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Concrete

From Code to Context

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Dijam Panigrahi, Co-founder and COO, GridRaster, explores the concepts of Spatial AI and Mixed Reality as the evolution of Industry 5.0 sets in motion.

Beyond the data-driven efficiencies of Industry 4.0, a new paradigm is emerging for cement manufacturers, clinker producers, and heavy materials processors: Industry 5.0. This next evolution emphasises a human-centric, resilient and sustainable approach, calling for a more symbiotic relationship between highly skilled plant operators and intelligent machines.
The goal is to leverage the precision and tireless nature of automation while keeping human ingenuity, judgment, and creativity at the core of the operation. This vision promises greater flexibility, higher quality, and improved safety, yet a massive, persistent hurdle stands in the way: the debilitating complexity of integrating industrial robotics and drones for dynamic, high-risk tasks.

The technological moat
For decades, deploying and reprogramming specialised automation such as inspection drones or robotic maintenance arms has been a task reserved for highly specialised, six-figure engineers. The geometry of a massive rotary kiln shell is non-uniform and constantly exposed to high heat. The internal structure of a cement silo is a confined, hazardous space.
Setting up a new task be it a complex, real-time measurement for hot kiln alignment, a precise path for refractory gunning inside a cooler, or a meticulous inspection route for crack detection on a kiln shell can take hours, days, or even weeks of meticulous, line-by-line coding and calibration. This lengthy, expensive process makes automation uneconomical for many high-risk maintenance procedures, effectively creating a technological moat that keeps advanced automation out of reach for tasks that truly need it.

The solution: Spatial ai shatters the code barrier
A confluence of technologies namely Spatial AI and Mixed Reality (XR) is poised to shatter this status quo, fundamentally changing the economics of automation in cement production.
Spatial AI enables machines to see, understand, and interact with the physical world in real-time, in three dimensions, and in context. In the cement plant, this means an inspection drone or robotic arm is no longer a blind piece of hardware executing pre-written code; it is a collaborative partner that understands the exact curvature of the clinker cooler, the precise location of a worn refractory brick, or the dynamic environment around a moving girth gear.
This technology allows robot programming to move from a complex coding process to a simple demonstration.
Instead of writing thousands of lines of code, a maintenance engineer simply dons a Mixed Reality headset and visually guides a drone or robotic arm through the necessary steps. The Spatial AI immediately translates the human movement, path, and intent into a precise, executable robot programme. The entire setup time for a new dynamic task, which once took days, can now be reduced to mere minutes.

The transformative impact on robotics and automation
This leap in ease-of-use does more than save time; it fundamentally transforms the capabilities of industrial robots, moving automation from rigid, pre-programmed processes to truly adaptive and cognitive systems.
The cement industry relies heavily on scheduled, resource-intensive shutdowns for critical refractory maintenance. Spatial AI transforms this process by empowering specialised robots with sub-millimeter precision. For tasks like gunning (applying new refractory material) or welding inside the massive kiln or cooler, the robotic arm can now utilise the real-time 3D plant map to dynamically compensate for thermal expansion, structural shifts, and non-uniform material wear.
A human operator, trained in refractory repair, can use the XR headset to define the optimal material application pattern on the damaged area. The Spatial AI captures this intent and programs the robotic arm to execute the task perfectly, ensuring precise coverage and material thickness, thereby extending refractory lifespan and improving energy efficiency. This is an automation that learns from expert human judgment and executes with superhuman consistency.

Adaptive automation beyond the kiln
The benefits extend far beyond the kiln and cooler and into the often overlooked, yet crucial, areas of material handling and logistics:
Stockyard Management: In large, dynamic storage domes or stockyards, Spatial AI allows autonomous heavy machinery such as dozers, stackers, and reclaimers to operate efficiently. The system constantly maps the changing shape of the stockpiles (a non-uniform, dynamic geometry) and calculates the most energy-efficient and shortest path for material movement. Robots can perform real-time volume calculations, significantly improve inventory accuracy and reduce fuel consumption from unnecessary movements.
Quarry Operations: Similarly, autonomous drilling and hauling equipment in the quarry can utilise Spatial AI to maintain optimal blast-hole patterns and navigate complex, frequently changing terrain, avoiding dynamic obstacles (like other vehicles or temporary rock falls) without human intervention. The ability to instantly train a new haul path via XR guidance drastically cuts the time needed to adapt to new quarry faces, maximising raw material throughput.

The shift to cognitive and collaborative automation
Traditional industrial robotics require a stable, predictable environment. Spatial AI introduces cognition, allowing automation to thrive in the chaotic, high-risk reality of a cement plant. Robots equipped with Spatial AI can:
Adapt to Non-Uniformity: They can perform tasks on surfaces that are hot, dirty, and physically deformed (e.g., an aging kiln shell) because they are constantly referencing a dynamic, live 3D model, rather than a fixed, pre-programmed path.
Coordinate Fleets: Spatial AI provides a common operating picture, enabling drones, stationary arms, and ground vehicles to share real-time location and task data. This is crucial for complex operations, such as having a drone inspect an area while a robotic arm is simultaneously performing a repair.

Elevating the role of the plant worker
The core of Industry 5.0 is the human operator. By having Spatial AI systems safely take over repetitive, monotonous, or highly dangerous tasks, plant personnel are liberated to focus on the highest-value work: complex process management, troubleshooting, and continuous process optimisation. This fosters a human-machine collaboration that drives innovation, enhances safety and ensures sustainability.
Spatial AI is not merely a theoretical leap in digital twin technology; it is a concrete, actionable technology that is delivering immediate, impactful change on the plant floor. By simplifying complexity and driving setup time down to minutes, this technology is the essential accelerator that makes advanced industrial automation truly accessible to all cement manufacturers, marking the definitive arrival of the human-centric, high-efficiency world of Industry 5.0.

About the author:
Dijam Panigrahi, Co-founder and COO, GridRaster is a performance-driven leader with over 20 years of global experience in market development, product management, and business growth.

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.

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