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A step into the future, today

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Interaction withPramesh Arya, Executive Director, Marketing, Dalmia Cement Bharat Ltd.

The lockdown announced by the Government to respond to the threat of a pandemic was a once in lifetime experience for India as a country. The Cement industry, taking cautious steps, responded to it using new age digital technologies. Here is a real story from Dalmia Cement, through an interview with Pramesh Arya, Executive Director- Marketing.

Vikas: When you restarted operations in April after the first phase of lockdown, what were the challenges you had to overcome and how did you manage?
Pramesh:
On the manufacturing front, as you can imagine, there was an issue of getting manpower because like many other industries, we work with a significant number of contractual workers, who had started migrating by then. That became one challenge to start full scale operations.

Another challenge was on the logistics side. The underlying reasons are all the same but manifested differently in different areas. The trucks were available but drivers weren’t around. Then, while our transportation partners were willing to work with us, there was the issue of inter-state movement of materials. In certain areas, local people were trying to deny entry to everyone, not just trucks carrying cement but everyone who was an outsider. There was this apprehension, that we don’t want any risk of infection even if it is with good intent of ensuring our world keeps running. Similarly, in our warehousing and Godown operations, there were manpower issues.

Fortunately, our close relationship with our vendors and contractors helped us get priority treatment from them within the limitations that existed. It’s at times like these, when your relationship with your vendors and suppliers and contractors gets tested. It’s heartening to say we, together with our entire network of partners, were able to resolve most, if not all challenges that came our way on a day to day basis.

For our sales and Technical Services teams, movement in the market was obviously restricted. We quickly moved to a virtual connect program right from the beginning of the lockdown, and it is still in action today. Wherever a little bit of on-ground connect is possible locally – within the markets that were in green zones, our teams are in the field to work with our dealers while taking all precautions – masks, social distancing etc.

Vikas: – Were you able to foresee these issues, during February-March, or did they come as a shock?
Pramesh:
– From the end of February but surely early March onwards, the signs were there- there were news reports from across the globe, on the way it has evolved in most countries. Everybody had this hope that India will escape mostly unscathed, like we did during H1N1. At the same time, there was always this likelihood we may have the same kind of scaling up of infections like in most countries. As a company, we wanted to ensure our business continuity plans were in place, and we started activating them at appropriate intervals.

Fortunately, Dalmia Cement has been on a major digital transformation journey across the company for the past few years – in many cases, before our industry itself started moving in this direction. During the lockdown, this preparation over the years helped tremendously.

Vikas: – How did you take care of the dealers because there must have been materials stuck either en route, or at your plants in silos or maybe in your warehouses? How was it taken care of, to protect everybody’s interests? Payments and cash flow must have become issues as well. So, how was this situation being handled?
Pramesh: –
On stock movement, we followed government guidelines, and for the first few days, our network quietened down. As and when local conditions changed, we took actions that met both business and safety needs. On the stock in the market, given the fast movement of cement across the network, dealers in this industry keep limited stocks in terms of inventory. In rural areas, beyond the first few days, as it was clear that Covid19 wasn’t present, markets picked up even as the lockdown was in effect, with construction work resuming. In May, even government projects resumed work- they had to complete certain jobs before the monsoons, including important local municipal projects etc. So whatever stock the dealers were holding got liquidated quickly, and we had fresh demand from dealers. How we overcame this was that we did most of our sales and supplies directly to the sites. We switched more or less to 100 percent direct delivery. Even the dealer community appreciated that being done from the company’s side. For challenges such as these, our strong technology and logistics backbone helped.

On the collection side, yes, there was a challenge. As a company, we practice healthy fiscal practices, keeping both our and dealers’ interest in mind, and there isn’t a lot of credit floating in the market at any time. During the lockdown, unique challenges emerged. Dealers in small towns wanted to make payments, but there was no one to collect the cheque. In smaller towns, it’s still not all digital, and we worked on logistics on how to get the cheque sent to the bank. Again, as a company we have worked hard on ensuring digital payment adoption is at a high level, so these challenges were far and few between.

