mississauga cement plant · in operation since 1956, the mississauga cement plant is a proud and...

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2 | Mississauga Cement Plant

Safety First

The safety and well-being of our employees, contractors and visitors is our number one priority. At the CRH Canada Mississauga Cement Plant, creating a safe work environment is part of our culture. We want everyone to go home safely at the end of every day and our ultimate goal is “ZERO Harm”.

To achieve this goal, we have a rigorous occupational health and safety system that touches every aspect of our operations. We believe that all injuries can be prevented through the vigilance and empowerment of every employee. Ongoing training is provided to ensure safety remains top of mind at all times. We encourage employees to find and share innovative ways to make their jobs and environment safer for themselves and others.

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Our People: 60 Years of Excellence

In operation since 1956, the Mississauga Cement Plant is a proud and longstanding member of the community with a strong legacy. Along with the Ogden Point Quarry, we employ approximately 200 people, many of whom live in the area. Our employees represent a wide range of skills and are all equally committed to quality and safety. Both current employees and retirees play an integral role in the success of our storied plant.

We aim to recruit, develop and retain the best people by providing a safe, inclusive and supportive working environment for everyone. After 60 years, we have a team comprised of seasoned veterans and recent recruits with many second and third generation employees. Our employees are proud to be a part of the team and a part of CRH, a global leader in the industry.

Our employees are deeply committed to the community. Many volunteer their time to participate in local events, serve on community boards and raise funds for community projects. From hosting open houses to tree plantings, we are dedicated to giving back and to continuously strengthening our ties with the community.

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Timeline

1956: Mississauga Plant begins production under the St. Lawrence Cement name with two wet process kilns each having a capacity of 800 tonnes per day.

1968: First large preheater kiln ever constructed in North America installed, more than doubling production capacity and substantially reducing fuel consumption.

1971: 2,600 kW mill is installed, significantly increasing cement grinding capacity.

1972: 1.6 km reversible belt conveyor system is built to transport raw materials into the plant and to transfer cement to the dock for loading onto ships.

1974: Cement Mill #7, one of the largest in North America, is installed.

1988: Addition of a precalciner increases capacity of Kiln #3 to 4,300 tonnes per day.

1989: Larger bag warehouse built to accommodate increasing variety of bagged products.

1990: Central Control Room upgraded with a Honeywell TDC 3000 control system.

1996: Start-up of the $16 million baghouses designed to reduce particulate emissions from the main and clinker cooler stacks.

1998: Capacity of Kiln #3 is increased to 4,500 tonnes per day.

2002: Removal of the Aerofall mill precipitator and installation of a baghouse and construction of lime injection system.

2002: Mississauga Plant is the first cement plant in North America to obtain ISO 14001 certification for its environmental management system.

2007: New Clinker Cooler installed and Vertical Roller Mill begins operation.

2008: Kiln Hot Gas Recovery System commissioned for producing CRH Slag Cement on the Vertical Roller Mill. Upgrade of Plant Control System initiated.

2009: St. Lawrence Cement becomes Holcim (Canada) Inc.

2015: Holcim (Canada) Inc. is acquired by CRH plc and becomes CRH Canada. CRH stands for Cement Roadstone Holdings.

2016: Mississauga Plant celebrates 60th anniversary.

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The CRH Canada Mississauga Cement Plant is one of the largest and most environmentally responsible suppliers of cement in Canada. Located in Mississauga, Ontario approximately 30 km west of Toronto, the Mississauga Plant has witnessed ongoing technological advancements designed to meet the increasing needs of the marketplace, to improve environmental performance, to enhance employee safety and to mitigate impacts on the local community.

The Mississauga Plant is part of CRH Canada Group Inc., a leading manufacturer of cement, aggregates and ready-mix concrete. CRH Canada also provides construction services to many of Canada’s largest infrastructure projects. With over 3,000 employees, CRH Canada has a portfolio of brands including Dufferin in Ontario and Demix in Quebec.

CRH plc is a global diversified building materials group, employing 89,000 people at 3,900 operating locations in 31 countries, with headquarters in Ireland. CRH is the largest building materials company in North America.

