2012 US & Canadian Labor-Energy Input Survey. AND CANADIAN LABOR-ENERGY INPUT SURVEY 2012 The...

2012 US & Canadian

Labor-Energy Input Survey

U.S. AND CANADIANLABOR-ENERGY INPUT SURVEY

2012

The following analysis is prepared by the Portland Cement Association’s Market Intelligence Group based on data sources believed to be reliable; however, accuracy cannot be guaranteed.

This report is not intended to represent the viewpoint of Portland Cement Association member companies. The Portland Cement Association assumes no legal responsibility

for the outcome of decisions or commitments made on the basis of this information.

The U.S. and Canadian Labor-Energy Input Survey may not be electronically redistributed or reproduced, in whole or in part, without authorization of the Portland Cement Association.

© 2013 Portland Cement Association

5420 Old Orchard RoadSkokie, Illinois 60077-1083MAIN 847.966.6200 FAX 847.966.0862www.cement.org

Edward J. Sullivan, Group Vice President & Chief Economist 847.972.9006Richard P. Bohan, Director of Manufacturing Technology 847.972.9038Brian Schmidt, Market Intelligence Analyst 847.972.9042Karen A. Arneson, Market Intelligence Specialist 847.972.9048

U.S. AND CANADIANLABOR-ENERGY INPUT SURVEY

2012 Page

Executive Summary ............................................................................................... i Survey Overview .................................................................................................... ii U.S. and Canadian Cement Industry Labor Statistics Historic Summary .............................................................. 1 Labor Efficiency Chart ................................................................................. 2 U.S. Output Per Employee-Hour Chart ....................................................... 2 U.S. Portland Cement Industry Tables Labor Productivity ....................................................................................... 5 Energy Consumption ................................................................................... 5 Energy Distribution ...................................................................................... 6 Alternative Fuel Summary ........................................................................... 6 Energy Distribution Chart ............................................................................ 7 Labor Productivity and Energy Efficiency ................................................... 8 Labor Productivity and Energy Efficiency Charts ........................................ 9 Summary Reports ....................................................................................... 10 Plant Ranking Report (Members Only) ............................................................ 26 Canadian Portland Cement Industry Tables Labour Productivity ..................................................................................... 31 Energy Consumption ................................................................................... 31 Energy Distribution ...................................................................................... 32 Alternative Fuel Summary ........................................................................... 32 Energy Distribution Chart ............................................................................ 33 Labour Productivity and Energy Efficiency ................................................. 34 Labour Productivity and Energy Efficiency Charts ...................................... 35 Summary Reports ....................................................................................... 36 Plant Ranking Report (Members Only) ............................................................ 45 Appendix ................................................................................................................ 46

United States

Labor Efficiency

U.S. labor productivity increased in 2012 with an industry average of 3.04 metric tons of cement being produced per employee hour (mtph). Productivity ranged from 7.21 mtph to 1.01 mtph. Productivity in wet process plants jumped 16.1%, while dry process plants reported a 5.5% increase in labor efficiency.

Energy Efficiency

The amount of energy, measured in BTU’s per metric ton, required to produce one ton of cement averaged 4.386 million BTU/ton in 2012, an industry decrease of 2.1% from 2011 levels – signaling higher energy efficiency. Individual plant energy efficiencies ranged from 2.41 million BTU/ton to 9.15 million BTU/ton. On average, wet process plants required 6.484 million BTU to produce one ton of cement in comparison to dry process plant energy requirements of 4.269 million BTU.

The cement production process in the U.S. is fueled by a combination of coal and petroleum coke which represents 63.3% of the fuel consumption mix. Natural gas’ contribution to the fuel profile surged from 3.9% in 2011 to 11.1% in 2012, likely due to favorable natural gas prices. Electricity consumption slightly increased to 11.6% of the fuel matrix. The use of petroleum products remained stable relative to overall energy consumption at 1.0% Alternative fuel consumption’s share of the fuel matrix decreased to 13.0% in 2012. More plants are, however, employing multiple alternative fuels as part of their energy profile. Three-quarters of all U.S. cement plants now incorporate alternative fuels in their energy consumption strategy. Alternative fuel usage included tire derived fuel, waste oil, solvents, other solids, and renewable energy such as wood and biomass.

CanadaLabour Efficiency

Canadian labour efficiency was flat in 2012 as it requires, on average, 3.05 employee hours to produce one tonne of cement. Labour productivity in the Canadian cement industry ranged from 7.01 mtph to 1.69 mtph.

Energy Efficiency

In 2012, an industry average of 4.449 gigajoules (GJ) were required to produce one tonne of cement. This represents a requirement of 5.1% more energy to produce one tonne of cement from the previous year’s survey. Canadian cement industry energy efficiency ranged from 3.62 GJ/tonne to 5.44 GJ/tonne.

Coal and coke usage decreased its percentage as the primary fuel of choice in 2012, now accounting for 61.5% of the Canadian cement industry’s fuel consumption mix. Natural gas usage jumped from 1.5% of the fuel mix in 2011 to 14.6% in 2012. On an energy consumption basis, alternative fuel usage increased to 9.9% of the energy profile. Half of all Canadian cement plants now incorporate alternative material in their fuel consumption strategy.

