imi nl 1007 layout1 - imi - irving materials, inc. · 2014. 6. 2. · in addition to the mall work,...

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IM PR I NT NEWS AND INFORMATION FOR EMPLOYEES OF IRVING MATERIALS, INC. VOL. 3, NO. 2 INSIDE THIS ISSUE 10/07 2 • Environment, continued 3 • Power Plants • KUDOS 4 • Project Spotlight 5 • Spectra colored concrete • Roller compacted concrete 6 • Clean water in Tennessee • My Safe Workplace 7 • Safety Team 8 • Truck Rodeo Roundup Our logo may be bright red, but our hearts are bright green when it comes to the environment. Reducing, recycling and taking care of the land are priorities that have made good business sense for our organization for years. “Long before ‘green this’ and ‘green that’ was in the headlines, imi has quietly been implementing ‘green’ practices,” said John Ware, presi- dent, imi North. “It is the responsibil- ity of our company to be good stewards of the environment and the land.” Here are a few of the ways the company “walks the talk”: Products E&B Paving buys 30,000 tons of scrap roof- ing shingles per year from Owens Corning to reuse in asphalt mixtures. This scrap would have been sent to a landfill. E&B incorporates approximately 330,000 tons of recycled asphalt into new asphalt mixtures. This saves over $1 million per year in asphalt oil that the company doesn’t need to buy. All iron and steel pieces and parts obtained from repairing worn machinery at aggregate facilities are sold as scrap and recycled. In terms of recycled concrete, our central Indi- ana business recycles the vast majority of our returned concrete (over 50,000 tons per year) either by crushing it into road base or making it into concrete blocks that we sell. • Our central Indiana business consumes 30,000 tons of fly ash, which is a by-prod- uct from the coal-fired power plant industry, and another 5,000 of slag cement, which is a by-prod- uct from the steel industry. These 35,000 tons total save 35,000 tons of cement, which means 35,000 fewer tons of CO2 entering the atmosphere (one ton of cement produced creates one ton of CO2 emis- sion). imi looks for every opportunity to use recy- cled materials in our concrete chemistry. For example, we use by-products of the wood and paper industry that have uses in our industry, and because we use them, they are not sent to landfills by the wood and paper suppliers. One of imi’s unique concrete mixtures, Eco- Pave, is a pervious concrete that has a positive environmental impact. It is a special type of pavement that allows rain and storm water to pass through it, thereby reducing the runoff from a site and surrounding areas. In addi- tion EcoPave filters some pollutants from the runoff. This rainwater will naturally replenish our water tables and aquifers. Caring for the environment is nothing new to imi (continued on page 2) Why Is This Man Smiling? See back page and special insert for details. SPECIAL INSERT 2007 Truck Rodeo Commemorative Poster

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Page 1: imi nl 1007 layout1 - IMI - Irving Materials, Inc. · 2014. 6. 2. · In addition to the mall work, E&B Paving sup-plied and installed all the asphalt and concrete for the 4.5 mile

IMPRINT N E W S A N D I N F O R M A T I O N F O R E M P L O Y E E S O F I R V I N G M A T E R I A L S , I N C . V O L . 3 , N O . 2

I N S I D E T H I S I S S U E

10/07

2 • Environment, continued

3 • Power Plants

• KUDOS

4 • Project Spotlight

5 • Spectra colored concrete

• Roller compacted concrete

6 • Clean water in Tennessee

• My Safe Workplace

7 • Safety Team

8 • Truck Rodeo Roundup

Our logo may be bright red, but our hearts are bright green when it comes to the environment. Reducing, recycling and taking care of the land are priorities that have made good business sense for our organization for years.

“Long before ‘green this’ and ‘green that’ was in the headlines, imi has quietly been implementing ‘green’ practices,” said John Ware, presi-dent, imi North. “It is the responsibil-ity of our company to be good stewards of the environment and the land.”

Here are a few of the ways the company “walks the talk”:

Products• E&B Paving buys 30,000 tons of scrap roof-

ing shingles per year from Owens Corning to reuse in asphalt mixtures. This scrap would have been sent to a landfi ll.

