Concrete
Ready Mix Concrete: A Better Choice
Published
4 years agoon
By
admin
Its multiple benefits and cost effectiveness has given Ready Mix Concrete a preferred choice status in the construction industry. ICR attempts to understand its manufacturing processes and distinct features to evaluate its long-lasting impact on the industry.
The construction industry uses two main types of concrete – the ready mix concrete and site mixed concrete. They both have specific applications, functions, advantages and is advantages.
The ready mix concrete (RMC) is usually made in a factory or a batching plant and is delivered in an unhardened and plastic state, ready to use, to the construction site. It is the most preferred mix of concrete for large projects that require a high volume or when less space is available for storing and mixing the construction materials. It is also often preferred over on-site concrete mixes because the ready mix variety can be mixed using specialised equipment to get just the right mixture. It is like using a set recipe and delivering it to the site by trucks with in-transit mixers.
The story of the genesis of ready mix concrete – when it was first delivered or first made – is disputed. Some sources say that concrete was delivered by a horse-drawn mixer that used paddles turned by the cart›s wheels to mix concrete en route to the jobsite in 1909, while others suggest it was first made in 1913 in Baltimore and by 1929 there were over 100 plants operating in the United States. In 1916, Stephen Stepanian of Columbus, Ohio, developed a self-discharging motorised transit mixer that was the predecessor of the modern ready-mixed concrete truck. Development of improved ready-mixed trucks was hindered by the poor quality of motor trucks in the 1920s. During the 1940s, the availability of heavier trucks and better engines allowed mixing drum capacities to increase, which in turn allowed ready-mixed concrete producers to meet the high demand for concrete caused by World War II.
The Chemical Makeup
Cement is the core component of any ready mix concrete. It is then combined with water and other aggregates to make a ready to use mixture at construction sites. Water sets off a chemical reaction when it comes in contact with the cement. Aggregates, such as sand, gravel and crushed stones that are obtained from quarries or other sources, add 60 to 70 per cent volume to this mixture. Some solid or liquid additives, like retarders, are also introduced to ready mix concrete before or during preparation to increase its durability and shorten its setting time, giving allowance to the transportation and placing the time of the concrete.
Each component of the ready mix concrete is manufactured separately. The proportions in which it is mixed are dictated by the requirement of its properties or the job that it is going to be used at. These components of the RMC are brought together in a rotating container, also known as the cement mixer and water is added to it. The proportions and measurements are carefully considered along with the time it will take to mix and travel to its destination. Once water hits the mixture, the cement mixer doesn’t stop rotating, even during the travel and rotates at approximately the speed of two to six rotations per minute.

Variety and Uses
There are mainly three types of ready mix concrete that are developed: Transit Mixed Concrete, Shrink Mixed Concrete and Central Mixed Concrete.
The Transit Mixed Concrete, also known as truck mixed concrete, has its materials batched at a central plant and are completely mixed in the truck in transit. Frequently, the concrete is partially mixed in transit and mixing is completed at the jobsite. Transit-mixing keeps the water separate from the cement and aggregates and allows the concrete to be mixed immediately before placement at the construction site. It is the most common type of ready-mix concrete used by building construction providers.
In Shrink Mixed Concrete, concrete is partially mixed at the plant to reduce or shrink the volume of the mixture and mixing is completed in transit or at the jobsite. The ingredients are added to the batching plants, and the required adjustments are made according to the strength requirements of the concrete. The ready-made concrete is then shifted through concrete pumps for transportation. The main purpose of this concrete is to increase the load capacity of the transporting vehicle. The balance mixing of the concrete is done during the transit time.
In this technique of the central mixed concrete, a stationary mixing unit is set and the concrete is mixed. It is followed by quality tests and is allowed to transport only after the tests are done and quality standards are met. It is also known as wet batch plants. However, the process is time-consuming and not always recommended.
RMC – Getting an Upper Hand
There are multiple advantages and disadvantages associated with the use of ready mix concrete.
The biggest advantage of using the same is the control on quality and ease of operations. RMC is mixed under quality controlled batch units, thus, the result and strength is assured and as per requirement. Another advantage is that it comes in a mobile mixture, so there is no need to store it at the construction site, thus reducing the handling and storing cost of the same. As the name suggests, ready mix concrete is a ready material to be used at construction sites and therefore, it accounts for reduced time of construction and accounts for no delays in completion of projects.
