INVESTMENT ANALYST
znahar@idlc.com
ABSTRACT
Bangladesh cement industry is the 40th largest market in the world. Currently capacity of the industry is about 20 mn tonnes (MT). Top 13 players are alone controlling over 78% of the total industry capacity. However, the balance capacity still remains quite fragmented. Per capita consumption remains poor when compared with the world average; only 65 kg (FY2009) while our neighboring countries, India and Pakistan, have per capita consumption of 135kg and 130kg respectively. This underlines tremendous scope for growth in the Bangladesh cement industry in the long term. Cement, being a bulk commodity, is a freight intensive industry and transporting it over long distances can prove to be uneconomical. For that reason, industry is regional in nature. Its also seasonal in nature, during Monsoon industry suffers from low demand. Four major costs are associated with the production of cement as provided: Cost elements
Power and fuel costs Raw material costs Transportation costs Other expenses
% of cost of sales
10% 75% 5% 10%
The pricing of cement of various players in the industry are very close to one another. The factories which would be using captive power (which is cheaper and more reliable than grid power) and backed by uninterrupted clinker supply at competitive price, are likely to be more cost efficient to emerge as the market leader. Currently, the standard price of one bag of cement produced by the multinational cement companies ranges within BDT 370 to BDT 390 per bag. On the other hand, price of one bag of cement produced by the local companies ranges within the price bracket of BDT 340 to BDT 365. The common technology which is widely used in our industry from the year 2003 is Portland Composite Cement (PCC) which is made following European Standard Methods (ESM). Earlier, Ordinary Portland Cement (OPC) had been used which was made following the American Standard Method (ASM). PCC gives equal strength and durability like OPC. The basic difference between them is in the manufacturing technology. Only 65%-80% of clinker is required to produce PCC while 95% of clinker is required to produce OPC. So, worldwide PCC has become popular which requires less clinker. Currently, Heidelberg, Holcim and Lafarge are the leaders among multinational cement manufacturers and Shah and Meghna are the leading domestic manufacturers. Shah cement is the market leader with close to 14.20% of the market share, followed by Heidelberg with about 9.30% of the market share. During the 2010, many small local manufacturers like Premier, Seven Circle, Crown, Fresh and King cement increased their sales drastically riding on their benefits of economies of scale, backward linkage and aggressive marketing effort. In Bangladesh, cement consumers are categorized as follows: 1. Individual home makers (25%) 2. Real estate developers (35%) 3. Govt. organizations, i.e., LGED, RHW etc. (40%)
Page 2 of 23
90 80 70 60 50 40 30 20 10 0 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
45 30 20
48
50
52
55
59
61
2010
Cement consumption has steadiliy been rising. It is expected that cement companies will enjoy a good growth of margin over the next 3 years. Becasuse, in next couple of years when large capacities are expected to come on-stream, pass through of input cost will be easier and clinker (main raw material of cement) price is expected to remain stable at $53-$58. Currently, multinational cement companies are facing intensive competition with local companies. Local manufacturers have been pursuing more innovative and agressive business strategy compared to multinationals. Local manufacturers seek to seize large market by reaching mass people through economies of scale while multinationals cater the needs of specific group of customers by charging high price through superior brand value and quality. In addition, another basic trend in cement industry is smaller companies are shutting down and the bigger companies are becoming bigger. Leading cement manufacturers are now going for expansion. It is expected that if the ongoing expansion plans complete within FY2011, the total production capacity of the industry will rise by 61%. Cement industry expects the consumption to rise by 25% (it will be much higher if Government projects come on stream). Though it seems that the industry will run overcapacity but as mentioned earlier, industry is dependent on only 13 companies production. So it reveals that the cement industry will fall short of supply if the demand increases in line with the big infrastructural projects of Government as expected in future and this symbolizes the huge growth potential of our cement industry. Industry Demand & Production
Year 2005 2006 2007 2008 2009 2010 Consumption (m n M T ) 7 .6 0 8 .4 0 8 .2 0 8 .5 4 1 0 .5 7 1 3 .9 3 Growth rate % 18.50% 10.53% -2 . 3 8 % 4 .1 0 % 23.82% 31.80% Ca p a c i t y ( m n M T) 1 1 .1 7 1 1 .9 1 1 2 .2 0 1 4 .4 4 1 7 .3 5 1 9 .9 5 Growth rate % 5 .2 0 % 6 .6 3 % 2 .4 8 % 18.38% 20.14% 14.96%
Considering the Life cycle of the industry, currently cement industry of Bangladesh is in the growth stage. Sales of cement are increasing due to growing demand for cement in both the local and foreign markets. The industry realized about 30% and 21% growth in 2009 and 2010 respectively
Page 3 of 23
after suppressed demand from previous years. Industry expected demand growth is 20%-25% for the next three years based on the assumptions below. 1. Government would be able to materialize its important ADP. 2. According to the UN Population Fund (UNFPA) report 2010, 28% people of our country live in urban areas where the population growth is 3.2 per thousand. Urbanization and demand for accommodation are increasing day by day. Thus it is expected that the real sector will grow steadily with the household users increasing cement consumption pattern. 3. Private sector may get interested to invest in real estate for getting tax advantages of their undisclosed funds 4. Good number of large infrastructure construction projects (Padma Bridge, Flyovers, highways) are on the pipeline. 5. There is no Substitute for Cement. Steel can be used in construction but in limited extent due to its high cost.
