CARBON FIBRE REINFORCED POLYMER

CARBON FIBRE REINFORCED POLYMER
The main impetus for development of carbon fibres has come from the aerospace industry with its need for a material with combination of high strength, high stiffness and low weight. Recently, civil engineers and construction industry have begun to realize that this material (CFRP) have potential to provide remedies for many problems associated with the deterioration and strengthening of infrastructure. Effective use of carbon fibre reinforced polymer could significantly increase the life of structures, minimizing the maintenance requirements.
Carbon fibre reinforced polymer is a type of fibre composite material in which carbon fibres constitutes the fibre phase. Carbon fibre are a group of fibrous materials comprising essentially elemental carbon. This is prepared by pyrolysis of organic fibres. PAN-based (PAN-poly acrylo nitrile) carbon fibres contains 93-95 percentage carbons, and it is produced at 1315°C (2400°F). Carbon fibres have been used as reinforcement for albative plastics and for reinforcements for lightweight, high strength and high stiffness structures. Carbon fibres are also produced by growing single crystals carbon electric arc under high-pressure inert gas or by growth from a vapour state by thermal decomposition of a hydrocarbon gas.
CFRP materials possess good rigidity, high strength, low density, corrosion resistance, vibration resistance, high ultimate strain, high fatigue resistance, and low thermal conductivity. They are bad conductors of electricity and are non-magnetic.
Carbon fibre reinforced polymer (CFRP) is currently used world wide to retrofit and repair structurally deficient infrastructures such as bridges and buildings. Using CFRP reinforcing bars in new concrete can eliminate potential corrosion problems and substantially increase a member’s structural strength. When reinforced concrete (RC) members are strengthened with externally bonded CFRP, the bond between the CFRP and RC substrate significantly affects the members load carrying capacity.
Strengthening measures are required in structures when they are required to accommodate increased loads. Also when there are changes in the use of structures, individual supports and walls may need to be removed. This leads to a redistribution of forces and the need for local reinforcement. In addition, structural strengthening may become necessary owing to wear and deterioration arising from normal usage or environmental factors.
The usage of composite materials like CFRP is still not widely recognized. The lack of knowledge of technology using CFRP and the simplicity of it will make some people hesitant to use it. Carbon Fibre strengthening system includes laminate and sheet products for increasing the strength of concrete structures. Carbon, Aramid and E-glass can be used to solve problems from change of use to increased load carrying capacity to bomb blast protection. Simple installation, minimal increase of deadload and ability to deal with complex strengthening requirements make this a problem solve.

Strengthening of a structure may be necessary if increases in loads, changes in structural articulation or intended use occur, and also, after accidental damages. Depending on the location of structure, access to the repair area, or the time allow for the repair, several materials and technique have to be considered. Carbon Fiber Reinforced Polymer Strip is an external strengthening system that can be used on structural elements comprised of concrete, wood, or steel. This system consists of a pultruded, pre-cured carbon fiber reinforced polymer (CFRP) strip and a high modulus/high strength epoxy gel. The strips are adhered using epoxy gel to structural elements to increase flexural capacity, fatigue resistance and reduce deflection.

