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Skill development initiatives in India

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Skill development is a major challenge and initiatives have been taken not only by the Government but also by industry to facilitate skill development, but the task is gigantic and more needs to be done, says Dr Rajen Mehrotra.

To benefit from the demographic dividend, the Government of India both during the United Progressive Alliance (UPA) Government (i.e. 2004-14) plus the National Democratic Front (NDF) Government (i.e. 2014-24) have been making efforts by coming forward with various initiatives / schemes to improve the availability of skilled youth in India. Around 90 per cent of the workforce in developed countries is vocationally qualified, while in India the number is still only 5-7 per cent[1]. Skill development is a major challenge and initiatives have been taken not only by the Government but also by industry to facilitate skill development, but the task is gigantic and more needs to be done.

Apart from skill development, skill up gradation is a continuous process. Skill up-gradation is needed in all the fields not only in manufacturing but also in services. Upgradation can be from basic to advanced and finally to expert and can be at various stages, however this article is dealing with skill development at the initial stage for the youth of the country. India needs basically expertise through skill advancement for the youth in various fields. Along with skill development mentoring is an important area during skill upgradation and having good mentors helps the candidate to develop and grow. Industrial training institutes
Industrial training institutes (ITIs) with a focus on skill development were started in 1950 in India. These are presently under the Ministry of Skill Development and Entrepreneurship. The Government of India is running 2,293 ITIs and there are 10,812 private ITIs, thus having a total strength of 13,105 ITIs in the country as per published figures in April 2016. Vocational training of quite many ITI’s is not necessarily meeting the present-day requirement of advanced manufacturing enterprises, hence after completing the courses the young students passing out struggle to find meaningful employment.

The United Progressive Alliance (UPA) Government in 2007 went in for a Public Private Partnership (PPP) scheme asking industry to help upgrade the quality of training in the Government run ITIs. Quite many enterprises collaborated with the Government in this task of upgradation. Under PPP scheme, the Government of India provided interest free loan of Rs. 25 million to the Institutes Management Committee (IMC) Society of the partnered ITI and the repayment of the loan had a moratorium of 10 years from the year in which the loan had been received by the IMC Society. After the moratorium the loan amount had to be repaid in equal annual instalments over a period of 20 years, the first instalment repayable from the 11th anniversary of the date of receipt of money. This was a unique PPP scheme primarily aimed at improving the quality of training to benefit the students of the ITI in improved knowledge and skill for better chances of employability or being self employed. Many enterprises of the corporate sector supported this scheme, so as to improve the quality of skill development of the students and also improved the infrastructure of ITI’s which needed upgradation, though much more needed to be done.

Enterprises Running Training Institute
Certain manufacturing companies in order to get skilled workers in specific trades use to run a basic training centre wherein the youth acquired the requisite skill and also went through some knowledge acquisition by attending classes. In quite many cases these were confined to trades relevant to the industry in which the enterprise operated. Some of these enterprises got their trainees to qualify for the trades specified under the ITIs and some did not do that. I had an experience of this when I worked with Mukand Iron & Steel Works (now called Mukand) and also with ACC. There are quite many old companies that had this practice and still continue with this practice, as it helps the youth of the country to develop.

The modern vocational institutes set by companies like Mahindra and Mahindra, L&T and many leading companies are very good and the trainees from such institutions have no problem getting meaningful employment. Also, the trainees have competencies to set up small start-up’s and do well over time as they are trained with modern technology unlike the ones from the traditional ITIs. Some old enterprises have discontinued this practice later, as they were not in a position to absorb these trainees and it tended to create industrial relations problems. Most enterprises including the small and medium enterprises cannot undertake such an activity, and hence expect such trained personnel to be provided by the Government or by private agencies.

The Apprenticeship Act, 1961
In India we have The Apprenticeship Act, 1961 under which enterprises engaged the youth of this country as an apprentice in their premises to undergo apprenticeship training. This Act went through a major amendment in 2014 when the Apprentices (Amendment) Act 2014 came with the concept of "optional trade", which means any trade or occupation or any subject field in engineering or non-engineering or technology or any vocational course as may be determined by the employer for the purpose of the Act. There were enterprises that have introduced the provision of "optional trade" based on the business of the enterprise got their certified industrial employment standing orders amended to engage apprentices for a fixed duration of training. Some of these enterprises in the initial period have absorbed the enterprise apprentices as regular workers based on vacancies, however later they are finding it tough to absorb this trained youth.

National Employment Enhancement Mission (NEEM)
The Government through All India Council for Technical Education (AICTE) in April 2013 has launched a program known as National Employment Enhancement Mission (NEEM). The objective of the programme as mentioned is to develop a competent workforce which could take the country ahead in the industrial world. Under the programme, a NEEM agent can place a maximum number of 5,000 trainees in industry and the trainees can be a person between the age of 18 to 40 years, who has discontinued studies or is studying any course or completed a course leading to a graduation/diploma in any technical/non-technical stream. The period of training can be for a minimum period of three months and a maximum period of thirty-six months and the NEEM agent shall pay all enrolled NEEM trainees a stipend, which shall be at par with the prescribed minimum wage for unskilled category in the enterprise where they are placed.

The NEEM trainees in any enterprises are to be taken through a registered NEEM agent, who shall have at least a turnover of Indian Rs.50 million per financial year for the previous three financial years or a section 25 company (not for profit company under section 25 of The Companies Act, 1956. Which presently is called section 8 company under The Companies Act, 2013) is formed to meet the objectives of NEEM. This scheme has become very popular in the last three years and a large number of manufacturing enterprises are taking NEEM trainees who work along with regular workers of the enterprise.

