CHAPTER-3 CORPORATE PROFILE OF SELECT CEMENT …shodhganga.inflibnet.ac.in/bitstream/10603/56312/11... · Most of the building foundations in the Roman Forum were constructed of a

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CHAPTER-3 CORPORATE PROFILE OF SELECT CEMENT

COMPANIES IN INDIA 1. HISTORY OF CEMENT

It must be interested to know how cement is made today vis-à-vis the

historical background. Ever since civilizations stepped in the earth, people

sought a material that would bind stones into a solid, formed mass. The

Assyrians and Babylonians used clay for this purpose, and the Egyptians

advanced to the discovery of lime and gypsum mortar as a binding agent for

building such structures as the Pyramids.

The Greeks made further improvement and finally the Romans

developed cement that produced structures of remarkable durability. The secret

of Roman success in making cement was traced to the mixing of slaked lime

with pozzilana, a volcanic ash from Mount Vesuvius. This process produced

cement capable of hardening under water. During the middle Ages this art was

lost and it was not until the scientific spirit of inquiry revived that we

rediscovered the secret of hydraulic cement that will harden under water.

Most of the building foundations in the Roman Forum were constructed

of a form of concrete, placed in some locations to a depth of 12 feet. The great

Roman baths built about 27 B.C., the coliseum, and the huge Basilica of

Constantine are examples of early Roman architecture in which cement mortar

was used. Portland cement today, as in Aspin’s day, is a predetermined and

carefully proportioned chemical combination of calcium, silicon, iron and

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aluminum. Natural cement gave way to Portland cement, which is a

predictable, known product of consistently high quality. Aspdin established a

plant in Wakefield to manufacture Portland cement, some of which was used in

1828 in the construction of the Thames RiverTunnel.

But it was almost 20 years later when J.D. White and Sons set up a

prosperous factory in Kent that the Portland cement industry saw its greatest

period of early expansion, not only in England, but also in Belgium and

Germany. Portland cement was used to build the London sewer system in

1359-1867.

Thomas A. Edison was a pioneer in the further development of the

rotary Kiln. In 1902, in his Edison Portland Cement Works in New village,

N.J., he introduced the first long kilns used in the industry-150 feet long in

contrast to the customary 60 to 80 feet. Today, some kilns are more than 500

feet long. Parallel improvements in crushing and grinding equipment also

influenced the rapid increase in production. Since grinding process consumes

most of the energy various grinding systems like ball mill/vertical roller

mill/Roller presses has been the bottom to aerate the contents. Various new

designs were also developed to increase the efficiency of mixing.

2. WHERE IT IS HEADING?

The boom-and-bust syndrome normally characterizes a typical cyclical

industry. A huge potential market and rapid growth in the early stages lead to a

surge in interest and a flurry of research. The projected growth rates point to a

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lucrative market. The buoyant markets and huge profits raked in by players

tempt more players into the market. Capacities increase in excess of demand

and a glut in capacity is created.

Competition increases, prices fall and margins come under pressure.

Capacity addition comes to a halt; weaker players shut shot or sell off to larger

ones. Demand catches up and the cycle is repeated all over again. Perhaps, of

all the cyclical industries, the Indian cement industry exhibits this boom-and-

bust cycle most visibly. Consider the following:

Temptation

A huge potential market, easy availability of raw material and cheap

labor leads to a flurry of activity and a surge in interest. The easiest way to

estimate the potential that exists is the per capita consumption of cement,

which is abnormally low in India at 85 kgs as against a world average of 256

kgs and Asian average of 200 kgs. Although the growth of the industry depends

more in the level of consumer spending rather than on the capita consumption,

nevertheless, it serves as an easy benchmark to estimate the potential that

exists.

Fuel to Fire

The projected growth rates in demand (based on the potential per capita

consumption growth or other demand drivers like the expected GDP growth

rate) fuels stock market rallies. Consider the boom in cement stocks in 1994.

Every cement company was attracting valuations it never dreamt about.

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Scarcity induced by lower capacities and to a large extent on non-availability of

power, drove cement prices to the hilt. The kind of money minted by most

cement companies as well as investors in that period drove strategists to plan

enormous increase in capacity. This explains why capacity creation starting

1994, was so enormous.

The Rush

The amounts of profits that are being raked tempt more players into the

industry. Contagious enthusiasm sweeps the industry and suddenly there is a

glut of new players. Capacities start increasing at a rate greater than the

demand growth rates. A scenario of excess supply to demand becomes

imminent. Average annual capacity addition during the three-year period 1994-

95 to 1996-97 was 8.33 mt., while that for the five years till 1994-95 was just

3.3 mt. Against demand growth rate of 8 per cent capacity addition rose at over

10 per cent during 1995-96 and 1996-97, and over 9 per cent in 1997-98.

The Anguish

With competition increasing and growth in supply exceeding demand

growth, prices begin to fall. This is also the time when players realize that

Greenfield capacity addition would be to their own detriment. Consolidation

within the industry starts. Most of the players weakened during the excess

supply induced recession sell off to larger and stronger players. Hostile

takeovers are also witnessed during this period as the only way to expand is by

take-over. The slew of takeovers in the last two years culminating in Gujarat

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Ambuja taking a stake in ACC, the largest cement in India bears ample

testimony to this fact. Till now, over 12 mt. has changed hands, excluding

Indian Rayon’s transfer of 3 mt to group company Grasim.

3. HOW CEMENT IS MADE?

Two main methods of cement manufacturing were prominent, the dry

process and the wet process. Dry process now has almost replaced the wet

process consumes high thermal energy for drying the moisture. When rock is

the principal raw material, the first step after quarrying in both processes is the

primary crushing. Mountains of rock are fed through crushers capable of

handling pieces as large as an oil drum. The first crushing reduces the rock to a

maximum size of about 6 inches. The rock then goes to secondary crushers or

hammer mills for reduction to about 3 inches or smaller. It is then ground in

ball mill to fine powder with other ingredients like clay/iron ore/bauxite to

create a combination of values for silica/alumina/lime etc. in the mixture. If the

process is wet, the grinding goes on in with water so that slurry is resulted after

grinding. This slurry is further mixed in mixers and pumped to the kiln. For a

dry process kiln, the ground powder is sent to blending silos for uniform

mixing of components added during the grinding stage. This blended material

is fed to the preheater/calciner. The preheater is a group of cyclones placed

over one another wherein material comes down and hot gases goes up heating

the material and calcining it in the process. Calcinations means liberating

carbon dioxide and converting calcium carbonate to calcium oxide. Calciner is

nothing but a duct added to give more reaction time to material for calculation.

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This partially calcined material then comes to the kiln, which is refractory lined

rotating tube having burner fitted in the other end. This burner fires coal/ oil/

natural gas to create a temperature of 1600 C at the discharge end.

As the material in the kiln rolls down towards the discharge end, various

reactions take place amongst the components resulting in a mass known as

clinker. This clinker is cooled in coolers. The coolers are either planetary type

or grate type.

Grate coolers of modern times are much efficient resulting in better heat

recuperation and allows reusing this heat in the kiln. Cooled clinker then either

goes to storage silo or clinker yard. From the clinker yard it is taken for

grinding. In case of Ordinary Portland cement is made only gypsum (4-6%) is

added before grinding. In case of Portland pozzolona cement additives like fly

ash/brick etc. are added. Grinding again is same like for raw material grinding

it ball mill or with latest technologies like vertical mill/Roller presses etc. The

cement powder then taken to packing plant or discharged from silo to a buck

loader directly.

4. HOW CONCRETE IS MADE?

The combination of cement, water, sand, and coarse aggregates

(particulars of gravel or rushed stone)as normally occurs in the process of

concrete mixing is perhaps best described in terms of a simple three-part

system:

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1. Portland cement+water=cement paste

2. Cement paste+sand=mortar

3. coarse aggregates+mortar=concrete

The cement paste component functions in the first instance to coat and

“lubricate” the individual grains of sand, thereby imparting “workability” to the

mortar phase. In turn, the mortar serves to lubricate the coarse aggregate

particles and so give workability to the fresh concrete. The quantities of cement

paste and mortar necessary to achieve adequate levels of workability will

depend on the amounts of sand and coarse aggregate present in the concrete, on

the associated “grading” of constituent particle sizes, and on the actual level of

workability required for the job. If there is insufficient mortar or cement paste

the mix will tend to be “harsh” and unworkable. Conversely, too much mortar

or cement paste will promote the likelihood of “segregation” effects whereby

the coarser aggregate fractions tend to separate out from the remainder of the

mix. Contrary to popular belief, concrete does not set and harden through a

physical drying-out process. Setting and hardening is due instead to a series of

chemical reactions between the Portland cement and water present in the mix;

as a result of this so-called hydration process the original cement paste phase is

transformed into a sort of “mineral glue” which acts to bind the sand and coarse

aggregate fractions together.