Carbon Fiber Reinforced Polymer (CFRP) is a Polymer Matrix Composite material reinforced by carbon fibers.
The reinforcing dispersed phase may be in form of either continuous or discontinuous carbon fibers of diameter about 0.0004” (10 mkm) commonly woven into a cloth.
Carbon fibers are very expensive but they possess the highest specific (divided by weight) mechanical properties: modulus of elasticity and strength.
Carbon fibers are used for reinforcing polymer matrix due to the following their properties:
• Very high modulus of elasticity exceeding that of steel;
• High tensile strength, which may reach 1000 ksi (7 GPa);
• Low density: 114 lb/ft³ (1800 kg/m³);
• High chemical inertness.
The main disadvantage of carbon (Graphite) fibers is catastrophic mode of failure (carbon fibers are brittle).
The types of carbon fibers are as follows:
• UHM (ultra high modulus). Modulus of elasticity > 65400 ksi (450GPa).
• HM (high modulus). Modulus of elasticity is in the range 51000-65400 ksi (350-450GPa).
• IM (intermediate modulus). Modulus of elasticity is in the range 29000-51000 ksi (200-350GPa).
• HT (high tensile, low modulus). Tensile strength > 436 ksi (3 GPa), modulus of elasticity < 14500 ksi (100 GPa).
• SHT (super high tensile). Tensile strength > 650 ksi (4.5GPa).
Carbon fibers are also classified according to the manufacturing method:
1. PAN-based carbon fibers (the most popular type of carbon fibers).
In this method carbon fibers are produced by conversion of polyacrylonitrile (PAN) precursor through the following stages:
• Stretching filaments from polyacrylonitrile precursor and their thermal oxidation at 400°F (200°C). The filaments are held in tension.
• Carbonization in Nitrogen atmosphere at a temperature about 2200 °F (1200°C) for several hours. During this stage non-carbon elements (O,N,H) volatilize resulting in enrichment of the fibers with carbon.
• Graphitization at about 4500 °F (2500°C).
2. Pitch-based carbon fibers.
Carbon fibers of this type are manufactured from pitch:
• Filaments are spun from coal tar or petroleum asphalt (pitch).
• The fibers are cured at 600°F (315°C).
• Carbonization in nitrogen atmosphere at a temperature about 2200 °F (1200°C).
The most popular matrix materials for manufacturing Carbon Fiber Reinforced Polymers (CFRP) are thermosets such as epoxy, polyester and thermoplastics such as nylon (polyamide).
Carbon Fiber Reinforced Polymers (CFRP) materials usually have laminate structure, providing reinforcing in two perpendicular directions.
Carbon Fiber Reinforced Polymers (CFRP) are manufactured by open mold processes, closed mold processes and Pultrusion method.
Carbon Fiber Reinforced Polymers (CFRP) are characterized by the following properties:
• Light weight;
• High strength-to-weight ratio;
• Very High modulus elasticity-to-weight ratio;
• High Fatigue strength;
• Good corrosion resistance;
• Very low coefficient of thermal expansion;
• Low impact resistance;
• High electric conductivity;
• High cost.
Carbon Fiber Reinforced Polymers (CFRP) are used for manufacturing: automotive marine and aerospace parts, sport goods (golf clubs, skis, tennis racquets, fishing rods), bicycle frames.
Properties of some Carbon Fiber Reinforced Polymer Composites
(Materials Data)
• Epoxy Matrix Composite reinforced by 70% carbon fibers
• Epoxy Matrix Composite reinforced by 50% carbon fibers
• Polyether Ether Ketone B Matrix Composite reinforced by 30% carbon fibers

The Use of Steel Fibre Reinforced Concrete

Fibers have been used as reinforcement since ancient times, when straw was used to reinforce otherwise brittle mud bricks. Similarly, concrete on its own is a relatively brittle substance, with low tensile and ductile strengths. Steel fiber reinforced concrete, or SFRC, is concrete containing small steel fibers which increase concrete's structural capacity. For this reason SFRC is favorable in applications where additional durability and ductile strength are required.


How Does It Work?


When added to the concrete mixture, steel fibers help enhance many of concrete's mechanical characteristics. The fibers can be between 30mm and 100mm in length, and come in straight, textured and hooked varieties. These fibers improve structural properties, including toughness, durability and tensile strength of the concrete. Most importantly, the fibers help to restrain cracking which occurs during the curing process, by restricting movement of the concret

Shotcrete

Shotcrete is a highly fluid type of concrete which can be sprayed onto almost any surface. It is used in applications where the concrete is being projected onto irregular or vertical surfaces. Steel mesh can be installed prior to spraying, to provide a substrate for the shotcrete to adhere to. Shotcrete is often reinforced with steel fibers to increase its cohesion during application, which eliminates the need to install traditional steel wire mesh.

Precast Elements

Precast concrete elements are made in an off-site facility before transportation and installation on site. They are used in almost all types of construction, including apartment buildings, offices, bridges and tunnels. Steel fibers are often added to the concrete mix in the casting facility for applications such as bridge building, where qualities such as durability and flexural strength are required. In some cases, the addition of steel fibers also allows smaller, lighter sections to be made, as there is no requirement for traditional steel bar reinforcement.

