the concrete producer cover story

8/8/2019 The Concrete Producer Cover Story

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22 The Cct Pdc | August 2010 | www.theconcreteproducer.com

By Josh Krol

As many hit the gym a baa s a as a a a sm-m by, sy asas smm w. B s wg ssam w , aks a-s ws my s Ga

Dpss 1930s.N spsgy, CP100, he

Concrete Producers aa svy v, sw 2009 was a sappgya. May ps av g bs

a a wg wa k awasm. Sm saw a makab 50% pg

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Dav Bxm, w SpFab-C Cp., a pas p F W, xas, may av smm

p bs: Paby s w, mp- s , a jb payms a sw.

W Ps Baak Obama sg $787 b Ama Rvy a

Rvsm A Fbay 2009, -s sy p w a w

sa . O a a a yas a, p-s a s g ssay a

wg w a a my w.T sms pgams by U.S. a-

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T Pa Cm Assa ams aay $60 b sms pa s ag

Concrete producersadjust to new

economic realities.

SlimmingDown


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y a as vsm, a-g xa am s s gyba. May bsvs as smaa y ab -a sms

s av b sb, magm bsss s b pp.

Sovl- spiT pmay pas pgam s-s ss -sv a m sv-ay pjs. O s, ap-pvas a s a wk a sag away g s pa. TU.S. C Mays as a s ams 19,000 s pjs. Ab $27b w b aa Dpa-

m aspa pa asa bgs a amp a waPs Obama as a 21s yas.

Ts s a b ps s asDa C, a ay-mx p Cap Gaa, M. Ias wkas -a Das bsss.Da ay ay mpys -g ss a aay saw a v- as v s pas ya.

Os av b as a.

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As s as pjs mv , smp sw a as 5.4%, ag Pa Cm Assa.

Y may pass ag ag sgs ag gway a am gvms Pg Ama Bak Wk. B

sm pjs a ss vsb m ya sa. Dka Pas Napv,I., s sppyg pas pas ag aa a s g Lkp,

I. (S sba.)

Ms: oN wk s mp w- a ay . W mas amba abyas, ps,a a, ps y sa,mma, a pb wks s-. Ts saps av b akg sg mbs sm m w. As2010 was , mas g

sms a bssss wsg xpa, a sm aspg (w as 70% my) ma wak.

Da G, ga maag Da C, says a sg as a 20% vm s bsss.

Dsp a sww a s-g ax s xp Ap, -mss w s asg a avagas 15% v as yas mag554,000 sg sas.

T Naa Assa Hm-bs (NAHB) xps a 14% as

Sorc: Rcovr.org

Standard Concrete Productso Columbus, Ga., has rehiredin some o its plants but isdownsizing in others.

RobnNelson/BlackStar

Revenue Projections for 2010

As the recession slows, producers are gaining

confidence. They hope for a better 2010

but still remain wary.

Expected Revenue,

2008 vs. 2009

Higher 28%

Lower 36%

Similar 36%

Recession Layoffs

Many producers were forced to lay off

employees across the board due to tough

economic times.

Layoffs During

Recent Recession

Yes 80%

No 20%

Tax Benefits

Awarded/$288BReceived/$163B

Contracts/Grants/Loans


Entitlements


Stimulus Funds

Although the stimulus package has been in

place for over a year, only about half of the

funds have been allocated.


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sg sas s ya. Ag

Builder magaz, NAHB -ms Dav Cw bvs a sgw swy mpv g s- a s ya a x ya,bs by w mgagas, aab sg ps, a ampvg jbs mak.

W sg sas a vasav a sva yas, mm-a s s js w akg sbag. W xp 2010 b a ya mma a,

says m Hms, v ps sas Hg C Gp. I sbm s a 2011.

A s ps pss pb- s a -my. Ag a aayss -a spg by Assa GaCas Ama, sms asg m swg s s- spg ass pbvsms as.

Ts mak saby as

mpas bm m vs. U-sss Cp., a psss p Ps, Mass., k m vspjs, g a g w apw pa. Cmpay ps PPa ass a a bs-ss s yas qa.

Lo pi W s sy m-pym sas a 20%, W

A series o 36-oot-tall panels arebeing installed along the Chicago

Sanitary & Ship Canal.

