Concrete

Evolving with Time

Published

1 year ago

September 22, 2023

admin

Concrete and precast shapes are playing an increasingly important role in the construction sector today. We look at the challenges and innovations in this segment.

The journey of precast concrete has been long. Joseph Aspdin patented the making of Portland cement in late 1700 and much later Joseph Monier was the first to use reinforced concrete in 1867. He went on to patent concrete pipes, basins, beams and panels. These panels proved to be the precursor to precast concrete production for construction. In 1905, city engineer John Alexander Brodie invented the first modern example of precast concrete in Liverpool, England. Although precast concrete forming of panels wasn’t popular in England, it flourished around the world.
Advances in the precast concrete industry continue to make the material indispensable. In addition to precast/prestressed concrete structural members that keep parking garages and bridges upright, it’s the concrete used underground that make it so valuable.
Precast concrete is a construction product produced by casting concrete in a reusable mould or ‘form,’ which is then cured in a controlled environment, transported to the construction site and maneuvered into place. Examples include precast beams, and wall panels for tilt-up construction. In contrast, cast-in-place concrete is poured into site-specific forms and cured on site. Recently lightweight expanded polystyrene foam is being used as the cores of precast wall panels, saving weight and increasing thermal insulation.
Precast concrete is employed in both interior and exterior applications, from highway, bridge and hi-rise projects to tilt-up building construction. By producing precast concrete in a controlled environment (typically referred to as a precast plant), it is afforded the opportunity to properly cure and be closely monitored by the plant employees. Using a precast concrete system offers many potential advantages over onsite casting. Precast concrete production can be performed on ground level, which maximises safety in its casting. There is greater control over material quality and workmanship in a precast plant compared to a construction site. The forms used in a precast plant can be reused hundreds to thousands of times before they have to be replaced, often making it cheaper than onsite casting in terms of cost per unit of formwork.
Precast concrete forming systems for architectural applications differ in size, function and cost. Precast architectural panels are also used to clad all or part of a building facade or erect free-standing walls for landscaping, soundproofing and security. In appropriate instances precast products – such as beams for bridges, highways and parking structure decks – can be prestressed structural elements. Stormwater drainage, water and sewage pipes as well as tunnels also make use of precast concrete units.
Precast concrete moulds can be made of timber, steel, plastic, rubber, fibreglass or other synthetic materials, with each giving a unique finish. In addition, many surface finishes for the four precast wall panel types – sandwich, plastered sandwich, inner layer and cladding panels – are available, including those creating the looks of horizontal boards and
ashlar stone. Colour may be added to the concrete mix, and the proportions and size aggregate
also affect the appearance and texture of finished concrete surfaces.
Some of the examples of precast concrete products and shapes are given below:

Precast concrete products for foundations
Isolated footings: They are commonly used for shallow foundations to carry and spread concentrated loads, caused for example by columns or pillars. Isolated footings can consist either of reinforced or non-reinforced material. These are used for smaller structures and residential buildings.
Pocket footings: They offer more strength to shallow foundations to carry and spread concentrated loads. They are used for commercial and
industrial buildings.
Combined footings: These concrete footings are usually rectangular and support two or more columns that are so close to each other their footings would overlap. They are used for commercial and industrial buildings.
Precast piles: They are prefabricated piles made of prestressed concrete that are driven into the ground using diesel or hydraulic hammer. The piles are made of prestressed concrete and have fixed dimensions. These piles are used for the most conventional foundation method.
RCC beams: These are structural elements designed to carry transverse external loads that cause bending moment, shear forces, and in some cases torsion across their length. RCC beams generally have concrete resisting on the compression region and steel resisting applied loads on the tension region. It can be classified as per size into- rectangular, T-Beam, I-Beam, Circular Beam and L-Beam. It is used to support the building’s floors, roof, walls
and cladding.
Prestressed beams: FRP-prestressed beams are greater than those of steel-prestressed beams.
It is very easy to install with reduced on-site labour needs and costs. It comes in a wide range of depths to meet exact building needs It provides much-needed reinforcement for multi-story buildings and industrial applications.
Shell beams: Shell beams are commonly used with precast floor systems to streamline building programmes and reduce on-site labour. Pre-stressed shell beam units, with the addition of a reinforcing cage and on-site concrete. Band depths of 290mm to 600mm and widths of 600mm to 2,400mm are possible.
RCC slabs: This type of slabs is used for support conditions in buildings. RCC slabs, with thickness that ranges from 10 to 50 centimetres, are most often used for the construction of floors and ceilings. Thin RCC slabs are also used for exterior paving purposes. In domestic and industrial buildings, a thick concrete slab, supported on foundations or directly on the subsoil, is used to construct the ground floor of a building. In high rises buildings and skyscrapers, thinner, precast concrete slabs are slung between the steel frames to form the floors and ceilings on each level.
Prestressed hollow core slabs: A hollow core slab, also known as a voided slab, hollow core plank, or simply a concrete plank is a precast slab of prestressed concrete typically used in the construction of floors in multi-story apartment buildings. The production of these elements is achieved using our Extruder and Slipformer machines that cast in one phase along a production bed without the need for any formworks.
Prestressed solid slabs: The solid slab is a customised, loosely reinforced, full concrete slab that is used in residential and industrial construction. Mounting parts, such as electrical outlets, wiring, openings, etc. or even heating conduits can be previously installed in the solid slab in the precast plant.
Double tee slabs: A double tee or double-T beam is a load-bearing structure that resembles two T-beams connected side by side. The strong bond of the flange (horizontal section) and the two webs (vertical members, also known as stems) creates a structure that is capable of withstanding high loads while having a long span. It can be applied in roofing, parking and bridges.