Most natural aggregate are a good deal stronger than the sort of cement

pastes found in typical concretes; i.e. the “mineral glue” tends to function as

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the weakest link. Accordingly, the strength of a hardened concrete is normally

controlled y the strength of its cement paste phase. In turn, for any given

quantity of cement, the associated paste strength is governed first and foremost

by the water content of the original mix; thus, the lower is the total amount of

mix water employed, the greater is the ultimate strength potential of motor (and

vice versa). Conversely, if the total mix water is held constant, the higher (or

lower) is the level of cement usage, the higher (or lower) becomes the potential

strength capacity of the cement paste phase.

The actual quantity of cement paste has no real influence here, it is the

amount of cement as compared to the amount of water, which is the main

factor. Concrete aggregates should be relatively clean. (The squeezing of

“dirty” sand will generally produce a noticeable stain on the plam). Dirty or

dusty aggregates tend to require far more mixing water, unless correspondingly

higher levels of cement usage match this additional “water demand”, strength

losses are likely.

The presence of dusts, silts, or clays can also inhibit the degree of bond

between individual coarse aggregate particles and the surrounding mortar,

again to the ultimate detriment of strength; in certain circumstances the adverse

effects of using dirty aggregates any even extend to interference with the

normal processes of cement hydration. It is often supposed that aggregates

serve to “enhance” the strength of concrete. While this rarely applies in

practice, neither is it the case that the aggregate fractions merely function in the

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role of cheap fillers. If or when a concrete dries out, the associated cement

paste, the higher is its shrinkage potential.

Normal aggregates on the other hand, show little or no shrinkage on

drying. Accordingly, the greater are the amounts of sand and coarse aggregate

materials present in a concrete mix, the lesser will be the net influence of paste

shrinkage. For a typical concrete in which the combined aggregate fractions

generally occupy somewhere between 70-80 per cent of the total volume, the

shrinkage potential is probably of the order of 10-20 per cent of the

corresponding value for the paste component acting alone.

5. TYPES OF CEMENT

Ordinary Portland Cement (OPC)

The Ordinary Portland cement is popularly known as grey as cement,

which is produced by grinding clinker with 5 per cent gypsum. It is used in all

general concrete construction, mass and reinforced concrete. It accounts for

about 70.60 per cent of the total production.

Portland Pozzolona Cement(PPC)

It is cheaply manufactured because it uses fly ash/burnt clay/coal as the

main ingredient. PPC has a lower heat of hydration, which is of advantage in

preventing cracks where large volumes are being cast. PPC accounts for 18.3

per cent of the production.

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Portland Blast Furnace Slag Cement (PBFSC)

It is made by grinding granulated blast furnace slag, steel industry by

product (up to 65%), gypsum (5%) and clinker (balance). PBFSC has a heat of

hydration even lower than PPC and is generally used in construction of dams

and similar massive construction. It contributes nearly 10 per cent to the total.

White Cement

Basically it is OPC: clinker using fuel oil (instead of coal) and with iron

oxide content below 0.4 per cent to ensure whiteness. Special cooling

technique is used. It is used to enhance aesthetic value, in tiles and for flooring.

White cement is much more expensive than grey cement.

Specialized Cement

Oil Well Cement: is made for clinker with special additives to prevent

any porosity.

Rapid Hardening Portland cement

It is similar to OPC, except that it is ground much finer, so that on

casting the compressible strength increases rapidly. Water proof Cement: OPC

with small portion of calcium stearate or non-saponifibale oil to impart

waterproofing properties.

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6. USES OF CEMENT

1. Ordinary Portland Cement (OPC): Presently Bureau of Indian Standard

has classified OPC in three grades based on the strength of cement. These

grades are:

1) Grade-33-IS-269-1989

2) Grade-43-IS-6112-1989

3) Grade-53-IS-12269-1987

These type of cement are suited for all modern types of constructions

including all kinds of masonry and concrete works such as pre-cast and pre-

stressed concrete. They are also suitable for all kinds of repair works in

masonry and concreting. The higher the grade of cement used, the greater

would be the economy, durability and technical advantages. Moreover

construction time is also reduced.

2. Blended Cement: Milling Portland clinker gypsum and insert materials in

suitable proportions and grinding the mixture to get a thorough and intimate

mix obtain it.

3. Portland Pozzolona cement (PPC): Clinker+Gypsum+Pozzolona (Flyash,

burnt clay etc). Portland blast furnace slag-Cement Clinker +Gypsum +

granulated slag Masonry Cement - Cement Clinker + Gypsum + Pozzolona

(Limestone Powder ad mixtures etc.)

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PPC: Suitable for most of the applications as stated in OPC ideally suited for

domestic consumption like plastering, brickwork, mass concerning works like

dams, large foundation. At his cement enhances the impermeability and

cohesiveness of concrete. As a result durability is enhanced. It also generates

low heat of hydration.

It is cheaply manufactured because it uses fly ash/ burnt clay/ coal waste

as the main ingredient. PPC has a lower of advantage in preventing cracks

where large volumes are being cast. PPC account for 18.3 per cent of the

production.

3. Slag Cement: Common application is similar to those of OPC. However

besides that it has more sulphate resistance properties than OPC and is suitable

for coastal construction. It is made by grinding granulated blast furnace slag,

still industry by product (up to 65%), gypsum (5%) and clinker (balance).

PBFSC has a heat of hydration even lower than PPC and is generally used in

construction of dams and similar massive construction. It contributes nearly 10

per cent to the total.

4. Masonry Cement: Exclusively meant for masonry works and plaster only.

5. Low heat Portland cement: Grinding and chemical composition are similar

to those of OPC. All applications requiring very early strength, very high early

removal of from works, very high handing of pre-cast element, high grade

precast and prestressed concrete product, slip form, cooling tower and pill

tower.

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6. Sulphate Resistant Cement: The chemical composition is designed in

designed in such a manner that C3A content in cement restricted to 5 per cent

and other chemical constituents are similar to OPC. Used in structures in

contact with soil or water having enough sulphate concentration.

7. Oil Well Cement-this is a special kind of cement for use in the drilling of

wells to fill the space between the steel lining tubes and the well wall. It sets

slowly in order to give the slurry made with it sufficient time to reach the large

depths of the oil wells. However once set it develops strength rapidly and

remains stable at high temperature.

8. White Cement: it is primarily used for decorative purpose and in

manufacture of titles. The raw materials are so chosen that the maximum iron-

oxide content is strictly limited to 1 per cent. Variety of colors can be obtained

by the addition of pigments.

9. Super Sulphate Cement: Intergrading makes super sulphate cement, a

mixture of 80-85 per cent selected granulated slag with 10-15 per cent calcium

sulphate and about 5 per cent of Portland clinker. It may be where high

sulphate, acid and organic oil attacks on structure is expected.

10. High Alumina Cement: The chemical composition is designed in such a

manner that the total alumina content is at least 32 per cent. This cement is

ideally suited for high temperature cast able refractory.

11. Grey Portland Cement: Chemical composition is similar to OPC expect

the following limitations, which ensures very strength, increased cohesiveness

and increased durability factor towards chemical attack. All applications where

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high-strength concrete is required ideally suited for railway prestressed

concrete sleepers, bridges and slip form construction.

Description Limits as per IRST-40 OPC as per IS-Spec

LSF 0.8-1.02 0.66-1.02

C3S 45% Min-

C3A 10% Max-

Fineness 3700Min-

7. CEMENT INDUSTRY IN INDIA

The Indian cement industry continues to suffer from excessive

production capacity a time when demand growth continues to be sluggish. The

industry remains highly fragmented and profit have been impaired by a series

of debilitating price wars as well as from steadily rising costs. The recent

arrival of Lafarge may herald some much needed industry consolidation.

Meanwhile cement capacity levels continue to be swollen by a sizeable new

building programmed.

