India Cement & Construction Materials (vol 1 / issue 3)

india CemWeek A CemWeek Publication

Cement VOLume 1

issue 3

november / december 2011

& construction Materials

NCB Conference

Construction Materials

event Highlights Interview with DG, Ashwani Pahuja

Prefab to beat Construction Woes Fly ash use in Indian construction

Southern Cement Market

Sparking Cement Production

Too Much Too Soon?

Benchmarking Electricity Costs Impact of Energy & Shipping News

|

Analysis

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Market Coverage

|

Interviews

|

People Moves

india CemWeek

FEATURES 4

DEPARTMENTS

CHANGING FACE OF THE SOUTHERN CEMENT MARKET A growing market or a growing concern?

6

THE SPARK OF CEMENT PRODUCTION Benchmarking the electricity costs of India’s cement companies

focus 10 12

FLY ASH OFFSETS CARBON EMISSIONS A closer look at the role of fly ash in the industry

NCB CONFERENCE RECAP

SHAPING THE INDUSTRY

16

ENERGY & TRANSPORTATION COST IMPACT ON THE CEMENT SECTOR

An interview with the Director General of NCB, Ashwani Pahuja

Rising coal and transportation prices plague the industry

22

EDITOR’S LETTER

2

NUMBERS IN BRIEF

ACC WADI EXPANSION One of the world's largest cement plants has gotten even bigger

REAL ESTATE PRICES CONTINUE UPWARD CLIMB

PREFABRICATED CEMENT A possible solution to the country’s construction woes?

construction & building materials

34

infrastructure & PROJECTS

36

EQUIPMENT UPDATES

Roadways undergo major face-lift with the assistance of foreign investors Valiant Corporation opens operations in India

Third quarter cement performance: details and analysis

PROFILES

42

ANALYST RECOMMENDATIONS

44

STOCK PERFORMANCE

Ambuja Cement: Building Efficiencies Through Strategic Development Highlights of the latest in broker recommendations Comprehensive data on major cement companies in India

cement 24

MARKET AND COMPETITION

26

VOLUME AND PRICING

27

PEOPLE

28

M&A and Finance

Prices set to escalate further in the coming months due in part to rising cement costs

38

Looking at the clouded horizon ahead

40

Highlights from the NCB Conference in New Delhi

14

18

1

Accusations of cement cartelization by the National Real Estate Development Council Cement prices on the rise Council of Indian Employment proposes raising workweek hours GP Goenka Group & Jaypee Development reportedly reach agreement over Andhra Cement

30

PROJECTS AND EXPANSIONS

33

REGIONAL UPDATE

Defunct Hundung Cement Factory may get a new lease on life Update on cement markets in the broader South Asia region

Cement & construction Materials

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CemWeek rOBERT MADEIRA CemWeek ANTHONY FITZGERALD CemWeek BMWeek BMWeek BMWeek

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letter from the editor

electric clouds ith the festival season behind us, industry stakeholders look ahead into a somewhat murky immediate future. Cement demand looks robust after a few dips, prices remain resilient, and the capacity steamroller appears to have slowed somewhat. All the same, we also don’t expect to be completely out of the woods just yet.

Perhaps not surprisingly, there is some pause in new plant project announcements after the earlier breakneck pace, but it clouds an otherwise compelling longer term outlook. The CW Group research team expects these clouds to pass, especially following recent announcements of a few large infrastructure programs.

Speaking of issues “clouding” the industry’s horizon, the CW Group remains focused on India’s energy problem and the impact it is having on cement manufacturers. In this issue of the India Cement & Construction Materials (ICCM) jour-

nal, we highlight recent benchmarking research on electricity consumption in the India cement sector and look at coal price trends. These concerns will likely continue to be central themes that we will continue to monitor both in the CW Group Advisory team and in this journal, as we do not see any immediate change in the trend. We know many of you are also monitoring this problem, so feel free to contact us to share your thoughts and to open a dialogue that may ultimately help others.

This issue also provides an update from the recent NCB conference in New Delhi (page 12) and shares the insights of a few industry leaders regarding the current situation and trends likely to emerge in India’s cement market. A candid interview with NCB’s General Director Ashwani Pahuja about the role of the NCB is also included (see page14).

Finally, in addition to our regularly featured departments, we take a closer look at the changing face of the southern cement

market. The region has attracted much attention over the last few years, with announcements by various cement players of Greenfield projects or capacity expansion efforts dominating industry news.

ICCM discusses the rapid changes that have taken place and where the region’s cement market may be headed (see page 4).

As always, your contributions and comments are welcomed. If you are interested in contributing to the ICCM magazine with an article, or simply want to share your feedback, contact us at editor@cemweek.com.

Robert Madeira publisher and head of research

INDIA CEMENT & CONSTRUCTION MATERIALS MAGAZINE

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numbers in brief Volumes and prices:

On the up and up emand for cement improved in October, with production following suit. Most regions of the country also reported a hike in cement prices, with the central region experiencing the highest price hike, ranging between Rs 15 to 35.

Sales and Production While September sales dipped by 4.3 percent from 13.43 million tons in August to 12.85 million tons in September, demand improved in October with an 11.9 percent gain, totaling 14.38 million tons.

and targeted sales in the trade segment, leaving non-traders high and dry. Demand also improved marginally, largely due to an anticipation of a further price hike in the second half of October that led to stockpiling by traders.

ber, as a shortage of sand continued to play havoc with construction schedules. However, with the end in sight for monsoons and the post-Diwali rush, prices were likely to improve in November as construction picks up.

A similar trend was observed for cement production, which fell by 5.8 percent from 13.65 million tons in August to 12.86 million tons in September but rose by 14.9 percent to 14.78 million tons the following month.

The central region witnessed the highest price hike, ranging between Rs 15 to Rs 35 as demand steadily picked up as the Diwali festival season approached. Similar to the northern region, scaled-back production led to no sales in the non-trade segment. It is expected that prices will harden further as lower production impacts availability of the product, especially in the post-Diwali construction phase.

Coal shortages and the political situation in Andhra Pradesh, coupled with increased freight charges and a roll back on discount rates offered to dealers earlier, resulted in a price hike of Rs 10 to 15 in the southern region.

Regional Pricing The northern region, which had already incurred a price hike of around Rs 15 in September in anticipation of the festival season, witnessed another sharp increase of Rs 20 to Rs 30. A shortage was to blame as manufacturers scaled back production

While the western region had battled with a price drop in September, it witnessed a subdued hike in the range of Rs 10 in Octo-

CEMENT DESPATCHES AND PRODUCTION (mtpy)

In the east, following a Rs 10 hike in September, average prices further hardened by more than Rs 20 in the wake of the Dassehra festival season that led to a renewed burst of construction activities. BMWeek CemWeek BMWeek BMWeek

CEMENT PRICES BY REGION (INR/bag)

15 North Central 13

East West South

11

Aug

Sept Production

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Oct

0

Despatches/Sales

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100 October

200 September

300

CemWeek CemWeek

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feature

The Changing Face of the Southern Cement Market

A Growing Market or a Growing Concern? he cement market in the southern region has experienced tremendous growth in regard to its production capacity—Growth that is expected to continue for the next two years. While a strategy of price discipline has worked to compensate for the stagnant demand that has lingered in the region, concerns are growing over the direction of the region’s cement market over the next few years.

India’s southern region has attracted much attention over the last few years as announcements by various cement players of Greenfield projects or capacity expansion efforts have dominated industry news. By 2010, the southern region represented an estimated 40 percent of the total India cement market, and cement capacity in the region had increased at an average CAGR of between 11 and 12 percent. Cement consumption in the region also grew at an average of 10 percent annually.

Those familiar with the region understand its draw. Many analysts are forecasting, and several cement manufacturers are relying on, an increase in cement demand by fiscal year 2013. Driven by growth in real estate development, specifically the housing sector, a push for infrastructure development, and the slow but sure recovery of the construction market

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is expected to drive the future demand for cement throughout much of the region.

Andhra Pradesh, Tamil Nadu, and Karnataka have become economic hotspots, as well as major cement consumption centers in the southern region.

Available incentives for businesses to either expand existing operations and/or establish operations are another bonus cement manufacturers cannot afford to overlook. The fact that the region is also rich in raw materials like limestone and coal provides the icing on the cake, so to speak.

Of the eight major identified limestone clusters in the country, four are located in the southern region alone.

A Crowded and Fragmented Arena The cement market in the southern region remains relatively fragmented. It is esti-

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mated that there are over eighteen cement manufacturers with an annual capacity of over one million tons, and around 22 companies currently producing in the southern market.

Jaiprakash Associates, JSW Cement, and UltraTech have undertaken the largest capacity additions in the region but they are not alone. Small to medium-sized producers like Sagar Vicat and Raghram are expanding capacity by also building Cement Plant Expansions in the Southern Region CAPACITY (MTPA)

PROJECTED COMMISSIONING

Jaiprakash Associates

4.5

2HFY12

UltraTech Cement

4.5

2HFY14

4

1HFY13

Madras Cements

2.5

1HFY12

Sagar Vicat

2.5

2HFY13

Total

18

COMPANY

JSW Cement

more plants, and new players following the growth of the region’s market have flocked to set up operations.

tion throughout much of this year, and that has assisted in keeping prices consistent, up to this point. How long this approach will remain effective is unknown. Producer discipline is being followed in the other regions, but problems have begun to arise with this approach in the eastern and central regions of the country. Similar cracks may eventually result in the southern strategy as well.

Over the long run, larger producers may prove successful in wrestling control of a greater percentage of market share. This may either result in many smaller players shuttering operations, or as many observers suggest, result in an increase in mergers and acquisitions within the region over the next few years. Such consolidations may in fact have a positive Capacity Share of Top Companies in Region impact on the performance of some regional cement players.

supply and freight costs have increased.

Furthermore, the cement industry, like other industries, is plagued by coal and power shortages. Regional conflict such as what has been witnessed in the Telangana region brought the Singareni Collieries, which are critical to the coal supply in the region, to a grinding halt in October, and forced cement manufactures like UltraTech and India Cement to increase their prices in the southern market.

Others

Currently, the market appears to be absorbing much of the price hikes. However, that could change and a partial decrease in prices could be seen, particularly in the southern region where demand is not projected to return to robust levels until 2012. Price volatility may well rear its ugly head in the next two years as additional capacity comes online and utilization rates remain low.

A Growing Concern UltraTech The addition of 82 million tons per year of capacity over the last India Cement two years has raised the counMadras Cement try’s total capacity to around 290 mtpa. Between FY 2009 Chettinad Cement and FY 2011, 60 mtpa of capacACC ity was added in the southern region. By FY 2011, accordSource: CW Group Research ing to IIFL Research, 102 mtpa of cement capacity existed in Moving Forward the southern region. AnothHistorically, the southern er 10 million tons of cement capacity was Prices Remain High region has struggled with an unfavoraexpected in the region in FY 2012, fol- The expectation of many observers was ble demand and supply equation with the lowed by 8.0 mtpa in FY 2013 and 3.0 mtpa that the increasing number of players in area suffering from large capacities and in FY 2014. If these projection hold true, the South and the additional production weak demand. The concern over burgeonthen the region can soon expect to see a capacity would drive prices down. How- ing capacities is persistent, but the region’s surplus of over 40 mtpa. ever, at this time the assumption has been redeeming feature appears to be projection unfounded, as prices have remained rela- for long-term demand. Given the fickle Recently, oversupply throughout India has tively high and stable in comparison to nature of demand though, cement manucaused a fall in capacity utilization rates other regions; a trend that is expected to facturers in the region may want to explore and India’s average capacity utilization continue at least over the next few quarters. other opportunities to deal with the roughrate in 2010-2011 dropped to 83.9 percent. ly 40 million tons of expected annual surOver the last decade, the rate had averaged Strong existing supply discipline mecha- plus capacity.

90 percent, and as early as five years ago, it nisms, as well as several other factors have trended at 96 percent. contributed to stable cement prices within One suggestion put forth by industry the region. Construction activities have watchers is for cement manufacturers in As of August of this year, cement manufac- begun to pick up as the monsoon season the region to explore export opportunities. turers in the South were running at 65 per- ends, infrastructure allocation are up, and With only 0.1 million tons exported in FY cent capacity utilization. This is a further various legislative measures to encourage 2011, the prospect to further boost export drop from the 75 percent rate reported for rural growth in infrastructure are on the demand and consume some of the region’s 2010-2011. horizon. All have contributed to keeping surplus definitely appears to be a viable prices up. option worth exploring. BMWeek CemWeek CemWeek BMWeek Like elsewhere in the country, manufacturCemWeek BMWeek ers in the South have moved in tandem to Operating costs such as transportation are keep a tight rein on capacity and produc- also on the rise, as rail wagons are in short

INDIA CEMENT & CONSTRUCTION MATERIALS MAGAZINE

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feature

The Spark of Cement Production:

Benchmarking the Electricity Costs of India’s Cement Companies

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ndia’s cement industry is the third largest industrial energy consumer in the country’s industrial sector. According to the International Energy Agency (IEA), India uses an estimated 78 kilowatt-hours (kWh) of electricity per ton of cement, and while the industry operates some of the most energy efficient kilns in the world, many cement manufacturers still struggle with soaring energy costs.

With energy costs continuing to climb, Indian cement companies keep searching for the most efficient mix of inputs in order to control the cost structure. The CW Group, as a part of our market analysis and work with clients, has taken a closer look at benchmarking electricity costs in the cement sector.