Industrial Ground Slabs

Steel fiber reinforced concrete is commonly used for industrial ground slabs, such as in warehouses and airport runways. Concrete slabs in these applications are subject to constant, repetitive use from forklifts and other traffic. In this environment, SFRC provides extra durability to the surface of the slab and added strength against cracking, particularly along edges and joints where the slab is more prone to weakness.

Tunnels

Tunnel linings are traditionally constructed from precast concrete elements, cast-in elements, shotcrete or a combination of these. Tunnels are under a constant load from either soil or water above, and require high resistance against these forces. Steel fiber reinforced concrete is commonly used in tunnel construction, as it provides additional flexural strength, reduces shrinkage cracking and reduces permeability.


Fiber reinforced concrete is a composite obtained by adding a single type (steel or synthetic) or a blend (steel + synthetic) of fibers to the concrete mix.

WIRAND® steel fibers are used to reinforce the concrete adding mechanical properties that can be used for structural design purpose.

FIBROMAC® synthetic fibers are used as a complement for the concrete to control the effects of moisture and water lost in the first stage (24 to 72 hours) of curing.

Adding fibers to concrete improves mechanical properties:

* Increases toughness
* Increases ductility and flexural resistance
* Gets higher and more stable tensile strength
* Increases shear resistance

And can improve control for the following effects:

* Fatigue
* Impact
* Shrinkage
* Fire resistance

Fiber reinforced concrete technology is in continuous growth and expansion, and is now included in most relevant concrete codes around the world. The codes refer to the technical considerations to define this material with or without structural responsibility for design purpose, and guide accurate use of the technology.

The traditional sectors where the fiber reinforced concrete is applied are:

* Lining for tunnels
* Industrial floors
* Precast elements

Dramix ® steel fibers for concrete reinforcement
Advantages

* High ductility and load bearing capacity
* Cost effective reinforcement solution
* Quick and easy to apply

Product description
Dramix
© Bekaert

What if you had a material that provided you with unlimited possibilities to build and develop your projects? Meet Dramix®, the proven steel fiber concept from industry specialist Bekaert, which has set a new standard for concrete reinforcement. What you get from Dramix® reinforced concrete is ductility and high load bearing capacity.


Technological features

Applications

* Construction
* Concrete reinforcement
* Dramix® for residential applications
* Dramix® for precast elements

* Dramix® for tunnel applications
* Dramix® concrete reinforcement for civil works
* Dramix® for industrial floors

Investor Prancis dan Cina Bangun Pabrik Semen Baru

TEMPO Interaktif, Jakarta - Produsen semen terbesar asal Prancis dan Cina berencana membangun pabrik semen di Indonesia. Produsen semen Prancis, Lafarge Cement, sedang menjajaki investasi untuk membangun pabrik di Jawa Timur. Sedangkan produsen semen Cina, China Triumph International Engineering Co. Ltd (CTIEC), akan membangun pabrik di Grobogan, Jawa Tengah.


Namun, Menteri Perindustrian, Mohamad Suleman Hidayat, menginginkan Lafarge membangun pabrik di luar Jawa. Alasannya, dengan pembangunan itu akan tercipta pemerataan pembangunan industri. Apalagi saat ini pembangunan mulai lebih banyak diarahkan ke luar Jawa. Alternatif lain selain Jawa adalah di Langkat, Sumatera Utara.


Lafarge sudah menginvestasikan dana US$ 300 juta untuk membangun pabrik berkapasitas 1,6 juta ton per tahun di Aceh. Rencananya pabrik baru itu akan memiliki kapasitas sama dengan pabrik di Aceh. Tapi nilai investasi baru itu belum diketahui. "Mereka sedang menghitung investasi yang dibutuhkan," ujar Hidayat.


Direktur Jenderal Basis Industri Manufaktur, Panggah Susanto, mengatakan, pembangunan pabrik milik China Triumph di Grobogan ini memiliki kapasitas produksi sebesar 2 juta ton per tahun. "Nilai investasinya mencapai US$ 350 juta.”


