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Building Materials - 2020 General Overview

 

Developments in 2020

Overseas Organization

In line with the long-term strategy of Sabancı Group to become a leading global player in the white cement trade, Cimsa Sabanci Cement BV was established by combining financial power with operational competence. Cimsa Sabanci Cement BV is a productive and financially sound platform operating overseas.

Flexible Business Model During the Pandemic

Akçansa and Çimsa met the demands in the domestic market and export by continuing production at full capacity with flexible business models despite the impact of the pandemic in 2020. Exporting to 17 countries in 4 continents from 3 ports at a record level, Akçansa achieved great success by reaching the highest monthly export volume in the Turkish cement industry’s history.

Technology-Oriented and Sustainable Production

Focusing on smart plant systems, data analytics and energy efficiency with the digital strategies they have developed, Akçansa and Çimsa produced greener products by increasing the use of waste as an alternative fuel source.

Priorities in 2020

Industry and Sabancı Building Materials Group companies

Turkish cement industry ranks first in Europe with 55 integrated production facilities, 22 grinding plants and a total annual production capacity of 100 million tons. With the recovery in the domestic market in 2020 after the contractions in 2018 and 2019, there has been an increase in the export volume of the Turkish cement industry.

 

Akçansa and Çimsa represent 16% of total Turkish clinker capacity

Akçansa produces cement and readymixed concrete in the Marmara, Aegean and the Black Sea regions. Akçansa operates 6 cement terminals in Ambarlı, Aliağa, Yalova, Derince, Trabzon and Marmara Ereğlisi in addition to Istanbul, Çanakkale and Ladik plants. Operating in the Marmara, Aegean and Black Sea regions of Turkey, Akçansa produces ready mix concrete at 26 ready mix concrete plants under the “Betonsa” brand and aggregate in the Saray, Kemerburgaz, Samsun and Bursa aggregate quarries under the “Agregasa” brand. Also, Karçimsa Cement Grinding and Packaging Facility has been established with the partnership of 51% Akçansa and 49% Karabük Demir Çelik İşletmeleri.

Çimsa operates in the cement and building materials industry with integrated plants in Kayseri, Mersin, Eskişehir, Niğde and Afyonkarahisar; two grinding plants in Houston/USA and Ankara; 21 ready mix concrete facilities and international cement terminals.

Focusing on sustainable production in 2020, Building Materials Group companies continued to create value to their stakeholders.

2020 Performance

In 2020, Building Materials companies contributed to the national economy with a combined export volume of TL 2 billion.

Exceeding its record in the history of the Turkish cement industry, Akçansa reached an export amount of 4.1 tons in 2020 thanks to the logistical advantage provided by Çanakkale and Ambarlı ports. Operating in important export markets with its effective port management and long-term customer portfolio, Akçansa’s export revenue rose by 26% compared to the previous year.

A world-renowned brand in white cement, Çimsa maintained its contributions to the Turkish economy in 2020. Via its seven terminals and one grinding plant abroad, Çimsa exports white cement and specialized products to more than 65 countries - especially in the Middle East, Europe, North Africa and North America. With the logistical advantage of its Mersin Plant, Çimsa increased its export revenue in 2020 compared to the previous year.

Operating at full capacity thanks to domestic and international sales, the sales income of the companies rose over
the prior year. Despite the rising energy costs due to the exchange rates, Building Materials Group companies managed to make a difference in the industry with the improvements in fuel and raw material usage recipes while making use of the advantages of their logistics networks.

With Buñol Plant joining the production and distribution network, Building Materials Group aims to establish a sound export network in North Africa and South America markets as well as Europe by having a say in a wider geography. With a 40% increase in production capacity thanks to this investment, it is expected that the group will rise to the leading position in the global white cement trade.

In 2020, the highest alternative fuel usage rate has been achieved

With an alternative fuel use of 19% in Akçansa and 7% in Çimsa (including Afyon factory), the Group reached the highest level in its history in the use of alternative fuel. Akçansa Büyükçekmece plant is positioned as the solution partner of Istanbul’s waste issue. By using most of the dried sludge from the treatment plants of İSKİ in Istanbul and the fluid waste from ships in the Sea of Marmara with the collaboration of İSTAÇ as fuel in the Büyükçekmece plant, energy recovery is provided. At the Sabancı Golden Collar Awards, Akçansa received the first prize in the Lean Transformation category with its Alternative Fuel Project.

Akçansa is the strategic solution partner in 1915 Çanakkale Bridge

Akçansa is among the suppliers of 1915 Çanakkale Bridge, which will be the “World’s largest suspension bridge with a span.” After the completion of the tower constructions, the construction of the concrete structures on the approach viaducts continued in 2020. A total of 480 thousand cubic meters of concrete was used in the project, including the construction of the approach viaduct decks. 1915 Çanakkale Bridge Project is an exemplary project with innovative product studies and zero-error project management while leaving a legacy to the generations to come.

Digitalization, Technology and Investments

Pioneer in technology-oriented and innovative production

By breaking new ground in the sector as a result of long-term R&D studies, Akçansa digitalized the traditional sampling management and launched the Smart Concrete product. The quality of the concrete is measured with digital sensors placed inside the concrete. As the first concrete company to prove the sustainability of its quality and share it with its customers thanks to the technological infrastructure provided by Vodafone Business, Betonsa controls the quality of the concrete used in its projects remotely with the application installed on customers’ mobile devices.

Building Materials companies created a cloud infrastructure to develop projects with big data, within the scope of the Advanced Data Analytics program commenced with SabancıDx. The company developed a machine learning initiative to reduce electricity consumption in kiln, cement and raw meal mills.

Focusing on Industry 4.0 projects by prioritizing smart factory systems, data analytics and efficiency in line with its digital strategies, Çimsa’s R&D Center Formula Center continues its activities inside the Mersin Plant as a global solution center for the needs of cement users.

The production of “Duro,” which is the most recently developed product in the Formula Center, is only carried out by Çimsa in Turkey. With a low melting point,

Duro helps to clean steel melts at 1,375˚C and does not include fluorine. Duro was offered to the iron and steel industry as an environmentally-friendly material.

Another project of Çimsa, “Forge” became one of 8 projects supported by the EU Commission within the scope of “nanotechnology, advanced materials, biotechnology, advanced manufacturing and processing technologies” areas under TÜBİTAK Horizon 2020 Program’s Industrial Leadership and Competitiveness category.

2021 Priorities and Industry Strategy

With the recovery started in the domestic market in 2020, Akçansa and Çimsa met the domestic demand and worked full capacity while maintaining its export volume. The priorities of the Building Materials Group companies in 2021 are to realize their high-added value digital transformation projects and to increase the use of alternative fuel. In this context, studies involving smart factory systems and cloud solutions are progressing at full speed to increase production and efficiency in energy usage. The Buñol Plant, which is a leading global white cement production facility, will be integrated into the Building Materials network.