Skill India Initiative
The NDA Government from 2014 launched various SKILL INDIA initiative to improve employability of the youth by enhancing their skill sets. Some of these initiatives are given below:

Deen Dayal Upadhyaya Grameen Kaushalya Yojana (2014) [2]: The Ministry of Rural Development (MoRD) announced the Deen Dayal Upadhyaya Grameen Kaushalya Yojana (DDU-GKY) Antyodaya Diwas, on September 25, 2014. DDU-GKY is a part of the National Rural Livelihood Mission (NRLM), tasked with the dual objectives of adding diversity to the incomes of rural poor families and cater to the career aspirations of rural youth. Over 180 million or 69 per cent of the country’s youth population between the ages of 18 and 34 years lives in rural area and around 55 million of them falls in the bottom of pyramid with no/marginal employment. DDU-GKY aims to skill such rural youth by providing them with jobs and ensuring regular monthly wages or above the minimum wages. DDU-GKY is present in 28 States and UTs, across 669 districts, impacting youth from over 7,294 blocks. It currently has over 1,242 projects being implemented by over 557 partners, in more than 585 trades from 50 industry sectors. Over 7.9 lakh candidates have been trained and over 3.6 lakh candidates have been placed in jobs as on July 11, 2019.

Pradhan Mantri Kaushal Vikas Yojana (2015) [3]: This scheme was launched by the Ministry of Skill Development and Entrepreneurship to formulate and implement the Pradhan Mantri Kaushal Vikas Yojana (PMKVY) through the National Skill Development Corporation in March 2015. Individuals with prior learning experience or skills will also be assessed and certified under Recognition of Prior Learning (RPL).

Here the government provides training with the help of third-party training partners. Apart from the training, the candidates shall also go through an assessment at the end of the training schedule. A certificate of merit shall also be issued to candidates at the end of this training period based on the assessment. Training and Assessment fees are completely paid by the Government and on an average a sum of Rs 8000 is to be rewarded to an individual enrolled in the scheme.

Financial Assistance for Skill Training of Persons with Disabilities (2015) [4]: This scheme helps in empowering the 26.8 million disabled population in India in accordance with the existing "The Persons with Disability Act 1995". The scheme provides special training stipend for person with disability less than 40 per cent and between the age group from 19 to 59. The scheme also consists of facilities such as hostels and accommodation, cost of transport and other incentives to the candidate enrolled. Also, an all-inclusive training cost of Rs 5,000 per trainee per month shall be provided for the entire duration of the training. The benefits are to be transferred in four instalments.

National Apprenticeship Promotion Scheme (2016) [5]: This scheme is the newest amongst the cluster. It was launched in August 2016, which promotes apprenticeship by sharing 25 per cent of the prescribed stipend of the apprenticeship burden (maximum of Rs 1,500 per month).

Craftsmen Training Scheme (1950) [6]: The scheme was launched in year 1950 to shape the future workmen. Because of this scheme, only at present Craftsmen Training Scheme are being offered through a network of 15,042 it is (Government: 2738 + Private: 12,304) located all over the country with total of 22.82 lakh trainees enrolled. This scheme has played and has been playing a significant role in restoring the traditional arts and crafts skills of the traditional Indian.

Pradhan Mantri Kaushal Kendra (2018) [7]: This scheme focuses on establishing special Model Training Centres (MTCs) established in every district of the country by Ministry of Skill Development and Entrepreneurship (MSDE). The model training centres envisage to:

Create benchmark institutions that demonstrate inspirational value for competency-based skill development training.
Focus on elements of quality, sustainability and connection with stakeholders in skills delivery process.
Transform from a mandate-driven footloose model to a sustainable institutional model.

These training centres can be built by receiving an amount of 75 per cent of the project investment from central government.

Skill Development for Minorities (2013) [8]: The scheme called "Learn and Earn" has been launched specially for minorities in 2013 to help the minorities to get better chances of employment even with minimum qualifications (at least class V). The Ministry of Minority Affairs has developed courses include majority of traditional skills being practiced by the minority communities, e.g. embroidery, chikankari, zardosi, patch work, gem and jewelry, weaving, wooden works, leather goods, brass metal works, glass wares, carpet, etc. The scheme bears full cost of the projects as per prescribed financial norms and also provides stipend and post placement support to the candidate.

Green Skill Development Programme (2017) [9]: The Green Skill Development Programme (GSDP) aims to fill the gap between the need and availability of skill sets to help sustain environment at various levels. It enhances the employability of people in jobs that contribute to preserving or restoring the quality of the environment with help of the 67 centres established by the government. The first GSDP course was formulated for skilling biodiversity conservationists (basic course) and Para-taxonomists (Advance Course) of 3 months’ duration each on a pilot basis in ten select districts of the country. BSI and ZSI were the nodal centres for the pilot programme.

All Indian Computer Siksha Mission (1999) [10]: The scheme has been in addition to the existing Rajeev Gandhi Computer Saksharta Mission. The Government of India has initiated Computer skill centres in association with the third-party partners where, candidates can get certificate courses, diploma courses, advance diploma courses, vocational courses to showcase their technical skills for better employment opportunities. AICSM has trained above 1.5 lakh till 2017 and placed above 42,000 students.