JoshKrol

Stimulus Money at WorkAbout 35 miles southwest o Chicagolies the suburb o Lockport, Ill. Estab-

lished in the early 1800s, Lockporteatures vintage architecture with amodern air. The town was able to growexponentially rom the time o its birthdue to the creation o the 97-mile Illinois& Michigan Canal that extended romthe Chicago River to the Illinois River atPeru, Ill.

Today, the Chicago Sanitary & ShipCanal runs straight through the heart oLockport and is the site o a stimulus-unded construction project. WalshConstruction was awarded $42.9 millionor the project and contracted Dukane

Precast o Naperville, Ill., to manuactureconcrete panels to realign the deterio-rating west side o the canal.

Dukanes new plant in Plainfeld, about10 miles rom the canal, started produc-tion o the panels in October 2009 andwill continue through the end o 2011.

The stretch o canal that runs throughLockport will need 1335 8-oot-wide,36-oot-tall concrete panels. Sitting 30eet under water, the panels interlock viamale and emale components.

Ater Walsh Construction was awardedthe project by the U.S. Army Corp. o En-

gineers, they both visited the plant sever-al times beore fnally settling on Dukane.We produced 50 panels initially, saysJohn Kime, vice president o operations.They (Walsh) were very pleased with theproduct and our efciency.

The recession has had a devastating e-ect on concrete producers, and Dukanewas no dierent. The precast producerlaid o employees or the frst time in itsshort history. The act that we survivedis a triumph in itsel, Kime explains.

As Dukane lobbied or the job, the pro-ducer elt it had a lot to oer the projectin terms o eectiveness and eco-riendlyprocesses.

A specialized production line helpsspeed up the process as the slab liter-ally moves itsel through every step othe panel ormation. Each one o the60,000-pound slabs eases its way romstation to station along the produc-tion line. Dukane utilizes the Europeanstyle isolation process to compact theconcrete instead o the more commonhigh-requency vibrations.

The plants other green initiatives

include soy-based insulation, concretemixes that include y ash, recycledaggregate, and recycled steel or rebar.Kime claims that more than 30% oevery dollar is recycled.

Thanks to the canal project, Dukanewas able to hire back veteran sta andbring on an additional dozen workers.I wouldnt say it was a liesaver, Kimesays. However, it did get the gearsrolling again.

Josh Krol

A look inside DukanePrecasts newly renovated

Plainfeld, Ill plant.


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25www.theconcreteproducer.com | August 2010 | The Cct Pdc

Hs ams gvm- pj-s av 680,000 w jbs. T sy as s a, assm ps svy a m a a mpys as w yas.

Hwv, a sgs .F sa, psss p N-s C Ps I., Cambsbg, Pa., a 40% s

wk s fs a pas. B p as aay bg sm

wks bak. Ns s a.Sva ps av sa ,ag ms say y a wag 2011 by w y p bs-ss a v v.

Os sk . Eps Pp-

s, a pas p Omaa,Nb., ay ay mpys.W vy a maa v-a wk by vg mapw,mpay vsa, a maa-

g ay bakgs, says mpayps Tmas Ega.

Looi W ask ab sy, Fabs makg

Aa Ka says, I ws I aa ysa ba.S a ysa ba mg sw gm-

ms p. T s a b-w a s ma mp a s, aspa, s swg-g av . I may ay

b ap s aspa, b s gg m ks s aby.C as a as as g as 30yas w sga pa. TPCA smas a by sg sa aspa, sas sav as

m as $100 b as b b-w w a 2015.Fay, sm a svg p-

a svv s agg mak.Vs a spps pag g g s fms, says Das G. TCP

Mtdgy

Th TCP100 compans ar rank b thr total North Amrcan rvn or th prvos ar (2009).

Or goal s to sho th larg scop o th compans nvolv n concrt procton, so procrs

ar lst b thr parnt compans nam an total rvn. Som fgrs r or fscal ars.

Rvn fgrs an othr normaton r acqr throgh qstonnars, tlphon, an -mal

rqsts. Rvn or compans that not prov normaton as obtan throgh annal

rports, prss rlass, ma sorcs, an th atabass o LsNs, Hoovrs, Manta, an th

Gal Bsnss an Compan Rsorc Cntr.