The Mississauga Plant:A Leader in the Cement Industry

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Calciner

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Gypsum Limestone

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Our Cement Manufacturing Process

Extraction

Our process begins at our Ogden Point Quarry located in Colborne, 150 km east of Toronto. Limestone is blasted, reduced in size

and then loaded onto a boat with a single load capacity of approximately 19,000 tonnes. During shipping season, the boat makes 4-5 trips per week between the quarry and the Mississauga Plant.

Raw Grinding

Raw materials are offloaded at the Mississauga dock and transported 1.5 km by covered conveyor to the stockpile. Stone is

ground with shale to a powder at a rate of 310 tonnes per hour to produce raw meal uniform in size and chemistry.

Kiln Processing

Raw meal enters the preheater, precalciner kiln—a large, rotating furnace—down a series of cyclones against the

stream of hot exhaust gases. Intense heat is necessary to generate the required chemical changes. Kiln burning zone temperatures exceed 1,450°C. As raw meal tumbles through the kiln, it becomes partially molten, causing molecular reactions that result in the

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Clinker Cooler

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Gypsum Limestone

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SlagSilo

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formation of new minerals with special hydraulic properties that, once ground, react with water to form a hard mass—the distinguishing characteristic of cement. The white hot substance that exits the kiln, called “clinker”, is air cooled with the hot air returning to the kiln to conserve energy.

The kiln production line is monitored and controlled by a sophisticated control system to continuously analyze and monitor every stage of the process.

Cement Grinding

General purpose cement (Portland) is composed primarily of clinker blended with gypsum to control setting time. These

materials are ground to the required particle size to provide the desired strength and other characteristics of the finished cement. Grinding occurs within the giant rotating drum with cascading steel balls producing 160 tonnes per hour of finished product.

The entire process is strictly monitored and carried out within rigorous environmental, process and quality parameters.

Quality You Can Trust

Cement and cementitious products manufactured at our Mississauga Plant are shipped to terminals for distribution in bulk or bagged form to our customers in Ontario, Western Canada and the Great Lakes. Our customers include ready-mix concrete producers; building contractors; manufacturers of brick, blocks, paving stones, pipes; building material dealers, and the mining industry.

Our ISO 9001 certification means that our quality management system is recognized for efficiency in managing product quality and customer service and ensures continuous improvement.

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A Focus on Quality

Our Services

At CRH Canada, we believe that what sets us apart is the value added services that we provide. Our team of experts assist our customers with trouble shooting and

resolution of technical issues, testing, mix designs, specification interpretation; and, specialty product development requirements.

Our Products

GU – General use Portland cement for both interior and exterior applications.

GUL – General use Portland-Limestone cement with environmental and sustainability benefits for both interior and exterior applications.

HE – Cement with high early strength characteristics used mainly in the precast industry.

ASTM TYPE 1 – Portland cement manufactured to ASTM standards for export to the United States.

CRH Slag Cement – Ground granulated blast furnace slag cement used as a replacement for Portland cement in concrete on a kilo for kilo basis. Slag cement has many sustainability benefits for environmentally friendly programs as well as improving the overall durability characteristics of concrete.

Masonry Type N – Masonry cement meeting the CSA requirements for a Type N. A medium strength masonry cement used in above grade applications.

Masonry Type S – Masonry cement meeting the CSA requirements for a Type S. Can be used where high-lateral strength is required and for below grade applications.

High Bond Type N – Masonry mortar cement meeting CSA requirements for a Type N (MCN) and available under the CRH Canada product name Mason’s Choice High Bond Type N.

High Bond Type S – Masonry mortar cement meeting CSA requirements for a Type S (MCS) and available under the CRH Canada product name Mason’s Choice High Bond Type S.

GUb-SF (HSF) – Blended Portland cement (GU) with silica fume used in high strength, high performance concretes. Particularly effective in reducing the permeability of concrete.