• E&B incorporates approximately 330,000 tons of recycled asphalt into new asphalt mixtures. This saves over $1 million per year in asphalt oil that the company doesn’t need to buy.

• All iron and steel pieces and parts obtained from repairing worn machinery at aggregate facilities are sold as scrap and recycled.

• In terms of recycled concrete, our central Indi-ana business recycles the vast majority of our

returned concrete (over 50,000 tons per year) either by crushing it

into road base or making it into concrete blocks that

we sell.

• Our central Indiana business consumes 30,000 tons of fl y ash, which is a by-prod-uct from the coal-fi red

power plant industry, and another 5,000 of slag

cement, which is a by-prod-uct from the steel industry.

These 35,000 tons total save 35,000 tons of cement, which means 35,000 fewer

tons of CO2 entering the atmosphere (one ton of cement produced creates one ton of CO2 emis-sion).

• imi looks for every opportunity to use recy-cled materials in our concrete chemistry. For example, we use by-products of the wood and paper industry that have uses in our industry, and because we use them, they are not sent to landfi lls by the wood and paper suppliers.

• One of imi’s unique concrete mixtures, Eco-Pave, is a pervious concrete that has a positive environmental impact. It is a special type of pavement that allows rain and storm water to pass through it, thereby reducing the runoff from a site and surrounding areas. In addi-tion EcoPave fi lters some pollutants from the runoff. This rainwater will naturally replenish our water tables and aquifers.

Caring for the environment is nothing new to imi

(continued on page 2)

WhyIs This

ManSmiling?

See back page and special insert for

details.

SPECIAL INSERT 2007 Truck Rodeo Commemorative Poster

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2

• EcoPave can be used as a pavement that doubles as a dry retention pond. Dry reten-tion ponds are an acceptable practice by storm water managers to meet EPA requirements for storm water mitigation.

• Using EcoPave as a parking area can reduce the need for large retention ponds thus in-creasing the options for using valuable land.

• EcoPave also contributes to enhanced air qual-ity by lowering atmospheric heating through lighter color and lower density, decreasing the impact of the “heat island” effect found in many cities.

• EcoPave counts toward Leadership in Energy and Environmental Design standard (LEED) certification for designing, building and oper-ating environmentally friendly buildings.

“Being involved in the development of many construction projects from the ground up allows us to educate developers and owners about the role concrete can play in making a construction site environmentally friendly,” said Joe Gruszc-zynski.

Operations

In addition to imi’s products, we encourage environmental responsibility in our operations. For example, in the Greenfield office, imi re-cycles paper and turns off computers and lights at night. The cleaning staff got involved and suggested the energy-saving mercury vapor light bulbs that are now used throughout the office. Old computers are also recycled throughout the organization.

Even imi’s signature fleet of over 1,200 concrete trucks are under scrutiny by the company. When the trucks are serviced, the used oil is stored and used in special heaters to heat the shop in the winter. Fuel efficiency is also a fo-cus. “In Tennessee, we are experimenting with

bio diesel, which helps our vehicles run cleaner at less cost,” said John Curtis, president, imi Tennessee.

“We continue to look for ways to recycle as many materials as possible. One challenge is our ‘bring back’ concrete,” said Brian Hood, director, Environmental Affairs. “Many of our plants are smaller plants that do not have a lot of land to store this product. We are able to re-cycle this material into a viable product in most markets. Contractors are increasingly finding this material useful as a good fill material. As a company imi does not produce waste. We have viable recycling for products that were once considered waste.”

At imi’s plants, safety and environmental stewardship go hand in hand. “When a plant is environmentally sound, its safety is great, too,” said Terry Jones, imi’s director of Environmental Health and Safety. “If safety is outstanding, then chances are, it is environmentally compliant as well. Good housekeeping shows the plant is organized and on top of things.”

Many plants use a series of clarifying ponds to allow sediments to settle out before returning the water into the environment. Such is the case at the plant in Nashville, TN, where strict laws regulate the quality of water that enters the Cumberland River, which flows through the city (See article on page 6). The plants along Geist Reservoir north of Indianapolis also use this technique.

