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Finer the fly ash or slag, more value it commands

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– Bhalchandra Shrikhande, a freelance consultant, speaks on split grinding cement units.

What is your opinion on the ease-of-doing business?
There is lot of hype on "ease-of-doing business", but very little has happened in reality at the ground level. The percolation of progressive policies framed at the macro level to promote fast growth in business and manufacturing are yet to make a difference at the working level. The reasons of this are many.

A few among them are lack of clarity in executing the new policies, non-removal of some old and redundant rules and regulations, insistence to go by the letter, and not the spirit of the rules/regulations, sense of apathy among the government officers due to the fact that doing nothing attracts no penalty, but doing something, albeit with good intention, and not getting the desired result does attract enquiry, audits and penalties. There is no compulsion on the decision-making authorities to take appropriate decisions within a reasonable time frame, and to avoid duplicity of efforts in seeking approvals. Let us all hope that sooner or later ease-of-doing business becomes a reality.

What is your assessment of a business model of split grinding cement unit? What are the critical success parameters?
In the beginning, let us look at the parameters of success of a standalone split grinding cement unit. If we evaluate the parameters along with an integrated cement plant, the picture will not be clear. The success of a split grinding cement unit should be measured by the capacity utilisation and the EBIDTA margin of the unit. While working out the manufacturing cost; one should be judicious enough to consider the market prices of all inputs. Special attention needs to be given to the transfer price of clinker from the integrated plant to the grinding unit. It should be close to the real price of clinker in the market. The cornerstones of successful business grinding unit are:

Volume addition is an essential factor in achieving a reasonably good standalone EBIDTA in split grinding cement units. This depends on the percentage addition of mineral components (MiC) like fly ash or slag at the split unit. It is thus very beneficial to have the location of split unit near the source of MiC, i.e. power plant or steel plant. Such a location also helps to get power generated by the power/steel plant at the split unit reliably and cheaply.

Nearness to market having high potential of growth is another important factor concerning location. This results in the "last mile connectivity" to the end consumer and substantial logistics cost saving as well.

Can more of bulk cement (loose cement despatched in bulkers) be a better option for split grinding cement unit along with a smaller proportion of bagged cement?
In today’s world, the operating strategies must keep the customer at the focal point. Customers have different requirements at different times. E.g.: when a construction project is nearing completion, the customer may need more of masonry cement or readymade dry plaster or blended cement of lower grade for flooring/ tiling applications, that too in bags. When concreting job is in progress, he will need cement (OPC) of higher grades in bulkers. Therefore, the grinding unit must be able to cater to all the requirements of the customers. No split grinding plant can survive on bulk cement supply alone. Generally bulk cement goes to large infrastructure and residential projects, and RMC plants. These locations have dedicated batching plants at site. Small retail end users however prefer cement in bags. For packing the cement of different grades in bags, you need to have a packing plant with more number of cement storage silos. For supply of cement in bulk, you need to have arrangements for accommodating different types of bulkers directly under the silos and loading arrangements. Therefore, in order to be successful, you will need all the flexibility in the grinding unit.

The last mile connectivity also eliminates need to have warehouses, reduces double handling and transportation to the point of consumption, on-time delivery, and better quality perception in the mind of the customers.

Logistic seems to be a big challenge for split grinding plants, please comment. Inward and outward movement of materials being critical, how important it becomes to monitor and manage logistics?
Yes, logistics is a considerable challenge and an important cost component especially when you are sourcing clinker as a vendor. Incoming material logistics is essentially a bulk movement either by a rail or a ship. Clinker is moved by railway wagons and directly unloaded by wagon tippler inside the plant. The outgoing movement of cement by rail is desirable but not always feasible. You however need to have good road connectivity for cement evacuation. Export-oriented cement units are required to be located at ports near sea to facilitate direct loading of ships/barges.

Should split grinding cement units be automated by using modern technology in a better way than normal cement plants?
As a corollary to my earlier statement, I would add that to meet challenging customer requirements, like quick delivery and better quality assurance, usage of modern technology is the need of the hour. IoT (Internet of Things) has been successfully used by some cement grinding units for despatch of cement. Today transporters are given smart cards where the entire data of sales order is stored. This results in faster turnaround time of a truck/trailer/bulker. Ready availability of different grades of cement simultaneously meets diverse customer needs. Flexible plant design can operate fast only if equipped with good automation. At short notice you have to shift from one to the other product, different quantities, and different packaging and this can be managed by IoT. Having weighbridges under the loading spouts, auto loading spouts, automatic bag placers, auto pelletizers and loaders, CCTV monitoring of operations etc. help in managing complex tasks easily. Dependence on labour is not only unreliable and costly, but can also lead to delays.

