Construction

Technology is improving cement production in Africa (Image source: Adobe Stock)

Improving efficiency: Hlulani Mathonsi, sales specialist, ABB South Africa, on how intelligent process control is reshaping Africa’s cement production

Africa’s cement industry is under growing pressure to produce more while consuming less. As urbanisation accelerates across the continent, demand for cement continues to rise, driven by infrastructure development, housing projects, renewable energy investments, and industrial expansion. Whilst the manufacturers are operating in an increasingly challenging environment marked by rising electricity costs, unstable power supply, sustainability pressures, and tighter operational margins.

Globally, cement manufacturing accounts for approximately 7-8 % of total carbon emissions, according to the International Energy Agency (IEA). The sector is also one of the most energy-intensive industries in the world, requiring substantial electricity and thermal energy to sustain production. The IEA estimates that cement production consumes around 100 kWh of electricity per ton produced, placing enormous pressure on energy systems and operational costs.

In South Africa and across Africa, the challenge is even more pronounced. Persistent energy instability and rising utility tariffs continue to impact industrial productivity, forcing manufacturers to rethink how operations are managed and optimised. In this environment, digitalisation and intelligent automation are becoming critical tools for improving resilience, efficiency, and competitiveness.

Industrial automation

Across global manufacturing, companies are increasingly investing in advanced process control, predictive analytics, and automation technologies to improve productivity while reducing waste. According to McKinsey research, industrial automation is rapidly expanding across process-intensive sectors such as mining, chemicals, and cement production as businesses seek greater efficiency, reliability, and sustainability.

For cement plants, this shift is particularly important because production environments are highly complex and highly variable. Small fluctuations in kiln temperature and fuel mix can significantly affect energy efficiency, product quality, and equipment lifespan. Traditional manual operating methods are increasingly unable to manage these variables effectively in real time.

Digital solutions

This is where advanced process optimisation technologies such as ABB’s Expert Optimizer are reshaping operations. Using model predictive control, neural networks, and real-time analytics, these systems continuously monitor and adjust plant conditions to stabilise performance and maximise efficiency. Expert Optimizer is a digital solution that provides advanced process techniques, including linear and non-linear model predictive control, fuzzy logic, neural networks and analytical AI to always make the best operational decisions accurately and consistently in high-pressure environments.

The global results demonstrate the value of this approach. ABB Ability Expert Optimizer results in maximising the use of alternative fuels, increasing recovery in product by 1% to 3%, reducing quality variation by up to 30%, and increasing throughput by up to 8%. In many use cases, plants have achieved return on investment in less than 12 months through lower fuel consumption, reduced downtime, and improved process stability.

Recent global projects further illustrate how integrated automation is transforming industrial production. ABB’s collaboration with Novada Cement in the USA is one such example. ABB deployed electrification, automation, and drives solutions at a new cement plant in Florida to improve process visibility, reliability, and control over cement production to provide operational decision-making across the facility.

Urgency and opportunity

For African manufacturers, this creates both urgency and opportunity. Many industrial facilities across the continent are currently modernising or expanding, creating an opportunity to adopt more advanced and efficient production systems from the outset. However, successful digital transformation is not only about technology deployment. It also depends on aligning systems, people, and operational priorities. Human expertise remains essential in industrial environments, particularly in operationally demanding sectors.

This collaboration between operational expertise and automation is increasingly shaping the future of industrial manufacturing globally. As energy costs rise and sustainability expectations intensify, operational efficiency will become one of the cement sector’s most important competitive differentiators. In fact, the future of cement production will not be defined solely by how much is produced, but by how intelligently, efficiently, and sustainably production is achieved.

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Volvo Trucks South Africa marks 250,000 km milestone as customer-operated electric trucks accelerate sustainable freight transport. (Image source: Volvo)

Volvo Trucks South Africa has marked a major milestone in its electromobility journey, with its customer-operated electric truck fleet surpassing 250,000 km since the vehicles were first introduced to the local market in 2023

The achievement highlights the growing adoption of battery-electric trucks across a range of commercial transport applications.

The fleet has been operating in diverse environments, helping customers reduce emissions while gaining first-hand experience in electric transport operations. The milestone was achieved using Volvo's current generation of heavy-duty electric truck models.

"While a quarter of a million kilometres may seem modest compared with the more than 400 million already accumulated by Volvo electric trucks globally, it represents a significant achievement in the South African context, where the majority of Volvo electric trucks are operating on shorter-route and urban distribution applications," said Eric Parry, senior manager sustainable solutions at Volvo Trucks South Africa.

Across the customer fleet, the vehicles are averaging approximately 2,000 km per month, while the highest-utilisation trucks consistently record around 10,000 km per month. Average energy consumption across the fleet stands at 1.77 kWh/km, covering a range of applications from eight-tonne 4x2 trucks carrying payloads of five to seven tonnes to 6x4 tractor units hauling interlink trailers with payloads exceeding 32 tonnes.

The milestone reflects customers' confidence in Volvo Trucks' electric mobility solutions and demonstrates that battery-electric trucks can reliably support everyday commercial transport operations.

Reflecting on the progress, Parry said, "Our customers have embraced this technology with a willingness to learn, adapt and pioneer new ways of operating. Reaching a quarter of a million kilometres is not only a testament to the capability of the trucks, but also to the commitment of the customers and drivers who are making this achievement possible."

The operational data collected over the past two years has also provided valuable insights into charging strategies, vehicle utilisation, uptime requirements and driver experience under real-world South African operating conditions.