Vikas: – We have been hearing a lot about the social responsibility work executed by Dalmia Bharat Group in such kinds of situations and particularly, taking care of your stakeholders. Will you be able to say something on that? Pramesh: – The Dalmia Bharat Group has always been into nation building. We actively partner towards such issues at the national to the grassroots levels. As an organization, we contributed Rs. 25 crores to the PM-CARES Fund. Our employees also generously raised over Rs. 1.6 crores through one-day salary donations. Separately, in many different states, we contributed to CM funds; and donations to selected non-government organisations which were working at the grassroots were also enabled.

While we supported governments, it was important our stakeholders could rely on us for help. Our technical services teams quickly moved to identify groups or communities of labour who were stranded, because the lockdown came suddenly. Across the country, we put together supply chains to help them with rations and other needed items. Where construction was still on, we worked on matching available manpower with active sites. This was done at a micro level, matching projects and labours at say, the taluka level in every state we are present in. And almost every single officer has such wonderful stories to tell.

We quickly moved to engage the contractors’ community on Do’s and Don’ts at construction sites through Whatsapp. We organized webinars with doctors from chosen local hospitals so they could ask all that question about Covid19, including for dealers and their families.

For our dealers, we launched a program called ‘Dalmia Cares: Stay Home Stay Safe’ – we rolled out over 20 different activities over the course of the lockdown. Every other day, we had different activities to keep them engaged and entertained, to keep them in a positive spirit, including their family members.

Vikas: So, this was done digitally?
Pramesh:
Wherever it was possible, fully digitally. For dealers, we run a platform called Dalmia Delight, which is used for loyalty and recognition programs. For all our other communities, our teams were in touch using Phone, Whatsapp and on ground help as it was required, keeping social distancing norms in mind.

Vikas: We will now come to the brand. When we talk of Dalmia, the mother brand- how do you look at building Dalmia as a brand and what are the attributes of the brand you feel people would like to remember it for?

Pramesh: As a brand, we have a legacy of 80 years. People around the country have placed their trust in us over generations. Last year, we built on this legacy, and launched a new brand positioning and identity, which positions the mother brand as Dalmia Cement ‘Future Today’.

As a brand, we are innovators and pioneers while being focussed on sustainability. Throughout the history of our organisation, we have been first to market with multiple products – we were the first company to launch oil well cement, railway sleeper cement and fast setting air strip cement.

As a company, our roots in sustainability are very deep. The CBP recognizes us as the world’s greenest cement company. Our CEO and MD, Mr. Mahendra Singhi, is a strong advocate of sustainability. He has represented India and our company on various global forums, including WEF, the global climate summit among others. And all this R&D, product launches have been possible only through technology.

As a brand, we want consumers to remember us for building next generation cement products; offering best in class, technology led service experience, and being able to choose the ‘greenest’ cement they can buy to build a home for life.

Vikas: – When we talk about the brand, even the packaging of cement becomes very important. The industry has been launching new packaging constantly. What’s your take on that?
Pramesh:
Packaging has a functional role and a branding role. We launched BOPP packaging for our premium product, Dalmia DSP, many years ago, which is moisture resistant, tear resistant and improves the performance of the product because it keeps cement fresh for longer.

I think the important part in packaging, talking about going beyond, is the performance of packaging. So there what matters is the consistency of quality, your entire vendor network, the flexibility and stability of supplies. So that’s another strength we have, we are able to ensure that all the plants get the right amount of packaging with the right quality all the time. Because as a brand, you get tested with every bag in the market, if a bag tears, the brand takes the damage. So, it’s important to sustain that quality day after day, batch after batch and in every location.

We are always on the lookout for modern packaging techniques and engage with packaging companies around the world to find best in class alternatives for consumers.