Throw some light on the power scenario of such grinding unit?
For a given split cement grinding unit, power requirement is generally of the order of 8 to 12 MW depending on the size of the unit. In majority of cases power is drawn from the adjoining thermal power plant. If there is steel plant, power can be tapped from the steel plant CPP. In most of the cases it is B2B type of transaction. The practical way is to route it through HT cables. Grid power is unreliable, but given the nature of the grinding unit, this can be managed. However, installing a captive power plant, which is based on multiple DG sets, is ruled out because of high cost. My suggestion is rules should be simplified to draw power from wherever it is convenient and simple.

Most of the split grinding plants are located close to sea or river for easy water way transportation is it correct?
Considering that a very small quantity of cement today is getting exported, in the present situation location near to a port hardly matters. But waterways transport by rivers is an interesting option, which needs to be explored. Water transport eases load on the roads, reduces pollution and is more cost effective.

Is it possible for a grinding plant to invest money in improving the quality of blended materials like fly ash or slag? What has been the practice?
It is very much essential to pre-process the fly ash or slag. Quality of fly ash differs in properties with its particle size distribution. Generally for processing of fly ash, mechanical air classifiers are deployed. Finer the fly ash or slag, more reactive it is, and more value it commands. Superfine fly ash/slag can be directly added to concrete to produce high-performance concrete (HPC). Medium grade fly ash/ground granulated blast-furnace slag (GGBS) can be used to manufacture common grades of concrete. Coarse fly ash can be used in the spilt grinding unit to be co-ground with clinker. In case of blast furnace slag, the problem is getting slag lumps that need to be separated. The extent of addition of fly ash/slag component in cement depends on its quality. With better quality of fly ash or slag, more proportion can be added in cement (within what is prescribed by Bureau of Indian Standards (BIS) and the profitability of the grinding unit will be better.

Do you suggest any better tax structure to make grinding units viable?
Today cement attracts GST at 28 per cent, which is in the highest bracket. Being a basic commodity of construction and infrastructure, the tax component is certainly on the higher side. If the overall industry gets a relief of lower tax rate, then the grinding units also will get the benefit.

Bhalchandra Shrikhande graduated from IIT, Bombay
in Chemical Engineering, and joined ACC Ltd in 1980. After working in ACC for 31 years, he then joined the Indiabulls (now, Rattan India) Group as President – Operations in 2011. At present, Shrikhande is working as a freelance consultant. The businesses in which he has worked are cement and ready-mix concrete.

The functional areas in which he has worked are R&D, process engineering and development, production, strategy/business planning, project execution and management, project engineering and design, management audits, consultancy assignments, organisational development and training.

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Economy & Market

RAHSTA Roundtable Sets Agenda for Smarter, Safer Highways

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Roundtable discussions focus on innovation for safer highways.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the RAHSTA Roundtable brought together stakeholders from across the highways and infrastructure ecosystem to shape the agenda for the 16th RAHSTA 2026, scheduled for 8–9 July 2026 at the Jio Convention Centre, Mumbai. The session focused on key industry themes including road construction, technology, safety and long-term sustainability.

Opening the discussion, Pratap Padode, Founder, FIRST Construction Council, said the roundtable marked the beginning of a broader consultative process leading up to the July event. The aim, he noted, is to bring together industry stakeholders to refine the agenda for discussions on the future of roads, bridges, tunnels and allied infrastructure.

Padode noted that while central road project awards have slowed in recent years, states are increasingly driving the next phase of infrastructure growth. Maharashtra, with its long-term road development plans and agencies such as MSRDC and MSIDC, is expected to play a significant role in this expansion.

RAHSTA Expo 2026 as a specialised platform dedicated to road infrastructure, covering highways, tunnels, bridges and flyovers along with construction technologies, safety systems and maintenance solutions. He also highlighted the growing importance of rural connectivity and said the organisers are engaging with government bodies to highlight rural road development initiatives.

Tanveer Padode, CIO, ASAPP Info Group, presented insights from IMPACCT, the group’s infrastructure intelligence platform. He pointed to a strong project pipeline despite slower highway awards earlier in the year, noting that states such as Maharashtra, Odisha and Arunachal Pradesh are emerging as key drivers of new projects. The data also revealed that only a small group of contractors participates in large-value infrastructure bids.