The quantities in ready mix concrete can be controlled and only that much can be ordered as much is required, which leads to reduced or no wastage. This is economically beneficial to the constructor as well as makes the same an environmentally friendly option.
Anil Bacchore, Managing Director, RDC, says, “Use of ready mix concrete at a construction site is cost efficient and has several advantages, making it a more viable and efficient alternative to site-mix concrete. It circumvents the messy and long-drawn task of producing the concrete on site. The consumption of required materials for making the concrete reduces by nearly 10 per cent to 12 per cent with better handling practices and proper mixing. RMC helps save on capital investments by not having to invest in plants and machinery for cement. The need to create storage facilities at the site of construction also reduces with ready mix concrete.”
“Faster pouring of concrete leads to less requirement of construction labours and makes the construction activity faster. Thus, RMC provides an alternative that reduces wastage of resources during the construction process. Furthermore, the responsibility of producing fresh concrete, its transportation, pumping and laying of concrete on the site lies with the RMC Players and their goal is to provide materials of the best quality with timely delivery, regardless of the size of the order,” he adds.
Precautionary measures
Some of the notable disadvantages of using ready mix concrete is that it requires an initial investment by the constructing party to order the required quantity of mix. Since the material is time sensitive, the readiness of the workforce becomes very important and labour at site must be ready to bring the material to use within its setting time.
The transport requirement of the same is also very specific. Special transport vehicles are required to bring ready mix concrete from batching plants to the site, which is again a monetary investment, and since the concrete is made ready to use at the plant, it becomes time sensitive to reach the site. Ready mix concrete must reach the site within 210 minutes from the batching plant. Any unforeseen delays or vehicle breakdowns can result in the onset of its setting and thus, resulting in wasted material and resources.

Fresh concrete has many applications and can be cast into circles, rectangles, squares and more. It can also be used for staircases, columns, doors, beams, lentils and other familiar structures. Concrete is made in different grades, including normal, standard and high-strength grades. These grades indicate how strong the concrete is and how it will be used in construction.
Raj Kamal Yadav, General Manager – Operations Strategy, Lodha Group, says, “The most widely used ready mix concrete in the industry is M30 and many of the experts shall agree to the same. M30 has proven to be a good design mix for low rise residential buildings and structures where the beams are of shorter span. M30 has also a wider usage in vertical members of a RCC structure. The choice of mix, however, changes depending upon the load on buildings. When we look at high-rise buildings, ready mix concrete grades like M40 and M50 are used in vertical and in many cases horizontal members as well. However, M30 becomes an obvious choice for structural members especially horizontal ones at higher levels of the building as loads on structure come down”.
“The choice of mix highly depends on the load (dead load or live load or wind load or earthquake), where the mix being used (foundation or columns or beams or slabs), methodology of construction and type of structure (framed or modular or precast or prestressed), other category of structure (bridge, dam, residential building, road, rail etc.) exposure of structure (windy, high moisture, marine), type of reinforcement and various other conditions. Having said that, M30 has a wide usage” he adds.
Manufactured Sand (M Sand)
Concrete is made with cement, water and aggregates. One of the most important aggregates is sand. However, owing to the shortage of naturally available sand, manufactured sand or M Sand is becoming a sustainable alternative for construction purposes as an aggregate for concrete.
Manufactured sand (M Sand) is artificial sand produced from crushing hard stones into small sand-sized angular shaped particles, washed and finely graded to be used as construction aggregate. An alternative to the naturally occurring river sand that is used in construction, manufactured sand is produced from crushing rocks, quarry stones, hard granite or larger aggregated pieces into sand-sized particles.
Sand is the world’s second most consumed natural resource after water. As urbanisation and infrastructure is rapidly growing, the demand for sand is also growing. This increasing need for sand as an aggregate for construction material is leading to an eventual exhaustion of natural sand resources. This also raises environmental concerns and thus, manufactured sand has emerged as a suitable and sustainable alternative to fine aggregate for the concrete mix.
