Concrete
Smooth Operator!
Published
3 years agoon
By
admin
A cement manufacturing plant owes its success to smoothly operating machinery, which relies on lubricating oils and grease.
ICR explores how lubricants can be used sustainably, both for economic and environmental benefits.
The cement manufacturing process is heavy duty. Activities such as carrying mined limestone on quarry belts to the pyroprocessor where clinker is produced at high heat levels cause immense load and severe operating conditions for equipment such as kilns, ball mills, conveyors, and quarry-side mobile plants. The cement making machinery works around the clock, subjecting its components like gearboxes and bearings to overheating and premature wear and tear.
It is essential that care be taken and regular maintenance work be done for each of these equipment as the plant shall endure heavy financial and production losses if there is machinery failure, shutdown or loss of heat and energy in the mining area or manufacturing plants. To avoid such a situation and any unscheduled downtime, maintenance operators and managers invest in high performing lubricants, oils and grease that reduce the harm on machinery components.
LUBRICANTS AT WORK
Specially formulated lubricants are required at all stages of the cement making process, namely, extraction, crushing, conveying, grinding, clinker production, grinding and some general lubricants are needed for processes that happen in between.
- Crushing: In the cement manufacturing process, raw materials such as limestone and clay are crushed to a fine powder. Crushers are used to break down large chunks of raw materials into smaller pieces. Lubricants are applied to the bearings and gears of the crushers to reduce friction and prevent wear and tear, ensuring the equipment operates smoothly and efficiently.
- Grinding: After the crushing stage, the raw materials are further pulverised in grinding mills to produce a fine powder called raw meal.
- Ball mills and vertical roller mills are commonly used for grinding in the cement industry.
- Lubricants are applied to the bearings and gearboxes of these mills to minimise friction, reduce energy consumption, and prevent damage to critical components.
- Kiln: The raw meal is heated in a rotary kiln to a temperature of around 1450°C, where it undergoes a chemical transformation to become clinker. The kiln is a crucial component in cement manufacturing and requires effective lubrication. Lubricants are applied to the kiln supporting rollers, bearings, and gears to reduce friction, prevent overheating and ensure smooth rotation and operation of the kiln.
- Conveyors: Throughout the cement production process, various types of conveyors are used to transport raw materials, clinker and finished cement. Lubricants are essential for the conveyor system’s smooth operation. They are applied to the bearings, chains and gears of conveyors to reduce friction, minimise wear and tear and prevent breakdowns or malfunctions that could disrupt the production flow.
- Fans and Blowers: Cement plants utilise fans and blowers for various purposes, such as providing combustion air, circulating hot gases within the kiln, and transporting materials. These fans and blowers have rotating parts that require lubrication to ensure their optimal performance. Lubricants are applied to the bearings, gears and shafts of fans and blowers to reduce friction, improve efficiency and extend their operational lifespan.
- Pumps: Pumps are used in cement plants for a range of applications, including the transportation of water, fuel and various process fluids. Lubricants are necessary for the pump’s bearings and seals to reduce friction, prevent overheating, and maintain the pump’s efficiency. Proper lubrication helps to minimise energy consumption and ensure reliable pump operation.
- Preheaters and Pre-calciners: Preheaters and pre-calciners are used to preheat and pre-calcine raw materials before they enter the kiln. These systems have moving parts, such as fans, rollers and chains, which require lubrication to reduce friction, prevent wear and maintain their performance and reliability.
- Cement Mills: After the clinker is produced in the kiln, it is finely ground in cement mills to produce cement. Lubricants are applied to the bearings and gears of these mills to reduce friction, enhance grinding efficiency, and prevent premature failure of critical components.
- Bag Filters: Bag filters are used in cement plants to capture and remove dust particles from the exhaust gases generated during various processes. These filters consist of fabric bags that require regular cleaning and maintenance. Lubricants are applied to the bag filter’s mechanisms and moving parts, such as valves and fan bearings, to ensure smooth operation and prevent any potential issues that could affect the filtration efficiency.In each of these functions, the selection of appropriate lubricants is crucial. Factors such as operating conditions (temperature and humidity), load, speed and type of equipment must be considered to determine the most suitable lubricants for each application. Regular lubrication and maintenance practices are essential to optimise the performance, reliability and lifespan of the equipment in a cement plant.
