September 2026
Bringing complex things into focus. For 165 years.
Contains AI-generated content
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CONTENTS
03 Comment 05 News
REGIONAL REPORT: NORTH AMERICA 10 Modernising For Tomorrow Amrize reveals how it is modernising operations across Canada to improve efficiency, expand capacity, and deliver lower-carbon building materials for tomorrow’s infrastructure. 16 From Carbon Targets To Concrete Reality Justin Dickey, Cemex US, explores how early-stage collaboration and the use of blended cements and supplementary cementitious materials are enabling lower-carbon concrete for hyperscale data centre construction. COVER STORY: GRINDING & MILLING 23 Powering Performance With Wear Protection Stephan Vilbusch, thyssenkrupp Polysius GmbH, explores how long-life compound cast rollers support stable HPGR grinding and underpin reliable, high-performance plant operation. ADDITIVES & ADMIXTURES 28 Clinker Cutback Chemistry Alejandro Velez, Sika Services AG, RymKenza Belhaj, Sika Maroc SA, and Mohsen Ben Haha, Sika Technology AG, explore how integrated chemical additives and process optimisation strategies enable clinker reduction while maintaining cement performance and efficiency.
CONDITION MONITORING & PREDICTIVE MAINTENANCE 43 The Connected Conveyor Code Elise Morse, Regal Rexnord, explores how connected conveyor technologies, predictive maintenance, and integrated reliability strategies are helping cement producers reduce downtime and turn data into actionable performance gains. LOW CARBON CEMENT 47 Building Better With Blended Cement CalPortland outlines how natural pozzolan-based blended cements can reduce clinker content while maintaining concrete performance and durability across large-scale infrastructure projects. 52 Plant Potential Unlocked Daniel Kopp and David Gersholowitz, Queens Carbon, explain how plant-compatible technologies and engineered cementitious materials can help producers scale lower-carbon cement production using existing infrastructure. 58 The Business Case For Low Carbon Cement Ryan Gilliam, Fortera, explores the business case for scaling low-carbon cement and explains why commercial execution will define the next phase of cement decarbonisation.
33 Siloxane Strength Solutions Dr. Wei Cai, Jim Greene, and Liang Jia, Wacker Chemical Corporation, examine how siloxane-based admixtures enhance moisture resistance and durability in lower-carbon cementitious systems. ELECTRIFICATION 39 Electric Economics Dr. Nate Weger, Pauliina Meskanen, and Dr. Fox Thorpe, Calectra, explore how thermal energy storage can convert low-cost, off-peak renewable electricity into affordable process heat, unlocking new economic and decarbonisation opportunities for cement producers.
September 2026
ON THE COVER Bringing complex things into focus. For 165 years. More process expertise. More engineering strength. More operational excellence. More value across the lifecycle of industrial assets. This is what has defined Polysius for 165 years. And this is only the beginning.
Bringing complex things into focus. For 165 years.
Contains AI-generated content
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COMMENT
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Annual subscription (published monthly): £160 UK includingpostage/£175 (€245) overseas (postage airmail)/US$280 USA/Canada (postage airmail). Two year subscription (published monthly): £256 UK including postage/£280 (€392) overseas (postage airmail)/US$448 USA/Canada (postage airmail). Claims for non receipt of issues must be made within 4 months of publication of the issue or they will not be honoured without charge. Applicable only to USA and Canada: WORLD CEMENT (ISSN No: 0263-6050, USPS No: 020-996) is published monthly by Palladian Publications, GBR and is distributed in the USA by Asendia USA, 17B S Middlesex Ave, Monroe NJ 08831. Periodicals postage paid at Philadelphia, PA and additional mailing offices. POSTMASTER: send address changes to World Cement, 701C Ashland Ave, Folcroft PA 19032 Copyright © Palladian Publications Ltd 2026. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the copyright owner. All views expressed in this journal are those of the respective contributors and are not necessarily the opinions of the publisher, neither do the publishers endorse any of the claims made in the articles or the advertisements. Uncaptioned images courtesy of Adobe Stock. Printed in the UK. Palladian Publications Ltd 15 South Street, Farnham, Surrey GU9 7QU, UK Tel +44 (0)1252 718999 Email: mail@worldcement.com Website: www.worldcement.com
September 2026 World Cement
I
DAVID BIZLEY, SENIOR EDITOR
t seems that barely a day now passes without some new AI-related controversy appearing in the news. Particularly popular at the moment are the breathlessly reported stories from companies like Anthropic or OpenAI, etc., that reveal in hushed, conspiratorial tones how their latest AI model has managed to ‘escape’ containment and commit various misdemeanours online. Now, as marketing campaigns go, I get it: “Our AI is too clever to be controlled” is a cool hook (even if it is basically demonstrating the product failing to work as intended), but have none of these people seen Terminator? Perhaps Skynet has sent a humanoid robot back from the future to set up a guerrilla marketing agency… It’s also true that I’m not the kind of big Silicon Valley tech guru smart enough to turn US$1 of revenue into US$4 of costs, but has nobody over there considered cutting off internet access to the machines hosting these truant models? There are also concerns about the environmental impact, primarily focused around the gargantuan resources demanded by the datacentres that keep it all running. Utah, for example, recently approved construction of a datacentre twice the size of Manhattan that will use more electricity than the entire state (up to 9 GW) and rely on water supplies already stretched by years of drought. One analysis has estimated that the waste heat generated by the facility will raise temperatures in the immediate area by as much as 2.7˚C during the day and 6.6˚C during the night. So much for ‘keeping 1.5 alive’… Then there’s the question of copyright, and the rather unpleasant fact revealed through court filings that at least one major AI company has been buying, scanning, and destroying books (including rare and antique editions) by the million to train its models. And, most recently, the governor of the Bank of England, Andrew Bailey, has warned G20 finance ministers that rogue or misused AI could threaten global financial stability and presents a major cybersecurity risk to financial systems, particularly as (ironically) more and more economic growth is centred on a relatively narrow band of AI companies. I have yet to work out whether Bailey is engaging in guerrilla marketing or not. Yet, despite the feeling that we’re living through a bit of a digital Wild West, AI continues to have increasingly valuable, tangible, real-world impacts, including in the cement sector. It’s also worth noting that AI companies aren’t a monolith and that the questionable actions of some (despite making for compelling reading) don’t represent them all. AI and machine learning technologies are already helping cement producers optimise their processes in ways that were previously unimaginable. From managing the complex and ever-changing dynamics of the kiln to supporting maintenance programmes, AI is already delivering measurable improvements in efficiency, reliability, and cost. To find out more about the good that AI is doing, register free-of-charge for Optimisation 2026, World Cement’s virtual conference on 29 October, which looks at the cutting-edge technologies driving the future of cement production: worldcement.com/events/optimisation-2026 With that to look forward to, I thought it would be appropriate to end on this quote from Sarah Connor: “The unknown future rolls toward us. I face it, for the first time, with a sense of hope.” 3
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NEWS
First hydrogen combustion test completed at Austrian cement plant
The production of cement clinker, the main component of cement, requires temperatures of 1450˚C and thus a significant amount of fuel. For many years, Rohrdorfer has relied on alternative fuels in its cement plants to reduce carbon dioxide (CO2) emissions. Another potential contribution to decarbonisation is the use of hydrogen (H2) from renewable sources – so-called ‘green H2’ – as a fuel. H2 combustion in kiln operations is technically challenging and has not yet been extensively tested in the cement industry. To gain its own operational experience with this new energy source, the Rohrdorfer Net Zero Emission team has conducted a large scale H2 combustion test on the cement clinker kiln at the Gmunden site, Austria. Unlike all conventional fuels, the combustion of H2 produces no CO2. As a result, CO2 emissions from the combustion process could be significantly reduced, depending on the proportion of H2 in the fuel mix. Since mid-2023, Rohrdorfer has therefore been conducting preparatory work for a pilot test. In early July 2026, preparations were completed, and the first H2 combustion test at an Austrian cement plant was carried out. Over two days of testing, part of the kiln’s heat output was covered by the co-firing of H2. During the test, the gaseous fuel proved to be fundamentally well-suited for use in cement clinker production. The H2 was supplied via truck trailers by Linde, a leading global industrial gas and engineering company, which developed a special mobile gas unloading station specifically for the trial. Florian Wesenauer, Project Manager for the H2 trial at Rohrdorfer, commented: “With this trial, we want to demonstrate that the use of so-called green H2 is a potential decarbonised alternative in the fuel mix of the future. However, economic viability is not yet foreseeable; the costs for this H2 are currently still many times too high.” When the price will drop to a competitive level depends on many factors and cannot be predicted at this time.
Limak Cement opens its low carbon cement Mediterranean terminal Limak Cement has commenced operations at its Low Carbon Cement (LCC) Mediterranean Terminal in Iskenderun, Türkiye. September 2026 World Cement
Developed in line with the company’s sustainability and high-quality vision, the new terminal will strengthen the international dispatch of Limak Cement’s high-performance products. Equipped with environmentally-focused, highly-automated infrastructure, the terminal entered operation on 19 July 2026 with its first shipment of low-carbon bulk cement to Italy. S. Mete Turan, Group Foreign Trade and Business Development Manager at Limak Cement, responded: “Our strategy is to minimise our carbon footprint at every stage, from production through to dispatch, and with the Limak Cement LCC Mediterranean Terminal we are taking environmental standards in our sector to the highest level. Completed to strengthen our company’s presence in low-carbon production and export markets, the new terminal will enable us to deliver our high-performance products to markets worldwide, combining durability, high quality, and strong environmental attributes.” Limak Cement developed the new terminal as part of its broader international market strategy, with a particular focus on Europe and countries across the Mediterranean Basin. In response to growing global demand for sustainable construction materials, the Limak Cement LCC Mediterranean Terminal is expected to improve the efficiency of export logistics while optimising operating costs. Designed for an annual throughput capacity of approximately 500 000 t, the facility will initially handle the storage and export of low-carbon, high-performance bulk cement produced at Limak Cement’s Kilis Plant. Depending on future operational requirements and planning, export activities from the Sanliurfa Plant will also be supported through the terminal. The Limak Cement LCC Mediterranean Terminal has commenced operations with three silos and 7500 t of storage capacity. Once all phases of the project are complete, the facility will comprise eight silos with a total storage capacity of 20 000 t. Advanced automation at the Limak Cement LCC Mediterranean Terminal is designed to minimise environmental impacts while enabling digital, loss-free, and real-time monitoring of dispatch operations. Cement transfer, from pneumatic conveying lines to air slides and screw conveyors, takes place within fully enclosed, sealed systems, preventing contact between the product and the external environment. During silo filling, displaced pressurised air passes through high efficiency pulse-jet filters before clean 5
DIARY
NEWS
Carbon Capture Global Summit 22 – 23 September, 2026 London, UK carboncaptureglobalsummit.com POWTECH TECHNOPHARM 2026 29 Sept. – 01 Oct., 2026 Nuremberg, Germany www.powtech-technopharm.com Slag & Ash Trade EMEA 2026 14 – 15 October, 2026 Madrid, Spain www.gmiforum.com/conferences Carbon Capture Technology World Expo 20 – 22 October, 2026 Hamburg, Germany www.carboncapture-expo.com
29 October, 2026 Virtual Conference www.worldcement.com/events/ optimisation-2026/ AUCBM AICCE29 23 – 25 November, 2026 Cairo, Egypt www.aucbm.net TÜRKÇİMENTO 01 – 05 December, 2026 Antalya, Turkey https://teknikseminer.com.tr
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air is released to the atmosphere. At the loading stage, telescopic double wall loading spouts and simultaneous dust extraction systems capture displaced dust-laden air under vacuum, preventing it from escaping into the surrounding environment. Level sensors at the ends of the loading spouts automatically stop the flow to prevent potential overfilling and dust generation. Together, these systems provide a cleaner and safer working environment while supporting product quality and the terminal’s sustainability objectives.
Sinoma EC Completes VICEM Haiphong Waste Heat Power Generation Project Sinoma EC has successfully completed all performance tests for the waste heat power generation EPC project of VICEM Haiphong Cement Company Limited and obtained the Provisional Acceptance Certificate (PAC), marking formal provisional handover of the facility. The whole project was fully delivered within the contracted 13‑month schedule. The EPC contract for the 6 MW waste heat power unit was officially signed at a ceremony held in Haiphong on 12 February 2025. Covering full‑scope engineering design, equipment supply, civil construction, erection, commissioning and performance guarantee obligations, the project sets a guaranteed net power output target of no less than 4.37 MW. Commissioning of the waste‑heat power station brings tangible operational gains to VICEM Haiphong. The recovered thermal energy is projected to satisfy 20 – 30% of the cement plant’s on‑site electricity demand. In accordance with the industry roadmap issued by the Vietnam Cement Association, all clinker production lines with a capacity of 2500 tpd and above are required to install waste heat recovery facilities. This retrofit enables VICEM Haiphong to meet local regulatory requirements while optimising overall energy‑related operating costs. As a landmark reference for Sinoma EC in Vietnam’s cement industry, the Haiphong project represents the country’s first cement production line equipped with Chinese‑origin waste‑heat recovery solutions. The 13‑month fast‑track turnkey execution and smooth PAC validation prove the strong adaptability and replicability of China‑developed waste heat recovery technologies for retrofitting ageing cement production lines across Southeast Asia. With the waste heat power facility now provisionally accepted, both parties have expressed willingness to explore further cooperation on new‑energy business streams, including photovoltaic power generation and energy‑storage projects.