On the flip side, some caution has to be maintained due to the current demand- supply gap leading to over capacity and falling margins and prices. Also, given the close linkages between them, the effect of a slowdown in real estate growth or hike in interest rates globally or price increase of imported raw materials should also be considered.
Page 4 of 23
ASM = American Standard Method BCMA= Bangladesh Cement Manufacturing Association CNF = Cost & Freight ESM = European Standard Methods OPC = Ordinary Portland Cement PCC = Portland Composite Cement UNFPA = UN Population Fund
Page 5 of 23
1.0
PREAMBLE
Gradual substitution of traditional building structures or patterns by modern high-rise ones has pushed up the use of cement. A faster growth in demand for cement has been observed only since mid-1980s, especially with implementation of large infrastructure projects, increased pace of urbanization, construction of apartment buildings and multistoried shopping complexes in urban areas and a shift in the taste of rural people for modern houses.
After a decade, currently 123 companies are listed as cement manufacturers in the country. Among them 63 have actual production capacity while 32 are in operation. The current installed capacity of the industry is 20.0 mn MT. This installed capacity has been calculated under two conditions below: 1. all factories are in operation 2. production is at its peak season Though the installed capacity is 20.0 mn MT, currently the acutal capacity is about 13.96 mn MT due to supply constraints for power and clinkers.
Page 6 of 23
19.95
13.93 10.57
2005
2006
2007
2008
2009
2010
Industry structure
Multinationals , 27%
Page 7 of 23
Bangladesh cement industry is known for its seasonality which can be as high as 50%. Cement demand declines during the monsoons due to a slowdown in construction activities. On the other hand, though the yearly capacity of the industry is saturated with overcapacity, market demand gets matched or cross the effective capacity during the first 5 to 6 months of the year. In addition, the cement industry, like most capital-intensive commodity industries, is cyclical in nature with respect to supply. Given the high gestation period of 24-30 months, there is a time lag between capacity build-up and cement demand. Cement demand is closely linked to the growth of the construction sector. Hence, when the construction sector is strong, demand increases. As a result, the profitability rises, leading to capacity additions by existing players and the entry of new players. However, since it takes 2 -2.5 years to build a cement plant, it is likely that before completion, demand could decrease or stagnate, or the capacity additions could exceed demand. This can lead to a fall in cement prices, and the industry could face a downturn, leading to reducing operating rates or shutting down capacities.
15.50%
Dhaka
Mongla
Chittagong
Sylhet
Rajshahi
Page 8 of 23
Key points Supply At present, the demand-supply situation is tightly balanced with the latter being marginally higher. As the cement industry is dependent on few companiess production, more expansion will be needed to meet the large demand of govt infrastructures. Housing sector acts as the principal growth driver for cement. However, recently industrial and infrastructure sectors have also emerged as demand drivers. High capital costs and long gestation periods. Access to cheap source of clinker supplier also acts as a significant entry barrier. Our cement industry depends on imported raw materials. Currently international price of clinker is stable. But any kind of volatility in its price remained a concern. End users of the product get benefited if they are near to the distribution plant of the company. But when their positioning is at distance from the distribution plant, companies used to charge premium. Moreover, brands used to charge premium on account of better quality perception also. Intense competition among players regarding price due to homogeneous product.