Challenges
India has more than 600 million people under the age of 25 years with a potential of being the most employable country in Asia Pacific. Every year, 25 million people attain the age of 21 years and come to work, so skilling such a large number is not easy. According to All India Survey of Higher Education by Azim Premji University of the 8 million students who graduate every year, only around 1 million receive professional degrees. Hence, skill development of youth who are non-graduates is a priority area. The Government of India has been working since 2009 by having launched The National Skills Development Corporation (NSDC). The Pradhan Mantri Kaushal Vikas Yojana was launched in 2015 with a separate budget of Rs 15 billion. There is also scope for skill development in the field of agriculture, horticulture, dairy, poultry etc. and this can facilitate in generating better quality jobs for the youth in rural India. This is an area where more focus is needed. Despite these many years of working on the problem there still persist two major challenges: Informational asymmetries and limited quality assurance.

A major hitch in India is that except for some leading companies, majority of the enterprises do not take much interest in supporting the skill development initiative. Many enterprises misuse the young trainees as a substitute for regular workers to achieve a cost arbitrage by utilising these youngsters to do regular nature of jobs in the garb of training; this is especially true with reference to NEEM trainees. Industry has a role and responsibility as part of corporate citizenship and needs to wholeheartedly support the skill development initiative in the nation’s interest.

A major challenge is that the youth today is inclined towards desiring to have higher education by studying in the college and university rather than acquiring skills under various schemes listed above. For this barrier to break enterprises and citizens will not only have to pay well to skilled category of workers but also treat them with dignity, so that they are attracted towards acquiring skills. In the western world, the skilled handy man who by and large is self-employed is paid well and treated well, so that he/she is happy doing that work rather than going in for higher college and university education.

References
1.https://www.thehindu.com/education/careers/A-potted-historyof-skilling-in-India/article17287918.ece
2.http://ddugky.gov.in/content/about-us-0
3.https://www.india.gov.in/spotlight/pradhan-mantri-kaushal-vikasyojana#tab=tab-1
4.http://disabilityaffairs.gov.in/upload/uploadfiles/files/fas1.pdf
5.http://www.mescindia.org/naps.php
6.https://dgt.gov.in/CTS
7.https://nsdcindia.org/pmkk
8.http://www.minorityaffairs.gov.in/schemesperformance/seekho-aurkamaolearn-earn-scheme-skill-development-minorities
9.http://www.gsdp-envis.gov.in/
10.https://www.aicsm.com/aicsmAimGoal.htm

Acknowledgement
The author is grateful to Mr. Vineet Kumar Oswal, First Year student of Post Graduate Programme in Management at Indian Institute of Management (IIM) Sirmaur for compiling information on the 9 schemes listed under Skill India. Published in November 2019 issue of Current Labour Reports and Arbiter.

The author is Past President of Industrial Relations Institute of India (IRII), Former Senior Employers’ Specialist for South Asian Region with Internation.al Labour Organization (ILO) and Former Corporate Head of HR with ACC and Former Corporate Head of Manufacturing and HR with Novartis India. He can be contacted on: Email: rajenmehrotra@gmail.com

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Concrete

SCMs encourage closed-loop systems

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As the cement industry prioritises sustainability and performance, Supplementary Cementitious Materials (SCMs) are redefining standards, explains Tushar Khandhadia, General Manager – Production, Udaipur Cement Works.

What role do supplementary cementitious materials (SCMs) play in enhancing the performance and sustainability of cement and concrete?
SCMs play a crucial role in enhancing the performance and sustainability of cement and concrete. These materials are added to concrete to improve its properties such as strength, durability, and workability, as well as to reduce the environmental impact of cement production. The addition of SCMs to cement reduces the amount of Portland cement required to manufacture concrete, reducing the carbon footprint of the concrete. These materials are often industrial waste products or by-products that can be used as a replacement for cement, such as fly ash, slag and silica fume.
SCMs also reduce the amount of water required to produce concrete, which reduces the environmental impact of concrete production. This is achieved through their ability to improve the workability of concrete, allowing the same amount of work to be done with less water.
In addition, SCMs improve the durability of concrete by reducing the risk of cracking and improving resistance to chemical attack and other forms of degradation.

How has your company integrated SCMs into its production process, and what challenges have you encountered?
The integration of SCMs into cement and concrete production may pose certain challenges in the areas of sourcing, handling and production optimisation.

  • Sourcing: Finding an adequate and reliable supply of SCMs can be a challenge. Some SCMs, such as fly ash and slag, are readily available by-products of other industrial processes, while others such as silica fume or metakaolin may be more difficult to source.
  • Handling: The storage, handling, and transportation of SCMs require special considerations due to their physical and chemical properties. For instance, some SCMs are stored in moist conditions to prevent them from drying out and becoming airborne, which could pose a safety risk to workers.
  • Production optimisation: The addition of SCMs into the mix may require adjustments to the production process to achieve the desired properties of cement and concrete. For example, the use of SCMs may affect the setting time, workability, strength gain, and other properties of the final product, which may require reconfiguration of the production process.
  • Quality control: The addition of SCMs may introduce variability in the properties of cement and concrete, and rigorous quality control measures are necessary to ensure the final product meets the required specifications and standards.

Proper planning, handling and production optimisation are essential in overcoming the challenges encountered during the integration process.

Can you share insights on how SCMs such as fly ash, slag and silica fume impact the durability and strength of concrete in different environmental conditions?

