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Rise in input costs exert pressure on manufacturer’s profitability: ICRA

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The total costs of cement manufacturers have risen over the last few months as the prices of major input materials ??coal, pet coke and diesel are on an increasing trend, resulting in higher power and fuel and freight expenses.

The rise in these costs which account for 50 to 55 per cent of total costs has been exerting pressure on profitability of industry players which as per an ICRA note is bound to adversely reflect in Q4 FY2021 performance.

On the input costs front, the increase in the coal prices in the recent months is majorly driven by the higher demand from China and other Asian countries. The price of diesel and pet coke increase in line with crude oil prices. The recent surge in oil prices led to increase in pet coke prices by 73 per cent year-on-year and 29 per cent quarter-on-quarter in Q4 FY21 and diesel prices by 20 per cent year-on-year and 10 per cent quarter-on-quarter.

Rajeshwar Burla, VP and Co Group Head, ICRA said, “The cement companies have undertaken price hikes by around 7 per cent year-on-year in March 2021 to pass on the increase in the power and fuel and freight expenses. However, the EBIDTA/MT is expected to contract in Q4 FY21 by around 8.7 per cent quarter-on-quarter to around Rs. 1,148/MT.”

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Concrete

Cement Additives for Improved Grinding Efficiency

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Shreesh A Khadilkar outlines that by integrating controlled specialty additives at the manufacturing stage, cement plants can deliver consistent, high-performance concretes tailored to specific environmental and structural challenges.

The water repellent cement (PPC based) was first launched in the Indian market in 2013, The cement was developed by the ACC R&D team, the specialty of the cement was that during hydration the cement sand mortar / concrete the cement particles reacts with water and also repel the permeation of water even at early ages. The cement was developed using alkoxy /alkyl silanol based emulsions with an aqueous / oil based property. Subsequently from 2017/18 many different brands of such cements became available in the different markets of the country. These cements which possess the water repellent properties alike hydrophobic cements but these cements are not actually hydrophobic and do not float on the water. These cements react with the water to fill the pores and capillaries of the cement and reacts with the calcium hydroxide of cement to form a hydrophobic resin within the capillary pores of the concrete, significantly reducing water absorption and permeability.
These studies carried out to explore the potential benefits of the water repellent cement on the mortar and concrete properties by assessing the Water Permeability Tests, which affects the overall durability of concrete. The results demonstrated that the water repellent PPC cement (flyash based) substantially reduced water permeability by up to 70 per cent, compared to normal PPC and water sorptivity by up to 50 per cent in both mortar and concrete cubes due to improved impermeability of the concrete made with water repellent cement and its effect on the hydration mechanism. This water repellence effect achieved without compromising the properties of the cement like compressive strength, setting time, expansion etc. of the mortar and concrete, which remained similar to the normal PPC cement.
Through the use of similar special cement additions (with small tweaking of the additives) we could have a water repellent / permeability resistant PSC (Portland Slag Cement) and PCC (Portland flyash slag composite cements. Thus, this niche property of water repellence makes the resultant concretes more durable.

Biocidal cement
Biocidal cements prevent mold, bacteria, algae, and fungi from growing on or inside the concrete. Types of Biocidal Additives for Cement:

