In an exclusive interaction with Homes & Buildings Magazine, MR. SHRIDHAR AYYAR, Senior Vice President & Head – Manufacturing, RMX at Nuvoco Vistas Corp., shares how the company is pioneering next-generation concretesolutions that balance strength, sustainability and smart technology. From low-carbon mixes and thermal- insulated concrete to circular economy practices and digital integration, Nuvoco is setting the foundation for a future-ready construction industry.
How is Nuvoco redefining the role of concrete in a rapidly urbanising and climate-sensitive world?
At Nuvoco, we’re reimagining what concrete can do in a climate-sensitive world. One of our latest innovations, Ecodore Thermal Insulated Concrete, is designed not just to build stronger structures but to create more comfortable and energy-efficient spaces.
What sets it apart is the use of specialised aggregates that reduce heat transfer, helping to keep buildings naturally cooler. This advanced formulation can lower indoor temperatures by up to 3°C – a significant advantage during peak summer months. As a result, buildings require less air conditioning, which translates into reduced energy consumption.
Additionally, it also reduces the cooling load and Energy Use Intensity (EUI) in buildings, resulting in several benefits – a 5% decrease in building EUI, a 6% reduction in space cooling load, and a 7% decrease in cooling capacity requirement. Moreover, its reduced density contributes to a lighter building load, which can lower construction costs.
What are your key innovations in low-carbon or carbon-neutral cement and concrete formulations? Could you elaborate on your use of SCMs like fly ash, GGBS, or rice husk ash?
Ecodore is our flagship innovation in sustainable construction – a next-generation concrete solution designed to lower the environmental footprint of building materials. Developed with a focus on reducing carbon intensity, Ecodore incorporates high-performance supplementary cementitious materials (SCMs) along with recycled aggregates. This unique blend enables up to 60% reduction in CO₂ emissions compared to conventional OPC-based mixes.
More than just a green alternative, Ecodore enhances the longevity and strength of structures, improves workability for construction teams, and promotes circularity by repurposing industrial by-products. In today’s context, where the construction sector is under pressure to decarbonise, Ecodore stands out as a solution that combines environmental responsibility with uncompromised performance.
Have you introduced or adopted advanced concrete types such as self-healing concrete, UHPC, 3D printable concrete, or fibre-reinforced concrete?
Please share project examples or testing outcomes. We’re really excited about the future of construction, and one of the areas we’re actively exploring is 3D printable concrete. While we haven’t launched a product in this space yet, the potential is huge — and we’re putting focused efforts into R&D to get there.
Additive manufacturing, or 3D printing, has started making waves in the ready-mix concrete world, and for good reason. With large-scale 3D printers, it’s now possible to create complex concrete structures faster, with less material waste, and far more design freedom. From cutting down on labour-intensive tasks to enabling bold architectural forms, the technology opens up a whole new dimension for the industry.
In addition to that, we’ve introduced Concrete Polibre — a polypropylene fibre-reinforced concrete. It helps control early-age shrinkage and micro-cracks, making the structure stronger and more durable from the get-go.
We also offer Concrete Permadure, a specialised mix designed to resist water seepage and minimise plastic shrinkage cracks. It’s packed with engineered fibres that make the concrete denser and more durable — perfect for long-lasting performance.
How does your product or production process address water consumption and energy intensity in cement manufacturing? Have you adopted any waste heat recovery systems or water recycling protocols in your plants?
Water and energy are two of the biggest focus areas for us when it comes to making our operations more sustainable.
Water and energy are two of the biggest focus areas for us when it comes to making our operations more sustainable.
Is your company exploring the integration of digital tools such as BIM compatibility, AI-powered mix design, or IoT-enabled quality control in concrete production?
We are actively integrating digital tools to enhance precision, consistency, and efficiency in our concrete production processes. One of our key initiatives has been the implementation of a uniform batching plant system across all locations, which has streamlined operations and enabled centralised, real-time control. This ensures consistency in quality and allows us to monitor and adjust production parameters with greater accuracy.
We also maintain a rigorous focus on quality through continuous monitoring of Internal Quality Protocols (IQPs) and compliance with BIS standards. Any deviations are promptly identified and addressed through our system-driven processes, helping us uphold the highest standards across every batch.
What is your company’s approach to circular economy practices such as concrete recycling, reuse of construction debris, or use of alternative fuels?
At Nuvoco, we believe sustainability begins with how we use and reuse our resources. One of the ways is by working closely with other industries to repurpose their by-products within our operations. By utilising waste and substitute materials in our product mixes — such as blended cement with reduced clinker content — we minimise waste disposal and significantly reduce carbon emissions.
In our Ready-Mix Concrete (RMX) plants, we’ve taken this further by using recycled aggregates sourced from construction and demolition (CAD) waste. Instead of letting this debris end up in landfills, we’re transforming it into high-quality concrete — building new structures from old ones.
On the energy front, we’re steadily reducing our dependence on fossil fuels by turning to alternatives such as biomass, liquid solvents, and refuse-derived fuels (RDF).
We’ve also introduced e-loaders at our RMX plants and plan to scale up their use, supporting our broader decarbonisation goals.
How does your company envision the future of cement and concrete by 2030? What long-term investments or strategies are you undertaking to lead this transition?
In the near future, we are poised for strategic growth and innovation. We foresee harnessing advanced technologies and sustainable practices to bolster operational efficiency and environmental stewardship. By embracing digital solutions like IoT-enabled sensors and real-time data analytics, we aim to optimise production processes and ensure consistent quality control.
Furthermore, our strategy includes expanding our RMX plant network strategically, aligning with growing cities and regulatory requirements. Our focus remains on continuous improvement in logistics, encompassing fleet management and route optimisation, to navigate complex urban environments more effectively.
Additionally, we remain steadfast in our commitment to sustainable practices, exploring alternative materials and fuel sources to reduce our carbon footprint and contribute positively to the evolving landscape of the construction industry.
