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Concrete Connection Issue 8 - Lafarge

December, 2009 > issue 08Lafarge Bath PlantconcreteconnectionIn this issueA Message fromthe Plant Manager...And the Winner is...Employee Spotlight:David Yokom, theProject Managerfor the West QuarryProject...A Cleaner,Greener Quarry ...Home SweetHabitat ...Bath RevitalizationProject ...

“I really liked the factthat Lafarge was sucha large company withso many operationsaround North Americaand the rest of theworld. I saw there wasa great opportunityfor advancement andthe potential of beingable to work in someinteresting place wasalso a big draw.”Employee Spotlight: Dave YokomIn every issue, we like to shine the spotlight on one of ouremployees to give you a chance to get to know the peoplebehind the plant. In this issue, we’d like to introduce youto Quarry Coordinator David Yokom, the man who engineeredthe move to our new quarry area.“I enjoy the experiencesand opportunities thatare presented to me.”Q: What did you study in school?A: I graduated from Queen’sUniversity in 2005 with a Master’sDegree in Mechanical andMaterials Engineering.Q: Why Engineering?A: My dad was an engineer, andI enjoyed problem solving as wellas math. Plus, engineers know howto party!Q: What brought you to Lafarge?A: While finishing my Master’s,I attended a job fair at Queen’s.Lafarge had a booth there andI was impressed with what theyhad to offer. I really liked thefact that Lafarge was such a largecompany with so many operationsaround North America andthe rest of the world.I saw there was a great opportunityfor advancement and the potentialof being able to work in interestingplaces was also a big draw. Fora new engineer, I also found itimportant to be given the propertraining and tools when I startedmy professional career – Lafargewas able to offer that.Q: What was your first job here?A: I started in the CementProfessionals program in theNew Works Department. (Thisis a program for recent gradsto familiarize them with cementmaking processes.)After doing that for two yearsand learning a huge amountof stuff about the cement industryand engineering in general,I moved to a more senior roleas Project Engineer. In early 2008,I was assigned to the West QuarryDevelopment project as SiteSupervisor.Q: What do you likebest about Lafarge?A: I enjoy the experiences andopportunities that are presentedto me. In my first three years here,I’ve been able to manage projectsof all shapes and sizes, includinga $12-million project. Now I havea lot of opportunities to managein the field. These experiencesare invaluable.Q: What do you do when you’renot at work?A: I really enjoy playing sports withthe Kingston Sports and Social Club.I pretty much play every sport theyhave to offer so it keeps me activeduring the week. My favourite sportis soccer though. I’m pretty mucha born striker. If things don’t workout with my engineering career Ialways have a professional soccercareer to fall back on.Concrete Connection, December, 2009 > issue 083

A Cleaner, Greener QuarryThe Bath Plant’s new limestone quarry will dramatically cutdown on the waste the plant produces. Because limestone isthe key ingredient in the cement-making process, the plant’sability to mine its own good quality limestone is criticalto its success.Top: An aerial view of the Bath plant andquarry; the West Quarry location is circled.Above: The crusher in it’s currentlocation in the west quarry.“The old portion of the quarry wasalmost mined out of cement-qualitylimestone, so we needed to openup a new part of the quarry,”says Project Manager David Yokom.”Busting the DustThe $12-million project allowsLafarge to mine a higher qualityof limestone, which, in turn, allowsthe plant to generate less waste.Yokom explains that the limestonein the old eastern part of thequarry contained higher levels ofchlorine, which can accumulate inthe cement-making process unlessreleased by removing a portion ofthe cement kiln’s internal materials,forming a by product called CementKiln Dust (CKD).Because chlorine levels in the newWest Quarry limestone are so low,Yokom says they now generatemuch less CKD and are on the wayto meeting Lafarge’s zero-CKD goalfor North America. “This is a muchgreener operation,” he says.Getting StartedThe project started when a studyidentified a viable limestone sourceabout one kilometre west of theoriginal quarried area, but stillwithin the licensed area. The ProjectTeam broke ground in Februaryof 2008.The first step was to clear outseveral acres of overburden – thesoil that had covered the ground.Although the Project Team removedhundreds of trees from the new site,they were able to preserve some ofthem and replant them elsewhere onthe property, adding to the 10,000sof trees planted at the plant overthe years.With the site cleared and theoverburden removed, it wastime to start blasting. TheTeam opened up a 14-metrepit, removing 400,000 tonnesof stone.4Concrete Connection, December, 2009 > issue 08

