For its environmental efforts, energy-saving innovations in the manufacturing process, and outstanding safety record, Lafarge North America's Alpena, Mich., plant recently garnered national recognition. When six U.S. facilities — including four Lafarge plants — received the third annual Cement Industry Environment and Energy Awards from the Portland Cement Association (PCA) and Cement Americas in April, the Alpena plant was given top honors for Overall Environmental Excellence, as well as Runner Up mentions in the Environmental Performance and Land Stewardship categories.

Alpena is Lafarge's largest North American cement plant and one of the longest-operating cement facilities in the United States Although the site has been in use since the late 1800s and in operation since 1908, company officials note that new investments have made Alpena one of the most environmentally advanced cement plants in the world.

As cited in the PCA award presentation, the company's Paxton Quarry rehabilitation involved converting an abandoned shale quarry on the Alpena property into a lake as well as grading embankments to create a natural appearance and provide access for wildlife. Plant personnel worked with local elementary schools and community partners to restore the area surrounding the lake, establishing wildlife habitats and nesting sites for migrating mallard ducks. With the assistance of elementary school children, more than 700 trees were planted on the site, including cherry, oak, pine and spruce. In addition, the company stocked the lake with more than 30,000 fish comprising fathead minnows, rainbow trout, catfish and bluegills.

Overall, Lafarge has invested more than $6 million on site beautification and environmental improvements at the Alpena facility. Following the company's 1986 acquisition of the quarry and plant, an extensive modernization program was implemented: more than 90% of the buildings have been demolished, and landscaping has graced the property with trees, grass, natural meadows, and native wildflowers.

PCA also recognized the Alpena plant for manufacturing innovations that reduce waste and conserve energy. Lafarge installed a system to mix cement kiln dust (CKD) with gypsum for use in its final product. Such recycling is projected to reduce the amount of CKD going to landfills by about 14,000 tpy. In addition, the plant captures excess heat created during the manufacturing process to generate power. Using energy that would otherwise be wasted, this system generates 95% of the electricity used at the plant, helping to reduce emissions of greenhouse gases.

For its outstanding safety record, the Alpena plant won two PCA awards: Safety Commendation for one year without a lost-time accident and the Safety Excellence award for 1 million hours with no lost-time accidents. Emphasizing the significant role of the plant operators in this achievement, Alpena Plant Environmental and Public Relations Manager Bob Budnik says, “We're proud of our employees' hard work to protect the environment and their fellow workers. We strive to partner with our neighbors to create a safe, healthy, and viable community for people and wildlife in the Alpena region.”

Further, plant personnel participate as active corporate citizens in the Alpena area, providing funding and support for a variety of local programs that include Alpena Community College, Habitat for Humanity and the new community ice arena. The facility also sponsors the annual Lafarge Riverfest and conducts open houses and community forums with many employees active in community organizations.

Company representatives contend that the Alpena plant initiatives reflect Lafarge's worldwide commitment to environmental stewardship. The company claims active land management and reclamation programs in 75 countries, partnering with WWF (World Wildlife Fund) and the Wildlife Habitat Council in a variety of environmental efforts.

This article was adapted from materials provided by Lafarge North America.