Concern for the environment means being a good neighbor, too. “It used to be our plants were isolated in rural areas,” said Terry. “Now these same plants have neighborhoods and busi-nesses adjacent to our property. There are laws against dust leaving imi property. Simple things like clean driveways in our plants can make all the difference.”

Caring for the environment (continued from page 1)

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imi is supplying over 80,000 yards of concrete at the EON-US power plant in Ghent, KY.

EON-US (Ghent facility) Ghent, KY • FGD project (fluoride gas desulphurization) • Construction Manager: Fluor Enterprises, Inc • Estimates: Yardage to date - 75,000. Yardage remaining - 5,000• Largest pour: 6,300 • Plants: Ghent, Carrollton & Warsaw

EON-US (E W Brown) Burgin, KY • FGD project (fluoride gas desulphurization) • Construction Manager: Fluor Enterprises, Inc. • Estimates: Yardage to date - 25,000. Yardage remaining - 40,000• Largest pour: 2,200 • Plants: Harrodsburg 1, Harrodsburg 2, & Lawrenceburg

imi contributes to cleaner energy along the Ohio RiverNew requirements by the Environmental Protec-tion Agency (EPA) for low emissions by power plants have spawned renovations and upgrades to coal plants along the Ohio River. imi’s con-crete work is the structural support for future improvements that will make the plants cleaner and more efficient.

2007 Power Plant Status

EON-US (Trimble County) Wises Landing, KY • Coal fired turbine addition • Construction Manager: Bechtel Power Corporation • Estimates: Yardage to date - 35,000. Yardage remaining - 10,000• Largest pour: 2,400 • Plants: Wises Landing & Carrollton

American Electric Power (AEP) (Indiana Kentucky Electric facility) Madison, IN • FGD project (fluoride gas desulphurization) • Construction Manager: Bowen Engineering • Estimates: Yardage to date – 1,000. Yardage remaining - 35,000• Largest pour (estimated): 7,000 • Plants: Madison, Scottsburg, Carrollton & Ghent

Kevin Swaidner, Brady Goebel, left, and Steve Hassler, far right, of imi Southwest, accept an award from West Side Nut Club President Mark Weinzapfel in Evansville, IN, during Founder’s Day celebrations in May. Since its humble beginnings in 1921, the Nut Club has raised over $2 million for area organizations and schools through an annual Fall Festival event. This year, imi donated $20,000 in concrete for the Nut Club’s new warehouse. “imi was the first and only company to have given the West Side Nut Club anything,” said Steve. “Needless to say, members were ‘floored’ when we offered to give them the concrete.”

Kudos

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What’s unique about this project: Not your typi-cal shopping mall, Hamilton Town Center is an open-air streetscape environment with 900,000 sq. ft. of retail space, featuring a diverse mix of stores, restaurants, and entertainment venues. Located at the southwest corner of I-69 and State Road 238 (relocated 146th St.) near No-blesville, IN, the project is a joint venture between Simon Property Group and Gershman Brown & Associates.

Both imi and E&B Paving have played key roles in Hamilton Town Center’s development since it began last spring. In this project alone, imi has poured for Manor Bros. (concrete contractor); Pepper Construction (general contrac-tor); R & W (concrete contractor); Smock Fansler (concrete con-tractor), and Gradex (excavating contractor), for an estimated total of more than 15,000 cubic yards in sidewalks and floors for the stores.

E&B has supplied 57,000 tons of stone (imi Stony Creek); 32,000 tons of asphalt (River Road and Stony Creek plants); 21,800 lineal feet of extruded curb; 11,650 lineal feet of regular curb, and 4,500 lineal feet of miscellaneous curb and gutter.

In addition to the mall work, E&B Paving sup-plied and installed all the asphalt and concrete for the 4.5 mile extension/rerouting of 146th Street in Hamilton County, which is the mall’s primary access road. The new road opened in September, and the first anchor store at the mall opened this month. The mall’s formal grand opening is scheduled for May 2008.