Lt Gen Rajeev Chaudhary, former Director General, Border Roads Organisation and Chairman of the RAHSTA Expo Committee, emphasised the need for stronger collaboration across the ecosystem, including policymakers, contractors, technology providers and financiers. He also called for addressing systemic issues within the sector and encouraged greater participation of women in infrastructure leadership.

The discussion also explored the evolving economics of road development. Phani Prasad Mandalaparthy, Associate Director, CRISIL Intelligence, noted that the slowdown in project awards reflects a shift towards higher-value logistics corridors rather than simple road widening projects. However, private participation through BOT and TOT models remains limited.

From the contractors’ perspective, Sudhir Hoshing, Whole-Time Director, Ceigall, said companies are becoming more selective in bidding, favouring projects with clearer payment mechanisms and efficient processes. While NHAI continues to offer greater operational clarity, states such as Uttar Pradesh and Bihar were cited as relatively supportive environments for project execution.

Durability and sustainability also emerged as key themes. Himanshu Agarwal, COO – Road & Infrastructure, Zydex Group India, highlighted the need to prioritise lifecycle performance and resilient pavements, while participants discussed the potential of alternative materials such as plastic waste, steel slag and industrial by-products in road construction.

Dr LR Manjunatha, Vice President, JSW Cement, emphasised that India has abundant fly ash, slag and other industrial materials that can improve durability and sustainability if integrated into specifications and policy frameworks.

Technology and equipment challenges were also discussed. Dr Lakshmana Rao Mantri, Dy General Manager, Afcons Infrastructure, highlighted the shortage of tunnel boring machines (TBMs), which is delaying several underground infrastructure projects. Participants agreed that developing domestic TBM manufacturing capabilities will be critical for future infrastructure expansion.

The future of concrete pavements was another area of discussion. Dr V Ramachandra, President, Indian Concrete Institute, stressed that the debate should focus on lifecycle performance rather than material choice alone, noting that evolving design standards are improving the feasibility of concrete roads.

Prof Dharamveer Singh of IIT Bombay added that while India has made significant progress in infrastructure development, stronger capacity building and better execution practices are essential to ensure consistent road quality.

The discussion also touched upon technology adoption in the sector. Rushabh Mamania, Partner & CBO, Roadvision, highlighted the growing role of AI in road infrastructure, noting that AI-driven monitoring systems are already being deployed across large stretches of national highways.

Overall, the roundtable underscored that the future of highway infrastructure will depend not only on the pace of construction but also on durability, safety, technology integration and sustainable materials. The discussions offered valuable insights that will help shape the agenda for RAHSTA 2026 and guide future collaboration within the industry.

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Economy & Market

CTS Roundtable Charts Tech-Led Roadmap for Construction

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CTS Roundtable Maps Technology Roadmap for Construction

Ahead of the Construction Technology Show (Con Tech Show) 2026, industry leaders, technology innovators and academia came together in Mumbai to deliberate on how digitalisation, automation and industrialised construction can reshape the sector. The discussion made one thing clear: construction can no longer afford to treat technology as optional.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the CTS Roundtable served as a precursor to the Construction Technology Show 2026, scheduled for 19–20 August 2026 at NESCO, Mumbai.

A platform to move from discussion to deployment

Opening the session, Pratap Padode, Founder and Editor-in-Chief, ASAPP Info Global Group, said construction technology has long remained close to his heart, especially given the sector’s traditionally slow pace of technology adoption. He noted that over the years, the Construction Technology Summit had steadily built interest, and the next step was now to expand it into a larger, more meaningful platform that could bring together technology providers, users, startups and innovators under one roof.

Padode said the vision for CTS is not limited to software alone. The platform aims to embrace all forms of technology that can improve construction efficiency, quality and execution—from digital tools and project management systems to lean construction, off-site fabrication and startup-led innovation. He also highlighted plans to deepen startup participation and create space for young companies to showcase emerging construction solutions.

Industry at a turning point

Moderating the roundtable, Naushad Panjwani, Chairman, Mandarus Partners, set the context by pointing out that the global construction industry, despite being a multi-trillion-dollar sector, continues to lag in productivity. He noted that while manufacturing has consistently improved efficiency, construction has remained slow to modernise.

Referring to both global and Indian trends, Panjwani underlined that the industry is now at a decisive moment. India, he said, is entering a major build cycle, and delivering the next phase of infrastructure and real estate growth through traditional methods alone is no longer viable. The goal of the roundtable, therefore, was not to debate technology in isolation, but to identify the most critical conversations that would bridge the gap between innovation and implementation.

