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Described as the largest capital investment in the history of St. Clair County, a more than $250 million expansion of National Cement’s plant in Ragland, Ala., is well underway. Officials say a new state-of-the-art kiln will save jobs and allow the plant to remain open for at least another half-century once the two-year project is completed. “Our present plant was built in the 1960s and modified and modernized in the late 1970s, early 1980s,” said Spencer Weitman, president of National Cement Company of Alabama Inc. “By building a new plant, we can incorporate the latest technology and will operate the most efficient plant in the U.S. The new plant will allow National Cement Company of Alabama Inc. (NCC-AL) to continue its operations for another 40 to 50 years into the future.” Weitman said now is a good time to perform the work. “With our existing plant, NCC-AL had maximized its production and would not be able to grow in the future and meet the needs of our customers. We needed to build the plant to position ourselves for future growth. Also, with the new technology and fuel that will be used, we will reduce our carbon footprint.” With a customer base in Alabama, Mississippi, Tennessee, Georgia and South Carolina, (Hugh Hunter photos) Among the project’s many challenges, the biggest is to keep the pace of the work NCC-AL is adding a new high-tech kiln line to its southeastern operation, which includes a steady, despite the situation COVID has created with health and safety rules and new roller mill, preheater, rotary kiln and clinker cooler. By Cindy Riley
CEG CORRESPONDENT
control of international deliveries.
see CEMENT page 2
Page 2 • May 5, 2021 • www.constructionequipmentguide.com • Alabama State Supplement • Construction Equipment Guide
Largest Capital Investment in County History Proceeds
(Hugh Hunter photo)
(Hugh Hunter photo)
Thyssenkrupp is the supplier for all the equipment, and H&M serves as the main contractor.
NCC-AL worked hand-in-hand with several entities to get the project started.
CEMENT from page 1
Overall completion of the project is approximately 60 percent, with general and detail engineering almost finished. In addition, civil works are close to wrapping up. Structural steel erection/plate work and equipment erection are the main current activities, with electrical work initiated. Pre-assembly work began in March 2020, with first clinker production expected in the first trimester of 2022. Seeing the project moving closer to completion is rewarding
for everyone involved in the project. “It is with great pride and a lot of humility that the project team approaches this last year before the commissioning,” said National Cement Project Manager Hervé Lapillonne. “NCC-AL’s goals for this project are timely commissioning of the plant while staying within the budget, continuing the construction work at the level of performance expected, while continuing to carefully observe all safety rules, and accomplishing it all despite the current
(Hugh Hunter photo)
Overall completion of the project is approximately 60 percent, with general and detail engineering almost finished.
COVID environment. “The project will improve the energy efficiency and increase the clinker production capacity of our manufacturing facilities by supplementing the existing kiln line capacity with the new kiln capacity (additional 5,000 mtpd) and adding an installation to receive and introduce alternative fuels at the calciner,” said Lapillonne. Thyssenkrupp is the supplier for all the equipment, and H&M serves as the main contractor.
“Both of these companies are well-suited to our project because they are well organized, technically knowledgeable and have construction experience with projects of similar scope and size of our project,” said Lapillonne. “Additionally, the vision, values and standards to which we hold ourselves are adhered to by each of these companies as well.” Cement operations began in 1908 at the current plant site in Ragland. The company was purchased by the Vicat Group of France in 1974. “Vicat was founded 170 years ago following in the footsteps of Louis Vicat, who invented artificial cement in 1817,” said Weitman. “Operating in 12 countries today, the group offers top-class mineral and biobased construction materials and service that meet the needs of the construction trades.” According to Lapillonne, of the project’s many challenges, the biggest is to keep the pace of the work steady, despite the situation COVID has created with health and safety rules and control of international deliveries. All activities are progressing at the expected pace, thanks to a joint team effort among the owner, project team and the onsite employees of the plant, supplier and contractor. The concrete structure was built using vertical slipform construction, which required days of round-the-clock ready mix deliveries to complete. “Coordination among the slipform contractor, the ongoing work at the construction site and the ongoing operations of the existing plant with concrete supplier Kirkpatrick Concrete was a challenging undertaking, but was handled superbly by all involved with coordinated management,” said Weitman. see CEMENT page 6
Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • May 5, 2021 • Page 3
Atlanta, GA 404.696.7210 Birmingham, AL 205.841.6666 Madison, AL 256.350.0006 Mobile, AL 251.633.4020 Montgomery, AL 334.262.6642 Oxford, AL 256.832.5053 Tuscaloosa, AL 205.848.4147 Pensacola, FL 850.479.3004
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Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • May 5, 2021 • Page 5
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Jefferson State Trains in Heavy Equipment Operation A pilot program to train a new generation of construction equipment operators recently graduated its first students from a branch of Jefferson State Community College near Birmingham, Ala. The initiative was designed by more than 20 construction businesses and industries across the central part of the state, in partnership with the Alabama Community College System. The program helps students ages 18 and older in obtaining nationally recognized certifications for heavy equipment operators. In doing so, it addresses the state’s need for more certified construction and heavy equipment workers for infrastructure projects statewide. The inaugural class of 12 students graduated April 9 from the community college’s Chilton-Clanton campus, according to the Alabama Political Reporter. “Alabama’s community colleges across the state are at the table with business and industry leaders to identify solutions to the state’s workforce needs,” said Alabama Community College System Chancellor Jimmy H. Baker. “The Heavy Equipment Operator program at Jefferson State is a prime example of identifying a need and working with industry to address it in a timely manner through a short-term training solution yielding qualified, certified students who are ready to work on day one.” The 12-week training model helps students in obtaining three nationally recognized certifications for heavy equipment operators while they train both inside a classroom and on job sites with area employers. The first graduating class