Precast concrete products for walls
Load bearing external walls: This wall is constructed to support the above slab or other building elements in a structure. These walls are generally 125 mm to 200 mm thick. The thickness depends on the load pattern.
Non-load-bearing walls: This wall holds up only itself as it carries only its own weight and may be any one of the types discussed under load-bearing walls. This type of wall is used to close in a steel or concrete frame building. It is usually carried by supports, normally steel shelf angles on each floor. These walls are generally 50 mm to 100 mm thick.

Precast joist roof
Precast joist roof is a building system in which precast reinforced cement concrete planks – rectangular slab elements – are placed on precast RCC joists. The roof gets completed with in-situ concrete poured over the haunches in planks and over the partially precast joists, thus ensuring monolithic action of individual precast elements.

Precast façade
Precast sandwich panels enable the strict requirements for thermal insulation to be met. Concrete structures have great insulation qualities, keeping the building warm in cold weather and cool when it is hot, stabilising the moisture and temperature inside. For the precast facade, a calculated age can be defined. One special feature of a precast façade is the panel joints

Glass Fibre-Reinforced Concrete (GFRC)
Glass fibre-reinforced concrete consists of high-strength, alkali-resistant glass fibre embedded in a concrete matrix. This is used especially for thin architectural cladding panels, but also for ornamental concrete such as domes, statues, planters and fountains. Recently, decorative concrete artisans have discovered the benefits of GFRC for decorative panels (such as fireplace surrounds), concrete countertops and artificial rock work.
Some of the advantages of precast concrete and shapes over in-situ concrete are as follows:
Simplified Material Inputs and Cost: Because precast products already contain the concrete, conduits and rebar needed, they eliminate the need to purchase and prepare these materials. Offsite casting also removes onsite casting needs, such as cardboard forms, from the equation. This simplifies the construction process to reduce hassle and
increase efficiency.
Reduced Installation Time: Precast concrete components are ready for immediate use upon delivery while cast-in-place concrete are not. This eliminates unnecessary time needed to set up cardboard forms, bend and position rebar, pour and vibrate concrete and then wait for the concrete to cure. The removal of these steps saves valuable time in terms of project duration and cost from labour needed.
Cost-effective for Large Projects: When compared to cast-in-place concrete, the cost associated with precast concrete decreases as project scale increases. Large-scale projects that require repeatable concrete components, such as installing airport taxiway lighting, are great candidates for precast concrete products, as the setup and install time required to hand pour all concrete would quickly increase project cost. Precast concrete is truly an economy of scale, which makes it ideal for businesses and contractors of large-scale construction projects.
Stronger than Cast-in-place Concrete: Precast concrete is often stronger than cast-in-place concrete. Not only are precast concrete products already reinforced with steel rebar, but the controlled curing process also ensures that the concrete will set correctly under ideal conditions for maximised strength. Precast concrete can also be stress-tested before being delivered to the final job site.
Higher-quality Control: Another advantage of precast concrete is its higher standard of quality control. Because precast concrete forms are created offsite, all products are inspected for defects before shipping out. The controlled process also eliminates unknowns related to temperature, humidity and imprecise tools.