Population: 935.7

Density 314

Area 279190

Capital City New Delhi

GNP Per Capita US$310

Urbanization 26 Per cent

Per Capita Cement Consumption 79kg

Official Language Hindi, English

Currency Rupee

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Year Production Consumption Exports Imports

2003 48.9 48.9 0.1 0

2004 53.61 53.61 0.4 0

2005 53.73 49.86 1.18 0

2006 54.09 52.91 2.83 0

2007 58.35 56.67 3.58 0

2008 69.32 60.64 4.8 0

2009 69.55 67.17 2.38 0

2010 76.22 73.52 2.7 0

2011 80 75.66 4.24 0

2012 84 80.6 3.4 0

8. INDUSTRY OVERVIEW: CONSTRUCTION MACHINERY

The demand for new construction equipment in India increased from

USD 1.4 billion in 2003 to USD 1.7 billion in 2004. Demand is expected to

increase to USD 2.1 billion by the end of 2005. During the following three

years, the Indian construction equipment industry is projected to grow 20 per

cent each year. Similarly, U.S. imports that now stand at USD 81 million are

expected to grow 27 per cent in each of the coming three years. Since the onset

of “economic liberalization” that occurred during Indian fiscal years (FY)

1996-97, the Government of India has adopted industrial policy changes that

have permitted deregulation.

Consequently, Indian companies have restructured and modernized.

Except for a few strategic industries, the private sector can establish joint

ventures with foreign firms.

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Now the Government of India allows majority of foreign equity

ownership for such ventures. Joint ventures with higher level participation can

also be considered if there are substantial benefits to the Indian economy. In

particular the GOI also encourages infrastructure ventures involving in private

sector. These initiatives have opened huge market and investment opportunities

for the private sector. Many global players are developing industrial and

infrastructure projects either individually or jointly with lending Indian firms.

Industry overview: Cement Producers

India was the fourth largest producer of cement in the world with 115

large plants with installed capacity of 96 Mt/yr belonging to 57 companies, 300

mini cement plants each with less than 2,00,000 t/yr overall installed capacity

in 2002 was about 105 Mt/yr (world cement, 2002). Redland PLC, based in the

United Kingdom, was negotiating with the Birla Group to set up a joint venture

to produce ready-mix concrete for the Delhi area, which has been undergoing

considerable growth. If realized, then both companies would have a 50 per cent

equity share (Industrial Minerals, 2002).

Problems of Cement Industry

The main impediments to the growth of cement industry in India may be

broadly listed as follows:

1. Shortage of Capital-the cement industry is capital-intensive in nature.

On account of its record on declining profitability, it is unable to raise

the required finance from the capital market.

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2. Power shortage-Power is an important infrastructure, which the cement

industry needs. The cement industry is being adversely affected with the

State Electricity Boards (SEBs), raising costs year after year

accompanied by diminishing quality of power supplied, in terms of

frequent voltage fluctuations, power cuts and interruptions.

3. Locational problems- Cement industries are mainly situated in Western

and southern regions producing about 71 per cent of the total output,

while the Northern and Eastern regions account form290 per cent of

total output. The southern and western regions consume only 57 per cent

of their total output, while the Northern and Eastern regions consume 43

per cent of their total production. There is excess production in the

Southern and Western regions while there is excess demand from

Northern and eastern regions. These factors lead do heavy transport cost.

4. Shortage of coal- Coal shortage affects production of cement industry

resulting in idle capacity and under utilization of capacity. Coal

requirement by the industry today, stands at 13mt, which is just 6 per

cent of the total cost produced in India. As a result, industry sources say

that, cement manufactures are left at the mercy of traders in coal, who

charge exorbitant prices. By 2005 AD, the need for coal will go up to

25mt per annum.

The availability and movement of coal has been a perennial problem of

the cement industry. Ninety per cent of the coal deposits occur in the four states

of Bihar, Orissa, West Bengal and Madhya Pradesh. Barring Madhya Pradesh,

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none of the other states have any limestone deposits and hence coal has to be

hauled over very long distances.

Keeping in view the likely production of 737mt of cement in 2001, coal

requirement will have to be doubled to level of 21mt and about 15mt will have

to be moved by rail against 8mt by rail in 1996.

Requirement of coal

Year Estimated Cement production(Mt.)

Estimated Coal Requirement

2004 54 14.0

2005 57 15.0

2006 62 16.5

2007 67 17.5

2008 72 19.0

2009 76 20.5

2010 80 22.1

2011 87 23.7

2012 N.A. 24.1

5. Non-availability of railway wagons- Non-availability of railway

wagons to considerable delay in bringing in the raw materials and in

dispatching the cement to various potential markets. Sending cement

by open railway wagons leads to pilferage and damage by rain. 55

per cent of cement is dispatched by rail and 45 per cent by road.

6. Defective method of transport- Methods of cement bagging and its

transportation in india are primitive which marketing inefficient and

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uneconomical. Hardly any quantity of cement at present is handled in

bulk.

7. Negligible share in world trade- India’s share in world trade is

negligible. Currently, India exports only about 3.5 lakh tones in a

year.

8. Technological obsolescence- The industry is in need of change in the

production process. There is a need for conversion from wet process

to dry process.

Apart from a modernization programmed involving Rs.300 crore,

technologies for computerized control systems, X-ray analyzers, pollution

control devices, captive power plants, upgrading quarry operations, etc, have

all been adopted by the industry.

Quality- In order to meet the challenge of globalization, the Indian

cement industry will have to adopt the ISO 9000/IS 14000 series of standard

and the Total Quality Management (TQM) system.

So far, only about 10 per cent of cement plants have gone in for this

international certification.

Cement manufactured in India is subjected to quality assurance checks

within the plant, and further scrutinized and certified by the autonomous

Bureau of Indian Standards (BIS). India is one of the few counties to have set

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up a limit of 0.5 per cent by weight, for chloride ions in cement for use in long

span reinforced concrete and priestesses concrete structures.

With eco-labeling and ISO-labeling, becoming major issues in several

countries, the Indian cement industry will have to conform to stiff norms for

international and environmental acceptance.

Cost factor: The single major item of expenditure is the cost of fuel (viz.

furnace oil/LSHS), which constitutes at least 60 per cent of the variable cost.

The industry has to find some means to reduce consumption of fuel oil of it is

to survive in the long term.

Modern packing materials will have to be introduced, which are strong

enough, but at the same time cheaper to counter the increasing price of jute and

paper.

Quality improvement and usage applications are major thrusts of the R

& D effort, to benefit usage in India and abroad. Identified areas for future

research and development include coal beneficiaries, quality modulation,

improved burners etc.

Mini Cement Plants

Mini cement plants play a vital role in socio-economic development. In

India, sizeable deposits of limestone, which is the main raw material required

for the production of cement, are spread over the country. In those places

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where there are limited quantities of time stone available, and it is not possible

to set up large plants, the Government has decided to start mini plants.

Process of Cement Manufacturing

Wet Process

It is the oldest process and it was originally used for easily crumbly

materials because it can help to control accurate mix of raw material. In this

process, the raw material is broken up and incorporated in wash mills. This

usually consists circular hall, covers inside by bricks or concrete and

containing a framework of iron in the walls to prevent the passing of raw

materials otherwise it will reduce the proportion of chalk and clay which are

fed in the required proportion in the wash mill together with sufficient water to

form materials which are reduced to a fine state of decision and pass as a slurry

through the screens in wall of the pit. The flints, which are included in the

chalk, remain at the bottom to the wash of mill and are removed periodically.

In the modern methods, the raw material are usually reduced in size by

treatment in another wash mill with finer screens in centrifugal screening mills,

or by passing it through a tube mill. If the raw material contains harder

limestone and shells the wash is not enough to affect the reduction.

In this case the raw material are crushed and passed into large tube mills

after adding the water to the mill, in an adequate quantity to form the slurry, if

the hard limestone and clay are the raw materials, the clay is passed through the

tube mill already dispersed in the water. At the same time it is ensured that the

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finished slurry does not contain more than a few percent of materials remaining

on a 170 mesh and the water content in it varies from 35-40 per cent with

different raw material. The slurry is pumped to slurry tanks or pool and mixed

by compressed air to keep the mixture homogeneous. To keep the limestone in

good proportion in the mix it is controlled by analysis and the supply to the

wash mill of tube mills is adjusted periodically as required. The final step to

adjustment of composition is often obtained by mixing the slurry from two

basins one which is kept slightly high and on slightly low in time.