Energy input prices The issue is illustrated by a look at the average price for power generated through coal and lignite based stations in FY 2010–2011 compared to FY 2008–2009. In FY 2008– 2009, average prices were calculated to be between Rs 1.67 and Rs 2.73 per kWh.

By FY 2010–2011, average prices ranged between Rs 1.29 and Rs 3.71 per kWh. Prices on the short-term market registered a decline, but that was mainly due to the government’s intervention in setting price caps to cool down the market.

Increases were observed for all types of fuel. However, coal remained the fuel with the biggest impact due to its extensive usage not only as a fuel source in the clinker production line but also as a fuel source for captive power production.

Today, about 90 percent of the power requirement coming from distribution companies is supplied through long-term contracts from state and central government-backed companies or independent producers. The remaining ten percent is covered by short-term market transactions.

Direct Costs Historically, power and fuel costs have comprised a big part of the direct expenses for cement companies, but the levels spent have declined from what they were in 2007 and 2008. Despite the decrease, power and fuel costs still represented the

highest share of direct costs at 56.7 percent in 2010. For a majority of cement companies, power and fuel costs combined with raw material costs constituted 90 percent of direct costs, even though when taken separately the differences in cost structure among companies were visible.

Consumption In terms of electricity consumption, companies consumed 1,258 kWh crores in 2010. Among the reported volume, 29.7 percent of the cement companies represented here purchased electricity, while the remaining 70.3 percent generated its needs internally. Overall, cement companies

Smaller companies were more susceptible to registering higher fuel costs

energy prices FY 2008 - 2009

FY 2010 - 2011

Coal and Lignite Stations

1.67 2.73

1.29 3.71

Gas/RLNG Based Power Stations

1.45 3.62

2.50 5.95

Liquid Fuel Based Power Stations

5.46 10.55

8.27 10.14

Hydro Stations

0.56 5.04

0.56 6.01

Price on Short Term Market*

5.71

4.15

Power Price (Rs/kWh)

*Combined weighted average price of electricity procured UI, traders, and power exchanges

Shree Cement, a big power generator

INDIA CEMENT & CONSTRUCTION MATERIALS MAGAZINE

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feature DIRECT CEMENT MANUFACTURING COSTS

DIRECT CEMENT MANUFACTURING COSTS Employee Costs

Raw Materials Consumed

Power and Fuel Costs

100

1500

50

750

0

2009

2010

Source: CW Group Research Note: Companies included in analysis represent 64.3 percent of India’s total cement capacity

Waste Heat Recovery System

Through DG Generator

Through Steam Generator

Purchased

0 2009 2010 Source: CW Group Research Note: Companies included in the analysis represent 59.8 percent from India’s total cement capacity.

consumed 20.9 percent more electricity in 2010 than in 2009.

Generation Sources In terms of costs, steam generated electricity was the most efficient with an average 3.14 rupee per kWh calculated in 2010, while electricity was purchased at a unit rate of 4.35 rupee. Companies that relied to a higher degree on distributed generation (DG) carried the largest burden, as the cost for one unit added up to Rs 8.43 in 2010.

Electricity cost per kWh from all sources grew in 2010 versus the previous year, with the highest increase seen in the electricity produced through DG (26.1%), followed by electricity produced through steam generators (17.7%). Rising energy costs like coal, diesel oil and gas have mostly fueled the increase. Because the domestic electricity market is controlled to some degree by the state—also the major supplier for purchased electricity by cement companies— the cost per unit component of purchased electricity increased by a more moderate 9.8 percent in 2010. Based on the realized costs per kWh produced, electricity produced through steam generation offers the lowest electricity costs per kWh.

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Share of Sales As a share of sales, power and fuel costs have come to average 24.3 percent.

Although sales in rupee-terms are obviously affected not only by volumes but also by prices, it may seem like an inappropriate metric at first. However, from an operating perspective it is important to shine the light on what percent of the realized sales energy actually represents (energy

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use per ton produced would be a more isolated metric that would avoid the pricing impact). The companies that own multiple production sites supported by in-house solutions for generating electricity reported lower shares of power and fuel of sales.

In addition, smaller companies were more susceptible to registering higher fuel costs mainly due to the reduced accessibility to cost-efficient coal sources.

SHARE OF CAPTIVE ELECTRICITY GENERATION SOURCES

Overall, cement companies consumed 20.9 percent more electricity in 2010 than in 2009

2010 Through Steam Generator 2010 Through DG Generator 2010 Purchased Electricity

Source: CW Group Research

In general, the companies that registered shares of power and fuel costs within sales lower than the 24.3 percent annual average were also the main cement producers in the country—Ambuja Cements, ACC, India Cements and UltraTech Cement—or belonged to global cement groups, such as HeidelbergCement India. This is not too surprising, as large-scale operators have long held an edge in India in regard to more modern and energy-efficient equipment.

The biggest captive electricity producer was UltraTech Cement, which produced around 33.7 percent of the total generated electricity by the 13 companies reviewed.

The company managed to cover around 85 percent of its electricity needs through self-generated sources. UltraTech is also one of the few companies in the Indian cement industry that has installed waste heat recovery systems, producing electricity at low cost with an estimated average of Rs 0.55 per kWh. The energy landscape is changing. Electricity produced through DG declines each year and is expected to continue doing so in the future as more waste heat recovery systems are implemented. Coal usage is projected by the IEA to decrease significantly (from 85 percent to roughly 50 percent in 2050), while the increased utilization of biomass and alternative fuels is expected to climb (to 30 percent of total

energy consumption by 2050), which will undoubtedly further influence both power usage and costs for cement companies over the next few decades.

Operational size has often proven advantageous in many areas, with the ability to better navigate fuel increases included. Larger companies with multiple production sites are utilizing in-house solutions to generate electricity and enjoying lower shares of power and fuel sales. Smaller companies, lacking scale, remain more suscepti-

ble to higher fuel costs and struggle with reduced accessibility to cost-efficient coal sources. In the end, both will continue to feel the pressure of rising fuel costs to varying degrees. However, each type of company’s response to the situation and the quest for alternative solutions will likely differ. BMWeek BMWeek BMWeek

Contact the CW Group Research and Analysis team to discuss our benchmarking solutions further at inquiries@cwgrp.com

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focus

Fly Ash Offsets Carbon Emissions

ith a growing population and burgeoning economy, India’s power-generating capabilities are increasing near-exponentially. More than 54 percent of the country’s current power generating capability lies in coal, as does most of its planned 100,000 MW expansion between 2012 and 2017. Unfortunately, with an increase in coal consumption comes an increase in associated waste materials that have proven harmful to both the environment and communities.

Fly ash, a residue generated during coal combustion, has historically been disposed of in ash ponds or dumped into landfills. In recent years, however, a new initiative has taken firm hold in the Indian construction industry that aims to recycle fly ash and, in doing so, produce higher quality concrete.

Production Fly ash contains a number of harmful elements, including arsenic, boron, chromium and chromium VI, lead and zinc.

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NOVEMBER/DECEMBER 2011

These pose a threat to both humans and the environment, which is why coal-based thermal power plants are now required to capture fly ash before it escapes into the atmosphere.

Between 2009 and 2010, more than 200 million tons of fly ash were generated in India, with ash ponds—a pond filled with ash slurry that allows the water to drain and evaporate over time—traditionally one of the most common forms of fly ash

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storage. Their popularity is now waning due to environmental concerns, such as the loss of fertile topsoil and the leaching of contaminated water into the ground.

Dry landfill storage and ash silos have been identified as alternatives to partially mitigate environmental concerns, but these still require a significant amount of space.

The Fly Ash Notification was published by the government in 1999 (amended August 2003) as a preventative measure seeking

to increase potential storage volumes by mandating the use of fly ash in construction materials. However, the amount of land consumed by ash ponds and landfill storage continues to increase. At present, stored fly ash occupies 65,000 acres or 26,304 ha of land, space that by the year 2020 could grow to as much as 82,200 ha (calculated at 0.6HA per MW).

As India’s power industry booms, initiatives are being developed to recycle more fly ash, thereby increasing potential storage volumes and reducing potential risks to the environment and communities. One such alternative is the use of fly ash as a partial substitute for clinker in the preparation of concrete.

Fly Ash as Concrete Constituent Dry fly ash is increasingly used to substitute 15 to 35 percent (sometimes up to 70%) of clinker during the concrete manufacturing process. The dry fly ash makes the concrete more durable, less permeable and enhances sulphate resistance.

Despite the fact that it requires a decreased water ratio, it remains easier to pump and work with.

Fly ash reacts with calcium hydroxide and carbon dioxide, converting problematic free lime to durable concrete. This makes fly ash an effective extender that requires less overall energy for the preparation of concrete because less cement is needed and, consequently, less energy-intensive clinker.

Wet fly ash from ash ponds has recently also been found to exhibit beneficial properties, especially in roller-compacted concrete (RCC), during the construction of safe, lasting structures like dams, foundations and roads. This has been shown to significantly reduce associated material costs and to increase potential wet storage volumes.

RCC is a technology where a dry concrete mix is developed and placed like soil cement. It requires much less internal heat and has almost non-existent slump. Fly ash

Weathered fly ash

plays a critical role, since it replaces some of the cement used and subsequently lowers the internal heat of the mixture, making it easier to use. Workability is especially a concern with the use of RCC since the moisture content is less than that of normal concrete.

Between 2009 and 2010, more than 200 million tons of fly ash were generated in India

Fly Ash Quality Despite the laudable merits of fly ash as a concrete constituent, its use in the Indian construction industry is relatively unknown and therefore not widely adopted. According to Mission Energy, only 60

million tons, or 30 percent, of current fly ash volumes are recycled each year, with 38 to 40 million tons used in the cement industry. One other aspect plays an important role that could further bolster the recycling of fly ash: quality.

Studies indicate that Indian coal contains 30 to 50 percent ash when shipped to power stations. Poor quality, high ash coal produces ash with a high-unburnt carbon content. This, in turn, diminishes the durability of concrete. At the same time, a lower carbon and sulphur content in fly ash reduces setting time in concrete, thereby increasing its overall quality.

New technologies like triboelectrostatic separation, carbon burnout in a fluidised bed, or froth flotation can effectively increase the quality of fly ash, which means greater volumes of fly ash can be used to substitute clinker during the production of concrete. Combined with new grinding methods currently being investigated, this could effectively increase the fly ash content of cement to 70 percent. Such high-ash content cement could drastically reduce the amount of storage required and positively impact both man and the environment. BMWeek CemWeek CW Group

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Co Co Co

update 12th NCB International Seminar on Cement and Building Materials

Makarand Marathe, Sr. Vice President, Polysisus India

Mike Kleinebecker, Dr. Joe Khor from Christian Pfeiffer, Gaurav Sood, CW Group

Marcel Habers,Sales Manager, HESS AAC Systems & Gaurav Sood, CW Group

Martin Gierse, President, KHD Humboldt Wedag India & Gaurav Sood, CW Group

Karin Albrecht, Sales Manager, Muhlen Sohn GmbH & Co. KG

he National Council for Cement and Building Materials (NCB)-the apex body in India for research, technology development and transfer, education and industrial services for cement and allied industries-held its 12th NCB International Seminar on Cement and Building Materials in New Delhi, India in November.

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The NCB Seminar has emerged as a singular significant biennial event in this part of the globe, and the international cement and construction industries look forward to participating. The ongoing interest and attendance of the participants over the years is an indication of the benefits the seminar yields.

Through the Technical Exhibition, NCB has given additional exposure to the latest in available technologies and services for the efficient operation of cement plants and construction activities. The event has served as an excellent connecting point for suppliers and clients.

This year’s event was well attended by leading Indian and international sponsors, exhibitors and delegates. The technical deliberations of the seminar covered a wide spectrum of issues ranging from the geological extraction of limestone to the manufacturing and utilization of cement and building materials with a focus on the latest innovations in technology.

The 100 technical paper and special-invitation lecture presentations by experts from the global cement industry covered several themes, including:

ing projects may be one reason. Year-onyear demand growth had been projected by some analysts to reach between eight to ten percent, but this has now been downgraded to a mere five to six percent for FY2011.

Wang Yi, Director of Marketing, Sinoma Energy had an interesting take on the Indian market. “The India market has big potential. It is a big cake but difficult to eat. Price pressures are compromised with quality," said Yi.

CemWeek met with several industry leaders and engaged in discussions on the current situation and trends in the Indian cement industry. A few shared their thoughts with Gaurav Sood from the CemWeek team:

Bjarne Moltke Hansen, MD and CEO, FLSmidth India shared his thoughts on the role of alternative fuels and energy costs in the country. “India will follow all international standards of cement manufacturing, with a focus on alternative fuels as it has a good system to collect it," said Hansen.

“The focus in the future will be on reducing energy cost, waste heat recovery, and environment norm compliance. Due to this, some plants will be scrapped or upgraded.”

Martin Gierse, President of KHD Humboldt Wedag India, said, “The indications are that 2012 may not be too strong, as

Wang Yi, Director Marketing, Sinoma Energy

■■ Raw material resource management ■■ Alternative fuels/waste fuels and raw material ■■ Energy conservation systems ■■ Productivity enhancement and process automation Despite the high level of participation in the event, in speaking with a number of the estimated 1,200 to 1,500 participants and delegates, an often voiced opinion was that this year’s seminar was not as exciting as the one held in 2009. The slowdown in global and Indian infrastructure and hous-

CemWeek also asked about plans in India. Each discussed different strategic approaches.

For example, Martin Gierse with KHD Humboldt Wedag talked about focusing on strengthening KHD’s service offering (i.e., training, spares and AMC contracts) and entry into new markets in South East Asia amid a backdrop of low CAPEX projects. According to FLSmidth’s Bjarne Hansen, FLS is launching a new FLS Cooler in the market, while Sinoma is looking for new partners for their EPC business in India.