The manufacturing process of M Sand involves crushing of stones or rocks of various sizes into aggregates using vertical shaft impact (VSI) crushers. This material is then fed into a Rotopactor for crushing the aggregates into sand to the desired grain size. This sand is then screened and further refined by removing fine particles and impurities through sieving
and washing.
Manufacturing Process
The production of manufactured sand is driven by the following factors advantages:
- Scarcity of natural sand is one of the key driving factors of manufactured sand production. Continuous mining of sand from river beds has led to its depletion and the need to have an alternative resource has become prominent.
- The aggregate particle size can be determined when the sand is artificially manufactured. Concrete creates its bulk with sand and other aggregates. They also determine certain properties which can be managed with manufactured sand.
- Natural sand pits that are licensed with the desired quality of sand may be located away from the site, which implies the cost of transport, various permissions and taxes. While manufactured sand solves this problem and becomes a cost effective solution, thus, the demand.
- Manufactured sand is a man-made aggregate that can be ordered as per required quantity. It is a processed material, free of impurities that allows concrete makers to reduce wastage as compared to that of natural sand.
- The use of manufactured sand in concrete making makes the batching process more efficient and productive as it is a quality controlled material, free of impurities.
While there are many advantages and drivers of manufactured sand, there are some disadvantages, too:
- M Sand is a coarser material and more angular than natural sand. Grains of natural sand are fine, almost spherical, that make it smooth due to natural gradation. The angular particles of M sand may lead to a higher water requirement to achieve its workability, which may add to some costs.
- At times, M Sand can contain larger amounts of micro fine particles as compared to that of natural sand. This also impacts the workability and strength of concrete.
- Manufactured sand is used for concreting,
- plastering and for brick or blockwork. It comes with its advantages and disadvantages but it has been proved to have economical and eco-friendly benefits for the concrete makers and construction activities. Ready mix concrete is a vital material in construction activities and is the preferred choice in the industry for multiple benefits and cost effectiveness it offers.
–Kanika Mathur
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Filtration Technology is Critical for Efficient Logistics
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Niranjan Kirloskar, MD, Fleetguard Filters, makes the case that filtration technology, which has been long treated as a routine consumable, is in fact a strategic performance enabler across every stage of cement production and logistics.
India’s cement industry forms the core for infrastructure growth of the country. With an expected compound annual growth rate of six to eight per cent, India has secured its position as the second-largest cement producer globally. This growth is a result of the increasing demand across, resulting in capacity expansion. Consequently, cement manufacturers are now also focusing on running the factories as efficiently as possible to stay competitive and profitable.
While a large portion of focus still remains on production technologies and capacity utilisation, the hidden factor in profitability is the efficiency of cement logistics. The logistics alone account for nearly 30 per cent to 40 per cent of the total cost of cement, making efficiency in this segment a key lever for profitability and reliability.
In the midst of this complex and high-intensity ecosystem, filtration often remains one of the most underappreciated yet essential enablers of performance.
A demanding operational landscape
Cement production and logistics inherently operate in some of the harshest industrial environments. With processes such as quarrying, crushing, grinding, clinker production, and bulk material handling expose the machinery to constant high temperatures, heavy loads, and dust, often the silent destructive force for engines.
The ecosystem is abrasive, and often one with a high contamination index. These challenging conditions demand equipment such as the excavators, crushers, compressors, and transport vehicles to perform and perform efficiently. The continuous exposure to contamination across every aspect like air, fuel, lubrication, and even hydraulic systems causes long-term damage. Studies have also shown that 70 to 80 per cent of hydraulic system failures are directly linked to contamination, while primary cause of engine wear is inadequate air filtration.
For engines as heavy as these, even a minor contaminant has a cascading effect; reducing efficiency, performance and culminating to unplanned downtime. Particles as small as 5 to 10 microns, far smaller than a human hair (~70 microns), can cause significant damage to critical engine components. In an industry where margins are closely linked to operational efficiency, such disruptions can significantly affect both cost structures and delivery timelines.