  • Fly ash is a by-product of coal combustion and is widely used as an SCM in the production of concrete. When added to concrete, fly ash reacts with the calcium hydroxide present in the concrete to form additional cementitious materials, resulting in improved strength and durability. Fly ash increases the durability of concrete by improving its resistance to sulphate and acid attacks, reducing shrinkage and decreasing the permeability of concrete. Fly ash also enhances the workability and pumpability of concrete while reducing the heat of hydration, which reduces the risk of thermal cracking. In cold climates, fly ash helps to reduce the risk of freeze-thaw damage.
  • Slag is a by-product of steel production and is used as an SCM because of its high silica and alumina content. When added to concrete, slag reacts with the calcium hydroxide present in the concrete to form additional cementitious materials, resulting in improved strength and durability. Slag increases the durability of concrete by improving its resistance to sulphate and acid attacks, reducing shrinkage and improving the strength of concrete over time. Slag also enhances the workability of concrete, reduces the heat of hydration, and improves the resistance of concrete to chloride penetration.
  • Silica fume is a by-product of the production of silicon and ferrosilicon alloys and is used as an SCM because of its high silica content. When added to concrete, silica fumes react with the calcium hydroxide present in the concrete to form additional cementitious materials, resulting in improved strength and durability. Silica fume increases the durability of concrete by improving its resistance to sulphate and acid attacks, reducing permeability, and improving abrasion resistance. Silica fume also enhances the workability of concrete, reduces the heat of hydration, and improves the resistance of concrete to chloride penetration.

Overall, the use of SCMs such as fly ash, slag and silica fume can significantly improve the durability and strength of concrete in different environmental conditions. Their impact on concrete varies depending on the availability, physical and chemical properties of the specific SCM being used and proper testing and engineering analysis should be done for each mix design in order to optimise the final product.

With the global push for sustainability, how do SCMs contribute to reducing the carbon footprint of cement production?
SCMs provide an environmentally friendly alternative to traditional Portland cement by reducing the amount of clinker required to produce cement. Clinker is the main ingredient in Portland cement and is produced by heating limestone and other raw materials to high temperatures, which releases significant GHG emissions. Thus, by using SCMs, less clinker is required, thereby reducing GHG emissions, energy use and the environmental impact of cement production. Some SCMs such as fly ash and slag are by-products of other industrial processes, meaning that their use in cement production reduces waste and enhances resource efficiency. Moreover, the use of SCMs can enhance the properties of concrete, thereby increasing its durability and service life which helps to further reduce the overall embodied carbon of the structure.
In short, the use of SCMs contributes to reducing the carbon footprint of cement production by improving the efficiency of resource utilisation and reducing greenhouse gas (GHG) emissions during the production process. This has led to an increased demand for SCMs in the construction industry, as environmental concerns and sustainable development goals have become more prominent factors in the selection of building materials.

What strategies or innovations has your company adopted to ensure a consistent and reliable supply of SCMs, given their reliance on industrial by-products?

  • Developing partnerships with suppliers: Many cement and concrete manufacturers establish long-term partnerships with suppliers of SCMs. These partnerships provide a reliable supply of high-quality SCMs, improve supply chain efficiency, and often provide access to new sources of SCMs.
  • Advanced SCM processing techniques: Many companies are investing in advanced processing techniques to unlock new sources of high-quality SCMs. Advanced processing techniques include new separation processes, calcination techniques, and chemical activation methods.
  • Alternative SCM sources: Many companies are exploring alternative SCM sources to supplement or replace traditional SCMs. Examples include agricultural by-products such as rice hull ash or sugar cane bagasse ash, which can be used in place of fly ash.
  • Quality control measures: Strict quality control measures are necessary to ensure consistent quality of SCMs. Many companies use advanced testing methods, such as particle size analysis, chemical analysis, and performance testing, to validate the quality of SCM materials used in production.
  • Supply chain diversification: Diversifying suppliers and SCM sources is another way to ensure a reliable supply. This reduces the risk of supply chain disruptions caused by factors such as natural disasters, market changes, or geopolitical risks.

The strategies and innovations adopted to ensure a consistent and reliable supply of SCMs include establishing long-term partnerships with suppliers, investing in advanced processing techniques, exploring alternative SCM sources, implementing strict quality control measures, and diversifying supply chains. By implementing these approaches, we ensure that use of SCMs in cement production is an effective and viable solution for reducing the environmental impact of operations

How does the use of SCMs align with your company’s broader goals around circular economy and resource efficiency?
Here are some ways in which the use of SCMs supports these goals:

  • Reducing waste: The use of SCMs, such as fly ash and slag, diverts significant quantities of industrial waste from landfills, turning it into a valuable resource that can be used in construction. This helps to reduce waste and conserve natural resources.
  • Reducing carbon emissions: Cement production is a significant contributor to greenhouse gas emissions, and the use of SCMs can significantly reduce the amount of cement required in concrete mixtures. This helps to reduce the carbon footprint of construction activities and move towards a low-carbon economy.
  • Enhancing resource efficiency: The use of SCMs can reduce the demand for raw materials, energy, and water in the production of concrete. This not only conserves natural resources but also reduces the costs associated with the extraction, transportation and processing of these materials.
  • Closing the loop: SCMs encourage closed-loop systems in the construction sector, where waste materials from one process become input materials for another. This can improve the efficiency and sustainability of the construction industry.
  • Supporting sustainable design practices: The use of SCMs can support sustainable design practices by improving the durability and performance of structures while also reducing their environmental impact. This supports a circular approach to design, construction and operation of buildings and infrastructure
    that improves their social, economic and environmental sustainability.