“This has been a big project for us,” said Mark Jones, Noblesville area manager, E&B Paving. “We owe its success to the hard work and dedi-cation of all our employees. They have really taken ownership and stepped up to the task.”

4

SpotLightP R O J E C T

Hamilton Town Center and 146th St. extension

Construction on the Ham-ilton Town Center mall in Noblesville is underway, with imi and E&B Paving

playing key roles.

E&B Paving puts the finishing touches on the 146th St. extension in Hamilton County, IN. Shown here are Gary Thompson, Roller Operator; Ryan Adams, Grade Control on paver; Matt Richmond, Paver Operator, and Steve Smith, Transfer Machine, all of E&B Paving in Noblesville.

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What kind of concrete is super strong and takes traffic in record time? It’s Roller Compacted Concrete!

Building a huge manufacturing plant can be a challenge for obvious reasons, but one of the biggest challenges is getting the pavement ap-plied without causing delays in other phases of the construction process while the pavement cures.

“Roller compacted concrete allows other construction traffic to drive on it within two to three days, with a compression strength of 6,850 psi after just seven days. With a huge building, the concrete must be capable of handling trucks, cranes, materials, and material storage around the exterior of the building,” said Ron Zink, vice president, E&B Paving. “With RCC, all the other contractors on the job can work when and where they need to right away. Things get done quicker, and time is money.”

RCC gets its superpowers from its special for-mula and application process. It has a low water

to cement ratio, and the newly placed mixture is smoothed with a heavy roller. It’s made on loca-tion in a pugmill mixer and triaxle trucks, not traditional mixer trucks, move it to the place-ment site.

RCC is being used at the new Honda Manu-facturing plant near Greensburg, IN. Although this is a new process for us, RCC has been used elsewhere for over 50 years. Honda had suc-cess with the product at its Alabama plant and ordered it for the new plant in Greensburg.Since mid June, E&B Paving has placed 275,000 square yards, 8 inches thick.

“RCC is typically placed in a big warehouse that gets heavy truck traffic over a large area,” said Ron. “In projects of this scale, RCC can be more economical than rigid concrete or flexible as-phalt. But there is a project and a place for every type of pavement.”

Other RCC projects are on the horizon in south-ern Indiana, Kentucky and Tennessee.

RCC: the “Superman” of concrete

“What color would you like?” is the question Gordon Goins, director of Marketing, Indiana, would like everyone to ask their customers when taking a concrete order.

Concrete suppliers in other parts of the coun-try that do this have increased their colored concrete orders by 75 percent. At imi, Gordon’s internal and external product awareness cam-paigns this year will triple sales over last year.

“It’s an easy sell,” said Gordon. “Colored concrete is very attractive and it adds only 50 cents per square foot in cost.”

To make everyone’s life easier, imi has honed in on the four most popular colors: Quarry Gray, Yosemite Sand, Rhode Island Red, and Canyon Clay. Gone are the days of hundreds of custom colors and the complexities that go with them. Because the color is integrally

mixed in the truck, the color between batches is consistent. It can be finished in a number of ways, including stamping, textured skins, hard trowel and broom finish.

The most popular of the popular colors? Quarry Gray. Concrete tinted Quarry Gray can be embossed to mimic slate, but is far more affordable. Slate costs about $22 to $25 per sq. ft., and colored concrete finished with a slate texture costs only about $9 per sq. ft. The price is the same regardless of the color.

The product has become so popular that Indianapolis-area home builders Davis Homes and Centex Homes have added Spectra colored concrete to their list of patio upgrades. Paul Shoopman Home Building Group of India-napolis features Spectra colored concrete as the standard interior concrete options for base-ments and garages.

imi’s “Spectra” colored concrete adds fashionable touch to concrete projects

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Use MySafeWorkplace to report issues such as:

• Ethics Violations

• Anti-Trust Issues

• Accounting Irregularities

• Substance Abuse

• Unfair Labor Practices

• Harassment

• Mistreatment

• Fraud

• Theft

• Industrial Accidents

• Threats of Violence

• Discrimination

• Unsafe Work Conditions

• Any other issues you have

Advantages of MySaveWorkplace:

• Anonymous

• East to Use

• Always Accessible

• Confidential

• Fast

• Free!

