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Manufacturing process of Instamix Xpress is different as compared to wet concrete

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Nuvoco came in the light when it acquired L&T?? ready-mix concrete business in 2008. Since then it has established itself not only as a cement producer but a player with innovative construction materials. It has successfully transformed itself from cement manufacturer to a building material supplier with a wide range of products. Prashant Jha, Chief of Ready Mixed Business, Nuvoco, speaks on one of the innovations he has recently launched.


Prashant Jha

Explain the idea behind introducing a new product during the pandemic. What is the market size, and what kind of growth do you expect from this product?

Through our interactions with customers and market studies, we observed that the construction industry is facing challenges of manufacturing concrete at the site due to the non-availability of superior quality raw materials like cement, sand, and aggregates. In the current scenario, the majority of small concrete work is done by mixing cement, aggregates, and water at the site. Then there is the issue of wastage of raw materials.

Most of the sites are still using the volumetric batching method, which generally results in poor quality concrete at site. Further due to the pandemic situation, there is a shortage of labour, moreover getting labour to do small jobs is generally a problem. All these factors resulted in an increased demand for well-graded pre-mix bag concrete. Although there are no published records, we are estimating the all India market size is more than 10,000 tonne per month, and it would be growing at 15 per cent per annum.

What is the manufacturing process ??is it the same as wet concrete? What is the batch size?

InstaMix Xpress is a pre-blended mixture of cement, sand, and aggregates with special admixtures, requiring only the addition of water before pouring the concrete. It is produced in a controlled environment and is fast, easy-to-use, and ready-to-pour in just three steps ??open, mix, and pour.

One needs to do is open the bag in a pan or mechanical mixer as per the requirement; add four to five litres of potable water per bag and mix the concrete uniformly; and finally, pour the preparation without making a mess. The manufacturing process of Instamix Xpress is entirely different as compared to wet concrete. In InstaMix Xpress, we have to ensure that there is 0 per cent moisture at any stage of production till packaging of the product. It is available in 50 kg special moisture-proof sealed bags, which are tested for quality. Batch size depends on the transit mixer capacity, which varies from 500 kg to 2,000 kg.

Is there any shelf life for the product?

Yes, it is good for use till three months of production.

Is the product covered under any BIS code? OR is the code in the draft stage?

No at this stage it is not covered under any BIS codes; however drafting of code for dry concrete is under process.

What has been the response from the users?

Initially, we have launched InstaMix Xpress in East and Northeast markets and the response is very encouraging. Structural consultants and contractors prefer to use the M-30 and M-40 grade of concrete, which is not possible to produce at the site and ready-mix concrete is not available in remote areas. InstaMix Xpress is an ideal solution as it is a pre-mixed, ready-to-use, bagged, dry concrete, which can be easily transported to these far-flung areas. Looking at the response, we are planning to launch this product in Northern and Western India very soon.

Does any other cement manufacturer cater the consumers with a similar product?

Yes, a few cement manufacturers tried to produce at the local level ready-mix plants but they were not able to control the quality of the product.

To what extent the strength will be compromised if more water is used or if the product is used beyond stipulated period?

It all depends on how much excess water has been added or how long InstaMix Xpress has been stored beyond the three months shelf life. We recommend using four to five litres of water per 50 kg bag (depending on the grade of concrete). If the product is used beyond the stipulated period, [definitely] the compressive strength will reduce from 10 to 50 per cent.

Concrete

Lower sales realization impacts margins for cement makers in Q2 FY25

The industry encountered several challenges, including an extended monsoon season.

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Major cement manufacturers reported a decline in margins for the September quarter, primarily due to lower prices, which led to decreased sales realization.

With the exception of three leading cement producers—UltraTech Cement, Ambuja Cement, and Dalmia Bharat—smaller companies, including Nuvoco Vistas Corp, JK Cement, Birla Corporation, and Heidelberg Cement, experienced a drop in both topline and sales volume during the second quarter of the current fiscal year.