All customer fleets currently charge their electric trucks either at depots or loading and off-loading facilities using their own charging infrastructure. Depending on operational requirements, customers utilise a combination of overnight slow charging and fast top-up charging.

"One of the most satisfying aspects of this journey has been seeing electric trucks move from being a future concept, to becoming part of everyday transport operations," said Parry. "Every kilometre travelled helps build confidence in the technology and strengthens the business case for broader adoption."

To support fleet operators, Volvo Trucks provides specialised dealer and workshop services for electric vehicles, including real-time battery pack monitoring, dedicated 24/7 roadside assistance and range prediction tools.

Next-generation electric trucks on the horizon

Building on the experience gained to date, Volvo Trucks South Africa is preparing to introduce its next generation of electric trucks later this year. The new models will offer longer operating ranges and additional power options, enabling electric transport solutions to be deployed across an even wider range of applications.

"The trucks currently operating in South Africa are laying an important foundation for what comes next. With increased range and capability on the horizon, we are excited about the opportunities the next generation of electric trucks will bring," explained Parry.

As more fleet operators begin adopting battery-electric transport, Volvo Trucks South Africa views the 250,000 km achievement as an important step in the country's transition towards cleaner commercial mobility.

"While a quarter of a million kilometres is an important milestone, it is what those kilometres represent that matters most: growing customer confidence, valuable operational experience, and a foundation for the next generation of electric transport," said Parry.

Uganda to get new Karuma Bridge (Image source: Adobe Stock)

Japan’s Zenitaka Corporation has signed a contract with Uganda for the new Karuma Bridge project

The new bridge will replace the existing ageing structure and is expected to improve transport and trade links to northern Uganda, South Sudan, and the wider region.

Groundbreaking works are scheduled for September 2026, with civil construction works expected to commence the following month.

The contract was signed in Tokyo recently by Osamu Tanabe on behalf of Zenitaka Corporation, the main contractor for the project, and Isaac Wani, Commissioner for National Roads at Uganda’s Ministry of Works and Transport.

The signing followed the issuance of the Notice of Award by the Ministry of Works and Transport to Zenitaka Corporation as the most responsive and successful bidder for the civil works.

Zenitaka Corporation, which will work alongside Oriental Consultants Global, the project consultants, previously delivered the Jinja Nile Bridge under Japanese funding.

Speaking at the Tokyo event, Wani highlighted the strategic importance of the new Karuma Bridge in restoring safe and efficient movement along the Kampala-Gulu highway.

He noted that the bridge will strengthen regional connectivity, support trade and investment, improve access to essential services, and enhance the resilience of Uganda’s national transport network.

Wani also expressed appreciation to the Japan International Cooperation Agency (JICA) and the Japanese government for their continued support through the Official Development Assistance (ODA) Grant Aid programme, which has enabled the implementation of key infrastructure projects, including the new Karuma Bridge.

Tophace Kaahwa, Uganda’s Ambassador to Japan, described Japan’s support as a “clear demonstration of the strong and cordial bilateral relations between Uganda and Japan.”

She also emphasised the need to further consolidate the partnership for the mutual benefit of both countries.

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Caterpillar drives digital innovation at Málaga technology showcase. (Image source: Caterpillar)

Caterpillar has brought together more than 400 customers and dealers from across Europe, the Middle East and Africa for its fourth Construction and Quarry Technology Days, held at the Caterpillar Demonstration & Learning Centre in Málaga, Spain

The two-week event welcomed representatives from 15 Cat dealers to explore the company's latest technologies and their practical applications across construction and quarrying operations.

The programme began with opening remarks from Kristin Gaskill, Caterpillar vice-president of technology in Construction Industries, followed by a live product demonstration focused on technology-driven solutions. Over the following days, attendees participated in guided sessions across five dedicated technology areas, allowing them to see how these solutions perform in real-world conditions and how they can be integrated into their own projects.

Gaskill highlighted Caterpillar's ongoing commitment to advancing digital transformation within the industry.

"Our focus is clear: accelerating technology and digital adoption to deliver measurable outcomes for our customers."

"This week in Málaga is a powerful example of how Caterpillar and Cat Dealers are working together to solve customer challenges using technology & digital solutions in the dirt and back office. Our goal is to ensure technology is easy to buy, easy to use and delivers value at scale. Ultimately, we’re here to help customers unlock new and different business outcomes by partnering with them for long-term success on the job site."

Throughout the event, Caterpillar demonstrated a range of technologies designed to address critical operational priorities. Featured solutions included Better Data for Better Decisions, Perfecting Payload, Safer Jobsites, Remote Site Control with Cat Command, and Cat 2D and 3D Grade technologies.

Together, these technologies are intended to help customers improve productivity, enhance jobsite safety and simplify operations while addressing one of the industry's ongoing challenges: attracting and retaining skilled equipment operators.

Now in its fourth edition, Construction and Quarry Technology Days continues to serve as a platform for strengthening collaboration between Caterpillar, its dealer network and customers across the region.

The event also provides opportunities for customers to exchange experiences, learn from industry peers and gain greater confidence in implementing new technologies. With support from the global Cat dealer network, participants can better understand how to scale digital solutions across their operations.

As digitalisation continues to reshape the construction and quarrying sectors, the Málaga event demonstrates Caterpillar's focus on helping customers transform data, connectivity and automation into measurable operational and business benefits.