Vikas: In the retail market in fact packaging becomes very important- it should appeal to a buyer otherwise cement as such is a mundane and routine product.

Pramesh: – While cement has traditionally been a low involvement product, today, not just in cement but across all categories in that context, it’s an opportunity. If we go back to the narrative we are presenting with Dalmia Cement Future Today, we have given a completely new identity to the bag with the same thinking – in this category, the bag is your first manifestation of the brand identity and a big one.

Our new bags are very vibrant looking, with standard colour codes and a focus on enticing the customer. When our bag is displayed at the dealers’ counter, we want it to inspire confidence in the consumer from the get-go.

Vikas: What can be done to improve the per capita consumption of cement in the country? If you compare to other countries, we’re at very, very lowest stage, ~250 kgs per capita?
Pramesh: Cement consumption is governed by two things, the housing sector and infrastructure. Being a rapidly developing country, we have a long way to go on both. Across the country in our villages, there is a lot of conversion happening from kuccha to pukka houses. We are also seeing increases in the average size of the dwellings and basic penetration of housing itself. The government is doing a lot with the PM Awaas Yojana among other programs. At the same time, at the upper end, in terms of multi-story apartment complexes, it is a long way to go. The main challenges we need to resolve are access to adequate land banks, further roll out of affordable housing, and a sustainable real estate industry based on global norms.

Vikas: Like other cement companies, Dalmia Cement has been associated with cricket. For every major event in the cricketing world, many cement companies associate with them for promotions. In what way does it really help in brand building?
Pramesh: –
As a brand, we want to be present in meaningful ways where our consumers are. It’s a good medium for us to reach the consumer in a format which they enjoy. And secondly, it allows for high reach, high frequency, and high engagement – all goals we solve for while planning our media strategy.

In our case, we don’t simply buy airtime – we create properties and partnerships. In the last few years, we have associated with major ICC tournaments and Team India’s away tours. Each of these associations, we have created a full-fledged property – on ground presence, dealer campaigns and tours and digital promotions.

Vikas: – Any other message from your side to the audience and readers?
Pramesh:
There are two things I’d like to express. One, strong, strategic investments in digitisation across all parts of the business, and an increases focus on digital marketing. In general, it is true for any industry that digital is here to stay and with Covid19, it’s only getting stronger.

During the lockdown, we have already worked out a virtual PJP, which is a virtual market visit and contact program for our Sales and Technical Services teams. So, they are connecting with trade and contractors and other stakeholders virtually – not just a phone call, but a systematic program to ensure tracking, conversions and customer delight. In a short span of time, we were able to shift the frontline teams from physical in-market movement to a robust virtual way of continuing business operations.

Secondly, with the launch of Future Today, we are turning to digital marketing as an integral part of our ‘go to market’ as a brand. From the moment the customer searches for cement, to the time he is ready to go to the cement dealership, we are investing in all parts of his journey using the digital medium.

In the past year, we’ve done an innovation with Alexa, where the home builder can ask Alexa questions about construction and get professional responses from Dalmia Cement. All customers need to do is say, "Alexa, Ask Dalmia" and it will answer their construction queries with resources from Dalmia Technical Experts.

Vikas: Very innovative!

Pramesh: Absolutely! We’ve just made a beginning – this will of course get richer and deeper as we progress. We are investing in building digital properties across the board. As an industry, we are laggards when it comes to digital adoption. Dalmia Cement wants to lead this journey, and bring consumers the future, today!

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Concrete

Refractory demands in our kiln have changed

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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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Concrete

Digital supply chain visibility is critical

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MSR Kali Prasad, Chief Digital and Information Officer, Shree Cement, discusses how data, discipline and scale are turning Industry 4.0 into everyday business reality.