ROLE OF LUBRICANTS
In the cement industry, lubricants play a crucial role in ensuring the smooth and efficient operation of various machinery and equipment involved in the production process. Cement manufacturing involves the extraction of raw materials, such as limestone and clay, which are then processed and transformed into the final product through a series of stages, including crushing, grinding, heating, and mixing. Throughout this complex and demanding process, lubricants provide essential benefits that contribute to the overall productivity, reliability and longevity of the equipment involved.

One of the primary functions of lubricants in the cement industry is to reduce friction between moving parts. Machinery used in cement plants, such as crushers, ball mills, conveyor belts, kilns and pumps, consist of numerous mechanical components that require smooth operation. By applying lubricants, a thin layer is formed between contacting surfaces, which reduces friction and minimises wear and tear. This helps to prevent damage to critical parts, reduce energy consumption, and improve the overall efficiency of the equipment.
Lubricants also play a vital role in protecting equipment from corrosion. Cement manufacturing involves exposure to harsh operating conditions, including high temperatures, humidity, and the presence of abrasive dust particles. These factors can lead to the deterioration of metal surfaces, which can significantly impact the performance and lifespan of machinery. Lubricants with anti-corrosion properties form a protective barrier that shields metal surfaces from moisture, chemical agents, and other corrosive elements, thereby preventing rust and corrosion and extending the equipment’s service life.
“The critical equipment like kiln, vertical rolling oil, ball mill, crushers, roller press, etc. operate continuously under challenging conditions. The gear boxes in this equipment are subjected to extreme loading conditions and may cause micro pitting, premature wear problems and consumes a lot of energy. MAK Lubricants offer energy efficient gear oils with anti-micro pitting resistance reducing energy consumption and extending the equipment life respectively,” says Sudhahar P, Executive Director (Lubes), Bharat Petroleum Corporation.
“Heavy loads, high pressures, and temperatures in the hydraulic system of the grinding mill causes increased stress on hydraulic oil and thereby reduces its service life. Our energy efficient long life hydraulic oil not only has a potential to save energy but also provide longer oil life along with improved reliability of equipment,” he adds.
Moreover, lubricants aid in the cooling of equipment. Many cement manufacturing processes generate considerable heat due to the grinding and calcination of raw materials. Excessive heat can negatively affect the performance and reliability of machinery. By using lubricants with high thermal conductivity, heat generated during operation can be efficiently dissipated, ensuring that the equipment operates within the desired temperature range. This helps to prevent overheating, reduces the risk of thermal damage and contributes to the overall safety and reliability of the production process.
In addition to the aforementioned functions, lubricants also provide effective sealing properties. Cement plants often employ rotary kilns, which are large cylindrical structures used for the high-temperature processing of raw materials. These kilns require a reliable sealing system to prevent heat and gas leakage. Lubricants, such as high-temperature grease and specialised sealants, create effective seals between moving parts, ensuring that the kilns operate efficiently and maintain the desired temperature and gas flow, while also minimising energy losses.
Furthermore, lubricants contribute to the overall maintenance and operational cost reduction in the cement industry. By using appropriate lubricants and implementing effective lubrication practices, equipment downtime due to mechanical failures can be minimised. Regular lubrication helps to keep the machinery in optimal condition, reduces the frequency of repairs and replacements, and extends the equipment’s lifespan. This translates into improved production efficiency, reduced maintenance costs and increased profitability for cement manufacturers.
It is important to note that selecting the right lubricants for each specific application is crucial to ensure optimal performance and maximise the benefits mentioned above. Factors such as operating conditions, equipment type, load, and speed must be carefully considered when choosing lubricants. Cement manufacturers often collaborate with lubricant suppliers or engage in extensive research and development to identify the most suitable lubricants for their specific requirements.