Executive Summary

December 31, 2012 Page i

Survey Overview

December 31, 2012 Page ii

The U.S. and Canadian Labor-Energy Input Survey presents information compiled by the Portland Cement Association on labor and energy usage in the U.S. and Canadian cement industries. Results in the accompanying tables report average measures of labor and energy efficiency in addition to comparisons over time. However, direct comparisons over time should be made with the understanding that differences in the reporting base and reporting accuracy can affect changes in operating efficiencies from year to year. It is for this reason that the overall trends in labor productivity and energy efficiency are viewed to be of more significance.

Survey results are reported in metric units for both the U.S. and Canada. However, U.S. and Canadian cement industry energy efficiency statistics cannot be compared directly since Canadian energy efficiency statistics are reported in Joules (J) and U.S. energy efficiency statistics are reported in British Thermal Units (BTU).

Only clinker-producing cement plants are eligible to participate in this program. Individual plant confidentiality is strictly maintained and only responding member companies are eligible to receive their individual plant and company summaries. White cement plants and “Grinding Only” operations are not included in this program.

Equivalent Labor and Energy Tons (Tonnes)

Because a plant’s clinker production may be disproportionate to its finished cement production, unit energy usage in this report is expressed in terms of equivalent tons (tonnes) of production to assure that comparable averages are being analyzed.

Energy consumed in the quarry, drying, raw grinding, and kiln stages of the manufacturing process corresponds directly to the production of clinker. Historical survey data indicates that production of clinker, on average, accounts for 92% of a plant’s total energy consumption. The remaining 8% is used in the production of finished cement and generally reflects electrical energy usage. Similarly for labor consumption, 85% of labor consumed is allocated to clinker production with the remaining 15% allocated to finished cement production.

In this report, the weights for an equivalent labor (labour) ton (tonne) are 85% clinker and 15% finished cement production. The weights for an equivalent energy ton (tonne) are 92% clinker and 8% finished cement production.

High and Low Heat Value

In Canada, and most other parts of the world, energy consumption is based on “low heat value.” In the U.S., by contrast, energy consumption is based on “high heat value.” Low heat value discounts the heat losses incurred by evaporation of fuel moisture as well as the water generated from the combustion of hydrogen. The difference in high and low heat values ranges from 3% to 7%. Canadian energy efficiency statistics are not directly comparable to similar U.S. data because of these differences in heat value measures.

United States

Cement Industry

Labor StatisticsPortland Cement Industry Historic Summary

December 31, 2012 Page 1

Clinker Employee-Hours per Production Capacity 1000 Metric Tons (Metric Tons)

Year Utilization Direct Indirect Total per Employee-Hour2012 70% 239 67 306 3.042011 64% 260 67 327 2.862010 62% 285 82 367 2.732009 57% 326 88 413 2.422008 80% 289 76 364 2.752007 91% 263 76 339 2.952006 93% 265 62 327 3.062005 91% 277 56 333 3.002004 91% 286 56 342 2.932003 89% 280 63 343 2.912002 88% 287 68 355 2.822001 89% 300 78 378 2.642000 93% 306 76 382 2.611999 95% 308 78 386 2.591998 95% 312 83 395 2.541997 94% 312 82 394 2.541996 91% 331 80 412 2.431995 92% 339 78 417 2.391994 89% 350 80 430 2.321993 83% 366 90 456 2.191992 82% 369 90 459 2.181991 80% 389 94 483 2.071990 89% 348 85 440 2.251989 91% 354 97 451 2.211988 87% 358 103 461 2.171987 88% 368 112 481 2.081986 81% 404 129 533 1.881985 78% 440 139 579 1.731984 78% 462 159 621 1.611983 71% 487 169 656 1.521982 67% 571 201 772 1.301981 74% 544 221 764 1.311980 83% 568 218 786 1.271979 87% 530 205 735 1.361978 83% 531 192 723 1.381977 80% 530 197 728 1.381976 78% 549 222 771 1.301975 73% 593 240 834 1.201974 90% 553 215 768 1.301973 94% 560 209 770 1.301972 93% 568 213 781 1.28


Labor Efficiency

1

1.5

2

2.5

3

3.5

73 75 77 79 81 83 85 87 89 91 93 95 97 99 01 03 05 07 09 11

U.S. & Canadian Cement Industry

-15

-10

-5

0

5

10

15

00 01 02 03 04 05 06 07 08 09 10 11 12

Manufacturing Non-Farm Business Cement

Output Per Employee Hour

Metric Tons per Employee Hour

Year-YearPercent Change

United States

Portland Cement Industry Tables

U.S. Labor Productivity(Equivalent Tons (1) per Employee Hour)


Energy Consumption by Type of U.S. Cement Plant(Million BTU per Equivalent Tons (1))

Energy Consumption by Type of U.S. Cement Plant(Gigajoules per Equivalent Tons (1))

% Change % Change1972 2006 2007 2008 2009 2010 2011 2012 2012/72 2012/2011

All Plants* 1.17 2.97 2.91 2.71 2.38 2.66 2.86 3.04 159.8% 6.3%

Wet Process 1.15 2.15 2.09 1.97 1.74 1.85 2.18 2.53 120.0% 16.1%

Dry Process 1.21 3.15 3.09 2.86 2.45 2.74 2.91 3.07 153.7% 5.5%

(1) Metric tons used to measure labor efficiency are an equivalent ton measure composed of 85% clinker production plus 15% finished cement production