More Than $1 billion

1 OLdcaStLe Inc. /ATLANTANo. 1 or the orth consective year, this sb-siiary o CRH plc. recently boht Schwabsassets in Ohio, inclin 12 reay-mix loca-tions, two block plants, an one areateistribtion terminal. www.olcastle.com

2 ceMex Inc. /HOuSTONMexico-base procer has sbsiiaries in

more than 20 contries. In response to the

economic owntrn Cemex was orce to sell

its Astralian operations. www.cemexsa.com

3 Lafarge nOrth aMerIca /

HeRNdON, VA.

Sales slmpe 24% over the past year or thisNorth American branch o Paris-base LaareS.A. North American sales acconte or 19% othe total. www.laarenorthamerica.com

4 heIdeLberg ceMent /ALLeNTOwN, PA.Ater a sccessl renancin bailot in 2009,Heielber experience a isappointin llyear trnover ecrease o 31%. Heielberoperates 19 North American cement plants.

www.heielbercement.com

5 hOLcIM /duNdee, MiCH.Switzerlan-base company acqire Cemex

Astralia. The procer now has interests in 70contries on every continent, inclin North

America, which mae p 16% o total sales in2009. www.holcim.com/s

6 trInIty cOnStructIOn PrOductSgrOuP /dALLASParent o Transit Mix Concrete an Materials,which starte in 1939 as a small reay-mixoperation in Beamont, Texas. Concrete an

areates accont or 63% o Trinitys revenes.www.trin.net/trinbsi/constrct.html

7 VuLcan MaterIaLS cO. /BiRMiNGHAM, ALA.

Early in 2009, procers markets lae the resto the nation in obliatin an awarin stimls-relate hihway projects. In sprin, the procerreporte the overall economy was improvin.www.vlcanmaterials.com

8 cOLaS S.a. /ROSeLANd, N.J.Base in France, Colas is consiere a worlleaer in roa constrction, accontin or abot

NORTH AMERICAS LARgESTCONCRETE PROduCERS

LaargeNorthAmerca

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N O R TH A M E R I C A S LA R G E S T C O N C R E TE P R O D U C E R S

80% o the companys bsiness. Expects NorthAmericas bsiness to improve thanks to u.S.inrastrctre projects in 2010. www.colas.com

9 Mdu reSOurceS /BiSMARCK, N.d.The Montana-dakota utilities Co. (Mdu) recentlycomplete a win eneration acility in Northdakota. Sch projects refect the companys

commitment to a sstainable environment anenvironmental responsibility. www.m.com

10 MartIn MarIetta MaterIaLS /RALeiGH, N.C.

Proces reay-mixe concrete in Arkansas

an Texas. It is the secon larest procer

o crshe stone, san, an ravel in the u.S.

www.martinmarietta.com

11 buzzI unIceM /BeTHLeHeM, PA.Create by the 2004 merer o RC Cement an

Lone Star Instries; serves the Miwest, Soth-

west, Northeast, an Sotheast areas o the u.S.

Recently bilt the River 7000 plant in St. Lois,which has the companys larest proction line.

www.bzzinicemsa.com

12MItSubIShI MaterIaLS /CORONA, CALif.

Company proces an sells constrction

materials in the u.S., China, Vietnam, an

other contries. Other branches incle

atomotive, electronics, an precios metals.

www.mmc.co.jp/enlish/

13 taIheIyO ceMent /GLeNdORA, CALi.Manactres an sells reay-mix throhot

the West Coast reion. In 2009, Taiheiyo ac-

qire Nihon Ceratec, manactrer o ceramic

machinery components an electronics parts.

www.taiheiyo-cement.co.jp/enlish

$501 Million To $1 billion

14 txI /dALLASMajor cement procer manactres concretein mch o Texas an central Loisiana. TXIemployees helpe bil a home eatre onExtreme Makeover: Home Eition in October2009. www.txi.com

15 ceMentOS argOS /MedeLLiN, COLuMBiA

The u.S. makes p 34% o this procers bsi-ness. Its reatest concrete proction capacityis in the u.S., where it can proce 11.6 millionyars per year. www.aros.com.co

