Cement Supply Set to Improve as Khayah Clinker Kiln Restarts After 26 Months

Cement availability is expected to stabilise following the revival of the Khayah clinker kiln, which has been brought back into operation after more than two years of inactivity. The restart comes after a US$20 million rehabilitation programme, Industry and Commerce Minister Mangaliso Ndlovu said yesterday.

Minister Ndlovu noted that a clinker kiln central to cement production operates at extremely high temperatures of around 1 600 degrees Celsius, heating raw materials such as limestone and clay to produce clinker, the key ingredient used in cement milling.

“This kiln behind me has been down for 26 months. The company has channelled over US$20 million into bringing it back to life,” he said.

He added that the kiln was switched back on last Saturday after a series of mechanical failures, maintenance shutdowns and border-related delays had combined to create severe shortages in recent weeks. Although the kiln is still stabilising, Minister Ndlovu said its resumption marks a major step toward restoring normal supply.

The recent cement strain was caused by multiple disruptions occurring simultaneously: a breakdown at PPC’s Harare plant, scheduled maintenance at Sino Cement in Kwekwe, and a fortnight-long interruption of clinker imports from Zambia. A border audit further slowed the movement of clinker into the country.

“All these issues happened at once, which is why the supply situation deteriorated so quickly,” Ndlovu explained.

He said the shortages triggered unjustified price hikes among some retailers, forcing the Government to temporarily open up imports, even though transporting cement over long distances is costly.

However, he stressed that importing cement is not a long-term fix. “A permanent solution comes from building our own production capacity,” he said.

Currently, a 50kg bag of cement is selling for between US$16 and US$22, depending on location. Minister Ndlovu warned that importers found abusing permits meant to stabilise prices risk losing access to those permits.

“If you are granted an import licence to support price stability but you use it to inflate prices, you will not get such a permit again,” he said.

The revived kiln will produce clinker mainly for Khayah itself, but national demand still outweighs domestic clinker output.

“Most of our cement businesses are millers. They buy clinker and grind it into cement,” he said.

Government is now considering a new clinker manufacturing plant as a national strategic investment, which would require between US$150 million and US$200 million.

The shortage of clinker has already forced two new milling plants in Hwange and one in Mashonaland West to halt operations.

“Clinker makes up between 60 and 80 percent of cement. If we bring in a third or even fourth kiln, the country will be in a much stronger position,” he added.

PPC sales manager Mr Nkosana Mapuma dismissed claims of deliberate shortages, saying the company was operating normally.

“We are producing, and our warehouses have enough cement. Our commitment is to ensure consistent supply,” he said.

Khayah Cement’s corporate rescue practitioner, Mr Bulisa Mbano, was optimistic that the kiln’s rehabilitation marks the beginning of a turnaround for the company, which has faced financial pressure and operational difficulties in recent years.

“The key takeaway is that all creditors will be paid, which immediately eases pressure and allows us to refocus on growth,” he said.

The US$20 million investment in the kiln is widely expected to play a pivotal role in stabilising Zimbabwe’s cement supply chain