The wet process is known as rotary of kilns in which the cement is

brunt. It is a long cylinder mixing on its axis which separates the materials

supplied at the upper and travels slowly to the lower end. The fuel is blown

inside by an air blast and fired in it. In the upper part of the kilns chains are

fixed to assist in the transfer of the heat from kilns gases to the raw materials.

The slurry is dried in the upper part of the kilns and water driven out as steam

and then as it descends the kiln, the dry slurry undergoes a series of reactions

forming in the most strongly heated zone hard granular masses mostly form 1/8

inch to ¾ inch diameter known as clinker mill where small quantity of gypsum

is added during cement passes to silos from which it is drawn for packing.

Dry Process

In this process the raw materials are crushed and dried by rotary dries,

proportional and ground in tube mills consisting of rotating steel cylinders

contain balls of different sizes. The mill is continuous in operation, and

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supplying raw material at one end discharging the ground material at the order.

The dried powder is transported to storage in silos where it is supplied to the

kiln. In this process it must be decided whether to use rotary kiln or not. The

use of any other device will practically give the same results as drive from use

of rotary kiln; the choice in this case will depend upon the cost factor, the

space, specific requirement and lastly the fuel. Shaft kilns required to slop fuel

and can, therefore only be employed in places where coke or anthracite are

readily available. Rotary kilns can fire with pulverized fat coal gas or oil.

Semi Dry Process

Next process of drying is called semidry process, the shaft kilns are

suitable filled with various types of discharging gates. It must discharge the

clinker from the kiln continuously at a uniform rate. The clinker, which formed

in the kiln, must be broken up while being discharged. The raw material and

fuel are mixed in a correct proportion and this mixture is then agglomerated

into nodules in conjunction with the addition of a suitable quantity of water, the

quantity of water is the ranger of 8 to 14 per cent depending upon the nature of

meal. Some types of machines for agglomerating the raw material may be

mentioned as disenoduliser , drumnoduliser, edge runner with perforated

runner tracks, rings in which run heavy roller which pass the material through

the Holes. In certain case its sufficient nearly to moisten the raw material in

simple paddle worn conveyor. For high capacity shaft kilns, the row meal and

fuel are nodules in a special revolving drum or in an inclined revolving disc or

pan. The finally divided material or agglomerate by the nodulisign into small

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balls or nodules, and has in present year come to general use as a most suitable

method of preparing the raw materials for shaft kiln. To pass the material

through the sintering zone as rapidly as possible, it is necessary to supply and

distribute air adequately. The shaft kiln are constructed with clear internal

diameter of 2-3 meter and the height of shaft in 8 to 10 meter for output

ranging from 13 to 200 tons of clinker per 24 hours a day. The consumption of

fuel is about 800 to 1200k. cal per kg of clinker.

Cement is the one of the core industries which plays a vital role in the

growth and expansion of a nation. The demand for cement, being a derived

one, depends primarily on the pace of activities in the business, financial, real

estate and infrastructure sectors of the economy. Cement is considered

preferred building material and is used worldwide for all construction works

such as housing and industrial construction, as well as for creation of

infrastructions like ports roads, power plants etc. Thus, it can said to be a

significant contributor to the government’s revenue collection and a pillar of

overall planned development of an economy.

In India, the foundation of a stable Indian cement industry was laid in

1914 when the Indian cement company ltd. manufactured cement at porbundar

in Gujarat. In the initial stages, particularly during the period before

Independence, the Growth of the sector had been very slow. The indigenous

production of cement was not sufficient to meet the entire domestic demand

and accordingly, the Government had to control its price and distribution

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statutorily. Also, the large quantities of cement had to be imported for meeting

the deficit in the economy. However, with liberalizations and introduction of

several policy reforms, the cement industries has been decontrolled which gave

impetus to its pace of growth. Today, it is one of the most advanced and

pioneering sectors in the country. Cement is a basic material input which

facilitates the promotional and developmental efforts, at the fast pace, in the

areas of infrastructural set up and other construction related works.

Indian cement industry is the second largest cement producer in the

world after China with a total capacity of 151.2 Million Tons (MT). In the spite

of it being second largest cement producer in the world, Indian cement

industries falls in the list of lowest per capita consumption of cement with 125

kg. The reason for this is poor rural people who mostly live in mud huts and

cannot afford to have the commodity. The demand and supply of cement in

India has grown up over the years. In a fast developing economy as India there

is always large possibility of expansion of cement industry. The Indian cement

industry is one of the vital industries for the economic development. The total

utilization of the cement in a year is used as an indication of economic growth.

Cement contributes as a necessary constituent of infrastructure development

and a key raw material for the construction industry, especially in the

government’s infrastructure development plan in the context of the nation’s

socio-economic development.

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The Indian cement industry is dominated by 20 companies, cement

production in India. Which account for almost 70% of the total cement

production in India? Cement Industry constitutes of 140 large and more than

365 mini cement plants. The Indian Cement industry plays a major role in the

growth of the nation for that case in any country. Industry Cement Industry was

under full control and supervision of the government. However, it got great

relief at a large extent after the economic reform which made its growth easier.

Still government interference, especially in the pricing, is evident in India.

Thus, the Indian cement industry has strong capacity base and produces

quality cement which meets the global standards. It has achieved a tremendous

success in technological up gradation and assimilation of latest technology.

There is also great scope for increase in export of cement. More importantly,

the gap between its demand and supply has been reduced to a very large extent

and the sector is likely to witness higher growth in the coming years. All this

indicates that the cement industry has an important role to play in the Indian

economy.

The major players of the study are ACC, Ambuja, Birla, J.K. cement,

Madras/Ramco Cement, Shree cement, Ultratech cement. This cement

companies are actively considering their expansions plans in order to accelerate

the growth and demand for the cement sector.

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9. ASSOCIATED CEMENT COMPANIES LIMITED (ACC)

ACC (ACC Limited) is India's foremost manufacturer of cement and

concrete. ACC's operations are spread throughout the country with 17 modern

cement factories, more than 40 Ready mix concrete plants, 21 sales offices, and

several zonal offices. It has a workforce of about 9,000 persons and a

countrywide distribution network of over 9,000 dealers.

Since inception in 1936, the company has been a trendsetter and

important benchmark for the cement industry in many areas of cement and

concrete technology. ACC has a unique track record of innovative research,

product development and specialized consultancy services. The company's

various manufacturing units are backed by a central technology support

services centre - the only one of its kind in the Indian cement industry.

ACC has rich experience in mining, being the largest user of limestone.

As the largest cement producer in India, it is one of the biggest customers of

the domestic coal industry, of Indian Railways, and a considerable user of the

country’s road transport network services for inward and outward movement of

materials and products.

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Among the first companies in India to include commitment to

environmental protection as one of its corporate objectives, the company

installed sophisticated pollution control equipment as far back as 1966, long

before pollution control laws came into existence. Today each of its cement

plants has state-of-the art pollution control equipment and devices.

ACC has made significant contributions to the nation building process

by way of quality products, services and sharing expertise. Its commitment to

sustainable development, its high ethical standards in business dealings and its

on-going efforts in community welfare programmer have won it acclaim as a

responsible corporate citizen. ACC’s brand name is synonymous with cement

and enjoys a high level of equity in the Indian market. It is the only cement

company that figures in the list of Consumer Super Brands of India.

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BOARDS OF DIRECTORS

Boards of directors of ACC are thirteen in number including chairman.

Given below are the names of the individuals who form the boards of directors

of the company

1. Mr N. S. Sekhsaria

Chairman

2. Mr Bernard Terver

Deputy Chairman

3. Mr Kuldip K Kaura

Chief Executive Officer & Managing Director

4. Mr Bernard Fontana

5. Mr M L Narula

6. Mr Shailesh Haribhakti

7. Mr Aidan Lynam

8. Mr Sushil Kumar Roongta

9. Mr Ashwin Dani

10. Mr Farrokh K. Kavarana

11. Mr Vijay Kumar Sharma

12. Mr Arunkumar Ramanlal Gandhi

13. Mrs Falguni Nayar

AWARDS AND ACHIEVEMENT

ACC Limited is India’s foremost manufacturer of cement and ready

mixed concrete with a countrywide network of factories and sales offices.