Lubricants play a vital role in the cement industry by reducing friction, protecting against corrosion, aiding in cooling, providing effective sealing, and contributing to maintenance and cost reduction. By utilising appropriate lubrication practices and selecting the right lubricants, cement manufacturers can enhance equipment performance, prolong the lifespan of machinery, improve operational efficiency and ultimately achieve higher productivity and profitability in their operations.

COST EFFICIENCY AND HIGH PRODUCTIVITY
Lubricants play a significant role in achieving cost efficiency and higher productivity in cement plants through various mechanisms.
Reduced equipment downtime: Proper lubrication with high-quality lubricants helps prevent equipment failures and breakdowns. Lubricants create a protective barrier between moving parts, reducing friction and wear. This minimises the risk of mechanical failures, such as bearing failures or gear damage, which can lead to unplanned downtime. By minimising equipment downtime, cement plants can maximise production output and avoid costly disruptions.
Extended equipment lifespan: Lubricants provide essential protection to the machinery by reducing friction, preventing wear and minimising corrosion. This leads to increased equipment lifespan, as components experience less stress and damage. By extending the lifespan of critical equipment such as crushers, mills, kilns and conveyors, cement plants can avoid or delay costly capital expenditures for replacements, resulting in significant cost savings over time.
Energy efficiency: Lubricants with low friction properties and high thermal conductivity contribute to energy efficiency in cement plants. By reducing friction between moving parts, lubricants help minimise energy losses due to heat generation. Additionally, lubricants that efficiently dissipate heat help maintain optimal operating temperatures, preventing excessive energy consumption. Improved energy efficiency directly translates into cost savings and higher productivity.
Maintenance cost reduction: Regular lubrication and the use of appropriate lubricants help maintain equipment in optimal condition. Lubricants reduce friction, wear, and corrosion, reducing the need for frequent repairs or replacements of components. By implementing effective lubrication practices, cement plants can minimise maintenance costs, save on spare parts and allocate resources
more efficiently.
“Generally, break down the journey to lubrication excellence into six categories: lubricant selection, reception and storage, handling and application, contamination control, lubricant analysis, and environmental disposal. This article will focus on the first five categories and provide examples of how to improve in regard to overall lubrication excellence and cost-effectiveness. While environmental disposal is critical, it’s not necessarily a good place to look for cost savings,” says Mukesh Saxena, Joint President, Star Cement.
“Selecting the proper lubricant from the beginning is the most important step you can take to improve machine productivity. Your equipment’s needs will drive the selection process, but having a thorough understanding of different lubricant properties will allow you to pick the optimum solution,” he adds.
Achieving cost efficiency and higher productivity with lubricants requires proper selection, application, and maintenance practices. Cement plants should work closely with lubricant suppliers or industry experts to identify the most suitable lubricants for their specific equipment and operating conditions. Regular monitoring, lubricant analysis, and adherence to recommended lubrication schedules are essential to maximise the benefits and optimise the performance of the lubrication program in a cement plant.
IMPACT OF ENVIRONMENT
The performance and effectiveness of industrial lubricants used in cement plants can be significantly impacted by the external environment. Factors such as temperature and humidity play a crucial role. Cement plants often operate in harsh conditions with high temperatures and humidity levels. Extreme temperatures can affect the viscosity of lubricants, compromising their ability to provide proper lubrication. High humidity can introduce moisture, leading to emulsion formation and affecting lubricant stability.
Dust and contaminants are another external factor that can impact lubricant performance. Cement production generates fine dust particles that can enter lubrication systems, compromising lubricant effectiveness and accelerating wear on equipment.
Chemical exposure is also a concern as cement manufacturing involves the use of various chemicals. Incompatible chemicals can lead to lubricant breakdown, loss of viscosity, and increased oxidation.
Operational loads and speeds of equipment in cement plants vary, requiring lubricants with appropriate viscosity, load-carrying capacity,
and film strength. Regulatory and environmental considerations are also important as lubricants must comply with regulations and be environmentally friendly.
Cement plants should collaborate with lubricant suppliers, implement regular monitoring and analysis, and ensure proper storage and handling to mitigate the impact of the external environment on lubricant performance.