Qassim Cement gets US$107 million for new production line Saudi Arabia’s Qassim Cement Company has signed a SAR 400 million (US$107 million) financing agreement with the Saudi Industrial Development Fund (SIDF) to support the construction of a new production line at its cement plant. World Cement September 2026
NEWS
The financing, completed on 13 August 2026, has a nine-year term, including a two-year grace period followed by seven years of repayments. The fourth production line is planned to have a capacity of 10 000 tpd and will replace certain existing production lines. The project is intended to improve energy efficiency and environmental performance. Qassim Cement said it plans to combine the SIDF financing with Sharia-compliant credit facilities from commercial banks to meet its funding requirements and reduce financing costs. The project was first announced by the company in August 2025.
Cemex supports landmark redevelopment in London Global building materials solutions supplier, Cemex, has supplied a high-quality, lower-carbon concrete for the sustainable redevelopment of 65 Crutched Friars – a transformational 20-storey former office building in the City of London, delivered by Consarc Architects and main contractor, McAleer & Rushe Contracts UK Ltd for real estate developer and operator, Dominus. Following demolition of the office block to basement level, the new 65 Crutched Friars will be a landmark mixed-use development, comprising a basement, ground floor with 20 upper storeys, reaching a height of 61 m. This imaginative residential scheme creates a distinctive blend of culture and community space in a prominent urban setting, located north of Fenchurch Street Station and the Tower of London. The development was shaped by a clear sustainability ambition, with a target of achieving a Building Research Establishment Environmental Assessment Methodology (BREEAM) Outstanding rating – the highest tier of the BREEAM, representing the top 1% of UK buildings for sustainability. This over-arching goal placed a critical emphasis on reducing embodied carbon, while continuing to meet the demanding structural and programme requirements. Construction of 65 Crutched Friars consists of a reinforced concrete basement and superstructure frame with a prefabricated unitised façade. Cemex delivered 13 000 m3 of lower carbon concrete which included slipform operations of approximately 1000 m3 slab pours. Post-tensioned concrete and steel frameworks were deployed to further bolster the strength and support. 8
The lower-carbon concrete solution, CEM II/A-L combined with GGBS, was specially selected to meet the project’s carbon requirements and wider sustainability ambitions. For the C40/50 floor slabs, Cemex supplied CEM II/A-L with 25% GGBS as an addition, further helping to reduce embodied carbon while meeting the required structural performance criteria. The introduction of this new lower carbon concrete marked Cemex’s first high-profile use of CEM II/A-L on a major project in the City of London. James Drobka, General Commercial Manager Cemex UK, commented: “Working closely with McAleer & Rushe and Ian Black Consulting early in the project helped us to develop a high-performance solution, which delivers a specialist lower carbon concrete to meet the critical BREEAM rating. A successful working relationship enabled us to supply a seamless service across the project through to completion, despite the challenging site conditions. Cemex is dedicated to reducing carbon where we can, and to helping clients and main contractors achieve their sustainability goals, combining product innovation with dependable delivery and proactive technical support.” Connor Graham, Purchasing Director, McAleer & Rushe, noted: “In addition to meeting the project’s rigorous sustainability objectives, 65 Crutched Friars occupies a tight urban corner plot, with limited site access – this presents many technical and logistical challenges. Meticulous planning and collaboration with Cemex enabled us to balance the project’s sustainability objectives with the practical high demands of the building’s construction.” Through the delivery of 782 purpose-built student accommodation rooms, the site will also include designated museum space providing the new permanent home of London’s Migration Museum. Additionally, both blue and green roofs have been incorporated. The student units are further complemented by green spaces with a new pocket park and accessible roof terrace. The existing building contained some features of historic value to the City of London, including two Friars Statues mounted to the façade, which were carefully removed and will be incorporated into the new external landscaping. Construction of 65 Crutched Friars is progressing towards practical completion in 2027, with the scheme scheduled to welcome students for the 2027/28 academic year. World Cement September 2026
Sustainability Isn’t New for Us — It’s Continuous. • Low-carbon cement & concrete • Circular solutions that reduce waste • Renewable energy & alternative fuels • Environmental leadership • Leading with science www.calportland.com
Amrize reveals how it is modernising operations across Canada to improve efficiency, expand capacity, and deliver lower-carbon building materials for tomorrow’s infrastructure. he Canadian cement industry is undergoing a period of rapid transformation. Rising infrastructure demand, ambitious low-carbon targets, and increasing expectations around domestic manufacturing are driving investments in the next generation of building materials production facilities.
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Across the country, Amrize is modernising operations to improve efficiency, expand capacity, and deliver lower-carbon materials capable of supporting tomorrow’s infrastructure. In Québec, one of the industry’s most significant investments is helping redefine what modern cement manufacturing can look like in Eastern Canada. Located approximately 25 km south of Montréal, the Amrize Saint-Constant plant has supplied cement for some of Québec’s most important infrastructure projects for more than seven decades. The facility is now entering a new chapter. In June, Amrize broke ground on the modernisation of the Saint-Constant cement plant – the largest investment in the Canadian cement industry in more than a decade. Once complete, the project will transform the facility
Groundbreaking ceremony at Amrize Saint-Constant Cement Plant. From left to right: Jacques Ramsay, MP for La Prairie-Atateken and Parliamentary Secretary to the Minister of Public Safety; Nollaig Forrest, CMO & Corporate Affairs, Amrize; Jaime Hill, President, Amrize Building Materials; The Honourable Nathalie Provost, MP Chateauguay-Les Jardins de Napierville and Secretary of State; Daniel Vadacchino, Saint-Constant Plant Manager.
Quebec flag and Canadian flag at Amrize Saint-Constant cement plant. 12
into the most advanced and sustainable cement plant in Eastern Canada, extending its operational life by more than 50 years and strengthening local manufacturing capacity to help meet Québec’s growing demand for lower-carbon building materials. The modernisation reflects broader trends shaping Québec’s construction market and Canada’s cement industry. Increasing infrastructure investments, the need for resilient domestic supply chains, and the industry’s ongoing sustainability transition are creating new opportunities – and expectations – for cement producers across North America.
A construction market on the rise
Québec is entering one of the most significant periods of infrastructure investment in its recent history. Governments at both the provincial and federal levels recently announced plans to invest nearly CAD$10 billion over the next decade to expand public infrastructure, transportation networks, healthcare facilities, and housing. The scale of these investments is expected to drive sustained demand for cement and concrete products across the province for years to come. At the same time, Canada’s construction industry continues to evolve. Population growth, urbanisation, and increasing project complexity are reshaping market requirements, while sustainability considerations are influencing procurement decisions across both public and private sector projects. For cement manufacturers, these market dynamics present a unique challenge: increasing manufacturing capacity while simultaneously reducing emissions and improving operational performance. Cement remains one of the most essential materials used in modern construction. From housing developments and public transit projects to bridges, airports, and energy infrastructure, virtually every major project relies on a secure and reliable supply of cement and concrete. With a legacy of building Québec for more than 70 years, Amrize has helped shape many of the province’s most important landmarks and infrastructure projects. Cement produced at the Saint-Constant plant has contributed to projects such as the Robert-Bourassa Generating Station, the Montréal Metro Blue Line, the Samuel Champlain Bridge, the Île-aux-Tourtes Bridge, Montréal-Trudeau International Airport, and Place des Montréalaises, among many others. World Cement September 2026
These projects demonstrate the critical role that locally manufactured cement continues to play in supporting Québec’s economic growth and infrastructure ambitions. As the province enters a new era of development, advanced manufacturing capabilities will be essential to ensuring access to the materials needed to support future growth.
A next-generation cement manufacturing facility
The Amrize Saint-Constant plant modernisation project represents a significant investment in the future of cement manufacturing in Québec. The project will fundamentally transform the plant’s clinker production process, replacing the facility’s two existing kiln lines with a single modern kiln line capable of producing the same amount of clinker as the current two lines combined. The new system will include a preheater, pre-calciner tower, and new tooling system, as well as a new vertical raw mill to feed the kiln. By optimising the clinker production process, the new kiln line will convert ground limestone and additives into clinker more efficiently and in a shorter timeframe compared with the
existing production lines, improving operational performance while supporting the plant’s long-term sustainability objectives. The project will introduce state-of-the-art, high-efficiency technologies designed to improve production, energy performance, storage capabilities, and logistics operations. In addition, hundreds of integrated sensors throughout the facility enable smart, data-driven plant management, allowing operators to optimise performance, improve efficiency, and support more agile manufacturing processes. In addition to modernising core production capabilities, Amrize’s investment will increase the speed and scale of advanced cement processing, enabling the production of high-performance, customised cement formulations designed to meet the evolving requirements of infrastructure and construction projects. Once complete, the modernisation will increase production capacity by 300 000 tpy, bringing the plant’s total capacity to 1.2 million tpy, which will help strengthen local cement supply as infrastructure and construction demand continues to grow across Québec and Canada. The modernisation will also expand cement storage capabilities at the Saint-Constant facility. Currently, Amrize relies on terminals located in Montréal’s east end to support distribution. Adding storage capacity directly at the plant will help streamline logistics, reduce transportation requirements, and lower associated emissions from material hauling. The project will also grow the plant’s workforce by 25%, reinforcing the importance of investing not only in technology but also in the skilled talent required to operate the next generation of manufacturing facilities.
Advancing the sustainability transition
Aerial view from Amrize Saint-Constant cement plant. 14
Decarbonisation remains one of the defining challenges – and opportunities – for the global cement industry. As governments, customers, and project owners pursue ambitious climate objectives, cement producers are investing in cleaner technologies and more efficient manufacturing processes to reduce their environmental footprint while maintaining performance standards. World Cement September 2026
Canada has emerged as an important market for industrial decarbonisation initiatives, supported by strong collaboration between government and industry. The Amrize Saint-Constant modernisation project is supported by the Government of Canada through the Low-Carbon Economy Fund(LCEF), as well as by the Government of Québec through the ÉcoPerformance programme and the Support Measure for the Decarbonisation of the Industrial Sector (MADI), two initiatives stemming from Québec’s 2030 Green Economy Plan and funded through the Québec carbon market. The modernisation is expected to improve the facility’s net carbon footprint by more than 40% by 2035, positioning it to deliver the lowest carbon emissions per tonne of cement in Eastern Canada. The modernised facility will also be engineered to co-process alternative fuels and raw materials, allowing it to repurpose approximately 150 000 tpy of materials and to avoid up to 2 million t of landfill-related emissions over its lifecycle – further supporting Québec’s transition toward a more circular and lower-carbon economy. These improvements highlight the increasingly interconnected relationship between sustainability and manufacturing excellence. Investments in lower-carbon cement production are no longer being pursued independently of operational improvements. Instead, manufacturers are integrating sustainability objectives directly into plant modernisation strategies.
Innovation beyond the plant
Innovation remains a critical component of the cement industry’s long-term success. Located in Montréal, Amrize’s Saint-Laurent laboratory serves as the company’s primary cement and concrete innovation hub in North America. The laboratory supports the development and testing of next-generation cement technologies and formulations designed to address evolving customer and market requirements. Research initiatives include evaluating recycled materials and emerging lower-carbon solutions that have the potential to further reduce the environmental footprint of cement and concrete manufacturing while maintaining the performance characteristics required for infrastructure applications. The proximity between Amrize’s Saint-Laurent laboratory and the Saint-Constant cement plant creates an integrated ecosystem of research, technical expertise, and advanced manufacturing capabilities. This connection allows research and development activities to be translated into large-scale production solutions, supporting September 2026 World Cement
customers with tailored cement and concrete formulations for increasingly complex construction and infrastructure projects.
Strengthening local manufacturing
Recent global supply chain disruptions have reinforced the strategic importance of domestic manufacturing capabilities for essential construction materials. Reliable access to domestically manufactured cement remains essential to delivering major infrastructure projects efficiently and sustainably. The Saint-Constant modernisation project reinforces the role that local manufacturing plays in Québec’s construction ecosystem. In addition to expanding production capacity, the investment supports local jobs, strengthens regional supply chains, and increases the availability of locally manufactured cement products. As part of this commitment, Amrize plans to offer “Manufactured in Québec” cement from the Saint-Constant facility, guaranteeing that production, from raw materials and processing to final manufacturing, is carried out within the province.
Building the next generation of cement manufacturing
The modernisation of the Amrize Saint-Constant cement plant represents more than a facility upgrade. It is a long-term investment designed to extend the plant’s operational life and strengthen Québec’s manufacturing capabilities for generations to come. The future of cement manufacturing will be defined by investments that successfully combine operational excellence, sustainability, innovation, and domestic manufacturing capabilities. As infrastructure demand continues to grow across Québec and Canada, modern cement plants will play an increasingly important role in supporting economic development and advancing lower-carbon construction. Projects such as the Saint-Constant plant modernisation demonstrate how strategic investments can simultaneously strengthen production capacity, improve environmental performance, and enhance supply chain resilience. By bringing together innovation, sustainability, and local manufacturing, the Saint-Constant modernisation project offers a compelling example of what the future of cement manufacturing can look like in Canada. As Québec prepares to build the homes, hospitals, transportation networks, and critical infrastructure that will define its next chapter, investments such as these will play an essential role in delivering the lower-carbon, high-performance building materials needed to support generations of growth. 15
Justin Dickey, Cemex US, explores how early-stage collaboration and the use of blended cements and supplementary cementitious materials are enabling lower-carbon concrete for hyperscale data centre construction. 16
he expansion of AI is creating one of North America’s most active construction sectors. While the digital economy is often discussed in terms of software and data streams, its infrastructure depends on a massive physical footprint. Behind every hyperscale data centre is a substantial investment in power distribution, cooling systems, connectivity, and structural concrete. For the cement and concrete industry, this growth represents more than a shift in
material volume. Many of the technology companies leading data centre development have established specific corporate commitments to reduce embodied carbon across their portfolios. As a result, discussions regarding cement composition, environmental product declarations (EPDs), and regional material availability are entering project planning much earlier than has historically been the case. Cemex is increasingly seeing owners engage directly with material producers during the
early design phases. Rather than treating concrete simply as a downstream commodity, developers want to understand what level of global warming potential (GWP) reduction is practically achievable within a specific market, and how those material decisions might influence mixture performance, cost, and the construction schedule. Supporting this market requires managing two connected operational challenges: maintaining the rapid delivery schedules required by hyperscale construction timelines
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while identifying predictable pathways to lower the carbon intensity of the concrete supplied.
