Economy & Market

Boosting Concrete Workability with Grinding Aids

Published

1 year ago

June 16, 2025

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Dr SB Hegde highlights how AdoCem® WE++ grinding aid improves cement fineness and reduces water demand, effectively minimising slump loss and enhancing concrete workability retention. The study confirms its role in improving both slump retention and compressive strength over time.

In the production of concrete, maintaining consistent workability is crucial for efficient mixing, transporting, and placing of the material. However, concrete slump loss, or the reduction in workability over time, is a common challenge, particularly in large-scale projects where the concrete mix needs to remain workable for extended periods, such as during long-distance transportation or complex placements. Slump loss greater than 150 mm within 3 hours can lead to difficulties in handling and finishing, impacting both the quality and the efficiency of construction.
One effective solution to control slump loss is the use of grinding aids during the cement production process. This technical note focuses on the application of AdoCem® WE++ grinding aid during the cement grinding of Ordinary Portland Cement (OPC) to resolve slump loss issues and improve concrete workability retention.

The role of AdoCem® WE++ grinding aid
AdoCem® WE++ is a high-performance grinding aid designed to improve the efficiency of cement grinding by reducing the energy required to achieve a desired fineness. It works by modifying the surface properties of cement particles, reducing agglomeration, and improving the flowability of the material. As a result, it enhances the production process, reduces specific energy consumption, and improves the overall quality of the cement.
In addition to its primary function in cement grinding, AdoCem® WE++ has been shown to have beneficial effects on the physical properties of the cement, particularly in terms of workability and water demand in concrete mixes. By optimising the cement particle size distribution, the grinding aid can reduce water requirements, resulting in better workability retention and lower slump loss over time.

Slump loss problem in concrete
Concrete slump loss is a significant issue
that affects the workability of fresh concrete. Over time, fresh concrete tends to lose its fluidity, which can lead to challenges in handling and placing the mix. The rate of slump loss is influenced by several factors, including:

Cement fineness: Finer cement particles tend to absorb more water, requiring higher water-to-cement ratios to maintain a constant slump. This leads to increased slump loss.
Cement composition: The chemical composition and particle size distribution of the cement affect hydration rates and, consequently, the workability over time.
Environmental conditions: Temperature, humidity, and mixing conditions also play a critical role in slump retention.

In this context, the introduction of AdoCem® WE++ grinding aid helps optimise cement properties, ensuring that the water demand is minimised and workability is better maintained over an extended period, thereby mitigating slump loss.

Research methodology 4.1 Materials

Cement: Ordinary Portland Cement (OPC) was used in this study.
Grinding aid: AdoCem® WE++ was used as the grinding aid, added at dosages of 0.06 per cent, 0.08 per cent, and 0.10 per cent by weight of cement.
Concrete mix: A standard concrete mix with a water-to-cement ratio of 0.50 was prepared. The target slump was 150 mm, with slump loss measurements taken at intervals up to 3 hours.

4.2 Experimental setup

Cement grinding: OPC was ground in a ball mill, with the addition of AdoCem® WE++ at the specified dosages. The energy consumption, fineness, and particle size distribution of the cement were analysed.
Concrete mix preparation: Concrete was mixed using cement treated with AdoCem® WE++ grinding aid, along with conventional mixing procedures.
Slump testing: Slump was measured using the standard slump cone test at 0, 30, 60, 90, and 180 minutes after mixing to determine the rate of slump loss.
Compressive strength: Concrete cubes (150 mm x 150 mm) were cast, cured, and tested at 7, 28, and 90 days to assess the impact of grinding aids on strength development.

Results and discussion
5.1 Cement fineness and energy consumption
The use of AdoCem® WE++ significantly improved the grinding efficiency, resulting in a more uniform particle size distribution. The cement treated with AdoCem® WE++ showed a Blaine fineness of 320 m²/kg, compared to 300 m²/kg for the control cement, indicating that the grinding aid allowed for finer grinding without increasing energy consumption. This reduced the production costs while improving cement quality.

5.2 Slump retention
The main focus of this study was to evaluate the effect of AdoCem® WE++ on slump retention. Concrete mixes with grinding aid-treated cement showed a notable improvement in slump retention over time compared to the control mix.

Control cement (no grinding aid): The control mix experienced a slump loss of 80 mm after
2 hours.
AdoCem® WE++ at 0.06 per cent dosage: Concrete with cement treated with 0.06 per cent AdoCem® WE++ showed a slump loss of 100 mm after 3 hours, a significant improvement over the control mix.
AdoCem® WE++ at 0.08 per cent dosage: At a dosage of 0.08 per cent, the slump loss was reduced to 120 mm after 3 hours, demonstrating further improvement.
AdoCem® WE++ at 0.10 per cent dosage: The highest dosage of AdoCem® WE++ resulted in the best performance, with only a 150 mm slump loss after 3 hours, which meets the target of maintaining workability over extended periods.