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Established in 1936, ACC is acknowledged as a pioneer and trendsetter in

cement and concrete technology. Among the first companies in India to include

environment protection as a corporate commitment, ACC regularly wins

accolades for best practices in environment management at its plants and

mines, and for demonstrating good corporate citizenship. The quality of its

products and customer services make ACC the most preferred brand in the

Indian cement industry. ACC Limited is part of the worldwide Holcim group.

ACC has achieved milestone and awards and accolades to its credit.

AWARDS & ACCOLADES

1. National Award for Excellence in Water Management by Confederation

of Indian Industry (CII)

2. Outstanding Corporate Vision, Triple Impact - Business Performance

Social & Environmental Action and Globalization for 2009-10 from

Federation of Indian Chambers of Commerce and Industry

3. Asia Pacific Entrepreneurship Award in two categories, Green

Leadership and Community Engagement by Enterprise Asia.

4. Indira Priyadarshini Vrikshamitra Award --- by The Ministry of

Environment and Forests for "extraordinary work" carried out in the

area of afforestation.

5. Subh Karan Sarawagi Environment Award - by The Federation of

Indian Mineral Industries for environment protection measures.

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CORPORATE SOCIAL RESPONSIBILITY

Today they define Corporate Social Responsibility as the way a

company balances its economic, social and environmental objectives while

addressing stakeholder expectations and enhancing shareholder value.

But ACC has undertaken social volunteering practices almost from its

inception, – long before the term corporate social responsibility was coined.

The company’s earliest initiatives in community development date back to the

1940's in a village on the outskirts of Mumbai while the first formal Village

Welfare Scheme was launched in 1952. The community living around many of

our factories comprises the weakest sections of rural and tribal India with no

access to basic amenities.

ACC is desirous of playing a meaningful role in the nationwide effort to

eradicate HIV/AIDS and has pledged to support the Confederation of Indian

Industry in their initiative. ACC recognizes that a fundamental step in this

respect involves a clear statement of the company’s internal policy to deal with

employees affected by HIV/AIDS. CII has framed a Code of Practice for

Industry to guarantee and safeguard the rights of employees infected and

affected by HIV/AIDS. They adopt this as ACC’s internal workplace policy for

HIV/AIDS.

OCCUPATIONAL HEALTH & SAFETY

Occupational Health & Safety (OHS) is a vital part of ACC’s journey

towards Sustainable development. Safety Audits are being carried out in ACC

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since 1995 by National Safety Council based on the 5 Star Auditing System of

British Safety Council. There is a continuous effort to measure and improve

Safety Management Systems to avoid accidents.

They have an Apex OH & S Committee headed by the Managing

Director. This committee oversees implementation of their OH & S policy

Each of our plants and manufacturing units have Professional Doctors and

medical facilities for continuous monitoring and observation of workplace

hygiene and occupational health.

10. AMBUJA CEMENT

Ambuja Cements Ltd(ACL) was incorporated in the year 1981 as

Ambuja Cements Pvt. Ltd. The company was established as a joint venture

between the public sector Gujarat Industrial Investment Corporation (GIIC)

and Narottam Sekhsaria & Associates. In May 19, 1983, the company was

rehabilitated into a public limited company. Subsequently, the company name

was changed to Gujarat Ambuja Cements Ltd. Further, the name was changed

to Ambuja Cements Ltd. Ambuja Cements is a major cement producing

company in India. The principal activity of the company is to manufacture and

market cement and clinker for both domestic and export markets. The company

has five integrated cement manufacturing plants and eight cement grinding

units. It is the first Indian cement manufacturer having a captive port with three

terminals along the country's western coastline to facilitate timely, cost

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effective and environmentally cleaner shipments of bulk cement to its

customer.

BOARDS OF DIRECTORS

1. Mr.Suresh Neotia (co-Founder)

2. Mr.Narotam Sekhsaria (Chairman)

3. Mr.Onne van der weijde (Managing Director)

4. Mr.B L Taparia (Company Secretary)

5. Mr.B B Tandon

6. Mr.P K Laheri

7. Mr.Manmohan Malhoutra

8. Mr.sharadchandra Kale

9. Ms.Padmini Somani

10. Mr.V K Jain

11. Ms.Pearl Tiwari

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PRODUCT & SERVICES

HIGH STRENGTH – HIGH PERFORMANCE

Ambuja Cement is committed to make high strength cement that would

enable our customers build strong and durable structures.

To achieve this, the finest quality of limestone is used and state-of-the-

art technology deployed. But our people have also used one more ingredient –

Innovation. They have developed an innovative way of using fly ash to produce

high strength Portland Pozzolana Cement (PPC)

Millions of tons of fly ash is generated as waste annually by thermal

power plants and poses a high environmental hazard. This waste is put to

productive use and this innovation has also meant 25% less limestone is used in

the production of cement.

Ambuja Cement latest breakthrough is the launch of Ambuja PLUS, a

high quality cement with a promise of “more strength”. This new cement, just

released in the eastern and western markets, offers twin advantages — higher

strength in concrete as well as long term durability.

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Sl. No. Year Award Name Reason

1 2004 Asian Institute of Management

The Asian CSR Awards for our contribution towards developmental activities

2 2006 Development Support Centre (DSC)

‘The Rural Development Award’ conferred on, Sr. Programmer Manager at Ambuja Nagar

3 2006 Development Support Centre (DSC)

‘The Rural Development Award’ conferred on, Sr. Programme Manager at Ambuja Nagar

4 2008 Excellent Water Management Initiative Award - Beyond the Fence

Awarded by CII-Godrej Green Business Centre for salinity mitigation work in Gujarat

5 2010 Social and Corporate Awards

Awarded by the Bombay Stock Exchange in January 2010.

6 2012 National Award for Excellence in Water Management 2012

" Excellent water efficient unit" ACL Rabriyawas under With-in the fence

7 2013 Best NGO Award for working in the cotton sector

Awarded by Northern Indian Cotton Association Ltd.

AWARDS

For its work on improving community living and encouraging

sustainable development, ACF has won national and international awards. With

such recognition our faith in our mission is renewed and it encourages us to

work towards our future objectives.

RECOGNITION

1. National Award for commitment to quality by the Prime Minister of

India.

2. National Award for outstanding pollution control by the Prime Minister

of India.

3. Eco-Gold Star by TERI

4. Best Export Award by CAPEXIL.

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5. Award for Corporate Social Responsibility by Business World –

FICCI

6. International Award For Rural Development by Asian Management

Institute (AIM)

7. ISO 9002 Quality Certification.

8. ISO 14000 Certification for environmental systems.

CORPORATE SOCIAL RESPONSIBILITY

In 1991, the company set up Ambuja Cement Foundation to trigger all-

round development of the people around its cement plants. The Foundation

decided to traverse the difficult but more productive path of helping the people

to help themselves. With great dedication and commitment, the foundation

energized the local people to participate and own their development process. It

became a facilitator and catalyst, rather than a one-time fund provider. It

developed easily replicable and sustainable modules for water management,

sustainable agriculture and healthcare.

1. Rural Upliftment- Ambuja Cement Foundation has established its

office in Sarnad Gujarat and has undertaken a needs assessment of the

four villages where developmental work has been proposed. Key issues

have been identified and initial activities have been kick-started through

participatory methods, and a good rapport has been established with the

villagers. As a part of these activities, a few important members of the

village community were taken to Ambujanagar to be introduced to the

activities being conducted there. The villagers have appreciated the

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work being done there and are keen on having similar activities in their

villages too. Development activities in Sanand will be focused on water

resource management and generation of alternate livelihoods.

2. A Social Impact Assessment -was carried out by ERM, which is an

external resource agency in Marwar Mundwa, Rajasthan, in the areas

surrounding the proposed cement plant. A workshop has been organised

by ERM, on the 10th of April, 2008, at Rabriyawas, for senior

management there to introduce the concept of social impact

assessments.

3. Training to rural communities-At Darlaghat in Himachal Pradesh,

ACF partnered with the Punjab National Bank to establish and run the

Skill and Entrepreneurship Development Institute (SEDI). The Institute

aims at providing short-term training courses for various fields that give

the members of the surrounding rural communities an opportunity for

alternate employment. One of the newest courses SEDI is offering is on

operating heavy motor vehicles. Thirteen individuals who were affected

by the Company’s land acquisition are being trained under this

programme. The training is expected to last between three to six months,

after which they will be able to operate heavy vehicles like cranes and

dumpers dexterously. After the training, all those who are trained are

absorbed by the Darla hat plant.