  1. Silver-based biocides – Silver ions disrupt microbial cell membranes, kills bacteria/fungi. Best for: Hospitals, water tanks, sewage systems. Dosage: 0.1 per cent to 0.5 per cent by weight of cement (often pre-dispersed in powder or liquid).
    Pro: Long-lasting, broad-spectrum, non-toxic to humans at low doses. But Expensive, may stain concrete slightly.
  2. Copper-based biocides – Copper ions inhibit enzyme activity in microbes. Best for: Marine structures, cooling towers, wastewater plants – Dosage: 0.2 per cent to 1.0 per cent (depends on environment). Very effective against algae and fungi, durable in wet conditions. However, it can accelerate corrosion of steel reinforcement need to e used with caution.
  3. Zinc-based biocides – Interferes with microbial metabolism. Best for: Interior walls, plaster, stucco – Dosage: 0.5 per cent to 2.0 per cent it is odorless, non-staining, less effective in alkaline environments (cement is highly alkaline pH).
  4. Quaternary ammonium compounds (Quats) – Disrupts cell membranes. Best for: Indoor concrete, flooring, sanitary areas – Dosage: 0.2 per cent to 0.8 per cent, Odorless, colorless, compatible with most admixtures, its use can reduce early strength if overdosed.
  5. Titanium dioxide (TiO2) – Photocatalysts UV light activates TiO2 ? generates reactive oxygen species ? kills microbes + breaks down organic stains., – Best for: Exterior facades, pavements, self-cleaning concrete – Dosage: 1 per cent to –5 per cent (often nano-sized for better dispersion), self-cleaning, eco-friendly, long-term durability, needs UV light to work, less effective indoors.

Photocatalytic cement
Types of photocatalysts used:

  1. Titanium dioxide (TiO2) – Most Common Form: Anatase (best photocatalytic activity), sometimes mixed with rutile for stability, Dosage: 2 per cent to 10 per cent by weight of cement (often 3 per cent to 5 per cent). Highly effective, non-toxic, stable, FDA-approved for food contact. The cement needs UV light (but newer versions work under visible light).
  2. Zinc oxide (ZnO) – Pros: Works under visible light, antibacterial, UV- blocking, Cons: Less stable in high pH (cement is alkaline), can
    leach zinc.
  3. Modified TiO2 (visible-light active) – Doped with metals (Ag, Cu, Fe), works under indoor/ambient light. Great for indoor applications (hospitals, offices).
    The Photocatalytic Cement react in presence of sunlight (UV or visible light) to break down organic and inorganic pollutants in the air and on the surface of cement, thus it results in self-cleaning walls, smog-eating streets, stain-resistant pavements.
    The mechanism of action is as follows:
  4. Sunlight hits TiO2 excites electrons, creates electron-hole pairs.
  5. Holes react with water, produce hydroxyl radicals (OH), super strong oxidisers.
  6. Radicals attack organic dirt, bacteria, NOx, VOCs, soot breaks them down into harmless stuff like CO2, H2O, nitrates
  7. Rain washes away residue ? surface stays clean!
    Where it can be used:
    Applications Benefits
    Façade Panels Self-cleaning, anti-algal and anti-fungal
    Roads and Side walks Reduces NOx pollution, stays white longer
    Tunnels and Bridges Cuts maintenance, improves visibility
    Parking Garages Less cleaning cost, healthier air
    Hospitals and Schools Reduces microbial load, improves IAQ

In a similar manner as above, we could have Cements with niche properties tailored to achieve specific performance in concretes.

Corrosion inhibiting cements
Types of corrosion inhibitors, which could be a part of the cements are:

  1. Calcium nitrite based inhibitors – Dosage: 2 per cent to 4 per cent by weight of cement (often 10–30 L/m3), anodic inhibitor forms a protective oxide film on steel surface, blocks chloride ion attack. Works even in cracked concrete.
  2. Organic compounds like amino alcohol based (e.g., triethanolamine, amino carboxylate) ? Phosphate-based ? Carboxylate based , less toxic than nitrites (some are non-hazardous) can be used in potable water structures for existing structures or low cover the cements would be applied as surface treatment or added to repair mortars the inhibitor component, migrates to steel, forms protective layer. The cements could have multifunctional combo additive, these additives also enhance the concrete performance besides the inhibition effect

ASR resistant cements
In certain regions of the country the aggregates available locally are reactive aggregates. For use of such aggregates, in say concrete road and other infra structural concretes the cements can be used, which would resist ASR reactions in resultant concrete, such cements could be either

