Concrete

Increasing Use of Supplementary Cementitious Materials

Published

1 year ago

October 19, 2023

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Jens Mose and John Terembula, Product Line Management, FLSmidth A/S, explore how cement manufacturers can utilise VRMs to reduce the clinker factor and meet their environmental targets, in the final part of this three-part series. You can find parts one and two in the August and September issues of Indian Cement Review.

OPTIMISING PARTICLE SIZE DISTRIBUTION
Experience has shown that practically every type of cement around the world can be – and is already being – produced in an OK MillTM.
While the particle size distribution (PSD) of the product is normally steeper in a VRM cement mill compared to a traditional ball mill, this can, to some extent, be modified by working with various parameters such as grinding pressure and dam ring height. The air flow and the separator speed are also used to customise the PSD curve to customer specific requirements.
However, as interest in greater utilisation of SCMs increases, cement manufacturers are keen to grind to an even steeper PSD curve to allow for the possibility of mixing more SCMs into the finished product.

THE ADVANTAGES OF VRMS FOR SCMS
When the VRM is designed specifically for grinding cement and cementitious materials, cement manufacturers experience better:

Efficiency: Lowest power consumption compared to other vertical roller mills on the market.
Reliability: The run factor is very high, > 95 per cent
Versatility: Rapid change between different feed compositions and the ability to grind a wide range of materials to very high Blaine or the lowest residues

The OK MillTM was designed with these priorities in mind, and has retained its original shape with a dual lobed roller surface and central grooved and bowl-shaped table design. As the only VRM in the market specifically designed for cement grinding, all rollers are active with each performing material bed compaction and de-aeration, and high-pressure grinding.
Sustainability is also a priority, which is why the mill is designed to require minimal water injection on the mill table, using an average 50 per cent less water than competing mill designs.

Maintenance is also a sustainability issue. Better to repair a part than replace it; better to be proactive than reactive. Predictive maintenance services aim to enable a higher level of proactivity, preventing unexpected downtime and reducing the cost of maintenance.
Over the last 20 years, in-situ rewelding or hard facing has become the standard maintenance practice for VRM, particularly for OK MillsTM with segmented wear liners that can tolerate repeated welding. Roller liner segments can be rewelded as many as 10 times or more and table segments 15 times or more. In order to improve its service capability for VRMs, FLSmidth works with welding services providers across the globe. We have also developed ceramic wear segments in an OK MillTM, which not only perform better but can also be recycled.

DIGITAL TOOLS FOR GREATER FLEXIBILITY
Digitalisation makes it easier to use SCMs and will enable further reductions in the clinker factor. The following are just a snapshot of the tools currently available; more are in development all the time:

Process control solutions give operators greater control over their mill operating parameters to optimise performance and ensure maximum efficiency.
Sensors continually monitor mill operation, enabling you to see any drop in stability as it happens and react swiftly.
Automated laboratories enable optimum quality control throughout the process.
Condition monitoring services and remote service support give you 24/7 access to expert assistance.

CONCLUSION
As the cement industry works to reduce its carbon footprint, investments have to be made in future-proof technologies capable of adapting to changing cement mixes and regulatory requirements. In the grinding process, cement manufacturers need a flexible, efficient system that is operated and maintained in an optimal manner. With the latest VRM technologies, advanced digital offerings and condition monitoring services, FLSmidth believes the industry is ready to achieve more widespread use of SCMs and achieve its carbon reduction goals.

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Concrete

Organisations valuing gender diversity achieve higher profitability

Aparna Reddy, Executive Director, Aparna Enterprises talks about company plans.

Published

6 hours ago

February 22, 2025

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The building materials industry is projected to grow by 8-12 per cent over the next five years. How is Aparna Enterprises positioning itself to leverage this momentum and solidify its market presence?

The Indian construction and building materials industry is projected to witness significant expansion, with estimates suggesting an 8-12 per cent compound annual growth rate (CAGR) over the next five years. This growth is fuelled by rapid urbanisation, increased infrastructure investments and sustainability-focused policies. With India’s real-estate market expected to reach $ 1 trillion by 2030, the demand for high-quality building materials is at an all-time high.

The Government of India’s flagship programmes, such as PM Gati Shakti, the Smart Cities Mission and the Housing for All (PMAY-Urban) initiative, are key drivers of this surge. The infrastructure sector alone is expected to receive a budgetary push of over Rs 11 trillion in FY25, with enhanced capital expenditure allocation.

At Aparna Enterprises, we are proactively aligning with this momentum through capacity expansion, product diversification, and cutting-edge technological integration.

Our key strategic priorities include:

Expanding operations in high-growth regions across Tier-2 and Tier-3 cities, ensuring access to quality building materials nationwide
Investing in automation, AI-driven quality control systems and digital integration, enhancing efficiency and precision in manufacturing
Scaling up production capabilities in our RMC, tiles, uPVC and other divisions to meet the anticipated surge in demand.