4. Education-The company will be creating a Trust of Rs.50 lacs for

providing educational support to all girl children in Darlaghat and

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Majathal Sanctuary in Himachal Pradesh. They are providing computer

literacy to school in Bhatapara

5. Krishi Vidyan Kendra work has started in Gujarat which will increase

the per capita income and economic development. It will be fully

functional by the end of this year.

6. Health care-Programmes have been launched on HIV/AIDS problems

on various fronts.- Rally on World AIDS day on December 2007.

11. BIRLA CORPORATION

Birla Corporation Limited is the flagship Company of the M.P. Birla

Group. Incorporated as Birla Jute Manufacturing Company Limited in 1919, it

was Late Mr. Madhav Prasad Birla who gave shape to it. As Chairman of the

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Company, Mr. Madhav Prasad Birla transformed it from a manufacturer of

jute goods to a leading multi-product corporation with widespread activities.

Under the Chairmanship of Mrs. Priyamvada Birla, the Company crossed the

Rs. 1300 - crore turnover mark and the name was changed to Birla Corporation

Limited in 1998.

After the demise of Mrs. Priyamvada Birla, the Company continued to

consolidate in terms of profitability, competitiveness and growth under the

leadership of Mr. Rajendra S. Lodha, late Chairman of the M.P. Birla Group.

Under his leadership, the Company posted its best ever results in the years

ended 31.3.2006, 31.3.2007 and 31.3.2008.

BOARDS OF DIRECTORS

Sl. No. Name Designation

1 Harsh V Lodha Chairman

3 BR Nahar Managing Director

2 Girish Sharma Company Secretary

4 Vikram Swarup Independent Non-Executive Director

5 Anand Bordia Independent Non-Executive Director

6 BB Tandon Independent Non-Executive Director

7 D N Ghosh Independent Non-Executive Director

8 Deepak Nayyar Independent Non-Executive Director

9 Pracheta Majumdar Whole Time Director

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AWARDS & RECOGNITION

1. Birla Corporation Limited has made it to the prestigious list of "200 Best

Under a Billion $" companies in the Asia-Pacific region, published by

Forbes Asia, in its October 9, 2009 issue.

2. Birla Corporation Limited received the Best Corporate Ethics Award for

2008 from the Indian Institute of Planning and Management.

3. Mr B R Nahar, ED & CEO, BCL, which has been recognized as one of

the Top corporate tax payers in West Bengal, being felicitated by Mr

Gautam Choudhury, Chief Commissioner of Income Tax, Kolkata (left),

at a function in Kolkata on 24 July 2010. Mr P K Chand, CFO, BCL, is

on the right.

4. Satna Cement Works & Birla Vikas Cement have received the IS/ISO

14001 certificate, an international recognition for "Implementation of

environmental management system".

5. SCW has received National Award for Excellence in Water

Management from CII, Hyderabad 'First Prize for Lowest Thermal

Energy Consumption K. Cal/kg clinker under the 10th FLS Energy

Award 2007. SCW received the Best Energy Consumption

Implementation Gold Award under the Rajiv Gandhi Memorial National

Award, Hyderabad, in 2004. It also received the First Prize for

Maximum Reduction in KWH/Ton of Cement in M.P. under FLS

Energy Award, Bhopal, in 2008.

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6. SCW has been awarded Green Tech Environment Excellence Award in

2008 by Green Tech Foundation, New Delhi.

7. NCBM has given BVC the "Second Best Improvement in Electrical

Energy Performance" Award for 2006-07.

BVC has received the National Award for Excellence in Water

Management from CII, Hyderabad "National Award For Energy Affiance in

Indian Cement Industry form NCCBM, New Delhi, Lowest Electrical Energy

Consumptions K.Cal/kg clinker under the 10th FLS Energy Award in 2007.

The Satna Unit received the Quality Circle Excellent Award from Quality

Circle Forum of India, Dugapur chapter "Quality Circle Excellence Award and

Quality Circle Distinguish Award From Quality Circle Forum of India, Kanpur

Chapter, in 2008.

BCL has regularly been receiving CAPEXIL awards for cement exports

since the last more than 15 years.

RECOGNITION

1. Its cement plant located at Rajasthan has received ISO 9001:2000

certification for quality management system and ISO 140001

certification for environment management. It received Lal Bahadur

Shastri Memorial National Awards for excellent pollution control

implementation.

2. Birla Corporation received the Best Corporate Ethics Award for 2008

from the Indian Institute of Planning and Management.

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3. Birla Corporation has made it to the prestigious list of '200 Best Under a

Billion $' companies in the Asia-Pacific region, published by Forbes

Asia, in its October 9, 2009 issue.

4. Birla Corporation has regularly been receiving CAPEXIL awards for

cement exports since the last more than 15 years.

CORPORATE SOCIAL RESPONSIBILITY

HEALTH CARE

Birla Corporation is a supporter of health, education, and social welfare

under the MP Birla Group. Priyamvada Birla showed interest in health care,

thus helping to build many hospitals and funding research ranging from eye

health to cardiology, neurology, and orthopedics. A well-known hospital in

Maharashtra is the Aditya Birla Memorial Hospital, which specializes in

preventive care and maternity care. Likewise, Priyamvada also founded the

Priyamvada Birla Cancer Research Institute and joined with Aravind Eye Care

Center to build the Priyamvada Birla Aravind Eye Hospital. Medical students

train at these hospitals with state-of-the-art medical equipment.

EDUCATION

To motivate and push students in academic excellence, the MP Birla

Foundation built many schools in India. These schools include institutions for

excellence, industrial training in computers, mechanical and electrical studies, a

Sanskrit school for students interested in Vedic studies. They also cater to

children of employees at Birla with a quality education taught in Hindi and

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financial aid for students. The Birla Foundation, founded by MP Birla, strives

to develop innovative and strong individuals and prepare them for the world.

12. JK CEMENT

JK Cement Limited (JK Cement) is one of the largest cement

manufacturers in Northern India and also the second largest white cement

manufacturer in India by production capacity. It is an affiliate of the J.K.

Organization, which was founded by Lala Kamlapat Singhania in the year

1994.J.K.Cement, started its commercial production in May 1975 in its first

plant Nimbahera in Rajasthan. The company was incorporated in the year

1994.Today J. K. Cement is one of the largest cement manufacturers in

north India. It is also second largest producer of white cement in India. The

company exports white cement to countries like South Africa,

Nigeria, Singapore, Bahrain, Bangladesh, Sri Lanka, Tanzania, UAE

and Nepal.The company has two manufacturing facilities located at Nimbahera

and Mangrol in the state of Rajasthan. The company produces white cement

and its production unit is located in Gotan at Rajasthan.During August 2009,

Allahabad HC had sanctioned the scheme of amalgamation of Jaykaycem a

wholly owned subsidiary with the company. Jaykaycem was implementing 3

million tones per annum Green Field Grey Cement Plant at Mudhol, District

Bagalkot, Karnataka state which was at final stage of implementation. The

installed capacity of grey cement of JK Cement with the merger increased to

7.5 million tones per annum.These plants have received various certifications

ISO-9001:2000 for quality management system, ISO-14001:2004 for

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environment management systems and OHSAS-18001:2005 for occupational

health and safety systems.

PRODUCTS

JK Cement produces ordinary Portland cement of 53-grade, 43-grade

and 33-grade. It markets these cements under the brand name J K cement and

Sarvashakitman. It also manufactures Portland Pozzolana Cement and markets

it under the name J K Super. It markets white cement under the name J K

White and Camel. J.K. Cement has introduced water repellent material in

powder form. It has also introduced white cement based putty for plastering

walls and ceiling and sells the same under the name JK Wall Puty.

BOARDS OF DIRECTORS

CHAIRPERSON

1. MD - Yadupati Singhania

Directors

2. Achintya Karati,

3. Anoop K Shukla,

4. Ashok Sharma,

5. Gaur Hari Singhania,

6. J N Godbole,

7. Jagendra Swarup,

8. Jayant Narayan Godbole ,

9. Jyoti Prasad Bajpai,

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10. Jyoti Prasad Bajpal,

11. K B Agarwal,

12. K N Khandelwal,

13. Kailash Nath Khandelwal,

14. Krishna Bihari Agarwal,

15. Paul Hugentober,

16. Paul Hugentobler,

17. Raj Kumar Lohia,

18. Shambhu Singh,

19. Suparas Bhandari,

20. Sushila Devi Singhania,

21. Yadupati Singhania

AWARDS

1. National Award for commitment to quality by the Prime Minister of

India.

