Concrete

Sustainability as a Culture

Published

1 year ago

January 12, 2024

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Tarun Mishra, Co-founder, Covacsis Technologies, explores the role of technology in driving the cement sector towards a sustainable future.

The industrial era of the 20th century had more sustainable business practices than the 21st century. However, the global community has realised the need to bring sustainable practices back into the manufacturing process. Thus, the idea of sustainability as a culture, not just a metric to comply with, has evolved. Right impetus on innovating and developing effective manufacturing technologies coupled with making sustainability a boardroom agenda are important steps.
Making the world sustainable by minimising all kinds of waste produced in manufacturing processes and by minimising consumption of natural resources are essential parts of sustainability.
The core idea of sustainability is to drive towards:

1. Zero impact on the environment due to operations
2. Zero impact on the society
Manufacturing industry worldwide ought to play a greater role in this endeavour. Cement industry must rise to take larger responsibility, and become a role model for other industries in developing this culture as part of business practices by employing design thinking and digital interventions.
Mineral processing and cement production are extremely energy intensive activities. Reaching net zero and decarbonising cement requires lengthy changes throughout the value chain.
Cement-based materials, such as concrete and mortars, are used in extremely large amounts. Cement plays an important role in terms of economic and social relevance since it is fundamental to build and improve infrastructure. On the other hand, this industry is also a heavy polluter. Cement production releases 5-6 per cent of the entire CO2 generated due to human activities, accounting for about 4 per cent of global warming. It can release huge amounts of persistent organic pollutants, such as dioxins and heavy metals and particles. Energy consumption is also considerable. Cement production uses approximately 0.6 per cent of all energy produced in the US.
A huge innovation and solution is underway to make cement greener and sustainable, such as the use of alternative materials that can be used to minimise CO2 production and reduce energy consumption, such as calcium sulphoaluminate and ß-Ca2SiO4-rich cements.
Also sustainability of the cement industry can be significantly improved by using residues from other industrial sectors. Under adequate conditions, waste materials such as tyres, oils, municipal solid waste and solvents can be used as supplementary fuel in cement plants.
While the role of research and development is necessary to improve cement industry sustainability over a long run, with intelligent systems it is possible to get immediate results by optimising complex cement plant’s energy use while maintaining high equipment availability. All this must start with measuring various sustainability metrics and dimensions within the organisation.

Measurement metrics
An effective measurement requires:

What to measure?
The sustainability metrics defined across the value chain becomes extremely important in the overall scheme of things. What is not measured never improves, therefore, a thorough study to map every value element and to identify sustainability metrics is imperative.
For example, cement manufacturers can think ways and means to measure:
a. Carbon neutrality at every stage such as kiln, cement mills, etc.
b. Waste produced or treated
c. Net health hazard in every process and job function
d. Net safety hazard in the process and job function
How to measure? What method to use for measuring?
Current manual mode of recording and logging information is limiting, ineffective and non-actionable. Furthermore, the current method is based on sample data collection once a shift or once a day. It does not fulfill beyond meeting compliance needs.
A new generation method using IIOT will eliminate manual methods and provide comprehensive, error free and valuable data along with the root cause analysis to improve further.
When do they get measured?
A comprehensive set of metrics getting measured using elaborate and error free methods is great but still not sufficient. Measuring these metrics in real time delivers unthinkable opportunities to the organisation to arrest performance compromises immediately and set things right without losing anything. Intelligent technologies like Covacsis’ Intelligent Plant Framework uses extensive data science to track all sorts of irregularities instantaneously and provides comprehensive root cause analysis with recommendations.
For example, C3S percentage change in kiln operation may affect the coal consumption per ton of clinker. Real time discovery and understanding of the right relation between C3S and other process parameters will allow the shop floor team to optimise coal costs. Some of these are not part of conventional distributed control systems (DCS), supervisory control and data acquisition (SCADA) and Historians.