5.3 Hydration behaviour and setting time
The addition of AdoCem® WE++ appeared to slightly delay the initial setting time compared to the control mix. This delay in setting time helps to extend the period during which the concrete remains workable, thereby reducing the risk of excessive slump loss. The improved hydration behaviour
also contributed to better overall consistency in the concrete mix.

5.4 Compressive strength
Concrete cubes made with cement treated by AdoCem® WE++ exhibited slightly higher compressive strength compared to the control mix. At 28 days, the compressive strength of the AdoCem® WE++ mixes were 5 per cent to 8 per cent higher, indicating that the grinding aid not only improved workability but also contributed to more efficient cement hydration and stronger concrete.

Conclusion
The addition of AdoCem® WE++ grinding aid during the cement grinding process significantly improves the workability retention of concrete, effectively maintaining slump loss over a 3-hour period. By optimising the particle size distribution of cement, AdoCem® WE++ reduces water demand and enhances the stability of the concrete mix, thereby ensuring that the slump remains within the desired range (150 mm) for an extended period. Furthermore, the grinding aid improves cement efficiency, reduces energy consumption during grinding, and enhances the strength development of concrete.
This study demonstrates that AdoCem® WE++ is an effective solution for mitigating concrete slump loss, making it a valuable tool for construction projects where concrete workability must be maintained over longer periods. The optimal dosage of AdoCem® WE++ for achieving the best performance in terms of slump retention and strength is around 0.1 per cent by weight of cement.

About the author:
Dr SB Hegde, a global cement industry leader with over 30 years of experience, is a Professor at Jain College of Engineering, India, and a Visiting Professor at Pennsylvania State University, USA.

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Leonard Unveils Dual-Head Robotic Arm for Hazardous Industrial Demolition

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2 days ago

October 30, 2026

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Leonard unveils Descender Duo, a dual-head robotic demolition arm designed to improve industrial safety and reduce shutdown time by up to 50 per cent.

Industrial robotics and refractory services specialist Leonard has launched Descender Duo, a dual-head robotic demolition arm designed to improve safety, accelerate maintenance and reduce shutdown times in hazardous industrial environments. The system made its debut at Lisahally Power Station in Northern Ireland, removing 25 tonnes of slag material within hours.

Developed for the cement, metals, waste-to-energy and petrochemical industries, Descender Duo enables remote-controlled refractory demolition, anchor cutting and welding, and refractory spraying inside boilers, calciners and silos. Its vertical-access design eliminates the need for personnel to enter confined, high-risk spaces during these operations.

Weighing less than two tonnes, the pre-assembled system requires an access opening of just 1.2 m². Supported by an external overhead hoist, it uses electrically operated hydraulic stabilising legs to secure itself inside vessels. The robotic arm offers 360-degree rotation and is suited to vessels approximately 9 m in diameter, with its operating reach extendable through strategically positioned access points.

Equipped with two independently controlled robotic heads, Descender Duo can perform identical or different tasks simultaneously, including refractory demolition, anchor cutting and spraying. Its remote-control system incorporates live camera feeds, allowing operators to monitor operations without entering hazardous environments.

According to Leonard, the technology can deliver time savings of up to 50 per cent compared with manual methods. Its ability to operate at temperatures exceeding 100°C allows maintenance to begin as early as 24 hours after burner shutdown. An all-electric power supply further supports cleaner and more cost-efficient operations.

First Deployment Demonstrates Shutdown Efficiency

The system was first deployed at Burmeister & Wain Scandinavian Contractor’s (BWSC) Lisahally Power Station in Londonderry, Northern Ireland. The facility generates electricity from grade C waste wood, supplying approximately 40,000 homes and businesses.

Leonard and BWSC collaborated to develop a customised solution for the plant’s 26-metre furnace, where extensive external pipework created significant access challenges.

Mark Leonard, Managing Director, Leonard, said, “It required new thinking and rather than step away from the problem we were committed to solving it for the customer, with the customer. We’re relentless in our approach to tackling complex challenges, head-on. We took our years of cement plant experience, coupled with our working knowledge of the BWSC plant, and designed, engineered and tested a completely new vertical solution within just seven weeks from that initial conversation with the customer. That solution was the Descender Duo as we know it today.”

Traditionally, the furnace required a cooling period of up to 36 hours before preparatory work could begin, followed by manual slag removal using rope-access personnel. With Descender Duo, work commenced just 24 hours after shutdown, reducing downtime by up to one day.

The deployment removed 25 tonnes of slag within hours, eliminated the need for at least six workers to enter the hazardous furnace interior and saved 26 hours in the shutdown programme.

“The effectiveness exceeded expectation,” said Martin Doran, Plant Manager at Lisahally Power Station.

“When the Descender Duo concept was first discussed, we had to spend some time with the team from Leonard looking at how it was going to be moved into the furnace. Every site is different and that presented its own challenges, but nothing that the team couldn’t overcome. Once it was installed we were hugely impressed by its efficiency.”

Expanding Industrial Robotics Applications

Descender Duo joins Leonard’s existing portfolio of robotic maintenance solutions, including the Axis horizontal-access arm, Nano confined-space access arm, Charger cement mill media recharging system and Calibre cement mill media grading system.