“Cement plants are process plants, thousands of rotating machines operating 24×7, 365 days, availability of these machines being critical and plant reliability is vital, operating conditions of cement plants is hostile, lubricants get contaminated before being filled in machines and while in service. 80 per cent of failures are due to lubrication errors,” says Gaurav K Mathur, Director and Chief Executive, Global Technical Services.
“System oriented approach for contamination free lubrication is the foremost requirement of industry TLM is implementation of SOPs for uniform adaptation of best lubrication practices, oil top up, oil disposal or grease replenishment in plummer block,” he adds.
SUSTAINABILITY THROUGH LUBRICANT EFFICIENCY

Cement plants can achieve sustainability in their lubricant use by implementing several strategies and practices. Here are some key approaches:
- Select environment-friendly lubricants: Cement plants can choose lubricants that are formulated with environmentally friendly ingredients and have minimal impact on the environment. This includes selecting lubricants that are biodegradable, non-toxic, and free from substances that are harmful to human health or ecosystems. Certifications such as the EU Ecolabel or the USDA BioPreferred programme can guide the selection of sustainable lubricants.
- Optimise lubricant consumption: Cement plants can optimise lubricant consumption by implementing proper lubrication practices. This includes regular monitoring of lubricant levels, applying the right amount of lubricant to each component, and avoiding over-lubrication. By optimising lubricant usage, cement plants can reduce waste, lower lubricant consumption and minimise the environmental footprint associated with lubricant disposal.
- Implement lubricant recycling and reclamation: Cement plants can explore options for recycling and reclaiming lubricants. Some lubricants can be reprocessed, filtered, or purified for reuse, extending their lifespan and reducing the need for new lubricant purchases. Implementing lubricant recycling programmes can minimise waste generation and conserve resources.
- Promote energy-efficient lubricants: Energy-efficient lubricants can help reduce energy consumption in cement plants. These lubricants have low friction properties and can contribute to energy savings by reducing mechanical losses in equipment. By selecting lubricants specifically designed for energy efficiency, cement plants can enhance their sustainability efforts and reduce their overall energy consumption.
- Proper lubricant storage and handling: Proper storage and handling of lubricants are crucial for maintaining their quality and preventing contamination. Cement plants should ensure that lubricants are stored in sealed containers, away from direct sunlight, excessive heat, or extreme temperatures. Adequate labelling and inventory management practices should be implemented to minimise the risk of lubricant spoilage or degradation.
- Regular lubricant analysis and monitoring: Implementing a lubricant analysis and monitoring program allows cement plants to assess lubricant condition and performance. Regular analysis can help identify issues such as contamination, degradation or excessive wear. By monitoring lubricant condition, plants can schedule maintenance activities effectively, avoid premature lubricant changes and optimise lubrication intervals, reducing waste and improving overall sustainability.
- Collaborate with lubricant suppliers: Cement plants can collaborate closely with lubricant suppliers and industry experts to identify sustainable lubrication solutions. Lubricant suppliers can provide guidance on selecting environmentally friendly products, offer training on best practices and assist with lubricant analysis and optimisation.
- Employee training and awareness: Promoting employee training and awareness programmes on sustainable lubricant use can foster a culture of environmental responsibility within the cement plant. Educating employees on proper lubrication practices, the importance of sustainability and the potential environmental impacts of lubricant use can empower them to actively contribute to the plant’s sustainability goals.
CONCLUSION
Lubricants play a vital role in the cement industry, ensuring smooth equipment operation and productivity. Proper lubrication practices lead to cost efficiency, extended equipment lifespan, and reduced downtime. Cement plants should select lubricants that withstand harsh conditions, comply with regulations, and prioritise environmental sustainability. Optimising lubricant consumption, promoting energy-efficient options, and implementing recycling programmes contribute to a greener approach. Regular analysis, collaboration with suppliers, and employee training further enhance sustainability efforts. By integrating these strategies, cement plants can minimise their environmental impact and achieve a more efficient and sustainable manufacturing process.
