Connect with us

Concrete

Green Cements and Potential Challenges

Published

on

Shares

Dr SB Hegde, Professor, Jain University, Karnataka State, India, and Visiting Professor, Pennsylvania State University, USA, discusses the varieties of eco-friendly cements and their key components while evaluating the difficulties in manufacturing them.

Today, cement is the commodity item that is used most widely, and each person uses about half a tonne of cement annually.
Cement, however, has a significant negative impact on the environment despite the important role it plays in society. Currently, the production of cement consumes 3 per cent of the energy used worldwide and contributes to 4.5 per cent of greenhouse gas emissions (GHGs) and as the demand for cement rises, so does its impact on climate change.
For the world to achieve its goal of keeping global warming to 1.5°C in order to avoid the worst effects of climate change, it is imperative to find ways to reduce emissions from the cement sector, but this industry has proven to be obstinately challenging to decarbonise. Today, a crucial chemical process known as calcination is responsible for between fifty percent and two thirds of all emissions from cement manufacturing. Escaping these emissions is challenging.
In order to bring the cement industry to comply with the Paris Climate Agreement, annual emissions must decrease by at least 16 per cent by 2030. This implies that efforts along the entire value chain, from demand management to increasing process efficiency to utilising cutting-edge technologies and solutions in the manufacture of cement and concrete, will be crucial. However, directly addressing the process emissions will have the biggest impact.

It is anticipated that using CCUS technology to decarbonise the cement industry will increase costs by more than $100 per tonne of cement

Types of Main Green or Low Carbon Cements
Green cement is a product that is friendly to the environment and reduces the carbon footprint of cement production. A variety of green cement types have been created after numerous attempts to produce green cements.
The majority of these are based on technological developments, such as new cement formulations, geopolymers, carbon-negative cements, and new concrete products. These include energy-efficient, low carbon production techniques. Additionally, the production of green cement reduces the consumption of cement, and its primary raw materials include fly ash and blast furnace slag, industrial waste.
Examples of green cement include Ekkomaxx cement, magnesium oxychloride cement, geopolymer cement, ferrocrete, calcium sulfoaluminate cement and sequestrated carbon cement. While some of these products have been commercialised and used in numerous projects, some of these cements have not yet been widely used in construction projects despite having significant potential.

Ekkomaxx Cement
It is a kind of green cement made by the American company Ceratech, and it contains 5 per cent liquid renewable additives and 95 per cent fly ash. This cement, made by Ceratech Company, has almost no carbon footprint based on standards like the International Code Council and United States Green Building Council.
Along with a 95 per cent reduction in the use of virgin materials, the process of making cement also requires 50 per cent less water.
High early strength, resilience, crack resistance, low chloride permeability, resistance to sulphate attack, durability and corrosion resistance that is more than three times that of conventional cement, and greater resistance to freezing and thawing than that of standard cement are the main characteristics of Ekkomax cement.

Ferrocrete Cement
By combining silica and iron, which are leftover byproducts from the steel and glass industries, ferrocrete cement is created. This material mixture is then CO2-cured, potentially resulting in the creation of carbon-negative material. Ferrocrete was created by researchers at the Pennsylvania State University, USA.

Sequestrated Carbon Cement
The Calera Corp. cement in California produced cement from seawater or brine mixed with CO2 that may be used as a Portland cement substitute. In this cement production process, CO2 rich gases are filtered through seawater.
In order to create cement that can be used in place of Portland cement, the Calera Corp. cement plant in California mixed brine or seawater with CO2. Seawater is used to filter CO2 rich gases used in the cement manufacturing process.

Cement Produced with Superheated Steam
The process of superheated steam can be used to change the cement particles in order to make them more reactive. In this process, the emitted CO2 can be captured after it has been separated.

Magnesium oxychloride Cement (MOC)
Magnesium oxide (MgO) powder and a concentrated solution of magnesium chloride are the two main components of magnesium oxychloride cement (MOC), environmentally friendly and carbon-neutral cement (MgC12). These are byproducts of the mining of magnesium.
The MOC has great compressive strength and sets quickly and MgO absorbs CO2 from the atmosphere, but water can reduce its strength considerably. However, this weakness of MOC can be tackled to certain extent by introducing 15 per cent of fly ash and the same amount of silica fume.
These additives fill the pore structure in MOC, which makes the concrete denser. Consequently, both strength and durability of concrete is improved considerably. Furthermore, it is required to add phosphoric acid and soluble phosphates to improve the resistance of this type of green cement against warm water.
This cement causes steel to corrode – it cannot be used to build reinforced concrete structures unless this issue is resolved.