His central message was clear: CTS 2026 must be shaped around themes that make CEOs, CIOs and CTOs feel they cannot afford to miss the event.

From BIM to AI, data to governance

A major theme that emerged through the discussion was the need for better data, better visibility and better decision-making. Dr Venkata Santosh Kumar of IIT Bombay echoed this, saying that the underlying data infrastructure itself needs attention. Construction projects, particularly remote ones, often face issues around connectivity, data collection and data use. Without this foundation, more advanced technologies cannot deliver their full value.

Chandra Vasireddy, CEO & Co-founder, Inncircles, expanded the discussion to governance, arguing that technology must help connect the many moving parts of a construction business. For him, the real value of digital transformation lies in creating better governance, clearer visibility and stronger business outcomes.

Tejas Vara of Inncircles stressed the importance of timely site data for leadership teams, especially in large and remote projects where decisions on materials, machinery and manpower often get delayed because information does not reach headquarters in time.

The role of AI also featured prominently. Rushabh Mamania, Partner and CBO, Roadvision said that while AI and machine learning are now common terms, vision intelligence and language intelligence have still not deeply penetrated the construction sector. He emphasised that startups in India are building relevant AI-led solutions and are already attracting international interest, showing that innovation need not be imported—it can be built locally and scaled globally.

Industrialised construction gains ground

The roundtable also placed strong emphasis on industrialised construction methods. Kalyan Vaidyanathan, CTO – Construction & R&D, Tvasta, called for greater focus on off-site fabrication and the broader industrialisation of construction. Bhargav Jog, General Manager, Dextra, highlighted precast technology and alternative sustainable materials as areas with immediate relevance.

Several participants agreed that modular, precast and pre-engineered approaches are no longer niche ideas. They are increasingly becoming practical responses to the sector’s challenges around labour shortage, timelines, quality control and predictability.

Anup Mathew, Sr VP & Business Head, Godrej, argued that the industry needs a fully integrated approach—from design and procurement to execution and asset management. Unless these are connected, technology adoption will remain fragmented and sub-optimal. He pointed to pre-engineered and modular systems as examples of how industrial thinking can compress timelines, improve quality and reduce dependence on difficult on-site conditions.

Adoption remains the biggest hurdle

While there was broad agreement on the promise of technology, the discussion repeatedly returned to one fundamental challenge: adoption.

Abhishek Kumar, COO, LivSYT, observed that the market is crowded with solutions, but many buyers still struggle to evaluate which technology suits which use case. According to him, the industry needs clearer frameworks to help users select, compare and adopt solutions, rather than expecting a single platform to solve every problem.

Dr Tenepalli JaiSai, Associate Professor, School of Construction(SoC), NICMAR University, noted that isolated technologies will not solve the productivity problem by themselves. What is required is an integrated Construction 4.0 approach, where digital, physical and cyber-physical systems work together rather than in silos.

That concern around silos was reinforced by Subodh Dixit, former Director, Shapoorji Pallonji, who said the issue is not just that technologies are disconnected, but that stakeholders are as well. Clients, consultants, contractors and partners often operate with different priorities. Unless these silos are broken, technology will struggle to percolate across the full project value chain.

Harleen Oberoi, Project Management, Tata Realty shared a practical perspective from the client side, saying that successful BIM implementation requires investment across the ecosystem, not just within one organisation. Trade partners, vendors and other stakeholders must also be trained and aligned if the technology is to deliver its intended results.

Beyond buzzwords

A notable takeaway from the session was that the industry is moving past the phase of treating technology as a buzzword. Participants repeatedly stressed that the real question is not whether technology should be used, but where it creates measurable value and how that value can be scaled.

The conversation also expanded beyond mainstream themes to include repairs and rehabilitation, construction and demolition waste, sustainability, circular economy, green sourcing, carbon measurement, design interoperability, generative design, robotics, and the role of horticulture and greener built environments.

Setting the agenda for CTS 2026

By the close of the session, the roundtable had surfaced a strong set of themes for the upcoming show: BIM and digital twins, AI and data platforms, industrialised construction, startup innovation, governance-led technology adoption, robotics, sustainable materials, and integrated project delivery.

More importantly, the session established CTS 2026 as more than an exhibition. It is shaping up to be a serious industry platform where users, technology providers, researchers and policymakers can collectively define the future of construction.

As Padode noted in his closing remarks, the conversation will continue through further consultations and possibly webinars in the run-up to the show. If the roundtable is any indication, CTS 2026 will aim not merely to showcase technology, but to push the industry towards meaningful adoption at scale.