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Since its launch in May 2006, the MySafe-Workplace hotline has given employees the opportunity to report incidents anony-mously anytime, day or night.

“It’s always best to talk to your supervisor about issues rather than calling the hotline, but ‘MySafeWorkplace’ gives you an alternative if the situation prevents you from going through the traditional chain of command,” said Michael Vasquez, vice president of Human Resources.

MySafeWorkplace is a confidential and anonymous tool that makes it easy to report workplace incidents. You can call 1-800-461-9330 or log on to www.MySafeWorkplace.com any time of the day or night to file a report. Your confidential report will be assigned a case number and instantly and discreetly forwarded to the vice president of Human Re-sources for review and proper handling. With this system, the company is obligated to respond within 48 hours. You may keep track of the company’s notes by phone or online as the investigation progresses.

We’re committed in helping you enjoy a safe, healthy and friendly work environment.

Be heard! Use MySafeWorkplace to report things that concern you. Let us know how you feel. Let everyone know you care.

Reminder: Report incidents anonymously with “My Safe Workplace”

When a sales representative of a water filtra-tion system tells you that he will drink the process water from your concrete plant after it goes through his filtration system, you kind of want to stop and listen...

Two years ago we had a severe need to improve the quality of our water being discharged at the West Nashville plant. And we did what all producers do, we began contemplating the need and the high costs to build bigger retention and sediment ponds. There were two problems with that thought process: 1) there was not enough room at that facility, and 2) we had a direct feed into the Cumberland River.

We finally settled on a water filtration system from Advance Filtration Systems (at a much lesser cost than building larger retention ponds). The system is fully self-functioning and

actually works. Through a series of micro-fiber filters, process water produced throughout the day is collected and settled through a series of six existing retention/sediment pits. At the sixth pit, the water is drawn from the top and continuously recycled through the system’s micro filters until sensors tell the internal com-puter that it is within the required tolerances for pH and suspended solids. Both of these have been tested monthly for two years and have yet to exceed the state mandated requirements.

Our long term plan is to capture this water and use it for batching. When this is done we will have a closed loop system and this will be a total non-discharge plant. By the way...the sales-man did drink the water.

Fletcher Taylor, Operations Manager imi-Tennessee

Through filtration, dirty water from washing trucks

is transformed into clean water that can be dis-

charged safely into the Cumberland River.

Nashville Plant protects Cumberland River

Page 7: imi nl 1007 layout1 - IMI - Irving Materials, Inc. · 2014. 6. 2. · In addition to the mall work, E&B Paving sup-plied and installed all the asphalt and concrete for the 4.5 mile

Bill Shipe, Safety manager, imi Tennessee

Although Bill’s title is

safety manager for

imi Tennessee, part

of his responsibility

is to cover all of imi if Terry or Walt Tharp

are not available. Bill started as a driver

over 19 years ago and moved into safety,

environmental and health at Allied Con-

crete in Charlottesville, Virginia. He came

to imi Tennnessee in April. Bill is a certi-

fied OSHA instructor (as well as CPR and

first aid) and has already begun training

throughout the organization. “No job is

so important that we cannot take time to

perform our work safely,” said Bill.

Steve Hender-son, director, Regulatory Affairs and EEO Officer, E&B Paving

Steve’s respon-

sibilities include

safety and environmental issues for E&B

Paving, as well as obtaining storm water,

air and water permits for imi’s ready mix

plants and zoning variances for portable

plants in Indiana. Steve is also building

imi’s industrial hygiene program, and

makes sure our exposure to hazardous

chemicals and noise is well below OSHA

limits. “Worker safety is important to imi,”

said Steve.

Brian Hood, director, Environmental Affairs

Brian is an expert at

environmental issues,

serving imi Tennes-

see, imi South and imi Southwest. His

role also includes identifying violations

and safety issues. He brings 18 years of

environmental consulting experience to

imi. “Safety and environmental aware-

ness tie together,” he said. “We have to

do things the right way for two reasons.

