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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.

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Concrete

30-Day Traffic Diversion In Place For CC Road Works In Madhapur

Diversions in place from May 16 for cement concrete road works

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The Cyberabad Traffic Police issued a traffic advisory as road works begin for the laying of a cement concrete (CC) road from Jaya Shankar Statue to RRR Restaurant at Parvathnagar in Madhapur limits. The advisory indicated that traffic diversions will be in place for 30 days from May 16 to ensure the smooth flow of vehicles and to minimise congestion on the affected stretch. The measure aims to balance uninterrupted construction activity with the movement needs of commuters.

Traffic moving from Toddy Compound towards Parvathnagar village will be diverted at Parvathnagar junction towards Sunnam Cheruvu and the 100 feet road. Local motorists and public transport operators have been advised to follow the diversionary route as directed by traffic personnel on duty. Alternate routes and signage have been planned to mitigate delays and to manage peak hour congestion.

Police officials said the diversion had been planned to facilitate uninterrupted road works while maintaining traffic movement in the area. Commuters were urged to plan their travel accordingly and to cooperate with traffic staff managing the stretch. Authorities indicated that enforcement of diversions would be active and that violations could attract penalties.

The 30 day schedule is intended to allow contractors to complete the laying and curing phases with minimal interruption to vehicular flow. Residents and businesses in adjacent localities have been advised to factor the diversion into deliveries and travel plans. The traffic police promised continuous monitoring of the works and the operational diversions and emphasised that temporary inconvenience was necessary for longer term improvement of the road network. Traffic personnel will be stationed at key junctions and additional signage and temporary markings will be displayed to guide motorists and pedestrians through the revised alignments while public transport services will follow the diversion where feasible and operators have been asked to adjust timetables to minimise disruption.

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Concrete

HeidelbergCement India Receives Consent For Khandwa Grinding Unit

Consent granted by Madhya Pradesh Pollution Control Board

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HeidelbergCement India (HeidelbergCement India) has received regulatory consent to establish a cement blending and grinding unit at Village Dongaliya, Tehsil Punasa, District Khandwa in Madhya Pradesh. The consent was granted by the Madhya Pradesh Pollution Control Board under the Water (Prevention & Control of Pollution) Act, 1974 and the Air (Prevention & Control of Pollution) Act, 1981 and is dated 17 May 2026. The company disclosed the development in a filing made under Regulation 30 of the SEBI (Listing Obligations and Disclosure Requirements) Regulations, 2015.

The project plan envisages procurement of long term availability of fly ash and the allotment of land on lease for setting up the unit. The proposed facility is described as a blending and grinding installation which will process cementitious materials sourced from nearby operations and suppliers. Company filings state the measures required to secure raw material logistics and statutory compliance before commencing construction.

The addition of a grinding unit in Khandwa is intended to strengthen regional supply and improve logistical efficiency by reducing haulage distances for finished product. The unit is expected to complement existing capacities in central India and to offer flexibility in product mix through blending operations. The reliance on fly ash as a supplementary cementitious material will necessitate long term supply agreements with thermal power producers and coordination with waste utilisation policies.

The disclosure to the regulator and to the stock exchanges follows standard corporate governance practice and aims to keep investors apprised of capital expenditure initiatives. The company indicated that subsequent permits and clearances would be sought in accordance with applicable environmental and land use rules. The project is presented as part of HeidelbergCement India’s broader strategy to optimise capacity distribution and to respond to regional demand dynamics.

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Concrete

PROMECON introduces infrared-based tertiary air measurement system for cement kilns

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The new solution promisescontinuous, real-time tertiary air flow measurement in cement plant operations.

PROMECON GmbH has launched the McON IR Compact, an infrared-based measuring system designed to deliver continuous, real-time tertiary air flow measurement in cement plant operations. The system addresses the longstanding process control challenge of accurate tertiary air monitoring under extreme kiln conditions. It uses patented infrared time-of-flight measurement technology that operates without calibration or maintenance intervention.

Precise tertiary air measurement is a critical requirement for stable rotary kiln operation. The McON IR Compact is engineered to function reliably at temperatures up to 1,200°C and in the presence of abrasive clinker dust. Its vector-based digital measurement architecture ensures that readings remain unaffected by swirl, dust deposits or drift. Due to these conditions conventional measurement systems in pyroprocess environments are often compromised.

The system is fully non-intrusive and requires no K-factors, recalibration or periodic readjustment, enabling years of uninterrupted operation. This design directly supports plant availability and reduces the maintenance overhead typically associated with process instrumentation in high-temperature zones.

PROMECON has deployed the McON IR Compact at multiple cement facilities, including Warta Cement in Poland. Plant operators report that the system has aided in identifying blockages, optimising purging cycles for gas burners, and supplying accurate flow data for AI-based process optimisation programmes. The practical outcomes include more stable kiln operation, improved process control, and earlier detection of process disturbances.

On the energy side, real-time tertiary air data enables reduction in induced draft fan load and helps flatten process oscillations across the pyroprocess. This translates to lower fuel and energy consumption, fewer unplanned shutdowns, and a measurable reduction in NOx peaks. This directly reflects on the downstream cost implications for plants operating SCR or SNCR systems for emissions compliance.

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