Mobile Crushermoving to thenew quarry.Limestone on the MovePerhaps the biggest logisticalproblem surrounding the newquarry was getting the limestoneback to the plant. The new siteis a full kilometre away from theprevious site, which is where theconveyor system that transportsthe limestone to the plant is located.The Team decided to movethe quarry’s mammothlimestone crusher to the newsite and build a new conveyorto move the limestone backto the old quarry.Going UndergroundTo make the new conveyor work,the Team had to negotiate a set ofcomplicated logistics. The conveyorhad to go underneath the nearby railsiding and a power line that feedsthe entire plant. They built a 150-metre underground tunnel fromthe old quarry to the new one.Moving the MonsterThe Team knew that the enormousmobile crusher could never makethe three-kilometre journey tothe new site on its own. Someonewould have to move it. They hired2009 Canadian Business of the YearWinner Mammoet to do the job– the same firm moving windmillsonto Wolfe Island. The firm useda flatbed transporter with over100 hydraulically-powered wheelsto support the crusher’s weight.Although the trip was less thanthree kilometres, it took overfour hours to complete. “It was acomplicated ride,” says Yokom. “Itwas like parallel parking a building.”With the tunnel installed and thecrusher in its new home, the WestQuarry was ready for mining.Lafarge employees mined theirfirst piece of limestoneon December 15th, 2008.What’s Next?The old quarry area still containslots of mineable limestone, butbecause the West Quarry limestoneis of higher quality, Lafarge hastemporarily shut down miningoperations at the old site. Yokomsays when the time comes, manydecades from now, they planto flood the old quarry and turnit into a lake.Many decades from now, Lafarge plansto flood the old quarry and turn it into a lake.Lafarge would like to thankthe many contracting andengineering firms whohelped us move to the WestQuarry including: Mammoet.Bayshore Mechanical, MorvenConstruction, Martin Electric,McNally’s, and many others.Concrete Connection, December, 2009 > issue 085

A few months ago, plant workers rescuedthis orphan fawn (pictured left) after it’smother was killed in a traffic accident. Bathworkers contacted the Sandy Pines WildlifeCentre in Napanee who took the fawn inand nursed it back to health and the plant’sadopted fawn has now grown into a healthydoe as pictured above.Home Sweet HabitatSupporting SustainableHabitats Everywhere6Did you know that Lafarge isthe only cement manufacturerin the world to form a partnershipwith one of the world’s leadingenvironmental protectors?It’s true. In 2000, Lafargebecame the World Wide Fund forNature (WWF)’s leading industrialconservation partner and agreedto make a series of practicalcommitments to ensurecontinued respect for peopleand the environment. Thesecommitments include:• Continual reductionof CO 2 emissions• Developing a plan to reducewater consumption• Increasing biodiversitywhenever possible• Promoting sustainableconstruction practices, productsand systems throughout thebuilding – construction chainThe corporation also devisedSustainability Ambitions 2012,a vehicle to extend the partnershipby setting ambitious targets forall plants to reach in the next fewyears with respect to health andsafety, CO 2 emissions and quarryrehabilitation.The Bath plant shares the parentcompany’s passion for sustainabilityand supports it in many ways, themost visible of which is the plant’scommitment to preserving andenhancing the lands surroundingthe property as wildlife habitats.Plant employees have earnedrecognition from the WildlifeHabitat Council for theirefforts – often on their owntime – to make these landsmore welcoming to theirnon-human neighbours.One of their most visible effortsis a native tree and shrub plantingprogram in partnership withScouts Canada.Because these plants have been partof the ecosystem for so long, theyprovide food and shelter to literallyhundreds of species of insects,birds and mammals. And theyrequire far less fertilizer and waterthan their non-native counterparts.Other initiatives include buildingbird boxes and bat boxes andplanting additional forage grassesand wildflowers to attract bees.The plant’s commitment tosustainable habitats extends beyondits own borders. Lafarge recentlydonated $20,000 to the CataraquiRegion Conservation Authoritytoward the purchase of theBayview Wetland Area, just northof Amherstview.Home to 379 species of vascularplants and numerous animalspecies, the Wetland had beenowned by the estate of the lateJudge William Henderson. TheConservation Authority decidedto buy the property to protect itfrom development and to enablebotanical and zoological researchto continue there.“We had an opportunity toacquire it and we did so withthe help of local businessesand individuals,” saidCRCA General Manager SteveKnechtel. “Lafarge was one ofthe significant donors. Theyhelped make the purchasepossible. We couldn’t havedone it without them.”Concrete Connection, December, 2009 > issue 08

