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Waste Glass as Pozzolana

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Dr SB Hegde, Professor, Jain University and Visiting Professor, Pennsylvania State University, United States of America, gives a detailed account of the use of waste glass as Pozzolana, a sustainable solution for cement production, in a two-part article.

The increasing demand for cement, coupled with growing environmental concerns, has led to a search for alternative materials that can reduce the carbon footprint of cement production. Waste glass, a significant environmental concern itself, has emerged as a promising alternative due to its pozzolanic properties.
This paper delves into the concept of utilising waste glass as a pozzolanic material in cement production, highlighting its benefits, challenges and potential for sustainable development based on the research and development work carried out by the author. This is part one of the study; part two will be featured in the consecutive issue of the magazine.

Generation and Availability of Waste Glass
On a global scale, this only amounts to a recycling rate of less than 35 per cent. Worldwide, around 130 million tonnes (Mta) of glass are currently produced annually.
India alone produces three million tonnes of glass waste annually, of which only 35 per cent is recovered, and the rest often ends up in landfills or down cycled into construction material aggregates. Glass is found in municipal solid waste (MSW), primarily in the form of containers such as beer and soft drink bottles; wine and liquor bottles; and bottles and jars for food, cosmetics and other products. India is one of the largest consumers of glass in the world, and as a result, it also generates a significant amount of waste glass. Waste glass, also known as cullet, can come from various sources such as bottles, jars, containers, windows and other glass products.
The availability and generation of waste glass in India depend on several factors, including population, consumption patterns, recycling infrastructure and waste management practices. Glass waste can be generated from residential households, commercial establishments and industries as well as construction and demolition activities. In recent years, there has been growing awareness about the importance of recycling glass waste in India. Recycling glass has several environmental benefits, such as reducing the consumption of raw materials, saving energy and reducing landfill waste.

Infrastructural requirement
To effectively use waste glass as a pozzolanic material in a cement plant, certain facilities and processes can be implemented. Here are some key facilities that can be created:

  1. Glass Sorting and Preprocessing: A facility for sorting and preprocessing waste glass is essential to segregate glass by colour and removing contaminants such as paper, plastics and metals. Crushing or grinding equipment can be used to reduce the glass to a suitable particle size.
  2. Glass Storage and Handling: Adequate storage facilities should be established to store the sorted and processed glass. It is important to protect the glass from moisture and other environmental factors that can affect its quality.
  3. Glass Dosing System: A dosing system should be set up to accurately measure and control the amount of waste glass being added to the cement production process. This can involve automated feeders or other equipment to ensure a consistent and controlled addition of glass.
  4. Glass Grinding or Milling Equipment: Depending on the desired fineness of the waste glass, a grinding or milling unit may be required to further reduce the particle size. This equipment can include ball mills, vertical roller mills, or specialised glass grinding mills.
  5. Blending and Mixing Facilities: Cement plants typically have blending and mixing facilities where various supplementary cementitious materials, including waste glass, can be combined with other raw materials. This ensures homogeneity and uniformity in the cement production process.
  6. Quality Control and Testing: Facilities for quality control and testing should be in place to assess the chemical and physical properties of the waste glass, as well as the performance of the cementitious mixtures incorporating the glass. This can include laboratory testing equipment and personnel trained in relevant testing methods.
    It’s important to note that the specific facilities required may vary depending on the scale of the cement plant and the volume of waste glass being processed. Detailed engineering studies and consultations in cement production and waste management can help determine the optimal design and layout of these facilities within a cement plant. Additionally, it is advisable to comply with relevant environmental regulations and obtain any necessary permits or approvals from statutory bodies in that particular country for handling and using waste glass within the cement plant.