* Grinding only and white cement plants not included

% Change % Change1972 2006 2007 2008 2009 2010 2011 2012 2012/72 2012/2011

All Plants* 7.436 4.640 4.703 4.641 4.535 4.453 4.479 4.385 -41.0% -2.1%

Wet Process 7.978 6.464 6.485 6.448 6.359 6.714 7.043 6.484 -18.7% -7.9%

Dry Process 6.669 4.367 4.434 4.384 4.383 4.303 4.332 4.269 -36.0% -1.5%No Preheater 5.738 5.717 5.575 5.541 6.065 5.967 5.886 -1.4%Preheater 4.410 4.646 4.556 4.774 4.714 5.050 4.676 -7.4%Precalciner 4.095 4.151 4.165 4.193 4.101 4.110 4.094 -0.4%Preheater/Precalciner** 4.152 4.235 4.227 4.275 4.180 4.224 4.162 -1.5%

% Change % Change1972 2006 2007 2008 2009 2010 2011 2012 2011/72 2012/2011

All Plants* 7.845 4.895 4.962 4.897 4.785 4.698 4.726 4.626 -41.0% -2.1%

Wet Process 8.417 6.820 6.842 6.803 6.709 7.084 7.431 6.841 -18.7% -7.9%

Dry Process 7.036 4.607 4.678 4.625 4.624 4.540 4.571 4.504 -36.0% -1.5%

(1) Metric tons used to measure energy efficiency are an equivalent ton measure composed of 92% clinker production plus 8% finished cement production

* Grinding only and white cement plants not included** Includes plants that are Preheater only

Distribution of Energy Consumption*(U.S. Cement Plants)

Alternative Fuel Summary(U.S. Cement Plants)


1972 2005 2006 2007 2008 2009 2010 2011 2012

Coal and Coke 36.1% 75.4% 75.8% 75.6% 74.3% 69.9% 70.8% 69.7% 63.3%

Natural Gas 45.1% 3.6% 3.2% 3.0% 2.6% 3.8% 2.9% 3.9% 11.1%

Petroleum Products 12.2% 0.8% 0.9% 0.9% 1.1% 1.3% 1.2% 1.0% 1.0%

Electricity 6.6% 11.0% 11.2% 11.1% 11.3% 12.8% 12.1% 11.4% 11.6%

Alternative Fuels 0.0% 9.2% 8.9% 9.4% 10.7% 12.2% 13.0% 14.0% 13.0%

Total Fuel 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0%

* Based on Btu's consumed

2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

Total Plants Reporting 97 96 96 98 98 97 90 88 84 84Plants using Alternative Fuels 56 62 64 65 64 66 63 64 62 63

Percent 58% 65% 67% 66% 65% 68% 70% 73% 74% 75%

Types of Alternative Fuels Utilized*Tire Derived 35 44 52 47 41 43 40 39 37 36Waste Oil 13 16 17 16 15 18 18 16 11 11Solvents 13 12 11 10 10 11 11 11 9 9Other 22 28 36 40 39 42 43 45 49 67

Renewables 13

Other Solid 35

Other 19

*Plants may use more than one type of alternative fuel; Renewable fuels included as 'Other'

U.S. Energy ConsumptionPercent Distribution

(Based on BTU’s consumed)


Natural Gas, 45.1%

Coal & Coke, 36.1%

Electricity,6.6%

Petroleum Products,

12.2%

1972

Natural Gas, 11.1%

Coal & Coke, 63.3%

Electricity, 11.6%

Petroleum Products,

1.0%

Alternative Fuels, 13.0%

2012

Total Labor Productivity and Energy Efficiency2012

(U.S. Cement Plants)


Tons(1) per Million BTU perEmployee Hour Metric Ton(2)

All Plants* 3.04 4.386

Less than 500,000 tons capacity 1.66 6.065500,000 tons or more capacity 3.14 4.320

Built or Modernized

Before 1960 2.15 5.918Between 1960-1971 2.25 5.5651972 and After 3.13 4.284

Wet Process 2.53 6.484

Less than 500,000 tons capacity 1.67 6.167500,000 tons or more capacity 3.19 6.612

Dry Process 3.07 4.269

Less than 500,000 tons capacity 1.66 5.994500,000 tons or more capacity 3.13 4.227No Preheater 3.12 5.886Preheater 2.22 4.676Precalciner 3.23 4.094Preheater or Precalciner 3.07 4.162

(1) Metric tons used to measure labor efficiency are an equivalent ton measure composed of 85% clinker production plus 15% finished cement production

(2) Metric tons used to measure energy efficiency are an equivalent ton measure composed of 92% clinker production plus 8% finished cement production


U.S. Labor Productivity2012


U.S. Energy Efficiency2012

0.0

2.0

4.0

6.0

8.0

10.0

(1) Equivalent Labor Ton per definition

(2) Equivalent Energy Ton per definition

Metric Tons (1)

Per Employee Hour

Million BTU PerMetric Ton (2)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

U.S. LABOR AND ENERGY SURVEY - SUMMARY REPORT

All Plants

III. ENERGY INFORMATION

I. INDUSTRY INFORMATION

II. LABOR INFORMATION

Clinker Production 64,122,786Finish Cement Production 69,784,206Annual Practical Clinker Capacity 91,793,978Capacity Utilization Rate (%) 69.9

Metric Tons

Number of EmployeeEmployees Hours Employee Hour

Tons per

8,122 16,701,695

2,491 4,696,590

10,613 21,398,285

6,873 13,979,3682,721 5,376,1661,019 2,042,751

3.89

13.83

3.04

4.6512.0931.81

Direct Labor

Indirect Labor

Total Labor

Hourly LaborSalaried LaborContract Labor

Fuel Type Quantity (Billions)BTUs BTUs

per Ton

Electricity (1000 kWh) 32,895.78

6,054,9001,394,758

30,731

1,086,875266,978

9,641,201

2,141,895.76635,068.12486,235.27

2,093.96354.38

9,895.44167,807.15172,065.39119,692.7346,979.93

509,414.17

Total Fuel: 250,320.52

Total: 283,216.30

3,876,388.77

4,385,802.94

Coal (tons)Petroleum Coke (tons)Natural Gas (millions cu. ft.)