However, there are some challenges as well that must be taken care of as follows:
Higher Upfront Costs: The good news is precast concrete makes up for the high initial costs in the long run. Because concrete is so strong and durable, there is typically very little maintenance over the life of the precast concrete fence.
Transportation: If your project site is located far away from our plant, the transportation can take a while and cost more. Precast concrete isn’t fine China. Some bumps and bruises aren’t going to hurt it. But you will need to be prepared when installing the precast shapes.
Hard to Modify: Precast concrete has a ton of options during design phase but once designed and built it is not possible to modify in part or whole.
The market for precast products and shapes have been growing very fast and because of the nature of customisation possibilities it is likely to be the product of choice for not only government projects but also for residential construction.

-Procyon Mukherjee

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Concrete

Smart-Tech in Cement!

Published

17 hours ago

March 11, 2025

Roshna

An invigorating discussion amongst industry experts, on digital transformation, sustainability and cybersecurity, threw interesting insights.

The cement industry is at a crucial juncture, with digital transformation, sustainability, and automation shaping its future. The panel discussion explored key points on digitalisation, sustainability and automation, emphasising the importance of a multidisciplinary approach to modern cement manufacturing.
The webinar was moderated by Dr SB Hegde, Professor, Jain College of Engineering & Technology, Hubli; and Visiting Professor, Pennsylvania State University, USA.

Speakers included:

Dr Hemantkumar Aiyer, VP & Head R&D, Nuvoco Vistas Corp
Dr Raju Goyal, Executive President, Chief Technical and Sustainability Officer,

UltraTech Cement

Dr Rizwan Sabjan, Head – Global Sales and Proposals, Process Control and Optimisation, FLSmidth Cement
Prosenjit Dutta, Director Operations, PS Digitech-HR India
Raghu Vokuda, Chief Digital Officer,

JSW Cement

Sachin Vaidya, Regional GM – Digital, Process Industries, ABB

Role of digital transformation
Dr Hegde emphasised the need for integrating emerging technologies with a multidisciplinary approach to enhance cement plant efficiency. He highlighted that “understanding of systems and how to integrate them” is essential for maximising the benefits of digital tools.
Sabjan echoed this sentiment, stressing that cement plants need to embrace a cultural and mindset shift to fully leverage digital technologies. He pointed out, “Software can do wonders for the plant, but only if the workforce understands and implements it effectively.” He warned against isolated implementations, advocating for a holistic approach where departments like OT, quality control and automation work together.

Sustainability: The road ahead
With sustainability becoming a global priority, cement manufacturers must adapt to new environmental regulations and carbon reduction goals. Dr Hegde posed a critical question: “How is the cement industry moving towards sustainability, and how can plants prepare for these changes?”
Sabjan responded by highlighting the importance of long-term planning and commitment. “Often, discussions happen, but after two months, we forget about them and restart from scratch. This approach will not work. We need a structured, goal-oriented plan with defined KPIs,” he said. Sabjan emphasised the need for a systematic approach, focusing on tangible metrics such as energy savings. “If a plant aims to improve energy efficiency by five percent, it must set this as a goal and track progress,” he suggested.
The discussion also underscored the need for strong leadership to drive digital adoption. “A motivated team and a dynamic leader can make all the difference,” Dr Hegde noted.

Enhancing durability with digital tools
Strength and durability remain critical concerns in cement production. Goyal explained, “Machine learning-based lab technologies enable predictive analysis, allowing manufacturers to forecast 28-day, 7-day, and 1-day strengths before the material leaves the mill.” He also emphasised the importance of soft sensors, which “help predict strength and optimise mix design before production.”
He elaborated on the role of XRF/XRD analysis: “These tools provide elemental and mineralogical insights, allowing for quick adjustments to raw materials and ensuring consistent quality.” Furthermore, digital twins are revolutionising cement quality optimisation. “They allow us to simulate and test mix designs before implementation, reducing errors and optimising durability.”