K Srinivasan, VP, FLSmidth Airtech India

2011 did not see focus on the CAPEX projects by the cement producers.”

Makarand Marathe, Sr. Vice President of Polysius India, shared the same sentiments: “The market is slowing down from the new projects perspective and the cement producers are focusing more on consolidation, upgradation and process optimization. In history, the cement demand has always been around eight to ten percent and has never dipped down despite the economic slowdown, but government expenditure has slowed down.”

Overall, sentiments from the NCB Seminar indicated an underlying optimism about the future of India and its evolving cement market. Exciting innovations and changes loom on the horizon for an industry that is still searching for its unique competitive advantage. Following the sector’s evolution and its ongoing ascension in the global market is one that CemWeek and India Cement & Construction Materials will continue to monitor. BMWeek CemWeek

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shaping the industry

CemWeek speaks to DG of the NCB, Ashwani Pahuja

emWeek’s Gaurav Sood caught up with the Director General of NCB, Ashwani Pahuja, to discuss this year’s NCB Seminar. In this interview, Mr. Pahuja talks about the highlights of this year’s seminar, the NCB’s role in the Indian cement industry, and a few of the initiatives the organization is currently exploring.

CemWeek: What are a few of the highlights of this year’s NCB Seminar?

A. Pahuja: There are quite a few exciting highlights at this year’s NCB International Seminar. One is the participation from the industry at a record level, with the total number of delegates exceeding 800 and the number of technical exhibitors reaching 55. More than 80 delegates from abroad also registered for this year’s seminar.

Another highlight is the three special lectures organized and presented by international experts on emerging / contemporary topics such as alkali activated alumino-silicate binders, Portland cements containing different additives, including dolomite and concrete durability and service life prediction, all much appreciated by participants.

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Additionally, new topics such as Portland limestone cements, composite cements, alternate fuels and materials, waste heat recovery systems and an algal photo bioreactor for CO2 sequestration are the talk of the industry. Finally, there are the reports by various authors on the world’s biggest cement plant and the latest developments in crushing, grinding and pyro-processing that are of interest to attendees.

CemWeek: How is the NCB shaping the industry agenda and development through the event?

A. Pahuja: The NCB Seminar is instrumental in highlighting new and emerging areas for the benefit of the Indian cement industry as just mentioned. Deliberations at the seminar help speed up the formu-

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lation of national standards on Portland limestone and composite cements and provide impetus to further research geopolymeric cements. The NCB Seminar has also highlighted applications of nanotechnology to cement and concrete for greater sustainability.

Another key area is the reduction in carbon emission, which has been discussed in previous seminars also. The results are reflected in the industry. For example, CO2 emission is 0.82 tons per ton of cement at present compared to the substantially higher level of 1.12 in 1996. Further, the concept of co-processing of wastes like ETP sludge, municipal solid waste, spent wash, plastic waste, scrap trees, etc. has been used in cement plants with the active participation of the NCB. Papers on these

aspects have been presented at the Seminar. The encouraging results will encourage others to follow.

in crushing technology are just some of the examples that can be immediately implemented in the plant environment.

nano-practices—such as nano-silica on cement performance—has been investigated, and future work is in progress.

CemWeek: What do you hope delegates take away from the event and return to share with their companies and the industry?

CemWeek: What are the NCB’s most important initiatives now and how will these benefit India’s cement sector?

Investigations on geopolymeric binders based on waste materials such as fly ash have been undertaken. Geopolymeric cements can be described as non-limestone bearing, alkali activated, amorphous alumino-silicate cementitious binders.

Further work on various applications of these alternate eco-friendly binders has been taken up.

A. Pahuja: The delegates will take away and share with their companies and industry the latest developments in cement manufacturing technology reported by various authors. These include co-processing of different types of alternate fuels such as tyre chips, sludge, paints, spent wash, etc. Additionally, the latest developments in grinding technology, cooler technology and innovative ideas on project engineering and execution and dust suppression will be shared. Papers on cement and concrete performances also enrich the Seminar and benefit the delegates. Papers containing practical ideas to reduce energy consumption, achieve a “Zero-accident” goal when setting up cement plants, environmentfriendly loading of cement bags, advances

A. Pahuja: NCB’s most important initiatives at the moment include co-processing of alternate fuels, the application of nanotechnology to cement and concrete for improving performance, further development of geopolymeric and composite cements, maximizing utilization of low grade and marginal grade limestone, waste materials such as fly ash in cement and concrete, and design parameters for high strength concrete.

Ongoing R&D activities for the future include carrying out investigations on applications of nanotechnology to cement and concrete for developing eco-friendly, high performance cements/binders and concrete with improved performance and durability characteristics. The impact of

NCB has also carried out investigations on composite cements using granulated blast furnace slag and fly ash, and the results have been sent to BIS to facilitate the development of national standards on composite cements. The manufacturing of composite cements would facilitate greater utilization of industrial wastes.

These initiatives will be helpful in enhancing sustainability and lowering the CO2 footprint of the Indian cement industry. BMWeek

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analysis Energy and Transportation Cost Concerns Dominate THE CEMENT CO AGENDA

Cement manufacturers struggle with rising coal and transportation prices. Escalating prices leave companies scrambling to find solutions as costs skyrocket, affecting the bottom line. ising domestic and imported coal prices, along with shipping costs, are topics of great concern for the Indian cement industry. Coal often tops the list as the fuel component that has the most influence over energy costs, thus motivating many companies to now look for alternative fuel solutions that may offer some relief from increasing costs.

In the financial year ending on 30 March 2011, Indian cement companies faced explosive energy costs on both the domestic and international levels. The largest cement producer of India, UltraTech

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Cement, declared 23 percent higher energy costs. The increase followed on the heels of another noted increase last year. During the financial year, the company’s imported coal prices jumped from US$88 per ton to US$121 per ton, a 37.5 percent increase.

Domestically, the situation was just as disconcerting as Coal India, India’s largest coal producer, indicated it planned to institute a series of price increases to align domestic coal prices with international markets. The company's new pricing grid, published in March 2011, appeared to support this goal as it reflected price increases ranging from 30 to 150 percent.

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Peak Levels When analyzing the evolution of the main coal indexes over the last 24-month period, the cost increase experienced by cement companies becomes apparent.

After a sharp increase registered in the beginning of 2010, levels remained somewhat unchanged for most of the year, with major hikes witnessed at the end of 2010 and again at the start of 2011. The Australian thermal coal index reached its peak value in January 2011 at US$141.94/MT, a 68.12 percent increase from November 2009. The Indonesian coal reference price (HBA) followed shortly, reaching its peak

value in February 2011 with an 84.2 percent increase over November 2009.

AUSTRAILIAN THERMAL COAL (USD/MT)

The months following the peak levels show a downward trend that stabilized at US$130.4/MT for the February to October 2011 period. The Australian thermal coal index averaged 91.9 percent of the January 2011 peak value, and US$119 per ton for the March to October 2011 HBA averaged 93.7 percent of the February 2011 peak value.

150

120

Sep-11

Jul-11

May-11

Mar-11

Jan-11

Nov-10

Sep-10

Jul-10

May-10

Nov-09

120

Nov-11

Sep-11

Jul-11

May-11

Mar-11

Jan-11

Nov-10

Sep-10

Jul-10

May-10

Mar-10

Jan-10

60

Nov-09

90

BALTIC DRY INDEX 4,000

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2,500

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Nov-09

Indian cement companies apply several strategies to leverage the price volatility in the coal market. Locking in long-term supplier contracts and securing coal blocks and linkages are a few techniques used by manufacturers. However, stability in price is not the only concern. Railway bottlenecks, the decreasing supply of quality domestic coal requiring supplementation by qualitative but expensive imported coal, and the pressure added by coal importers that refuse to sell coal at reduced prices, particularly when the rupee is weak, are just a few others. These and other problems have arisen recently, requiring cement manufacturers to scramble for long-term, cost-effective strategies. BMWeek CemWeek

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Shipping Costs The Baltic Dry Index (BDI) evolution offers further insight and possible concern for the cement companies as coal is usually shipped with large bulk carriers like capsize vessels that carry at least a minimum of 100,000 tons of coal. While coal prices evolved upwards over the last 24 months, the Baltic Dry Index registered a reversed pattern, declining from its maximum value of 3903 calculated for November 2009 to its recent October 2011 figure of 2072.

However, after a constant evolution in the first eight months of 2011, the recent trend shows that the index is gaining once again.

Ironically, should the BDI revert to its former peak value, companies may find themselves faced with an 88.4 percent increase in shipping costs.

Jan-10

90

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Examining India’s ACC Wadi's Newest Expansion One of the world's largest cement plants has gotten even bigger

ince its incorporation in 1936, ACC Limited (ACC), a unit of Holcim, has been celebrating a series of growth milestones. ACC is now honoring its 75th year of operation with the completion of one of the world’s largest cement plant expansion programs at its Wadi location. With this expansion, the firm is positioning itself as a leader in the market in terms of capacity, environmental, and technological innovation.

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The journey to creating one of the biggest operating cement plants in the world did not happen overnight. The expansion site was carefully chosen and special engineering plans were drafted to accommodate the unprecedented size of the operating components. Exploring the transitions from the existing infrastructure to the creation of the new plant—all without halting ongoing production—provides insight into the future for cement plants of all size.

The Beginning The Wadi site traces its roots back to the late 1960's, opening its doors in 1968. The site is located near the Wadi railway junction, on the central line between Solapur and Gurmitkal. The location provides a convenient connection to Mumbai, Hyderabad, and Bangalore by rail, supported with a growing road network to move inputs and product to and from the facility.

Full-scale production began at the site in 1979, according to ACC, and the site quickly celebrated a significant achievement. In 1982, ACC commissioned Wadi as the first one million ton per annum plant in the country. This was a major achievement, but just the first step in turning Wadi into one of the largest plants in the world.

By 2001, the Wadi site had one of the largest kilns in the world thanks to the commissioning of a 2.6 mtpa capacity kiln, now known as the New Wadi or Wadi II plant.

When the footprint for the 2001 New Wadi plant was established, it was laid out with the goal of someday becoming the world's largest pyroprocessing line able to consistently produce 10,000 tons per day. The realization of this goal occurred in late spring of 2011 when blending two-satellite cement grinding plant lines with a new kiln capable of consistently producing

12,500 tons per day came online. Since the Wadi location was already one of the largest production sites in India, it could not be taken offline while the new infrastructure was installed, requiring ACC to complete its expansion without disrupting regular plant operations.

Upgrading Operations The current upgrade to the Wadi site began in 2007, largely supported by FLSmidth. It includes substantial capacity increases for operating equipment as well as upgrades for existing systems based on emerging technologies and environmental issues.

Each capacity increase was built not as an end product, but as something which could be later expanded or replaced to permit ACC's ongoing expansions.

A major concern was expanding the size of the line without disrupting the exist-

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focus grate cooler. While it could have been upgraded, ACC chose to replace it with a 6x8 SF Cross-Bar cooler, the largest of its kind moved into active production. This replacement cooler was preassembled in three modules, so when the moment came to switch out the old cooler, total downtime was just under three days. This included time for dismantling and removing the old cooler, dragging the preassembled replacement into place, and reconnecting the cooler to the production line.

ACC also increased the size and capacity of its hammer breaker. Prior to the size increase, the plant relied on a hammer crusher. For the new system, ACC chose a heavy-duty roll breaker, installing a breaker that is one of the largest of its kind in the world to keep the system moving.

Other improvements for speed, capacity, and environmental management included the strategic upgrade of supporting systems. For example, the plant's older Duoflex burner was replaced with the newer 204 MW Duoflex burner, emission control systems were built, and waste co-processing systems were installed. As a result, the plant now offers not just more production capacity than almost anyone else, but more environmentally friendly capacity.

ing capacity systems. To do this, engineers broke ground for a second preheater tower immediately adjacent to the first. Both towers would eventually feed one massive kiln, but the dual system ensured that the older tower could feed the kiln until the newer tower came fully online.

the first tower. It is a 6-stage two-string ILC low-NOx unit. Maximum capacity is up to 7,000 tons per day, providing ACC with room for additional growth in the future through a production line capable of delivering 13,000 tpd, well above their original 10,000 tpd goal.

The new tower incorporated several heating efficiency and environmental advances that weren't available when ACC installed

Another key area of upgrade came in the clinker cooling systems. Before the upgrade, the plant was using a Coolax

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The Future ACC continues to move forward with an eye to innovation, using the site to reinforce its position as an industry leader in cutting edge and environmentally compatible production. Though everyone from Kuldip Kaura, CEO & Managing Director, to ground-level employees agree that the expansion was a major undertaking, their enthusiasm remains directed toward what lies ahead, including new regional partnerships and major government contracts across the country. ACC is among the biggest players in the cement industry, but just like their plants, they have no plans to stop growing. BMWeek CemWeek CW Group Coal Week BMWeek BMWeek

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We know the cement industry well. Let us guide you. For more information please contact us at inquiries@cwgrp.com or on +1-702-430-17 48 848 N. Rainbow Blvd., Box #1658, Las Vegas NV, 89107, USA

focus

Cement Trickle-Through:

Real Estate Prices Continue Upward Climb

lready high real estate prices in India are set to escalate further in the coming months due in part to rising cement costs. However, the long-term outlook for the real estate market remains positive, thanks in part to government initiatives in the pipeline and high housing demand.