2. National Award for outstanding pollution control by the Prime Minister

of India.

13. MADRAS CEMENT/ RAMCO CEMENT LTD

Birth of The Ramco Cements Limited (Formerly Madras Cements Ltd)

In the 1950s, investment in Cement Industry was not attractive due to

price controls and the massive investments required. Only those entrepreneurs

who were not profit-minded but cared for the country's development came

forward to invest in the Cement Industry.

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When Shri. Manubai Shah, Central Minister for Industries in late fifties

came to Madras to meet the Industrialists, he called upon Shri P A C

Ramasamy Raja and requested him to start a cement factory in TN. This was

readily accepted by Shri PACR and this marked the birth of The Ramco

Cements Limited (Formerly Madras Cements Ltd) in 1961.

Concern for Investors

On the night of September 3, 1962, while the whole city slept, PAC

Ramasamy Raja lay on his bed in the Madras General Hospital, seriously ill.

As all his near and dear watched with tears in their eyes, PAC Ramasamy Raja

summoned his son Ramasubrahmaneya Rajha to his bedside. "There is no more

hope", he whispered, "You should take care of everything from now. My main

concern is for The Ramco Cements Limited (Formerly Madras Cements Ltd). I

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have taken a lot of money as shares from well-wishers and I have not paid them

back any dividends as yet. This has to be taken care of immediately". Those

were his last words.

PACR's Dream Come True

PACR's last wish was dutifully fulfilled by the present Chairman Shri.

P.R.Ramasubrahmaneya Rajah. Today, The Ramco Cements Limited

(Formerly Madras Cements Ltd) is not only one of the most respected cement

companies in the country but also leads in giving the best return to the

investors. With a cement capacity of 15.5 million tons per annum, the company

is the fifth largest producer of cement in India. It is also one of the largest wind

energy producers in the country with a capacity of 159.185 MW.

Birth of Cement Plants

The first plant of RCL at Ramasamy Raja Nagar, near Virudhunagar in

Tamil Nadu, commenced its production in 1962 with a capacity of 200 tonnes,

using wet process. In 70s, the plant switched over to more efficient dry process.

A second kiln was also added to bring the total capacity to 15 lakh tons per

annum.

The second venture of RCL is its Jayanthipuram plant near Vijayawada

in A.P., set up in 1987. The 36.50 lakh ton per annum plant employs the latest

state-of-the-art technology.

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The third venture of RCL is at Alathiyur in TN. It was set up in 1997

and expanded by addition of another line in 2001. The 30.50 lakh tons per

annum plant is the most modern plant in the country.

Ariyalur plant started operations in 2009 with a capacity of 2 MTPA. It

is well-equipped with modern quality control systems.Currently Line 2 of the

plant with a capacity of another 2 MTPA was commissioned in 2012.

Other Ventures: In 2000, RCL acquired Gokul Cements situated in Mathod

in Karnataka whose capacity is 2.90 lakh tons per annum. Being an eco-

friendly company, RCL set up the Ramco Windfarm in 1993 at Muppandal in

TN. This was followed by wind farms in Poolavadi near Coimbatore in 1995,

Oothumalai in 2005 and in Mathod - the combined capacity of the wind farms

is about 159 MW.

In the year 1999, RCL commissioned the most sophisticated Ready Mix

Concrete Plant in Medavakkam in South Chennai. In 2002, a state-of-art Dry

Mortar plant was commissioned near Sriperumpudur, Tamilnadu which

manufactures dry mortar; cement based putty and tile fix compound.

BOARD OF DIRECTORS

Management - Ramco Cements

Name Designation

P R Ramasubrahmaneya Rajha Chairman & Managing Director

R S Agarwal Director

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M M Venkatachalam Director

Chitra Venkatraman Addnl. & Ind.Director

Name Designation

P R Venketrama Raja Director

M B N Rao Director

Swaran Singh Nominee Director

Products

Cement:

Ramco Cement Is PPC grade cement manufactured as per IS

1489(Part1):1991.

Ramco Cement Is produced either by grinding together Portland cement

clinker and pozzolona with addition of gypsum or calcium sulphate, or by

intimately and uniformly blending Portland cement and fine Pozzolona.

World over Ramco Cement is preferred due to its ability to produce a

durable concrete where the life of a concrete structure is given more

importance.

Ramco Cement produces less heat of hydration and offers greater

resistance to the attack of aggressive waters than normal Portland cement.

Moreover, it reduces the leaching of calcium hydroxide liberated during the

setting and hydration of cement.

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Ramco Cement 43 Grade (OPC 43)

Ramco Cement OPC 43 confirms to IS 8112. The grade is based on the

28-day compressive strength of the cement mortar (tested as per IS 4031),

which in this case is not less than 43 MPa.

Ramco Cement 53 grade (OPC 53)

Ramco Cement OPC 53 confirms to IS 12269. The grade is based on the

28-day compressive strength of the cement mortar (tested as per IS 4031),

which in this case is not less than 53 MPa.

Ramco Sulphate Resisting Cement (SRC)

Ramco SRC is manufactured as per IS 12330. This cement is used in

marine conditions where soil or water contains excess sulphates. However SRC

is weak in resisting chloride attack. Hence, wherever chlorides are present in

combination with sulphates, it is advisable to consider the usage of Ramco

Cement after a detailed examination. The C3A phase of SRC is maintained at

lower values <5%.

Sleeper Grade Cement (53 S):

This cement finds its application in the manufacture of precast products

and railway sleepers 53 S Cement is manufactured as per IS 12269 where apart

from all requirements of 53 Grade, specific requirements in terms of C3A and

C3S need to be adhered to. C3A is limited to 10% and C3S is limited to 45%.

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Dry Mix Range of Products – for Non Structural Applications:

Ramco Super Plaster:

This Plaster is a cement-lime modified premixed dry mortar with sand

and additives for internal and external applications. It is a hassle-free

alternative to conventional site mixed plaster.

Variants of Ramco Super Plaster are:

General Purpose Plaster: Premixed mortar for all types of plastering

applications

Water Repellant Plaster: Premixed mortar with water repellant property for

external applications

Brick /Block Mortar: Premixed Mortar for brick/block laying.

Ramco Super Fine Cement-based Putty:

Ramco Super Fine This Putty is a perfect match for walls and a better

alternative to gypsum or acrylic putty.

Ramco Super Fine Cement-based Putty

Ramco Teli FixeThis product is a specially-formulated engineered tile

adhesive. It is a polymer modified, cement-based and ready-to-use tile

adhesive. It is the easiest, fastest and most convenient way to fix tiles and it

protects the tiles and ensures a long life for floor surfaces.A wide range is

available ranging from T1 to T6 depending on application and the required

bond strength.

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Ramco Concrete - for Structural Concrete Applications:

High-performance Concrete based on customer requirements is made in the

RMC Unit. Concrete with various permutations based on concrete grades,

workability and site-conditions are available.

AWARDS

Winner of the Four Leaves Award

The Ramco Cements Limited (Formerly Madras Cements Ltd) is the

only Company in the Indian Cement Industry to win the Four Leaves Award

(instituted by Centre for Science & Environment) for taking steps to protect

the environment by ensuring dust free and clean factory premises

Winner of the Cleaner Production Measures Award

Andhra Pradesh Pollution Control Board and Environment & Forest

Dept, Government of AP, presented the Award to The Ramco Cements Limited

(Formerly Madras Cements Ltd), Jayanthipuram Unit in recognition of

practicing Cleaner Production Measures, on the eve of World Environment

Day celebrated at Hyderabad on 05-06-12

Winner of CII Environmental Best Practices Award

Alathiyur Unit bagged the CII Environmental Best Practices Award

2012. The Award being presented by Mr.L.S.Ganapati, Chairman, CII

Environmental Best Practices Award Committee, 2012.