Gasoline (gallons)LPG (gallons)

Alternative Fuel - OilAlternative Fuel - SolventsAlternative Fuel - Tire DerivedAlternative Fuel - Other SolidAlternative Fuel - Misc.

138,314.4241,009.9731,398.98

135.2222.88

639.0110,836.2611,111.247,729.243,033.76

17,257,1353,521,191

34,607.437,611.84

Middle Distillates - Diesel Middle Distillates - Fuel Oil

2,234.80491.54

225,139 52,081.38Renewable (tons) 3,363.19



Less Than 500,000 Clinker Capacity





Metric Tons


Tons per

593 1,201,496

131 259,779

724 1,461,275

468 954,431188 365,92768 140,917

2.02

9.36

1.66

2.556.65

17.26

Direct Labor

Indirect Labor

Total Labor



per Ton


261,54642,0553,935

37,759

423,489

2,393,176.85520,500.77

1,647,579.65

1,951.596,327.81

708,737.7255,113.0568,572.46

597,122.92


Total: 14,675.78

5,467,641.26

6,064,764.18


Gasoline (gallons)Alternative Fuel - OilAlternative Fuel - SolventsAlternative Fuel - Tire DerivedAlternative Fuel - Other Solid

5,791.121,259.533,986.89

4.7215.31

1,715.03133.37165.93

1,167,40855,947

62,474.823,206.52


151.187.76



500,000 and Greater Clinker Capacity





Metric Tons


Tons per

7,529 15,500,199

2,360 4,436,811

9,889 19,937,010

6,405 13,024,9372,533 5,010,239

951 1,901,834

4.03

14.10

3.14

4.8012.4832.88

Direct Labor

Indirect Labor

Total Labor



per Ton


5,793,3541,352,703

26,796

1,049,116266,978

9,217,712

2,132,112.92639,528.44441,021.95

2,099.50368.17

10,034.34146,747.70176,618.56121,682.9448,808.95

505,999.51


Total: 268,540.52

3,814,438.32

4,320,437.83




132,523.3139,750.4427,412.10

130.5022.88

623.699,121.23

10,977.887,563.313,033.76

16,089,7273,465,244

33,522.507,783.35


2,083.62483.78

225,139 54,109.00Renewable (tons) 3,363.19



Built or Modernized Before 1960




Clinker Production 791,025Finish Cement Production 822,471Annual Practical Clinker Capacity 949,709Capacity Utilization Rate (%) 83.3

Metric Tons


Tons per

139 285,683

44 83,611

183 369,294

133 275,63748 89,5612 4,096

2.79

9.52

2.15

2.898.88

194.27

Direct Labor

Indirect Labor

Total Labor



per Ton

Electricity (1000 kWh) 424.22

27,66539,4431,168

2,912

124,333

853,753.911,497,117.501,515,687.01

458.96296.30

571,143.14904,277.11

534,596.88


Total: 4,695.94

5,383,108.63

5,917,705.50


Gasoline (gallons)Alternative Fuel - OilAlternative Fuel - SolventsAlternative Fuel - Tire Derived

677.491,188.021,202.76

0.360.24

453.23717.58

247,405 40,374.69Middle Distillates - Diesel 32.04



Built or Modernized Between 1960-1971





Metric Tons


Tons per

641 1,251,701

303 602,379

944 1,854,080

627 1,236,423256 501,57061 116,087

3.33

6.91

2.25

3.378.30

35.88

Direct Labor

Indirect Labor

Total Labor



per Ton


623,91348,7101,118

49,274

667,481

3,367,923.14354,828.58279,434.56

1,497.773,721.46

663,044.38210,207.4687,550.681,602.71

553,502.77


Total: 22,896.42

5,011,166.52

5,564,669.29


Gasoline (gallons)Alternative Fuel - OilAlternative Fuel - SolventsAlternative Fuel - Tire DerivedAlternative Fuel - Other SolidAlternative Fuel - Misc.