Real estate prices in India are forecasted to rise 15 to 20 percent in the next months, driven by a rise in cement prices, according to the Indian National Real Estate Development Council (NAREDCO). This is unwelcome news, considering real estate prices are already on an upward climb despite a slowdown in demand. Slow economic growth, repeated interest rate hikes

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by the Reserve Bank of India, and high inflation have all contributed to higher real estate prices in recent months.

Economic Environment The Reserve Bank of India (RBI) has raised interest rates by 300 basis points in only 15 months. In September 2011, the RBI raised its policy lending rate by 25 basis

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points to 8.25 percent, the 12th interest rate hike since March 2010.

According to the International Monetary Fund, India’s economic growth is likely to slow down to around eight percent for 2011, down from ten percent in the previous year. Investment growth slowed to 0.37 percent in Q1 2011 from 7.8 percent

the previous quarter, due to rising interest rates. Consumer spending growth was eight percent, down from 8.6 percent in the previous quarter.

Developers and consumers alike are feeling the pressure. In such an economic environment, some major investment projects are postponed and investors are eyeing markets that are more profitable. Developers are feeling the strain of higher financing fees and rising costs for input materialsmainly cement-which is ultimately putting pressure on cash flow. Consumers are also shying away from borrowing given the jump in interest rates.

Still optimism prevails, at least in terms of the forecasts, as the Confederation of Real Estate Developers’ Association of India

cent, according to real-estate firm Liases Foras.

Cement’s Impact India’s cement industry has been struggling with weakening demand as construction slowed amidst a rapid increase in production capacity and output. NAREDCO recently alleged that cement producers were trying to create an artificial shortage on the market in order to increase the price of cement to profit margins, subsequently delaying projects and forcing developers to import cement from Pakistan and other countries. The organization asserts that the cement industry has pushed prices up in anticipation of an increase of activity following the end of the monsoon season, when construction traditionally picks up.

INDIAN CEMENT: DOMESTIC DEMAND, PRODUCTION, EXPORTS (2005-2010) YEAR FY 2005 - 2006

DEMAND

PRODUCTION

EXPORT

135.56

141.81

5.98

FY 2006-2007

149.34

155.64

5.89

FY 2007-2008

164.03

168.31

3.65

FY 2008 - 2009

177.98

181.61

3.2

FY 2009 - 2010

196.12

201

2.27 Source: NIS

(CREDAI) projects that India will need 27 million housing units built between 2012 and 2017, a need that will require an estimated investment of US $3.2 trillion. Currently, housing accounts for approximately 4.5 percent of the country’s GDP. Meanwhile, housing prices continued to rise, with India ranked second out of 50 countries for annual growth of residential prices in Knight Frank’s latest global housing price index. India’s National Housing Bank (NHB) reported that in New Delhi, for example, house prices rose 33.64 percent during the year to Q2 2011 (22.7% in real terms) and by 16.67 percent from the previous quarter (15.84% in real terms). At the same time, sales were down by 30 per-

CRISIL Research expects the cement industry’s profitability to decline by 2012 or 2013 to its lowest level in the past ten years. Cement production capacities will rise in the next two years by 60 million tons per annum (mtpa) with demand set to increase only 30 mtpa.

As India is the second largest producer of cement in the world, the industry has outpaced growth rates of other sectors, helped by the rising demand in the real estate market, infrastructure projects, and construction recovery.

ture sector in the five year period beginning in FY 2012-2013. The latest development outlook of the Indian government includes plans to attract foreign funds for infrastructure projects in order to ensure financial support for the construction sector. CARE estimates the investments planned for the industry will increase cement demand by more than 400 tons.

According to Business Monitor International, the construction industry’s real growth will average eight percent per annum between 2011-2012 and 20152016, a figure that indicates there are still significant opportunities, reflected in key projects valued at an estimated US $400 billion.

In the short-term, BMI revised the real growth forecast for India’s construction industry to 7.3 percent in 2011-2012 (previously 9.5 percent), while the long-term outlook for the sector remains positive due to the government’s attempts to address access to long-term financing, robust interest from foreign investors in project financing, and implementation and liberalization of some infrastructure sectors.

In the short-term, it appears as if the real estate market in India is set for a rather bumpy road. However, long-term forecasts indicate that major projects coupled with government initiatives will like assist the real estate industry in achieving a strong growth rate. BMWeek CemWeek CW Group BMWeek BMWeek

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DEMAND FOR CEMENT

FY 2010 - 2011

231.66

FY 2011 - 2012

257.61

FY 2012 - 2013

290 Source: NIS

Construction Sector Boost According to government plans, India will spend over US $1 trillion in the infrastruc-

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cement market & competition

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arket and competition

ccusations of cement cartelization are claimed once again, this time by the National Real Estate Development Council, while the National Congress Party asked for a probe into alleged illegal mining activities in Meghalaya by at least eight cement firms. Meanwhile, India based cement makers turned in better than expected performances in October despite consecutive price hikes. sition and clearances, political uncertainty in Andhra Pradesh, and unavailability of key raw materials were cited as key reasons for the sluggish demand.

The utilisation rate is also expected to decline to 76 percent in FY 2012, as the incremental demand of 12.5 MT is likely to be negated by 18 MT of capacity additions. Rates are expected to improve starting in FY 2013 (79%) as the incremental demand (20 MT) will keep pace with effective capacity addition (23 MT).

Cement Cartelization Claims Raised The National Real Estate Development Council (NAREDCO) has approached the Competition Commission of India (CCI) seeking intervention against alleged cement cartelization. The group alleges that the cartelization of cement is hitting real estate developers hard. The group found it incredulous that cement prices would shoot up by 66 percent in three months and believes the problem is an artificial scarcity being created by cement cartels.

Therefore, they are requesting intervention by the CCI.

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The group suggests that if cement prices continue rising, real estate costs could go up by 15 to 20 percent. This would delay the completion of several construction projects, with the added cost ultimately passed on to consumers.

Sluggish Demand Analysts expect cement sales to be muted, hitting six percent year-on-year in FY 2012. The rising cost of capital, slowdown in government projects, delay in construction activities due to issues in land acqui-

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Better Than Expected India based cement makers turned in better than expected performances in October despite consecutive price hikes, with the exception of UltraTech Cement, which registered a seven percent drop in sales due to the ongoing Telangana conflict.

According to analysts, the rise in demand has enabled firms to pass on a portion of their incremental production costs to end users. Prices rose by Rs 10-50 a bag each in two installments last month. Analysts caution, however, that profit margins will remain under pressure, as companies

CEMENT: MARKET AND COMPETITION

will find it difficult to pass on the entire increase in production costs through price hikes. Furthermore, Indian companies have been hit badly by the steep increase in costs of coal, fuel, and freight.

Limestone Mining Probe The opposition bloc National Congress Party (NPC) has asked for a probe into alleged illegal mining activities in Meghalaya by at least eight cement firms. The NPC claims that at least eight cement plant companies including Star Cement, Topcem, Adhunik, JuD Best and Hills Cement have set up the cement plants without prior permission from the Union Ministry of Environment and Forests (MoEF), before using forestland for non-forestry purposes.

Recovery on the Horizon ACC expects things to turn around for the cement industry by the December quarter, as the monsoon season subsides. Chief Executive of the southwest region Ramit Budhraja said, “With monsoon receding, we expect revival to pick up in coming months. Demand has moderated since February. We expect a growth of eight to ten percent from the December quarter against five to six percent registered in the preceding two quarters."

Expansion Efforts Slow Prism Cement has slowed down its expansion drive due to weak demand. Company sources admit work on the planned 4.5 million ton Greenfield cement plant in Andhra Pradesh has been put on hold due to weak demand.

focus ACC May Launch Environment Friendly Cement

ACC is studying plans to launch a 'green' cement variant. According to a recent report, “The development is almost complete and ACC is now doing the pilot testing. It will take about another one year to commercially launch the product as pricing, branding and some other issues have not been decided yet,” The new environment friendly cement will emit 400-450 kg of CO2 per tons at the time of burning limestone during its production, while it’s about 900 kg in the case of conventional cement. The new product offering will likely be more expensive than ordinary cement.

S&P Maintains Positive Stance on Industry

“The approvals, the mining lease and the Cement prices in India have returned to required land acquisition have been compre-monsoon levels, helping to maintain pleted. It typically takes around 30 months Standard and Poor's positive rating on the to construct a cement plant, we will start industry. construction work as and when demand revival is visible in a 30-month timeThe price of cement corrected 4.6 percent frame,” said an official on the condition in 2Q FY 2012 from the 1Q FY 2012 average. of anonymity. BMWeek CemWeek CW Group Coal Week The largest correction was in Central India, BMWeek BMWeek

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where the price has fallen 7.7 percent from the 1Q FY 2012 average. According to reports, domestic cement demand growth has been anemic in the first five months of FY 2012. The situation in Andhra Pradesh has deteriorated. After declining 17 percent in FY11, Andhra Pradesh demand has declined at the rate of 20 percent.

"The demand decline in Andhra Pradesh is primarily because of the unstable political scenario. The Telangana issue is crippling the state. With no solution to the problem in sight, development activity has practically come to a standstill. Whatever little demand is left is primarily from the stable retail segment. We thus do not expect any dramatic improvement in South India any time soon," a source said.

Cement Makers Go Abroad for Coal

Ambuja Cements is looking at new shiploads of thermal coal from South Africa, sources familiar with the transaction told sources.

UltraTech Cement has also requested offers for 100,000 metric tons of South African coal for delivery next month. The shipments are expected between December 2011 and January 2012.

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cement volume and pricing

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olume and pricing

oor demand growth and expanding capacity led to a drop in cement capacity utilization rates in the first half of the year. Cement prices in general were on the rise in October as the monsoon season ended.

Prices on the Rise Heidelberg Cement plans to increase its cement prices by Rs 75 per bag. Rising costs for fuel and power has hit the company’s earnings hard this quarter. The company posted a net loss of Rs 8.2 crore for Q3CY11 against a net profit of Rs 2.8 crore year-on-year. This comes after coal prices went up by about 35 to 40 percent, power by 20 percent and distribution expenses by about 10 percent. The company expects cement prices to jump to Rs 325 to 350 per bag from Rs 250 per bag.

tation. Unrest in Andhra Pradesh hiked cement prices by as much as Rs 25 per bag.

Cement prices in general were on the rise in October as the monsoon season ended.

According to Institutional Equities, prices have increased by Rs 5 to 20 per bag in October in all regions (except the South).

Nationally, average prices increased nine percent month-on-month.

Various reasons for the decline were cited, including poor demand growth and expanding capacity. Additionally, existing inventory levels remain high as manufacturers deal with carryover from last year, which needs to be sold in addition to the ongoing production.

Demand was reported as sluggish in most regions except the west and central regions, Gujarat and Uttar Pradesh, which were showing stronger demand, primarily due to pre-election spending by state governments. It was also noted that construction activities in Andhra Pradesh were negatively impacted by the Telangana agi-

Southern Market In a recent report, India Cements suggested that southern India might see stable prices for cement in the near term. CFO VM Mohan said, "The only thing that we are not sure about is a couple of capacities that are coming in the pipeline in the next three to six months. We will have to

Utilization Rates Decline Cement capacity utilization rates fell in the first half of the year, even as prices pointed higher and demand was expected to expand post-monsoon. According to reports, the cement industry, from April to September, witnessed a fall in capacity utilisation across the country to 75 percent, down from 78 percent in the same period last year.

wait and see how those players are going to play out and whether that is going to have any impact on the prices. Otherwise, we believe we are likely to have a reasonable price situation.”

Mohan went on to suggest, that for India Cements, the South provided a “reasonably decent pricing pattern.” Going forward, the company may look at passing on any cost increases that may take place but remained optimistic that despite poor capacity utilizations, it was able to maintain its current price level.

Price Slash Urged The state of Hichamal expressed concern over rising area cement prices and requested a reduction. State Industries Minister Kishan Kapoor said that it was a matter of concern that in spite of various incentives provided by the state government to cement plants, cement rates were higher in Himachal compared to neighboring states.

Kapoor suggested that cement factories located in the state should work to ensure that the cement was made available to the people at a reasonable rate in the state.

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CEMENT: volume & pricing / people

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ouncil of Indian Employment proposes streamlining the factory registration process and raising workweek hours. Protesters come out to voice dissatisfaction over proposed new plants.

Online Approval Sought Indian employers are pushing for online approvals, licensing and registrations of factories, according to sources. The process for seeking licensing and registration of factories is viewed as cumbersome, with inspecting staff holding too much power over the process. The hope is that shifting the process online will assist in streamlining the paperwork.

Employers are also seeking to have the functional head of a factory accepted as its “Occupier” and not the Director of the Board, as it currently is. The designated “Occupier,” employers argue, should be nominated by a resolution of the Board of Directors of a company.

The Council of Indian Employers (CIE) forwarded the suggestions to the Labour Ministry that is working to amend the Factories Act 1948.

Raise in the Work Week The Council of Indian Employers (CIE) is seeking an amendment to the Factories Act 1948 which would raise the current workweek from 48 to 60 hours, including overtime. Such a move, the CIE suggests, would increase national productivity, glob-

al competitiveness, as well as employee earnings among factory workers.

Employers also want worker absenteeism to be addressed, citing excessive unauthorized absenteeism as a hindrance to pro-

ductivity. Employers view the existing law as weak when it comes to dealing with job absenteeism and suggests that the worker should be automatically terminated if they have a seven day unauthorized absence. BMWeek BMWeek BMWeek

focus Protests Over New Plant

Protests greeted a proposed cement plant project in Rambilli, regarding Kerneos India Aluminate Technologies, a former Lafarge unit, bid to build a calcium aluminate cement unit in the area. While shouting slogans against the government at the public hearing on the plant, agitators demanded that the project be immediately cancelled.