Dust management: A persistent challenge
Dust is a natural by-product in cement operations. From drilling and blasting in the quarries to packing in plants, this fine particulate matter does occupy a large space in operations. Dust concentration levels in quarry and crushing zones often create extremely high particulate exposure for equipment. These fine particles, when enter the engines and critical systems, accelerates the wear and tear of the component, affecting directly the operational efficiency. Over time every block fall; engine performance declines, fuel consumption rises, and maintenance cycles shorten. In this case, effective air filtration is the natural first line of defence. Advanced filtration systems are designed to capture high volumes of particulate matter while maintaining consistent airflow, ensuring that engines and equipment operate under optimal conditions.
In high-dust applications, as in cement production, even the filtration systems are expected to sustain performance over extended periods without the need of frequent replacement. This becomes crucial in remote quarry locations where access to frequent maintenance may be limited.
Fluid cleanliness and system integrity
Beyond air filtration, fluid systems also play a crucial role for equipment reliability in cement operations. Fuel systems are required to remain free from contaminants for efficient working of combustion and injection protection. Additionally, lubrication systems also need to maintain the oil purity to reduce friction and prevent any premature wear of moving parts. The hydraulic systems, which are key to several heavy equipment operations, are especially sensitive to contamination.
If fine particles or water enters these systems, it can lead to reduced efficiency, erratic performance, and eventual failure of the system. Modern filtration systems are designed with high-efficiency media capable of removing extremely fine contaminants, with advanced fuel and oil filtration solutions filtering particles as small as two to five microns. Multi-stage filtration systems further ensure that fluid performance is maintained even under challenging operating conditions.
Another critical aspect of fuel systems is water separation. Removing moisture helps prevent corrosion, improves combustion efficiency and enhances overall engine reliability. Modern water separation technologies can achieve over 95 per cent efficiency in removing water from fuel systems.
Ensuring reliability across the value chain
Filtration plays a critical role across every stage of cement logistics:
• Quarry operations: Equipment operates in highly abrasive environments, requiring strong protection against dust ingress and hydraulic contamination.
• Processing units: Crushers, kilns, and grinding mills depend on clean lubrication and cooling systems to sustain continuous operations.
• Material handling systems: Pneumatic and mechanical systems rely on clean air and fluid systems for efficiency and reliability.
• Transportation networks: Bulk carriers and trucks must maintain engine health and fuel efficiency to ensure timely deliveries.
Across these operations, filtration plays a vital role; as it supports consistent equipment performance while reducing the risk of unexpected failures.
Effective filtration solutions can reduce unscheduled equipment failures by 30 to 50 per cent across heavy-duty operations.
Uptime as a strategic imperative
In cement manufacturing, uptime is currency. Downtime not only delays the production, but it also greatly impacts the supply commitments and logistics planning. With the right filtration systems, contaminants are kept at bay from entering the
critical systems, and they also significantly extend the service intervals.
Optimised filtration can extend service intervals by 20 to 40 per cent, reducing maintenance frequency while maintaining consistent performance across demanding operating conditions. Filtration systems designed for heavy-duty applications sustain efficiency throughout their lifecycle, ensuring reliable protection with minimal interruptions. This leads to improved equipment availability, lower maintenance costs, and more predictable operations, with well-maintained systems capable of achieving uptime levels of over 90 to 95 per cent in challenging cement environments.
Supporting emission and sustainability goals
With the rising environmental awareness, the cement industry too is aligning with the stricter norms and sustainability targets. In this scenario, the operational efficiency is directly linked to emission control.
Air and fuel systems that are clean enable
much more efficient combustion. They also reduce emissions from both the stationary equipment and transport fleets. Similarly, with a well-maintained fluid cleanliness, emission systems function better. Poor combustion due to contamination can increase emissions by 5 to 10 per cent, making clean systems critical for compliance.
Additionally, efficient and longer lasting filtration systems significantly reduce any waste generation and contribute to increased sustainable maintenance practices. Extended-life filtration solutions can reduce filter disposal and maintenance waste by 15 to 20 per cent. Smart and efficient filtration in this case plays an important role in meeting the both regulatory and environmental objectives within the industry.
Advancements in filtration technology
Over the years, there has been a significant evolution in the filtration technology to meet the modern industrial applications.
