Economy & Market

Prefab Cement Sheets

Published

5 years ago

October 14, 2021

admin

Smart Board is a smooth surfaced cement board manufactured without using asbestos, as opposed to conventional cement boards. Its composite-cement manufacturing process does not create any industrial dust, dirt and oil. Harsh Bhutani, Executive Director, Hydrobaths Ramco Marketing, explains why smart boards have great potential in India.

Investment in the construction sector has increased from 5.4 per cent to 11 per cent of GDP from the 1970-71 till date. The industry is expected to grow at a rate of 26 per cent annually, as Rs.1 invested in this sector gives an increase of Rs.0.80 in GDP. There is a need for adaptation of strong, durable, environment friendly, ecologically appropriate, energy efficient yet cost- effective material and technology for construction. The building construction cost can be divided into two parts Ã» building material cost, which accounts for 65-70 per cent, and labour that makes-up the remaining 35-30 per cent of the cost. Factors that affect the cost of the project primarily include project accessibility, labour rates, material cost, economic pressure and the time of the year. There is an urgent need to encourage mechanisation to build up the sector’s capacity to deliver the critical infrastructure needed for economic development. The poor state of technology adopted by the construction sector adversely affects its performance and upgradation of technology is required, both in the manufacturing of construction materials and in the construction activities. A well planned, technologically advanced constructed space is now well within their grasp and its being reflected in the growing construction industry.

Better building materials

The building materials sector in India is a key constituent of the country’s construction industry. One of the biggest problems for project delays in India lies in the way we build partition walls. Even though we use the most advanced structural systems to make buildings faster and better, our technology to make walls remains pretty much the same as it was a hundred years ago. There really has not been much of innovation in wall technology in India. Over 95 per cent of the partition walls built in India are primarily brick/block walls with cement plaster and POP covering. This system is time-consuming, dirty, cumbersome, and heavy and labour intensive. In addition to these problems, the procurement of good quality bricks, good quality labour, construction sand, water and other materials is becoming more and more expensive and difficult by the day. Globally most countries have graduated to the drywall technology several decades ago. The drywall technology was originally designed with gypsum based construction. But the gypsum based system has many problems especially in India and other south- east Asian countries due to the weak nature of the gypsum board. Brickless products will be successful in India if they have strength and durability of a brick wall and can be setup with the efficiency and speed of a drywall.

Technological demand

Advancing technology has allowed the consumer to demand more and better products. The cost- conscious consumer today is looking for a product with a longer life. The building materials sector in India is a key constituent of the country’s construction industry. Growth rate expected for prefab products in India in the next three to five years would be about 30 per cent. We need to build structures that are stronger, more durable, leaks and cracks- proof and far more weather resistant than traditional homes, in almost half the time taken to construct compared to the traditional methods. Brickless formwork is well integrated with pre-fabricated and pre-engineered concrete form system that works as an alternate to plyboard and gypsum.

Brickless technology

Brickless technology is not new concept. In fact, internationally it has been used for many decades. Smartwalls from Smartboard as a product/solution, counters all the weaknesses of gypsum boards and combines the best of the both the worlds by giving the walls the strength and durability of a brick wall with the efficiency and speed of a drywall. Brickless technology has been spoken and tested in India since the last three to five years. However, it has gained popularity only in the last two years. Usually, pre-engineered or pre-fabricated houses show better performance, as factory or the assembly-line-produced homes are manufactured to stricter norms. Such building solutions use cutting edge technology and reduce the number of manufacturing defects given the strong quality checks that can be put in place. It reduces the dead load (1/6th the weight of a conventional 4.5" brick wall) of the building resulting in cost savings in steel /concrete/ foundation in the building structural system. Since the wall thickness is reduced (approx 3"), it results in more saleable /usable area.

It will help developers to plan accurately and reduce the risk of fluctuation, enable them to forecast and plan cost, anticipate return on investment and evaluate the impact of increased delivery commitment on developer’s reputation. These products possess special properties such as low thermal conductivity and high fire resistance, making them adaptable to virtually any climatic environment or seismic condition such as earthÂ¡quakes and cyclones. They are also waterproof, termite- proof and possess high strength.

Benefits

Strength and durability: Smartboards can take a lot of heavy beating without any damage and are also flexible enough to be bent if needed. They can be used both in interiors and exteriors. The board has high point load strength and can hang heavy paintings or TV screens without any special framing in the back. Each point can carry a load of 80-90 kg.

Speed: The wall can be set up 30 times faster than a conventional wall. The average efficiency of brick wall with a good team of 1 skilled mason and 2 helpers is around 35 sq ft/ day. With Smartwall, one can achieve an efficiency of 1,000-1,200 sq ft in one day with a skilled team. Large amounts of money can be saved due to faster completion of projects.

Easy maintenance: Since all the electrical, plumbing conduits are within the hollow wall, the wall can be opened if repair and maintenance is required and then easily and closed up.

Economical: The direct cost of this system is similar to the construction cost of a 4.5Ã¶ brick wall but with indirect cost saving due to light weight, faster speeds, and more carpet area, which would be about 20-30 per cent cheaper than the conventional systems.