Kerneos, with an investment of around Rs 90 crore, has reportedly received an industrial license from the Secretariat of Industrial Assistance from the Department of Industrial Policy and Promotion to set up the project in the coastal village and to produce nearly 30,000 tons of cement per annum.

'We are shocked at the blatant violation of the high court order that requires that prior notice be given to the local people before the visit of the MoEF's expert appraisal subcommittee to inspect and hear grievances," a local petition sent to the Ministry of Environment and Forests.

Lafarge India had previously signed a memorandum of understanding with the Himachal Pradesh government to set up a cement manufacturing facility in Karsog and to undertake mining of three million tons of limestone.

Opposition for Lafarge Plant Mounts A Lafarge Greenfield cement plant in Hichamal Pradesh is facing local opposition, as residents there say they were not properly consulted.

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P Goenka Group and Jaypee Development reportedly reached an agreement for Jaypee to buy a controlling stake in Andhra Cement. Century Textiles agreed to merge its cement unit with UltraTech, and the court approved the merger of Ambuja Cement India with Holicm India. company afloat. The deal brings to an end the GP Goenka Group’s ongoing restructuring and leaves it debt-free.

Take Over It has been reported that the GP Goenka Group and Jaypee Development reached an agreement allowing Jaypee to buy a controlling stake in Andhra Cement. The proposed deal, valued at Rs 280 crore, would give Jaypee an 80 percent stake in Andhra Cement and leave the GP Goenka Group with a six percent stake in the company, on which the Jaypee Group would have right of first refusal. Other major shareholders in Andhra Cement include Infrastructure Development Finance Company and Housing Development Finance with 17.38 and 14.94 percent, respectively.

Under the terms of the deal, Andhra will issue around 147.5 million in new shares for Rs 12 each, giving the Jaypee Group a 50.25 percent stake. Concurrently, the Goenka Group will sell 48.11 million shares from its total holding of 65.8 million shares for Rs 12 each. The Goenka Group currently has 45.11 percent of the company’s shares. The transactions will lead to the Jaypee Group making an open offer to acquire 26 percent more of Andhra Cements’ shares.

Andhra Cements has been trying to enhance capacity to 3.5 mtpa from 1.5

28 NOVEMBER/DECEMBER 2011

Mergers in the Works Reports suggest Century Textiles agreed to merge its cement unit with UltraTech.

According to sources, Kumar Mangalam Birla has finally agreed to move forward with the long-awaited merger, and a deal is likely to be inked in the next few months.

The agreement will mark the group’s third consecutive cement deal in recent years after its overseas acquisition of ETA Cement and the merger of Grasim’s cement division with UltraTech last year.

mtpa. At present, only two thirds of the ongoing planned expansion has been completed taking, the company's total capacity to over 3 mtpa.

Andhra Cements incurred a loss of Rs 35.50 crore on net sales of Rs 65.48 crore last year, and two of its units have been nonoperational since June 2010. Fund infusion by financial institutions such as JP Morgan, ICICI Bank, HDFC, and IDFC has kept the

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The BK Birla Group’s cement business under Century, Kesoram and Mangalam Cement has a collective cement capacity of around 17 mtpa. Of that, Century Textiles controls 7.8 mtpa of capacity.

Aditya Birla has refused to comment on what it calls the “speculative” nature of the deal. However, it did confirm the company had initiated talks with the Jaypee Group to buy part of its cement business, which it is selling to raise funds to reduce its Rs 40,000 crore debt burden. Aditya is said

Meanwhile, the Delhi High Court has approved the merger of Ambuja Cement India with Holcim India. Holcim, a 35.77 percent owner in Ambuja, applied for approval to merge the two companies last year. The court ruled that the companies have fulfilled all legal requirements for the merger. The court directed the Registrar of Companies to facilitate the merger in a month’s time, which has also received the approval of the country’s antitrust authority.

Not Feeling the Pinch….Yet India cement makers are not feeling the pinch of a looming coal shortage just yet, as high inventory stocks and stable cash flow serve as buffers. According to Shree Cement CMD HM Bangur, “We have enough stock of coal to last our operations.

The coal shortage will not affect companies that can afford to pay higher prices. I do not see any immediate impact. I believe, those companies which are at the bottom of the pyramid may be affected."

Currently, prices of domestic as well as imported coal are almost the same. The 30 percent increase in coal prices by Coal India early this year has bridged the gap between the two. Prices of higher-grade imported coal are around US$130 a ton, while that of poor quality with higher moisture content is available in the range of US$75-90 a ton. UltraTech, Ambuja Cements, India Cements are major importers of a higher quantity of coal.

On a related note, Prism Cement signed an agreement with India Resources, Australia for mining, development and operation of the Sial Ghogri coal block near Chhindwara, Madhya Pradesh. Prism Cement said coal from its Sial Ghogri coal block

will be used for captive consumption of the cement plant located at Satna, Madhya Pradesh.

quarter under review against a loss of Rs 34 crore in the same quarter last year.

india's Profit Reports India's top cement makers have turned in better than expected numbers in the September quarter. UltraTech Cement managed a 140 percent growth in net profits, while ACC and Ambuja Cements made a 67 percent and 13 percent increase in net profits, respectively.

Shree Cement reported its profits tripled in the quarter ending September 30, on stronger sales. Profits hit Rs 38 crore for the quarter against Rs 11 crore during same period last year. Net sales grew by 19 percent to Rs 855 crore. Cement production and dispatches during the quarter rose by 14 percent, against demand growth of six percent.

India Cements brushed off continued sluggishness in the domestic construction market to post higher numbers in Q2 based on higher prices. The company’s EBIDTA rose to Rs 255 crore for the second quarter this year. Net profit hit Rs 70 crore for the

Madras Cement reported third quarter earnings rose because of stronger revenues despite a nine percent year-on-year dip in cement sales. Revenue rose 27 percent to Rs 825.7 crore. Net profit was in line with estimates at Rs 110.9 crore. BMWeek CemWeek BMWeek BMWeek

CEMENT: m&A and finance

to be offering to buy a majority stake in Jaypee's cement business. Jaypee's cement business is currently valued at US$3.6 billion and was recently spun off into a subsidiary called Jaypee Cement Corporation.

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focus Cimpor's India Acquisition

It is rumored that Cimpor, Portugal’s biggest cement maker, is to acquire a 51 percent stake in India’s Sree Jayajothi Cements. Talks have reached a critical phase and a deal may be announced in the next few weeks. Sources cited T.R. Kannan, managing director of Sree Jayajothi on the negotiations.

Demerging Cement Unit

Orient Paper will reportedly demerge its cement unit by April of 2012. The company’s managing director ML Pachisia is quoted as saying, "The process of demerge is currently on. We have already received the NSE approval but we are waiting for BSE approval and various other formalities will be in place.”

Trinetra Cement Allots Shares

Trinetra Cement is planning to allocate shares worth around Rs 615 crore to Chennai-based India Cements through preference shares. India Cements acquired Trinetra Cement through its subsidiary ICL Financial Services in March 2010.

The company, which had set up a cement plant at Banswara, Rajasthan, with a

capacity of 1.5 mtpa, commenced trial production in August 2010 and commercial production from January 2011. It is reported that the company is also in the process of commissioning a 20 MW thermal captive power plant and is acquiring lands for mining with an eye to future expansion.

India Cements buys coal mine

India Cements has reportedly bought an Indonesia based coalmine for US$20 million.

It is also reported that the company is in the process of setting up a 50 MW power plant near Tirunelveli in Tamil Nadu.

N Srinivasan, Vice Chairman and Managing Director of India Cements, was quoted as saying, “The coal mine acquisition is a strategic decision, it will reduce our exposure to the fluctuating coal price internationally. Despite a four percent fall in demand across south India, the company managed to post good profit. Its capacity utilisation was around 68 percent, due to the excess capacity in South India, which is currently around 100 million tons.”

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teel-maker RINL is looking for a partner for a new cement plant at Visakhapattanam. Defunct Hundung Cement Factory may soon get a new lease on life, and Prism Cement receives a land allotment for cement plant in Kurnool district. Expansion efforts continue for ACC, JK Lakshmi, and UltraTech.

Wanted: Partner Steel maker RINL is looking for a partner to set up a 3 mtpa plant at Visakhapattanam. Heidelberg, Ultratech and Reliance Cements have already expressed interest in the JV, as have Zuari Cements, Bhavya Cements, JP Cements, and Binani Cements. Selection and finalisation of the partnership is expected to take two to three months, with the JV formed before the end of the current fiscal year.

No decision has been made yet, however, on how much of a stake the steel maker is willing to give up, but a 74 percent stake to the partner has been suggested since cement making is not RINL’s core business.

The proposed venture would use fly ash and slag from RINL’s Vizag plant, two key raw materials for the making of cement.

Around Rs 1,000 crore would be required to set up the cement plant. Costs are expected to be shared by the two firms, with production at the plant likely to start in two years from the zero date of construction.

Further Capacity Expansions ACC plans to continue expanding its oper-

30 NOVEMBER/DECEMBER 2011

Cement Projects/Expansion Table

COMPANY/LOCATION Kishan Group/Rajkot

COMMENTS Investing Rs 250 to 300 crore to set up a new cement plant. Construction work on the new plant is on the verge of completion with production to start by Diwali this year. The production capacity of the new cement plant will be 900,000 tons per year, which can be upgraded in future.

Table available in the India Cement & Construction Materials journal Print Edition

ACC Cement/ Karnataka

Invested Rs 1,634 crore on a new clinker line in Wadi and two integrated grinding units in Kartanaka. The company recently completed the integrated cement project in Karnataka comprised of an expanded clinker line of 12,500 tons per day at Wadi, together with two satellite cement grinding plants.

Jai Bhole Cement/Maharashtra

Signed an agreement with the Maharashtra government to build a new clinker cement plant with a 20 lakh ton capacity per annum.

Jaypee Cement/Uttar Pradesh

Spending around Rs 1,350 to expand current capacity. Company has already

www.cemweek.com/subscribe started work on a Greenfield project at Durg and will put up a grinding unit at the district Jharli in Haryana.

TNPL/Tamil Nadu

Building a 600-ton a day cement plant for producing cement from lime sludge and fly ash waste generated during paper manufacturing. The new unit will be commissioned during January next year.

ations, upping its installed capacity by 3 mtpa to 30 mtpa. ACC had cut down its supply in key south Indian markets like Bangalore and Kerala due to capacity constraints; however, capacity expansions are expected to restore those levels. Currently, ACC has a capacity utilization of roughly 80 percent, and wants to improve that rate to 90 percent by 2012.

JK Lakshmi Cement reports it will also

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hike its installed capacity to 5.5 mtpa by next year, as it expects new production lines to come online. The company plans to spend Rs 1,350 crore for capacity expansion plans. Plans include putting up a grinding unit at district Jharli in Haryana for an investment of about Rs 100 crore.

Works has also started on the Greenfield project at Durg, a 2.7 mtpa initiative. The plant is expected to commission by October 2013.

CEMENT: projects and expansions

UltraTech Cement wants to expand capacity to 62 mtpa, and spend Rs 11,000 crore to do so. It plans to add 10 mtpa capacity by the first quarter of FY 2013-14.

The proposed funds will be used on clinker plants through brownfield expansions at Chhattisgarh and Karnataka, installing waste-heat recovery systems, instituting a bulk packaging terminal and setting up of ready-mix concrete plants.

The capacity expansion will be funded through a mix of internal accruals and borrowings.

Land Allotment Granted The Andhra Pradesh government granted the allotment of 1,000 acres of land to Prism Cement for its cement plant in Kurnool district, a move the government believes will aid in the further development of the region. The land was offered to the company at a cost of Rs 100,000 per acre.

Prism Cement plans to set up a cement plant with a capacity of two million tons at Kothapadu and Kalvartha in Kurnool district at a cost of Rs 5 billion.

Captive Power Plant for KCP KCP will build a 36 MW coal based captive power unit for a cost of Rs 164 crore.

The company is also seeking coal linkages.

Currently, the company is dependent on imports for its cement plant, bringing in about 15,000 tons of coal a month, roughly half its requirement. The company recently completed the expansion of its cement production to 2.13 million tons a year. The addition of the 1.52 mtpa at Muktyala will boost production significantly.

Commissioning Pushed Back Jaypee Cement expects delay in the commissioning its two-million ton clinker unit in Uttar Pradesh. The plant, originally scheduled for commissioning in October, may now not come online until February

Bangalore city skyline

focus Maharashtra Secures Investments Maharashtra Chief Minister Prithviraj Chavan signed agreements with eight companies, including Jai Bhole Cements, involving investments of Rs 6,458 crore in the state, mostly in the manufacturing sector.

"We will provide these investors with all the necessary facilities, including land, water, electricity and infrastructure," Chavan told reporters after inking the deals.

The agreement with Jai Bhole Cement proposes to invest Rs 1,502 crore in the first phase to establish a clinker cement plant of 20 lakh ton capacity per annum. The proposal also involves setting up a 72 MW captive power plant in the Yavatmal district.

10,000 tpd clinker production line in Maihar Reliance Cementation has contracted ThyssenKrupp Polysius to engineer and supply a 10,000 tpd clinker production line. The new plant is to be constructed in Maihar in the province of Satna, part of the northern Indian state of Madhya Pradesh.