13,857.671,459.981,149.76

6.1615.31

2,728.17864.92360.24

6.59

799,449480,453

25,161.2616,194.51


103.5366.63



Built or Modernized 1972 and After





Metric Tons


Tons per

7,342 15,164,311

2,144 4,010,600

9,486 19,174,911

6,113 12,467,3082,417 4,785,035

956 1,922,568

3.96

14.96

3.13

4.8112.5431.21

Direct Labor

Indirect Labor

Total Labor



per Ton


5,403,3221,306,605

28,445

1,034,689266,978

8,849,387

2,074,481.81642,928.40486,804.95

2,156.81383.53

10,448.86128,292.05159,697.21123,501.0550,733.89

506,038.96


Total: 255,623.95

3,778,097.41

4,284,136.37




123,779.2638,361.9729,046.46

128.6922.88

623.467,654.879,528.747,369.013,027.17

16,210,2813,040,738

35,182.127,121.23


2,099.23424.91

225,139 56,365.50Renewable (tons) 3,363.19



Wet Process





Metric Tons


Tons per

501 987,739

194 371,830

695 1,359,569

463 931,882193 366,95539 60,732

3.48

9.25

2.53

3.699.37

56.62

Direct Labor

Indirect Labor

Total Labor



per Ton


499,021107,909

1,779

18,799

463,188

3,307,520.23950,877.67536,168.12

687.914,548.81

501,778.11622,433.7865,616.75

462,386.42


Total: 22,160.10

6,021,129.15

6,483,515.57


Gasoline (gallons)Alternative Fuel - OilAlternative Fuel - SolventsAlternative Fuel - Tire DerivedAlternative Fuel - Other Solid

11,304.823,250.021,832.58

2.3515.55

1,715.032,127.43

224.27

771,40955,947

29,227.602,270.18


99.907.76



Wet Process - Less Than 500,000 Clinker Capacity




Clinker Production 979,953Finish Cement Production 1,061,370Annual Practical Clinker Capacity 1,404,258Capacity Utilization Rate (%) 69.8

Metric Tons


Tons per

241 474,328

62 118,583

303 592,911

208 408,74182 155,38513 28,785

2.09

8.37

1.67

2.436.39

34.47

Direct Labor

Indirect Labor

Total Labor



per Ton


114,95139,427

73

9,516

153,496

2,384,210.231,196,569.63

75,936.52

1,206.5015,522.40

1,738,564.38168,211.23

530,913.66


Total: 6,083.41

5,635,959.56

6,166,873.22


Gasoline (gallons)Alternative Fuel - OilAlternative Fuel - SolventsAlternative Fuel - Other Solid

2,351.941,180.38

74.91

1.1915.31

1,715.03165.93

364,67255,947

47,872.937,865.74


47.237.76



Wet Process - 500,000 and Greater Clinker Capacity





Metric Tons


Tons per

260 513,411

132 253,247

392 766,658

255 523,141111 211,57026 31,947

4.76

9.66

3.19

4.6811.5676.58

Direct Labor

Indirect Labor

Total Labor



per Ton


384,07068,482

1,706

9,283

309,692

3,682,117.49851,197.67722,889.25

477.5196.70

874,962.1723,993.01

434,584.15


Total: 16,076.69

6,177,396.79

6,611,980.94


Gasoline (gallons)Alternative Fuel - OilAlternative Fuel - Tire DerivedAlternative Fuel - Other Solid

8,952.882,069.641,757.67

1.160.24

2,127.4358.34




Dry Process





Metric Tons


Tons per

7,621 15,713,956

2,297 4,324,760

9,918 20,038,716

6,410 13,047,4862,528 5,009,211

980 1,982,019

3.92

14.23

3.07

4.7212.2831.05

Direct Labor

Indirect Labor

Total Labor



per Ton


5,555,8791,286,849

28,952

1,068,076266,978

9,178,013

2,076,752.70617,418.52483,444.68

2,172.54374.18

10,194.25149,142.57146,895.72122,714.8749,605.49

512,042.41


Total: 261,056.20

3,756,526.02

4,268,568.43




127,009.6037,759.9529,566.41

132.8722.88

623.469,121.238,983.827,504.973,033.76

16,485,7263,465,244

34,908.097,910.37


2,134.90483.78

225,139 54,992.04Renewable (tons) 3,363.19



Dry Process - Less Than 500,000 Clinker Capacity





Metric Tons


Tons per

352 727,168

69 141,196

421 868,364

260 545,690106 210,54255 112,132

1.98

10.20

1.66

2.646.84

12.84

Direct Labor

Indirect Labor

Total Labor



per Ton


146,5952,6283,863

28,243

269,993

2,399,347.7755,222.94

2,729,201.27

2,464.3793,042.44

642,688.84


Total: 8,592.37

5,351,802.80

5,994,491.64


Gasoline (gallons)Alternative Fuel - Tire Derived

3,439.1779.16

3,911.98

3.53133.37




Dry Process - 500,000 and Greater Clinker Capacity





Metric Tons


Tons per

7,269 14,986,788

2,228 4,183,564

9,497 19,170,352

6,150 12,501,7962,422 4,798,669

925 1,869,887

4.01

14.36

3.13

4.8112.5232.14

Direct Labor

Indirect Labor

Total Labor



per Ton


5,409,2841,284,221

25,090

1,039,833266,978

8,908,020

2,069,010.46630,911.14429,546.81

2,165.53383.16

10,438.91152,721.97148,188.20125,660.0150,796.01

508,906.91


Total: 252,463.82

3,718,239.58

4,227,146.49




123,570.4337,680.7925,654.43

129.3422.88

623.469,121.238,850.457,504.973,033.76

15,682,9903,465,244

34,005.318,100.22


2,030.95483.78

225,139 56,311.84Renewable (tons) 3,363.19



Dry Process - No Preheater





Metric Tons


Tons per

417 902,626

153 318,768

570 1,221,394

185 370,969374 827,54511 22,880

4.22

11.95

3.12

10.274.60

166.46

Direct Labor

Indirect Labor

Total Labor



per Ton


442,293277,838

1,013

33,263

592,023

2,651,980.802,200,004.38

275,591.46

1,101.42134,260.0744,360.351,745.89

534,788.79


Total: 22,231.90

5,351,090.57

5,885,879.35


Gasoline (gallons)Alternative Fuel - Tire DerivedAlternative Fuel - Other SolidAlternative Fuel - Misc.