Green product

The essence of green building refers to a structure constructed using a process that is environmentally responsible and resource-efficient throughout a building’s life-cycle. Smartboard is a non- asbestos product that qualifies it as an environment friendly/green product. It also registered with USGBC. The production process and products of this brickless technology includes sustainability before, during and after the application incorporated. During several stages in the production process, the water is reused and recycled. The production uses the pulp from farmed trees which means that no green forests are sacrificed or harmed in the process.

Smartboard

Smartboard is manufactured by Siam Cement Public Company (SCG). With an investment of $50 million, the Thailand-based SCG is mulling setting up a manufacturing plant in India within the next two years. The company makes smartboard fibre cement sheets and smartwood fibre cement based wood alternatives. Currently, SCG’s annual sales of its two products in India stands at 3,00,000 sq mts; the company will go ahead with its plans to have its manufacturing base once the sales volumes of Smartboard and Smartwood touches the critical volume of 1 million square metre (sq mts) a year in India. Listed on the Thailand Stock Exchange, SCG is stated to have annual sales of $20 billion worldwide. Hydrobaths Ramco Marketing, a producer of bath products, is a joint venture partner of SCG in India.. It markets SCG products in India.

Growth rate

expected for prefab products in India in the next three to five years would be about 30 per cent.

Harsh Bhutani, Executive Director, Hydrobaths Ramco Marketing,

Concrete

UltraTech becomes first Indian cement firm to cross 2 GW green energy

Published

1 hour ago

October 7, 2026

admin

UltraTech Cement has crossed 2 GW of captive green energy capacity, with renewables and waste heat recovery meeting 48 per cent of its power needs.

Mumbai

UltraTech Cement Limited has surpassed 2 GW of installed green energy capacity for captive use, becoming the first cement company in India to achieve the milestone. The Aditya Birla Group company commissioned 116.55 MW of wind capacity at its Inter-State Transmission System-connected wind-solar hybrid project in Barmer, Rajasthan, along with 10 MW of Waste Heat Recovery System capacity at Sarlanagar Cement Works in Karnataka.

With these additions, UltraTech’s cumulative installed green energy capacity has reached 2,024 MW. This includes 1,580 MW of renewable energy capacity and 444 MW of waste heat recovery capacity, together meeting around 48 per cent of the company’s current power requirements.

The company said the milestone reflects the progress of its long-term energy transition strategy. In FY27 so far, nearly one-third of UltraTech’s 76 manufacturing units in India have maintained green energy utilisation above 50 per cent of their electricity requirements, while five units have crossed 95 per cent.

K C Jhanwar, Managing Director, UltraTech Cement Limited, said, “Crossing the 2 GW green energy milestone is the result of a strategy we have pursued consistently over the past decade. Cement is an energy-intensive, hard-to-abate sector, and showing that reliability and growth can go hand in hand with a rapid shift to green energy sets a benchmark for the industry. With nearly half of our power needs now met through green energy, we are significantly less exposed to fossil fuel supply constraints and power price volatility. As we scale up renewables, waste heat recovery and battery storage across our operations, we are building an energy foundation for stable, long-term growth.”

UltraTech commissioned 430 MW of green energy capacity in FY26 and continues to expand its renewable energy and waste heat recovery portfolio.

The company is also progressively integrating Battery Energy Storage Systems across its operations to improve renewable energy utilisation and supply reliability.

In 2025, UltraTech operationalised what it described as India’s first on-site hybrid round-the-clock renewable energy project at Sewagram Cement Works in Gujarat. The project combines solar, wind and battery storage.

As part of its decarbonisation strategy, UltraTech said it has not invested in new captive thermal power capacity for either greenfield projects or brownfield expansions at its integrated units for more than a decade.

The company said its expanding green energy portfolio is helping reduce dependence on conventional grid electricity and fossil fuel-based power, while lowering exposure to fluctuations in coal and electricity prices.

UltraTech aims to increase green energy’s share in its total power mix to 85 per cent by 2030. As a member of RE100, it has also committed to meeting 100 per cent of its electricity requirement through renewable sources by 2050.

UltraTech Cement, the cement flagship of the Aditya Birla Group, has a total grey cement capacity of 210.1 MTPA and white cement and putty capacity of 3.5 MTPA. The company is also a signatory to the GCCA Climate Ambition 2050 and has committed to the GCCA Net Zero Concrete roadmap.

Concrete

Shiva Cement Merges with JSW Cement

Published

4 hours ago

October 7, 2026

admin

JSW Cement has announced a scheme of arrangement to merge its listed subsidiary Shiva Cement with itself, creating a single unified cement platform. The boards of both companies have approved the proposal, which will require clearances from stock exchanges, the Securities and Exchange Board of India, the National Company Law Tribunal, Odisha Industrial Infrastructure Development Corporation and other applicable authorities.

The transaction is expected to be completed within 12 to 14 months, subject to the necessary approvals from regulators, shareholders and creditors. Under the scheme, JSW Cement will issue 5 equity shares with a face value of Rs. 10 each for every 41 equity shares with a face value of Rs. 2 each held by Shiva Cement shareholders other than JSW Cement.