What future trends or developments do you foresee in the use of SCMs within the cement industry?
Future trends in the use of SCMs within the cement industry are likely to focus on: increased utilisation of diverse waste-derived SCMs, development of new SCM sources to address potential shortages, advanced characterisation techniques to optimise SCM blends and data-driven approaches to predict and optimise SCM usage for reduced carbon footprint and improved concrete performance; all driven by the growing need for sustainable cement production and stricter environmental regulations.
Key aspects of this trend include:

  • Expanding SCM sources: Exploring a wider range of industrial byproducts and waste materials like recycled concrete aggregate, activated clays and certain types of industrial minerals as potential SCMs to reduce reliance on traditional sources like fly ash, which may become increasingly limited.
  • Advanced material characterisation: Utilising sophisticated techniques to better understand the chemical and physical properties of SCMs, allowing for more precise blending and optimisation of their use in cement mixtures.
  • Data-driven decision making: Implementing machine learning and big data analysis to predict the performance of different SCM combinations, allowing for real-time adjustments in cement production based on available SCM sources and desired concrete properties.
  • Focus on local sourcing: Prioritising the use of locally available SCMs to reduce transportation costs and environmental impact.
  • Development of new SCM processing techniques: Research into methods to enhance the reactivity and performance of less readily usable SCMs through processes like activation or modification.
  • Life cycle analysis (LCA) integration: Using LCA to assess the full environmental impact of different SCMs and optimise their use to minimise carbon emissions throughout the cement production process.
  • Regulatory frameworks and standards:Increased adoption of building codes and industry standards that promote the use of SCMs and set targets for reduced carbon emissions in cement production.

– Kanika Mathur

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Concrete

Sustainable Procurement Practices

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Partha Dash, Managing Director, Moglix, discusses how India’s cement industry, a key player in the country’s construction growth, is at a critical juncture as it faces the challenge of balancing expansion with sustainable practices.

According to research by construction blog Bimhow, the construction sector contributes to 23 per cent of air pollution, 50 per cent of the climatic change, 40 per cent of drinking water pollution, and 50 per cent of landfill wastes. Over the last decade cement has been one ubiquitous element in India’s construction growth story. As the world’s second-largest producer, we are seeing an impressive growth trajectory. Major players like Birla, Adani, Dalmia Bharat, JK Cement and Shree Cement are expanding fast, with plans to add 150-160 million tonnes of capacity over the next five years. This follows a substantial increase of 120 million tonnes in the past five years, pushing India’s total capacity to around 600 million tonnes. But with all this expansion, we have got a big question – How do we ensure sustainable procurement practices, in such an energy dependent industry?

Energy-intensive nature of cement production
Making cement takes a lot of energy. Process starts with limestone being mined, crushed, and grounded, using about 5-6 per cent of the total energy. The biggest energy use happens during clinker production, where around 94-95 per cent of the energy is used. Here is where limestone is heated to very high temperatures in a kiln, which needs a lot of energy from fossil fuels like coal and pet coke. Electricity is also used to run equipment like fans and kiln drives.
Once the clinker is made, it’s ground into cement. This grinding process uses another 5-6 per cent of the energy and usually happens at facilities close to where the cement is needed. Facilities that handle both clinker production and grinding in one place are generally more energy-efficient. Many of these places use coal-powered plants to supply the heat needed for the kilns, keeping production steady.

Transitioning to bulk cement
Making cement use more efficient is key to reducing the industry’s carbon footprint. In India, as per research by World Economic Forum around 75-80 per cent of cement is sold in 50kg bags to small-scale builders and individuals. But there’s often little insight into how this bagged cement is used. Research from the World Economic Forum also shows that about 40 per cent of this cement is mixed by hand. Builders sometimes use more cement than needed, thinking it will make the structure stronger, which increases emissions.
It’s crucial to educate these small-scale users about using cement efficiently. Builders need accurate information on mixing ratios and should be encouraged to adopt design techniques that use less cement. One idea suggested in the report is to put embodied carbon labels on cement bags to provide this information, helping to promote more sustainable practices at the grassroots level.
On the flip side, bulk cement, which now makes up 20-25 per cent of India’s cement use, has its own set of challenges and opportunities. Bulk cement is often used for large-scale projects that need high-strength concrete, which tends to be more carbon-intensive. However, it also makes it easier to mix in supplementary cementitious materials (SCM), which can reduce the carbon intensity of the cement. As bulk cement use grows, especially in big infrastructure projects, balancing structural needs with lower-carbon solutions will be crucial.

Challenges in sustainable procurement
The cement industry finds it hard to adopt sustainable procurement because many companies aren’t fully on board with it. Sometimes, sustainability isn’t a big focus for the company, which means top management doesn’t fully support it. This lack of support slows down collaboration with environmental experts and limits the adoption of green practices. Additionally, many clients still prefer traditional materials, which means there’s less demand for sustainable options.
In terms of knowledge and innovation, there’s a gap in understanding how to incorporate green procurement into existing practices. Many companies aren’t fully aware of the benefits of adopting green strategies or getting environmental certifications. This lack of knowledge also affects the public sector, where innovation in sustainable practices is often held back due to a shortage of technical support and experts.
There’s also a common belief that green procurement is more expensive, which can be a significant barrier, especially when resources for sustainable products are limited. Awareness and readiness for green practices are still low. Many people don’t fully understand the importance of sustainable procurement in construction, and there’s a lack of information about the market for green materials. Without adequate training and a clear structure for green purchasing, it’s difficult for companies to fully commit to sustainability. Moreover, existing policies and regulations aren’t strong enough to drive real change and without enforcement and incentives, the availability of green materials remains limited.