10,016.958,309.771,040.95

4.16507.12167.56

6.59

771,741424,506

26,459.1615,587.04


99.9458.87



Dry Process - Preheater





Metric Tons


Tons per

1,181 2,495,641

266 539,540

1,447 3,035,181

998 2,138,772359 714,43690 181,973

2.70

12.48

2.22

3.159.42

37.00

Direct Labor

Indirect Labor

Total Labor



per Ton


748,9526,5736,108

105,342

1,145,304

2,567,340.9029,565.15

933,564.79

1,968.27

29,764.94242,339.79138,083.56

5,978.58

583,790.73


Total: 31,301.01

4,092,330.97

4,676,121.70


Gasoline (gallons)

Alternative Fuel - OilAlternative Fuel - Tire DerivedAlternative Fuel - Other SolidAlternative Fuel - Misc.

17,185.26197.90

6,249.09

13.18

199.241,622.17

924.3040.02

2,067,247469,801

39,993.519,733.89


267.7165.16

39,267 93,997.58Renewable (tons) 629.20



Dry Process - Precalciner





Metric Tons


Tons per

6,023 12,315,689

1,878 3,466,452

7,901 15,782,141

5,227 10,537,7451,795 3,467,230

879 1,777,166

4.14

14.71

3.23

4.8414.7128.69

Direct Labor

Indirect Labor

Total Labor



per Ton


4,364,6341,002,438

21,832

929,471266,978

7,440,686

1,969,098.97577,117.97439,490.10

2,279.33451.48

8,369.38179,952.65135,232.80126,524.1958,933.42

500,872.14


Total: 207,523.28

3,593,352.76

4,094,224.90




99,807.3829,252.2822,276.36

115.5322.88

424.229,121.236,854.526,413.112,987.15

13,646,7382,570,937

34,866.117,097.49


1,767.25359.75

185,872 53,938.88Renewable (tons) 2,733.99



Dry Process - Preheater or Precalciner





Metric Tons


Tons per

7,204 14,811,330

2,144 4,005,992

9,348 18,817,322

6,225 12,676,5172,154 4,181,666

969 1,959,139

3.90

14.41

3.07

4.5513.8029.46

Direct Labor

Indirect Labor

Total Labor



per Ton


5,113,5861,009,011

27,940

1,034,813266,978

8,585,990

2,038,887.51513,242.61497,126.90

2,243.05398.81

10,865.30158,960.08147,727.48127,872.6652,755.91

510,545.09


Total: 238,824.29

3,651,561.60

4,162,106.69




116,992.6429,450.1828,525.45

128.7122.88

623.469,121.238,476.707,337.413,027.17

15,713,9853,040,738

35,464.257,405.05


2,034.96424.91

225,139 58,611.97Renewable (tons) 3,363.19


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Canadian

Portland Cement Industry Tables

Canadian Labour Productivity(Equivalent Tonnes (1) per Employee Hour)

Energy Consumption by Type of Canadian Cement Plant(Gigajoules per Equivalent Tonnes (1))


% Change % Change1980 2006 2007 2008 2009 2010 2011 2012 2012/1980 2012/2011

All Plants* 5.326 4.461 4.425 4.504 4.541 4.264 4.234 4.449 -16.5% 5.1%

Wet Process 6.645 NA** NA** NA** NA** NA** NA** NA**

Dry Process 4.711 4.424 4.388 4.484 4.541 4.264 4.234 4.449 -5.6% 5.1%No Preheater 4.913 4.916 5.001 5.347 5.001 4.124 4.902 18.9%Preheater 4.328 4.426 4.625 4.467 3.643 4.297 4.015 -6.6%Precalciner 4.325 4.205 4.248 4.279 4.329 4.231 4.502 6.4%Preheater/Precalciner 4.326 4.283 4.378 4.344 4.093 4.253 4.345 2.2%

(1) Metric tonnes used to measure energy efficiency are an equivalent tonne measure composed of 92% clinker production plus 8% finished cement production

* Grinding only and white cement plants not included** Data withheld due to disclosure restrictions

% Change % Change1980 2006 2007 2008 2009 2010 2011 2012 2012/1980 2012/2011

All Plants* 1.61 3.49 3.18 2.94 2.70 3.13 3.06 3.05 89.4% -0.3%

Wet Process 1.50 NA** NA** NA** NA** NA** NA** NA**

Dry Process 1.70 3.50 3.19 2.99 2.70 3.13 3.06 3.05 79.4`% -0.3%

(1) Metric tonnes used to measure labour efficiency are an equivalent tonne measure composed of 85% clinker production plus 15% finished cement production

* Grinding only and white cement plants not included** Data withheld due to disclosure restrictions

Distribution of Energy Consumption*(Canadian Cement Plants)

Alternative Fuel Summary(Canadian Cement Plants)