Geopolymer Cement
Alkali-activated cement, also known as geopolymer, is made from aluminosilicates rather than the more environmentally hazardous calcium oxide.
The aluminosilicates are made from by-products of industry, such as fly ash. The performance and price of the geopolymer cement are comparable to those of regular Portland cement, and it emits 95 per cent less CO2 overall.

Potential Challenges
Technology for carbon capture, utilisation, and storage (CCUS) offers one potential answer to these challenging process emissions. In CCUS, CO2 is extracted from cement manufacturing facilities’ exhaust gases and either used as a raw material for the production of valuable chemicals and fuels or stored deep underground in geological formations. Up to 90 per cent of all emissions from cement manufacturing could be eliminated by CCUS. However, there are a number of significant obstacles to overcome before the technology can be scaled up to meet sector demands. The challenges are as follows:

Clinkerisation is the most carbon intensive process in cement making and manufacturers are targeting this process mainly for carbon reduction.

A. CO2 Content
Compared to other industrial processes targeted by CCUS, cement production emits flue gas with a CO2 concentration of less than 20 per cent. Because of this, CO2 capture from cement plants is expensive. The efficiency and economics of the capture process could be improved with the use of creative kiln designs that separate exhaust gases, but doing so would require significant investment and plant redesign.

B. Geographic Limitations
Plants must be located close to an appropriate geological formation for carbon storage, which is neither common nor evenly distributed throughout the world. The cost of storing and transporting the captured CO2 in conjunction with a low-value product like cement poses a significant obstacle to the widespread use of this technology.

C. Capital Expenditure
The deployment of CCUS technology at scale is still a long way off and remains an expensive option. Although it is possible to capture cement plant emissions for about $100 per tonne of CO2, the costs are still higher than for other hard-to-abate industries like steel and fertiliser production.

D. Influence the Customers
It is anticipated that using CCUS technology to decarbonise the cement industry will increase costs by more than $100 per tonne of cement. This entails increasing the cost of cement from its current average of about $ 80-90 120 per tonne by a factor of two and consequently raising the cost of concrete by a factor of about 30 per cent. In a market where prices are so sensitive, this is a significant barrier.
Although CCUS technology is well-positioned to contribute to the decarbonisation of the cement industry, these difficulties make it unlikely that it will solve all problems and difficulties.

Low-Carbon or Green Cement – The Real Solution
Low-carbon cement can reduce process emissions by 10 to 100 per cent when compared to conventional ordinary Portland cement (OPC), which emits 0.6 tonnes of CO2 equivalent per tonne of cement and contains more than 90 per cent clinker. The most energy- and carbon-intensive step in the cement manufacturing process, the ‘clinker’, is directly targeted by low-carbon cement in order to reduce carbon emissions. There are numerous approaches to accomplish this, including:

Green cement is a product that is friendly to the environment and reduces the carbon footprint of cement production.

  • Reducing the amount of clinker used in cement by substituting a portion of it with alternatives called supplementary cementitious materials, or SCMs
  • Readjusting the way clinker is made by reducing the amount of limestone in feedstocks or modifying the calcination process
  • Reformulating cement chemistries by developing new binders based on novel materials and low-carbon processes.

Supply-Side Restrictions Stranded Resources
It costs between $200 million and $300 million to build a plant that can produce one million tonnes of ordinary Portland cement, the most widely used type of cement. Since there are currently more than 2,000 cement kilns in use, the industry is very resistant to any solution that calls for a redesign of manufacturing facilities.

Raw Material Availability
Cement is a low-value product that is consumed in enormous quantities, so the raw inputs need to be cheap, reliable and plentiful.

Efficiency of carbon capture process can be Improved with creative kiln designs.

Sales-Marketing Barriers Customer Unrest
Because safety is typically the top priority for engineers, architects and contractors, they prefer to use a reliable and well-known product. Low-carbon cements could differ from conventional OPC in terms of their setting times or early strength. This may lead to the perception that these products are risky, expensive or challenging to use.

Broken Value Chain
Numerous players participate in the construction industry at various stages of the project. This further discourages the use of alternative products by reinforcing the desire to use standardised, predictable and consistent products.

Testing Standards
Current testing standards for cements and concrete are highly prescriptive, often dictating the exact composition required for specific applications. These standards have been designed for OPC and may not be suitable for assessing the true performance of cements based on new chemistries. Setting new standards can take decades, and adoption by customers can be even slower.

Way Forward for Low Carbon or Green Cement
Low-carbon cements are a crucial way to significantly reduce emissions from cement production, despite these legitimate worries. Although there has never been a market for low-carbon cements, large corporations, government organisations, and real estate developers are all demanding solutions to lower the carbon footprints of their infrastructure and buildings, which is mandating pilot scale studies and venture capital interest in this field.