had been funded by the Craft Training Board of Alabama to complete the program. “Working alongside our business and industry partners creates positive outcomes for everyone and we’re eager to expand on the success of this pilot program,” said Jefferson State President Keith Brown. “The Heavy Equipment Operator Program will increase the number of skilled operators to help meet industry demands and it will help individuals acquire valuable jobs to make a better life for themselves and their families.” The Alabama Political Reporter reported that new equipment operators take up to two weeks of on-the-job training to learn basic operations before being able to learn company specific skills. With industry leaders designing the curriculum, the Heavy Equipment Operator program was customized to ensure students completing the program would enter the job market with a mastery of basic safety and operation skills in addition to eight hours of “seat time,” or operation time, with the equipment. Classes are currently offered on Tuesday and Thursday evenings with hands-on training on Saturdays and Sundays to provide needed flexibility for individuals looking to enter the construction industry. Jefferson State’s next Heavy Equipment Operator class will begin on May 25. The curriculum is based on the National Center for Construction Education and Research (NCCER) Soft Skills Training Certification, Wheeled Loader Certification and Wheeled Excavator Certification. Industry feedback on the program design ensures that students who complete the pro-
gram have the skills needed for immediate employment as equipment operators. “As Alabama continues to develop the training needed for all jobs, both with academic and technical training, the trade skills gap continues to grow. As one generation begins to enter the retirement age, another generation is not trained to fill those shoes,” said Chilton County Industrial Development Board Executive Director Whitney Barlow. “To address this gap, leaders must work together to find creative and expansive solutions to meet the needs of employers across the state. The pilot program at Jefferson State is a prime example of an innovative solution to meet local industry needs.” According to Alabama Political Reporter, the state has more than 2,800 construction job openings each year, with a need for more than 600,000 heavy equipment operators nationwide through December 2022. Operating engineers and other construction equipment operators had a median wage of $21.03 per hour in the Birmingham area in 2019. Across Alabama, the state’s community college system is working with business and industry to develop unique training opportunities for students to enter in-demand, well-paying jobs across multiple sectors, including manufacturing, construction, healthcare and information technology. Jefferson State’s Heavy Equipment Operator program is one of many efforts to ensure classroom learning and skills training prepares students for what they will experience as members of the labor force.
Communication Key to Keeping Ragland Plant Operating CEMENT from page 2 (Hugh Hunter photo)
Described as the largest capital investment in the history of St. Clair County, a more than $250 million expansion of National Cement’s plant in Ragland, Ala., is well under way.
The slipform work was, in fact, an intense undertaking. “Once the pouring started, there was no stopping until it was complete. It was a ‘slipform pour.’ which means the forms were constantly moving up as concrete was being placed. Total amount of concrete was approximately 5,000 cubic yards with a total placing time of 10 days. The pour was 24 hours per day.” The concrete structure is almost completed, with only a few minor unfinished areas remaining. Two large foundation pours were made, including a mud mat to provide a foundation for a large mat pour. “The mud mat totaled about 800 cubic yards and was poured in two parts (600 cu. yds./200 cu. yds.),” said Weitman. “The foundation pour totaled about 1,500 cubic yards and was completed in one pour. Three Kirkpatrick plants were utilized in the foundation pour. Two plants could have handled that volume, but a third was added to ensure there would be no problems.” Lapillonne said construction milestones include initial activity at the site, the first structural steel erection and the blending silo civil works completion last December. Tasks yet to be completed include kiln erection in June 2021, refractory works scheduled to begin June 2021 and the accelerated pace of electrical
works anticipated for May 2021, following mechanical erection works. Massive equipment being installed includes a new roller mill, preheater, rotary kiln and clinker cooler, with an additional phase calling for a new clay crusher and storage operation. This called for utilization of two major crawler cranes at the site for the duration of the construction, with additional cranes being added as construction needs dictated. Main materials required on the job include concrete and rebars, structural steel, steel plates and electrical items. As for the most time-consuming part of the work, said Lapillonne, “That would be the coordination of all personnel involved, timely order and delivery of equipment and supplies and communication among the companies and subcontractors involved in this project. Our success in this regard, all while keeping the Ragland plant operating at its standard level, has been the key to our success with this project to this point.” Weitman noted that the city, county and state were all helpful in bringing the project to reality. “NCC-AL worked hand-in-hand with each of these entities and their leadership to get our project started. By building the new plant, we have secured a place for our employees to work at good jobs with great pay and benefits well into the future.” CEG
Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • May 5, 2021 • Page 7
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