Opportunities in sustainable procurement
To fully understand the opportunities in sustainable procurement, Indian construction companies need to make it a key part of their business approach. This requires strong support from top leadership, including CEOs and boards of directors. When sustainability is a central focus in a company’s goals, it not only improves environmental impact but also sets the company apart in the market. Firms that focus on green practices can attract clients who value sustainability.
Working together with industry, academic institutions and government bodies is crucial for advancing green procurement. Top institutions in India like IIMs and IITs should collaborate with agencies like the Central Pollution Control Board and the Ministry of Environment. These partnerships can help develop shared goals and standards, like ISO 14000 for Environmental Management Systems, and offer training programs across the country.
It’s crucial to help clients understand how green buildings can save money over time. These sustainable structures not only cut down on running costs but also enhance the quality of life for those who live or work in them. Organisations such as the Construction Federation of India and the Builders Association of India should promote green products, which can drive demand and reduce costs by boosting production.
The government’s role is also vital. Programmes like the Pradhan Mantri Awas Yojana should focus on using green materials to show that sustainable construction can be affordable. To encourage use of sustainable materials, giving incentives like tax breaks, just like the ones for electric vehicles, could make a big difference.
Establishing a national certification for green procurement professionals, backed by organisations like the Indian Green Building Council, can help create a skilled workforce that can lead sustainable practices in the construction industry. By seizing these opportunities, India can move toward a more sustainable future in construction.

India’s leadership in sustainable cement production
India has made impressive strides in sustainable cement production. As per a research report by JMK research and analytics in 2022, the global cement industry accounted for 26.8 per cent of industrial emissions, but Indian manufacturers have been proactive in reducing their carbon footprint. The same report also states that between 2017 and 2022, the industry cut its emissions intensity by 19.4 per cent, thanks to a rise in alternative materials like fly ash and slag Blended cements, which now make up 81 per cent of India’s output, are a big part of this progress.
Leading cement producers in India, including Ultratech Cement, Shree Cement and Dalmia Cement, have committed to reducing emissions by 20 per cent by 2030, with a long-term goal of achieving net-zero emissions by 2050. Recently, the industry introduced 150 electric trucks to reduce carbon footprints, though challenges like limited charging infrastructure and high costs remain. Still, this move is expected to cut logistics expenses by 25-40 per cent. The industry is also pushing for policy support to accelerate the adoption of electric trucks and further its sustainability goals. According to report published by India Brand and Equity Foundation, some of the major investments in renewable energy and energy storage solutions include:

  • UltraTech Cement plans to deploy 500 electric trucks and 1,000 LNG/CNG vehicles by June 2025, cutting transport emissions by 680 tonnes annually. They aim to reach 85 per cent green energy use by 2030 and boost production capacity to 200 million tonnes.
  • Shree Cement completed a 6.7 MW solar project in Haryana in September 2022.
  • Dalmia Cement aims to produce 100 per cent low-carbon cement by 2031, supported by a $405 million carbon capture investment.
  • JK Cement signed an agreement with PRESPL in October 2021 to increase the use of biomass and alternative fuels, reducing reliance on coal.

Is the impossible possible?
The Indian construction and cement industries are making prudent strides toward sustainability. Recent research shows a strong link between the use of renewable energy and economic growth, highlighting the importance of reducing reliance on traditional energy sources. The construction industry, which has a large environmental impact, must adopt greener practices to help reduce pollution and waste.
The Indian cement industry is leading the way, with plans to significantly increase its use of renewable energy by 2026. This shift not only helps reduce costs but also sets a positive example for other sectors. The focus on renewable energy, like solar and wind, and efforts to avoid new thermal power plants show a clear commitment to a more sustainable future.
As the cement industry continues to push for net-zero emissions by 2050, its proactive approach is setting a new standard. These efforts not only benefit the industry itself but also provide a roadmap for others to follow. By embracing greener practices, the cement industry is helping to pave the way for more sustainable and environmentally friendly procurement practices in India.

About the author:
Partha Dash, Managing Director, Moglix, is a sales and marketing professional with 15+ years of hands-on experience in shaping businesses especially in the emerging markets.

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Concrete

The Circle of Life

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The circular economy offers a transformative approach for the cement industry, focusing on resource efficiency, waste minimisation, and sustainable practices. ICR finds out why integrating alternative materials, reducing carbon emissions and embracing innovative technologies, is crucial for the cement sector.