Concrete
Akhoya Gets New 2.2 Km Road Link Under SASCI
Two cement concrete roads opened at Rs 29.1 million (mn) cost
Published
21 hours agoon
July 3, 2026By
admin
Two cement concrete pavement roads covering a total stretch of 2.2 km in Akhoya village were inaugurated on 27th June 2026 by MLA Nuklutoshi Longkumer, who attended as the special guest. The project comprises the one km L Pangersowa Road and the one point two km Longchara Junction to RC Chiten Jamir Memorial Government High School road. A formal programme followed the inauguration at the school auditorium.
A technical report was presented by Er Waloniba of the Urban Engineering Wing-III, Kohima, which stated the project was sanctioned in March 2026 under the Special Assistance to States for Capital Investment scheme for 2025-26 at a sanctioned cost of Rs 29.1 million (mn). The work order was issued to M/s Ensign Construction on thirtieth April 2026 with a stipulated completion period of 12 months. Work commenced on fourth May 2026 and was completed on sixth June 2026, with the contractor and team finishing the tasks in around two months. The project included a single-lane cement concrete pavement with side drains, two slab culverts and breast walls at required locations.
Longkumer acknowledged the Chief Minister, the advisor for urban development, contractors and other stakeholders for the allocation and support, and he commended the contractor for early completion. He noted that cooperation from landowners and the community had been important in resolving land related issues that can otherwise delay developmental works. He emphasised that planned developmental activities carried out with collective effort would enable more projects to be implemented successfully.
The headmaster of RC Chiten Jamir Memorial Government High School, I Chubasenba Longkumer, outlined the school background, noting it was established in 1962, was earlier known as Government High School Changtongya and was renamed in 2014. Local representatives said the improved approach roads would ease access for students, staff, patients and the general public and fulfil a long standing aspiration of residents. A dedicatory prayer was offered by the pastor and the programme concluded with a ribbon cutting attended by village council and town council representatives.
Indian Cement Review (ICR) and Fuller Technologies brought industry, policy and technology leaders together to discuss how cement innovation can drive green construction at scale, writes Rakesh Rao.
India is building at a pace few countries can match. Highways, airports, housing, logistics parks, industrial corridors and urban infrastructure are reshaping the country’s economic geography. But beneath this growth story lies a difficult question: can India continue to build at scale without locking itself into a high-carbon future?
That question formed the core of an online panel discussion titled “Driving Green Construction Through Cement Innovation”, organised by Indian Cement Review (ICR) in association with Fuller Technologies as the Presenting Partner on June 25, 2026. The webinar brought together experts from cement technology, R&D, global industry platforms, building performance policy and international development cooperation to examine how low-carbon cement and material innovation can accelerate India’s green construction transition.
The discussion came at a crucial time. India has committed to achieving net-zero emissions by 2070 and reducing the carbon intensity of its economy by 45 per cent by 2030. At the same time, the country’s construction sector is expanding rapidly, driven by urbanisation, infrastructure development, housing demand and industrial growth. Cement, as one of the most widely used construction materials, sits at the heart of this transition. It is indispensable to development, but also central to the challenge of reducing embodied carbon in buildings and infrastructure.
Moderated by Nitika Krishan, Senior Urban Infrastructure and Sustainable Policy Consultant, the panel featured:
- Kiranmai Sanagavarapu, Director, Low Carbon Solutions, Fuller Technologies;
- Dr Hemantkumar Aiyer, VP and Head R&D, Nuvoco Vistas Corp Ltd;
- Devika Wattal, Innovation Lead, Global Cement and Concrete Association (GCCA);
- Dr Sunita Purushottam, MD, GBPN India (Global Buildings Performance Network); and
- Vaibhav Rathi, Senior Technical Advisor, GIZ (the German Agency for International Cooperation)
Setting the tone for the discussion, Nitika Krishan underlined the scale of the challenge before the sector. “The question before us is no longer whether we build, but how we build sustainably,” she said. She pointed out that construction accounts for nearly 40 per cent of global energy-related carbon emissions when both operational and embodied carbon are considered. Cement production, she added, remains one of the hardest industrial processes to decarbonise.
For India, this is not merely an environmental issue. It is a development issue, a competitiveness issue and increasingly, a market issue. As one of the world’s largest cement producers and among the fastest-growing construction markets, India’s material choices will influence the carbon trajectory of its built environment for decades. As Krishan observed, sustainability solutions in economies such as India must not remain limited to laboratory success. They must be scalable, commercially viable and practical at national level.