Key developments include:
• High-efficiency filtration media capable of capturing very fine particles without restricting flow
• Compact and integrated designs that combine multiple filtration functions
• Extended service life solutions that reduce replacement frequency and maintenance downtime
• Application-specific engineering tailored to different stages of cement operations
Modern multi-layer filtration media can improve dust-holding capacity by up to two to three times compared to conventional systems, while maintaining consistent performance. These advancements have transformed filtration from a basic maintenance component into a critical performance system.
Adapting to diverse operating conditions
The cement industry of India operates across diverse geographies. Spanning across regions with arid regions with higher dust levels, to the coastal areas with higher humidity, challenges of each region pose different threats to the engines. Modern filtration systems are thus tailored to address these unique challenges of each region.
Indian operating environments often range from 0°C to over 50°C, with some of the highest dust loads globally in mining zones.
Additionally, filtration technology can also be customised to variations which then align the system design with factors like dust load, temperature, and equipment usage patterns. Equipment utilisation levels in India are typically higher than global averages, making robust filtration even more critical. This approach ensures optimal performance and durability across different operational contexts.
Impact on total cost of ownership
Filtration has a direct and measurable impact on the total cost of ownership of equipment.
Effective filtration leads to:
• Lower wear and tear on critical components
• Reduced maintenance and repair costs
• Improved fuel efficiency
• Extended equipment life
• Higher operational uptime
Effective filtration can extend engine life by 20 to 30 per cent and reduce overall maintenance costs by 15 to 25 per cent over the equipment lifecycle. These benefits collectively enhance productivity and reduce lifecycle costs. Conversely, inadequate filtration can result in frequent breakdowns, increased maintenance expenditure, and reduced asset utilisation.
Building a more efficient cement ecosystem
With the rising demand across various sectors, the cement industry is expected to expand at an unprecedented rate. This growth is forcing the production to move towards a more efficient and resilient system of operations. This requires attention not only to production technologies but also to the supporting systems that enable consistent performance. Filtration must be viewed as a strategic investment rather than a routine consumable. By ensuring the cleanliness of air and fluids across systems, it supports reliability, efficiency, and sustainability.
The road ahead
The future of cement logistics will be shaped by increasing mechanisation, digital monitoring, and stricter environmental standards. The industry is also witnessing a shift towards predictive maintenance and condition monitoring, where filtration performance is increasingly integrated with real-time equipment diagnostics.
In this evolving landscape, the role of filtration will become even more critical. As equipment becomes more advanced and operating conditions more demanding, the need for precise contamination control will continue to grow. From quarry to construction site, filtration technology underpins the performance of every critical system. It enables equipment to operate efficiently, reduces operational risks, and supports the industry’s broader goals of growth and sustainability. In many ways, it is the unseen force that keeps the cement ecosystem moving, quietly ensuring that every link in the value chain performs as expected.
About the author
Niranjan Kirloskar, Managing Director, Fleetguard Filters, is focused on driving innovation, operational excellence, and long-term business growth through strategic and people-centric leadership. With a strong foundation in ethics and forward-thinking decision-making, he champions a culture of collaboration, accountability, and technological advancement.
Jignesh Kindaria highlights how Thermal Substitution Rate (TSR) is emerging as a critical lever for cost savings, decarbonisation and competitive advantage in the cement industry.
India is simultaneously grappling with two crises: a mounting waste emergency and an urgent need to decarbonise its most carbon-intensive industries. The cement sector, the second-largest in the world and the backbone of the nation’s infrastructure ambitions, sits at the centre of both. It consumes enormous quantities of fossil fuel, and it has the technical capacity to consume something else entirely: the waste our cities cannot get rid of.
According to CPCB and NITI Aayog projections, India generates approximately 62.4 million tonnes of municipal solid waste annually, with that figure expected to reach 165 million tonnes by 2030. Much of this waste is energy-rich and non-recyclable. At the same time, cement kilns operate at material temperatures of approximately 1,450 degrees Celsius, with gas temperatures reaching 2,000 degrees. This high-temperature environment is ideal for co-processing, ensuring the complete thermal destruction of organic compounds without generating toxic residues. The physics are in our favour. The infrastructure is not.
Pre-processing is not the support act for co-processing. It is the main event. Get the particle size wrong, get the moisture wrong, get the calorific value wrong and your kiln thermal stability will suffer the consequences.