Shifting toward early-stage collaboration
The traditional construction procurement sequence can place multiple layers between the owner and the material producer. Typically, an owner establishes project requirements, the design team translates those requirements into structural specifications, the general contractor bids the project, and the ready-mix producer is engaged at the end of the chain to supply a conforming product.
Aerial view of a hyperscale data centre campus with supporting power and cooling infrastructure.
While this linear process works for standard projects, it becomes inefficient when managing specific embodied-carbon targets. Carbon optimisation cannot easily be treated as a product substitution made shortly before construction begins. By the time a concrete specification is locked and the project schedule is established, many practical material options may no longer be logistically or technically viable. This is why data centre developers are increasingly participating in early material selection. Many hyperscale owners now utilise dedicated engineering and sustainability teams to evaluate cement types, supplementary cementitious material (SCM) replacement levels, and product-specific environmental data well ahead of procurement. From a producer’s perspective, early engagement allows for a more comprehensive technical discussion. It provides the runway to outline which materials are available in a given market, how those materials can be combined to reduce GWP while maintaining required performance, and what performance trade-offs may accompany those choices. Crucially, it provides the necessary time to evaluate alternative binders, confirm regional supply chains, and conduct laboratory and field trials before full-scale production begins. The intent is not for the material producer to dictate the project's sustainability goals, but rather to help translate corporate carbon objectives into a constructible mixture that can be reliably manufactured, transported, and placed under actual field conditions.
Balancing global targets with regional supply constraints
A crane lowers a tilt-up concrete wall panel into position during data centre construction.
A large-scale data centre campus comprises multiple facilities and supporting infrastructure. 18
Although an owner's corporate sustainability objectives are typically standardised across a national or global portfolio, cement and concrete supply chains remain highly regional. Ready-mix concrete must be produced within a practical transit distance of the job site to ensure workability and performance. Furthermore, the availability of cement types and SCMs is strictly governed by local manufacturing capabilities, terminal networks, transport logistics, and existing market demand. Aggregate characteristics also vary significantly by source, directly impacting water demand, chemical admixture response, and total cementitious content. Consequently, a carbon-reduction strategy that proves successful in one market may be considerably more difficult to implement in another. A project framework designed for Atlanta cannot automatically be applied to a project in Phoenix or Reno. One region may
World Cement September 2026
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have consistent, cost-effective access to slag or fly ash, while another may rely more heavily on portland-limestone cement (PLC), natural pozzolans, or intensive aggregate optimisation. Local climates and regional construction practices also dictate specific setting times, early strength development, and finishing requirements that must be respected. Regional benchmarks and EPDs reflect the baseline materials and industrial practices already established within a specific market. A uniform percentage-reduction mandate may appear consistent on paper, but the technical pathway to achieve it will vary by location. Owners must therefore maintain a distinction between a common carbon objective and a uniform material recipe, allowing producers the flexibility to optimise mixtures based on local infrastructure and material realities.
Leveraging scalable, existing technologies
A significant portion of the public conversation around cement decarbonisation centres on emerging technologies, such as carbon capture, utilisation, and storage (CCUS), novel alternative binders, and completely new manufacturing processes. While these innovations are critical
Crews construct the concrete foundation and structural frame of a large data centre facility.
to the industry’s long-term transition, hyperscale data centres are actively being designed and constructed now. Project teams cannot rely entirely on technologies that have not yet achieved broad commercial scale or regulatory acceptance. The industry currently possesses several proven tools that can reduce embodied carbon immediately: f Blended cements. Utilising formulations like portland-limestone cement to lower clinker content while maintaining standard structural performance. f SCM utilisation. Replacing a portion of traditional portland cement with fly ash, slag, or calcined clays. f Aggregate optimisation. Engineering particle size distribution to improve packing density and minimise water and paste demand. f Chemical admixtures. Deploying advanced water reducers and performance enhancers to maintain workability while optimising total cementitious content. The engineering challenge lies in balancing these tools within a reliable production system. For instance, high SCM replacement levels can extend setting times and slow early strength gain while also potentially extending conventional psi acceptance ages. On fast-tracked data centre projects with tight, repetitive slab-placement cycles, these delays can disrupt the construction schedule if not properly managed. A binder formulation that performs well in a controlled laboratory must still prove compatible with local aggregates, admixtures, and batching equipment under field conditions. Implementing these solutions also requires operational adjustments at the ready-mix plant. Introducing alternative materials often requires dedicated storage silos, revised handling procedures, and updated quality-control protocols. Plant personnel must be trained to manage these variables consistently, and contractors frequently require comprehensive field mock-ups to gain confidence in the handling and finishing characteristics of a modified mixture before major structural pours begin.
Evaluating system-wide SCM availability
Multiple phases of construction take place across an expansive data centre campus. 20
Fly ash and slag have supported clinker reduction efforts for decades, but they are not available in unlimited quantities. The ongoing retirement of coal-fired power generation plants has structurally reduced the production of fresh fly ash in many North American markets. While harvested ash from legacy economic stockpiles represents a significant alternative resource, reclaiming and processing it requires substantial capital World Cement September 2026
investment and time to develop. Similarly, slag availability remains constrained by regional steel production, import terminal capacity, and demand across the broader concrete market, including infrastructure, commercial, and industrial construction. As demand for lower-carbon concrete grows within the hyperscale market, it raises an important system-level consideration. A specific project may successfully lower its reported embodied carbon by securing a high volume of a constrained local SCM. However, if that material is simply diverted away from an adjacent project that must then use standard portland cement, the net regional carbon reduction is not increased. To achieve meaningful, widespread decarbonisation, the industry must expand the qualified cementitious material supply base. Natural pozzolans, ground glass, and calcined clays represent important pathways forward, but their adoption depends on consistent production volumes, technical qualification, and dependable distribution networks. The scale of the data centre market can help accelerate this transition; large developers can provide the predictable, long-term demand signals needed to justify producer investment in these emerging material supply chains.
Analysing the economics of material optimisation
It is occasionally assumed that lower-carbon concrete mixtures should inherently cost less because certain SCMs were historically priced below portland cement. In the current market, this assumption no longer applies. Elevated demand, extended transportation distances, specialised chemical admixture packages, and the capital expenditure required for plant storage modifications mean that lower-carbon concrete formulations can carry a cost premium. Evaluating the economic case requires looking beyond the line-item cost of the concrete package in isolation. Hyperscale data centres are highly capital-intensive facilities where the primary expenditures are driven by advanced computing equipment, specialised cooling systems, and electrical infrastructure. While structural concrete represents a modest percentage of the total capital investment, cement-related decisions impact a significant portion of the project's upfront embodied carbon. When viewed from an asset-lifecycle perspective, optimising the concrete mixture can offer a practical, cost-effective carbon mitigation strategy relative to the overall facility cost. Rather than treating carbon reduction as a rigid pass-or-fail metric, project teams should evaluate cost, carbon intensity, technical risk, and schedule impact concurrently. This balanced analysis allows owners to determine where material investments 22
yield the most reliable performance and carbon returns.
Operational execution at scale: a Houston case study
A Houston AI-ready data centre project provides a practical example of how these considerations come together. The project required approximately 45 000 yd³ of concrete, with some placements pumped through roughly 400 ft of delivery system. The challenge was not limited to one material or performance requirement. The team needed to develop a concrete system that could be produced consistently while supporting pumping, placement, strength development, and long-term performance across a large volume of work. Early coordination allowed the project team to evaluate the cementitious materials, aggregate grading, fibres, and chemical admixtures as one complete system. Rather than making isolated product substitutions, the team considered how each material decision would affect production and field performance. The broader lesson is that lower-carbon and performance objectives are most effective when they are addressed early and validated under actual project conditions. For large data centre projects, early collaboration can help convert broad owner requirements into a concrete mixture that can be reliably produced, transported, and placed.
Conclusion: turning ambition into implementation
The digital economy may be driven by computational capacity, but its build-out remains dependent on physical industrial materials and regional supply chains. For the cement and concrete industry, the growth of the hyperscale market provides a clear opportunity to demonstrate that industrial-scale sustainability can be executed under rigorous commercial conditions. The technical tools required to lower embodied carbon are already available. The primary challenge is coordination and execution across the value chain. Producers must provide transparent information regarding regional supply limitations, designers must author flexible, performance-based specifications that permit local optimisation, contractors must participate in early testing to build field confidence, and owners must engage the supply chain early enough for producers to plan and respond. The ultimate value the material industry can offer to the technology sector is not merely supplying increased volume but helping turn corporate carbon goals into predictable, constructible, and economically viable reality. World Cement September 2026
Stephan Vilbusch, thyssenkrupp Polysius GmbH, explores how long-life compound cast rollers support stable HPGR grinding and underpin reliable, high-performance plant operation. ement producers worldwide face increasing pressure to maximise equipment availability, improve operational efficiency, and reduce lifecycle costs. As one of the most energy-efficient grinding technologies, high pressure grinding rolls (HPGRs) (Figure 1) play a key role in achieving these objectives. In general, the long-term performance of each grinding equipment depends heavily on the condition of its grinding tools. While wear protection is often regarded as a maintenance issue, it also directly affects process performance. For an HPGR, changes in roller surface condition can influence material
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draw-in, pressure distribution, throughput, and energy consumption, ultimately affecting grinding efficiency and plant availability. This article examines the relationship between roller surface wear and process performance and highlights how compound cast roller technology helps maintain stable grinding conditions over extended operating periods. By combining exceptional wear life with high reliability, compound cast rollers enable cement producers to improve operational stability and maximise the value of their HPGR installations.
The hidden cost of roller wear
In a lot of applications, roller surface wear is primarily evaluated from a maintenance perspective. Plant operators typically focus on direct costs such as reprofiling, roller refurbishment, or replacement, and
the associated labour expenses. Although these costs can be substantial, they represent only a fraction of the actual economic impact of roller wear throughout the equipment lifecycle. The more significant costs are often hidden within day-to-day performance. As roller surface wear progresses, the geometry and surface condition of the rollers gradually deteriorate, which negatively affects material draw-in behaviour, reduces gripping efficiency, and changes the pressure distribution across the roller width. Over time, these changes can lead to lower throughput, higher circulating loads, less consistent product quality, higher specific energy consumption, and reduced grinding efficiency, often long before major maintenance becomes necessary. These performance losses accumulate gradually and remain unnoticed, creating a significant hidden/indirect cost that can have a larger impact if the intervals between major roll maintenance are short. Considering the combined costs of direct and indirect impacts of roller surface wear, it becomes clear that choosing the optimal roller wear protection is critical for maximising plant performance and minimising lifecycle costs.
Roller condition and process performance
Figure 1. Integrated HPGR.
Figure 2. Grinding principle of a HPGR. 24
The performance of an HPGR is determined by the interaction of machine design, operating parameters, and the condition of the grinding rollers. While grinding pressure, feed characteristics, and process control are considered key drivers of HPGR performance, the roller surface is often overlooked and is viewed as a maintenance-related issue. In reality, it is a key factor influencing grinding performance. The primary function of an HPGR is to create a stable and highly compressed material bed between two counter-rotating rollers. Efficient comminution depends on effective draw-in of feed material and consistent grinding pressure distribution across the roller width. As the primary interface between the machine and the feed material, the roller surface condition and geometry directly influence these operating conditions and ultimately affect the overall HPGR performance. A well-maintained roller surface promotes reliable material draw-in and stable bed formation (Figure 2), allowing the grinding force to be transferred efficiently into the particle bed. As a result, the HPGR can operate close to its design parameters, delivering stable throughput and efficient energy utilisation. As wear progresses, however, changes in roller geometry and surface characteristics can reduce efficiency and alter pressure distribution within the grinding zone. The resulting performance losses are often gradual and may manifest as declining World Cement September 2026
throughput, increasing specific energy consumption, and greater process variability. The consequences extend beyond the HPGR itself. Changes in the HPGR product, such as different particle size distributions and/or less fines generation, influence separator efficiency, circulating loads, and the performance of downstream grinding equipment. Maintaining stable and effective roller surface conditions is, therefore, essential to ensuring stable and efficient operation of the entire grinding circuit. These requirements have driven the development of advanced wear protection concepts such as compound cast roller technology, which combines exceptional wear life with sustained grinding performance.