Ketua Umum Asosiasi Semen Indonesia, Urip Timuryono, memprediksi, tahun ini konsumsi semen naik sekitar 7,5 persen menjadi 43 juta ton dari 40 juta pada tahun lalu. "Konsumsi semen masih dominasi pulau Jawa sebesar 65 persen, Sumatera sudah 29 persen, Kalimantan dan Sulawesi sebanyak 10 persen.”


Urip mengatakan, tahun ini permintaan semen yang cukup tinggi mengikuti pertumbuhan properti yang terus berkembang. Urip menjelaskan, rata-rata produksi semen secara nasional per tahun mencapai 66 juta ton. Dari jumlah ini sebanyak 43 juta ton diserap di dalam negeri dan sisanya untuk ekspor.


Data Kementerian Perindustrian menyebutkan, kapasitas produksi semen tahun ini 52 juta ton. Produksi tahun lalu 40,7 juta ton. Pada 2012-2013, kapasitas industri semen bakal bertambah 6,8 juta ton menyusul investasi tiga produsen: PT Semen Gresik Indonesia 2,5 juta ton pada 2012, PT Semen Tonasa 2,5 juta ton pada 2011, dan PT Holcim Indonesia 1,8 juta ton pada 2014.


Meski ekspansi produsen dan pasar terus bertumbuh, ekspor semen diprediksi tidak maksimal. Ekspor tahun ini sekitar 1,5 juta ton, turun dari ekspor tahun lalu sekitar 1,5-2 juta ton. Tipe tekstur semen yang padat membuat ekspor relatif sulit. “Ongkos angkut untuk ekspor mahal tapi harus dijual lebih murah. Ini akan cenderung menggerus margin produsen," kata Urip.

Lafarge Ngotot Bangun Pabrik Semen di Jawa Timur

JAKARTA--MICOM: Produsen semen asal Prancis Lafage telah menyatakan minatnya untuk membangun pabrik semen di Jawa Timur. Lafarge baru menyelesaikan pembangunan kembali pabrik di Aceh yang terhantam tsunami pada Desember 2004.

Demikian disampaikan Menteri Perindustrian MS Hidayat di sela pameran keramik, kaca, dan bahan bangunan di Plaza Kemenperin, Jakarta, Selasa (7/6).

"Saya ingatkan resikonya besar karena di Jawa persaingannya sangat ketat. Syarat Amdal-nya juga lebih ketat," ujar Hidayat.

Hidayat sebetulnya mengharapkan Lafarge menginvestasikan uangnya untuk pabrik semen di luar Pulau Jawa. Sebab, pemerintah memang tengah mendorong industrialisasi di luar Jawa.

Lafarge sendiri baru saja mengoperasikan kembali pabrik mereka yang terhantam tsunami Aceh, Desember 2004. Pabrik di Lhoknga yang selesai dibangun Maret 2011 tengah memulai produksi percobaan. Pabrik berkapasitas 1,6 juta ton per tahun tersebut menghabiskan dana sekitar US$300 juta.

Menurut Dirjen Industri Manufaktur Kemenperin Panggah Susanto, sebelumnya Lafarge juga telah menyampaikan minatnya untuk membangun pabrik di Langkat, Sumatera Utara. "Sekarang sedang menjajaki bahan bakunya. Kira-kira kapasitasnya 1,5 juta ton. Nilai investasinya US$275 juta," katan Panggah.


Bupati undang Lafarge investasi pabrik semen di Kab. Malang

MALANG: Bupati Malang Rendra Kresna mengundang Lafarge, salah satu produsen semen terbesar di dunia asal Perancis, untuk investasi di daerah tersebut dengan mendirikan pabrik semen.

Di temui di sela-sela Kirab Adipura, hari ini, Bupati mengatakan pihaknya akan menyurati Badan Koordinasi Penanaman Modal (BKPM) yang menginformasikan bahwa Kab. Malang tertarik untuk menerima Lafarge investasi di daerah tersebut.

“Kami mempunyai keunggulan bila dibandingkan daerah lain karena sudah feasibility study (FS) terkait dengan kapasitas bahan baku semen di daerah ini,” kata Rendra Kresna hari ini.