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Concrete

Global Start-Up Challenge Launched to Drive Net Zero Concrete Solutions

Innovandi Open Challenge aims to connect start-ups with GCCA members to develop innovations

Published

2 days ago

February 21, 2025

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Start-ups worldwide are invited to contribute to the global cement and concrete industry’s efforts to reduce CO2 emissions and combat climate change. The Global Cement and Concrete Association (GCCA) and its members are calling for applicants for the Innovandi Open Challenge 2025.

Now in its fourth year, the Innovandi Open Challenge aims to connect start-ups with GCCA members to develop innovations that help decarbonise the cement and concrete industry.

The challenge is seeking start-ups working on next-generation materials for net-zero concrete, such as low-carbon admixtures, supplementary cementitious materials (SCMs), activators, or binders. Innovations in these areas could help reduce the carbon-intensive element of cement, clinker, and integrate cutting-edge materials to lower CO2 emissions.

Thomas Guillot, GCCA’s Chief Executive, stated, “Advanced production methods are already decarbonising cement and concrete worldwide. Through the Innovandi Open Challenge, we aim to accelerate our industry’s progress towards net-zero concrete.”

Concrete is the second most widely used material on Earth, and its decarbonisation is critical to achieving net-zero emissions across the global construction sector.

Concrete

StarBigBloc Acquires Land for AAC Blocks Greenfield Facility in Indore

The company introduced NXTGRIP Tile Adhesives alongside its trusted NXTFIX and NXTPLAST brands.

Published

3 days ago

February 19, 2025

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StarBigBloc Building Material, a wholly-owned subsidiary of BigBloc Construction, one of the largest manufacturers of Aerated Autoclaved Concrete (AAC) Blocks, Bricks and ALC Panels in India has acquired land for setting up a green field facility for AAC Blocks in Indore, Madhya Pradesh. Company has purchased approx. 57,500 sq. mts. land at Khasra No. 382, 387, 389/2, Gram Nimrani, Tehsil Kasrawad, District – Khargone, Madhya Pradesh for the purpose of AAC Blocks business expansion in central India. The total consideration for the land deal is Rs 60 million and Stamp duty.

StarBigBloc Building Material Ltd currently operates one plant at Kheda near Ahmedabad with an installed capacity of 250,000 cubic meters per annum, serving most part of Gujarat, upto Udaipur in Rajasthan, and till Indore in Madhya Pradesh. The capacity utilisation at Starbigbloc Building Material Ltd for the third quarter was 75 per cent. The planned expansion will enable the company to establish a stronger presence in Madhya Pradesh and surrounding regions. Reaffirming its commitment to the Green Initiative, it has also installed a 800 KW solar rooftop power project — a significant step toward sustainability and lowering its carbon footprint.

Narayan Saboo, Chairman, Bigbloc Construction said “The AAC block industry is set to play a pivotal role in India’s construction sector, and our company is ready for a significant leap forward. The proposed expansion in Indore, Madhya Pradesh aligns with our growth strategy, focusing on geographic expansion, R&D investments, product diversification, and strategic branding and marketing initiatives to enhance visibility, increase market share, and strengthen stakeholder trust.”

Bigbloc Construction has recently expanded into construction chemicals with Block Jointing Mortar, Ready Mix Plaster, and Tile Adhesives, tapping into high-demand segments. The company introduced NXTGRIP Tile Adhesives alongside its trusted NXTFIX and NXTPLAST brands, ensuring superior bonding, strength, and performance.

In May 2024, the board of directors approved fund-raising through SME IPO or Preferential issue to support expansion plans of Starbigboc Building Material subject to requisite approvals and market conditions, Starbigboc Building Material aims to expand its production capacity from current 250,000 cubic meters per annum to over 1.2 million cubic meters per annum in the next 4-5 years. Company is targeting revenues of Rs 4.28 billion by FY27-28, with an expected EBITDA of Rs 1.25 billion and net profit of Rs 800 million. In FY23-24, the company reported revenues of Rs 940.18 million, achieving a revenue CAGR of over 21 per cent in the last four years.

Incorporated in 2015, BigBloc Construction is one of the largest and only listed AAC block manufacturer in India, with a 1.3 million cbm annual capacity across plants in Gujarat (Kheda, Umargaon, Kapadvanj) and Maharashtra (Wada). The company, which markets its products under the ‘NXTBLOC’ brand, is one of the few in the AAC industry to generate carbon credits. With over 2,000 completed projects and 1,500+ in the pipeline, The company’s clients include Lodha, Adani Realty, IndiaBulls Real Estate, DB Realty, Prestige, Piramal, Oberoi Realty, Tata Projects, Shirke Group, Shapoorji Pallonji Group, Raheja, PSP Projects, L&T, Sunteck, Dosti Group, Purvankara Ltd, DY Patil, Taj Hotels, Godrej Properties, Torrent Pharma, GAIL among others.