Compound cast technology: engineering for long-term reliability The ability to maintain stable HPGR performance over many years depends largely on the wear
Figure 3. Compound cast roller prior to dispatch.
protection concept applied to the grinding rollers. While conventional forged and hard-faced rollers require frequent refurbishment to compensate for wear and fatigue-related degradation, compound cast technology was specifically developed to maximise service life while preserving the mechanical integrity of the roller throughout its lifecycle. The concept combines two material properties that are difficult to achieve in a single material. The outer wear layer is manufactured from a highly wear-resistant cast material designed to withstand the severe abrasive conditions typically encountered in raw material and cement grinding. Beneath this layer, a ductile core provides the toughness and structural strength required to absorb operational loads, including occasional impacts from tramp material. Both materials are metallurgically bonded during the casting process, creating a robust roller body capable of handling the demanding conditions of continuous HPGR operation. Unlike conventional solutions, where fatigue can become a limiting factor over time, the operational experience of more than 500 sold compound cast rollers (Figure 3) has shown that wear remains the primary life-limiting mechanism. This shifts the maintenance strategy from frequent repair activities toward predictable and planned inspections. As a result, service intervals can be significantly extended, more than 80 000 hours of operation for some operations, as long as the equipment is operated according to the manufacturer’s operation and maintenance instructions. The benefits extend beyond wear resistance. By preserving the original grinding surface over extended operating periods, compound cast rollers help maintain stable operating conditions and consistent comminution performance. This enables the HPGR to operate closer to its design performance for a much longer period compared to conventional wear concepts. Compound cast technology was developed to combine outstanding wear service life and structural reliability while minimising the impact of wear on process performance. This allow sfor long-term plant availability, stable operating conditions, and predictable production, while reducing the frequency and extent of maintenance activities related to roller surface wear protection.
Proven performance and reliable operation worldwide
Figure 4. Compound cast roller after 80 000 hours of operation. 26
The track record of this wear technology is both extensive and well documented. The accumulated operational experience demonstrates not only exceptional wear life and structural reliability, but also the ability to maintain consistent grinding performance and plant productivity throughout the roller's service life. The benefits of long-lasting HPGR rollers extend far beyond reduced wear rates and lower spare World Cement September 2026
part consumption. Their greatest value lies in enabling stable and reliable operation over extended periods of time. Every maintenance intervention introduces operational disruption. Production must be interrupted, resources allocated, and equipment recommissioned. Even well-planned maintenance activities can lead to temporary variations in operating conditions and process performance. Consequently, the frequency of required interventions has a direct impact on plant availability and operational stability. By maintaining their surface and structural integrity, compound cast rollers significantly reduce the need for refurbishment and repair activities. Fewer maintenance shutdowns allow operators to maintain consistent throughput, predictable grinding performance, and higher equipment utilisation throughout the lifecycle of the HPGR. These benefits become particularly valuable in remote or resource-constrained regions, where maintenance activities often present significant logistical challenges. Conventional wear protection concepts frequently depend on specialised welding crews and regular hardfacing campaigns, requiring extensive planning and mobilisation efforts. In locations where qualified maintenance personnel are hard to find, shutdown durations can increase considerably, resulting in additional production losses and operational uncertainty. Long-life compound cast rollers minimise this dependence on external resources by extending service intervals and reducing the frequency of major maintenance activities. As a result, operators can focus on production optimisation rather than planning their shutdowns for maintenance works. Ultimately, the value of long-lasting rollers is not only measured by the number of operating hours achieved, but by the stability and reliability they provide throughout those hours. By reducing maintenance requirements while maintaining consistent operating conditions, compound cast technology helps cement producers maximise availability, improve operational reliability, and sustain process performance, regardless of plant location. As an example, a cement grinding application in Europe has accumulated more than 80 000 operating hours since commissioning, while requiring only two major maintenance shutdowns. Even after this extended operating period, inspections revealed only limited wear and a substantial remaining service life. Similar results have been achieved at cement plants in the Middle East, Americas, Asia, and other regions, where rollers have accumulated years of operation while maintaining their functional surface characteristics and requiring only minimal maintenance interventions. Such a remarkable September 2026 World Cement
service record highlights the long-term durability and reliability of the compound cast wear protection technology under demanding operating conditions. It is noteworthy that such results are achieved not only through robust equipment design but also through disciplined operation and maintenance. The commitment of the plant personnel to consistently follow the manufacturer’s operation and maintenance recommendations is a key factor in maximising the service life. Although operating conditions differ from one plant to another, the practical advantages have proven consistent across installations. Extended wear life reduces the frequency of unplanned shutdowns and helps avoid interruptions in the operation. It also decreases reliance on specialised maintenance resources while allowing operators to maintain stable grinding conditions through the service life of the rollers. As a result, operators benefit not only from lower maintenance costs but also from increased plant availability and more predictable production performance. These references highlight an important aspect of modern wear protection strategies: the greatest value is not necessarily achieved through maximum wear resistance alone, but through the ability to maintain process performance over an extended period. By combining long service life with stable operating characteristics, compound cast rollers help transform wear protection from a recurring maintenance challenge into a long-term contributor to plant reliability, operational efficiency, and lifecycle profitability.
Conclusion
Wear protection in HPGR applications should no longer be regarded solely as a maintenance issue. The condition of the roller surface directly influences grinding efficiency, throughput, product quality, process stability, and ultimately plant availability and overall performance. By maintaining roller geometry and surface characteristics over extended operating periods, compound cast rollers help preserve stable grinding conditions while significantly reducing maintenance requirements and production interruptions. The result is consistent process performance, improved operational reliability, and lower lifecycle costs. The value of a wear protection system should therefore not be measured only by its service life, but by its ability to sustain the performance of the entire grinding circuit. In this respect, compound cast rollers represent a true process-performance upgrade. In modern HPGR operation, the most effective performance upgrade may not be a new machine, but a wear solution that allows the machine to operate at peak performance for decades. 27
Alejandro Velez, Sika Services AG, RymKenza Belhaj, Sika Maroc SA, and Mohsen Ben Haha, Sika Technology AG, explore how integrated chemical additives and process optimisation strategies enable clinker reduction while maintaining cement performance and efficiency. 28
he cement industry is undergoing a profound transformation in response to decarbonisation pressures, rising costs, and increasing global demand. The urgent need to reduce CO2 emissions, reinforced by stricter regulations and carbon pricing, is a primary driver. At the same time, rising energy and production costs, combined with an increase in global cement demand, are pushing producers to improve efficiency and optimise resource utilisation. As clinker production accounts for most of the emissions associated with cement manufacturing, one of the most effective levers is reducing clinker content. In parallel, the use of supplementary cementitious materials (SCMs), such as limestone, pozzolans, and
calcined clays (CC), enables both environmental and economic benefits by lowering CO2 emissions. However, the transition towards high-SCM cements presents significant technical and operational challenges, particularly regarding reactivity, variability, and process stability. Addressing these challenges requires more than simply replacing materials. An integrated approach combining advanced chemical solutions, process optimization, and data-driven strategies is required. This article explores how the synergy between chemistry and process optimisation enables cement producers to successfully implement clinker reduction while maintaining performance, efficiency, and sustainability.
SCMs as a decarbonisation driver
SCMs offer a practical and scalable solution for reducing clinker content and lowering the environmental footprint of cement. Cement manufacturers can substantially reduce CO2 emissions by partially replacing clinker with locally available SCMs. Slag Slag, a by-product of the steel industry, remains one of the most efficient SCMs for reducing clinker content. It normally offers attractive economic benefits and delivers superior performance compared to other SCMs, particularly long-term strength and durability. Its availability is linked to the geographical location
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of steel production, and the increasing pressure to decarbonise the steel sector may further constrain supply. Limestone Limestone is one of the most accessible and widely distributed raw materials. It is characterised by its chemical stability and minimal processing requirements. This makes it a particularly cost-efficient and sustainable SCM. At low substitution levels, limestone has a positive effect on early strength development through its filler properties. However, at higher replacement levels, the dilution effect may dominate, potentially reducing strength unless compensated by optimised grinding conditions or the use of performance enhancer additives. Pozzolanic materials Pozzolanic materials can partially replace clinker and contribute to hydrating reactions. Only specific deposits with sufficient amorphous content and purity are suitable for cement production. The use of pozzolanic cements is already well established in different regions and is becoming more relevant due to increasing CO2 constraints. However, their effective use remains challenging due to variability in composition, limited reactivity and
inconsistent availability. This requires careful control of the production process and formulations. Calcined clays Calcined clays, especially those in combination with limestone (so-called LC³: limestone calcined clay cement), represent a major advance in sustainable cement technology. LC³ systems typically consist of 50% clinker, 30% calcined clay, 15% limestone, and 5% gypsum. Using calcined clay significantly reduces the demand for clinker while relying on widely available, cost-effective raw materials. Additionally, clay calcination requires lower processing temperatures than clinker production. Despite these advantages, the increased use of SCMs also introduces variability and performance challenges that must be addressed to ensure consistent cement quality: Early-age reactivity One of the most significant limitations of SCM-rich cements is their lower inherent reactivity compared to clinker. As the SCM content increases, its contribution to early hydration decreases, often resulting in a significant reduction in early-age strength. This can make it difficult to meet performance requirements, especially in applications where fast strength development is essential. Material performance Natural pozzolans and calcined clays can vary considerably depending on their geological origin, mineralogical composition, and processing conditions. This variability impacts cement performance and makes industrial production more difficult.
Example of a cement additive.
Water demand and rheology An increased specific surface area and differences in particle morphology can lead to a higher water demand and less favourable rheological properties. Consequently, cement processing and applications, such as concrete workability, can become more challenging. Availability Although some SCMs offer clear performance benefits, they are not universally available. Consequently, cement producers often rely on the more widely available, but less reactive and variable in quality, natural SCMs.
Chemical additives enabling new technologies New technologies and cement trends. 30
Advanced chemical additives play a key role in enabling high-SCM cement systems. World Cement September 2026
During grinding, they improve particle dispersion and reduce agglomeration, resulting in optimised particle size distribution and improved mill efficiency. At the same time, performance enhancer additives promote the hydration and activation of clinker, and to a certain extent SCMs, compensating the reduction of clinker. These functionalities allow better trade-offs between the CO2 goals and cost expectations to better manage the dilemma between sustainability and performance.
Process optimisation
Cement production is one of the most energy-intensive industrial processes worldwide. Among its different stages, grinding represents the largest share of electrical energy consumption, often accounting for more than half of a plant’s total power demand. Despite the increasing adoption of vertical roller mills (VRMs) and roller presses, the ball mill remains a widely used grinding technology due to its operational robustness, flexibility, and ability to consistently deliver cement quality that meets market requirements. However, each grinding technology presents specific operational challenges that directly affect efficiency and product performance. In ball mills, common issues such as particle agglomeration and coating of grinding media and internal surfaces can significantly reduce grinding efficiency, increase electrical energy consumption, and lead to unstable product quality. In contrast, VRMs are typically
associated with challenges related to grinding bed stability and process vibrations, which can limit throughput and require careful operational control. These instabilities are often influenced by material characteristics, moisture content, and process conditions, making consistent operation more complex. Without regular inspections, plants risk high electrical energy consumption, reduced throughput, and unexpected breakdowns. A structured cement mill control system is therefore a powerful tool to secure competitiveness, optimise costs, and ensure product consistency. Audits provide an evaluation of the grinding process, combining mechanical inspection, process analysis, and electrical energy review. The objectives are clear: f Electrical energy optimisation. Reduce specific consumption (kWh/t) through ball charge management, separator efficiency, and moisture control. f Reliability improvement. Detect wear, predict lifetime of internals, and prevent costly unplanned shutdowns. f Productivity increase. Adapt mill parameters to seasonal demand peaks and maximise throughput. f Quality assurance. Maintain Blaine targets and cement performance while balancing electrical energy and production.
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The following key areas become relevant in a mill optimisation process: f The filling ratio and ball size distribution directly influence both electrical energy demand and output. General studies show that lowering the filling ratio from 30% to 25% can reduce electrical energy consumption by up to 20%, while increasing it to 32% maximises throughput. Regular ball sorting every 1 – 2 years is essential to maintain efficiency and manage wear rates. f The separator efficiency plays a key role in cement quality and electrical energy efficiency. A regular inspection includes the following: » Visual and functional inspection of fan blades, air guides, cyclones for wear and debris. » An analysis of the Tromp curve quantifies the sharpness of separation between fine and coarse particles, identifying bypass rates that lead to increased energy consumption and over-grinding. » Airflow and pressure monitoring affect cement fineness and electrical energy use. » Internal inspection during shutdown to identify damage that may not be visible during operation. f Small changes in the feed moisture can drastically increase electrical energy consumption. Plants must ensure proper drying systems (burners, hot gases) and silo management to stabilise feed conditions. f Every cm²/g increase in Blaine adds kWh/t to power consumption. Inspections help balance Blaine targets with market requirements, avoiding unnecessary over-grinding. f Regular inspections of internal liners, diaphragms, and lifters, together with preventive maintenance cycles reduce mechanical failures. Internal inspection of the mill is crucial to ensuring optimal performance and include liner inspection, diaphragm
Solutions for cement mills are also available. 32
condition check, lifter evaluation, and vibration and noise analysis. Case insights from several cement plants demonstrate the significant operational and economic benefits achieved through technical process optimisation. In multiple cases, energy savings were achieved after optimising the ball charge in grinding mills. Additional improvements, such as separator upgrades and ball sorting, enhanced production efficiency. Inspections can also reduce purge times during product changes. Furthermore, sulfate optimisation through precise gypsum adjustment ensured consistent cement strength and durability.