An Organisational Practice
Platforms, tools or solutions like Intelligent Plant Framework provide easy, automatic and autonomous real time understanding with complete visibility about every anomaly.
A large part of assistance is provided through autonomous alerts and notifications mechanisms to users outlining those activities which are potentially compromising on sustainability metrics along with a detailed root cause analysis.
Sustainability is a cross functional agenda in every organisation. Production, quality, engineering, planning, utility, cost, human resource and other departments are required to form a cross functional committee to drive the agenda of sustainability.
Every process in the value stream must have a sustainability index. This index is to be computed in real time and published on a live screen and dashboard along with detailed analytics. Likewise, every department must have sustainability rating done automatically and autonomously on a daily basis to enforce the culture of sustainability.
Every individual must have a sustainability score in the organisation as part of their performance. This will help the human resource department in organising the right training for the right people in the organisation. Digital boot camp on sustainability is a great way to make the agenda pervasive across the organisation.

ABOUT THE AUTHOR:

Tarun Mishra, Co-founder, Covacsis, is a proponent of industrial IOT since 2009. He helps companies built a profitable business by redefining manufacturing operations and its performance.

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Concrete

Transforming Interior Spaces: Trendy Wall Putty Designs to Enhance Your Home

Published

5 days ago

March 19, 2025

admin

When it comes to interior design, walls are more than just structural elements—they serve as the canvas for self-expression, setting the mood and personality of a space. While paint and wallpaper have long been the go-to choices for wall finishes, wall putty is emerging as a game-changer in home décor. With its smooth finish, durability, and versatility, wall putty opens a world of creative possibilities. In this article, we explore trendy wall putty designs that can elevate your interiors, turning ordinary walls into extraordinary design statements.

Wall Putty is a Must-Have in Modern Homes

Wall putty is no longer just a preparatory material for painting; it plays a significant role in modern home aesthetics. It enhances the finish of walls, making them smoother, stronger, and resistant to cracks and moisture. Additionally, high-quality putty like Birla White Wall Putty ensures better paint adhesion, resulting in long-lasting vibrancy.

Beyond its functional benefits, wall putty allows homeowners to experiment with textures and patterns, giving walls a designer touch without the hassle of high-maintenance materials like stone or wood. Whether you’re aiming for a minimalist, rustic, or ultra-modern aesthetic, wall putty designs can help achieve the look effortlessly.

Trendy Wall Putty Designs for Stunning Interiors

1. Textured Wall Putty for a Tactile Appeal

Textured walls are a popular interior trend, adding depth and dimension to living spaces. By using wall putty, homeowners can create a variety of textures, including:

Rustic Texture: Mimicking natural stone or aged plaster for an earthy, vintage feel.
Wave Patterns: Adding a sense of movement and fluidity to walls, perfect for living rooms and entryways.
Sand Finish: A subtle grainy effect that provides a sophisticated touch.

Textured putty walls work exceptionally well in accent areas, such as behind a television unit or as a backdrop for artwork.

2. Sleek and Smooth Walls for a Luxurious Look

For those who prefer a refined and elegant aesthetic, a smooth putty finish is ideal. A flawlessly smooth wall creates a premium appearance, amplifying the impact of high-quality paints. Opting for a high-performance putty like Birla White WallCare Putty ensures a glass-like finish that complements modern and contemporary interiors.

This design is perfect for:

Monochrome interiors where walls serve as a sleek backdrop.
High-gloss or matte-painted walls that need a seamless base.
Spaces with minimal décor where the walls themselves make a statement.

3. Geometric & Abstract Patterns for a Contemporary Edge

Wall putty can be artistically applied to create striking geometric or abstract patterns, adding a unique character to interiors.

Popular designs include:

Chevron or Herringbone: A dynamic, sophisticated look that pairs well with both modern and mid-century décor.
3D Raised Panels: Using putty to craft subtle raised patterns, adding a sculptural effect to the wall.
Asymmetrical Shapes: For a bold and avant-garde touch.
These patterns work best in bedrooms, study areas, or accent walls in open spaces.