Demand
Barriers to entry
Competition
Page 9 of 23
Clinker Gypsum and Fly ash Thailand, Indonesia, Malaysia, China, Philippines and India
Source: IDLC research
Cost derivation of Clinker (on an average) CNF (cost & freight) cost in CTG Vat on landing at CTG Total cost of Clinker (landing at CTG) Vat on landing at Dhaka Total cost of Clinker (landing at Dhaka)
$ 53.00 BDT 350 or $5 /ton $ 58.00 BDT 840 or $12 /ton $ 65.00
Source: IDLC Research
Apart from clinker, other raw materials used by the cement industry are fly ash, ironslag and gypsum.
3. Transportation cost
The weight/ price ratio of cement effects transportation cost significantly. Location of a cement plant and the cost to transport the cement to its distribution terminals, determines the plants competitive position and price it may charge.
Page 10 of 23
Although in a minimal percentage but rising loading restriction imposed on vehicles crossing over the Jamuna Bridge and priority movement of vehicles carrying food grain are also causing setbacks for the industry by increasing transportation cost.
4. Other expenses
Other expenses include employee costs, administration expenses, others. These account for 5-10% of the cost of sales.
Page 11 of 23
5.0 PRODUCT AND TECHNOLOGY 5.1 Ordinary Portland Cement (OPC) and Portland Composite Cement (PCC)
Till 2002, only one type of cement was available in Bangladesh was Ordinary Portland Cement (OPC) which is made following the American Standard Method (ASM). From the year 2003, various types of cements became available in Bangladesh which helped the cement industry to provide differentiated and improved products to the customers. The cement which is widely used from the year 2003 is the Portland Composite Cement (PCC) which is made following European Standard Methods (ESM). Holcim (Black Cement) was the first company to launch this type of cement in the market. Currently ratio of production of PPC and OCC is 95:5. PCC gives equal strength and durability like OPC. The basic difference between them is in the manufacturing technology. Only 65%-80% of clinker is required to produce PCC while 95% of clinker is required to produce OPC. So, worldwide PCC has become popular which requires less clinker.
Portland Composite Cement (PCC) Ingredients used in PCC Clinker Slag Fly Ash Limestone Gypsum Ordinary Portland Cement (OPC) Ingredients used in OPC Clinker Gypsum
5.2 Technology
The manufacture of cement is a two-phase process. Firstly, Clinker is produced. Most common methodology of producing clinker is to mix up calcareous minerals such as chalk, limestone containing silica and alumina and heat upto 1450 degree C. After cooling it, clinker is formed. Secondly, the clinker is ground with calcium sulphates and with industrial processes wastes such as blast furnace slag, limestone and fly ash to produce Portland cement. Two basic types of clinker production processes exist, depending on the way the raw materials are prepared before entering the kiln system: Wet method (use in Bangladesh) Dry method
In the wet method, water is added to form wet thick slurry and dry process is based on drying the bulk materials to form a dry powdered meal. The choice of process depends on moisture content of the available raw material. When wet raw materials (moisture content over 20%) are available, the wet process can be preferred. However, in Europe, todays new cement plants are all based on the dry
Page 12 of 23
process as the wet process requires approximately 56% to 66% more energy. For dry processes, current state-of-the-art technologies are kiln systems with multistage cyclone preheaters and precalciners. Each step in manufacture of portland cement is checked by frequent chemical and physical tests in plant laboratories. The finished product is also analyzed and tested to ensure that it complies with all specifications.
Standardization-Bangladesh is maintaining
Standardization Main constituents BSTI (Bangladesh Standardization Authority) has been adopted the European Norms and titled as BDS EN 197-1:2003 a) Clinker b) Slag c) Fly ash d) limestone e) Gypsum
Bangladesh has adopted EN197- 1:2000 as Bangladesh Standard, titled BDS EN 197-1:2003. Under this Standard there are 27 products in the family of common cements, which are grouped into five main cement types as follows:
CEM I Portland cement CEM II Portland- composite cement CEM III Blast furnace cement CEM IV Pozzolanic cement CEM V Composite cement
Source: www.cembureau.be
While clinker is the main component in all types of cements, the kind and the amount of the other constituents determine the type of cement. For example, Portland cement consists of 95% clinker, whereas Portland composite cement contains of only 65% clinker. All cement types also contain up to 5% of calcium sulphates. In our country recently, the availability of PCC is 95% against 5% of OPC.