  1. Low alkali cement
  2. PPC with class F flyash — 20 per cent to 30 per cent replacement or with ground granulated blast furnace slag (GGBS) — 40 per cent to
    60 per cent replacement , or use of 5 per cent silica fume or 10 per cent to 15 per cent Metakaolin (The SCMs bind the alkalis ad prevent
    ASR reaction)
  3. Cements with lithium nitrate (LiNO3) — 0.5 per cent to 1.5 per cent by weight of cement Lithium ions compete with sodium/potassium ? suppresses formation of expansive gel, proven to stop ASR even in highly reactive system. Doesn’t affect strength or setting time significantly.
    Thus, depending on the additive used we could have shrinkage compensating cements, fragrant cements (cements with fragrance) etc.
    Lastly it could be stated here that having such cements with niche properties would have a consistent performance in concrete as these cements would be manufactured in plants, the active compound would be monitored and controlled effectively thus, the performance concrete would be ensured.

This is concluding part of the series.

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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Concrete

NDMC Rolls Out Intensive Sanitation Drive Across Lutyens Delhi

Municipal body intensifies cleaning and monitoring across the capital

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The New Delhi Municipal Council has launched an intensive sanitation drive across Lutyens’ Delhi, aiming to raise cleanliness standards in the capital’s central precincts. The programme will combine enhanced manual sweeping with mechanised cleaning and systematic waste removal to cover parks, heritage precincts and prominent thoroughfares. Authorities described the initiative as a sustained effort to improve public hygiene and reduce environmental hazards while maintaining the area’s civic image.

Operational teams have been instructed to prioritise drain clearing and litter hotspots, with special attention to markets and transit nodes that attract heavy footfall. Coordination with city utilities and waste processing units will be stepped up to ensure timely collection and disposal, and supervisory rounds will monitor adherence to cleaning schedules. Officials also intend to use data-driven planning to deploy resources efficiently and to identify recurring problem areas.

The council plans to engage resident welfare associations and business stakeholders to foster community participation in maintaining cleanliness and to support behavioural change campaigns. Public communication will be amplified through notices and outreach to encourage responsible waste handling and to inform residents about collection timings and segregation norms. Enforcement measures for littering and unauthorised dumping will be reinforced as part of a broader strategy to deter violations and sustain cleanliness gains.

The move reflects a focus on urban sanitation that officials link to public health priorities and to the city administration’s commitment to maintaining civic amenities. Monitoring mechanisms will include regular reporting and inspections to review outcomes and to recalibrate operations where necessary, according to municipal sources. The council emphasised that continued community cooperation will be essential for the drive to deliver lasting improvements in the appearance and hygiene of the capital’s core areas.

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Concrete

UltraTech Appoints Jayant Dua As MD-Designate For 2027

Executive named to succeed current managing director in 2027

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UltraTech Cement has appointed Jayant Dua as managing director (MD) designate who will take charge in 2027, the company announced. The appointment signals a planned leadership transition at one of the country’s largest cement manufacturers. The board has set a clear timeline for the handover and has framed the move as part of a structured succession plan.

Jayant Dua will be referred to as MD after assuming the role and will be responsible for overseeing operations, strategy and growth initiatives across the company’s network. The company said the designation follows established governance norms and aims to ensure continuity in executive leadership. The appointment is expected to allow a phased transfer of responsibilities ahead of the formal changeover.

The decision is intended to provide strategic stability as UltraTech Cement navigates domestic infrastructure demand and evolving market dynamics. Management will continue to focus on operational efficiency, capacity utilisation and cost management while aligning investments with long term objectives. The board will monitor the transition and provide further information on leadership responsibilities closer to the effective date.

Investors and market observers will have time to assess the implications of the announcement before the change is effected, and analysts will review the company’s outlook in the context of the succession. The company indicated that it will communicate any additional executive appointments or organisational changes as they are finalised. Shareholders were advised to refer to formal filings and company releases for definitive details on governance or remuneration.

The leadership change will be managed with attention to stakeholder interests and operational continuity, and the company reiterated its commitment to delivery on ongoing projects and customer obligations. Senior management will engage with employees and partners to ensure a smooth handover while maintaining focus on safety and compliance. Further updates will be provided through official investor communications in due course.

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