1980 2005 2006 2007 2008 2009 2010 2011 2012

Coal and Coke 25.6% 76.7% 77.8% 76.0% 74.6% 73.7% 73.9% 75.6% 61.5%

Natural Gas 37.4% 3.0% 1.9% 2.0% 2.2% 2.1% 2.1% 1.5% 14.6%

Petroleum Products 26.9% 2.9% 2.0% 1.5% 1.3% 1.5% 1.2% 0.5% 0.9%

Electricity 9.9% 11.7% 12.3% 12.4% 12.9% 13.2% 13.6% 12.8% 13.1%

Alternative Fuels 0.2% 5.7% 6.0% 8.1% 9.0% 9.6% 9.2% 9.6% 9.9%

Total Fuel 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0%

* Based on kJoules consumed

2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

Total Plants Reporting 15 15 15 15 15 15 14 14 12 14Plants using Alternative Fuel 7 8 8 8 8 8 8 9 6 7

(Percent) 47% 53% 53% 53% 53% 53% 57% 64% 50% 50%

Types of Alternative Fuels Utilized*Tire Derived 3 4 5 6 5 5 5 5 5 5Waste Oil 5 5 5 5 5 5 5 5 4 5Solvents 2 2 1 1 1 2 2 3 1 3Other Solid 4 5 4 5 4 6 5 5 5 5Other 0 0 1 3 1 2 3 3 1 4

* Plants may use more than one type of waste fuel

Canadian Energy ConsumptionPercent Distribution

(Based on kJoules consumed)


Natural Gas, 37.4%

Coal & Coke, 25.6%

Electricity, 9.9%

Petroleum, 26.9%

1980

Natural Gas, 14.6%

Coal & Coke, 61.5%

Electricity, 13.1%

Petroleum, 0.9%

Alternative Fuels, 9.6%

2012

Total Labour Productivity and Energy Efficiency

2012

(Canadian Cement Plants)


Tonnes(1) per Gigajoules perEmployee Hour Metric Tonne(2)

All Plants* 3.05 4.449

Dry Process 3.05 4.449

No Preheater 2.52 4.902Preheater 2.64 4.015Precalciner 3.57 4.502Preheater/Precalciner 3.20 4.345

(1) Metric tonnes used to measure labour efficiency are an equivalent tonne measure composed of 85% clinker production plus 15% finished cement production

(2) Metric tonnes used to measure energy efficiency are an equivalent tonne measure composed of 92% clinker production plus 8% finished cement production


Canadian Labour Productivity2012


Canadian Energy Efficiency2012

2.0

2.5

3.0

3.5

4.0

4.5

5.0

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

Metric Tonnes (1) Per Employee Hour

Gigajoules Per Metric Tonne (2)

(1) Equivalent Labour Tonne per definition

(2) Equivalent EnergyTonne per definition

CANADIAN LABOUR AND ENERGY SURVEY - SUMMARY REPORT

All Plants



II. LABOUR INFORMATION


Metric Tonnes


Tonnes per

1,530 3,085,247

332 669,705

1,862 3,754,952

1,303 2,616,514380 765,925179 372,513

3.71

17.08

3.05

4.3714.9430.71

Direct Labour

Indirect Labour

Total Labour

Hourly LabourSalaried LabourContract Labour

Fuel Type Quantity (Billions)kJoules kJoules

per Tonne


607,618480,261214,995

295,802361,008

1,846,399

1,385,361.871,350,481.70

652,377.25

1,299.11721.90

46,059.3773,455.99

107,018.46181,784.64

6,504.28

581,355.45


Total: 50,841.54

3,867,760.12

4,449,115.56

Coal (tonnes)Petroleum Coke (tonnes)Natural Gas (1000 cu. meters)

Gasoline (liters)LPG (liters)


15,830.9915,432.417,454.93

14.858.25

526.34839.41

1,222.942,077.31

74.33

5,432,6091,014,989

22,417.5313,832.91


256.17158.07

23,054 26,445.10Renewable (tonnes) 302.20



Dry Process





Metric Tonnes


Tonnes per

1,530 3,085,247

332 669,705

1,862 3,754,952

1,303 2,616,514380 765,925179 372,513

3.71

17.08

3.05

4.3714.9430.71

Direct Labour

Indirect Labour

Total Labour



per Tonne


607,618480,261214,995

295,802361,008

1,846,399

1,385,361.871,350,481.70

652,377.25

1,299.11721.90

46,059.3773,455.99

107,018.46181,784.64

6,504.28

581,355.45


Total: 50,841.54

3,867,760.12

4,449,115.56




15,830.9915,432.417,454.93

14.858.25

526.34839.41

1,222.942,077.31

74.33

5,432,6091,014,989

22,417.5313,832.91

Middle Distillates - Diesel (liters)Middle Distillates - Fuel Oil

256.17158.07




Dry Process - No Preheater





Metric Tonnes


Tonnes per

385 712,966

71 143,134

456 856,100

351 647,29687 170,96218 37,842

3.02

15.05

2.52

3.3312.6056.92

Direct Labour

Indirect Labour

Total Labour



per Tonne


128,394110,42216,153

23,571

380,686

1,399,329.941,534,209.90

275,490.81

1,692.2413,583.96

254,855.90708,472.6634,722.25

639,870.11


Total: 10,493.07

4,262,049.03

4,901,919.14


Gasoline (liters)Alternative Fuel - OilAlternative Fuel - Tire DerivedAlternative Fuel - Other SolidAlternative Fuel - Misc.