The Fineness of Waste Glass
When waste glass is used as a supplementary cementitious material in cement production, it is important to consider the fineness or particle size distribution of the glass. The fineness of waste glass affects its reactivity and compatibility with
cement, which can impact the performance of the cementitious mixture.
The specific fineness requirements for waste glass can vary depending on the specific application, the type of cement being used, and the desired properties of the final concrete or mortar. However, in general, the waste glass particles should be finely ground to ensure effective pozzolanic or latent hydraulic reactions with the cement.
Here are some common guidelines for the fineness of waste glass used in cement:
• Particle Size Distribution: The waste glass particles should have a range of sizes to ensure good packing and fill the voids between cement particles. A typical particle size distribution for waste glass in cement applications is similar to that of cement, with a majority of particles passing through a 325 mesh (45 microns) sieve.
• Blaine Fineness: The Blaine fineness test is often used to measure the specific surface area of cementitious materials. The waste glass should generally have a Blaine fineness similar to or higher than that of cement. Typical values can range from 300 to 500 m²/kg or higher, depending on the application.
• Grinding or Milling: Waste glass may require grinding or milling processes to achieve the desired fineness. The grinding method can vary depending on the available equipment and the specific glass composition. Ball mills, vertical roller mills or specialised glass grinding equipment can be used.
• Gradation Control: It is important to control the gradation of waste glass during the grinding process. A well-controlled gradation can improve the flowability and workability of the cementitious mixture.
It is worth noting that the precise fineness requirements may vary depending on the specific standards, specifications, or guidelines established by statutory bodies of the particular country.

Attributes of Waste Glass as Pozzolana
Based on research and development investigations the following avenues are investigated for utilisation of waste glass.
• Pozzolanic Properties of Waste Glass: Pozzolanic materials, when combined with calcium hydroxide in the presence of water, react to form cementitious compounds. Waste glass, rich in amorphous silica, exhibits excellent pozzolanic properties. Through a process called pozzolanic reaction, waste glass can contribute to the strength, durability, and chemical resistance of cementitious materials.
• Environmental Benefits: Incorporating waste glass as a pozzolanic material in cement production offers significant environmental advantages. Firstly, it reduces the need for virgin raw materials such as limestone, thus conserving natural resources. Additionally, it mitigates the environmental impact associated with glass waste disposal, diverting it from landfills or incineration.
• Improved Concrete Performance: The use of waste glass as a pozzolanic material enhances the performance of concrete. Due to its pozzolanic activity, waste glass reacts with calcium hydroxide in the cement matrix, resulting in denser and more durable concrete. This leads to improved mechanical strength, reduced permeability, and increased resistance to chemical attack.
• Supplementary Cementitious Material: Waste glass can be used as a supplementary cementitious material (SCM) in cement production. When properly ground and processed, waste glass can replace a portion of cement without compromising the desired concrete properties. This substitution not only reduces cement consumption but also lowers the carbon dioxide emissions associated with cement production.
• Sustainable Development and Circular Economy: Utilising waste glass as a pozzolanic material aligns with the principles of sustainable development and the circular economy. It promotes resource efficiency, reduces waste generation, and contributes to a more sustainable construction industry. The integration of waste glass into cement production presents opportunities for collaboration between cement manufacturers, waste management companies, and regulatory bodies to develop innovative and eco-friendly solutions.

References

  1. Utilisation of Waste Glass Powder in Concrete by P. Manoj Kumar,
    K. Sreenivasulu, and M. Srinivasulu Reddy, International Journal of Innovative Research in Science, Engineering and Technology, 2013.
  2. Recycling of Waste Glass as a Partial Replacement for Fine Aggregate in Concrete Mix by W. A. Rahman, M. A. S. Al-gahtani,
    and M. A. K. El-Kourd, Journal of King Saud University – Engineering Sciences, 2010.
  3. Mechanical and Durability Properties of Concrete Containing Glass Powder as Partial Replacement of Cement by A. Shayan and R. Xu, Construction and Building Materials, 2004.
  4. Properties of Glass Concrete Containing Fine and Coarse Glass Aggregates by Z. Feng, S. Xie, and Y. Zhou, Journal of Materials in Civil Engineering, 2011.

ABOUT THE AUTHOR
Dr SB Hegde, Professor, Jain University and Visiting Professor, Pennsylvania State University, United States of America.

Concrete

Adani’s Strategic Emergence in India’s Cement Landscape

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Milind Khangan, Marketing Head, Vertex Market Research, sheds light on Adani’s rapid cement consolidation under its ‘One Business, One Company’ strategy while positioning it to rival UltraTech, and thus, shaping a potential duopoly in India’s booming cement market.