GUb-S – Blended Portland cement (GU) with slag cement is an alternative to GU when silo capacity is limited. When used it has both environmental and concrete property improvement benefits.

GUb-S/SF – Blended Portland cement (GU) with slag cement and silica fume. Used in high performance, high strength concretes where durability is an issue.

CRH Canada operates three cement plants strategically located close to major construction markets in the Greater Toronto, Greater Montreal and Northwestern US areas.

We produce and distribute a variety of high-quality general purpose and specialized cements, as well as a wide range of bagged cements through our extensive, integrated network of plants and terminals for projects across Canada, the Great Lakes Region and the Northwestern US.

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Glossary of Terms

Aggregate: Natural stone, sand or gravel used in various construction processes and applications such as cement, concrete and foundations.

Concrete: A common material used in the construction industry. It is the final product resulting from mixing cement, sand, aggregate, water and admixtures. It is initially malleable in its “wet” state and solidifies over time, gaining strength and durability.

Cement: A combination of clinker, limestone and gypsum. These materials are processed through a mill to reach a desired fineness. The resulting cementitious product is mixed with water, sand and/or aggregates to make mortar or concrete.

Clinker: A cementitious material produced in a kiln. Wherein applying a significant amount of energy, in the form of heat, the raw meal undergoes structural and chemical changes to form clinker.

Raw meal: A combination of low and high grade limestone, shale and/or other raw materials. These materials are processed through a mill to reach a desired fineness. This product is then used as kiln feed to produce clinker.

Cementitious materials: A product that serves as an adhesive for construction materials when combined with water. As the reaction occurs, the material hardens over time until it becomes a solid mass. It is typically mixed with sand and/or aggregates to make mortar or ready-mix.

CSA (Canadian Standards Association): An organization that sets technical standards for products that North American companies produce. Through testing and certifying product safety and performance requirements they ensure reliable and sustainable industry practices.

ASTM (American Society for Testing and Materials): An organization that strives to improve performance in manufacturing and materials, products and processes. Their goal is to understand commercial needs and ensure consumer confidence in products and services.

ISO (International Organization for Standardization): A member based organization that brings together experts and shares knowledge to develop market relevant international standards to ensure quality, safety and efficiency. They aim to facilitate international trade, support innovation and provide solutions to global challenges. Companies that are ISO certified have committed to make every effort to continuously improve. They are audited yearly to ensure compliance and retain their certification.

Slag: A by-product of the steel industry produced in the refining of ore. Slag is ground up in a mill to produce CRH Slag Cement, an environmentally friendly cementitious material.

The Importance of CSR at CRH

Corporate social responsibility (CSR) is an important mindset that is firmly embedded throughout our company. In Canada, CRH organizes more than 200 annual events that bring us closer to local communities. Our plants and quarries are visited annually by thousands of school children and local residents for open houses, tree plantings and other educational activities. We have a long-standing commitment to the communities where our facilities are located. CRH works alongside local communities on initiatives related to education and training, sustainable community development and improvements in local infrastructure.

Giving Back to Our Community

For over 60 years, CRH’s Mississauga facility has been a proud member of the South Mississauga business community providing volunteer, in-kind and financial support for many organizations and events that make Mississauga such a

wonderful place to live and work. The Mississauga Plant was honoured to receive the Mississauga Board of Trade’s 2011 Business Award of Excellence in Corporate Social Responsibility.

CRH Mississauga Community Advisory Panel

Engaging with local stakeholders is a critical component of our commitment to learn from their experiences as well as share our own; to consider their input as part of our decision making processes, and participate in a meaningful way in community life. Each community that we are a part of has its own unique needs and concerns, which is why CRH operates Community Advisory Panels (CAPs) with local representatives at its various locations throughout Canada.

In December 2009, CRH Canada hosted its first meeting of the Mississauga Plant’s Community Advisory Panel. Meetings provide a forum to engage in meaningful discussion, collaboration and information sharing.