2,995.413,284.14

589.72

3.6229.08

545.551,516.56

74.33

39,812781,374

16,300.0623,391.32


34.8950.07



Dry Process - Preheater





Metric Tonnes


Tonnes per

453 969,312

86 172,341

539 1,141,653

325 703,697113 226,295101 211,661

3.11

17.49

2.64

4.2813.3214.24

Direct Labour

Indirect Labour

Total Labour



per Tonne


74,189192,57952,849

120,226

471,504

649,038.902,090,330.69

604,037.42

1,346.53

71,078.99

565,086.48


Total: 12,054.13

3,450,085.65

4,015,172.13


Gasoline (liters)

Alternative Fuel - Tire Derived

1,948.516,275.481,813.41

4.04

213.39

1,702,14445,105

19,636.65552.94


58.951.66




Dry Process - Precalciner





Metric Tonnes


Tonnes per

692 1,402,969

175 354,230

867 1,757,199

627 1,265,521180 368,66860 123,010

4.47

17.71

3.57

4.9617.0150.99

Direct Labour

Indirect Labour

Total Labour



per Tonne


405,035177,260145,993

152,005361,008

994,209

1,732,345.38934,476.16803,841.08

1,142.561,312.64

79,123.42133,565.8673,831.5989,227.02

569,196.35


Total: 28,294.34

3,932,983.65

4,502,180.00



Alternative Fuel - OilAlternative Fuel - SolventsAlternative Fuel - Tire DerivedAlternative Fuel - Other Solid

10,887.085,872.805,051.81

7.188.25

497.26839.41464.00560.75

3,690,653188,510

25,829.6316,921.04


162.33106.34




Dry Process - Preheater or Precalciner





Metric Tonnes


Tonnes per

1,145 2,372,281

261 526,571

1,406 2,898,852

952 1,969,218293 594,963161 334,671

3.91

17.63

3.20

4.7215.6127.74

Direct Labour

Indirect Labour

Total Labour



per Tonne


479,224369,839198,842

272,231361,008

1,465,713

1,382,142.221,308,132.11

739,250.05

1,208.50888.30

53,544.9990,387.6972,941.7560,382.38

567,867.74


Total: 40,348.47

3,776,876.02

4,344,743.76



Alternative Fuel - OilAlternative Fuel - SolventsAlternative Fuel - Tire DerivedAlternative Fuel - Other Solid

12,835.5812,148.276,865.22

11.228.25

497.26839.41677.39560.75

5,392,797233,615

23,827.6111,629.68


221.28108.00




Contract Employee Count If contract employee count was not provided, but contract employee hours were indicated, the prior year's industry average for hours/contract employee was applied and the total employee count adjusted accordingly.

Annual Clinker ProductionIf annual clinker production was not provided, the value calculated from daily clinker capacity and reported down days provided in the annual Plant Information Survey was recorded.

Heat Content ValuesChanges to default values based on updated information from the Energy Information Administrationare indicated in the accompanying table.

U.S. Conversion Factor (1)

(Btu per Unit - High Heat Value)

Gasoline 125,071/gallonMiddle Distillates - Diesel 129,500/gallonMiddle Distillates - Fuel Oil 138,690/gallonCoal 22,565,000/tonNatural Gas 1,030,000,000/mmft3

Petroleum Coke 30,120,000/tonLPG 85,857/gallonElectricity 3,412,000/000kWhRenewables Specified by respondentAlternative Fuel-Oil Specified by respondent - Range: 95-150,000/gallonAlternative Fuel-Solvents Specified by respondent - Range: 85-100,000/gallonAlternative Fuel-Tire Derived Specified by respondent - Range: 22-35,000,000/tonAlternative Fuel-Other Solid Specified by respondentAlternative Fuel-Other Specified by respondent

Canada Conversion Factor(kJoules per Unit - Low Heat Value)

Gasoline 33,624/litreMiddle Distillates - Diesel 34,634/litreMiddle Distillates - Fuel Oil 36,803/litreCoal 28,066,000/tonneNatural Gas 34,313,000/000m3

Petroleum Coke 32,701,500/tonneLPG 22,851/litreElectricity 3,598,000/000kWhRenewables Specified by respondentAlternative Fuel-Oil Specified by respondent - Range: 33-35,000/litreAlternative Fuel-Solvents Specified by respondent - Range: 25-27,000,000/tonneAlternative Fuel-Tire Derived Specified by respondent - Range: 24-30,000,000/tonneAlternative Fuel-Other Solid Specified by respondentAlternative Fuel-Other Specified by respondent(1) Energy Information Administration, Manufacturing Consumption of Energy - 1994

APPENDIX

U.S. and Canadian Labor-Energy SurveyDefault Heat Content Values

PORTLAND CEMENT ASSOCIATION

MEMBER COMPANIES

© 2013 Portland Cement AssociationAll rights reserved

Alamo Cement CompanyAmerican Cement Company, LLC

Ash Grove Cement CompanyBuzzi Unicem USA Inc.

CalPortlandCapitol Aggregates, Ltd.

CEMEXContinental CementDrake Cement LLC

Essroc Cement Corp.Federal White Cement Ltd.

GCC of America, Inc.Lafarge North America Inc.

Lehigh Hanson, Inc.Mitsubishi Cement CorporationThe Monarch Cement CompanyNational Cement Company, Inc.

Phoenix Cement Company (Salt River Materials Group)St. Marys Cement Inc. (Canada)/VCNA

St. Marys Cement Inc. (U.S)/VCNASuwannee American Cement/VCNA

Texas Industries Inc.Titan America LLC

2012 US & Canadian Labor-Energy Input Survey. AND CANADIAN LABOR-ENERGY INPUT SURVEY 2012 The...

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