The company said the merger would consolidate financial, managerial, technical, distribution and marketing resources while reducing administrative duplication and compliance requirements. It would also provide greater funding flexibility, potentially lower financing costs and eliminate inter-company guarantees.

The consolidation is expected to strengthen backward integration by enabling JSW Cement to use Shiva Cement’s clinker manufacturing facility. This would reduce dependence on external clinker procurement and improve supply-chain efficiency. Public shareholders of Shiva Cement would receive direct ownership in JSW Cement, which has a broader institutional investor base and a more liquid listed presence.

JSW Cement acquired a controlling stake in Shiva Cement through transactions that began in January 2017. Shiva Cement operates a clinker facility in Odisha, near the borders of Odisha, Chhattisgarh and Jharkhand, and commissioned a 1 mtpa cement grinding unit at Sambalpur in FY26 through a commercial arrangement with Bhushan Power and Steel.

JSW Cement has 24.10 mtpa of cement grinding capacity and 9.74 mtpa of clinkerisation capacity. Its Indian operations comprise nine plants, including two integrated units, one clinker unit and six grinding units. The proposed merger is intended to simplify the corporate structure and align the financial statements of the two companies.

Concrete

Nuvoco Vistas, CleanMax Partner for Wind-Solar Hybrid Project in Rajasthan

Published

1 week ago

September 29, 2026

admin

The project – comprising 20 MW of wind and 26.4 MWdc of solar capacity – will support Nuvoco’s cement operations with cleaner power while strengthening its renewable energy and decarbonisation strategy.

Mumbai, September 29, 2026

Nuvoco Vistas Corp Ltd, part of Nirma Group and one of India’s leading cement companies, has partnered with Clean Max Enviro Energy Solutions Limited (CleanMax), a renewable energy solutions provider for the commercial and industrial (C&I) sector, to develop a 46.4 MW wind-solar hybrid renewable energy project in Rajasthan.

The project will support Nuvoco’s cement operations with cleaner power while strengthening its renewable energy and decarbonisation strategy. It is expected to increase the share of renewable energy in Nuvoco’s power mix, reducing fossil fuel consumption and associated emissions.

Developed by CleanMax, an Independent Power Producer (IPP), at Bhikamkhore, Rajasthan, the project will comprise 20 MW of wind capacity and 26.4 MWdc of solar capacity, along with a 2-MWh Battery Energy Storage System (BESS). Power generated from the facility will be supplied to Nuvoco through the State Transmission Utility (STU) Open Access network.

The hybrid project is expected to generate approximately 100 million units (MU) of renewable electricity annually and help avoid around 1,25,485 tonnes of CO₂ emissions every year across Scope 1 and Scope 2 emissions.

The initiative supports Nuvoco’s ongoing efforts to reduce the carbon intensity of its manufacturing operations through renewable energy adoption, Waste Heat Recovery Systems (WHRS), energy-efficiency measures and increased use of alternative fuels. It also aligns with the company’s DIRE (Digitalisation, Innovation and Renewables) agenda, which focuses on climate action, renewable energy transition, water stewardship, circularity and biodiversity conservation across its manufacturing ecosystem.

Commenting on the initiative, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said, “This marks an important step in advancing Nuvoco’s journey towards more sustainable and resilient operations. Our collaboration with CleanMax will increase the share of renewable energy across our Rajasthan operations, strengthening our energy mix while improving long-term cost efficiency and reducing our dependence on conventional power sources. Initiatives such as these reinforce our commitment to operational excellence and responsible growth, while supporting our vision of Building a Safer, Smarter and Sustainable World.”

Kuldeep Jain, Founder and Managing Director, CleanMax, said, “Cement plants run continuously, so the power behind them has to be dependable for decades, not years. We’re seeing manufacturing industries view clean energy as an integral part of their core operations and long-term strategy. Our partnership with Nuvoco reflects that shift, and we’re pleased to support its decarbonisation journey. This wind-solar hybrid project is designed to deliver long-term cost certainty while supporting the Company’s transition to cleaner power.”

Nuvoco has been advancing its sustainability initiatives through renewable energy, operational efficiency and technology-driven solutions. The company operates across Cement, Ready-Mix Concrete (RMX) and Modern Building Materials (MBM) segments, with a presence across East, North and West India.

The company began operations in 2014 with a greenfield cement plant in Nimbol, Rajasthan, and later acquired Lafarge India Limited, which entered India in 1999, along with Emami Cement Ltd in 2020 and Vadraj Cement Limited in April 2025. With planned expansion initiatives, including a new grinding mill at the Arasmeta Cement Plant and multiple debottlenecking projects, Nuvoco aims to achieve a cement capacity of 35 MMTPA.

The company reported total income of Rs 113.62 billion in FY 2025-26, reflecting its continued growth trajectory. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem brands, while its RMX business offers products under Concreto, Artiste, InstaMix, X-Con and Ecodure brands. Nuvoco also provides construction solutions under its Zero M range of modern building materials.