Headquartered in Northern Ireland, Leonard provides robotic refractory demolition, installation, inspection and industrial maintenance services across the cement, metals, energy, biomass, glass and civil engineering sectors.

Formerly known as G Leonard, the company has more than 35 years of industry experience and operates across Europe, North America, the Middle East, Africa and Asia-Pacific.

The latest innovation reinforces Leonard’s focus on replacing hazardous manual processes with robotic systems that improve workforce safety, enhance operational efficiency and minimise industrial downtime.

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Martin Engineering Appoints Ashwini Khunte as India General Manager

Published

2 days ago

October 30, 2026

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Martin Engineering names Ashwini Khunte India General Manager to strengthen operations and drive growth across key bulk material handling sectors.

Pune

Martin Engineering, a global provider of bulk material handling solutions, has appointed Ashwini Khunte as General Manager of its India business, strengthening its leadership as the company expands its presence across the country’s cement, mining, steel, power and infrastructure sectors.

Khunte brings more than a decade of experience with Martin Engineering, having joined its Indian operations in 2013 as a Design Engineer, shortly after the company established its presence in the country in 2012.

A mechanical engineer by qualification, she spent her initial five years developing bulk material handling solutions in collaboration with the company’s operations team. During this period, she gained extensive experience addressing operational challenges in the steel, cement and coal industries. She subsequently moved into project engineering, managing major engineering, procurement and construction (EPC) and original equipment manufacturer (OEM) projects from initial enquiry to commissioning. Her responsibilities later expanded to overseeing Martin Engineering’s conveyor product portfolio in India, involving customer engagement, technical presentations and site visits across heavy industries.

In 2024, Khunte was promoted to Head of Sales & Marketing for the company’s Europe, Middle East, Africa and India (EMEAI) region. The position broadened her international market exposure and strengthened her strategic and commercial leadership capabilities.

Commenting on her appointment, Ashwini Khunte, General Manager, Martin Engineering India, said: “India represents a tremendous opportunity for Martin Engineering. The country’s continued investment in cement, mining, steel, power and infrastructure is creating increasing demand for safer, cleaner and more productive bulk material handling, and that’s exactly what we do. My priority will be to build on the strong foundations already established in India, while continuing to develop our people, strengthen customer relationships and bring practical solutions to the challenges faced by our industry.”

Robert Whetstone, Area Vice President – EMEAI, Martin Engineering, highlighted Khunte’s technical expertise, market understanding and leadership experience.

“Ashwini brings an exceptional combination of technical understanding, customer knowledge and commercial leadership. She has grown as Martin Engineering has grown, and has consistently demonstrated outstanding capability to transform her expertise into practical solutions. Her knowledge of the Indian market, together with her international experience, makes her ideally suited to lead our India business through its next stage of growth for years to come.”

Since establishing its Indian business in 2012, Martin Engineering has expanded its local workforce, manufacturing capabilities and dealership network. The company supplies conveyor products, transfer point solutions, material flow aids, training and technical support to bulk material handling industries. Khunte’s appointment positions the company to further strengthen customer relationships and expand its solutions portfolio in India’s growing industrial and infrastructure markets.

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Fornnax Wins AIRIA’s Special Export Award for Rubber Machinery in 2025-26

Published

2 weeks ago

October 19, 2026

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Fornnax Technology Pvt. Ltd. has been honoured with the Special Export Award – Rubber Machinery for 2025–26 by the All-India Rubber Industries Association (AIRIA), in recognition of its highest exports of tyre recycling plants to the European region.

With more than a decade of experience in India’s tyre recycling industry, Fornnax has contributed to the development of advanced recycling technologies and infrastructure. The company currently holds a 90% market share in India’s domestic tyre recycling sector, while exports account for 30% of its business, spanning markets such as Europe, Australia and the GCC.

The award marks another milestone for Fornnax, whose tyre recycling lines and advanced shredding technologies are supporting the growth of the circular economy in India and international markets.

Commenting on the recognition, Mr. Jignesh Kundaria, Founder and Director of Fornnax, said:

“This honour from AIRIA is a reflection of an incredible journey we have undertaken over the years. When we started Fornnax, there was no established recycling industry in India to follow. We chose to build for the future instead. Today, when you see India’s tyre recycling sector, it has already transformed into a dynamic, high-growth industry and we are extremely proud to have played our part in building it.”

Unlike standalone equipment suppliers, Fornnax focuses on developing complete, high-capacity recycling infrastructure. Its integrated systems combine multiple stages of shredding and size reduction to enable efficient, continuous operations. This system-level engineering approach helps recycling operators improve throughput, equipment reliability and operational consistency.

The recognition reinforces Fornnax’s commitment to developing engineering technologies that contribute to a more efficient and circular recycling ecosystem.

Looking ahead, the company aims to expand its international presence while continuing to develop advanced shredding and recycling solutions to address the growing volumes and evolving requirements of the global recycling industry.

For more information, visit: www.fornnax.com