Conclusion
The cement industry is evolving in response to combined pressures including decarbonisation, rising costs, regulatory requirements, and growing global demand. As clinker factors continue to decline, SCMs are becoming an integral part of strategies aimed at reducing the carbon footprint of cement production. However, the increased use of SCMs introduces new challenges, such as lower early-age strength, greater variability in the quality and reactivity of raw materials, and greater complexity in process control. Meanwhile, cement grinding remains one of the most energy-intensive stages of production, further emphasising the need for efficient, robust manufacturing processes. Looking ahead, the increasing adoption of SCM-rich cement systems is expected to accelerate the transition towards more sustainable construction materials. However, realising their full potential will require a combination of optimised grinding technologies, effective process control, and bespoke chemical solutions that can address the performance limitations associated with clinker reduction. Although digitalisation and data-driven process optimisation are already playing an important role, cement performance fundamentals will continue to depend on the successful interaction between materials, chemistry, and process conditions. Designed to support this transition, the SikaGrind® portfolio offers solutions that address the key challenges of modern cement production. SikaGrind additives improve grinding efficiency, compensate for early- and late-strength losses, optimise water demand and rheological behaviour, and stabilise performance despite raw material variability. This enables higher SCM utilisation without compromising cement quality. When combined with dedicated technical support and extensive expertise in clinker reduction, these solutions help cement producers to achieve greater sustainability, operational efficiency, and production flexibility in real-world conditions. World Cement September 2026
Dr. Wei Cai, Jim Greene, and Liang Jia, Wacker Chemical Corporation, examine how siloxane-based admixtures enhance moisture resistance and durability in lower-carbon cementitious systems.
D
urability is increasingly central to the cement and concrete industry’s decarbonisation agenda. A lower-carbon concrete that deteriorates early can lose much of its lifecycle advantage if it must be repaired, overlaid, or replaced before its intended service life. This issue becomes more important as producers expand blended cements such as portland-limestone cement (PLC), slag-containing systems, and other clinker-reducing approaches. Industry guidance from the American Cement Association notes that PLC, or Type IL cement, can reduce the carbon footprint of concrete by up to about 10% when replacing ordinary portland cement.1 In this context, service life is part of the carbon equation, not a separate durability topic. Moisture control is therefore a practical intervention point. Water transports harmful
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substances, facilitates freeze-thaw cycling, promotes alkali-silica reaction (ASR), and can amplify cracking, staining, efflorescence, and
Figure 1. Producer screening of hydrophobised cement: retained material on No. 30 mesh after storage of 46 days under humidity.
Figure 2. Outdoor EV-pad field trial at the Ann Arbor Innovation Centre.
Figure 3. Karsten tube testing for the outdoor EV-pad field trial at the Ann Arbor Innovation Centre. After 24 hours, water absorption was 3.0 ml for the control, 0.7 ml for siloxane-treated section A, and 0.6 ml for siloxane-treated section B. 34
surface erosion. Reducing liquid-water ingress while maintaining vapour permeability can help obstruct moisture-assisted deterioration pathways. That is the rationale behind siloxane-based admixture technology. Integral admixtures are incorporated during batching and dispersed within the cementitious matrix, where organosilicon chemistry contributes hydrophobic functionality throughout the substrate rather than only at the exposed surface. Surface treatments remain very effective, while an integral admixture can provide additional moisture resistance even if the surface is abraded or locally damaged. For lower-carbon systems, whose performance may depend on binder combination, aggregate reactivity, curing, and exposure conditions, this matrix-based approach is most valuable when validated for the specific mixture and environment. A representative integral hydrophobising admixture can be formulated as a solvent-free aqueous emulsion based on organo-modified silanes and siloxanes. Such systems are designed for incorporation into ready-mix and precast cementitious products, including pavers and blocks, where they can reduce capillary water absorption, support water-beading behaviour, and help limit efflorescence formation. Typical dosage ranges depend on the application, binder system, and target performance, and should be optimised for compatibility with slump, air content, finishing, and compressive strength. Related integral technologies based on oligomeric siloxanes have also been evaluated where ASR mitigation, water repellency, and durability enhancement are important performance targets.2 For producers and formulators, the practical lesson is not that one product solves every durability problem. Rather, durability should be designed into lower-carbon concrete with the same importance as clinker reduction and embodied-carbon reporting. Key issues should be addressed early: What is the dominant deterioration mechanism in the target environment? How does the cement-aggregate-SCM package respond under accelerated screening? What happens to slump, air content, and compressive strength when a hydrophobising admixture is introduced? And do laboratory findings remain consistent with field placement and outdoor exposure?
Hydrophobising cement from the inside: plant-level trials A complementary route is to introduce hydrophobising functionality at the
World Cement September 2026
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cement-production stage, before concrete batching or post-construction surface treatment. In real-life production trials by a major cement producer in a very humid area of Central America, the target was both water repellency in the finished cementitious material and improved cement handling after humid storage. Cement from a plant trial was evaluated after 46 days of storage under humid conditions using retained material on a No. 30 mesh as an indicator of agglomeration or caking. The untreated reference retained 8.2%, while cement treated at 500 ppm and 1000 ppm retained 4.3% and 0.6%, respectively. These results demonstrate hydrophobisation under producer-relevant conditions, not only in a simplified laboratory test. The direct visual inspections showed stronger water-repellent behaviour at higher siloxane dosage, while the sieve-retention data confirmed an effect with practical relevance for cement handling. In humid or coastal supply chains, reduced caking can lower losses from hardened bags, silo build-up, filter plugging, production changeovers, and customer complaints related to cement flowability. The additive level must still remain compatible with intentional wet mixing: the goal is to suppress unwanted moisture uptake during storage and
transport while allowing proper dispersion and hydration in mortar or concrete. The CO2 relevance extends across the cement value chain. Less caking means less cement wasted before use, preserving the embodied carbon already invested in clinker production, grinding, and distribution. If hydrophobic functionality is also carried into mortars and concrete products, reduced capillary water uptake can help limit moisture-assisted deterioration such as efflorescence, chloride transport, freeze-thaw damage, and ASR-supporting moisture availability. This creates a bridge from plant-level efficiency to service-life durability.
From cement additive trials to concrete field performance
Cement-level hydrophobisation is most compelling when it carries through to concrete performance. The next question is therefore whether siloxane-based admixtures can reduce water uptake and preserve surface condition under realistic placement, finishing, curing, and weathering conditions. Outdoor trials on full-scale concrete elements, including field placements, provide a more realistic basis for assessing performance because durability claims must ultimately be confirmed under production, placement, finishing, curing and exposure conditions that reflect practical use. The Ann Arbor test site in Michigan was selected for these outdoor trials because it provides a relevant outdoor exposure environment, with a humid continental climate and strong seasonal contrasts, including warm and wet summers, cold winters, regular snowfall, and frequent transitions around freezing. Long-term climate normals indicate precipitation throughout the year, with both summer rainfall and winter snow contributing to repeated wetting, drying, freezing, and thawing. For concrete durability evaluation, this combination is valuable because Figure 4. Treated (left) versus untreated (right) AIC specimens may be exposed to moisture driveway slabs photographed in 2023 and 2024. ingress, freeze-thaw transitions, cycling, and regionally relevant deicing-salt exposure. This setting provides surface erosion and seasonal temperature variations that commonly contribute to service-life deterioration in northern US infrastructure. The Ann Arbor outdoor trials therefore provide a practical proving ground for evaluating whether siloxane-based admixtures can reduce water uptake and preserve surface condition under realistic weathering conditions. In the EV-pad trial, three segments were poured: an untreated control and two sections containing siloxane-based admixture variants Figure 5. Treated (left) versus untreated (right) AIC evaluated as field-test examples. The mix used driveway slabs photographed in 2025 and 2026. Type IL PLC with slag, with siloxane-containing 36
World Cement September 2026
sections dosed at 13 oz. per 100 lb of cement. Karsten tube testing showed 24-hr water uptake of 3.0 ml for the control, compared with 0.7 ml and 0.6 ml for the two treated sections. This field result indicates a substantial reduction in liquid-water absorption under an evaluated lower-carbon binder system. The same work also confirmed that fresh-concrete behaviour matters. One treated mixture showed higher entrained air and improved flow relative to the other mixtures, suggesting potential handling benefits but also reinforcing the need for dosage optimisation and air-void control. In practice, a suitable admixture must reduce water uptake without creating unacceptable disadvantages in slump, air content, finishing, or compressive strength. A long-running driveway trial placed in 2021 provides complementary outdoor evidence. Follow-up visual inspections in 2023, 2024, 2025, and 2026 showed that the treated section retained a favourable surface appearance, with less exposed aggregate and reduced surface erosion relative to the untreated section. The reported 28-day compressive strength for the treated slab was within the control range, indicating that durability improvement did not require a clear sacrifice in later-age strength under the tested conditions. The embodied CO2 from durability enhancement is best understood at the life-cycle level rather than as a single universal percentage. Industry environmental product declaration resources emphasise carbon accounting, product-specific data, and project-specific specification guidance.3,4 Related life-cycle assessment guidance also highlights that maintenance, repair, replacement, demolition, and disposal can influence total carbon outcomes.5 NRMCA case-study data provide an illustrative example of how maintenance and repair assumptions can influence life-cycle carbon outcomes: in one 12-storey building scenario, repair-related impacts were reported as approximately 6.0 kg CO2e/m2 for a concrete structure, compared with 25.5 kg CO2e/m2 for a steel alternative.5 When considered with the EV-pad result – 3.0 ml water uptake for the control versus 0.7 and 0.6 ml for the siloxane-treated sections – durability enhancement may help preserve the embodied-carbon gains targeted by lower-clinker concrete design if it reduces moisture-driven damage and avoids part of the repair, removal, and replacement burden over service life. The net benefit should still be evaluated by project-specific life-cycle assessment because admixture dosage, achieved service-life extension, and avoided maintenance scenario determine the final carbon balance. 38
This is why durability belongs at the centre of the decarbonisation discussion. Lower-clinker cements can reduce embodied carbon, but their sustainability value depends on how long the resulting concrete remains functional in service. Siloxane-based admixtures offer a technically credible route to protecting that value because they target liquid water, a common contributor to concrete deterioration. Producer trials show that hydrophobisation can improve cement handling under humid conditions, while field and laboratory evaluations indicate reduced water uptake, improved moisture resistance, and practical workability in PLC- and slag-containing systems. Longer service life is therefore not separate from concrete sustainability; it is one of its most practical expressions.
References
1. 'Blended Cements and Sustainability of Concrete Construction', American Cement Association – https:// www.cement.org/a-sustainable-future/reaching-our-goal/ blended-cements/ 2. DAVYDOV, D., GREENE, J., & CAI, W., 'Optimising with Oligomeric Siloxane', World Cement, September 2024. 3. American Cement Association, 'Quantifying Environmental Impact' – https://www.cement. org/a-sustainable-future/reaching-our-goal/quantifyingenvironmental-impact/ 4. 'Sustainability', National Ready Mixed Concrete Association (NRMCA) – https://www.nrmca.org/associationresources/sustainability/ 5. MERCKER, A., JIMENEZ, J., & BOOTH, M., 'Sustainability in Concrete: Reducing Environmental Impact Through Benchmarking and Alternatives', National Ready Mixed Concrete Association (NRMCA) – https://www.nrmca. org/wp-content/uploads/2022/07/RES_Sustainability20-21. pdf
About the authors
Dr. Wei Cai is a materials scientist who develops silane- and silicone-based construction technologies, with a focus on moisture protection, alkali-silica reaction mitigation, and long-term cement and concrete durability. Jim Greene holds a master’s degree in analytical chemistry and has nearly 30 years of experience with WACKER’s Construction Group. His work focuses on additives and siloxane technologies that improve cement production and concrete performance. Liang Jia has more than 16 years of experience in business development, product management and strategy. She earned an MBA from Cornell University and works with WACKER’s construction and coatings markets, including cement, concrete protection, and silicone-based building technologies. World Cement September 2026
Dr. Nate Weger, Pauliina Meskanen, and Dr. Fox Thorpe, Calectra, explore how thermal energy storage can convert low-cost, off-peak renewable electricity into affordable process heat, unlocking new economic and decarbonisation opportunities for cement producers. cross the world, wind and solar are being deployed at rates that have never been seen before. In 2024, over 94% of global new energy capacity additions were wind or solar.1 This does not include hydropower, which boosts these numbers even higher. The trend of increasing deployment of wind and solar is expected to continue, with the International Energy Agency predicting renewables and nuclear to make up 50% of global electricity production in less than 5 years.2 The overwhelming pivot from fossil-based energy sources to wind and solar has been largely driven by economics. Economies of scale have pushed the cost of building wind and solar to levels lower than ever before (Figure 2), and this has made wind and solar impossible to ignore for energy developers and other corporations in search of cheap energy.