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Concrete

Human Factor in Grinding Optimisation

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Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, discusses the role of skilled operators as the decisive link between advanced additives, digital control and world-class mill performance.

The industry always tries to reduce the number of operators in the Centre Control Room. (CCR) Though the concept was succeeded to certain extent, still we need a skilled person in the CCR.
In an era where artificial intelligence (AI) grinding aids, performance enhancers, and digital optimisation tools are becoming increasingly sophisticated, it’s tempting to believe that chemistry alone can solve the challenges of mill efficiency. Yet plants that consistently outperform their peers share one common trait: highly skilled operators who understand the mill as a living system, not just a machine.
Additives can improve flowability, reduce agglomeration, and enhance separator efficiency, but they cannot replace the nuanced judgement that comes from experience. Grinding is a dynamic process influenced by raw material variability, moisture, liner wear, ball charge distribution, ventilation, and separator loading. No additive can fully compensate for poor control of these fundamentals.

Operators see what additives cannot
When I joined the cement industry in 1981, not much modernisation was available then. Mostly the equipment was run from the local panel. Once I was visiting the cement mills section. The cement mills were water sprayed over the shell to reduce the temperature to avoid the gypsum disintegration.
The operator stopped the feeding for one of the mills. When I asked the reason, he replied that mill was getting jammed, and he added that he could understand the mill condition by its sound. I also learned that and it was useful throughout my career. In another plant I saw the ‘Electronic Ear,’ which checked the sound of the mill and the signal was looped with feed control!
Whatever modernisation we achieve, it is from the human factor that the development starts.
Additives respond to conditions; operators interpret them.
A skilled operator can detect subtle shifts, like a change in mill sound, a slight variation in circulating load, or a drift in separator cut point. It’s long before instrumentation flags a problem. These micro-observations often prevent major efficiency losses.
Additives work best when the process is stable
I would like to share one real time incident. The mill was running on auto mode looped with the mill outlet bucket elevator kilowatt. (KW)There was a decrease in the KW, and the mill feed was increased by the auto control (PID). After a while, the operator stopped both the feed and the mill. He asked the local operator to check the airslide between mill outlet and the elevator. They found the airslide was jammed and no material flow to the elevator!
The operator deduced the abnormality by his experience by seeing the conditions and the rate of increase of the feed by the auto control.
It’s always the human factor that adds value to the optimisation.

Grinding aids are multipliers,
not magicians.
They deliver maximum benefit only when:
• Mill ventilation is correct
• Ball charge is balanced
• Feed moisture is controlled
• Separator speed and loading are improved
• Blaine targets are realistic
Without these fundamentals, even advanced additives may become costly investments. The operator is responsible for ensuring process stability, whether using a ball mill or a vertical mill. After ensuring the system is stable, the operator observes it briefly before transitioning to automatic control. If there is any anomaly in the system the operator at once takes control of the system, stabilises and bring back to auto control.

Skilled operators adapt in real time
It will be interesting to note that the operators who operate from local panel start to operate from DCS also. They have the experience and the ability to adapt the changes. Operator checks each parameter deeply. Any meagre change in the parameters is also visible to him.
Raw materials change. Weather changes. Wear patterns change.
A skilled operator adjusts:
• Feed rate
• Water injection
• Separator speed
• Grinding pressure (in VRMs)
• Mill load distribution.
These adjustments require intuition built from years of experience, something no additive can replicate.

Human insight prevents over reliance on additives
Plants sometimes increase additive dosage to mask deeper issues like:
• Poor clinker quality
• Inadequate drying capacity
• Incorrect ball gradation
• High residue due to worn separator internals.


A knowledgeable operator finds root causes instead of chasing temporary chemical fixes.
The real optimisation sweet spot is reached when:
• Operators understand how additives interact with their specific mill.
• Additive suppliers collaborate with plant teams.
• Process data is interpreted by humans who know the mill’s behaviour.
This constructive collaboration consistently delivers:
• Lower kWh/t
• Higher throughput
• Better product consistency
• Optimum standard deviation.

Advanced additives are powerful tools, but they are not substitutes for human ability. Grinding optimisation is ultimately a human driven discipline, where skilled operators make the difference between average performance and world class efficiency. Additives enhance the process but operators
control it.

About the author:
Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, is a seasoned cement process consultant with 43+ years of global experience in plant operations, process optimisation, refractory management, safety systems and training multicultural teams across international cement plants.

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