Concrete

Cement Additives for Improved Grinding Efficiency

Published

3 months ago

March 18, 2026

admin

Shreesh A Khadilkar outlines that by integrating controlled specialty additives at the manufacturing stage, cement plants can deliver consistent, high-performance concretes tailored to specific environmental and structural challenges.

The water repellent cement (PPC based) was first launched in the Indian market in 2013, The cement was developed by the ACC R&D team, the specialty of the cement was that during hydration the cement sand mortar / concrete the cement particles reacts with water and also repel the permeation of water even at early ages. The cement was developed using alkoxy /alkyl silanol based emulsions with an aqueous / oil based property. Subsequently from 2017/18 many different brands of such cements became available in the different markets of the country. These cements which possess the water repellent properties alike hydrophobic cements but these cements are not actually hydrophobic and do not float on the water. These cements react with the water to fill the pores and capillaries of the cement and reacts with the calcium hydroxide of cement to form a hydrophobic resin within the capillary pores of the concrete, significantly reducing water absorption and permeability.
These studies carried out to explore the potential benefits of the water repellent cement on the mortar and concrete properties by assessing the Water Permeability Tests, which affects the overall durability of concrete. The results demonstrated that the water repellent PPC cement (flyash based) substantially reduced water permeability by up to 70 per cent, compared to normal PPC and water sorptivity by up to 50 per cent in both mortar and concrete cubes due to improved impermeability of the concrete made with water repellent cement and its effect on the hydration mechanism. This water repellence effect achieved without compromising the properties of the cement like compressive strength, setting time, expansion etc. of the mortar and concrete, which remained similar to the normal PPC cement.
Through the use of similar special cement additions (with small tweaking of the additives) we could have a water repellent / permeability resistant PSC (Portland Slag Cement) and PCC (Portland flyash slag composite cements. Thus, this niche property of water repellence makes the resultant concretes more durable.

Biocidal cement
Biocidal cements prevent mold, bacteria, algae, and fungi from growing on or inside the concrete. Types of Biocidal Additives for Cement:

Silver-based biocides – Silver ions disrupt microbial cell membranes, kills bacteria/fungi. Best for: Hospitals, water tanks, sewage systems. Dosage: 0.1 per cent to 0.5 per cent by weight of cement (often pre-dispersed in powder or liquid).
Pro: Long-lasting, broad-spectrum, non-toxic to humans at low doses. But Expensive, may stain concrete slightly.
Copper-based biocides – Copper ions inhibit enzyme activity in microbes. Best for: Marine structures, cooling towers, wastewater plants – Dosage: 0.2 per cent to 1.0 per cent (depends on environment). Very effective against algae and fungi, durable in wet conditions. However, it can accelerate corrosion of steel reinforcement need to e used with caution.
Zinc-based biocides – Interferes with microbial metabolism. Best for: Interior walls, plaster, stucco – Dosage: 0.5 per cent to 2.0 per cent it is odorless, non-staining, less effective in alkaline environments (cement is highly alkaline pH).
Quaternary ammonium compounds (Quats) – Disrupts cell membranes. Best for: Indoor concrete, flooring, sanitary areas – Dosage: 0.2 per cent to 0.8 per cent, Odorless, colorless, compatible with most admixtures, its use can reduce early strength if overdosed.
Titanium dioxide (TiO2) – Photocatalysts UV light activates TiO2 ? generates reactive oxygen species ? kills microbes + breaks down organic stains., – Best for: Exterior facades, pavements, self-cleaning concrete – Dosage: 1 per cent to –5 per cent (often nano-sized for better dispersion), self-cleaning, eco-friendly, long-term durability, needs UV light to work, less effective indoors.