Over the past five years, digitalisation in Indian cement manufacturing has moved decisively beyond experimentation. Today, it is a strategic lever for cost control, operational resilience and sustainability. In this interview, MSR Kali Prasad, Chief Digital and Information Officer, Shree Cement, explains how integrated digital foundations, advanced analytics and real-time visibility are helping deliver measurable business outcomes.

How has digitalisation moved from pilot projects to core strategy in Indian cement manufacturing over the past five years?
Digitalisation in Indian cement has evolved from isolated pilot initiatives into a core business strategy because outcomes are now measurable, repeatable and scalable. The key shift has been the move away from standalone solutions toward an integrated digital foundation built on standardised processes, governed data and enterprise platforms that can be deployed consistently across plants and functions.
At Shree Cement, this transition has been very pragmatic. The early phase focused on visibility through dashboards, reporting, and digitisation of critical workflows. Over time, this has progressed into enterprise-level analytics and decision support across manufacturing and the supply chain,
with clear outcomes in cost optimisation, margin protection and revenue improvement through enhanced customer experience.
Equally important, digital is no longer the responsibility of a single function. It is embedded into day-to-day operations across planning, production, maintenance, despatch and customer servicing, supported by enterprise systems, Industrial Internet of Things (IIoT) data platforms, and a structured approach to change management.

Which digital interventions are delivering the highest ROI across mining, production and logistics today?
In a capital- and cost-intensive sector like cement, the highest returns come from digital interventions that directly reduce unit costs or unlock latent capacity without significant capex.
Supply chain and planning (advanced analytics): Tools for demand forecasting, S&OP, network optimisation and scheduling deliver strong returns by lowering logistics costs, improving service levels, and aligning production with demand in a fragmented and regionally diverse market.
Mining (fleet and productivity analytics): Data-led mine planning, fleet analytics, despatch discipline, and idle-time reduction improve fuel efficiency and equipment utilisation, generating meaningful savings in a cost-heavy operation.
Manufacturing (APC and process analytics): Advanced Process Control, mill optimisation, and variability reduction improve thermal and electrical efficiency, stabilise quality and reduce rework and unplanned stoppages.
Customer experience and revenue enablement (digital platforms): Dealer and retailer apps, order visibility and digitally enabled technical services improve ease of doing business and responsiveness. We are also empowering channel partners with transparent, real-time information on schemes, including eligibility, utilisation status and actionable recommendations, which improves channel satisfaction and market execution while supporting revenue growth.
Overall, while Artificial Intelligence (AI) and IIoT are powerful enablers, it is advanced analytics anchored in strong processes that typically delivers the fastest and most reliable ROI.

How is real-time data helping plants shift from reactive maintenance to predictive and prescriptive operations?
Real-time and near real-time data is driving a more proactive and disciplined maintenance culture, beginning with visibility and progressively moving toward prediction and prescription.
At Shree Cement, we have implemented a robust SAP Plant Maintenance framework to standardise maintenance workflows. This is complemented by IIoT-driven condition monitoring, ensuring consistent capture of equipment health indicators such as vibration, temperature, load, operating patterns and alarms.
Real-time visibility enables early detection of abnormal conditions, allowing teams to intervene before failures occur. As data quality improves and failure histories become structured, predictive models can anticipate likely failure modes and recommend timely interventions, improving MTBF and reducing downtime. Over time, these insights will evolve into prescriptive actions, including spares readiness, maintenance scheduling, and operating parameter adjustments, enabling reliability optimisation with minimal disruption.
A critical success factor is adoption. Predictive insights deliver value only when they are embedded into daily workflows, roles and accountability structures. Without this, they remain insights without action.