Cybersecurity risks in IT-OT integration
As cement plants become increasingly digitalised, cybersecurity threats pose significant risks. Vaidya expressed concern that many manufacturers underestimate cybersecurity risks. “As a technology provider, I often struggle to convince cement manufacturers of the importance of cybersecurity. Some benefits are intangible but essential for plant security.”
He outlined major threats, including malware attacks, unauthorised network access, and operational disruptions. “Preventive measures include secure data transactions, network monitoring, and regular cybersecurity training for staff to minimise insider threats,” he said.
He urged cement companies to take cybersecurity seriously: “As digital transformation advances, cybersecurity is not an option—it is a necessity. Without proper security protocols, cement plants risk cyberattacks that could halt production.”
Dr Hegde agreed, adding, “People often ignore cybersecurity until they experience financial loss. Awareness must be proactive, not reactive.”
Dutta stated, “Advanced process control (APC) is a game-changer for cement manufacturing, allowing us to stabilise operations, optimise fuel efficiency, and reduce energy consumption through real-time data insights.”
He emphasised the transformative impact of real-time data analytics and advanced process control (APC) in cement manufacturing. He highlighted that APC enables manufacturers to optimise raw mix design, fuel efficiency and kiln operations through data-driven decision-making. By continuously monitoring critical parameters, APC minimises process variations, improves stability, and reduces energy consumption, leading to cost savings and enhanced productivity. Additionally, he stressed the role of predictive maintenance in preventing equipment failures, extending machinery lifespan and minimising downtime, ultimately ensuring consistent quality and operational efficiency in cement production.

Will Indian plants become fully autonomous?
With AI, robotics and digital twins transforming global cement production, the question arises: Can Indian cement plants become fully autonomous within the next 5–10 years?
Vokuda was skeptical about complete automation in the near future. “Indian cement plants will see significant automation, but full autonomy remains unlikely within a decade. A hybrid model, combining AI-powered decision-making with human oversight, is more practical.”
He highlighted key challenges: “Unlike developed nations, India’s low labour costs may make full automation less attractive. Additionally, digital twin technology in India is still in its early stages, focusing more on process twins than asset twins.”
Another challenge is data management. “AI-ML models require vast amounts of data, which necessitates ultra-low latency networks like 5G and edge computing. We are not yet at that level of technological maturity,” he explained.
Despite these hurdles, he remains optimistic: “While full automation may take longer, the industry will continue to evolve with advancements in digital twins, real-time analytics, and AI-driven insights.”

Conclusion
Experts agree that while technology holds immense potential, its successful implementation depends on cultural shifts, strong leadership, and structured execution.
Key takeaways from the discussion include:

Integration of digital tools: Multidisciplinary collaboration is essential for successful implementation.
Sustainability goals: Defined KPIs and a long-term approach are crucial.
Quality optimisation: Machine learning, real-time analysis, and digital twins are improving cement strength and durability.
Cybersecurity: As digital transformation progresses, cement plants must prioritise cybersecurity.
Automation: While full autonomy is unlikely soon, AI and digital tools will play a growing role in decision-making.
As the industry moves forward, cement manufacturers must embrace technological advancements while ensuring resilience against cybersecurity threats and operational challenges. With the right strategies, India’s cement sector can achieve greater efficiency, sustainability, and innovation in the years to come.

ICR’s virtual panel discussion was supported by FLSmidth Cement as the Presenting Partner and ABB as the Gold Partner.

Concrete

The Science and Application of Grinding Aids

Published

17 hours ago

March 11, 2025

admin

Dr SB Hegde discusses the importance of grinding aids as essential chemical additives that enhance cement grinding efficiency, reduce energy consumption and improve overall cement quality in the concluding part of his article.

Grinding aids represent a critical segment of the cement additives market, driven by their ability to enhance grinding efficiency, reduce energy consumption, and improve cement quality. The market dynamics of grinding aids vary significantly across regions, influenced by economic growth, cement production capacities and regulatory environments.

Global market size and growth projections
The global grinding aids market was valued at approximately US $ 1.2 billion in 2023 and is expected to grow at a CAGR of 5.5 per cent from 2023 to 2030, reaching nearly US $ 1.8 billion by 2030.
This growth is fueled by the increasing focus on energy efficiency and sustainable cement production practices worldwide.
Rapid urbanisation and infrastructure development, especially in emerging economies, are major growth drivers. Cement producers are increasingly adopting grinding aids to address rising energy costs, reduce carbon footprints, and improve production efficiencies. For instance, grinding aids have been shown to lower energy consumption by up to 25 per cent, making them a cost-effective solution for plants facing energy price volatility.

Regional trends: Developed vs. developing markets

Developed markets: Europe and North America represent mature markets for grinding aids. Europe, driven by stringent environmental regulations such as the EU Emissions Trading System (EU ETS), has witnessed a steady rise in the adoption of low-VOC and eco-friendly grinding aids. Leading players in these markets emphasise sustainability and compliance with regulatory frameworks, contributing to steady demand.
In North America, the focus is on productivity enhancements in large-scale cement plants, with grinding aids used to achieve finer cement grades and support blended cement production.
Developing markets: Emerging economies in Asia-Pacific, the Middle East, and Africa exhibit the fastest growth in grinding aid adoption. The Asia-Pacific region accounted for over 40 per cent of global grinding aid consumption in 2023, with countries like India, China, and Vietnam leading the way. The rapid urbanisation, rising construction activity, and increasing cement production capacities in these regions are
driving demand.