Photocatalytic cement
Types of photocatalysts used:

Titanium dioxide (TiO2) – Most Common Form: Anatase (best photocatalytic activity), sometimes mixed with rutile for stability, Dosage: 2 per cent to 10 per cent by weight of cement (often 3 per cent to 5 per cent). Highly effective, non-toxic, stable, FDA-approved for food contact. The cement needs UV light (but newer versions work under visible light).
Zinc oxide (ZnO) – Pros: Works under visible light, antibacterial, UV- blocking, Cons: Less stable in high pH (cement is alkaline), can
leach zinc.
Modified TiO2 (visible-light active) – Doped with metals (Ag, Cu, Fe), works under indoor/ambient light. Great for indoor applications (hospitals, offices).
The Photocatalytic Cement react in presence of sunlight (UV or visible light) to break down organic and inorganic pollutants in the air and on the surface of cement, thus it results in self-cleaning walls, smog-eating streets, stain-resistant pavements.
The mechanism of action is as follows:
Sunlight hits TiO2 excites electrons, creates electron-hole pairs.
Holes react with water, produce hydroxyl radicals (OH), super strong oxidisers.
Radicals attack organic dirt, bacteria, NOx, VOCs, soot breaks them down into harmless stuff like CO2, H2O, nitrates
Rain washes away residue ? surface stays clean!
Where it can be used:
Applications Benefits
Façade Panels Self-cleaning, anti-algal and anti-fungal
Roads and Side walks Reduces NOx pollution, stays white longer
Tunnels and Bridges Cuts maintenance, improves visibility
Parking Garages Less cleaning cost, healthier air
Hospitals and Schools Reduces microbial load, improves IAQ

In a similar manner as above, we could have Cements with niche properties tailored to achieve specific performance in concretes.

Corrosion inhibiting cements
Types of corrosion inhibitors, which could be a part of the cements are:

Calcium nitrite based inhibitors – Dosage: 2 per cent to 4 per cent by weight of cement (often 10–30 L/m3), anodic inhibitor forms a protective oxide film on steel surface, blocks chloride ion attack. Works even in cracked concrete.
Organic compounds like amino alcohol based (e.g., triethanolamine, amino carboxylate) ? Phosphate-based ? Carboxylate based , less toxic than nitrites (some are non-hazardous) can be used in potable water structures for existing structures or low cover the cements would be applied as surface treatment or added to repair mortars the inhibitor component, migrates to steel, forms protective layer. The cements could have multifunctional combo additive, these additives also enhance the concrete performance besides the inhibition effect

ASR resistant cements
In certain regions of the country the aggregates available locally are reactive aggregates. For use of such aggregates, in say concrete road and other infra structural concretes the cements can be used, which would resist ASR reactions in resultant concrete, such cements could be either

Low alkali cement
PPC with class F flyash — 20 per cent to 30 per cent replacement or with ground granulated blast furnace slag (GGBS) — 40 per cent to
60 per cent replacement , or use of 5 per cent silica fume or 10 per cent to 15 per cent Metakaolin (The SCMs bind the alkalis ad prevent
ASR reaction)
Cements with lithium nitrate (LiNO3) — 0.5 per cent to 1.5 per cent by weight of cement Lithium ions compete with sodium/potassium ? suppresses formation of expansive gel, proven to stop ASR even in highly reactive system. Doesn’t affect strength or setting time significantly.
Thus, depending on the additive used we could have shrinkage compensating cements, fragrant cements (cements with fragrance) etc.
Lastly it could be stated here that having such cements with niche properties would have a consistent performance in concrete as these cements would be manufactured in plants, the active compound would be monitored and controlled effectively thus, the performance concrete would be ensured.

This is concluding part of the series.

About the author:
Shreesh Khadilkar, Consultant & Advisor, Former Director Quality & Product Development, ACC, a seasoned consultant and advisor, brings over
37 years of experience in cement manufacturing, having held leadership roles in R&D and product development at ACC Ltd. With deep expertise in innovative cement concepts, he is dedicated to sharing his knowledge and improving the performance of cement plants globally.

Up Next

Powering Cement’s 700 MTPA Vision

Don't Miss

The Critical Role of Homopolymer Acrylic in High-Performance Filtration

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

Published

2 days ago

June 5, 2026

admin

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.

Concrete

Building a Greener Future Together

Published

3 days ago

June 4, 2026

admin

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.

Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

Published

6 days ago

June 1, 2026

admin

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.