The innovation gap: From technology to market
Experts believe that there is a need to bridge the innovation gaps for making decarbonisation in cement and concrete scalable. Devika Wattal of GCCA, explained, “The starting point must be the core cement manufacturing process itself. The first and foremost is the heart of our process, the heart of cement manufacturing. How do we reduce clinker? That is always a topic where industry is working very intrinsically.”
Clinker reduction remains one of the most important pathways for lowering emissions in cement. Since clinker production is energy-intensive and chemically emits carbon dioxide, reducing the clinker factor through supplementary cementitious materials (SCMs), blended cements and new chemistries can have a significant impact. Wattal also noted that carbon capture, utilisation and storage (CCUS) will have a role, though it may not be the first lever for all markets.
However, she stressed that innovation cannot stop at technology development. A solution that works in the lab must also be adaptable to industry, scalable in production and acceptable in construction practice. “It is important for that innovation to be adaptable, to be scalable, and so that it can be executed in real time,” she said.
Wattal also called for stronger enabling systems around innovation. These include performance-based standards, product-level embodied carbon databases and clearer frameworks for evaluating green materials. Without these, low-carbon cement products may struggle to compete with conventional materials in procurement and design.
R&D must balance carbon, cost and performance
Bringing in the R&D perspective into the discussion, Dr Hemantkumar Aiyer of Nuvoco Vistas emphasised that low-carbon cement development cannot be treated as a single-variable exercise. Cement must perform in real construction conditions. It must deliver strength, durability, consistency and cost competitiveness, while also reducing carbon.
“The root of understanding and balancing all these aspects lies in materials, and knowing the materials,” he said.
According to Dr Aiyer, R&D teams must understand the variability of raw materials such as fly ash, slag and clinker. Different sources produce different material behaviours. This makes mix optimisation, material characterisation and processing-property relationships critical. When performance is affected, cement manufacturers must understand how strength enhancers, admixtures and other performance chemicals interact with the material system.
He also linked material science with process efficiency. Clinkerisation takes place at extremely high temperatures, around 1,400 to 1,450 degrees Celsius. Any improvement in raw mix design, process control or energy optimisation can, therefore, help reduce emissions and cost. Dr Aiyer pointed to artificial intelligence-based optimisation, Cement 4.0 tools and advanced software as important enablers for real-time process and material control.
“The more you understand the materials, the more you can control it,” he said.
LC3: The promise is proven, the sequencing is not
Limestone calcined clay cement, commonly referred to as LC3, has attracted global attention because it can reduce clinker content significantly by using calcined clay and limestone while maintaining performance in many applications. Kiranmai Sanagavarapu of Fuller Technologies said the technology itself has already moved beyond proof of concept. Fuller Technologies has worked with calcined clay technology for nearly two decades and has seen plants running in France and Ghana. These plants, she said, are meeting local and national specifications, while the economics are beginning to make sense.
“The calciner is performing, the economics is stacking up, it is making business sense to produce,” she said.
But if the technology is viable, why has adoption not scaled faster? For Sanagavarapu, the answer lies in project sequencing. Too often, clay characterisation happens after equipment is specified. This, she warned, is a backward approach because calciner design depends on clay mineralogy, kaolinite content, iron levels, reactivity, moisture and other variables.
“If you don’t know what your deposit looks like before you commit for the equipment, you are, in a way, going blind into designing,” she said.
She also identified permitting and plant integration as major bottlenecks. Environmental clearances, mining permissions and local regulatory approvals must begin early. Similarly, calcined clay must be integrated into existing grinding, blending and logistics systems from the design stage, not treated as an afterthought during commissioning.
India already has IS 18189:2023 standard for LC3, but Sanagavarapu pointed out that the standard is not yet visible enough in procurement documents. “The gap between what is technically being permitted and what the procurement is asking is the single biggest bottleneck,” she said.
In her view, successful scale-up depends on getting the sequence right: clay characterisation first, permitting in parallel, standards aligned with construction, and integration built into plant design.