In Africa, grinding aids are gaining traction as manufacturers focus on optimising production costs in an environment of fluctuating raw material and energy prices.

Market size and adoption rate in India
India, the world’s second-largest cement producer, offers a significant growth opportunity for grinding aids. In 2023, the grinding aids market in India was valued at US$ 150 million, with a projected growth rate of over seven per cent CAGR through 2030. The adoption rate remains relatively low at smaller plants, which prioritise cost-saving over efficiency gains. However, leading manufacturers and integrated cement plants are increasingly embracing grinding aids, particularly for blended cement production.
Blended cements, such as Portland Pozzolana Cement (PPC) and Portland Slag Cement (PSC), account for more than 70 per cent of the Indian cement market. Grinding aids tailored for fly ash and slag-blended cements are in high demand, with some products delivering up to a 15 per cent increase in mill throughput and improved early strength development.

Emerging trends

Eco-friendly formulations: The growing demand for sustainable grinding aids has prompted companies to develop low-VOC and biodegradable alternatives.
Customised solutions: Grinding aid formulations are increasingly tailored to address specific raw material challenges and production processes, such as VRMs or high-SCM cement blends.
Digitalisation: Smart dosing systems integrated with real-time mill monitoring are enabling optimised grinding aid usage, ensuring consistent performance across diverse production conditions.

Bridging the Trust Gap
For cement plant operators, the quality and performance of grinding aids often appear as a ‘black box.’ The lack of transparency in the formulation and quality checks of these additives has historically limited trust and widespread adoption. Grinding aid manufacturers must address this issue by fostering transparency and providing detailed insights into the testing and validation of their products. This would not only instill confidence but also strengthen collaboration with cement companies.
Grinding aid producers should provide robust documentation outlining the physical and chemical characteristics of their formulations, supported by consistent performance data from laboratory tests, industrial-scale trials, and third-party validations. This transparency is essential to demystify grinding aids’ performance and demonstrate their effectiveness across diverse operational conditions.

Emerging innovations in grinding aid chemistry
The path forward for grinding aid manufacturers lies in innovation. Recent research highlights the potential of hybrid formulations combining traditional amines and glycols with advanced polymeric additives like polycarboxylate ethers (PCEs). These hybrid products can address specific challenges such as improving grindability in blended cements containing fly ash or slag, where traditional additives often underperform. Nano-engineering of grinding aids, incorporating nanoparticles for optimised dispersion and enhanced hydration kinetics, represents another promising avenue.

Leveraging AI for optimisation

The integration of artificial intelligence (AI) and machine learning tools into grinding aid application systems is reshaping the cement industry. AI-driven systems enable real-time optimisation of grinding aid dosages by analysing mill performance data, such as power consumption, throughput, and particle size distribution. For example, a cement plant in Europe reported a 15 per cent reduction in specific energy consumption and a 10 per cent
increase in mill throughput using AI-optimised dosing systems. This innovation reduces operational variability and improves the predictability of grinding aid performance.

Expectations from grinding aid producers
The cement industry demands more than just products; it seeks partnerships with grinding aid manufacturers. Key expectations include:
1. Customised formulations: Tailored products designed for specific raw materials, clinker compositions, and mill configurations to maximise efficiency and performance.
2. Eco-friendly additives: Grinding aids with low volatile organic compound (VOC) emissions and biodegradable ingredients that align with the industry’s sustainability goals.
3. Comprehensive technical support: On-site training and technical services to help plant operators understand grinding aid chemistry, application techniques and performance optimisation strategies.
4. Advanced quality control systems: Transparent testing protocols, including real-time quality assurance of grinding aids delivered to cement plants. Regular reporting of performance consistency through defined KPIs like grindability index and Blaine fineness is essential.

Role of cement companies in promoting grinding aid usage
Cement producers must take an active role in promoting grinding aid adoption. Sharing success stories of energy savings, improved mill performance, and enhanced cement quality can encourage industry-wide adoption. For example, an Indian cement manufacturer recently documented a 20 per cent improvement in 28-day compressive strength and a 10 per cent reduction in energy consumption with glycol-based additives, driving interest among peers.
Moreover, collaborative initiatives between cement producers and grinding aid manufacturers, such as joint research programs and knowledge-sharing forums, could lead to significant advancements in grinding technology. Organisations like the Cement Manufacturers’ Association of India and the World Cement Association can facilitate these partnerships.