India is the second-largest cement-producing country in the world, following China. This expansion is being driven by tremendous public investment in the housing and infrastructure sectors. The industry is accelerating, with a boost from schemes such as PM Gati Shakti, Bharatmala, and the Vande Bharat corridors. An upsurge in affordable housing under the Pradhan Mantri Awas Yojana (PMAY) further supports this expansion. In May 2025, local cement production increased about 9 per cent from last year to about 40 million metric tonnes for the month. The combined cement capacity in India was recorded at 670 million metric tonnes in the 2025 fiscal year, according to the Cement Manufacturers’ Association (CMA). For the financial year 2026, this is set to grow by another 9 per cent.
In spite of the growing demand, the Indian cement industry is highly competitive. UltraTech Cement (Aditya Birla Group) is still the market leader with domestic installed capacity of more than 186 MTPA as on 2025. It is targeted to achieve 200 MTPA. Adani Cement recently became a major player and is now India’s second-largest cement company. It did this through aggressive consolidation, operational synergies, and scale efficiencies. Indian players in the cement industry are increasingly valuing operational efficiency and sustainability. Some of the strategies with high impact are alternative fuels and materials (AFR) adoption, green cement expansion, and digital technology investments to offset changing regulatory pressure and increasing energy prices.

Building Adani Cement brand
Vertex Market Research explains that the Adani Group is executing a comprehensive reorganisation and consolidation of its cement business under the ‘One Business, One Company’ strategy. The plan is to integrate its diversified holdings into one consolidated corporate entity named Adani Cement. The focus is on operating integration, governance streamlining, and cost reduction in its expanding cement business.
Integration roadmap and key milestones:

  • September 2022: The consolidation process started with the $6.4 billion buyout of Holcim’s majority stakes in Ambuja Cements and ACC, with Ambuja becoming the focal point of the consolidation.
  • December 2023: Bought Sanghi Industries to strengthen the firm’s presence in western India.
  • August 2024: Added Penna Cement to the portfolio, improving penetration of the southern market of India.
  • April 2025: Further holding addition in Orient Cement to 46.66 per cent by purchasing the same from CK Birla Group, becoming the promoter with control.
  • Ambuja Cements amalgamated with Adani Cement: This was sanctioned by the NCLT on 18th July 2025 with effect from April 1, 2024. This amalgamation brings in limestone reserves and fresh assets into Ambuja.
  • Subject to Sanghi and Penna merger with Ambuja: Board approvals in December 2024 with the aim to finish between September to December 2025.
  • Ambuja-ACC future integration: The latter is being contemplated as the final step towards consolidation.
  • Orient Cement: It would serve as a principal manufacturing facility following the merger.

Scale, capacity expansion and market position
In financial year-2025, Adani Cement, including Ambuja, surpassed 100 MTPA. This makes it one of the world’s top ten cement companies. Along with ACC’s operations, it is now firmly placed as India’s second-largest cement company. In FY25, the Adani group’s sales volume per annum clocked 65 million metric tonnes. Adani Group claims that it now supplies close to 30 per cent of the cement consumed in India’s homes and infrastructure as of June 2025.
The organisation is pursuing aggressive brownfield expansion:

  • By FY 2026: Reach 118 MTPA
  • By FY 2028: Target 140 MTPA

These goals will be driven by commissioning new clinker and grinding units at key sites, with civil and mechanical works underway.
As of 2024, Adani Cement had its market share pegged at around 14 to 15 per cent, with an ambition to scale this up to 20 per cent by FY?2028, emerging as a potent competitor to UltraTech’s 192?MTPA capacity (186 domestic and overseas).

Strategic advantages and competitive benefits
The consolidation simplifies decision-making by reducing legal entities, centralising oversight, and removing redundant functions. This drives compliance efficiency and transparent reporting. Using procurement power for raw materials and energy lowers costs per ton. Integrated logistics with Adani Ports and freight infrastructure has resulted in an estimated 6 per cent savings in logistics. The group aims for additional savings of INR 500 to 550 per tonne by FY 2028 by integrating green energy, using alternative fuel resources, and improving sourcing methods.

Market coverage and brand consistency
Brand integration under one strategy will provide uniform product quality and easier distribution networks. Integration with Orient Cement’s dealer base, 60 per cent of which already distributes Ambuja/ACC products, enhances outreach and responsiveness.
By having captive limestone reserves at Lakhpat (approximately 275 million tonnes) and proposed new manufacturing facilities in Raigad, Maharashtra, Adani Cement derives cost advantage, raw material security, and long-term operational robustness.

Strategic implications and risks
Consolidation at Adani Cement makes it not just a capacity leader but also an operationally agile competitor with the ability to reap digital and sustainability benefits. Its vertically integrated platform enables cost leadership, market responsiveness, and scalability.