The regulatory push is real
The Solid Waste Management (SWM) Rules 2026 mandate that cement plants progressively replace solid fossil fuels with Refuse-Derived Fuel (RDF), starting at a 5 per cent baseline and scaling to 15 per cent within six years. NITI Aayog’s 2026 Roadmap for Cement Sector Decarbonisation targets 20 to 25 per cent Thermal Substitution Rate (TSR) by 2030. Beyond compliance, every tonne of coal replaced by RDF generates measurable carbon reductions which is monetisable under India’s emerging Carbon Credit Trading Scheme (CCTS). TSR is no longer a sustainability metric. It is a financial lever.
Yet our own field assessments across multiple Indian cement plants reveal a sobering reality: the primary barrier to scaling AFR adoption is not waste availability. It is the fragmented and under-engineered pre-processing ecosystem that sits between the waste and the kiln.
Why Indian waste is a different engineering problem
Indian municipal solid waste is not the material that imported shredding equipment was designed for. Our waste streams frequently exceed 40 per cent to 50 per cent moisture content, particularly during monsoon cycles, saturated with abrasive inerts including sand, glass, and stone. Plants relying on imported OEM equipment face months of downtime awaiting proprietary spare parts. Machines built for segregated, low-moisture waste fail quickly and disrupt the entire pre-processing operation in Indian conditions.
The two most common failures we observe are what I call the biting teeth problem and the chewing teeth problem. Plants relying solely on a primary shredder reduce bulk waste to large fractions, but the output remains too coarse for stable kiln combustion. Others attempt to use a secondary shredder as a standalone unit without a primary stage to pre-size the feed, leading to catastrophic mechanical failure. When both stages are present but mismatched in throughput capacity, the system becomes a bottleneck. Achieving the 40 to 70 tonnes per hour required for meaningful coal displacement demands a precisely coordinated two-stage process.
Engineering a made-in-India answer
At Fornnax, our response to these challenges is grounded in one principle: Indian waste demands Indian engineering. Our systems are built around feedstock homogeneity, the holy grail of kiln stability. Consistent particle size and predictable calorific value are the foundation of stable kiln combustion. Without them, no TSR target is achievable at scale.
Our SR-MAX2500 Dual Shaft Primary Shredder (Hydraulic Drive) processes raw, baled, or loosely mixed MSW, C&I waste, bulky waste, and plastics, reducing them to approximately 150 mm fractions at throughputs of up to 40 tonnes per hour. The R-MAX 3300 Single Shaft Secondary Shredder (Hydraulic Drive), introduced in 2025, takes that primary output and produces RDF fractions in the 30 to 80 mm range at up to 30 tonnes per hour, specifically optimised for consistent kiln feeding. We have also introduced electric drive configurations under the SR-100 HD series, with capacities between 5 and 40 tonnes per hour, already operational at a leading Indian waste-processing facility.
Looking ahead, Fornnax is expanding its portfolio with the upcoming SR-MAX3600 Hydraulic Drive primary shredder at up to 70 tonnes per hour and the R-MAX2100 Hydraulic drive secondary shredder at up to 20 tonnes per hour, designed specifically for the large-scale throughput that higher TSR ambitions require.
The investment case is now
The 2070 Net-Zero target is not a distant goal for India’s cement sector. It starts today, with decisions being made on the plant floor.
The SWM Rules 2026 are already in effect, requiring cement plants to replace coal with RDF. Carbon credit markets are opening up, and coal prices are not going to get cheaper. Every tonne of coal a cement plant replaces with waste-derived fuel saves money on one side and generates carbon credit revenue on the other. Pre-processing infrastructure is no longer just a compliance requirement. It is a business investment with a measurable return.
The good news is that nothing is missing. The technology works. The waste is available in every Indian city. The government has provided the policy direction. The only thing standing between where the industry is today and where it needs to be is the commitment to build the right infrastructure.
The cement companies that move now will not just meet the regulations. They will be ahead of every competitor that waits.
About the author
Jignesh Kundaria is the Director and CEO of Fornnax Technology. Over an experience spanning more than two decades in the recycling industry, he has established himself as one of India’s foremost voices on waste-to-fuel technology and alternative fuel infrastructure.
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