance, predictability and life-cycle value now matter more than routine replacement in cement kilns.
As Indian cement plants push for higher throughput, increased alternative fuel usage and tighter shutdown cycles, refractory performance in kilns and pyro-processing systems is under growing pressure. In this interview, Radha Singh, Senior Manager (P&Q), Shree Digvijay Cement, shares how refractory demands have evolved on the ground and how smarter digital monitoring is improving kiln stability, uptime and clinker quality.
How have refractory demands changed in your kiln and pyro-processing line over the last five years?
Over the last five years, refractory demands in our kiln and pyro line have changed. Earlier, the focus was mostly on standard grades and routine shutdown-based replacement. But now, because of higher production loads, more alternative fuels and raw materials (AFR) usage and greater temperature variation, the expectation from refractory has increased.
In our own case, the current kiln refractory has already completed around 1.5 years, which itself shows how much more we now rely on materials that can handle thermal shock, alkali attack and coating fluctuations. We have moved towards more stable, high-performance linings so that we don’t have to enter the kiln frequently for repairs.
Overall, the shift has been from just ‘installation and run’ to selecting refractories that give longer life, better coating behaviour and more predictable performance under tougher operating conditions.
What are the biggest refractory challenges in the preheater, calciner and cooler zones?
• Preheater: Coating instability, chloride/sulphur cycles and brick erosion.
• Calciner: AFR firing, thermal shock and alkali infiltration.
• Cooler: Severe abrasion, red-river formation and mechanical stress on linings.
Overall, the biggest challenge is maintaining lining stability under highly variable operating conditions.
How do you evaluate and select refractory partners for long-term performance?
In real plant conditions, we don’t select a refractory partner just by looking at price. First, we see their past performance in similar kilns and whether their material has actually survived our operating conditions. We also check how strong their technical support is during shutdowns, because installation quality matters as much as the material itself.
Another key point is how quickly they respond during breakdowns or hot spots. A good partner should be available on short notice. We also look at their failure analysis capability, whether they can explain why a lining failed and suggest improvements.
On top of this, we review the life they delivered in the last few campaigns, their supply reliability and their willingness to offer plant-specific custom solutions instead of generic grades. Only a partner who supports us throughout the life cycle, which includes selection, installation, monitoring and post-failure analysis, fits our long-term requirement.
Can you share a recent example where better refractory selection improved uptime or clinker quality?
Recently, we upgraded to a high-abrasion basic brick at the kiln outlet. Earlier we had frequent chipping and coating loss. With the new lining, thermal stability improved and the coating became much more stable. As a result, our shutdown interval increased and clinker quality remained more consistent. It had a direct impact on our uptime.
How is increased AFR use affecting refractory behaviour?
Increased AFR use is definitely putting more stress on the refractory. The biggest issue we see daily is the rise in chlorine, alkalis and volatiles, which directly attack the lining, especially in the calciner and kiln inlet. AFR firing is also not as stable as conventional fuel, so we face frequent temperature fluctuations, which cause more thermal shock and small cracks in the lining.
Another real problem is coating instability. Some days the coating builds too fast, other days it suddenly drops, and both conditions impact refractory life. We also notice more dust circulation and buildup inside the calciner whenever the AFR mix changes, which again increases erosion.
Because of these practical issues, we have started relying more on alkali-resistant, low-porosity and better thermal shock–resistant materials to handle the additional stress coming from AFR.
What role does digital monitoring or thermal profiling play in your refractory strategy?
Digital tools like kiln shell scanners, IR imaging and thermal profiling help us detect weakening areas much earlier. This reduces unplanned shutdowns, helps identify hotspots accurately and allows us to replace only the critical sections. Overall, our maintenance has shifted from reactive to predictive, improving lining life significantly.
How do you balance cost, durability and installation speed during refractory shutdowns?
We focus on three points:
• Material quality that suits our thermal profile and chemistry.
• Installation speed, in fast turnarounds, we prefer monolithic.
• Life-cycle cost—the cheapest material is not the most economical. We look at durability, future downtime and total cost of ownership.
This balance ensures reliable performance without unnecessary expenditure.
What refractory or pyro-processing innovations could transform Indian cement operations?
Some promising developments include:
• High-performance, low-porosity and nano-bonded refractories
• Precast modular linings to drastically reduce shutdown time
• AI-driven kiln thermal analytics
• Advanced coating management solutions
• More AFR-compatible refractory mixes
These innovations can significantly improve kiln stability, efficiency and maintenance planning across the industry.
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