Rotary

presentation
February 23th, 2009
Pueblo Plant Overview
89 Employees
54 Hourly @ $30.59/ hour average
35 Salary @ $73,263/ year average
78% Hired Locally
Total Annual Payroll
$6,524,422
Taxes
$3,400,000 County
$700,000 Sales Tax
Pueblo Plant Overview
Royalties
$750,000 State Education Fund
$32,800 State Education Fund
Purchase Locally
$18,000,000 Annually Pueblo County and
Colorado
Community Budget
$38,950 Annually
GCC Competitive Advantage
HP/CI
Self Directed Work Teams
Plant Overview

Quarry
Crushing capacity of
500 tph
Product size 5 to
fines
Mobile crusher due
the type of quarry
Limestone storage
Continuous stacking
and reclaiming
Blending ratio 8 to 1
Capacity 17,000 ton
Longitudinal storage
One stacker for raw materials (Mill scale, Sandstone, kaolin, coal )
2 reclaimers (one for raw materials and one for coal)
Raw mill
4 materials ( limestone 88%,
sandstone 5%, kaolin/clay 5%, mill
scale 2% )
225tph
Active vibration damping
(AVD) system
Raw mill and Finish mill
Blending silo
7,500 ton capacity ( 1.5 days of kiln
operation )
Blending ratio 8 to 1
7 programmed outlets to blend the
material

Pyro system
2,900 tpd capacity
5 stages preheater with calciner
Heat consumption 725 kcal/kg
Friction drive
Tangensial tyre suspension
DeSOx
Low NOx calciner
Kiln
Low NOx calciner
Reduction zone
At high temperature
Kiln
DeSOx system
Dry scrubber for sulfur
Fix sulfur in the raw mix avoiding emissions
Kiln
Tangential suspension
Free radial expansion of the shell to minimize ovality and maximize refractory
life
Bracket are bolted onto the tyre
Dog bone keep the tyre in position
Welded blocks rest on elastic brackets bolted to sides of tire with spring-loaded
wedges in between
Spring keeps wedge on position as dimension change with heat expansion

Kiln
Friction drive
No lubrication needed usage
Roller-tire friction
Maintenance free

Clinker cooler
Cools clinker from 2600
F to 150 F
Mechanical flow
regulator system for
air control
Hydraulic drive
Hydraulic roller
breaker
Clinker cooler
Mechanical Flow Regulator (
MFR ) system in the cooler
Automatic control of cooling air
Energy savings
Transport separate from cooling
Clinker cooler
Hydraulic Roller braker (HRB):
Uniform clinker size of clinker for the finish mill
Less maintenance
Smooth operation

Coal system
Capacity 26 tph
Prepare for high moisture coal grinding
CO2 system for fire
protection
Coal tube/pipe conveyor

Clinker dome storage
110,000 ton capacity
6 outlets
Concrete wall design
Finish mill
180 tph
Type I/II low alkali cement
95% clinker 5% gypsum
Active vibration damping
(AVD) system
Raw mill and Finish mill
Active vibration damping system (AVD)
Raise roller to stabilize operation
Reduced vibration levels
Maintain high mill runtime factor
Minimize restarts that affects the main motor
Better control of grinding pressure
Cement silos and shipping
4 silos 10,000 ton each
385 tph loading capacity
Railcar and truck load spouts
Certified scales for railcars and trucks
GCC Rio Grande
Pueblo Plant
Team Building
Vision Statement
Key on Team Leaders
Leadership team
Weekly meetings
Training
No one better than anyone
No lies
Union defense
Pay and Benefits
Process Overview
General Operations Methodology
Vision
We are a world class producer of quality cement.

We are highly productive and profitable because we are well trained,
highly motivated employees who are dedicated to using state-of-the-
art technology and continuously improving our processes in a safe and
clean environment.

Our commitment to all employees is based on trust, mutual interest,
respect and honesty.

We create opportunities that allow all to seek their level of excellence.

We reach our shared vision through a plant wide philosophy that
empowers all employees through leadership and the practice of
Continuous Improvement.

<<Each team created their own vision aligned to this one>>
Leadership
Key on Team Leaders
Lead and understand
Leadership Team
Everyis an apprentice

Communication
Weekly meetings
Communicate expectations
Listen!!
Respond with business reasons
Reinforce operations values
Safety
Environment
Equipment
Quality
Production
High Performance and CI
Ownership
NO ONE IS BETTER THAN ANYONE ELSE!
Through our actions
Communicate all, everything
Answer all, everything
ALL RESPONSES- BUSINESS BASED
NO LIES!!
Training
Basic platform
PCC
In house
Specific
OJT (L-0, L-1) and Process Operation Guideline (POG)
PMR development
Equipment parts catalog
Sister operations visit/run
Vendors
Skilled workforce
Pay and benefits
Leader in community
$23.78/ hour average- hourly
$73,650 annual average- salary
Expect more
Involvement and participation
CI methodology
Ideas for improvement
JOBS-verification and versatility
Cement manufacturing process
Structure
Plant Leadership Team
S1(6)
S2 (6)
S3 (6)
S4 (6)
Quarry (7)
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Shipping RRU (10)
Maintenance Support
One electrician/instrumentation on
each area of responsibility team (3)
PC
PACC
Plant Mgr
ENV
HR
HP&ISO
One electrician and
one mechanic within
each shift team
Procurement
Reliability
Raw Materials
Raw Mill-Kiln
Finish Mill-Shipping Electrical
Engineer
System administrator
CI Methodology
SET OBJECTIVES IN KEY
MEASURES & VISIBLY
MEASURE PERFORMANCE
TOWARD THE OBJECTIVE
FOCUS IMPROVEMENT
EFFORTS TO IDENTIFY
WHERE, WHAT, & WHEN
PROBLEM PATTERNS OCCUR
ANALYZE & SOLVE
PROBLEMS TO PREVENTION
RESOLVE PERFORMANCE
ISSUES CONSISTENTLY OR
ORGANIZE & IMPLEMENT
PROJECTS ON TIME
STEP ONE
STEP TWO
S
T
E
P

T
H
R
E
E
SET OBJECTIVES IN KEY
MEASURES & VISIBLY
MEASURE PERFORMANCE
TOWARD THE OBJECTIVE
FOCUS IMPROVEMENT
EFFORTS TO IDENTIFY
WHERE, WHAT, & WHEN
PROBLEM PATTERNS OCCUR
ANALYZE & SOLVE
PROBLEMS TO PREVENTION
RESOLVE PERFORMANCE
ISSUES CONSISTENTLY OR
ORGANIZE & IMPLEMENT
PROJECTS ON TIME
STEP ONE
STEP TWO
S
T
E
P

T
H
R
E
E
A disciplined DATA driven process involving every team in
the organization