Republic Cement is disrupting the cement industry by using data science and artificial intelligence (DSAI) to cut carbon dioxide (CO2) emissions and produce stronger and more consistent cement.
At a virtual press briefing yesterday, the cement manufacturer bared that data science can be a tool to instantly predict cement strength from the current practice of a 28-day waiting period.
Under the traditional method, samples cast from one batch of cement are molded into cubes, cured, and tested for its strength using a compressive strength testing machine. The compressive strength testing machine applies pressure to the cement cube until the sample breaks, making the load or weight at which the sample breaks the strength of the cement batch.
Cement strength has been traditionally determined through this process and projects can only be fully certain of a cement batch’s strength and quality after this 28-day test. This is done to ensure that the quality of the cement used will lead to safe and strong structures that conform to Philippine National Standards (PNS) as well as the standards required by the project.
Republic Cement has put in place a comprehensive data infrastructure to collect relevant data about the various states and chemical compounds present in cement across the whole manufacturing process and identifying its qualities after curing for 28 days. These data are then processed into relevant information that can be used in decisions that affected the 28-day strength testing results, which largely relied on reactive decisions based on these results.
The consequences of not having this data to support the cement manufacturing process was the inefficient use of raw materials, which translated to higher costs. This overcompensation is done to ensure that the cement meets both the PNS on 28-day strength as well as Republic’s own more stringent quality standards.
In exploring how to turn its data into relevant information, Republic Cement teamed up with the Aboitiz Data Science (ADI) to build an Artificial Intelligence (AI) tool for its cement manufacturing operations. The product is designed as a DSAI application to help operators and quality managers optimize concentrations of raw ingredients in the cement mix by instantly harnessing complex algorithms, thus saving time and resources. The development of the product also led to innovative data-driven adjustments making it important for the company to embed the tool as part of daily operations.
“The application of DSAI in cement is extremely exciting as it demonstrates that DSAI can be a core differentiator in traditional industries while also allowing them to flourish digitally. This is just the start, our focus is to innovate and systematically operationalize DSAI benefits in areas such as customer engagement, operations and in materializing ESG [Environmental, Social, and Corporate Governance] goals,” said Dr. David Hardoon, Aboitiz Data Innovation managing director.
To date, two of Republic’s manufacturing plants are now utilizing the AI tool as part of the overall process strategy, yielding positive results. Improvements on the first deployment are also underway, while expansion to all Republic sites is ongoing.
In line with its decades-long commitment to a greener environment, Republic has always sought to reduce CO2 emissions through manufacturing greener cement. In the manufacturing process, this is done through using alternative fuel that substitutes for non-renewable fuels, continuously upgrading to more energy efficient technologies, and embedding sustainability throughout the manufacturing process.
Through the application of data science and being able to accurately predict 28-day cement strength, Republic has been able to further optimize its manufacturing process. By better managing its resources, coupled with the increased efficiency of raw materials used in cement production, the company effectively reduces CO2 emissions while maximizing cement quality and strength. These adjustments, coupled with Republic’s numerous greening initiatives, will also lead to more sustainable operations in the long term.
“Sustainability and building a greener environment for generations to come remains a top priority at Republic Cement. Through this, we intend to do our part in restoring and preserving our environment while producing the best quality cement for the Filipino consumer,” said Lloyd Vicente Republic Cement vice president for Manufacturing