The scope of supply includes two raw grinding systems, each equipped with a POLYCOM high-pressure grinding roll with 2 x 1,250 kW drives and a SEPOL-PC separator. The grinding systems will have a rated output of 375 tph and 400 tph of raw meal. This plant section also includes a 25,000 ton tangential blending silo. The kiln system will consist of a 6-stage, 2-string DOPOL preheater with PREPOL-MSC calcining system, the rotary kiln and a POLYTRACK clinker cooler.

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cement projects and expansions FLSmidth Releases Next Generation ECS/ProcessExpert

The new version introduces an innovative way of easily configuring, customizing and maintaining applications. It comes with a range of unprecedented industry specific intelligent building blocks representing specific process equipment. Intelligent building blocks are standardized based on 30 years of experience and are available for applications such as kilns and coolers, multi-fuel optimization, raw and cement mills. Benefits include easy adaption to future plant modifications, leading to easier maintenance and higher run factor.

To ensure long term utilization of the advanced process control solutions, FLSmidth has introduced a proactive "plant line service" concept which includes remote monitoring of key performance indicators as an integral part of the system package, maximizing benefits for customers.

FLSmidth has released a new version of its advanced process control solution, ECS/ ProcessExpert. The new ECS/ProcessExpert, available for different cement plant applications, stabilizes the plant, optimizes production, manages and corrects process disruptions and minimizes wear on the plant equipment−all to ensure highly efficient and optimum plant performance.

ECS/ProcessExpert uses advanced techniques such as model predictive control and fuzzy logic rules to continuously monitor the plant’s process and quality parameters. It continuously computes new control set points, enabling ECS/ProcessExpert to make adjustments to the process more frequently and reliably than a human operator.

or March of next year. Environmental clearance appears to be the hold up.

Factory, a partner of the Satyam Group of Industries based in Assam, permission to re-establish and run the Hundung Cement Factory.

The company was asked by the Ministry of the Environment and Forests to stop construction work at the clinker facility in eastern Uttar Pradesh in late May. Jaypee is on a major expansion drive and aims to raise its capacity to 35.5 million tons by the end of this financial year.

Hundung Resurrected The defunct Hundung Cement Factory may soon get a new lease on life as the state government has agreed to lease it out to a private firm. Officials gave the Super Ores

32 NOVEMBER/DECEMBER 2011

The new generation ECS process control solutions are based on the latest Microsoft .NET technology and the Microsoft Windows 7 64-bit operating system. The new technology enables flexible and rapid application development using cement plant specific intelligent objects. "The close relationship between the customers and our development team enables continuous innovation and is essential to maintain a competitive edge," says Global Product Manager, Joju Jacob.

Along with licensing the private company to re-establish the factory, the government has asked the private company to furnish its mining plan for leasing out the mining plant together with the defunct factory.

It is reported that the company has set a target of manufacturing 1500 metric tons of cement everyday, which is three times higher from its earlier target of 500 metric tons per day. BMWeek CemWeek CW Group Coal Week BMWeek BMWeek

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update

Pakistan, Bangladesh, Sri Lanka, Nepal & Bhutan: Sri Lanka The construction boom in Sri Lanka is fueling the cement market as the country moves to expand its cement capacity. One producer eyeing a return to the booming market is Sri Lanka Cement Corporation.

The company’s factory ceased operations in 1990 following the escalation of violence in the country. SLCC is currently studying several options including the restarting of production at Kankesanthurai.

The government approved the construction of a US $15.6 million cement plant

by Pakistan's Thatta Cement to be built in an industrial zone next to the Hambantota Port. Work on the plant is scheduled to start this month, and it is expected to be operational in the next 6 to 18 months.

Pakistan The Pakistani cement sector registered a turnaround profit of RS 2.54 billion in FY 2011—an accomplishment after experiencing a loss of RS 2.59 billion in 2010.

Sales volume had declined, but a 32 percent increase in prices helped to offset the drop. Sales revenues rose 14 percent to RS 115.6 billion in FY 2011. The biggest winners in terms of gains were Kohat Cement, Pioneer Cement, Fauji Cement, Dewan Cement, and Mustehkam Cement.

Cement manufacturers were quick to pass on input cost increases to consumers in order to secure their higher profit margins. As a result, cement prices continued to rise in Pakistan despite regulatory inter-

vention. Cement makers approached the government seeking approval to increase prices. Higher input costs, including rising electricity and fuel rates, were cited as factors for the desired increase.

Pakistan cement makers are hoping that a Most Favored Nation (MFN) status will hike exports to India. Local cement manufacturers believe that India is a place where they can offload their huge surplus productions, as their supplies are restricted against productions. Pakistan cement manufacturers have a combined installed capacity of around 44 million tons, whereas cement demand stands at around 31 million tons, leaving around 10 million tons of surplus capacity.

Bangladesh Bangladesh cement exporters are expecting higher export volumes to India. Cement exporters are looking at doubling exports of the construction materials to the northeast Indian states, known as the “seven sisters.” The news comes after India declared it would give duty-free access to all goods from LDC states in the Saarc region, including Bangladesh. Currently, around two lakh tons of cement are being exported to India annually. Industry insiders suggest the potential benefit would be visible in the upcoming construction season.

Global manufacturer Holcim is planning to expand its operation in Bangladesh.

According to a recent report, the company has entered into a deal with the Enexco Teknologies of the Beumer Group to launch a capacity expansion project that will begin commercial production in the middle of 2013. The expansion is expected to allow for the production of 7 lakh tons of cement a year, which will raise the company’s annual production to 2 million tons. BMWeek

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ndia’s roadways undergo a major face-lift with the assistance of foreign investors, while the government clears the way for the construction of industrial parks in several major states. Housing is also at the forefront as Mumbai-based Hiranandani Upscale and New Delhi-based Arbatec each expand into other major city markets.

NEW PROJECTS Road Ministry to Invest in Road Widening Projects The Road Transport Ministry is planning to invest 5.78 lakh crore in widening 55,000 km of highways across India by 2016. The ministry planned the move after realizing that only 23 percent of the total national highways in the country are four and six laned. The plan was undertaken with an eye to attracting foreign investors.

Several foreign firms have already shown an interest in working on this project, and some have formed joint ventures with Indian firms. For instance, South Korean firms are executing four roadway projects, whereas joint ventures of Indian-Dubai and Malaysian-Indian firms are working on three projects each. Indian-Russian firms are working on nine projects now, and Indian-Spanish firms are working on five projects.

Through August 2011, out of the 214 projects under the implementation of the National Highway Authority of India (NHAI), Indian firms with the participation of foreign firms were implementing 40

34 NOVEMBER/DECEMBER 2011

projects. Additionally, consultancy work has extended foreign firm participation to around 64 projects.

The Highway Minister of India, CP Joshi, also invited Chinese investors to participate in the road projects and has asked Chinese investors to invest an estimated 4,900 crore in the country’s mega road projects.

Vijaywada-Machilpatnam FourLaning Approved The Cabinet Committee on Infrastructure approved the four-laning project of the Vijaywada-Machilpatnam section of the NH 9 in Andhra Pradesh. The project is planned under the NJDP Phase IV-A on a DBFOT basis in BOT mode of delivery.

The total estimated cost of the four-laning of the highway is around 736 crore. From these funds, 130 crore will be set aside for land acquisition, rehabilitation and resettlement under pre-construction efforts.

The government plans to complete the project in two years.

The project is set in the Krishna district and, once completed, will reduce cost, time, and traffic congestion between Vijaywada and Machilipatnam.

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Birmitrapur-Barkote NH23 Approved The Infrastructure Committee approved the four-laning of the BirmitrapureBarkote section of the NH23 in Orissa under the National Highway Development Program (NHDP) Phase IV-A on a DBFOT basis in BOT mode of delivery.

The 1098.90 crore project when completed will benefit travelers going between Birmitrapur and Barkote. Of the 1098.90 crore allocated for the 125.65 km project, 320.75 crore will be used for land acquisition, rehabilitation and resettlement.

Premium Real Estate Projects Hiranandani Upscale has decided to set up a premium real estate project in the luxury housing segment at an investment of around 5,868 crore. This time, Hiranandani has decided to move away from its Mumbai base and is now planning to build luxury houses in other major cities such as Chennai, Hyderabad and Bangalore.

To expedite the housing plan, the company will utilize 500 crore of equity raised three years ago through a financial service company and intends to raise upwards of US $50 million from various real estate funds.

Construction materials: infrastructure & projects

DLF to Launch Major Projects Realty leader DLF is planning to launch new housing projects in major cities such as Bangalore, Gurgaon, Delhi, Chennai and Cochin to the tune of 1,500 crore.

One of the new housing projects already launched in October in Bangalore and cost an estimated 225 crore.

Under the project, DLF plans to offer 4 to 4.5 million sq. ft. plots for sale in cities such as New Chandigarh, Lucknow, Gurgaon and Panchkula. In total, the company plans to offer 7 to 8 million sq. ft. of plots for sale by the end of March 2012.

TRIL-PKNS Team Up The Mumbai-based Tata Realty and Infrastructure (TRIL) and the Malaysia-based realty major Selangor State Development Corporation (PKNS) have teamed up to build an affordable housing project within Mumbai. The cost of constructing the planned 1,000 housing units is not yet known. The project is geared to housing workers in the industrial growth areas and is considered one of a kind in India.

Mixed Use Delhi Projects Arbatec, builders of the famous Burj Khalifa in Dubai, and New Delhi-based Raheja Builders have formed a joint venture (JV) and are planning to construct three mixeduse projects in some of the major cities of India including New Delhi and Gurgaon.

The JV is said to be one of a kind in India, where the Dubai-based Arabtec holds a major stake of 63 percent.

The projects are expected to be completed in four years and will include a total investment of 1,000 crore. The JV is part of Arabtec’s strategy to diversify its activities and expand overseas operations beyond Dubai’s real estate sector.

Industrial Park Developments The government cleared the road for the construction of industrial parks in several

major states. The industrial parks will be set up in some major states of the country such as Maharashtra, Rajasthan, Gujarat, Andhra Pradesh, Himachal Pradesh, West Bengal, Tripura and Jammu and Kashmir.

The parks will be built through Public Private Partnerships (PPPs), and the government hopes to attract an investment of around 9,000 crore.

The work on 24 industrial parks has already started and has attracted a total investment of 18,800 crore. The government is planning to complete PPP textile park projects over the next three years and has already committed to providing a subsidy of around 40 crore for the construction of each park. The textile parks will be constructed under the Technology Upgradation Funds Scheme (TUFS).

New Steel Plant Deal Inked The construction of a steel plant by the state-owned National Mineral Development Corporation (NMDC) and the Russian-based Severstal is set to begin by 2017. The project is a 50:50 joint venture between India and Russia, which involves the construction of a plant that spreads over 2,800 acres of land at Bellary in the southern state of Karnataka.

The estimated cost of the plant is around 400 crore and would be funded on a 70:30 debt to equity ratio through the Indo-Russian partners. The project is the biggest Russian investment in the Indian steel sector to date and will involve some of the latest steel making technology.

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quipment updates

anadian-based Valiant Corporation opens operations in India. SCAFF expands its product offerings, introducing international products related to formwork, centering and scaffolding solutions to the market, and BEML introduces the Chinese mining industry to its high capacity equipment. more, it has a sound level as low as 66 dBA at 7 m.

The tower comes with special elliptical light fixtures that are able to diffuse and illuminate without glare. Furthermore, the factory-install light fixtures can be manually adjusted without tools.

The LTN 6L light tower is the first light tower to utilize a stamped 10-gauge steel tub base designed to provide superior strength and full protection from ground debris. The easy-to-service unit is also covered in a highly durable material that makes it virtually rust and dent proof.

First 350T Forging Crane Delivered Anupam Industries manufactured and supplied two of the first ever forging cranes with a 350/50T capacity to L&T Special Steel and Heavy Forging’s plant at Hazira in Gujarat. L&T intends to use the cranes for forging a heavy-duty turbine shaft.

The crane manufactured by Anmpam Industries is the first ever forging crane with a 350T capacity manufactured in

36 NOVEMBER/DECEMBER 2011

India. The cranes consist of large fabricated structures, electrical drives (E-room), high-end mechanical sub-assemblies, and PLC programming for smooth functioning and controlling.

Heavy Duty Lighting Tower Wacker Neuson is highlighting its new LTN 6L light tower product offering. The unit delivers exceptional lighting, yet requires less room to operate. Further-

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SCAFF India Solutions New-Delhi-based SCAFF India, which offers its services to high-end real estate developers and construction companies through its multi-location marketing and production facilities, is expanding into a Formwork, Centering and Scaffolding solutions line. With an eye to reducing labor and material input costs, SCAFF India is working to bring new high-tech products utilized in other countries to India.

SCAFF product offerings introduced to the Indian market include Austrian-based

BEML Unveils High Capacity Machines Indian heavy equipment manufacturer BEML recently unveiled several high capacity machines including dozers and dumpers in China. The equipment should assist China’s mining industry in accessing the country’s mineral reserves at greater depths.

Rapid expansion of China’s mining industry, current technological limitations associated with mining at deeper depths, and a demand for high capacity equipment has presented BEML with an opportunity to bring its products to China. However, BEML acknowledges it will face challenges with regard to strong competition from other new entrants as well as established firms such as Caterpillar and Komatsu.