Conclusion
The potential of low-carbon cement cannot be made successful by only cement and concrete manufactures alone. Scaling innovation will require support from and collaboration among a diverse set of people like, cement manufacturers, builders, government and investors, whose input will be crucial at different stages of this project.

ABOUT THE AUTHOR:
Dr S B Hegde is a Professor at Jain University, Karnataka, India and also a Visiting Professor of Pennsylvania State University, United States of America. He had occupied ‘Leadership Positions’ in major and top cement companies in India and overseas. He has published more than 150 research papers in national and international journals. Dr Hegde is a recipient of the ‘Global Visionary’ Award in 2020.

Concrete

Driving Sustainability Through Innovation

Published

on

By

Shares



The 15th Cement Expo 2025 will spotlight India’s cement industry’s growth, innovation, and sustainability, showcasing cutting-edge solutions for a greener future.

The cement industry in India, the second-largest in the world, is on the cusp of remarkable growth as it continues its transition toward sustainability, innovation, and expansion. The 15th Cement Expo 2025, scheduled for November 12-13, 2025, at the Yashobhoomi Convention Centre in Delhi, will be the premier event where the industry’s foremost stakeholders converge to explore state-of-the-art technologies and solutions.
Co-located with the 11th Indian Cement Review Conference and the 9th Indian Cement Review Awards, the expo promises to be a pivotal event for professionals in the cement, construction, and infrastructure sectors. This year’s theme, “Driving Sustainability Through Technology,” highlights the sector’s commitment to decarbonisation, efficiency, and technological advancement. With India poised to add 80 to 100 million tonnes of cement capacity by 2024-25, the event will address the urgent need for sustainable, low-carbon solutions to meet the growing demand.
Before we look ahead to the 15th Cement Expo, let’s reflect on the remarkable success of the Cement Expo Forum 2025, held on March 5-6, 2025, in Hyderabad. The event attracted over 500 industry professionals and featured groundbreaking discussions on sustainability, logistics, and decarbonisation. Key sponsors and partners, such as ABB, Gebr Pfeiffer, JK Cement, and Flender Drives, showcased their latest innovations, contributing to the forum’s success.
Pratap Padode, Founder and President of First Construction Council, spoke at the event, noting, “The PPP pipeline is complemented by a provision of Rs 1.5 trillion in interest-free loans to states, earmarked for capital expenditure. With this, we have a solid plan in place. What needs to be done is to ensure that the PPP actually takes off as envisaged. To make this happen, trust must be established, and policies must be investor-friendly. Telangana, in this regard, has demonstrated ease of doing business exceptionally well.”
He added, “These financial injections into the infrastructure sector are expected to create a ripple effect, driving demand for cement as a key material in construction and development projects. The growing demand for cement is evident as infrastructure projects continue to rise across the country.”
The forum also provided invaluable networking opportunities, with attendees gaining insights from over 35 distinguished speakers and connecting with more than 50 exhibitors. The event laid a strong foundation for the upcoming Expo, showcasing the significant strides the cement industry is making toward a greener, more efficient future.
The 15th Cement Expo 2025 will focus on advancing the industry’s next big step toward sustainable growth. With India’s cement sector making significant progress in decarbonisation, a key focus will be on technologies and innovations that support carbon capture, low-carbon cement production, and energy-efficient solutions.
The expo will feature over 50 exhibitors representing all aspects of the cement industry. Whether you are a manufacturer, raw material supplier, technology provider, or logistics partner, the Cement Expo 2025 offers an ideal platform to showcase your products and solutions. Attendees will have the opportunity to explore the latest advancements in cement production technology, automation, logistics, and environmental solutions, all geared toward building a greener and more sustainable future.
Exhibitor profiles will include cement manufacturers, raw material suppliers, technology and automation solutions providers, environmental and sustainability solutions providers, cement packaging and logistics, construction equipment manufacturers, admixtures and chemical suppliers, and concrete reinforcement and structural systems.

11th Indian Cement Review Conference

Held alongside the Expo, the 11th Indian Cement Review Conference will offer delegates invaluable insights into the latest trends and innovations shaping the cement industry. Focusing on sustainability, the conference will address critical issues such as energy efficiency, plant design, and emerging technologies like carbon capture and automation.
Industry leaders will share their expertise in technical forums, while specialised activities, such as plant tours and energy audits, will provide practical guidance on improving operations and efficiency. This is a prime opportunity to network with industry stakeholders, gain hands-on experience with new technologies, and acquire actionable knowledge to enhance your business.