Seperti diberitakan harian ini, Lafarge menjajagi pembangunan pabrik semen dengan perkiraan investasi US$300 juta di Jawa Timur.

Menurut Bupati, semua bahan baku semen ada di Kab. Malang. Bahan-bahan baku berada di kawasan perbukitan kapur, yakni di Sumbermanjing Wetan, Kalipare, Donomulyo, Gedangan, Wajak, dan Pagak.

Bahan-bahan dimaksud, yakni pasir, tanah liat, pasir kuarsa, dan batu kapur. Deposit batu kapur di Kab. Malang mencapai 600 tahun dengan asumsi pabrik semen berproduksi 2 juta ton per tahun, sedangkan deposit tanah liat mencapai 60 tahun dengan asumsi masa produksi yang sama.

Asumsi itu jika memperhitungkan juga pemanfaatan tanah milik Perhutani. “Tapi tanah liat tersebut kan bisa didapatakan dari daerah lain, seperti Blitar dan Lumajang, jika bahan terserbut di Kab. Malang sudah habis dieksploitasi.”

Pabrik ke-5 Semen Tonasa di Sulsel bakal beroperasi di kuartal IV 2011

JAKARTA. Kapasitas pabrik PT Semen Tonasa bakal bertambah, seiring segera selesainya pembangunan pabrik di Pangkep, Sulawesi Selatan. Kapasitas pabrik semen milik anak usaha PT Semen Gresik itu mencapai 2,5 juta ton.

Saat ini, proses pembangunan pabrik sudah rampung 80%. "Kami targetkan pabrik itu bisa beroperasi pada November tahun ini," kata Direktur Utama Semen Tonasa, Sattar Taba, Kamis (14/4).

Pabrik yang menghabiskan investasi sebesar Rp 3,5 triliun ini menjadi pabrik kelima milik Semen Tonasa. Jika pabrik ini beroperasi secara komersial, produksi semen mencapai 6,5 juta ton. Saat ini, kapasitas produksi Semen Tonasa hanya sebesar 4 juta ton.

Dengan tambahan kapasitas dari pabrik baru ini, Semen Tonasa menargetkan bisa menjual 4,3 juta ton semen tahun ini, naik 7,5% dari penjualan tahun lalu yang sebanyak 4 juta ton.

Selain itu, Semen Tonasa juga tengah membangun pembangkit berkapasitas 2x35 MW dengan investasi US$144 juta. Proyek ini diharapkan bisa rampung pertengahan 2012.

”Tahap pemancangan sudah dimulai Juli 2010 lalu. Proyek ini hampir sepenuhnya menggunakan muatan lokal. Sekitar 80% komponennya adalah produksi dalam negeri. Pengerjaannya juga dilakukan PT Rekayasa Industri yang juga BUMN," kata Sattar.

Sebagai bagian dari upaya untuk memperbesar penguasaan pasar di Indonesia timur, Semen Tonasa juga sedang membangun packing plant di Papua, Sultra, Kaltim, dan Ternate. Masing-masing packing plant berkapasitas 600.000 ton per tahun. Saat ini Semen Tonasa sudah mempunyai delapan packing plant.

Semua ekspansi Semen Tonasa itu menjadi bagian dari upaya Grup Semen Gresik untuk memacu kapasitas produksi perusahaan. Saat ini kapasitas produksi Semen Gresik mencapai 20,5 juta ton. Targetnya, di 2013 kapasitas produksi perusahaan plat merah ini bisa naik menjadi 27 juta ton.

Genjot Produksi, Indocement Bangun Pabrik Baru

Perseroan telah melakukan beberapa survei geologi dan studi kelayakan dalam menentukan lokasi pabrik semen baru dengan total 2-3 juta ton semen per tahun antara lain di beberapa lokasi seperti din Citeureup dan Tarjun, serta area Jawa Tengah. Dwitya Putra

Jakarta–Produsen semen, PT Indocement Tunggal Prakarsa Tbk (INTP) pada tahun ini akan melakukan penambahan satu pabrik semen baru dengan kapasitas 2 juta ton per tahun di wilayah Citeurup, Jawa Barat.