One, it’s the right thing to do, and two,

we are more efficient when we do so.”

Walt Tharp, Indiana Division manager, Envi-ronmental, Health and Safety

With his engineer-

ing degree, Walt is

licensed to certify our plants in Indiana,

Kentucky and Ohio for the National

Ready Mix Concrete Association. Many

clients now require the plant location to

have a special certification from NRMCA

to be able to supply concrete. Plants

must be recertified every 24 months, so

the inspection process is ongoing.

“Being certified by the NRMCA means

a step up in our commitment to quality

and safety – both for our employees as

well as our customers,” said Walt.

Safety training throughout the organization continues to be a priority for Terry Jones, imi’s director of Envi-ronmental Health and Safety. Having the right people in the right places helps Terry get the safety message out among imi’s multiple sites.

Each member of the safety team is being cross trained to look for environmental as well as safety issues. (See “Environmental” article on pages 1-2).

In addition to the safety team and the required month-ly training at each site, Terry has arranged for extra training sessions for managers and other leaders. For example, this fall, five imi employees will be attend-ing a mine safety conference in Savannah, GA, to learn about the new mine safety health laws.

In house training saves lives and money

Terry also wants all plant managers to participate in a 10-hour OSHA (Occupational Safety and Health Ad-ministration) training class, which will be presented internally by our own Bill Shipe at very little cost to the company. Bill has the necessary certification to present the OSHA course, which usually costs $100 to $150 per person.

“The more our managers know about safety, the bet-ter prepared they can be to over-come the everyday burdens they might face and having this knowledge makes it easier to recognize unsafe conditions at their plant,” said Terry. “Why not correct the unsafe condi-tions before employees get hurt?”

7

imi builds a safety network

Here’s “who’s who” on the safety team:

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A BIG THANK YOU to all the IMI Truck Drivers and IMI Personnel for your suort and encouragement that you have given me in the past few weeks in the Concre Truck Drivers Compitions. I am proud to hold the Title of the “Bt of the Bt” of the IMI Concre Truck Drivers. I am going to Phoenix, AZ in October and will do my very bt to bring back The Trophy and Title of the #1 Ready Mixer Concre Truck Drivers.

“Wild Bill” Emerson

22 winners came to Indianapolis to competeOne driver, Bill Emerson, of imi South, was the first place champion. Everyone who participated in the 2007 Mixer Driver Skills Competition in Indianapolis on September 15th was a winner before the event even began... the 22 participants were regional winners from throughout company.

Pictured here, listed alphabetically by region:

imi Tennessee: Maydell Biggs, Ashland City; Chris Daniels, Lebanon; Jarrod Johnston, Tul-lahoma; Jimmy Mabe, Sparta; imi Southwest: Monty Lindsey, Paoli; Jon Shoultz, Evansville; Verlin Wagler, Washington; imi South: Bill Emerson, New Albany; Chip Klein; Selinda; Kevin Marcum, Madison; Dennis Watterson, Madison; Mike Williams, Dover; Anthony Wilson, Middletown; imi Indiana: Mike Bacon, Crawfordsville; Dustin Bowersock, Bloomfield; Jeff Campbell, Lafayette; Kent Davis, Nobles-ville; Preston Gwinn, Bloomington; Jeff Sedam, Logansport; Jeff House, Sullivan; Tim Wells, Bloomington; Joe Zygas, Lafayette.

Unable to participate in Indianapolis yet win-ners in their region were imi South’s Stanley Brown, Scottsburg, and Tim Ray, Bowling Green, and imi Indiana’s Tim Cole, Morris Street.

2007 imi Drivers’ Skills Competition

Scenes from the Competition Day

Dennis Watterson, Madison Plant, waves

to fans while awaiting his turn.

Terry Jones talks to officials before

beginning the competition.

Calvin Cash watches as driver Verlin Wa-

gler, Washington Plant, inspects a truck.

Joe Zygas, Lafayette Plant, buckles up

for safety before hitting the course.

Special thanks to Velma Vaughan for her extraordinary photographs of the day’s events.

Velma is the wife of John Vaughan, Tech Services director, imi South.