9th Indian Cement Review Awards

The 9th Indian Cement Review Awards will recognise the fastest-growing cement companies and industry leaders for their outstanding contributions to the sector. This prestigious event will serve as a platform to honour the pioneers of innovation, sustainability, and performance within the cement industry, highlighting the sector’s commitment to growth and environmental responsibility.
As we look forward to the 15th Cement Expo 2025, we invite you to join us for two exciting days of networking, learning, and innovation. This event offers a unique opportunity to be part of the next wave of growth and sustainability in the global cement sector.

Continue Reading

Concrete

Transforming Interior Spaces: Trendy Wall Putty Designs to Enhance Your Home

Published

on

By

Shares



When it comes to interior design, walls are more than just structural elements—they serve as the canvas for self-expression, setting the mood and personality of a space. While paint and wallpaper have long been the go-to choices for wall finishes, wall putty is emerging as a game-changer in home décor. With its smooth finish, durability, and versatility, wall putty opens a world of creative possibilities. In this article, we explore trendy wall putty designs that can elevate your interiors, turning ordinary walls into extraordinary design statements.
Wall Putty is a Must-Have in Modern Homes
Wall putty is no longer just a preparatory material for painting; it plays a significant role in modern home aesthetics. It enhances the finish of walls, making them smoother, stronger, and resistant to cracks and moisture. Additionally, high-quality putty like Birla White Wall Putty ensures better paint adhesion, resulting in long-lasting vibrancy.
Beyond its functional benefits, wall putty allows homeowners to experiment with textures and patterns, giving walls a designer touch without the hassle of high-maintenance materials like stone or wood. Whether you’re aiming for a minimalist, rustic, or ultra-modern aesthetic, wall putty designs can help achieve the look effortlessly.
Trendy Wall Putty Designs for Stunning Interiors
1. Textured Wall Putty for a Tactile Appeal
Textured walls are a popular interior trend, adding depth and dimension to living spaces. By using wall putty, homeowners can create a variety of textures, including:
  • Rustic Texture: Mimicking natural stone or aged plaster for an earthy, vintage feel.
  • Wave Patterns: Adding a sense of movement and fluidity to walls, perfect for living rooms and entryways.
  • Sand Finish: A subtle grainy effect that provides a sophisticated touch.
Textured putty walls work exceptionally well in accent areas, such as behind a television unit or as a backdrop for artwork.
2. Sleek and Smooth Walls for a Luxurious Look
For those who prefer a refined and elegant aesthetic, a smooth putty finish is ideal. A flawlessly smooth wall creates a premium appearance, amplifying the impact of high-quality paints. Opting for a high-performance putty like Birla White WallCare Putty ensures a glass-like finish that complements modern and contemporary interiors.
This design is perfect for:
  • Monochrome interiors where walls serve as a sleek backdrop.
  • High-gloss or matte-painted walls that need a seamless base.
  • Spaces with minimal décor where the walls themselves make a statement.
3. Geometric & Abstract Patterns for a Contemporary Edge
Wall putty can be artistically applied to create striking geometric or abstract patterns, adding a unique character to interiors.
Popular designs include:
  • Chevron or Herringbone: A dynamic, sophisticated look that pairs well with both modern and mid-century décor.
  • 3D Raised Panels: Using putty to craft subtle raised patterns, adding a sculptural effect to the wall.
  • Asymmetrical Shapes: For a bold and avant-garde touch.
  • These patterns work best in bedrooms, study areas, or accent walls in open spaces.
4. Venetian Plaster for a Luxe European Aesthetic
Venetian plaster, an age-old technique, is making a grand comeback in modern interiors. With wall putty, you can achieve this exquisite marble-like effect, which exudes luxury and timeless charm.
This design works well for:
  • Statement walls in living rooms and foyers.
  • Elegant dining areas where a touch of opulence is desired.
  • Boutique-style bedrooms with a rich, textured finish.
A high-quality white cement-based putty can replicate this effect beautifully, making the walls look naturally luminous.
5. Dual-Tone or Ombre Walls for a Soft Gradient Effect
The ombre effect, a gradient transition between two colors, is a trendy and artistic way to enhance interiors. When applied over a smooth wall putty base, the gradient blends seamlessly, offering a dreamy, watercolor-like appeal.
This style is perfect for:
  • Children’s rooms or play areas, creating a fun and dynamic atmosphere.
  • Bedrooms with a soothing pastel gradient for a calming effect.
  • Dining spaces where a bold color fade adds character.
6. Metallic & Glossy Finishes for a Chic Look
For homeowners who love glamour and sophistication, combining wall putty with metallic paints or glossy finishes can create a high-end appeal. The smooth base of putty enhances the reflective qualities of metallic shades like gold, silver, or bronze, resulting in an opulent and dramatic effect.
Best suited for:
  • Luxurious master bedrooms and dressing areas.
  • Accent walls in dining rooms or home bars.
  • Commercial spaces like boutiques and salons.
How to Achieve the Best Wall Putty Designs
  • Choose the Right Putty: Opt for a premium wall putty like Birla White WallCare Putty to ensure durability, a smooth finish, and long-lasting appeal.
  • Prepare the Surface: Ensure the walls are clean, dry, and free from loose particles before application.
  • Apply in Layers: Depending on the design, putty can be applied in single or multiple layers for the desired effect.
  • Use the Right Tools: Trowels, spatulas, sponges, or patterned rollers help create specific textures and patterns.
  • Seal with Paint or Polish: Once the putty is dry, finishing it with paint, polish, or protective coatings enhances its aesthetic and durability.
Conclusion
Wall putty has evolved beyond its traditional role, now serving as a medium for creative interior design. Whether you prefer textured finishes, sleek smooth walls, or artistic patterns, wall putty designs can elevate your home’s aesthetics while offering durability and elegance. By selecting the  best putty for wall and application technique, you can transform your interior walls into stunning masterpieces, setting the perfect backdrop for your lifestyle.
For high-quality wall finishes that stand the test of time, Birla White WallCare Putty ensures both beauty and performance, making your dream interiors a reality.