Page 13 of 23
6.0 PRODUCERS AND CONSUMERS OF THE INDUSTRY 6.1 Major Producers of the Industry
The largest 13 cement manufacturers hold 78% of the market share. Heidelberg, Holcim and Lafarge are the leaders among multinational cement manufacturers and Shah and Meghna are the leading domestic manufacturers. Shah cement is the market leader with close to 14.20% of the market share, closely followed by Heidelberg with about 9.30% of the market share. During the 2010, many small local manufacturers like Premier, Seven Circle, Crown, Fresh and King cement increased their sales drastically riding on their benefits of economies of scale, backward linkage and aggressive marketing effort. Market share of major cement companies Market share
Shah cement Heidelberg Cement Meghna Cement (MCML-King) Seven Circle BD Ltd. Lafarge Surma Cement Ltd. Holcim BD Ltd. Unique Cement (Fresh) MI Cement (Crown) Premier Cement Akij Cement Royal Cement Mongla Cement (SKS)-Elephant MTC Cement (Tiger) 14.2% 9.3% 7.4% 6.9% 6.7% 6.4% 6.1% 4.9% 4.0% 3.7% 3.0% 2.9% 2.8%
78.29%
Source: BCMA
27%
Source: BCMA
Page 14 of 23
Market/ Area
Market Share
6.7% 0.8% 7.5% 5.7% 14.2% 4.9% 4.0% 6.4% 6.9% 6.1% 2.8% 1.4% 2.8% 1.0% 1.0% 3.7% 1.0% 1.6% 63.5% 3.6% 0.8% 1.5% 0.4% 3.0% 0.6% 0.4% 1.7% 12.0% 7.4% 2.9% 1.8% 1.2% 2.3% 15.5% 1.5% 1.5% 100%
Sylhet Area
Dhaka Area
Chittagong Area
Page 15 of 23
Current and Upcoming Capacity of Running Cement Industries in Bangladesh Present capacity (mn MT/year)
2.25 1.44 1.26 1.20 1.20 1.20 1.02 0.90 0.90 0.18 0.84 0.80 0.72 0.72 0.60 0.60 0.36 0.51 0.50 0.40 0.35 0.25 0.21 0.18 0.18 0.18 0.18 0.18 0.18 0.18 0.18 0.10 1.65 1.26 0.81 0.60 0.47 2.49 End 2011
Sl.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Running industry
Shah Cement Meghna Cement Mills Ltd. Akij Cement Ltd. Heidelberg (Scan) Lafage Cement Premier Cement Seven Circle cement Ltd. Heidelberg (Rubi) Holcim Cement (BD) ltd. (Dhaka) Holcim Cement (BD) ltd. (Mongla) M.I Cement Factory (300 days) Unique Cement Ryal Cement Mongla Cement Factory Emirates Diamond Cement Factory M.T.C Cement Ltd. Aramit Cement Ltd. Confidence Cement Ltd. S.Alam Cement Mills Ltd. Cemex (BD) Ltd. Olympic Cement Anwar cement Ltd. N.G.Saha Cement Mills Ltd. Chatak Cement Ltd. Aman Cement Factory Ltd. Mir Cement Metropoliatan Cement Ltd. Eastern Cement Ltd. Dubai (BD) Cement Mills Ltd. Alhaj Mustafa Hakim Cement Noapara Cement Mills Ltd.
0.65
Dec-11
Total
20
16
36
Source: IDLC Research
2012
32.06 22.44 17.41
in mn MT Growth rate
61% 61% 25%
Supply-Demand Ratio
100%
129%
Source: IDLC Research
Page 16 of 23
Real estate developers and Govt. projects are the dominant users of cement. During 2007-2008 public sector construction works were slowed down under caretaker government. Unwillingness to disclose the source of income contributed to the downward trend in real estate sector, i.e., building of apartments, flats etc. during that time period.
GR %
11% -2% 4% 24% 32%
83%
Source: IDLC Research
90 80 70 60 50 40 30 20 10 0 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
45 30 20
48
50
52
55
59
61
2010
Page 17 of 23
All these companies are exporting in very low quantity to the neighboring countries (India and Myanmar) which are easily accessible through water transportation such as ships and mother vessels. Transportation cost is major concern to export cement. Thus exporting this product to countries which are reachable through connecting water bodies is much more feasible in terms of cost and accessibility. High duty charge is one of the main stumbling-block of cement export. Cement manufacturers in our country produce cement by importing clinker from China and Indonesia (mainly) at a high rate of shipping cost and duties which make the present cost structure impracticable to tap the export potentials for cement. If the government make the duty structure more industry-friendly by exempting some duties on exportable cement and granting cash incentives, cement exporting to Sri Lanka,Nepal,Bhutan and the Middle Eastern (ME) countries will be feasible in future.
