Concrete

The consistent goal in the cement industry is to use fewer natural resources

Published

3 years ago

December 13, 2022

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Sanjay Joshi, Chief Manufacturing Officer, Nuvoco Vista, highlights the various supplementary cementitious materials that are used to make cement production more cost-effective and environmentally sustainable.

What are supplementary cementitious materials? Tell us more about their nature
of origin.
Cement products often have other materials incorporated that help increase the product’s strength and durability, reduce permeability, as well as help reduce the impact on the environment. These materials are known as supplementary cementitious materials.
The most used supplementary cementitious materials are fly ash or blast furnace slag. While fly ash is a by-product of thermal power generating stations, slag is a glassy, granular material formed during the smelting process of iron ore; it is quenched mostly by water sprays or immersion in water and then subsequently ground to cement fineness.
Gypsum is another cementitious material that is added to the cement. It is found naturally and as a by-product of chemical industries. Chemically, it is a sulphate of calcium (CaSO4.2H2O), which helps in delaying the setting time of cement and makes it workable.

Tell us about the supplementary cementitious materials and their composition used by your organisation.
We are using all the above-listed cementitious material as it is prevalent in the industry. The
C/K ratio (cement to clinker ratio) indicates the composition of cementitious materials used. We are operating at a level of ~1.8., which means we are producing ~1.8 tonnes of cement for every tonne of clinker consumed. It makes us the leading player in the industry, manufacturing products with high cementitious addition. We operate close to the 34-34.5 per cent fly ash addition in fly ash based cement. In slag-based cement, we are operating in the range of 55-65 per cent slag, based on the product requirement. Gypsum usage ranges from 3-5 per cent in all cement types, and it varies based on the requirement of
setting time.

Does the use of supplementary cementitious materials impact the process of cement manufacturing?
Yes, cementitious materials impact the energy consumption of cement manufacturing. These materials are easy to grind when compared to clinker which is the major constituent of cement. Thus, higher usage of cementitious materials helps in reducing energy consumption.
Also, clinker usage directly involves limestone consumption as a raw material. Therefore, by using higher cementitious materials in the cement-making process, we are preserving the limestone available naturally.
Another aspect of adding cementitious material is the change in equipment required. Slag and fly ash are abrasive in nature thus the equipment being used in cement manufacturing will wear out faster in the case of PPC and PSC making. This lower clinker consumption ultimately lowers CO2 emission/tonne of cement production.

What are the key advantages of using supplementary cementitious materials in the cement manufacturing process?
Cement manufacturing is a closed loop wherein all raw materials from limestone mining to clinker production remain fully under controlled process parameters. The company focuses on reducing clinker consumption by increasing the blended cement ratio. Using these SCM, Nuvoco is also aiming to save fossil fuel, along with the obvious reduction in carbon emissions. Additionally, SCM increase the strength and durability of the product and reduce permeability.

How does the use of supplementary materials increase the profitability of cement manufacturing for your organisation?
Clinker manufacturing is the main cost-intensive step of the cement manufacturing process. Thus, a higher percentage of clinker in cement leads to a higher cost of manufacturing. By using SCM to the maximum extent possible, we can make cement at a lower cost without impacting its key properties.

Tell us about the quality standards and checks implemented for the final product made using supplementary materials.
Nuvoco has a dedicated NABL-accredited Construction Development and Innovation Centre (CDIC) located in Mumbai. It serves as the incubation centre for innovative products and can conduct over 100 mechanical tests. Apart from that, it also offers third-party external testing services, offering products and solutions that have passed the highest standards and holds global validation.
Additionally, Nuvoco also exceeds/meets BIS standards for cement quality. We also have a robust internal quality check procedure for continuous monitoring and course correction if any.

What are the major challenges you face while using supplementary materials for cement manufacturing?
The major challenge would be ‘Procurement, Distribution, Quality and Cost’. If any of this gets compromised, it will result in increased cement costs. Cost plays an important role and is majorly affected by the lead distances and availability of cementitious material quality determines the level up to which we can optimise the addition of the cementitious material in consideration.

How does the use of cement made of supplementary materials impact its carbon footprint?
Taking care of our environment and being sustainable have always been our focus. The use of such SCM lowers the energy in the concrete and counterbalances almost a ton of carbon emissions for every ton of cement that is replaced.
The addition of cementitious material (fly ash and slag) in cement helps to reduce the carbon footprint in cement as waste from a different industry is utilised in products in the market. The second benefit is the reduction of clinker consumption which in itself is a carbon-intensive product as it requires the usage of fossil fuels and also consumes limestone which in turn requires mining and other processing activities.

How do you foresee the future of the global cement industry in terms of using alternative materials for cement manufacturing and running the race of decarbonisation?
With our sustainability initiatives, we are looking to create value for all our stakeholders.
Our outlook remains optimistic, both in the short-term and in the long-term, concerning India, the cement industry and Nuvoco, in particular. There are substantial opportunities for growth and impact.
The consistent goal in the cement industry is to use fewer natural resources. Limestone, the primary natural resource used in cement production, is reduced as blended cement production rises. This benefits not only the company but also the businesses that produce trash, such as the steel and power industries.

–Kanika Mathur

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Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

Published

3 days ago

June 5, 2026

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

Concrete

Building a Greener Future Together

Published

4 days ago

June 4, 2026

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

Published

7 days ago

June 1, 2026

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.