4. Venetian Plaster for a Luxe European Aesthetic

Venetian plaster, an age-old technique, is making a grand comeback in modern interiors. With wall putty, you can achieve this exquisite marble-like effect, which exudes luxury and timeless charm.

This design works well for:

Statement walls in living rooms and foyers.
Elegant dining areas where a touch of opulence is desired.
Boutique-style bedrooms with a rich, textured finish.

A high-quality white cement-based putty can replicate this effect beautifully, making the walls look naturally luminous.

5. Dual-Tone or Ombre Walls for a Soft Gradient Effect

The ombre effect, a gradient transition between two colors, is a trendy and artistic way to enhance interiors. When applied over a smooth wall putty base, the gradient blends seamlessly, offering a dreamy, watercolor-like appeal.

This style is perfect for:

Children’s rooms or play areas, creating a fun and dynamic atmosphere.
Bedrooms with a soothing pastel gradient for a calming effect.
Dining spaces where a bold color fade adds character.

6. Metallic & Glossy Finishes for a Chic Look

For homeowners who love glamour and sophistication, combining wall putty with metallic paints or glossy finishes can create a high-end appeal. The smooth base of putty enhances the reflective qualities of metallic shades like gold, silver, or bronze, resulting in an opulent and dramatic effect.

Best suited for:

Luxurious master bedrooms and dressing areas.
Accent walls in dining rooms or home bars.
Commercial spaces like boutiques and salons.

How to Achieve the Best Wall Putty Designs

Choose the Right Putty: Opt for a premium wall putty like Birla White WallCare Putty to ensure durability, a smooth finish, and long-lasting appeal.
Prepare the Surface: Ensure the walls are clean, dry, and free from loose particles before application.
Apply in Layers: Depending on the design, putty can be applied in single or multiple layers for the desired effect.
Use the Right Tools: Trowels, spatulas, sponges, or patterned rollers help create specific textures and patterns.
Seal with Paint or Polish: Once the putty is dry, finishing it with paint, polish, or protective coatings enhances its aesthetic and durability.

Conclusion

Wall putty has evolved beyond its traditional role, now serving as a medium for creative interior design. Whether you prefer textured finishes, sleek smooth walls, or artistic patterns, wall putty designs can elevate your home’s aesthetics while offering durability and elegance. By selecting the best putty for wall and application technique, you can transform your interior walls into stunning masterpieces, setting the perfect backdrop for your lifestyle.

For high-quality wall finishes that stand the test of time, Birla White WallCare Putty ensures both beauty and performance, making your dream interiors a reality.

Concrete

Dalmia Bharat to add 6 MnTPA Cement Capacity in Maharashtra and Karnataka

Published

5 days ago

March 19, 2025

admin

Investment in alignment with the strategic goal of becoming a PAN India company and achieving 75 MnT capacity by FY28
Increases capacity primarily to meet growing demand in Western India along with existing regions

Dalmia Bharat Limited, one of India’s leading cement companies, through its subsidiaries, has announced a strategic investment of approximately Rs 3,520 Crore in the states of Maharashtra and Karnataka. As part of this initiative, the company will establish a 3.6 MnTPA clinker unit and a 3 MnTPA grinding unit at its existing Belgaum plant, Karnataka coupled with a new greenfield split grinding unit with a capacity of 3 MnTPA in Pune, Maharashtra. The capex will be funded through a combination of debt and internal accruals. With this expansion, Dalmia Bharat’s total installed cement capacity will increase to 55.5 MnTPA, after considering the ongoing expansion of 2.9 MnT at Assam and Bihar. These new units are expected to be commissioned by Q4 FY27.

The Belgaum Grinding Unit will cater to the underserved Southern Maharashtra markets while enhancing share in the existing region by improving penetration. On the other hand, Pune Grinding Unit will entirely cater to the untapped Western Maharashtra markets. The initiative is a part of the company’s vision to be a PAN India player and achieve 75 MnTPA capacity by FY28 and 110-130 MnT by 2031.