Dalam keterbukaan perseroan, di Jakarta Jumat, 18 Maret 2011, disebutkan, pembangunan pabrik baru tersebut diharapkan akan beroperasi pada tahun 2012 atau selambat-lambatnya pada 2013.

Disamping itu, jika kondisi domestik tetap bertumbuh perseroan juga berencana untuk melakukan ekspansi dengan membangun semen pabrik baru dalam 3-4 tahun ke depan.

Untuk langkah tersebut saat ini perseroan telah melakukan beberapa survei geologi dan studi kelayakan dalam menentukan lokasi pabrik semen baru dengan total 2-3 juta ton semen per tahun antara lain di beberapa lokasi seperti din Citeureup dan Tarjun, serta area Jawa Tengah.

Sekedar informasi, laba bersih INTP sepanjang 2010 tercatat Rp 3,225 triliun, tumbuh 17,4% dibanding periode lalu yang sebesar Rp 2,747 triliun. Laba bersih per saham sendiri mencapai Rp 876,05.

Laba perseroan tersebut disokong oleh pendapatan yang naik 5,31% dari Rp 10,576 triliun di 2009 menjadi Rp 11,138 triliun. Beban pendapatan per 31 Desember 2010, Rp 5,597 triliun. Ini menjadikan laba kotor INTP mencapai Rp 5,541 triliun, meningkat 8,47% dari periode yang sama tahun lalu, Rp 5,108 triliun. (*)

Lafarge Rencanakan Bangun Pabrik Semen di Langkat

Langkat, Sumut (ANTARA) - Lafarge salah satu perusahaan semen terbesar di dunia, merencanakan membangun pabrik semen di Kabupaten Langkat, Sumatera Utara (Sumut).


Lafarge merencanakan membangun pabrik semen itu disekitar Kuala dan Bahorok, kata Kepala Dinas Perindustrian dan Perdagangan Langkat, T Nilfan Shahari di Stabat, Kamis.


"Kita akan terima secara terbuka investasi yang mau masuk ke Langkat, seperti akan dilaksanakan Lafarge membangun pabrik semen di Bahorok, "katanya.


Kesungguhan pihak Lafarge untuk segera membangun pabrik semen dibuktikan melalui berbagai sosialisasi yang sudah dilakukan kepada masyarakat setempat beberapa waktu lalu.


T Nilfan Shahari menjelaskan bahwa Lafarge akan membangun pabrik berkapasistas 1.500.000 ton, dengan nilai investasi mencapai US 275.575.000.


Lafarge sudah mempunyai lokasi seluas 200 hektare di Desa Parit Bindu Kecamatan Kuala (berupa tanah liat), 73 hektare di Desa Batu Katak Kecamatan Bahorok (berupa tanah liat), dan 227 hektare di Desa Batu Katak Bahorok (berupa tanah kapur).


T Nilfan Shahari juga menjelaskan komitmen Lafarge melakukan rehabilitasi daerah bekas tambang agar keberadaan lingkungan di daerah tersebut tetap terjaga.


Selain itu, kata T Nilfan Shahari mereka sangat peduli dan perhatian terhadap bidang pendidikan, kesehatan, ekonomi dan sosial masyarakat yang berada di sekitar pabrik semennya.


"Kita bisa lihat, apa yang dilakukan Lafarge di daerah bekas tambang akan menjadi taman nasional, seperti pabrik semen Bamburi dekat Mombasa, Kenya, pada awal tahun 1970, katanya.