The circular economy is an innovative model aimed at minimising waste and maximising the use of resources by closing the loop of product life cycles through greater resource efficiency, recycling, and reusing. Unlike the traditional linear economy, which follows a ‘take-make-dispose’ pattern, the circular economy emphasises a restorative approach that seeks to maintain the value of products, materials and resources in the economy for as long as possible.
In the context of the cement industry, which is known for its resource-intensive processes and substantial environmental footprint, embracing circular economy principles is crucial. Cement production typically involves high energy consumption and generates significant greenhouse gas emissions. By adopting circular practices, the industry can reduce its reliance on virgin raw materials, lower waste and emissions and enhance overall sustainability.
The relevance of the circular economy in cement production is evident in several key areas:
• Resource efficiency: Utilising alternative and recycled materials, such as industrial by-products or waste, can significantly reduce the demand for raw materials and lower the environmental impact of cement production.
“Utilisation of alternative raw materials in the cement industry is a key strategy for enhancing sustainability and resource efficiency. Wonder Cement has substituted traditional raw materials like limestone with industrial by-products such as fly ash, marble slurry, chemical gypsum, red mud, mine telling reject, alumina slat, iron sludge, etc. Wonder Cement not only reduces its reliance on natural resources but also mitigates environmental impacts,” says Nitin Jain, Unit Head – Integrated Plant, Nimbahera, Wonder Cement.
“Low-carbon cement production is an innovative approach by Wonder Cement aimed to reduce the carbon footprint associated with traditional cement manufacturing. This process involves several strategies to minimise CO2 emissions, which are typically high due to the energy intensive nature of clinker production. The production of blended cement, Portland Pozzolana Cement (PPC) involves mixing clinker with supplementary materials like fly ash. This not only reduces CO2 emissions but also enhances the durability and performance of the cement,” he adds.

  • Waste management: Implementing strategies to manage and repurpose waste products not only helps in minimising landfill use but also creates valuable resources for reuse in cement manufacturing.
  • Energy optimisation: Circular economy practices promote energy-efficient technologies and the use of renewable energy sources, contributing to a reduction in carbon emissions associated with cement production.
  • Product lifecycle: By focusing on the entire lifecycle of cement products, from production to disposal, the industry can develop more sustainable practices and innovative solutions for recycling and reusing cement-based materials.

Adopting a circular economy approach is not only essential for reducing the environmental impact of cement production but also for driving innovation, enhancing resource security, and fostering long-term economic resilience in the industry.

Use of Alternative and Recycled Materials
The cement industry is undergoing a transformative shift with the increasing adoption of alternative and recycled materials. This shift is driven by the
need to reduce environmental impact, conserve natural resources, and enhance the sustainability of cement production.
Alternative materials: Alternative materials, such as industrial by-products and waste materials, are increasingly being used as partial replacements for traditional raw materials like clinker.

Common examples include fly ash, slag, natural pozzolans, etc.
Recycling plays a crucial role in minimising waste and promoting a circular economy within the cement industry. Key recycled materials include:

  • Recycled concrete aggregate (RCA): Reclaimed from demolished concrete structures, RCA can be used as a partial replacement for natural aggregates in new concrete, reducing the need for virgin resources.
  • Construction and demolition waste: Incorporating materials from construction and demolition activities not only diverts waste from landfills but also provides valuable resources for cement production.

The use of these alternative and recycled materials helps in reducing the environmental footprint of cement production by lowering greenhouse gas emissions, conserving natural resources, and minimising waste. Furthermore, it supports the industry’s transition towards more sustainable and circular practices, contributing to the overall goal of reducing the sector’s impact on the environment.
According to an article published by McKinsey & Company in March 2023, the cement value chain is well positioned to create closed loops, or automatically regulated systems, for carbon dioxide, materials and minerals, and energy (see sidebar ‘Three categories of circular technologies in cement’). This entails circular economies, which are based on the principles of eliminating waste and pollution, circulating products and materials, and regenerating nature. With these points in mind, circularity can work jointly with reducing carbon emissions in cement production because circular technologies follow the paradigm of three crucial decarbonisation strategies: redesign, reduce and repurpose. According to the organisation’s estimates and expected carbon prices, circularity technologies will be value-positive by 2050, with some already more profitable than today’s business-as-usual solutions.
The report estimates show that an increased adoption of circular technologies could be linked to the emergence of new financial net-value pools worth up to roughly €110 billion by 2050, providing a new growth avenue for cement players that would otherwise face shrinking demand for their core business and significant external costs. Adopting circularity is required to mitigate at least 50 percent of this value at risk. Emerging new technologies and business models will create additional value to mitigate the residual value at risk.

Reducing and Managing Industrial Waste
Efficient waste management is critical for the sustainability of the cement industry. Reducing and managing industrial waste not only minimises environmental impact but also offers opportunities to turn waste into valuable resources. Here are some key strategies of waste-to-resource initiatives:

Waste minimisation at source

  • Process optimisation: Implementing advanced technologies and practices to improve process efficiency can significantly reduce the amount of waste generated. Techniques such as precise control of raw material inputs and process conditions help minimise production losses.
  • Cleaner production techniques: Adopting cleaner production methods, such as the use of less polluting raw materials and more efficient equipment, can reduce waste generation at the source.

Recycling and reuse

  • Alternative fuels: Industrial waste, such as tire-derived fuel or biomass, can be used as alternative fuels in cement kilns. This not only helps in reducing the consumption of traditional fossil fuels but also diverts waste from landfills.
  • By-product utilisation: By-products from other industries, such as fly ash or slag, can be integrated into cement production processes. These materials not only enhance the properties of the final product but also reduce the need for virgin raw materials.

