Concrete
Economic Implications of Using SCMs
Published
2 years agoon
By
admin
ICR analyses how the integration of supplementary cementitious materials (SCM) and the strategies thereof has catalysed the cement industry’s economic landscape, fostering streamlined processes and enhanced resource utilisation, ultimately shaping a more resilient and profitable sector within India’s economy.
The way to look at any cementitious material in modern times would be to look at the carbon intensity inherent in it in terms of CO2 emissions, such as clinker, which forms the basis for making cement. After grinding the clinker (95 per cent) with gypsum and some correctives (together at 5 per cent), its emission intensity is 849-868 kg per tonne of output. Thus, when you produce ordinary Portland cement (OPC), which contains only clinker as the base cementitious material, the emission intensity is the highest at 750-860 kg of cement output. The lower end of the band is reserved for those who use the best technology that improves thermal efficiency and electrical efficiency.
Now, OPC could be the best suited for giving the early strength of cement measured by the compressive strength in MPa. Whether you take a 3-day or 7-day or 28-day strength, OPC would remain at the highest when you compare with any other form of cement that supplements clinker in the OPC with other cementitious materials like fly ash, slag, silica fume, natural pozzolans – such as calcined clays, shale and metakaolin, sugarcane bagass ash (SCBA) or rice husk ash (RHA).
The purpose of using supplementary cementitious material is two-fold:
- Economic
- Environmental
The way to deal with this subject would be to look at the life cycle assessment of each of these and compute the impact. To make matters simple one may first look at the carbon intensity in each in terms of emissions and attach an appropriate environmental cost to it. Let us look at some of these numbers:
Portland Pozzolana Cement (PPC) uses a mix of 60-65 per cent clinker, 5 per cent gypsum and 25-30 per cent fly ash thus taking the overall emission to an average 700 kg per tonne of cement. Efforts have been always to look at ways of maximising fly ash and PPC specifications allow for even 35 per cent fly ash to meet the compressive strength guidelines. However, we must note that compressive strength will be lower for 3 days, 7 days and 28 days for PPC when compared with OPC by at least 8-10 per cent. If one considers the cost of fly ash that is replacing clinker, the economic impact is huge as the cost of the former is a fraction of the latter.
Economic Implications
To compute the economic benefits of fly ash in PPC there are two important factors to be considered. The grinding units that are the final delivery points of cement units must be logistically located such that the cost of fly ash could be minimised. But this is a network optimisation question and the optimisation would entail outbound logistics cost of cement as well. Most advanced economies, India included, have looked at fly ash as an economic agent that not only turns waste into wealth but also reduces environmental impact of cement emissions (850 kg to 700 kg per tonne). The reduction in the landed cost of fly ash would further improve the economics through better logistics cost optimisation and mode-mix improvements. In recent times freight charges on rail in India for fly ash have been reduced to move fly ash over longer distances.
The environmental impact over long distance haulage of fly ash thus could be brought down
using rail as the mode, a crucial factor for the life cycle assessment.
The wider economic implication could be seen in the alternative deployment of a waste that was put to landfill is now an economic alternative to clinker. Some fly ash producers like NTPC or TATA Power or Adani Power, who together produce more than 100 million tonnes of fly ash per year, could be powerful actors to sway economic balance. Fly ash brick manufacturers who operate in the smaller concentrated networks, mostly SMEs, could be the next contenders in the value balance.
Slag based cement, uses 50 per cent clinker and 45 per cent slag and 5 per cent gypsum on an average. It is the next best example of SCM making a huge difference to the economic as well as environmental impact. By replacing a large amount of clinker, slag-based cement thus makes the emission intensity of cement come down to less than 500 kg per tonne of cement. This when looked at the back of the cost of slag vis-à-vis clinker, which it replaces in the cement, the economic implication is huge. The total production of blast furnace slag is growing, despite its environmental impact and it makes an economic case for GGBS.
However, blast furnace slag or the copper smelter slag, as inputs mixed together, is not free and must compete as commodities with clinker. But game theoretic approaches to price negotiations have fructified into either contracts that are short or medium term tenured (a sharp departure from the past) or pure spot contracts through auctions, that could be well mired in quasi-collusion dynamics of all kinds (in the past). Slag producers seeing an economic opportunity (as opposed to the environmental impact they face otherwise) have mostly experimented with a mix of spot and contracting strategy. The slag benefit in cement over clinker could be in the range of 30-40 per cent looking at the range of cost dynamics that would also include transportation cost by rail.
When one adds the CO2 emission impact benefit, fly ash and slag make a stunning case.
Exploring Other Options
The next most talked about SCMs are silica fumes and natural pozzolans, but their use has been limited in most parts of the world due to economic evaluations, including logistics cost. However, this economics could be lopsided in Europe where fly ash is hardly available and slag could be following suit. Natural pozzolans like calcined clay and metakaolin are therefore in news today, especially in Europe. In India, for example, they could be traded at cement cost, whereas in Europe they could well be lower than the clinker cost.
Utilisation of fly ash in cement has been improving in India but it is still far from the developed world numbers. The old wet fly ash lying in ponds and the dry lying in ash mounds could together be in excess of 100 million tonnes. While the vertical roller mills (VRM) technologies offer great benefits overall ball mills in grinding for absorption of wet fly ash, some innovative methods to use wet fly ash without adding to cost have been developed by some. Similarly, those having a logistics advantage towards a mix of fly ash and slag have settled for composite cement that could use a blend of fly ash and slag in their grinding mix. These could offer negotiating leverage while settling contracts in fly ash and slag.
At the end, to weigh the environmental impact in concrete, which uses a mix of sand, gravel, cement and water, one must see the equation differently: in a one cubic metre of concrete, using 14 per cent cement in the mix, the CO2 emission would be of the order of 410 kg/cubic metre compared to 290 kg per cubic using 30 per cent fly ash in PPC.
- –Procyon Mukherjee
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Concrete
Adani’s Strategic Emergence in India’s Cement Landscape
Published
5 days agoon
September 16, 2025By
admin
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.
Concrete
Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series
Published
1 month agoon
August 16, 2025By
admin
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.

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.

Adani’s Strategic Emergence in India’s Cement Landscape

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

Driving Measurable Gains

Reshaping the Competitive Landscape

CCU testbeds in Tamil Nadu

Adani’s Strategic Emergence in India’s Cement Landscape

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

Driving Measurable Gains

Reshaping the Competitive Landscape