Indonesian Cement Industry starts expansion

Indonesian Cement Industry starts expansion
The improvement in the country's economic condition in 2010 has boosted development of the country's cement industry. Work in a number of infrastructure and property projects, shelved earlier, has been resumed. The residential building projects have been the largest consumer of cement in the country. Many people build and renovate houses with the improvement in the people's welfare.
In 2009, cement industry suffered a setback. Demand for cement was weak amid the global slump followed the crisis late 2008. It was shown in the cement production that shrank 3.6% to 36.9 million tons in 2009 from 38.3 million tons in the previous year despite an increase in production capacity. The country's cement production capacity was 47.9 million tons per year in 2009, up 9% from 44 million tons in 2008. The cement industry, therefore, had large idle capacity in 2009.
In 2010, demand for cement grew fast and many factories have operated almost at full capacity. Many producers, therefore, plans expansion. Meanwhile, PT Semen Andalas has resumed operation in Aceh since September 2010, after being out of business when its factory was destroyed by tsunami that devastated Aceh late 2004. The operation of PT Andalas, which is owned by France's cement giant Lafarge brought the country's total production capacity to around 50.8 million tons in 2010..
The capacity expansion by cement industry is planned to keep pace with growing demand that follows the country's economic growth. In addition, replacement of old factories is needed as they are no longer efficient. It would not be easy for small capacity producers to compete in the market especially with the increase in production cost with the higher fuel cost. The prices of coal as the main fuel for cement factories have increased to follow the rise in the oil prices.
Small players like Semen Kupang, Semen Baturaja, and Semen Bosowa could not take full advantage of the rise in cement demand. There are a number of hurdles that keep them out of contention such as locations being tool far from potential markets--Java, Sumatra and Sulawesi and difficulty in transport.
The availability of energy is a vital factor in the development of cement industry. Modernization and modification of factories are made using energy saving machines and to use secondary energy.
The availability and prices of coal are among important factors determining plan for capacity expansion as fuel cost is a major element of production cost. A number of cement producers, planning capacity expansion have to carry out studies to ascertain that coal supply is well secured. The certainty of supply is important as high coal prices in international market may result in more coal exported causing shortage on the domestic market.
Types of cement produced
There are a number of types of cement produced in Indonesia. The main type is OPC (Ordinary Portland cement) or Portland Cement Type I which accounts for 80% of the country's total production. Another main type is composite cement. Other types are produced in small quantity.
Production capacity expands 9%
In the past several years, the country's cement production capacity has remained unchanged. Capacity expansion began only in 2002 for clinker--from 43,780,000 tons to 44,425,000 tons a year or an increase of 1.5% and for cement--to 47,490,000 tons from 47,140,000 or an increase of 0.7%.
However, in 2005 and 2006, the cement production capacity fell as one of the major producers PT. Semen Andalas stopped operation as its factory was destroyed by tsunami late 2004. In addition some old factories were out of function such as those of PT. Semen Padang with capacity of 100,000 tons/year of clinker and 200,000 tons/year of cement; PT. Semen Gresik with a capacity of 800,000 tons/year of clinker; PT. Semen Tonasa with a capacity of 60,000 tons/year of clinker; and PT. Holcim Indonesia with a capacity of 1 million tons/year of clinker and 1 million tons of cement per year.
According to ASI, until 2008, the country's cement production capacity remained unchanged at 44,890,000 tons per year, as there was no producers expanded their capacity or build new factories. In 2009, the country's installed capacity rose 9% to 47.9 million tons per year.
Capacity utilization was 76%. Based on production capacity, private cement companies are larger than state cement companies. Private companies account for 60% of the country's total production capacity with state companies for 40%.
In 2010, the country's production capacity is expected to increase by 2.9 million tons to 50.8 million tons per year. The additional capacity is contributed by five producers, which will invest around US$ 645.6 million for capacity expansion. A new cement mill with a capacity of 1.5 million tons of Indocement is already operational in Cirebon. A new factory with a capacity of 1.6 million tons is being built in Aceh by PT Semen Andalas to replace its old factory destroyed by Tsunami late 2004.
Producers
PT. Semen Gresik, Tbk (PT. SG)