Leeboy Launches Motor Grader Bangalore-based LeeBoy India Construction Equipment launched the first ever Motor Grader: the 785i. The Motor Grader is manufactured and engineered in India to international standards. The machine is a 12.4 ton, 150 horsepower proven workhorse that helps in leveling, ripping, cutting and spreading various types of roads and surfaces as per specifications.

focus Volvo Invests Heavily in India

Volvo Construction Equipment (Volvo CE), part of the Volvo Group, is looking to India to expand its equipment business. According to a Volvo CE executive, the company, which introduced the ‘Made in India’ excavators, is now looking at opportunities to launch its backhoe loader in the Indian market.

“Presently, Volvo does not have a backhoe loader in its portfolio for India. This is one product that is missing in our basket.

However, we are presently studying the Indian market for launching this product. We have no definite timeframe to bring it here and take a decision at an appropriate time,” Vincent Tan, president of Volvo CE, Asia Region said.

its operations in India. The company plans to serve the Asia Pacific region and provide solutions for welding and production automation systems throughout the region.

The company is putting special emphasis on working with the automotive industry.

Powerscreen Unveils Products Powerscreen is set to display the machines it manufactured in India at the 2011 Excon exhibition. Some of the equipment that the firm wants to unveil includes the Metrotrak Jaw Crusher, Chieftain 1400 and the 1000SR mobile plant.

The Metrotrak is a compact, high performance tracked mobile jaw crushing plant with an aggressive crushing action and a

Volvo is projecting 20 percent sales growth in India. The company is banking on continued strong activity in road building and real estate projects in 2012, as well as a possible resurgence of the mining sector to account for the growth level.

CEMENT: construction materials

Kauffmann HT-20 Plus Timber Beams, state-of-the art formwork solutions by Chinese distributor Beijing Zulin, and Turkish provider Neru Formworks revolutionary Tunnel Formwork for high-rise building resulting in casting of One Slab every day.

A M Muralidharan, managing director of Volvo India said, “We have just completed an investment program of Rs 90 crore in our Bangalore plant to manufacture excavators to meet the demand from the domestic market. Plans are in place to ramp up excavator production significantly next year, and this new development will see factory capacity tripling in 2012.”

high output at tight settings. The Metrotrak wants to suit the needs of the small to medium sized operators in mining, quarrying and recycling industries. The Chieftan 1400 is a compact, high production screen and is the most popular unit of the company to date. The 1000SR mobile plant combines the enhanced performance of the 1000 Maxtrak with a recirculating system and a double deck sizing screen all on an integrated chassis. This provides customers with a closed circuit screening plant, thus the need to use a separate screening. The company plans to present the benefits and features of this equipment to participants at the 2011 Excon Exhibition held November 24-27 in Bengaluru. BMWeek BMWeek BMWeek

This is just one of many future product offerings for the company in the coming six to eight months. These mostly include a 15-ton Motor Grader, a Backhoe Loader, a 22-ton Crawler Excavator and a range of Concrete Batching Plants and Asphalt.

Valiant-TMS Systems Comes to India Valiant-TMS Systems, a division of the Canadian-based Valiant Corporation, a company that provides global manufacturing and automation solutions, has started

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CONSTRUCTION materials

The Answer To India's Construction Woes May Be Ready-Made Growth in the prefabricated cement sector has the potential to revitalize construction markets

ndia has eagerly embraced innovation in healthcare, energy, finance, and government-why shouldn't the construction market evolve as well? With construction costs rising and delays lengthening, prefabricated concrete products are poised to meet market needs. “For centuries, we have seen the same traditional methods of construction being deployed,� complains Feroz Khan, Director of India-based Fabtech Sterling Building Technologies (Fabtech). His firm is a leading player in India's booming prefabricated construction market, but he's frustrated that the pace of growth isn't faster.

There's certainly a case to be made for evolution. Throughout India, builders struggle to keep pace with demand for new homes, offices, and industrial compounds.

Cost overruns are common, as are ongoing delays. No wonder the prefabricated and

38 NOVEMBER/DECEMBER 2011

pre-engineered concrete products industry grew by more than 30 percent over the last 12 months. An understanding of cement market basics and the unique elements of India's markets in particular leading up to a boom helps explain why, despite some consumer complaints, there is a major push by Fabtech and others to make prefabricated cement a bigger part of India's future.

Prefabricated Market Basics The prefabricated concrete market in India is still considered by many to be in its infancy. The market commands an annu-

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al business of Rs 2000 crore, which is not on its own an outstanding figure. However, analysts believe that if prefab building materials can gain acceptance in even a fraction of India's planned projects, the market could leave its 30 percent growth rate behind in favor of a 10-fold increase.

Caveats to this potential growth rate do, however, hinge on acceptance and taxes. Currently, acceptance of prefabricated concrete products is spreading, but it is by no means universal. Urban and upscale markets are less welcoming than commercial and rural sectors, which have eagerly

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embraced prefab. The industry also benefits from a tax exemption for concrete products that are prefabricated on site, lowering the cost of use for builders. The relative costs and novelty of the product make it an item of interest whose full potential remains to be seen.

Why PreFab Booms Now Fabtech and others believe that the potential of prefab will be realized sooner rather than later due to the combined issues of time, money, and people facing India.

Unlike previous five-year plans, the coming plan faces a serious time crunch to meet goals, a lack of funding due to the global economic downturn, and a major lack of skilled laborers to complete construction ventures. Only one product can overcome all three of those challenges at once: prefabricated concrete.

Prefabricated concrete products take less time to install than similar structures made in the traditional model. Thanks to their tax status, they also cost less to buy, helping to address the ongoing cost overruns that currently plague the industry. Prefabricated products have even more financial advantages when factoring in their laborer friendly status; installation of prefabricated concrete takes fewer people and less skilled labor than building from scratch.

This allows talent scarcity to be less of an issue in pushing a project through to completion, particularly in rural areas.

Cautious Support This is not to say that everyone is a fan of prefabricated products. Many still view the products with suspicion, worried about their quality and disdainful of their overall aesthetic in the upper echelons of the construction market. Industry players like Khan refer to this as a “psychological barrier” in leaving behind brick and mortar construction. However, critics are having a hard time continuing their stance as more data about prefabricated products emerges.

It seems when the numbers are added up, prefabricated products are cleaner, greener, and leaner than the competition. In terms of cleanliness and health safety, using prefabricated products eliminates the mess and health risks of most construction dust, sealants and adhesives, pegged as the leading causes of indoor pollution. From an ecological perspective, prefabricated concrete products can contain a significant percentage of recycled plastic and composite cement boards and be molded to imitate wood without harming old-growth forests. The products are also lean, using less material overall in a building than brick and mortar while simultaneously requiring fewer human inputs, conserving more resources and time overall. This trifecta is winning over all but the staunchest critics and building purists.

Future Growth Potential The future growth potential for prefabricated concrete products is an undefined upward curve. While early forays into India's markets have focused on commercial office structures and rural residential developments (1500 and 500 crore of the market, respectively), the key growth sectors ahead are industrial and urban. The lower health hazards in building and availability of non-seamed flooring have made prefab popular in the healthcare sector, while housing shortages are bringing the speed of prefabricated construction materials to the forefront in urban housing considerations. Major projects in both areas are a part of the next plan, opening the door for prefabricated concrete to grow even more.

26

Dispatches & Production Ambuja Cement reported that its sales rose 1.7 percent in October to 1.78 mm tons and production climbed 1.81 million tons from 1.75 million tons a year earlier.

Dalmia Cement's cement production fell by ten percent to 3.85 lakh tons and dispatches fell by 15 percent to 3.73 lakh tons in October. The company’s subsidiary, OCL India, reported a 0.5 percent fall in the cement production to 2.95 lakh tons and a 2.4 percent dip in the cement dispatches to 2.95 lakh tons in October. From April to October 2011, Dalmia Cement recorded 14 percent growth in the cement production at 30.49 lakh tons, while the dispatches also grew by 14 percent to 30.33 lakh tons.

focus CCIL to Double Capacity

The Cement Corporation of India reported it would double its capacity at its Bokajan unit in the Northeast. Company sources said the expansion was necessitated by the fact that there had been considerable rise in the demand for cement in the domestic as well as export sectors.

A comprehensive study of demand for cement, prepared by the National Council of Applied Economic Research, had revealed that the cement demand in Assam was likely to rise to 3.05 million tons by 2010/2011. The report projected an additional increase of 0.45 million tons, if the region’s economic growth rate was eight percent.

The firm has already turned in the environmental impact assessment report for the Bokajan factory capacity upgrade project, and the ground is set for a public hearing — a prerequisite for the project to get environmental clearance.

India's construction woes don't have to continue. A solution is waiting, and it's a ready-made problem solver. By moving past the psychological barriers and traditionalist holdouts against prefabriThe estimated cost of the project, aimed cated products, India can speed the pace at enhancing the present 600 tons per day and lower the cost of its building projects, capacity of the plant to 1,200 tons per day, making up for lost time and bringing the is Rs 142.4 crore. whole country forward more efficiently. BMWeek CemWeek CW Group Coal Week BMWeek BMWeek

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profile

Ambuja Cements Building Efficiencies through Strategic Development

arotam Sekhsaria and Suresh Neota founded Ambuja Cements Ltd (ACL), formerly Gujarat Ambuja Cements Ltd, in 1983. Cement production began in 1986, with current production capacities standing at 27 million tons per annum (mtpa) across five integrated manufacturing plants and eight cement grinding units. The company is known as one of the most efficient producers in India, a reputation it is improving upon annually with new shipping capacity, private power generation, and clinker developments.

New Partner Dirk India FY 2011 growth has been sluggish compared to previous years, but ACL is currently in an expansive mode when it comes to partnerships. The company, already in a major partnership arrangement with the Swiss-based global cement firm Holcim, acquired a 60 percent stake in Dirk India for RS 16.51 crore in September 2011.

While the partnership with Holcim helped expand ACL's global reach, the partnership with Dirk India speaks directly to ris-

40 NOVEMBER/DECEMBER 2011

ing raw materials costs and supply chain issues facing the industry as a whole.

with other manufacturers and the national government.

Dirk India, a processed fly ash manufacturer, has a daily fabrication capacity of 2,500 tons, and ACL will be taking their stake in the form of equity with both Dirk and subsidiary Dirk Pozzocrete being folded into existing units of ACL. This will provide the firm with first line access to necessary raw materials and bring in new revenue streams through Dirk's existing contracts

Other major developments within ACL will help the firm address ongoing logistical challenges. ACL is unique among Indian cement producers in that it has its own captive port for shipping, with three dedicated terminals on the western coastline and seven ships serving the current supply.

Three more ships (one delivered, two en route) are being added, with full integra-

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Cement Plant Annual Capacity (mn tons)

COMPANY

CAPACITY (MTPA)

Gujarat

6.70

Himachal Pradesh/ Punjab

6.10

Rajasthan

2.80

Chhattisgarh/ West Bengal

4.30

Maharashtra

3.60

Uttar Pradesh

1.50 Source: Ambuja Cements Ltd.

Currently, ACL is working at about 80 percent utilization. Net sales are estimated to be 8.5 percent higher for 2011 compared to 2010, though dispatch levels have not been consistent month to month, as some analysts had expected. The launch of the 12th five-year plan and several new real estate projects in the northern regions are expected to improve both consistency in sales and overall profitability in the coming quarters.

tion expected by the end of 2011. Adding these ships is expected to improve operational efficiency and lower overall operational costs.

ACL's clinker and shipping expansions have not yet translated into increased volumes and cost savings, nor have they been fully accounted for in analysts' estimates.

More Capacity, More Power In addition to the added shipping capacity, ACL is expanding its private clinker capacities and power generation programs.

ACL has commissioned new clinkers at Bhatapara and Maratha and is increasing its clinker capacity in Rajasthan, bringing total capacity from 25 mtpa to 27 mtpa and eliminating the need for ACL to purchase expensive outside clinker as it did in 2010.

The firm is also in the process of reducing its dependency on outside power sources by commissioning 66 MW of captive power generation in 2010: 33 MW for Bhatapara and 33 MW for the plant at Ambuja Nagar. When these power generation plants and clinkers fully come online, they will help the firm to control costs and margins moving forward.

The Bottom Line Even so, it is broadly suggested that these adjustments may be enough to offset the unpredictable raw materials charges and rising fuel costs plaguing the industry. The 30 percent Coal India price hike, fully realized in the 2nd quarter, led to an 11 percent decline in ACL's reported bottom line, but did not significantly impact analyst optimism for the firm's future. Fiscal year 2012 and 2013 estimates show a return to net profit margin growth (from the current 15.4 percent estimate to 15.8 percent) and a nearly ten percent increase in net sales.

The fresh link with Dirk India will only likely enhance these numbers.

This cost control will be a significant factor for ACL over the next few years. The company's operations are concentrated in the north and west regions of the country, where supply expansions have been met with softening demand. Most analysts suggest the current demand lull is a temporary side effect of the end of the 11th fiveyear plan and the global market downturn, but maintaining margins and building further efficiencies will be crucial for ACL as it strives to maintain a positive bottom line while long-term demand recovers.

sion investments and capacity improvements. The decision to build on its ability to offset fuel prices and raw materials costs through enhanced internal logistical infrastructure systems and strategic partnerships with raw materials suppliers such as Dirk India shows a savvy reading of the market. These developments will be critical advantages for the firm as it seeks to maintain a profitable balance and bottom line while expanding its capacity and footprint in the global cement markets. BMWeek BMWeek BMWeek

Looking ahead, ACL appears well positioned to make the most of its 2011 expan-

A L Kapur MD Ambuja Cements Ltd

INSTALLED CAPACITY (mtpa) 30

15

0

CY2008

CY2009

CY2010

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analyst recommendations ACC Despite a strong performance in the third quarter that saw realizations improving by 11.5 percent YoY and revenue improving by 13.3 percent YoY, 12 percent higher costs in production shrank profit margins, curtailing EBITDA growth to 29.7 percent.