In a cost-sensitive market like India, how do cement companies balance digital investment with price competitiveness?
In India’s intensely competitive cement market, digital investments must be tightly linked to tangible business outcomes, particularly cost reduction, service improvement, and faster decision-making.
This balance is achieved by prioritising high-impact use cases such as planning efficiency, logistics optimisation, asset reliability, and process stability, all of which typically deliver quick payback. Equally important is building scalable and governed digital foundations that reduce the marginal cost of rolling out new use cases across plants.
Digitally enabled order management, live despatch visibility, and channel partner platforms also improve customer centricity while controlling cost-to-serve, allowing service levels to improve without proportionate increases in headcount or overheads.
In essence, the most effective digital investments do not add cost. They protect margins by reducing variability, improving planning accuracy, and strengthening execution discipline.

How is digitalisation enabling measurable reductions in energy consumption, emissions, and overall carbon footprint?
Digitalisation plays a pivotal role in improving energy efficiency, reducing emissions and lowering overall carbon intensity.
Real-time monitoring and analytics enable near real-time tracking of energy consumption and critical operating parameters, allowing inefficiencies to be identified quickly and corrective actions to be implemented. Centralised data consolidation across plants enables benchmarking, accelerates best-practice adoption, and drives consistent improvements in energy performance.
Improved asset reliability through predictive maintenance reduces unplanned downtime and process instability, directly lowering energy losses. Digital platforms also support more effective planning and control of renewable energy sources and waste heat recovery systems, reducing dependence on fossil fuels.
Most importantly, digitalisation enables sustainability progress to be tracked with greater accuracy and consistency, supporting long-term ESG commitments.

What role does digital supply chain visibility play in managing demand volatility and regional market dynamics in India?
Digital supply chain visibility is critical in India, where demand is highly regional, seasonality is pronounced, and logistics constraints can shift rapidly.
At Shree Cement, planning operates across multiple horizons. Annual planning focuses on capacity, network footprint and medium-term demand. Monthly S&OP aligns demand, production and logistics, while daily scheduling drives execution-level decisions on despatch, sourcing and prioritisation.
As digital maturity increases, this structure is being augmented by central command-and-control capabilities that manage exceptions such as plant constraints, demand spikes, route disruptions and order prioritisation. Planning is also shifting from aggregated averages to granular, cost-to-serve and exception-based decision-making, improving responsiveness, lowering logistics costs and strengthening service reliability.

How prepared is the current workforce for Industry 4.0, and what reskilling strategies are proving most effective?
Workforce preparedness for Industry 4.0 is improving, though the primary challenge lies in scaling capabilities consistently across diverse roles.
The most effective approach is to define capability requirements by role and tailor enablement accordingly. Senior leadership focuses on digital literacy for governance, investment prioritisation, and value tracking. Middle management is enabled to use analytics for execution discipline and adoption. Frontline sales and service teams benefit from
mobile-first tools and KPI-driven workflows, while shop-floor and plant teams focus on data-driven operations, APC usage, maintenance discipline, safety and quality routines.
Personalised, role-based learning paths, supported by on-ground champions and a clear articulation of practical benefits, drive adoption far more effectively than generic training programmes.

Which emerging digital technologies will fundamentally reshape cement manufacturing in the next decade?
AI and GenAI are expected to have the most significant impact, particularly when combined with connected operations and disciplined processes.
Key technologies likely to reshape the sector include GenAI and agentic AI for faster root-cause analysis, knowledge access, and standardisation of best practices; industrial foundation models that learn patterns across large sensor datasets; digital twins that allow simulation of process changes before implementation; and increasingly autonomous control systems that integrate sensors, AI, and APC to maintain stability with minimal manual intervention.
Over time, this will enable more centralised monitoring and management of plant operations, supported by strong processes, training and capability-building.

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Concrete

Cement Additives for Improved Grinding Efficiency

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Shreesh A Khadilkar discusses how advanced additive formulations allow customised, high-performance and niche cements—offering benefits while supporting blended cements and long-term cost and carbon reduction.