Building a Better BathThanks in part to a generousdonation from Lafarge, the Villageof Bath is about to undergoa renaissance.The three-year Bath RevitalizationProject aims to restore the village’smain street to its former glorywith a heritage-themed renovation.“It’s a very involved project,”says Andy Fitzgerald, Chair of theBath Community RevitalizationCommittee. “We want to becomea destination point.”The first of the project’s four stagesinvolved organizing supporters intocommittees to identify tasks and getstarted on them.The second stage, which is nowunderway, involves the physicalimprovements to the town’s publicareas, including renovationscurrently underway in CentennialPark. “We’re also working on buyingnew street furnishings – benchesand lighting and that sort of thing,”says Fitzgerald. “We want to becomemore attractive to pedestrians andentice cars to want to stop here.”Workers in Bath creating the beautifulpaving shown in the picture to the right.Next up is the economicdevelopment stage, in whichthe village will try to securegovernment funding to help localbusiness owners spruce up theirstorefronts. The final phase willbe a concentrated marketing push,including a sleek new website andsignage on Highway 401.To pay for it all, the committeeis hoping to raise $95,000 overthe three-year period: $65,000 fromlocal businesses and $30,000 fromthe community. The money will bematched by the Ontario Ministry ofAgriculture, Food and Rural Affairs.Halfway through the campaign,they’ve raised an impressive $23,000from the community and $53,000from local businesses, including$20,000 from Platinum SponsorLafarge. “Lafarge has been incrediblysupportive of our effort,” saysFitzgerald. “They were one of thefirst businesses to come on boardand they came in at the highestsponsorship level. They also gaveus a subsidized rate on the concretefor the building projects. They’rea tremendous community partner.”BiomassUpdateAs part of its commitment tosustainability, the Lafarge BathPlant is taking a step towardconverting part of its operationto run on biomass fuels.Biomass fuels – any naturalmaterials, like plants, thatare consumed as fuel – are anenergy-efficient, locally-grownalternative to fossil fuels.Over 140 people came to apublic meeting in the springto discuss the project. Plantofficials incorporated theircomments into the applicationto secure the neededgovernment approvals. Thoseapprovals have since beensecured and the processingsystem is designed, with initialconstruction now underway.Meanwhile, with the helpof area farmers, the biomasscrops have been harvestedand the first 400 bales areat the plant and ready foruse. The biomass fueldemonstration run originallyslated for this fall will nowtake place in the springof 2010.Concrete Connection, December, 2009 > issue 087

The Lafarge BathPlant was theonly Canadiancement plantto be recognizedfor superiorperformance atthe 2009 CementIndustry Energy& EnvironmentalAwards in Ottawain MayLafarge North America,Bath Plant is committedto being an environmentallyresponsible organization.This newsletter is printed onEnviro100 – 100% post-consumerrecycled, Environmental ChoiceCertified, Processed Chlorine Freepaper made with bio gas energyEditorRob CummingWriting contributions byEmma BuckleyDeborah Melman-ClementDesign byBmDodo Strategic Designwww.bmdodo.comPrinted byDigiGraphics, Inc.Lafarge North AmericaBath Plant, Box 160Bath, ON Canada K0H 1G0Tel: (613) 352-7711 ext.

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