39
Case study: Southern California
are being produced at times when nobody has a use for it. An extreme example of this scenario is occurring in Southern California, home to several of the largest solar facilities in the world. Solar has been rapidly deployed in California, with the state briefly achieving a 100% renewable grid for the first time in 2022.4 The widespread deployment of solar has had a predictable effect. Electricity is produced during the day, and this does not perfectly match electricity demand because peak demand typically occurs later in the afternoon as people return home from work. This effect is shown clearly in Figure 3, where electricity prices drop tremendously during the day while solar is generating power, and prices are much higher at all other times. This is where the opportunity becomes obvious. Electricity that is produced at times of high supply and low demand is cheaper, to the extent that off-peak electricity (blue line) is significantly cheaper than even natural gas (gray line). In the extreme case of Southern California, with Figure 1. Percentage of newly built energy capacity so much electricity produced during the that is wind and solar.1 middle of the day, the price becomes negative and utilities will sometimes even pay for consumers to use that energy. This situation is not limited to Southern California. Everywhere wind and solar account for a meaningful portion of the total produced energy, there is a strong chance that off-peak electricity can be purchased at prices competitive with or much cheaper than coal or natural gas. As shown in Figure 1, wind and solar are being deployed much faster than any other sources of energy. This trend Figure 2. Cost to produce energy in the US.3 is expected to continue, with intermittent wind and solar making up larger and larger fractions of global energy production.6 This will result in more fluctuations in electricity prices and more opportunities to take advantage of new off-peak electricity prices that are outperforming the status quo. The recent influx of wind and solar presents an opportunity: an electricity grid that has historically consisted of stable, steady energy sources like coal and natural gas is now receiving massive amounts of power from energy sources that vary in output by the minute. The deployment of these intermittent energy sources is leading to a mismatch between the time that energy is produced and the time that energy is required for use. Already today, enormous quantities of power
The storage solution Figure 3. Average hourly electricity profile in Southern California in 2024 (blue) compared to natural gas (gray).5 In practice, costs even lower than these can be achieved because the 4 lowest-cost hours per day do not always occur consecutively as they do in the chart. The actual achievable energy cost is -US$8.37/MWh. 40
Wind and solar were never going to provide the majority of energy as standalone energy sources; their intermittency prohibits this. The solution World Cement September 2026
to intermittency is energy storage – batteries. Batteries can take intermittent energy sources as an input and output stable, reliable energy streams on demand, just as expected from sources like coal and natural gas. And similarly to wind and solar, traditional batteries are being produced at rates the world has never seen before, thanks in large part to exponential cost reductions caused by economies of scale.7 Despite this, wind and solar are being deployed at rates much faster than batteries, and with current trends, incomprehensible amounts of energy are expected to be curtailed and thrown away over the coming years (Figure 4). 600 TWh of wasted energy in 2050 in the US is equivalent to about 15% of the country’s current annual energy production. A major limitation on the further adoption of batteries, and the reason so much energy is forecasted to be wasted, is the cost of batteries. They are still high today, high enough that the opportunity of low-cost, off-peak electricity often falls apart when the cost of a traditional battery is included.
The cement potential
Energy costs, especially for generating extremely high-temperature heat, are a major expense for cement manufacturers, making
up to 20 – 25% of total operating costs.9 The cement industry has long relied on coal and natural gas as its primary energy sources, with the occasional alternative energy sources mixed in. In the cement industry, which operates on particularly low margins, any significant change in energy prices can greatly affect a company’s ability to compete on the global market. This has been especially true in recent months, when disruptions in fuel supply chains have led to increasingly volatile energy costs. The flip side of this is also true, where reductions in energy costs can put a cement manufacturer well ahead of the competition. This is where the real opportunity lies. Access to lower energy costs is the key for a cement manufacturer to take advantage of the market and achieve higher profit margins.
The heat battery for cement production
Calectra, a US Department of Energy-backed startup based in the San Francisco Bay Area, is building a thermal battery technology (Figure 5) to make this new source of lower-cost energy accessible to the cement industry. Like a traditional battery, a thermal battery takes in low-cost, off-peak electricity and stores
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that energy. However, while traditional batteries store energy via electrochemical reactions, a thermal battery converts electricity into heat and stores that instead. A major benefit of storing heat in a Calectra thermal battery is that this can be done at extremely low costs because the storage medium is just refractory ceramics, which are very cheap materials already used widely throughout heavy industry. Once this low-cost electricity is converted into high-temperature (up to 1600˚C and higher) heat by the Calectra thermal battery, the heat is stored in Calectra’s patented system, a large, insulated box of ceramic bricks that can retain high-temperature heat for several days at a time. Finally, ambient air is blown into the system, the air heats up as it passes by the hot ceramic material, and hot air is delivered from the thermal battery through insulated piping directly into an industrial process. In the cement industry, there are several processes where the implementation of Calectra’s thermal battery could lead to significant cost (and emissions) reductions. These include the kiln, the precalciner/preheater tower, any drying
processes, as well as adjacent processes that require large quantities of heat, such as clay calcination and carbon capture. In these processes, Calectra’s thermal battery can be retrofitted into existing industrial processes, bringing rapid cost reductions that do not require a wait for the construction of a new cement plant. Additionally, heat from Calectra’s thermal battery can be used in parallel with existing fuel burners, giving cement manufacturers the flexibility to choose which mix of energy they prefer to use in their specific kilns. To summarise, recent developments in global energy production present an opportunity to procure energy at prices well below typical fuel prices. Calectra’s thermal battery technology enables the cement industry to access these low energy prices and apply them to cement manufacturing processes, resulting in cheaper and cleaner cement production. Calectra plans to build its pilot demonstration system in 2027.
References
1. 'Renewable capacity statistics 2025', International Renewable Energy Agency. 2. 'Electricity 2026', IEA, Paris, License: CC BY 4.0. 3. LAZARD, 'Lazard Levelized Cost of Energy+ v18.0', June 2025, pp. 14–15. 4. KENNEDY, R., 'For the first time in history, California’s demand was 100% matched by renewable energy generation', Pv Magazine USA – https://pv-magazine-usa. com/2022/05/02/for-the-first-time-in-historycalifornia-was-100-powered-by-renewableenergy 5. CALECTRA (internal analysis). 6. 'Electricity generation in the Current Policies Scenario and Stated Policies Scenario, 2015–2035', IEA, Paris, License: CC BY 4.0. Figure 4. Battery capacity vs. curtailed energy forecast, 7. RITCHIE, H. & ROSADO, P., 'Battery 8 US. costs have declined by 99% in the last three decades, making electrified transport a reality', Published online at OurWorldinData. org. – https://archive.ourworldindata. org/20260518-090244/battery-price-decline. html 8. GAGNON, P., PEREZ, P., FLOREZ, J., MORRIS, J., VELASQUEZ, M., & EISENMAN, J., 'Cambium 2024 Data', National Renewable Energy Laboratory – https://scenarioviewer. nrel.gov 9. MADLOOL, N. A., SAIDUR, R., HOSSAIN, M. S., & RAHIM, N. A., 'A critical review on energy use and savings in the cement industries', Renewable and Sustainable Energy Reviews, 15(4), – https://doi. Figure 5. Calectra’s power-to-heat thermal battery org/10.1016/j.rser.2011.01.005 system. 42
World Cement September 2026
Elise Morse, Regal Rexnord, explores how connected conveyor technologies, predictive maintenance, and integrated reliability strategies are helping cement producers reduce downtime and turn data into actionable performance gains.
C
ement operations run demanding, continuous operations where equipment failure carries a significant cost. Lost production from unplanned downtime, emergency repair or replacement spending, and employee safety risks add up quickly when operations go down.
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In a cement facility, conveyors are some of the most critical and vulnerable pieces of equipment. Running for hours, sometimes days at a time, belt, drag, and pan conveyors are used to move materials throughout the facility, in many cases across long distances. A single failure point can bring the entire process to a halt. For decades, operators and maintenance teams have done their best to stay ahead of these failures by using time-based replacement schedules and then incorporating condition monitoring tools. Today, making the shift from reactive maintenance to predictive maintenance is easier than ever. The evolution of maintenance strategies and equipment reliability solutions has culminated in smart conveyor systems that convert data into
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operational confidence. The tools and technologies available today are connected and intelligent, and they can be the key to stopping unplanned downtime for good.
The evolution from reactive to predictive maintenance
Condition monitoring is not new. In fact, it has been around in some form for over 60 years. To some extent, the first condition monitoring tools were the human senses: using sight, smell, and touch to notice equipment abnormalities and potential problems. Touching a piece of equipment to determine if it is too hot, smelling something that could be burning, and checking vibration by seeing how fast a coin will fall off a piece of equipment are just a few of the previous ways humans have monitored equipment. The practice of condition monitoring has largely stayed the same, but the tools have changed over time. Time-based maintenance became the industry's default, modelled on military practices. Maintenance teams would replace or service components on a schedule to attempt to avoid equipment failure. This strategy may prevent unplanned failures, but it could also limit the true life of the component. Without knowing exactly how close to the end of its life a component or system is, there is a risk of replacing something that could have lasted for additional months or even years without issue. Over-servicing or prematurely replacing equipment could end up being just as expensive over time as an unplanned downtime event. Through time-based maintenance, preventive maintenance strategies began to take shape. This approach was more sophisticated than relying on replacement intervals, with tools and practices introduced to more accurately monitor and test equipment. Rather than replacing or servicing a part every 90 days whether or not it needs it, preventive maintenance provides flexibility based on the observed condition of the equipment. This approach can extend equipment life when executed consistently, but still mostly requires physically observing equipment, which can be difficult to keep up with in large plants or dangerous applications. World Cement September 2026
This led to the adoption of predictive and prescriptive maintenance and reliability strategies and technologies. Tools such as IoT sensors on equipment, remote condition monitoring with cloud-based software, AI connectivity, and actionable data collection informed by reliability engineers provide continuous visibility across equipment and enable accurate forecasting of failures before they occur. These tools can also predict when intervention is required for specific pieces of equipment and, in some cases, recommend appropriate corrective actions. As these technologies advance, maintenance team size and budget constraints are no longer a barrier with more user-friendly interfaces and increased accessibility. With these tools more readily available commercially, they are easier to adopt, and plants are accelerating their reliability journeys to increase productivity and uptime.
How connected equipment is redefining cement conveyor reliability
Integrating these technologies into conveyors throughout a cement facility can ensure lines remain operational and avoid unplanned downtime. These connected conveyor systems include both hardware and software that not only monitors the equipment but also connects the plant’s assets and puts the data into the cloud for a more holistic view. Where one person can only be in one place at a time, these technologies can manage thousands of different data points across the entire operation with rules and AI thresholds to point towards areas that require attention the most. Now, instead of going to each piece of equipment with suitcases full of tools needed to measure each aspect, a supercomputer can do it all. The expanded capabilities of these sensors and other connected conveyor technologies allow for the measurement and monitoring of critical parameters such as vibration, temperature, motor current, oil levels, and more on each conveyor component. This allows operators to gain a more comprehensive view of their equipment's health, clearer insight into how and why failures are occurring, and the information to plan timely, targeted maintenance based on what their equipment is trying to tell them. Some sensors, such as those from Regal Rexnord™ Perceptiv™ Intelligent Reliability Solutions, are purpose-built to provide the flexibility and durability to withstand different environments, like a harsh and demanding cement facility. These technologies have evolved to be resilient enough to stand up to heat, dust, constant operation, and unpredictable outdoor environments. By using a combination of cellular 46
signal and Wi-Fi, these reliability solutions can also be used in remote environments to monitor critical equipment metrics. As technology continues to advance, condition monitoring and predictive maintenance capabilities will expand as well. By utilising cloud-based software, upgrades and updates can be easily implemented to keep things up to date as these advancements occur.
Why true reliability demands a single, integrated partner
Identifying a problem on a piece of equipment is only half of the equation. Once an issue is detected, plants need more than just data points to understand the full breadth of what is going on and how to move forward. Having a single, integrated partner can help make sense of the data and figure out next steps when problems arise. An integrated partner delivers across the full reliability cycle. Outside of product intelligence and predictive maintenance hardware and software, they can also help with asset management cataloguing right in the same system. Maintaining a digital catalogue of all equipment within a facility, including associated warranties, provides more than a simple overview of assets; it also helps address workforce decline and the loss of institutional knowledge as experienced staff retire. An integrated partner can also help manage a shrinking workforce by acting as an extension of the maintenance team. Expert technicians can come on-site to troubleshoot and repair components. Sourcing replacement parts and upgrades is also easier with a single partner, with ordering built right into the user interface. Through continuous monitoring, actionable data interpreted by reliability experts, AI algorithms, service support, and a centralised platform, a single, integrated partner can help with the transition from reactive to prescriptive, predictive maintenance. This technology does not promise a problem-free plant, but it does promise a more prepared one. In an industry known for relentless, continuous production in harsh environments, planning ahead is a necessity. Every unplanned shutdown creates additional pressure on the maintenance team and the bottom line. For cement plants ready to advance on their reliability maturity journey, proven technologies and trusted partnerships are available to help transform data into uptime and provide practical solutions to keep conveyors running when maintenance is required. World Cement September 2026
CalPortland outlines how natural pozzolan-based blended cements can reduce clinker content while maintaining concrete performance and durability across large-scale infrastructure projects.
educing the carbon footprint of cement and concrete while maintaining performance is one of the most significant challenges facing the construction industry today. Because clinker production accounts for most of the CO2 emissions associated with cement manufacturing, reducing clinker content is among the most effective strategies for lowering the embodied carbon of concrete. The challenge, however, is achieving meaningful carbon reductions without compromising strength development, durability, constructability, or production efficiency. In California and Arizona, the demand for lower-carbon construction materials continues to grow as public agencies, private owners, and developers pursue sustainability goals while maintaining high-performance expectations for infrastructure and building projects. To address this need, CalPortland
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developed ADVANCEMENT™ HPT, a blended cement manufactured with locally sourced natural pozzolan and limestone. Recently redesignated under ASTM C595 as a Type IP cement, ADVANCEMENT HPT delivers approximately 20% lower global warming potential (GWP) than conventional ASTM C150 Type II/V portland cement Table 1. Comparison of concrete formulations made using Type II/V vs low carbon blended cement, ADVANCEMENT HPT, at the same cement content. Performance
Concrete (portland cement)
Concrete (ternary blended cement)
Slump (in.)
8.2
8
7-day strength (psi)
5010
4930
28-day strength (psi)
5650
5900
Figure 1. Apparent chloride diffusion profile by bulk diffusion test, indicating ADVANCEMENT™ HPT outperforms portland cement for chloride ingress.