Cement additives are chemicals (inorganic and organic) added in small amounts (0.01 per cent to 0.2 per cent by weight) during cement grinding. Their main job? Reduce agglomeration, prevent pack-set, and keep the mill running smoother. Thus, these additions primarily improve, mill thru-puts, achieve lower clinker factor in blended cements PPC/PSC/PCC. Additionally, these additives improve concrete performance of cements or even for specific special premium cements with special USPs like lower setting times or for reduced water permeability in the resultant cement mortars and concrete (water repellent /permeation resistant cements), corrosion resistance etc.
The cement additives are materials which could be further differentiated as:

Grinding aids:
• Bottlenecks in cement grinding capacity, such materials can enhance throughputs
• Low specific electrical energy consumption during cement grinding
• Reduce “Pack set” problem and improve powder flowability

Quality improvers:
• Opportunity for further clinker factor reduction
• Solution for delayed cement setting or strength development issues at early or later ages.

Others: materials which are used for specific special cements with niche properties as discussed in the subsequent pages.
When cement additives are used as grinding aids or quality improvers, in general the additives reduce the inter-particle forces; reduce coating over grinding media and mill internals. Due to creation of like charges on cement particles, there is decreased agglomeration, much improved flowability, higher generation of fines better dispersion of particles in separator feed and reduction of mill filling level (decrease of residence time). However, in VRM grinding; actions need to be taken to have stable bed formation on the table.
It has been reported in literature and also substantiated by a number of detailed evaluations of different cement additive formulations in market, that the cement additive formulations are a combination of different chemical compounds, typically composed of:

  1. Accelerator/s for the hydration reaction of cements which are dependent on the acceleration effect desired in mortar compressive strengths at early or later ages, the choice of the materials is also dependent on clinker quality and blending components (flyash / slag) or a mix of both.
  2. Water reducer / workability / wet-ability enhancer, which would show impact on the resultant cement mortars and concrete. Some of the compounds (retarders) like polysaccharide derivatives, gluconates etc., show an initial retarding action towards hydration which result in reducing the water requirements for the cements thus act as water reducers, or it could be some appropriate polymeric molecules which show improved wet-ability and reduce water demand. These are selected based on the mineral component and type of cements (PPC/PSC /PCC).
  3. Grinding aids: Compounds that work as Grinding Aid i.e. which would enhance Mill thru-put on one hand as well as would increase the early strengths due to the higher fines generation/ or activation of cement components. These compounds could be like alkanol-amines such as TIPA, DEIPA, TEA etc. or could be compounds like glycols and other poly-ols, depending on whether it is OPC or PPC or PSC or PCC manufacture.

Mechanism of action — Step By Step—

  1. Reduce Agglomeration, Cement particles get electrostatically charged during grinding, stick together, form “flocs”, block mill efficiency, waste energy. Grinding aid molecules adsorb onto particle surfaces, neutralise charge, prevent re-agglomeration.
  2. Improve Powder Flowability, Adsorbed molecules create a lubricating layer, particles slide past each other easier, better mill throughput, less “dead zone” buildup.
    Also reduces caking on mill liners, diaphragms, and separator screens, less downtime for cleaning.
  3. Enhance Grinding Efficiency (Finer Product Faster), By preventing agglomeration, particles stay dispersed more surface area exposed to grinding media, finer grind achieved with same energy input, Or: same fineness achieved with less energy, huge savings.
    Example:
    • Without aid ? 3500 cm²/g Blaine needs 40 kWh/ton
    • With use of optimum grinding aid same fineness at 32 kWh/ton 20 per cent energy savings
  4. Reduce Pack Set and Silo Caking Grinding aids (GA) inhibit hydration of free lime (CaO) during storage prevents premature hardening or “pack set” in silos. especially critical in humid climates or with high free lime clinker.
    It may be stated here that Overdosing of GA can cause: – Foaming in mill (especially with glycols) reduces grinding efficiency, retardation of cement setting (especially with amines/acids), odor issues (in indoor mills) – Corrosion of mill components (if acidic aids used improperly)
    The best practice to optimise use of GA is Start with 0.02 per cent to 0.05 per cent dosage test fineness, flow, and set time adjust up/down. Due to static charge of particles, the sample may stick to the sides of sampler pipe and so sampling need to be properly done.
    Depending on type of cements i.e. OPC, PPC, PSC, PCC, the grinding aids combinations need to be optimised, a typical Poly carboxylate ether also could be a part of the combo grinding aids

