PPC Western Cape Calcined Clay trial cuts costs and carbon emissions
By Larry Claasen
PPC Cement says the results of its Calcined Clay pilot in the Western Cape were very promising, and could open the way for lower production costs and reduced carbon emissions in cement production.
The use of Calcined Clay in the making of cement could have a marked environmental impact, as it could reduce CO2 emissions by as much as 40% according to some estimates.
PPC, a leading supplier of construction materials, said in its half-year to end September results presentation that it was “excited about its potential.”
Aside from cutting emissions, the use of Calcined Clay also had the potential to reduce cement production costs, PPC CEO Matias Cardarelli said in November.
PPC Western Cape Calcined Clay explained as a low carbon alternative
Calcined Clay is a natural material, typically rich in the mineral kaolinite, that is transformed into a highly reactive, sustainable ingredient for cement by heating it to around 700-800°C, a process called calcination. Its primary value lies in its ability to replace a significant portion of traditional cement clinker, which is the most energy-intensive and CO2-heavy component of concrete.
Beyond its environmental benefit, it enhances the concrete’s strength and durability, and because suitable clay deposits are abundant worldwide, it offers a cost-effective and locally available solution for producing lower-carbon concrete.
Using Calcined Clay to make cement has been known about since the 1820s, but it was only when the Swiss Agency for Development and Cooperation funded research into it in 2014 that it was taken more seriously.
Its partnership with Indian researchers eventually saw it being used in construction projects in India, Cuba, Colombia and Denmark.
Aside from the promising findings of its Calcined Clay trial, Cardarelli said last month the development of its RK3 Project in Riebeek-Kasteel, in the Western Cape, was on track. The RK3 Project is a R3 billion integrated cement plant, which will produce 1,5 million tons of cement per annum.
Cardarelli said this project was a “game changer,” and that it remained on schedule and within budget. Engineering is nearly complete, equipment manufacturing has started, and civil works are advancing.
The new plant is expected to be commissioned by the end of the calendar year 2026.
PPC Western Cape growth linked to infrastructure and market demand
Though there has been talk of an upswing in the economy, PPC has yet to see it. Sales volumes in South Africa only increased by about 2% for the 10 months to January.
This modest rise reflected Finance Minister Enoch Godongwana saying in his national budget speech that the growth outlook was expected to be 1,6% in 2026.
Companies like PPC are set to benefit from the government’s commitment to spend R1 trillion on infrastructure over the medium term. This will see R577,4 billion spent by state-owned companies and other public entities, R217,8 billion by provinces, and R205,7 billion by municipalities.
PPC saw its revenue increase 6.2% to R5.38 billion, and profit after tax surge 15.75% to R368 million. Its full-year numbers will be published on 9 June.