Continue Reading

Concrete

Dalmia Bharat to add 6 MnTPA Cement Capacity in Maharashtra and Karnataka

Published

on

By

Shares



  • Investment in alignment with the strategic goal of becoming a PAN India company and achieving 75 MnT capacity by FY28
  • Increases capacity primarily to meet growing demand in Western India along with existing regions

Dalmia Bharat Limited, one of India’s leading cement companies, through its subsidiaries, has announced a strategic investment of approximately Rs 3,520 Crore in the states of Maharashtra and Karnataka. As part of this initiative, the company will establish a 3.6 MnTPA clinker unit and a 3 MnTPA grinding unit at its existing Belgaum plant, Karnataka coupled with a new greenfield split grinding unit with a capacity of 3 MnTPA in Pune, Maharashtra. The capex will be funded through a combination of debt and internal accruals. With this expansion, Dalmia Bharat’s total installed cement capacity will increase to 55.5 MnTPA, after considering the ongoing expansion of 2.9 MnT at Assam and Bihar. These new units are expected to be commissioned by Q4 FY27.

The Belgaum Grinding Unit will cater to the underserved Southern Maharashtra markets while enhancing share in the existing region by improving penetration. On the other hand, Pune Grinding Unit will entirely cater to the untapped Western Maharashtra markets. The initiative is a part of the company’s vision to be a PAN India player and achieve 75 MnTPA capacity by FY28 and 110-130 MnT by 2031.

Speaking on the development, Mr. Puneet Dalmia, Managing Director & CEO, Dalmia Bharat Limited, said, “This investment is a significant step in our Phase II expansion strategy, bringing us closer to strengthen our position as a pan-India player and to reach intermittent goal of 75 MnT capacity by FY28. The increase in our production capacity is primarily to meet the growing infrastructure demand in Western India.” He further added, “We remain committed in realising our goals of capacity expansion, while staying focused on operational excellence and creating long-term value for our stakeholders. The capacity additions will also continue to be in line with Dalmia Bharat’s sustainability-driven approach and its commitment to supporting India’s infrastructure and development goals.”

About Dalmia Bharat: Founded in 1939, Dalmia Bharat Limited (DBL) (BSE/NSE Symbol: DALBHARAT) is one of India’s pioneering cement companies headquartered in New Delhi. With a growing capacity, currently pegged at 46.6 MnT, Dalmia Bharat Limited (including its subsidiaries) is the fourth-largest cement manufacturing company in India by installed capacity. Spread across 10 states and 15 manufacturing units.  Dalmia Cement (Bharat) Limited, a subsidiary of Dalmia Bharat Limited, prides itself at having one of the lowest carbon footprint in the cement world globally. It is the first cement company to commit to RE100, EP100 and EV100 (first triple joiner) – showing real business leadership in the clean energy transition by taking a joined-up approach.

Continue Reading

Trending News

SUBSCRIBE TO THE NEWSLETTER

 

Don't miss out on valuable insights and opportunities to connect with like minded professionals.

 


    This will close in 0 seconds