India’s LC3 journey: Progress, but demand remains thin
Providing details of India’s LC3 commercialisation experience, Vaibhav Rathi of GIZ noted that JK Cement carried out the first commercial production of LC3 at its Rajasthan plant, followed by JK Lakshmi Cement three months later. These initiatives were supported by the International Climate Initiative of the Government of Germany, with IIT Delhi contributing deep institutional knowledge on LC3 research and BIS certification.
Rathi said India’s early experience has produced clear lessons. One of the biggest was the need to build capacity among regulators. While BIS certification existed, State Pollution Control Boards were unfamiliar with the technology and unsure about the approval pathway.
“The capacity building is not just needed amongst the producer and the users of the cement, but also the regulators who are working with this technology for the first time,” he said.
He also highlighted the need for better information on China clay deposits. Since China clay is currently classified as a minor mineral, centralised data on availability, quality and location is limited. If cement manufacturers are to adopt LC3 at scale, stronger mineral intelligence will be important.
The third issue is demand. LC3 has already been used in projects such as Palava City in Mumbai and Noida International Airport, but these remain limited examples. “It is in a chicken and egg situation,” Rathi said. “Cement companies are saying we need more demand, and users are saying there is not enough cement available.”
Public procurement, he suggested, could help break this cycle. If agencies such as CPWD and other public bodies begin testing, accepting and specifying LC3, it could create the market confidence needed for cement companies to invest in production and storage.
Building codes must catch up with innovation
Dr Sunita Purushottam of GBPN India argued that material choices will determine built environment emissions over the long term, but India’s current policy signals remain fragmented. Although LC3 has received BIS recognition, she pointed out that building codes, municipal bylaws, schedules of rates and sustainability codes do not yet provide uniform guidance on low-carbon cement.
“The current cement regulations are largely prescriptive and favouring traditional materials,” she said. This limits the ability of alternative materials to compete on performance, durability and emissions.
Dr Purushottam also raised the issue of taxation. Cement, including LC3, currently falls under the same GST bracket as conventional cement. A differentiated tax structure, she argued, could help accelerate market adoption. “In order for the market to demand LC3, that differentiation in the GST could go a long way,” she said.
She noted that green building certifications such as IGBC and GRIHA are already creating demand for low-carbon materials by assigning points for embodied carbon and sustainable material use. However, she said large-scale adoption will require regulatory mandates, particularly through building codes and state-level notifications.
She also cautioned that low-carbon cement alone does not solve the entire building performance problem. A material may reduce embodied carbon, but the operational carbon of a building depends on thermal performance, design, insulation and energy use. “The energy part has two elements,” she said. “One is the embodied carbon of the material itself, and the other is the operational carbon.”
Collaboration is the bridge between invention and impact
Wattal said GCCA sees innovation as a strategic priority and works through platforms that connect industry with academia and start-ups. “There is no way we will decarbonise our sector without innovation,” she said.
However, she stressed that research must be connected to actual industry challenges. Innovations developed in isolation may fail when they encounter real-world barriers such as raw material variability, plant integration, cost, standards and finance. Start-ups, too, need industry mentorship and scale-up pathways.
Wattal also flagged the importance of finance. Even strong technologies may struggle to attract investment if there is no common understanding of bankability. “We have always put projects into, is this a bankable project? But the definition of a bankable project has never been defined,” she said.
For India, she saw strong potential in its academic and start-up ecosystem, but said the challenge lies in alignment and prioritisation. The country has the research base, industrial capacity and market size. What it now needs is a coordinated route from innovation to deployment.
There is a practical concern for cement manufacturers: how can existing plants be adapted for lower emissions without compromising reliability or commercial viability?
Kiranmai Sanagavarapu addressed, “The reliability risk in calcined clay retrofit is definitely real, but it is almost always self-inflicted. The risk arises when a new process is added to an existing circuit without properly redesigning grinding and blending configurations.”
Existing cement plants, she explained, can take two broad routes. The first is external sourcing of calcined clay combined with mill optimisation. This requires lower capital investment and can potentially move in 12 to 18 months if other conditions are in place. It may reduce emissions by around 20 to 30 per cent. The second route is integrated calcination on site, which requires higher capital expenditure and longer lead times, but provides greater control over quality, supply and emissions reduction potential.