PT. SG has three factories located in Tuban and Gresik, East Java with a total production capacity 8.5 million tons per year. PT. SG has two cement special ports in the two cities, one cement packaging plant in Ciwandan, Banten and 11 units of buffer warehouses in various areas Java and Bali.
On 15 September 1995, PT. SG took over both PT. Semen Padang (SP) and PT. Semen Tonasa (ST) and became its subsidiaries with 99.9% stake.
PT SP in Padang, West Sumatra, is strategically located to supply market in Sumatra. It is the largest supplier of cement for Sumatra. Part of its production is also sent to Java. It also exports part of its production. It has 6 units of packaging plant to support cement distribution in Padang, Medan, Banda Aceh, Batam, Jakarta and Banten. SP also have 14 units of buffer warehouses and cement special port in Teluk Bayur, and Ciwandan of Banten.
The types of cement produced by SP are Ordinary Portland Cement (OPC), Portland Pozzoloan Cement (PPC), Portland Composite Cement (PCC), Oil well Cement (OC) and Super Masonry Cement (SMC).
In 2009, cement production of SP totaled 5.4 million tons down 8.1% from 5.8 million tons in 2008. The decline was a result of major earthquake that rocked Padang in 2009.
PT Semen Tonasa (ST) in Pangkep, South Sulawesi has three factories producing the types of OPC and PPC. ST is the largest supplier of cement for eastern Indonesia including Sulawesi, Kalimantan and Nusa Tenggara. PT ST has 8 units of cement packaging plant in Makassar, Bitung, Samarinda, Palu, Banjarmasin, Ambon and Bali and 5 buffer warehouses. It also has special port to facilitate shipments of its production in Biringkassi.
Currently the SG group has a total production capacity of 19 million tons per year including 9 million tons of PT. Semen Gresik, 5.9 million tons of PT. Semen Padang and 4.1 million tons of PT. Semen Tonasa.
SGG has planned to build 2 new factories each with a capacity 2.5 million tons in Java and Sulawesi. The new factories are expected to come on line in 2012 bringing the production capacity of SGG to 23.9 million tons. Originally SGG planned to build 10 units of coal-fired power plant with a total capacity of 410 megawatts. Construction of the facilities is estimated to cost US$573 million to be operational in 2011. The facilities were to be built to supply power for the
Tuban factories with a capacity of 2 x 65 MW; for the Indarung factories in West Sumatra 3 x 35 MW, for Tonasa factories in Sulawesi 1x35 MW, for new cement factories in Java 2x32MW and for a new cement factory in Sulawesi 2x35 MW).
However, later the company decided to build only two more urgent power plants with a total capacity of only 2x35 MW to cost US$ 114 million in Sulawesi. In 2009, PT. Semen Tonasa secured a loan of Rp 3.5 trillion from syndicate of state banks to build the power plants.
SG also plans to build 4 units of packing plant to cost around Rp600 billion internally financed. The plants will be built in Sorong of Papua, Pontianak of West Kalimantan, East Kalimanatan and Banyuwangi of East Java to facilitate cement distribution.
The company also plans to build a cement plant in Papua if the market expands warrant investment in factory. In 2010, SG sets aside USS 402 million for capital expenditure. Part or US$ 264 million of the fund would be used to finance the construction of new cement factories . The company allocates US$ 1.26 billion for capital spending. For the 2008--2014 period.
The business lines of the SGG quite vary . In addition to cement production by PT. Semen Gresik Tbk, PT. Semen Padang and PT. Semen Tonasa; and cement packaging by PT. Industri Kemasan Semen Gresik, the group has business in industrial estate by PT. Kawasan Industri Gresik; limestone mining by PT. United Tractors Semen Gresik; steel fabrication, civil contracting service by PT. Swadaya Graha; general transport service, general trading, inter-island trade, business agency and good distribution under PT. Varia Usaha; and asbestos and building material production and casting industry by PT. Eternit Gresik.
Cemex sells stake to Blue Valley Pte. Ltd.
Dispute over share ownership in PT SG between the government and CEMEX ended with the Mexican cement giant selling its 24.9% stake to the Rajawali Group through an investment vehicle company Blue Valley Pte. Ltd. at a price of US$ 337 million .
The Rajawali Group, which is controlled by Peter Sondakh, acquired the stake after the government decided not exercises its rights to buy back the stake from Cemex. Under conditional sale and purchase agreement in Sept. 1998, the government was the first party to receive any offer by Cemex to sell its stake. Offer could be made to other buyers if the government decided not to buy the stake. Cemex also agreed to drop its legal suit against the government filed earlier with an international arbitration body.
Cemex acquired the stake from the government in Sept. 1998 at a price of US$ 1.38 per share and sold it to the Rajawali Group with a profit margin of US$ 0.9 per share.
Currently, PT. SG is 51.01% owned by the government 24.9% by Blue Valley Hodings, Pte and 24.09% by investing public.