Figure 2. ASTM C1260 results on a local aggregate showing deleterious ASR expansion in portland cement while innocuous behaviour in ternary blended cement. 48
while maintaining the performance characteristics required by concrete producers and contractors. The development of this product required much more than introducing a new supplementary cementitious material (SCM) into cement. It involved years of research, extensive testing, manufacturing modifications, quality-control enhancements, and collaboration throughout the construction value chain. The experience also highlighted an important reality of cement decarbonisation: success depends not only on developing lower-carbon products, but also on ensuring they can be manufactured consistently and used effectively in concrete applications.
Developing and manufacturing a low-carbon cement
CalPortland's objective was clear from the beginning: create a cement containing significantly less clinker while maintaining performance characteristics as close as possible to conventional portland cement. The target was to achieve a meaningful carbon reduction through the incorporation of natural pozzolan and limestone while preserving workability, early-age strength, long-term strength development, and durability. The natural pozzolan selected for the project is sourced near CalPortland's Mojave and Oro Grande cement plants in Southern California. This regional availability creates an important advantage for both California and Arizona because it enables a relatively short supply chain while supporting local production of lower-carbon cement. Unlike some SCMs whose availability has become increasingly constrained, natural pozzolan offers a scalable solution capable of supporting future clinker-reduction strategies in the Southwest. However, incorporating natural pozzolan into cement manufacturing introduced new operational challenges. One of the first considerations involved handling and storage of the raw material. While the Mojave and Oro Grande plants are in predominantly arid climates, Southern California occasionally experiences intense storms that can affect moisture levels in stockpiled materials. Increased moisture content can influence conveying systems, grinding efficiency, and overall mill performance. To address this issue, the plants rely on large stockpile management practices that help preserve dry material and maintain production consistency. Consistency of the raw material itself represented another critical challenge. Natural pozzolans can vary in mineralogy and reactivity, both of which influence cement performance. Extensive characterisation work and thousands of laboratory tests were conducted to establish World Cement September 2026
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confidence in the source material and define acceptance criteria for routine production. Additional quality-control measures were implemented to monitor both incoming raw materials and the finished cement product. Introducing a new blended cement also required changes within the manufacturing facilities. The Mojave and Oro Grande plants were originally designed to produce conventional portland cement. As a result, modifications were necessary to efficiently handle and proportion natural pozzolan while maintaining product consistency. New feeders and material-handling systems were implemented to achieve accurate dosing of the pozzolan component. Process controls were refined, and laboratory
procedures evolved to verify clinker replacement levels and ensure consistent product quality. An additional challenge involved the grinding systems themselves. CalPortland's Southern California plants utilise both ball mills and vertical roller mills, two technologies that operate through fundamentally different grinding mechanisms. These systems also generate different thermal profiles during finish grinding, which can influence the performance of blended cement. Considerable effort was required to optimise process conditions and ensure that ADVANCEMENT HPT delivered consistent behaviour regardless of where it was produced. The resulting product is a carefully engineered ternary blended cement consisting of clinker, natural pozzolan, limestone, and gypsum. Through optimisation of particle size distribution and overall formulation, the cement was designed to provide concrete performance similar to a portland cement based mix while having lower clinker content.
From cement performance to concrete performance
Figure 3. Low carbon concrete with ADVANCEMENT HPT cement – pour in residential foundations in Central Coast California.
Figure 4. Example of field application with ternary blended cement. 27-storey residential tower in Tempe, Arizona. 50
Successfully manufacturing low-carbon cement is only part of the challenge. Cement is ultimately used within concrete, and the transition from laboratory development to field performance is often where new products are truly tested. The natural pozzolan incorporated in ADVANCEMENT HPT contains reactive aluminosilicate minerals that contribute to pozzolanic reactions during cement hydration. These reactions consume calcium hydroxide released by clinker hydration and generate additional calcium-silicate-hydrate (C-S-H), the primary binding phase responsible for strength and durability in concrete. Because pozzolanic reactions typically occur more slowly than clinker hydration, maintaining early-age performance can be challenging when clinker content is reduced. Extensive laboratory development was therefore required to optimise the blended cement system and maintain a balance between sustainability and performance. Testing demonstrated that concrete produced with ADVANCEMENT HPT achieved fresh properties and strength development comparable to those obtained with conventional Type II/V cement. Concrete mixtures evaluated at equivalent water-cement ratios exhibited similar workability and comparable compressive strengths. One of the most significant outcomes of the development programme was that carbon reduction did not come at the expense of durability. In fact, durability has become one of the major advantages of the product. World Cement September 2026
As hydration and pozzolanic reactions continue over time, the concrete microstructure becomes denser and more refined. This results from the refinement of the micro- and nanoporous structure of hardened concrete through the formation of additional hydration products. This refined structure significantly reduces the rate of diffusion of aggressive ions, such as chlorides from seawater, de-icing salts, and sulfates from soil in contact with concrete, while also reducing alkali-silica reaction (ASR) expansion in reactive aggregate (Figure 1). As a result, the service life of concrete can be significantly extended. These benefits are particularly relevant for infrastructure throughout California and Arizona. California includes extensive coastal infrastructure exposed to chloride-rich marine environments, while both states contain regions with sulfatebearing soils and groundwater. In addition, long design service lives require concrete capable of resisting deterioration over decades of exposure. Enhancing durability therefore supports sustainability not only by lowering embodied carbon initially, but also by extending service life and reducing future maintenance needs.
Challenges during market adoption
Adoption of a new cement requires more than technical validation. It also requires confidence from concrete producers, contractors, engineers, and project owners. Concrete is a complex system consisting of cement, aggregates, water, chemical admixtures, and sometimes additional SCMs. When one component changes, interactions within the system may also change. Consequently, introducing a lower-clinker cement often requires verification of mixture proportions, admixture compatibility, and construction practices before full implementation. CalPortland's experience in California and Arizona showed that successful implementation often begins with trial batching and close collaboration among project stakeholders. In many cases, only minor adjustments to admixture dosage or mix proportions were needed to achieve desired performance. Nevertheless, these evaluations played an important role in building confidence among concrete producers and contractors. Contractors occasionally observe subtle differences in fresh concrete behaviour compared with conventional portland cement mixtures. Changes in finishing characteristics, workability retention, or setting behaviour can occur with any new cement technology. The key to successful adoption was communication between cement producers, ready-mix suppliers, contractors, and design teams. By working together and sharing field experience, project teams were able to implement lower-carbon concrete without affecting productivity or quality. This collaborative approach helped September 2026 World Cement
demonstrate that lower-carbon concrete does not require sacrificing constructability. Rather, it requires understanding how the material behaves and making appropriate adjustments when necessary.
Proven results across California and Arizona
The successful use of ADVANCEMENT HPT on commercial projects throughout California and Arizona demonstrates the practicality of low-carbon cement in real-world construction. One notable example is a data centre project in Arizona that established a target of reducing concrete GWP by 35%. By using ADVANCEMENT HPT in combination with a carefully optimised concrete mixture design, the project achieved an approximately 40% GWP reduction, surpassing its sustainability objective. Another significant application involved a 27-storey residential tower in Tempe, Arizona. Approximately 25 000 yd3 of concrete incorporating ADVANCEMENT HPT cement was used throughout the structure, including high-strength columns, core walls, elevated slabs, and foundations. The project incorporated concrete mixtures reaching compressive strengths of 10 000 psi while maintaining pumping performance, workability, finishing characteristics, and strength development comparable to conventional portland cement concrete. These projects demonstrate that meaningful reductions in embodied carbon can be achieved without compromising structural performance, construction efficiency, or durability. They also illustrate the importance of close collaboration across the construction value chain when introducing innovative materials.
Building a lower-carbon future
As California and Arizona continue advancing ambitious sustainability and infrastructure goals, reducing the embodied carbon of cement and concrete will remain a critical priority. CalPortland's experience demonstrates that locally sourced natural pozzolans can provide a practical and scalable pathway to lower-carbon cement while maintaining the performance expected by the market. The development of ADVANCEMENT HPT highlights the fact that successful decarbonisation extends far beyond clinker reduction alone. It requires raw material qualification, manufacturing innovation, rigorous quality control, concrete mixture optimisation, and collaboration among producers, contractors, engineers, and owners. When all these elements work together, lowercarbon cement becomes more than a sustainability initiative. It becomes a proven solution for delivering durable, resilient, and lower-carbon infrastructure throughout California and Arizona. 51
Daniel Kopp and David Gersholowitz, Queens Carbon, explain how plant-compatible technologies and engineered cementitious materials can help producers scale lower-carbon cement production using existing infrastructure.
52
hroughout its history, the cement industry has advanced through practical innovation rather than wholesale reinvention. The transition from wet-process to dry-process kilns dramatically improved efficiency while preserving the industry's existing manufacturing footprint. Suspension preheaters and precalciners increased productivity without changing the fundamental business model. More recently, portland limestone cement (PLC) achieved widespread adoption by fitting existing cement plants, standards, and distribution networks rather than requiring producers to build entirely new manufacturing facilities. And the industry finds itself again at another such inflection point. Reducing clinker content has become central to improving cement economics, strengthening supply chains, improving concrete durability, and lowering carbon emissions. Yet the supplementary cementitious materials (SCMs) that enabled clinker substitution over the past 50 years (primarily fly ash and blast furnace slag) are becoming increasingly scarce as coal-fired power generation declines and steel production evolves. Producers must continue delivering lower-clinker cements while securing new sources of cementitious materials that are compatible with their operations, product specifications, and business objectives. At Queens Carbon the answer lies not in finding new external SCM sources but in giving all cement plants the ability to manufacture them. This next era must build on the industry’s strengths and compound the value of its plants, processes, and expertise rather than asking producers to abandon them.
From byproducts to manufactured materials
Historically, and in most cases today, SCMs were not manufactured. Fly ash originated as a byproduct of coal-fired electricity generation, while GGBFS was produced during iron/steel manufacturing. Both became valuable because they were abundant, economical, and improved concrete performance while reducing clinker consumption and therefore embodied carbon. That model worked because these materials were readily available, a condition that is increasingly no longer true. As coal-fired power generation declines and iron/steel production shifts toward lower-emission processes, the availability of traditional SCMs is shrinking even as demand grows. For an industry increasingly focused on clinker reduction and consistent performance, securing a reliable supply of SCMs is now a defining challenge. Because building sufficient new capacity will take time, scalable solutions must be identified by 2030 so the industry can begin deploying them aggressively in the decade that follows.
Alternative SCM pathways are emerging to help address this supply gap. Natural pozzolans can provide excellent performance but depend on geographically limited mineral deposits. Calcined clay has attracted considerable industry interest, but commercial deployment typically requires suitable clay resources, dedicated green-field plants, new process lines, and/or new supply chains. The same is true for ash harvesting, with substantial investment required to establish reliable supply. Each approach can address an important part of the challenge, but each also depends on new raw materials, new production assets, low consistency in performance, economic challenges, or all of the above. Queens Carbon approached the problem from a different perspective – by exploring how existing cement plants can manufacture engineered cementitious materials with the addition of new production equipment that leverages the feedstocks, infrastructure, and workforce they already possess.
A flexible manufacturing platform that makes existing plants more capable
The cement industry has invested hundreds of billions of dollars in its existing plant footprint, including quarries, raw-material handling systems, grinding circuits, laboratories, logistics networks, and production facilities. These assets will continue operating for decades and should not be viewed as liabilities that must be replaced, but as engines for future innovation and business growth. Queens Carbon developed the Q-System to operate in harmony with existing cement production lines using the same feedstocks that producers already quarry, process, and understand: limestone, sand, and clay. The modular hydrothermal manufacturing platform (Q-System) converts these industry-standard feedstocks into reactive SCMs. These materials can then be blended with clinker or PLC to produce lower-carbon blended cements, including performance-based cements. Unlike clinker production, the Q-System does not calcine limestone. Instead, the hydrothermal reactions retain the carbon contained in the limestone, keeping it permanently bound within the cementitious material rather than releasing it into the atmosphere as process CO2. This fundamentally changes the mass balance of cement manufacturing: Conventional clinker production: 1.5 t of raw meal → 1 t of clinker + 0.5 t of limestone-derived CO2 Queens Carbon’s Q-System: 1.5 t of raw meal → 1.5 t of Q-SCM + zero limestone-derived CO2
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In other words, the same 1.5 t of raw meal used to produce approximately 1 t of clinker can instead produce approximately 1.5 t of Q-SCM. This represents approximately 50% more cementitious product from the same quantity of mineral feedstock, increasing productivity and extending the useful life of existing quarry reserves and raw-material infrastructure. This focus on working with and adding value to existing cement-plant assets extends throughout the Q-System. Rather than requiring narrowly specified raw materials or standardised operating conditions, the platform is designed to accommodate the variability already present across cement plants. It can process a broad range of locally available mineral feedstocks, including naturally variable materials and lower-grade limestone, while intelligent process controls continuously adjust operating conditions to maintain product performance and consistency. The Q-System also provides flexibility in how energy is supplied. Conventional clinker production relies on direct combustion to reach material temperatures of approximately 1450˚C. At the heart of the Q-System is the Q-Reactor, which instead uses steam, pressure, and indirectly supplied heat to drive hydrothermal reactions at approximately half that temperature. Because heat is supplied indirectly, producers can select the most practical and economical energy source available at each plant, including conventional fuels, AFs, industrial heat, electricity, or an efficient combination of these. The Q-Reactor itself is combustion-free, separating the energy source from the reaction environment and creating a practical pathway toward increasingly electrified cement manufacturing. Operating at substantially lower temperatures and having a favourable thermodynamic
profile, the Q-System reduces energy demand by approximately 30%. Rather than reproducing conventional clinker mineralogy, the hydrothermal process creates highly reactive cementitious phases through controlled reaction pathways. This gives producers the flexibility to tailor material properties for modern blended cements while avoiding the process emissions and energy intensity associated with conventional clinker production. The combination of flexible heat inputs, adaptable feedstocks, modular equipment, intelligent controls, and plant-compatible integration enables the same core Q-System platform to be deployed across a wide range of cement operations. The Q-System allows existing plants to produce more cementitious material from their current mineral resources, expand their product portfolios, and reduce both the clinker content and carbon intensity of the cement they sell – all while improving plant economics.