For Sanagavarapu, the principle is simple: low-carbon retrofits must be designed with intent. “Design it with an intent properly from the start. Start in the market conditions where the economics are already working,” she said.
Circularity: The overlooked advantage
According to Vaibhav Rathi, fly ash and slag are already well established in cement and construction (C&D), but construction and demolition waste remains underutilised. “C&D waste is a growing business opportunity which not many have taken up,” he said. India’s continuous construction and demolition activity creates huge volumes of waste, much of which contributes to air pollution, land degradation and material inefficiency. With the right processing and standards, this waste can be converted into useful construction products.
Rathi also pointed out that LC3 has a circular economy dimension that is often overlooked. It can use low-grade kaolin-rich clay left behind after high-grade clay is extracted for other applications. “LC3 is not only a low-carbon solution, but also a circular economy solution,” he said.
At the same time, he cautioned that LC3 in India is not yet cheap because it has not reached scale. Site-specific techno-commercial feasibility studies, supported jointly by development agencies and industry, could help companies assess whether LC3 production makes technical and financial sense at a given location.
Dr Purushottam added that India must address both low-carbon cement and construction waste together. “Both low-carbon cement and C&D waste go hand in hand. India does not have an option but to work on both,” she said.
Dr Aiyer called for policy shifts from both government and industry, including preferential purchasing of sustainable materials, minimum supplementary cementitious material requirements in public and public-private projects, and faster regulatory implementation. “If we can fast-track the regulatory standards and their implementation on the ground, that is the way to go,” he said.
From green ambition to green construction
Cement innovation is no longer only about chemistry. It is about systems. Low-carbon cement will scale only when technology, standards, procurement, finance, regulation, education and construction practice move together.
LC3 and other low-carbon technologies have shown promise. India has early commercial examples, strong research capability and growing market interest. But mainstream adoption will depend on whether demand can be created, regulators can be capacitated, standards can be embedded in procurement, and manufacturers can see a clear business case.
For a country building at India’s scale, the opportunity is enormous. Cement will continue to be central to infrastructure and urban development. The challenge now is to ensure that the cement used in India’s growth story carries a lower carbon burden.
- Rakesh Rao
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Concrete
JK Cement Declared Preferred Bidder For Gilund Limestone Block
Shares Edge Higher As Company Wins Rajasthan Block
Published
4 days agoon
June 30, 2026By
admin
JK Cement gained after being declared preferred bidder for the Gilund Limestone Block in Chittorgarh, Rajasthan, a lease area of 370.96 hectares. The firm saw its shares trade at Rs. 5550.05, up by 28.45 points or 0.52 per cent from the previous close of Rs. 5521.60 on the BSE. The scrip opened at Rs. 5569.15 and touched a high of Rs. 5625.00 and a low of Rs. 5531.00.
The stock recorded turnover of 1742 shares on the counter and the BSE group A stock with face value Rs. 10 has a 52 week high of Rs. 7565.00 on 20-Aug-2025 and a 52 week low of Rs. 4670.05 on 12-Jun-2026. Last one week high and low stood at Rs. 5625.00 and Rs. 5329.00 respectively. The promoters holding in the company stood at 45.66 per cent, while institutions and non-institutions held 40.61 per cent and 13.73 per cent respectively.
The e-auction conducted by the Government of Rajasthan resulted in the company being declared preferred bidder for the mining lease, and the allocation will enable the company to plan phased development of the deposit, subject to regulatory approvals. The Gilund block spans 370.96 hectares and its allocation is intended to support raw material security for the company’s cement operations in the region. The designation follows the government auction process and will allow the company to plan development and integration of the deposit into its supply chain.
The current market capitalisation stands at Rs. 430.38 billion (bn), reflecting market response to the mining news and prevailing valuation levels for the sector. Investors and analysts will watch for formal allotment and related disclosures that can clarify timelines, capital expenditure and expected production profiles. The report is intended for informational purposes and does not constitute investment advice, and market participants are advised to consult advisers before making decisions.
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