Challenges potentially include:

  • Integration challenges across systems, corporate cultures, and plant operations
  • Regulatory sanctions for pending mergers and new capacity additions
  • Environmental clearances in environmentally sensitive areas and debt management with input price volatility

When materialised, this revolution would create a formidable Adani–UltraTech duopoly, redefining Indian cement on the basis of scale, innovation, and sustainability. India’s leading four cement players such as Adani (ACC and Ambuja), Dalmia Cement, Shree Cement, and UltraTech are expected to dominate the cement market.

Conclusion
Adani’s aggressive consolidation under the ‘One Business, One Company’ strategy signals a decisive shift in the Indian cement industry, positioning the group as a formidable challenger to UltraTech and setting the stage for a potential duopoly that could dominate the sector for years to come. By unifying operations, leveraging economies of scale, and securing vertical integration—from raw material reserves to distribution networks—Adani Cement is building both capacity and resilience, with clear advantages in cost efficiency, market reach, and sustainability. While integration complexities, regulatory hurdles, and environmental approvals remain key challenges, the scale and strategic alignment of this consolidation promise to redefine competition, pricing dynamics, and operational benchmarks in one of the world’s fastest-growing cement markets.

About the author:
Milind Khangan is the Marketing Head at Vertex Market Research and comes with over five years of experience in market research, lead generation and team management.

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Concrete

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

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PowerBuild’s flagship Series M, C, F, and K geared motors deliver robust, efficient, and versatile power transmission solutions for industries worldwide.

Products – M, C, F, K: At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. PowerBuild answers this need with its flagship geared motor series: M, C, F, and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.
Series M – Helical Inline Geared Motors: Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.
Series C – Right Angled Heli-Worm Geared Motors: Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.
Series F – Parallel Shaft Mounted Geared Motors: Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes, and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.
Series K – Right Angle Helical Bevel Geared Motors: For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining, and material handling. Its flexibility in mounting and broad motor options offer engineers’ freedom in design and reliability in execution.
Together, these four series reflect PowerBuild’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design, and field-tested reliability. Whether the requirement is speed control, torque multiplication, or space efficiency, Radicon’s Series M, C, F, and K stand as trusted powerhouses for global industries.

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Concrete

Driving Measurable Gains

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Klüber Lubrication India’s Klübersynth GEM 4-320 N upgrades synthetic gear oil for energy efficiency.

Klüber Lubrication India has introduced a strategic upgrade for the tyre manufacturing industry by retrofitting its high-performance synthetic gear oil, Klübersynth GEM 4-320 N, into Barrel Cold Feed Extruder gearboxes. This smart substitution, requiring no hardware changes, delivered energy savings of 4-6 per cent, as validated by an internationally recognised energy audit firm under IPMVP – Option B protocols, aligned with
ISO 50015 standards.

Beyond energy efficiency, the retrofit significantly improved operational parameters:

  • Lower thermal stress on equipment
  • Extended lubricant drain intervals
  • Reduction in CO2 emissions and operational costs

These benefits position Klübersynth GEM 4-320 N as a powerful enabler of sustainability goals in line with India’s Business Responsibility and Sustainability Reporting (BRSR) guidelines and global Net Zero commitments.

Verified sustainability, zero compromise
This retrofit case illustrates that meaningful environmental impact doesn’t always require capital-intensive overhauls. Klübersynth GEM 4-320 N demonstrated high performance in demanding operating environments, offering:

  • Enhanced component protection
  • Extended oil life under high loads
  • Stable performance across fluctuating temperatures

By enabling quick wins in efficiency and sustainability without disrupting operations, Klüber reinforces its role as a trusted partner in India’s evolving industrial landscape.

Klüber wins EcoVadis Gold again
Further affirming its global leadership in responsible business practices, Klüber Lubrication has been awarded the EcoVadis Gold certification for the fourth consecutive year in 2025. This recognition places it in the top three per cent
of over 150,000 companies worldwide evaluated for environmental, ethical and sustainable procurement practices.
Klüber’s ongoing investments in R&D and product innovation reflect its commitment to providing data-backed, application-specific lubrication solutions that exceed industry expectations and support long-term sustainability goals.

A trusted industrial ally
Backed by 90+ years of tribology expertise and a global support network, Klüber Lubrication is helping customers transition toward a greener tomorrow. With Klübersynth GEM 4-320 N, tyre manufacturers can take measurable, low-risk steps to boost energy efficiency and regulatory alignment—proving that even the smallest change can spark a significant transformation.

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