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14. SHREE CEMENT

Shree Cement Ltd is one of India's premier cement makers and the

largest in North India. The company is an energy conscious & environment

friendly business organization. They have three brands under their portfolio,

namely Shree Ultra Jung Rodhak Cement, Bangur Cement and Rockstrong

Cement. Their manufacturing units are located at Beawar, and Ras in

Rajasthan. They are also having the grinding units in Khushkhera in Rajasthan.

The company is headquartered in Kolkata, India. Shree Cement Ltd was

incorporated in the year 1979.

The company was promoted by Calcutta-based industrialists P D Bangur

and B G Bangur. The company is one of the largest cement producers in

Rajasthan (Beawar) and is the largest single location manufacturer in Northern

India. During the year 1994-95, the company undertook new activities in the

field of leasing and hire purchase. The company made a tie up with Christian

Pfeiffer & Company, Germany, for installing a horizontal impact crusher to

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pre-crush clinker before using it in the cement mill for upgrading cement

output and save energy. Also, they made a tie up with IKN, Germany, for

incorporating their KIDS system in the clinker cooler.

BOARDS OF DIRECTORS

1. Shri B.G.Bangur, Chairman

2. Shri H.M.Bangur, Managing Director

3. Shri R.L.Gaggar, Director

4. Shri O.P.Setia, Director

5. Shri Shreekant Somany,Director

6. Dr. Y.K.Alagh, Director

7. Shri Nitin Desai, Director

8. shri Prashant Bangur,whole Time Director

9. Dr.Leena Shrivastava, Director

10. Shri Ramakant Sharma,Director

AWARDS

1. CII-ITC Sustainability Award - 2010 for nurturing innovation,

promoting excellence, building trust and contribution towards

sustainable future for all

2. 2011-12 First prize for overall performance in 25th Mines Safety Week

under Director General of Mines safety, Ajmer region to Ras mines

3. 2012-13 Financial Express – Emergent Venture India Green Business

Leader Award, 2011-12

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4. 2012-13 First Prize for Energy conservation during mines environment

& conservation week by IBM

5. 2012-13 Golden Peacock Business Excellence Award for the year 2013

CORPORATE SOCIAL RESPONSIBILITY

1. Shree has since inception been engaged in developing the community

around its plants’ periphery. In order to provide sustainable development, Shree

has a policy to employ people from the areas in the vicinity of its

manufacturing sites and a majority of the

Company’s staff is from the nearby areas. This helps in raising their

standard of living and also helps the Company in containing attrition. Shree

promotes engagement of local suppliers and contractors for supplying materials

and services. This initiative promotes local industries and creates a value chain

for them. This also fosters economic growth in the communities. Shree also

supports hiring of local people scaling up the income and standard of living of

the local communities.

2. Company’s socially responsive measures cover the entire range of

community development activities. Apart from support to the basic needs in the

area of health, literacy, water and employment, it also provides avenues for

cultural expression. Regular health check-ups of villagers, visits by doctors to

nearby areas to check possible epidemics, AIDS awareness campaigns, polio

campaigns, eye camps etc are organized to cater to the health issues.

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3. It celebrates safety week and safety day and promotes health & safety

awareness among employees by providing proper training and safety

equipment to them. Activities towards promoting literacy includes distribution

of books, study materials, uniforms etc. amongst the students of local schools

and installing computers to promote computer literacy. Supplying water in

water-scanty areas, providing shelters to natural calamity affected people, in

kind assistance in form of supplying product at concessional rate etc. are also

some of the activities undertaken by the Company towards its commitment of

repaying society.

4. “Shri Sankatmochan Hanuman Varshikotsav”, an annual cultural fest is

organized every year on the occasion of anniversary of ShriHanuman Temple.

The function acts as an outlet of cultural bonding and enjoyed by both the

employees of the Company as well as the people in the nearby villages.

During the year the Company contributed Rs. 1 crore towards development of

neurosurgical centre at JLN Hospital,Ajmer.

15. ULTRATECH CEMENT

Ultratech Cement was incorporated in 2000 as Larsen & Toubro. Later

it was demerged and acquired by Grasim and was renamed as Ultra Tech

Cement in 2004. Today Ultatech cement a part of Aditya Birla group, is the

country’s largest exporter of cement clinker. UltraTech Cement Limited has an

annual capacity of 52 million tones. It manufactures and markets Ordinary

Portland Cement, Portland Blast Furnace Slag Cement and Portland Pozzalana

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Cement. It also manufactures ready mix concrete (RMC). All the plants have

received ISO 9001 certification.

The company has 11 integrated plants, one white cement plant, one

clinkerisation plant in UAE, 15 grinding units 11 in India, 2 in UAE, one in

Bahrain and Bangladesh each and five terminals, four in India and one in Sri

Lanka.The export markets span countries around the Indian Ocean, Africa,

Europe and the Middle East. Narmada Cement Company Limited

was amalgamated with UltraTech in May 2006, while Samruddhi Cement

Limited was amalgamated with UltraTech Cement Limited in July

2010.UltraTech Cement Middle East Investments Limited, a wholly owned

subsidiary of the Company acquired management control of ETA Star Cement

together with its operations in the UAE, Bahrain and Bangladesh in September,

2010UltraTech's other subsidiaries are Dakshin Cements, Harish Cements,

UltraTech Ceylinco (P) and UltraTech Cement Middle East Investments.

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BOARDS OF DIRECTORS

Sl. No. Name Designation

1 Kumar Mangalam Birla Chairman

2 S K Chatterjee Company Secretary

3 O P Puranmalka Managing Director

4 D D Rathi Non Executive Director

5 Rajashree Birla Non Executive Director

6 Adesh Gupta Non Executive Director

7 Rajiv Dube Non Executive Director

8 Sukanya Kripalu Additional Director

9 Renuka Ramnath Additional Director

10 Arun Adhikari Non Executive Independent Director

11 R C Bhargava Non Executive Independent Director

12 G M Dave Non Executive Independent Director

13 S B Mathur Non Executive Independent Director

14 S Rajgopal Non Executive Independent Director

PRODUCT

It manufactures ordinary portland cement commonly used in dry-lean

mixes, general-purpose ready-mixes, and even high strength pre-cast and pre-

stressed concrete.

It produces Portland blast furnace that has features like lighter color,

better concrete workability, easier finish ability, higher compressive and

flexural strength, improved resistance to aggressive chemicals and more

consistent plastic and hardened consistency. It also manufactures Portland

pozzolana cement.

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Ultratech cement exports over 2.5 million tons per annum which

accounts for 30% of country’s total exports. It exports to countries like Africa,

Europe and the Middle East.

CORPORATE SOCIAL RESPONSIBILITY

1. In the healthcare domain

In the healthcare domain, they have made impressive strides. This year

through their medical camps, coupled with their rural mobile medical vans

services, they reached out to over 10 lakh villagers.

2. Sparking the desire to learn

This year their focus has been on the girl child and on women

empowerment. As you are aware the girl child faces a long battle in our

country. Not only in the rural areas but also in cities, and small towns. The

consistently declining child sex ratio, that is, the number of female children per

1,000 male children in the age group of 0-6 years is a cause for concern. The

2011 census of India data has revealed that the sex ratio in the 0-6 age group is

the worst since independence. In 1981, it was 971 girls for every 1,000 boys. In

1991, it came down to 927. In 2011, it is as low as 914. This is a social

distortion. It can lead to severe societal problems in the country if this trend

continues. Hence, the thrust on the girl child.

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3. Safe drinking water and sanitation

In villages at Shambhupura, Khor, Malkhed, Reddipalyam (Tamil

Nadu), Tadipatri, Hirmi, Awarpur, Kovaya, Ratnagiri (Maharashtra), Durgapur

(West Bengal) and Jafrabad, their safe drinking water projects provide relief to

52,000 people. This year, a water tank was constructed in the Amarpura village

(Chittorgarh).

4. Sustainable livelihood

In a unique Public Private Partnership (PPP) Watershed Management

Project, they are collaborating with the Rajiv Gandhi Watershed Mission and

the Water and Irrigation Department of the Government of Madhya Pradesh.

In a phase-wise implementation, spread over 5 years, our collective efforts

will bring 5,742 hectares of land under irrigation, directly benefiting 20,000

farmers and their families.

5. Self Help Groups

Currently, they have 873 Self Help Groups (SHG) with a membership of

7,941 women, engaged in tailoring, making soft toys and cloth bags,

embroidery, handicrafts, vermi-compost, making candles and chalks and as

beauticians