The industry encountered several challenges, including an extended monsoon season, flooding, and a slow recovery in government demand, all contributing to weak overall demand.

Despite these challenges, power, fuel, and other costs largely remained stable across the industry. The all-India average cement price was approximately Rs 348 per 50 kg bag in June 2024, which represented an 11 per cent year-on-year decrease to Rs 330 per bag in September, although it saw a month-on-month increase of 2 per cent.

In the first half of FY25, cement prices declined by 10 per cent year-on-year, settling at Rs 330 per bag. This decline was notable compared to the previous year’s average prices of Rs 365 per bag and Rs 375 per bag in FY23, as reported by Icra.

Leading cement manufacturer UltraTech reported a capacity utilization rate of 68 per cent, with a 3 per cent growth in volume. However, its sales realization for grey cement declined by 8.4 per cent year-on-year and 2.9 per cent quarter-on-quarter during the July-September period.

In response to a query regarding cement prices during the earnings call, UltraTech’s CFO Atul Daga indicated that there had been an improvement in prices from August to September and noted that prices remained steady from September to October. He mentioned that the prices had risen from Rs 347 in August to approximately Rs 354 currently.

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Concrete

Steel companies face Rs 89,000 crore inventory crisis

Steel firms grapple with Rs 89,000 crore stockpile amid import surge.

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Steel companies in India are facing a significant challenge as they contend with an inventory crisis valued at approximately Rs 89,000 crore. This situation has arisen due to a notable increase in steel imports, which has put pressure on domestic producers struggling to maintain sales in a competitive market.

The surge in imports has been fueled by various factors, including fluctuations in global steel prices and increased production capacities in exporting countries. As a result, domestic steel manufacturers have found it difficult to compete, leading to rising stock levels of unsold products. This inventory buildup has forced several companies to reassess their production strategies and pricing models.

The financial impact of this inventory crisis is profound, affecting cash flows and profitability for many steel firms. With domestic demand remaining volatile, the pressure to reduce prices has increased, further complicating the situation for manufacturers who are already grappling with elevated production costs.

Industry experts are urging policymakers to consider measures that can support local steel producers, such as imposing tariffs on imports or enhancing trade regulations. This would help to protect the domestic market and ensure that Indian steel companies can compete more effectively.

As the steel sector navigates these challenges, stakeholders are closely monitoring the situation, hoping for a turnaround that can stabilize the market and restore confidence among investors. The current dynamics emphasize the need for a robust strategy to bolster domestic production and mitigate the risks associated with excessive imports.

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Concrete

JSW and POSCO collaborate for steel plant

JSW Group and POSCO ink MoU for steel project.

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JSW Group has signed a Memorandum of Understanding (MoU) with South Korea’s POSCO Group to develop an integrated steel plant in India. This collaboration aims to enhance India’s steel production capacity and contribute to the country’s growing manufacturing sector.

The agreement was formalized during a recent meeting between executives from both companies, highlighting their commitment to sustainable development and technological innovation in the steel industry. The planned facility will incorporate advanced manufacturing processes and adhere to environmentally friendly practices, aligning with global standards for sustainability.

JSW Group, a leader in the Indian steel industry, has expressed confidence that the joint venture with POSCO will bolster its position in the market and accelerate growth. The project is expected to attract significant investments, generating thousands of jobs in the region and contributing to local economies.

As India aims to boost its steel output to meet domestic demand and support infrastructure projects, this partnership signifies a crucial step toward achieving those goals. Both companies are committed to leveraging their expertise to develop a state-of-the-art facility that will produce high-quality steel products while minimizing environmental impact.

This initiative also reflects the increasing collaboration between Indian and international firms to enhance industrial capabilities and foster economic growth. The MoU sets the stage for a promising future in the Indian steel sector, emphasizing innovation and sustainability as key drivers of success.

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