Conclusion
Grinding aids play a pivotal role in modern cement manufacturing, offering significant advantages in energy efficiency, mill productivity and cement quality. Despite their transformative potential, adoption remains inconsistent due to challenges like raw material variability, operational concerns and limited trust in product formulations. Transparency and collaboration between grinding aid producers and cement manufacturers are critical to addressing these issues and fostering broader acceptance.
Innovations in grinding aid chemistry, including hybrid formulations and nano-engineered additives, have unlocked new possibilities for enhancing grindability and hydration performance. Meanwhile, advancements in artificial intelligence and data analytics have opened avenues for real-time optimisation, ensuring precise dosing and measurable cost savings. These developments underscore the evolving synergy between technology and grinding aid applications.
Globally, the grinding aid market is poised for growth, with developed regions leading adoption and emerging economies like India offering immense potential driven by infrastructure demands. However, tapping into these opportunities requires grinding aid producers to align with industry expectations. Cement manufacturers expect customised solutions, eco-friendly formulations, technical support and transparent quality assurance processes to build trust and confidence.
The path forward demands a collaborative approach. Grinding aid producers must continue investing in research and innovation while actively engaging with the cement industry to educate stakeholders and demonstrate measurable benefits. Concurrently, the cement industry must champion adoption through case studies, knowledge sharing, and regulatory support. Together, these efforts will ensure grinding aids fulfill their promise of enabling a more efficient, sustainable, and resilient cement manufacturing sector.

References
1. Gao, J., Zhang, S., Wang, X., & Ma, B. (2011). “Effect of organic grinding aids on cement properties and the analysis via liquid chromatography-mass spectrometry.” Construction and Building Materials, 25(8), 3600–3605.
2. Amritphale, S. S., Patel, M., & Singh, R. (2017). “Grinding aids: A study on their mechanism of action in cement grinding processes.” Indian Cement Review.
3. Cembureau – The European Cement Association. “Cement grinding optimisation through grinding aids.” Industry Report, 2023.
4. Flatt, R. J., & Schober, I. (2012). “Superplasticisers and the rheology of concrete.” International Journal of Cement Chemistry, 64(4), 91–109.
5. Mejeoumov, G. G. (2007). “Improved cement quality and grinding efficiency by means of closed mill circuit modeling.” PhD Dissertation, Texas A&M University.
6. Global Cement. “Advances in grinding aids: Market trends and new technologies.” Published October 2024.
7. Statista. “Global grinding aids market size and forecast (2023-2030).” Published March 2024.
8. Pal, B. K., & Rath, P. C. (2020). “Influence of grinding aids on particle size distribution, strength, and hydration of cement.” Journal of Materials Science and Applications, 45(2), 234–246.
9. Indian Cement Review. “Emerging market scope of grinding aids in India.” Published July 2023.
10. Zhang, H., Li, X., & Zhao, Y. (2022). “The role of grinding aids in improving cement hydration kinetics.” Journal of Advanced Materials Science, 17(6), 527–540.
11. Sika AG. “Technical Report on Polycarboxylate Ether (PCE) based grinding aids.” Published 2022.
12. Cement and Concrete Research. “AI-driven optimisation in cement grinding: Case studies and industrial applications.” Volume 152, 2023.
13. Taylor, H. F. W. (1997). Cement Chemistry (2nd Edition). Thomas Telford Publishing.
14. Indian Bureau of Mines (IBM). “Market trends and challenges in cement manufacturing.” Annual Report, 2024.
15. World Cement Association. “Sustainability in grinding aids and cement additives.” Published 2024.

About the author:
Dr SB Hegde, a global cement industry leader with over 30 years of experience, is a Professor at Jain College of Engineering, India, and a Visiting Professor at Pennsylvania State University, USA. Recipient of the ‘Global Visionary’ award, Dr Hegde advises India’s think tank CSTEP on hydrogen usage in cement and consults for major cement companies. He also serves on expert panels of key industry bodies and journals globally.

Concrete

Smart sustainable solutions

Published

18 hours ago

March 11, 2025

admin

Efficient bulk material handling has always been critical for seamless production, cost reduction and environmental compliance. Kanika Mathur delves into advanced automation, smart sensors and sustainable transport solutions that are key to overcoming challenges.