Speaking on the development, Mr. Puneet Dalmia, Managing Director & CEO, Dalmia Bharat Limited, said, “This investment is a significant step in our Phase II expansion strategy, bringing us closer to strengthen our position as a pan-India player and to reach intermittent goal of 75 MnT capacity by FY28. The increase in our production capacity is primarily to meet the growing infrastructure demand in Western India.” He further added, “We remain committed in realising our goals of capacity expansion, while staying focused on operational excellence and creating long-term value for our stakeholders. The capacity additions will also continue to be in line with Dalmia Bharat’s sustainability-driven approach and its commitment to supporting India’s infrastructure and development goals.”

About Dalmia Bharat: Founded in 1939, Dalmia Bharat Limited (DBL) (BSE/NSE Symbol: DALBHARAT) is one of India’s pioneering cement companies headquartered in New Delhi. With a growing capacity, currently pegged at 46.6 MnT, Dalmia Bharat Limited (including its subsidiaries) is the fourth-largest cement manufacturing company in India by installed capacity. Spread across 10 states and 15 manufacturing units. Dalmia Cement (Bharat) Limited, a subsidiary of Dalmia Bharat Limited, prides itself at having one of the lowest carbon footprint in the cement world globally. It is the first cement company to commit to RE100, EP100 and EV100 (first triple joiner) – showing real business leadership in the clean energy transition by taking a joined-up approach.

Concrete

Dalmia Bharat Commences Commercial Production of its New Grinding Unit of 2.4 MTPA at Lanka, Assam

Published

5 days ago

March 19, 2025

admin

Dalmia Bharat Limited (DBL), India’s leading cement company, has successfully commenced commercial production of its 2.4 MTPA increased Cement Grinding Capacity at Lanka, Assam. With this, the total cement manufacturing capacity of the Group stands at 8 MnT in North-East and overall 49 MTPA Pan-India. The new unit is part of the company’s planned investment of Rs 3,642 Cr, which was announced in May-23, to strengthen its market presence and meet the growing demand in the region. This Grinding Unit’s integrated Clinker Unit of 3.6 MnT is on an advanced stage of commissioning and expected to come in Q2 FY26.

On the commissioning of the new grinding unit, Mr. Puneet Dalmia, Managing Director & CEO, Dalmia Bharat Limited, said: “I am happy to say that the commissioning of 2.4 MnT capacity makes us the largest cement manufacturers of the North-East India. There is an increased focus for infrastructure development in the North-East and this capacity will help us cater to the growing cement demand. We will continue to partner with the states for the creation of landmark projects in the region.”

Dalmia Bharat has had a strong presence in the Northeast for more than 10 years. With a total manufacturing capacity of 8 MTPA, the company operates four cement plants—three in Assam and one in Meghalaya. It has been a key contributor to landmark projects such as the Dhola-Sadiya Bridge, Sela Tunnel, and Dhuburi-Phulbari Bridge. Its social initiatives focus on skill development, community welfare, and environmental conservation, aligning with its long-term vision for responsible growth.

About Dalmia Bharat: Founded in 1939, Dalmia Bharat Limited (DBL) (BSE/NSE Symbol: DALBHARAT) is one of India’s pioneering cement companies headquartered in New Delhi. With a growing capacity, currently pegged at 49 MnT, Dalmia Bharat Limited (including its subsidiaries) is the fourth-largest cement manufacturing company in India by installed capacity. Spread across 10 states and 15 manufacturing units. Dalmia Cement (Bharat) Limited, a subsidiary of Dalmia Bharat Limited, prides itself at having one of the lowest carbon footprints in the cement world globally. It is the first cement company to commit to RE100, EP100 and EV100 (first triple joiner) – showing real business leadership in the clean energy transition by taking a joined-up approach.