Since attending their first meeting, Mississauga CAP members have given their personal time and energy to represent their communities in developing an open dialogue with our Mississauga team. As ambassadors of their local Mississauga and Oakville communities, our CAP members play an important role in raising community awareness of plant operations while also helping CRH better understand the needs of local communities. Members of the Mississauga CAP include include local residents, local ratepayer & community associations, regional health units, the Ontario Ministry of the Environment and Climate Change, and local government.

We would like to thank Mississauga CAP members for their dedication and commitment.

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Environmental ResponsibilityCRH is committed to addressing the challenges of climate change and to support progress towards a sustainable, low-carbon economy. We are proud of being a good neighbour, our environmental performance and the relationships we have built in the community, to enhance collaboration and share information.

The Mississauga Plant participates in Ontario’s Cap and Trade system that launched in July 2016, and will continue to help to fight climate change and seek opportunities to improve efficiencies, conserve non-renewable natural resources, and utilize alternative raw materials and low-carbon fuels.

We operate a comprehensive air emission monitoring program on a number of parameters in order to optimize operating conditions and demonstrate our performance.

Our environmental performance is continuously evaluated to improve air emissions, noise, fugitive dust, wastewater discharges and natural resource utilization.

We have invested significantly in efforts to successfully reduce air emissions, in particular for Particulate Matter (PM2.5 and PM10), Nitrogen Oxides (NOx), Sulfur Dioxide (SO2) and Carbon Dioxide (CO2) emissions, and to control noise, fugitive dust and wastewater discharges.

We are a leading member of the Clarkson Airshed Study Industrial Association.

The Mississauga Plant has operated as an ISO 14001-certified Environmental Management System facility since 2002.

Portland-Limestone CementPortland-Limestone cement (PLC) is a more sustainable building choice than regular Portland cement, but just as strong and durable. Although new to Canada, PLC has been used in Europe for over 25 years. It is included in the CSA A 3000 Cementitious Materials Compendium and the CSA A 23.1 Concrete Materials and Methods of Construction guidelines. It is referenced in the National Building Code of Canada (NBCC) and in the Ontario Building Code (OBC) as of the beginning of 2011.

What is Portland-Limestone Cement?While regular Portland cement may contain up to 5% limestone, PLC is manufactured by intergrinding Portland cement clinker with 6% - 15% limestone. The clinker used to produce PLC is the same used to manufacture regular Portland cement. PLC produces a concrete as strong and durable as that made with regular Portland cement. It is suitable for a variety of applications from cast-in-place to masonry, and precast to ready-mixed concrete. PLC can be used in applications where sulphate resistance is required as per CSA A3000 & A23.1. When blending PLC with supplementary cementitious materials (SCM), such as slag or fly ash, similar performance is achieved as when they are used in combination with Portland cement.

Strong Environmental and Sustainable Construction CredentialsWith up to 15% of the clinker used to pro-duce regular Portland cement replaced by limestone, PLC manufacturing generates significantly lower greenhouse gas emis-sions and up to 10% fewer CO2 emissions.

This replacement of clinker with limestone also reduces natural resource consumption since 1.6 tonnes of limestone are required to obtain 1 ton of clinker.

Both the Mississauga and Joliette cement plants currently manufacture PLC, and the material has already been supplied for consumption in Ontario and Quebec.

Our Commitment to Sustainability

Peregrine Falcons have been nesting at the Mississauga Plant for over a decade. Working closely with the Canadian Peregrine Foundation and Ministry of Natural Resources, over 25 chicks have been banded since 2003.

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www.crhcanada.com

CRH Mississauga Cement Plant2391 Lakeshore Road WestMississauga, Ontario L5J 1K1Tel.: 905-822-1653Fax: 905-822-7445

www.cementportal.com

CRH Ogden Point Quarry176 Victoria Beach RoadColborne, Ontario K0K 1S0Tel.: 905-355-2534Fax: 905-355-2667

Corporate OfficeCRH Canada Group Inc.2300 Steeles Avenue West, 4th FloorConcord, Ontario L4K 5X6Tel.: 905-761-7100Fax: 905-761-7200

Front cover: The Mississauga Plant has been a proud member of the south Mississauga business community since 1956.