Software intelligence turns manufacturing flexibility into operational reality
The Q-System’s manufacturing flexibility depends not only on its hydrothermal chemistry but also on the intelligence layer that allows the platform to adapt to real-world operating conditions. Designed as an integrated physical and digital platform, the Q-System helps producers maintain consistent performance across installations with different feedstocks, energy sources, and plant configurations. The Q-System combines feedstock characterisation, process measurements, laboratory results, and AI-enabled predictive models to anticipate
A generated rendering demonstrates how the Q-System integrates in harmony with an existing cement footprint. 54
World Cement September 2026
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finished-material performance during production. It recommends process adjustments or, within predefined operating limits, executes them automatically. Operators can see how changes in raw-material composition or operating conditions are expected to affect the product, allowing them to intervene before out-of-specification material is produced or released. These operator interventions provide feedback that helps train the Q-System to make increasingly autonomous process adjustments within predefined limits. This approach helps reduce dependence on plant-specific operating practices and individual operator experience. It facilitates the transfer of process knowledge between sites, shortens the learning curve for new installations, and supports consistent product quality across a producer’s operations. The platform keeps operators in control while supporting progressively higher levels of automation. Building on conventional process-control capabilities, the Q-System integrates equipment operation with material-performance prediction, product consistency, and production economics. As additional Q-Systems are deployed, operating data from across a producer’s installed base will improve the platform’s predictive capabilities. The software also generates production records, quality documentation, and carbon-intensity data to support product qualification, quality assurance, and customer reporting. For the plant operator, it all comes down to one additional monitor in the control room – a minor addition to the operator's existing responsibility.
Commercialising through the industry’s existing frameworks
Technical innovation alone does not create commercial adoption. New cementitious materials must demonstrate consistent performance, integrate into established supply chains, and qualify through standards the industry already recognises. Queens Carbon's commercialisation strategy therefore
runs through established qualification pathways rather than requiring the industry to adopt entirely new frameworks. The company’s first commercial product, Q-SCM, is an engineered SCM designed to replace 20 – 50% of clinker while maintaining the performance expected of modern blended cements. Independent third-party testing has demonstrated that Q-SCM satisfies the requirements of key performance standards (such as ASTM C1912, C595, and C1157), demonstrating compatibility with existing industry specifications. These US qualification pathways are part of a broader strategy designed to align with relevant EN standards and comparable national specifications in other markets. The objective is the same in every region: to allow producers to evaluate and adopt Q-SCM through familiar testing protocols, quality systems, product portfolios, and customer specifications. Queens Carbon has progressed from benchtop development starting in 2022 to continuous mini-pilot operation in 2025 and pilot-scale manufacturing in 2026. Queens Carbon is now producing material by the tonne, enabling prospective customers to conduct qualification programmes using commercially representative material rather than small scale lab samples. Producers can evaluate manufacturing consistency, concrete performance, and compatibility within their own cement and concrete systems. This progression has demonstrated the scalability of the Q-System and established the manufacturing process required to produce Q-SCM at commercial scale. Now, the focus shifts from proving the material to proving the model: integrating new cementitious manufacturing capability into the plants that already define the industry. To do that, Queens Carbon is building a 10 tpd demonstration plant with Buzzi Unicem USA at its Stockertown, Pennsylvania cement plant. This is designed to prove the Q-System's core commercial concepts under industrial conditions: integration with existing plant operations, continuous production, intelligent control
Third-party testing of a concrete with 30% Q-SCM demonstrates superior performance to legacy and next-gen SCMs. 56
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of the manufacturing process, consistent Q-SCM performance at scale, and the operating and economic data required to design future commercial installations. Successful operation at Stockertown will establish the bridge from demo manufacturing to repeatable commercial deployment across a range of existing cement plants. To support this next phase, Queens Carbon is launching a 2026 fundraising round to finance the transition from demonstration to its first commercial installation.
Looking forward
The cement industry's transition toward lower-clinker, lower-carbon cement is underway but remains limited. The job of innovators is to provide practical, economically viable ways for the industry to transform at global scale. Queens Carbon works to generate returns for cement producers under current market conditions, using infrastructure they already own. That strategy supports increasing levels of decarbonisation, too. Q-SCM is the first commercial application of the Q-System, providing producers with a new source of engineered SCMs manufactured from feedstocks already available within their plants. From day one, Q-SCM will cost less to produce than clinker and be price-competitive with other SCMs, without relying on tax incentives or carbon credits. Beyond Q-SCM, Queens Carbon is
developing novel hydraulic cements on the exact same hydrothermal platform with the potential to replace up to 100% of conventional clinker. They would come to market under ASTM C595, C1157, or similar performance-based cement standards that evaluate materials on what they do rather than what they contain. When the industry is ready, future Q-Systems can, over a well-planned transition period, replace the kiln and calciner entirely rather than operate alongside them, producing next-generation SCMs and cements with near zero emissions. As the cement industry evolves, success will depend not only on new materials but also on manufacturing systems that can produce them reliably and economically, at industrial scale. Queens Carbon believes the Q-System is uniquely positioned to lead that transition because it combines manufactured materials, plant-compatible equipment, flexible heat and feedstock inputs, and an intelligent operating platform in one scalable, tunable system. The future of cement manufacturing will be shaped not only by new materials but by manufacturing systems that make existing plants more capable, more adaptable, and more productive. The Q-System was purpose built to enable this, making plants more capable, more flexible, more profitable, and more responsive to demands for change and improvement from the market.
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Ryan Gilliam, Fortera, explores the business case for scaling low-carbon cement and explains why commercial execution will define the next phase of cement decarbonisation. or much of the past decade, the cement industry's decarbonisation efforts have been defined by innovation. Supplementary cementitious materials (SCMs) like fly ash and slag, carbon capture technologies, alternative fuels (AFs), and process improvements have demonstrated that meaningful reductions in emissions are possible. More recently, progress has come through the addition of new chemistries like calcined clay and natural pozzolans, alongside new technologies that aim to recreate the feedstocks, chemistry, or processes. The industry has proven it can innovate. Now the question is: how can the industry deploy these solutions to have a meaningful impact at a global scale while maintaining the reliability, profitability, and performance that producers and customers depend on every day?
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The next chapter of cement decarbonisation will not be defined by laboratory breakthroughs alone. It will be defined by commercial execution.
Cement's dual challenge
Cement has always been the foundation of economic growth. Every bridge, highway, airport, manufacturing facility, school, hospital, data centre, and housing development depends on it. As populations grow and infrastructure ages, demand for cement continues to increase across both developed and emerging markets. According to the UN Environment Programme, half of the buildings that will exist globally in 2050 have yet to be built. With governments focusing on emissions reduction policies, infrastructure owners tracking carbon emissions, and customers placing greater emphasis on sustainability, a strategy is clearly required to reduce the embodied carbon in the infrastructure to come. The challenge for producers is manufacturing more cement while reducing emissions, all without compromising product performance or economic competitiveness. Success will require solutions that fit within the realities of industrial manufacturing rather than asking producers to choose between sustainability
Five drivers of low-carbon cement adoption. 60
and competitiveness. Green cannot be a compromise.
Bridging the adoption gap
Across industrial sectors, one consistent challenge emerges: the gap between pilot projects and commercial deployment. Many technologies perform exceptionally well in research environments and pilot projects, yet relatively few achieve broad commercial adoption. The reasons are rarely technical. More often, they are economic and operational. Does implementation increase production costs? Does it require significant changes to existing operations? Can it be integrated into current manufacturing assets? Does it depend on ongoing subsidies or incentives? Will customers adopt it without fundamentally changing specifications or construction practices? Can the plants be operated at high capacity factors with traditional operating staff? These are the questions every producer must answer before investing in new technology. History reminds us that industrial transformation does not occur simply because better technology exists. It occurs because that technology creates measurable business value.
What drives adoption?
The cement industry has never been reluctant to innovate. It has consistently embraced technologies that improve productivity, strengthen competitiveness, and create long-term value. The transition from wet-process to dry-process kilns dramatically improved energy efficiency. AFs expanded because they reduced both operating costs and emissions. Uptake of SCMs like fly ash, slag, and now limestone has been relatively fast. Each of these innovations has something in common: they strengthened the business while improving operations. That same principle will determine which low-carbon technologies achieve widespread adoption over the next decade. Successful technologies should satisfy five key drivers for low-carbon cement adoption: f Economics. Deliver a compelling return on investment and strengthen plant profitability. f Operational excellence. Integrate into existing manufacturing and supply chains while improving efficiency, reliability, and productivity. f Product performance. Meet or exceed the strength, durability, consistency, and quality customers expect. f Scalability. Deploy efficiently across existing manufacturing infrastructure and supply chains with practical capital requirements. World Cement September 2026
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f Market demand. Align with evolving customer expectations, procurement requirements, and regulatory frameworks while creating a competitive advantage. Environmental performance is no longer separate from these drivers; it is becoming part of them. The technologies that will define the next generation of cement will not succeed simply because they reduce emissions. They will succeed because they make better business sense. When lower embodied carbon is paired with stronger economics, superior performance, and scalable manufacturing, adoption becomes a commercial decision rather than an environmental one.
Turning CO2 into an asset
One of the more interesting shifts occurring across heavy industry is a changing perspective on carbon itself. Historically, CO2 has been viewed almost exclusively as a liability, a waste stream that must be avoided, captured, transported, or permanently stored. Increasingly, however, new approaches are asking a different question: what if CO2 could become a valuable manufacturing input? Carbon mineralisation is one example of this evolving mindset. Rather than treating industrial CO2 solely as an emission, mineralisation technologies convert it into stable cementitious materials that become part of finished construction products. This changes the conversation. Instead of focusing exclusively on carbon avoidance, producers can begin evaluating opportunities to improve resource efficiency, reduce process
emissions, increase product output, extend the value of existing assets, and position facilities for emerging carbon markets. More importantly, it reframes decarbonisation as an opportunity to create value rather than a cost centre.
Scaling through existing infrastructure Another lesson repeated throughout industrial history is that scale follows infrastructure. The technologies that achieve the broadest adoption are often those capable of integrating into existing manufacturing systems and supply chains rather than replacing them entirely. For cement producers, existing plants represent decades of investment in equipment, permitting, workforce development, logistics, customer relationships, and regional supply chains. Modernising these assets is often a faster and more capital-efficient pathway than building entirely new production systems. Technologies that leverage existing infrastructure reduce implementation and permitting risk, accelerate deployment, and improve the return on invested capital. As global demand for cement continues to grow, enabling producers to extract greater value from assets already in operation may prove just as important as developing entirely new manufacturing approaches.
An emerging demand signal
The market is changing as well. Infrastructure developers, commercial builders, architects, public agencies, and owners are increasingly evaluating embodied carbon alongside
Bridging the adoption gap. 62
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traditional measures of cost, durability, schedule, and performance. One of the strongest demand signals is coming from large-scale infrastructure investment. Data centres supporting AI, advanced manufacturing facilities, energy projects, transportation networks, and housing developments are driving unprecedented construction activity across North America. While these customers are committed to reducing their carbon footprints, they still expect reliable supply, competitive pricing, and proven performance. For producers capable of delivering lower-carbon cement without sacrificing quality, scale, or pricing, this represents an emerging competitive advantage.
The next decade of cement decarbonisation
Looking ahead, the next decade of cement decarbonisation will be defined less by scientific discovery and more by commercial execution. The technologies that ultimately scale will be those that integrate seamlessly into existing manufacturing and supply chains, demonstrate attractive project economics, deliver consistent product performance, earn market acceptance, and make efficient use of capital.
Those characteristics are what transform promising technologies into widely adopted industrial solutions. Innovation will always remain essential. Research will continue to expand what is technically possible. But the industry's greatest opportunity now lies in translating those innovations into practical solutions that producers can confidently deploy and customers are eager to specify.
From possibility to practice
The future of low-carbon cement depends on more than innovation. It depends on adoption. As the industry works to meet growing global demand while reducing emissions, the most impactful technologies will be those that align environmental performance with business performance. Solutions that improve competitiveness while lowering carbon intensity will ultimately define the next generation of cement manufacturing. The path to large-scale decarbonisation is not simply creating new technologies. It is creating technologies that producers, customers, and investors have the confidence to scale. That is how meaningful industrial transformation occurs. And that is how the industry moves from innovation to adoption.
GORCO S.A.
LEIOA (Bizkaia) Spain +34 944 635 244 gorco@gorco.es www.gorco.es
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khd.com
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CalPortland www.calportland.com
Dracyon Corp. www.DracyonCorp.com
Endress + Hauser www.endress.com
Fuller Technologies www.fuller-technologies.com
GORCO www.gorco.es
HÄGGLUNDS www.hagglunds.com
HEKO Group www.heko.com International Colloquium on Refractories www.ecref.eu/icr
KHD Humboldt Wedag
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25
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OBC
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02
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MAAG maaggear.com
MAPEI www.mapei.com
PSCL www.pscl.com
Sinoma Energy Conservation ltd www.sinoma-ec.cn
SKF www.skf.com
Slag & Ash Trade 2026 www.gmiforum.com
thyssenkrupp Polysius www.thyssenkrupp-polysius.com
World Cement www.worldcement.com
IFC
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