Cement additives for niche properties of the cement in concrete.
The cement additives can also be tailor made to create specific niche properties in cements, OPC, PPC, PSC and PCC to create premium or special brands. The special niche properties of the cement being its additional USP of such cement products, and are useful for customers to build a durable concrete structure with increased service life.


Such properties could be:
• Additives for improved concrete performance of cements, high early strength in PPC/PSC/PCC, much reduced water demand in cement, cements with improved slump retentivity in concrete, self-compacting, self levelling in concrete, cements with improved adhesion property of the cement mortar
• Water repellence / water proofing, permeability resistance in mortars and concrete.
• Biocidal cement
• Photo catalytic cements
• Cements with negligible ASR reactions etc.

Additives for cements for improved concrete performance
High early strengths: Use of accelerators. These are chemical compounds which enhance the degree of hydration of cement. These can include setting or hardening accelerators depending on whether their action occurs in the plastic or hardened state respectively. Thus, the setting accelerators reduce the setting time, whereas the hardening accelerators increase the early age strengths. The setting accelerators act during the initial minutes of the cement hydration, whereas the hardening accelerators act mainly during the initial days of hydration.
Chloride salts are the best in class. However, use of chloride salts as hardening accelerators are strongly discouraged for their action in promoting the corrosion of rebar, thus, chloride-free accelerators are preferred. The hardening accelerators could be combinations of compounds like nitrate, nitrite and thiocyanate salts of alkali or alkaline earth metals or thiosulphate, formate, and alkanol amines depending on the cement types.
However, especially in blended cements (PPC/PSC/PCC the increased early strengths invariably decrease the 28 day strengths. These aspects lead to creating combo additives along with organic polymers to achieve improved early strengths as well as either same or marginally improved 28 days strengths with reduced clinker factor in the blended cement, special OPC with reduced admixture requirements. With use of appropriate combination of inorganic and organic additives we could create an OPC with substantially reduced water demand or improved slump retentivity. Use of such an OPC would show exceptional concrete performance in high grade concretes as it would exhibit lower admixture requirements in High Grade Concretes.
PPC with OPC like properties: With the above concept we could have a PPC, having higher percentage flyash, with a combo cement additive which would have with concrete performance similar to OPC in say M40/M50 concrete. Such a PPC would produce a high-strength PPC concrete (= 60 MPa @ 28d) + improved workability, durability and sustainability.
Another interesting aspect could also be of using ultrafine fine flyash /ultrafine slags as additions in OPC/PPC/PSC for achieving lower clinker factor as well as to achieve improved later age strengths with or without a combo cement additive.
The initial adhesion property at sites of especially PPC/PSC/PCC based mortars can be improved through use of appropriate organic polymers addition during the manufacture of these cements. Such cements would have a better adhesion property for plastering/brick bonding etc., as it has much lower rebound loss of their mortars in such applications.
It is needless to mention here that with use of additives, we could also have cement with viscosity modifying cement additives, for self-compaction and self-leveling concrete performance.
Use of Phosphogypsum retards the setting time of cements, we can use additive different additive combos to overcome retardation and improve the 1 day strengths of the cements and concretes.

About the author:
Shreesh Khadilkar, Consultant & Advisor, Former Director Quality & Product Development, ACC, a seasoned consultant and advisor, brings over 37 years of experience in cement manufacturing, having held leadership roles in R&D and product development at ACC Ltd. With deep expertise in innovative cement concepts, he is dedicated to sharing his knowledge and improving the performance of cement plants globally.

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