The cement industry is a cornerstone of infrastructure development, contributing significantly to economic growth. However, cement production involves the handling and transportation of vast quantities of raw materials such as limestone, clay, iron ore, fly ash and gypsum, as well as the final product—cement itself. Efficient bulk material handling (BMH) systems are crucial in ensuring uninterrupted production, reducing operational costs, minimising material wastage and improving overall efficiency.

In an industry where material losses, dust emissions, and energy consumption are major concerns, advancements in bulk material handling technology are playing a vital role in optimising operations. Automated and energy-efficient bulk handling solutions, such as pneumatic conveying systems, belt conveyors and stacker-reclaimer systems, are transforming the way cement plants manage their raw materials and finished products. This article explores the key aspects of bulk material handling in the cement industry, the latest technological advancements, and the challenges and opportunities in this space.

Importance of bulk material handling
Cement manufacturing requires the continuous movement of raw materials from mines and quarries to processing plants, followed by the transportation of the finished product to storage facilities and distribution networks. Bulk material handling systems ensure that this process runs smoothly, reducing downtime and enhancing productivity.
According to the Global Cement Report (2023), inefficient material handling contributes to 5 – 10 per cent of total cement production losses in India. Additionally, poor handling practices lead to high levels of dust pollution, which is a significant environmental and health concern. With cement production in India expected to reach 500 million metric tonnes by 2025, the demand for advanced and automated material handling systems is increasing rapidly.
Jacob Jose, CEO and Managing Director, Methods India, says, “With our advanced pipe conveyors, downhill conveyors and cross-country conveyors, we have revolutionised the way cement plants transport raw materials. Our technology helps reduce operational costs, minimise environmental impact and improve energy efficiency. Over the years, we have observed a positive impact in the industry, particularly with the growing adoption of pipe conveyors and cross-country conveyors, which have proven to be more efficient and environmentally friendly alternatives to traditional transport methods.”

Key bulk material handling technologies
1. Belt conveyors: The workhorse of cement plants
Belt conveyors are one of the most widely used bulk material handling solutions in the cement industry. They transport raw materials, clinker and finished cement over long distances within the plant and to storage facilities. Modern high-capacity belt conveyors can handle loads exceeding 10,000 tonnes per hour, significantly improving efficiency.

Advantages: High efficiency, low operational costs, and reduced manual intervention.
Challenges: Belt wear and tear, spillage, and maintenance requirements.
Technological advancement: The introduction of heat-resistant and fire-retardant conveyor belts has improved durability, while sensor-based predictive maintenance systems help detect belt failures before they occur.

2. Stacker and reclaimer systems: Optimising storage and retrieval
Stackers and reclaimers are essential for managing bulk raw materials in cement plants. Stackers pile materials such as limestone, coal, and gypsum, while reclaimers retrieve them for processing. These systems ensure homogeneous blending, reducing material variability and enhancing cement quality.

Latest innovation: Automated stacker and reclaimer systems with AI-driven optimisation help maximise storage space and minimise
retrieval time.
Efficiency gains: Newer stacker-reclaimer designs allow for material recovery rates of over 90 per cent, reducing wastage and ensuring a steady feed to the production line.

3. Pneumatic conveying systems: Dust-free material transfer
Pneumatic conveying systems use air pressure or vacuum systems to move powdered and granular materials such as fly ash, cement and kiln dust through pipelines. They are particularly useful in reducing dust emissions and preventing material contamination.

Advantages: Dust-free operation, reduced environmental impact, and minimal maintenance.
Industry adoption: Many Indian cement plants are shifting from mechanical conveyors to high-pressure pneumatic conveying systems to comply with pollution control regulations set by the Central Pollution Control Board (CPCB).

4. Screw conveyors and bucket elevators: Compact and versatile solutions

Screw conveyors: Used for short-distance material movement, particularly for handling fine and powdered materials such as cement, gypsum, and pulverised coal.
Bucket elevators: Ideal for vertical material transport, commonly used for lifting raw meal, cement, and clinker to storage silos.
Technological upgrades: The introduction of wear-resistant alloy buckets and variable-speed drives has enhanced the reliability and efficiency of these systems.

Challenges in bulk material handling
Despite significant advancements, several challenges continue to hinder bulk material handling efficiency in cement plants:
1. Material spillage and dust emissions
Material spillage and dust emissions pose environmental, health, and financial challenges. Uncontrolled dust emissions from conveyors, transfer points, and storage facilities not only violate regulatory norms but also lead to material losses. Studies show that up to three per cent of bulk materials are lost due to improper handling in Indian cement plants.

Solution: Enclosed conveyors, dust suppression systems, and bag filters help reduce dust pollution.