However, higher income from other sources and lower tax rates raised net profit by 67.5 percent to Rs 1.67 billion. While cost pressures continue to play a role, the hike in cement prices is expected to offset this imbalance. With a favorable growth projection for CY13, Emkay has recommended ‘Accumulate’ for ACC with a price target of Rs 1,290 against a CMP of Rs 1,184.

While net sales for ACC went up 31 percent YoY, the EBITDA margin fell below ICICI estimates owing to higher expenses and poor demand in the third quarter that was further compounded by a fall in cement prices. Despite a YoY increase in sales volume as newly commissioned capacities increased production and a YoY increase in realizations, QoQ figures remained low. ICICI has recommended a ‘Hold’ on ACC with a target price set as Rs 1,105 against a CMP of Rs 1,184. ambuja cement Third quarter results indicate a better than expected performance with EBITDA that rose by ten percent YoY to Rs 3.11 billion against an estimated Rs 2.9 billion, while

cement realizations improved by seven percent leading to a 15.4 percent hike in revenues, despite lower volumes. Additionally cement prices are expected to revise upwards in the coming days. With renewed interest in infrastructure and housing projects, profitability for the company is set to look up, though the new mining tax may increase production costs by Rs 80 per ton. Emkay has remained neutral on Ambuja Cement with a ‘Hold’ recommendation and a price target has been set as Rs 165 against a CMP of Rs 157.

Lower demand and higher costs played havoc with QoQ statistics in realization and EBITDA, though Ambuja Cement managed to post a seven percent hike in realizations in YoY analysis. As EBITDA figures also dropped by five percent YoY, ICICI has recommended ‘Hold’ with price target set as Rs 144 against a CMP of Rs 155.

ICICI has given the green signal for India Cements with a ‘Buy’ recommendation despite lower sales figures, as blended realizations increased by as much as 45 percent in the wake of product discipline introduced by the company to offset the increase in costs. As a result, EBITDA per ton and OPM increased significantly. The price target recommended is Rs 84 against a CMP of Rs 71.

BROKER

COMPANY

RATING

TARGET PRICE

CURRENT MARKET PRICE

2-Nov-11

ICICI

ACC

Hold

1105.00

1184.00

2-Nov-11

Emkay

ACC

Accummulate

1290.00

1184.00

2-Nov-11

ICICI

Ambuja Cement

Hold

144.00

155.00 157.00

3-Nov-11

Emkay

Ambuja Cement

Hold

165.00

17-Nov-11

ICICI

India Cements

Buy

84.00

71.00

21-Nov-11

ICICI

JK Cement

Buy

123.00

99.00

3-Nov-11

Angel

JK Laxmi

Buy

52.00

43.00

11-Nov-11

Emkay

Madras Cement

Hold

125.00

116.00

9-Nov-11

ICICI

Mangalam Cement

Buy

139.00

103.00

14-Nov-11

Emkay

Shree Cement

Accummulate

2400.00

2025.00

14-Nov-11

ICICI

Shree Cement

Buy

2246.00

2025.00

42 NOVEMBER/DECEMBER 2011

Despite a QoQ decline, YoY figures showed promise with realizations that went up by 17 percent, leading to a hike in EBITDA despite rising production costs. ICICI gave a ‘Buy’ recommendation, setting a price target as Rs 123 for JK Cement against a CMP of Rs 99. jk lakshmi Higher dispatches in the second quarter and improved realizations lead to a robust operating margin. Despite an increase in production cost, JK Lakshmi managed a 48.9 percent hike in operating profits and an increase of 14.1 percent in bottom line figures. With strong prospects for improved sales, Angel Broking predicts a 12.9 compounded annual growth rate for top line earnings in FY12-13 and has given a recommendation of ‘Buy’ with a price target of Rs 52 against a CMP of Rs 43.

india cements

ratings changes DATE

jk cement

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madras cement Strong realizations that surpassed expectations despite lower sales volume led to an increase in revenue and a higher EBITDA for Madras Cement. While production cost increased marginally on account of an increase in freight expenses, this is expected to be offset by an upswing in cement prices that will positively impact FY12E. However, with lower sales and higher costs, Emkay has recommended a ‘Hold’ for Madras Cement with a price target of Rs 125 against a CMP of Rs 116. mangalam cement ICICI has recommended a ‘Buy’ for Mangalam Cement with a price target of Rs 139 against a CMP of Rs 103 on the rationale that YoY realizations and EBITDA increased though QoQ figures posted a decline owing to poor demand and increased costs.

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35

ONGOING PROJECTS Vizag Port Project Closer to Completion Leighton Welspun Contractors recently completed 70 percent of the upgrade work on the Vishakhapatnam Port. The project involves a 21-meter extension of the existing berth towards the sea, conducting stockyard soil improvements, building a conveyor gallery, administration and terminal operation development, and stockyard soil improvement.

shree cement With higher realizations and EBITDA that towered above expectation and lower power costs, Emkay has recommended an ‘Accumulate’ for Shree Cement. While cost of production also increased due to an increase in the cost of raw materials, the company was able to achieve a nine percent YoY growth in cement volumes and a 13.3 percent increase in realizations. As cement prices revise upwards and demand picks up, Shree Cement is expected to post strong profit margins. Moreover, the company is also set to rake in additional revenue from the expected sale of power to various SEBs. The price target has been set at Rs 2,400 against a CMP of Rs 2,025.

Leighton Welspun Contractors started working on the project as an SPV joint venture in November of last year and is expected to finish in October 2012. The overall estimated cost of the project is 500 crore.

UPDATES HCC Given Clearance The Union Environment Ministry of India gave the nod to the Hindustan Construction Company to continue its construction of a township at Lavasa, located near Pune, Maharashtra. The Lavasa Lake City project is India’s first planned city spread out over 2,000 hectares (ha) of area. It is expected to be built at an estimated cost of 3,000 crore.

The HCC had previously started the construction of 681.27 ha of the 2,000 planned ha but had to halt construction after the state government of Maharashtra filed a criminal case against the firm alleging a violation of the green laws. After an extensive review, approval for the project to continue came with 47 conditions that must be followed during construction and another ten to be implemented during the operational phase.

While YoY analysis shows improved cement sales that went up by seven percent and realizations that improved by 15 percent, QoQ statistics suggest a muted performance, largely due to poor demand.

Similarly, despite a QoQ dip of nine percent in EBITDA/ton, YoY statistics indicate an increase of 38 percent. As such ICICI recommends a ‘Buy’ for Shree Cement with a price target of Rs 2,246 against a GMR to Raises Funds Coal Week CMP of Rs 2,025. BMWeek CemWeek CW Group GMR Infrastructure is planning to underCemWeek CW Group Coal Week BMWeek the 555-km Kishangarh-AhmedabadCemWeek BMWeek CW Group take Coal Week

Udaipur road project worth 6,000 crore.

The project will involve six-laning the existing four-lane road. The highway project was one of the largest highway projects bid out by the National Highway Authority of India (NHAI) in July 2011 and is a part of the proposed Delhi-Mumbai Industrial Corridor. The company is planning to raise funds for the project through domestic loans.

Upgrade to Mumbai Region Infrastructure The government of Maharashtra is set to invest 2.74 lakh crore in the regeneration of Mumbai’s infrastructure. The Mumbai makeover will bring a large investment in roads, railways, the water supply, power, transport, and rental housing. Around 54 percent of the planned investment is going to come through public-private partnerships (PPP) and other modes.

The plan is set to be implemented in three phases and is expected to be completed by 2031. The government plans to complete the first phase by 2016, the second by 2021, and the third by 2031. The project would bring 24 new metro corridors connecting 17 towns in the Mumbai urban region, as well as construction of new townships in the 12 growth areas of the capital city.

Funding of around 43,000 crore is already committed, and projects worth 10,000 crore are in the pipeline.

Gujarat Gets a Theme Park The Gujarat Industrial Development Board and Gujarat Tourism Board have paved the way for the construction of a theme park in Gujarat. The project is awaiting the nod of the Gujarat government, which is also set to come in the next weeks. The theme park will be constructed at an estimated cost of 200 crore in Surat by the Mumbaibased Atlanta Infrastructure. The theme park will spread across 13 square kilometers. The first phase of the construction is set to begin in April 2012. BMWeek CemWeek

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stock performance Stock performance of leading cement companies As a regular service to our readers, we will provide here a listing of the latest in stock performance, keeping you up to date with the latest in stock trends. Additional company stock performance information is available on our website: www.cemweek.com/india.

Performance in the past 90 days Company

Start Date

Start Price

End Date

End Price

Difference

% Change

Top advancers MADRAS CEM

2-Sep-11

86.55

1-Dec-11

111.75

25.2

29.12

SHREE CEMENT

2-Sep-11

1668.35

1-Dec-11

2098.85

430.5

25.8

ACC LTD

2-Sep-11

1015

1-Dec-11

1170.75

155.75

15.34

AMBUJA CEME

2-Sep-11

135.35

1-Dec-11

149.2

13.85

10.23

PRISM CEMENT

2-Sep-11

40.25

1-Dec-11

44.25

4

9.94

INDIA CEMENT

2-Sep-11

67

1-Dec-11

72.95

5.95

8.88

ULTRATECH CM

2-Sep-11

1100.1

1-Dec-11

1163.15

63.05

5.73

JK LAKSHMI

2-Sep-11

39.65

1-Dec-11

41.5

1.85

4.67

CHETTINAD CEM

2-Sep-11

460

1-Dec-11

475.35

15.35

3.34

RAIN COMMODI

2-Sep-11

29.05

1-Dec-11

29.9

0.85

2.93

SAGAR CEM.

2-Sep-11

133.5

1-Dec-11

137.2

3.7

2.77

DECAN CEMENT

2-Sep-11

145.05

1-Dec-11

148.45

3.4

2.34

N C L IND

2-Sep-11

34.7

1-Dec-11

34.95

0.25

0.72

OCL INDIA L

2-Sep-11

92.85

1-Dec-11

93.45

0.6

0.65

Top Laggards PANYAM CEMEN

2-Sep-11

51.9

1-Dec-11

42.5

-9.4

-18.11

BIRLA CORPOR

2-Sep-11

316.9

1-Dec-11

261.7

-55.2

-17.42

HEIDEL CEM

2-Sep-11

33.65

1-Dec-11

28.9

-4.75

-14.12

MANGALAM CEM

2-Sep-11

101.85

1-Dec-11

92.9

-8.95

-8.79

KAKATIYA CEM

2-Sep-11

69.35

1-Dec-11

65

-4.35

-6.27

KEERTHI

26-Aug-11

40.75

24-Nov-11

38.5

-2.25

-5.52

KALYANPUR CE

10-May-11

25.6

28-Sep-11

24.35

-1.25

-4.88

JK CEMENT

2-Sep-11

107.4

1-Dec-11

102.85

-4.55

-4.24

KCP LTD

2-Sep-11

25.9

1-Dec-11

25.7

-0.2

-0.77

44 NOVEMBER/DECEMBER 2011

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Most popular on CemWeek.com The most-read stories on CemWeek over the past two months reflect the industry's mixed outlook. The India column shows the 20 most popular stories from CemWeek featuring India-related coverage, and the Global column shows the global events that gathered the most attention worldwide during the period. Visit CemWeek.com to access the full stories.

India

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

global

Aditya Birla in talks with Jaypee India: Jaypee Cement greenfield plant faces hurdles Sources: Century to merge cement unit with Ultratech Cimpor rumored to be close to India acquisition Report: Jaypee looking to sell off part of cement business India: ACC may launch environment friendly cement next year India cement capacity utilization dips in H1 India cement makers start hiking prices post monsoon Ultratech Cement to build unit in West Bengal India: Maharashtra signs off on new plant Report: India cement consumption to remain sluggish India's ACC sets 5% alt fuels target India's Dalmia cement production off, denies acquisition Indian cement industry seen to have positive outlook India's Prism gets nod for AP plant Ambuja, Holcim merger allowed S&P maintains positive stance on India cement industry JK Cements to hike capacity to 5.5 mm tons GP Goenka to divest Andhra stake Binani to hike cement prices Jaypee Group to take over Andhra Cement Reliance orders line from Polysius India India cement prices increase India's Dalmia on the lookout for fresh acquisitions Workers missing after industrial accident in India

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Argos closes acquisition of Lafarge US assets Report: Votorantim, Camargo near carve-up of Cimpor Dangote unveils plans to build railways to transport cement Holcim mulling offering board seat to Russian group Lafarge maintains leadership position CRH might purchase shares of Basel Cement Italcementi to upgrade Rezzato plant Chinese firm to build cement unit in Mozambique Lafarge to undergo reorganization Dangote to set up new unit in Ethiopia Cementos Portland puts Giant Cement unit on the block Holcim Brasil orders world’s largest vertical roller mill PPC, Nova Cimangola bid for Congo's CINAT Votorantim lines up funding to buy Cimpor Eurocement to install new plants in Russia Lafarge reorganization may hit workforce Report: Major Holcim stakeholder to hike share Cimpor Egypt awards upgrade contract US: Lafarge to close down Fredonia plant Cemex hopes to strengthen ties to Anhui Conch Accident kills one in Egyptian cement plant Sinoma completes project in Vietnam Saudi Cement acquires 40% of Kuwait cement firm Cimpor confirms new Morocco unit Canada: Colacem seeking permit for new plant

INDIA CEMENT & CONSTRUCTION MATERIALS MAGAZINE

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