Page 18 of 23
Page 19 of 23
Industry expected demand growth is 20%-25% for the next three years based on the assumptions below. 1. Government would be able to materialize its important ADP of building big infrastructure projects. 2. According to the UN Population Fund (UNFPA) report 2010, 28% people of our country live in urban areas where the population growth is 3.2 per thousand. Urbanization and demand for accommodation is increasing day by day. Thus it is expected that the real sector will grow steadily with the household users increasing cement consumption pattern.
Population Growth rate of Bangladesh Total Number of population Year (mn) 2000 140.77 2001 143.29 2002 145.80 2003 148.28 2004 150.73 2005 153.12 2006 155.46 2007 157.75 2008 160.00 2009 162.22 2010 (est.) 164.40 2050 176.53 (forecasted)
Population Growth Rate 1.8% 1.8% 1.8% 1.7% 1.6% 1.6% 1.5% 1.5% 1.4% 1.4% 1.3% 7.4%
Page 20 of 23
3. Private sector may get interested to invest in real estate for getting tax advantages of their undeclared funds 4. Good number of large infrastructure construction projects (Padma Bridge, Flyovers, highways) are on the pipeline. 5. There is no Substitute for Cement. Steel can be used in construction but in limited extent due to its high cost. On the flip side, some caution has to be maintained due to the current demand- supply gap leading to over capacity and falling margins and prices. Also, given the close linkages between them, the effect of a slowdown in real estate growth or hike in interest rates globally or price increase of imported raw materials should also be considered.
The largest global players are Lafarge (France), Holcim (Switzerland) and Cemex (USA). In terms of cement production, Bangladesh ranks about 40th in the world. According to Global Industry Analysts, Inc., global demand for cement is forecasted to rise 4.1% per year and reach to 3.5 billion metric tons in 2013. Gains will be fueled by rising investments in
Page 21 of 23
infrastructure among the developing countries of the world, driven by economic growth and increasing per capita income levels.
Page 22 of 23
14.0
CONCLUDING REMARK
The cement industry is likely to maintain its current growth momentum and continue growing at around 20% to 25% in the medium to long term. Government initiatives in the infrastructure sector and the housing sector are likely to be the main growth drivers. Our cement consumption per year was only 65kg in FY2009 whereas, in India its 135 kg and in Pakistan its 130kg. So there is a lot of opportunity to grow in this industry. If the import duty structure of various cement products, e.g. finished cement, semi-finished cement and basic raw materials for cement (25%, 12% and 7% respectively) continues i.e. import duties is on favor of the local manufacturers and the construction sector remains booming with smooth power supply than nothing to be surprised that cement industry will be the most evolving industry in the next three to five years. The importance of the housing sector in cement demand can be gauged from the fact that it consumes almost 60%-65% of the country's cement. If housing sector growth wanes, it would impact the growth in consumption of cement, leading to demand supply mismatch.
Threats
Construction sector dwindling Energy price and supply International pricing of raw materials Growing usage of steel materials for construction
Disclaimer: This Document has been prepared and issued by IDLC on the basis of the public information available in the market, internally developed data and other sources believed to be reliable. Whilst all reasonable care has been taken to ensure that the facts & information stated in the Document are accurate as on the date mentioned herein. Neither IDLC nor any of its director, shareholder, member of the management or employee represents or warrants expressly or impliedly that the information or data of the sources used in the Document are genuine, accurate, complete, authentic and correct. Moreover none of the director, shareholder, member of the management or employee in any way be responsible about the genuineness, accuracy, completeness, authenticity and correctness of the contents of the sources that are publicly available to prepare the Document. It does not solicit any action based on the materials contained herein and should not be construed as an offer or solicitation to buy sell or subscribe to any security. If any person takes any action relying on this Document, shall be responsible solely by himself/herself/themselves for the consequences thereof and any claim or demand for such consequences shall be rejected by IDLC or by any court of law.
Page 23 of 23