2. High energy consumption
Bulk material handling systems consume a significant amount of energy, especially in large cement plants where materials need to be transported over long distances. According to a CII (Confederation of Indian Industry) report (2023), energy costs account for nearly 40 per cent of total production expenses in cement manufacturing.

Solution: Energy-efficient conveyor motors, regenerative braking systems, and smart automation can help reduce power consumption.

3. Wear and tear of equipment
Continuous exposure to abrasive materials like limestone and clinker leads to significant wear and tear in bulk material handling equipment, increasing maintenance costs and downtime.

Solution: The use of wear-resistant liners, ceramic-coated conveyor belts, and automated lubrication systems extends equipment life and reduces maintenance downtime.

4. Logistics and transportation bottlenecks
Moving bulk materials from cement plants to distribution centers requires an efficient logistics network. Rail and road congestion, inadequate infrastructure, and high transportation costs often result in delays and increased operational expenses.

Solution: Integrated bulk terminals and automated dispatch systems improve supply chain efficiency. The Indian government’s push for multi-modal logistics parks (MMLPs) is expected to enhance cement transportation efficiency.

Indrendra Singh Raghuwanshi, Sales Head – Cement Division, ATS Conveyors, says, “Ensuring that our systems handle diverse alternative fuels reliably is at the core of our engineering approach. Alternative fuels, such as biomass, MSW, RDF and industrial waste vary significantly in terms of composition, size, moisture content, and combustibility. All our systems are designed with flexibility and robustness to meet the unique challenges posed by these fuels while maintaining operational efficiency and safety. Also, before deployment to site, we conduct extensive testing for our equipment to ensure that they can reliably handle alternative fuels under a variety of conditions. This includes testing different fuel types, moisture levels, and feeding rates to identify any potential challenges. Our systems are then fine-tuned during the commissioning phase to ensure optimal performance in real-world conditions.”

The future is automation and digitalisation

The future of bulk material handling in the cement industry lies in automation, artificial intelligence (AI), and digital twin technologies. Leading cement manufacturers are investing in IoT-enabled bulk handling systems that provide real-time monitoring, predictive maintenance, and AI-based process optimisation.

1. Smart sensors and predictive maintenance
AI-powered sensors are now being integrated into conveyors and stackers to detect early signs of wear and tear, enabling proactive maintenance and reducing unplanned downtime.
Nishith Kundar, Co-Managing Partner, Cemtech Engineering Solutions, says, “One of our latest advancements is the introduction of drone inspection technology. Since silos are confined spaces, it is often difficult to assess their internal condition, particularly at the top. We have incorporated drone inspections for both pre-cleaning and post-cleaning assessments. Pre-cleaning drone inspections help us analyse the extent of material buildup, while post-cleaning inspections ensure that the silo has been thoroughly cleaned. This technology is also applicable to pre-heaters, allowing us to monitor internal conditions in confined spaces. By leveraging drone technology, we provide precise and efficient cleaning services, improving safety and operational efficiency.”

2. Digital twin technology
Digital twin models create a virtual replica of bulk handling systems, allowing operators to simulate various scenarios and optimise material flow before implementing changes in real time.

3. Automated Guided Vehicles (AGVs) and robotics
The adoption of AGVs and robotic material handling systems is gaining traction in cement plants for automated raw material transport, warehouse management, and truck loading/unloading.
Gaurav Gautam, Business Unit Head,
Beumer Group, says, “A major recent focus has been integrating digital monitoring tools into our equipment. These tools include condition monitoring sensors that track temperature variations, vibrations and operational anomalies in real-time. By capturing this data, plant operators can take proactive actions when conditions start deviating from normal parameters. This approach prevents sudden breakdowns and, in the long term, enhances the durability and reliability of the equipment.”
“Moving forward, digitalisation will play a key role in tackling wear and tear challenges. By increasing the number of data capture points and applying advanced analytics tools, we can gain deeper insights into equipment health and performance, ensuring a more efficient and predictive maintenance strategy,” he adds.

Conclusion
Efficient bulk material handling is the backbone of cement manufacturing, ensuring a seamless flow of raw materials and finished products while minimising environmental impact and operational costs. As India’s cement industry moves towards higher production capacities and stricter environmental norms, investing in advanced, automated and energy-efficient bulk handling solutions will be key to maintaining competitiveness.
By embracing smart technologies, automation and sustainable handling practices, cement manufacturers can enhance productivity, reduce material losses, and contribute to a greener and more efficient future for the industry.