Nitin Sharma, CEO and General Manager, Clariant IGL Specialty Chemicals (CISC), says, “As our climate gives us increasing and alarming signals of change, individuals and industries are looking for ways to reduce their environmental footprints, and the demand for bio-based chemicals is set to grow strongly in the coming years. In several applications, the use of petrochemicals and fossil carbon remains a significant issue. The transition to bio-based carbon chemistry represents a significant challenge for manufacturers.”

Waste-to-resource initiatives

  • Recycled concrete aggregate (RCA): Demolished concrete can be crushed and recycled into aggregate for use in new concrete mixes. This reduces the demand for natural aggregates and decreases the volume of construction waste.
  • Co-processing of waste: The cement industry is increasingly adopting co-processing techniques where various types of industrial and municipal waste are processed in cement kilns. This approach helps in recovering energy and material value from waste streams while simultaneously treating hazardous materials.
  • Zero-waste initiatives: Some cement plants are aiming for zero-waste targets by implementing comprehensive waste management systems that ensure all waste is either recycled, reused or recovered.

Partha Dash, Managing Director, Moglix, says, “There’s also a common belief that green procurement is more expensive, which can be a significant barrier, especially when resources for sustainable products are limited. Awareness and readiness for green practices are still low. Many people don’t fully understand the importance of sustainable procurement in construction, and there’s a lack of information about the market for green materials. Without adequate training and a clear structure for green purchasing, it’s difficult for companies to fully commit to sustainability. Moreover, existing policies and regulations aren’t strong enough to drive real change, and without enforcement and incentives, the availability of green materials remains limited.”
These strategies and initiatives reflect a growing commitment to sustainability within the cement industry. By effectively managing and repurposing industrial waste, cement producers can not only reduce their environmental impact but also contribute to a more circular and resource-efficient economy.
According to the report Indian Cement Industry: A Key Player in the Circular Economy of India published July 2020, the Indian cement industry is playing a key role by enhancing the application of renewable energy for electrical power generation. The renewable energy installed capacity (wind and solar) in cement plants increased by more than 40 per cent to 276 MW from 2010 to 2017. Out of the total, 42 MW is solar power, while off-site wind installations account for 234 MW. A company has undertaken the target of switching over to renewable energy for 100 per cent of all electrical energy needs by 2030. Big players like UltraTech Cement are targeting 25 per cent share of their total power consumption by green energy technologies.
Apart from the solar photovoltaic route, the cement industry is making efforts to tap solar energy through thermal routes.

Government initiatives
The Indian government is actively promoting circular economy principles through various policies and regulations aimed at enhancing sustainability and resource efficiency. The National Clean Energy Fund (NCEF) supports innovative projects in energy efficiency and emission reduction, including those incorporating circular economy practices.
The Swachh Bharat Mission (SBM) and Solid Waste Management Rules, 2016, focus on improving waste management and recycling, encouraging the use of recycled materials in construction and cement production. The Plastic Waste Management Rules, 2016, emphasise recycling and the use of recycled plastic, including as alternative fuel in cement kilns. The National Resource Efficiency Policy (NREP) promotes resource efficiency across sectors, including cement, and the government’s clean technology schemes incentivise the adoption of green technologies.
Additionally, the draft National Circular Economy Policy, currently in development, aims to provide a comprehensive framework for advancing circular economy practices across all industries. These initiatives collectively support the transition towards more sustainable and circular practices in the cement sector.

Emerging trends in circular economy
The cement industry is witnessing several emerging trends in circular economy practices, reflecting a shift towards greater sustainability and resource efficiency. One notable trend is the increased use of alternative fuels and raw materials. Cement producers are exploring the use of industrial and municipal waste, such as tires, plastics, and biomass, to replace traditional fossil fuels and raw materials, reducing their carbon footprint and conserving natural resources.
Another significant trend is the advancement of circular product design and lifecycle management. Cement companies are focusing on designing products that are easier to recycle or reuse at the end of their lifecycle. This includes developing new types of cement and concrete with enhanced durability
and recyclability.
Waste-to-resource initiatives are also gaining traction. Innovations in waste processing technologies enable the conversion of waste materials into valuable resources for cement production, such as incorporating recycled concrete aggregate (RCA) and by-products like fly ash and slag into new cement products.
Digitalisation and data analytics are emerging as crucial tools in advancing circular economy practices. Advanced monitoring and analytics technologies help optimise resource use, track waste streams, and improve overall efficiency in cement production.
Finally, there is a growing emphasis on collaborative partnerships. Cement companies are increasingly collaborating with governments, NGOs, and other industries to drive circular economy initiatives and develop innovative solutions for sustainable development. These trends highlight a transformative shift towards a more circular and sustainable approach in the cement industry, aligning with global efforts to reduce environmental impact and promote resource efficiency.

Conclusion
The adoption of circular economy principles in the cement industry is proving to be a pivotal step towards enhancing sustainability and reducing environmental impact. By embracing alternative and recycled materials, the industry is reducing its reliance on virgin resources and minimising waste. Government policies, such as the National Clean Energy Fund and Solid Waste Management Rules, provide crucial support for these practices, fostering a regulatory environment conducive to circular economy initiatives. Emerging trends, including the use of alternative fuels, circular product design, waste-to-resource innovations, and advanced digital technologies, underscore the industry’s commitment to resource efficiency and sustainability. Collaborative efforts across sectors further drive these advancements, paving the way for a more resilient and environmentally responsible cement industry. As the sector continues to integrate circular economy principles, it not only aligns with global sustainability goals but also sets a benchmark for other industries striving for a circular future.

– Kanika Mathur

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