16 gruPO ceMentOS de chIhuahua /CHiHuAHuA, MexiCO

Reporte a oble-iit ecline in concrete,block, an areate sales in 2009. Reneoti-ate its ebt in May 2010 an reporte rowthin u.S. concrete an cement sales in this yearssecon qarter. www.cc.com

17 cLyde cOMPanIeS /OReM, uTAHAware a contract or a $2.7 million overpassconstrction project in Twin Falls, Iaho. This yearreoranize into two ivisions: heavy/hihway anspecial projects. www.clyeinc.com

18 u.S. cOncrete Inc. /HOuSTONFile or Chapter 11 bankrptcy protection

in April 2010, an reports plans to emererom bankrptcy by the en o Ast 2010.www.s-concrete.com

$101 Million To $500 Million

19 dunn cOnStructIOn cO. /BiRMiNGHAM, ALA.

Oriinally a railroa constrction company,dnn starte Mississippi Materials Co. (MMC)in 1927, now the larest reay-mixe concretespplier in Mississippi. MMC, an sbsiiaryBayo Concrete, serve the Sotheast u.S.www.nnconstrction.com

20 ItaLceMentI grOuP /NAzAReTH, PA.Transparent cement is a recent innovation o thiscompany, which has 39 concrete plants in North

America. The Italian Pavilion at the Shanhai Expowas bilt with this avance constrction mate-rial. www.italcementirop.com

21 VOtOrantIM /BRidGeView, iLL.A major player in Brazil, Votorantim has severalNorth American plants. In Feb. 2010, it bohtportions o Cimpor, Laare, an Cinveste. Itsaribsiness is one o the larest procers oconcentrate orane jice. www.votorantim.com

22 tItan aMerIca /NOROLK, VA.This sbsiiary o greek-owne Titan CementCo. is a leain cement an bilin materialsprocer in the Eastern u.S.; sbsiiaries in-cle Essex, Roanoke, Separation, an Tarmac.www.titanamerica.com

23 bOraL /ROSweLL, GA.Heaqartere in Astralia, this mltinationalcompany has extensive operations in the u.S.an Asia. This year, Boral was ranke #61 onCorporate Knightsmaazines global 100 list othe most sstainable companies in the worl.

www.boral.com

24 IrVIng MaterIaLS Inc. /GReeNieLd, iNd.

Spplies reay-mix in Iniana, Kentcky, Tennes-see, sothwestern Ohio, sotheastern Illinois, annorthern Alabama. Sbsiiaries incle Special-ties Company an E & B Pavin. www.irvmat.com

25 IMPuLSOra tLaxcaLteca /MexiCO CiTy

Focse on Mexican inrastrctre evelopment,this procer is Mexicos leain manactrero precast concrete strctres, constrction an

rehabilitation o railways, an concrete sleepers.www.itisa.com.mx

26 PaVeStOne /dALLASSince 1980, this company has manactresemental concrete procts or variosmarkets. The Pavestone Institte o HarscapeTechnoloy oers a crriclm in harscape

bsiness. www.pavestone.com

27 cardI cOrP. /wARwiCK, R.i.This hihway constrction company one in1900 provies concrete to Rhoe Islan an otherparts o New Enlan; also operates HopkinsHill San & Stone in Rhoe Islan. Procer wasaware ns to rerbish the Sakonnet Riverbrie portion o Rote 24. www.cari.com

28 cOunty MaterIaLS /MARATHON, wiS.A procer o circlar an elliptical concretepipes, alon with precast concrete procts, thiscompany has more than 30 Miwest locations.

www.contymaterials.com29 VIcat grOuP /STOCKBRidGe, GA.Joseph Vicat starte the French company in1853. Crrent projects incle fiht terminalsat Atlantas Hartsel-Jackson Airport ana hih-perormance concrete block hose.www.vicat.com

30 MetrOMOnt cOrP. /GReeNViLLe, S.C.Precast procer is plannin a new plant inFloria. In Jne 2010, CEO Rick Pennell wasname chairman o the boar or precast entity

Altsgrop Inc. www.metromont.com

irvngMateralsinc./

LucentPhotography

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27www.theconcreteproducer.com | August 2010 | The Cct Pdc

31 MeadOw VaLLey /PHOeNixThis heavy constrction contractor has beenproviin reay-mix to Las Veas an Phoenixsince 1980. Has been aware three utahdepartment o Transportation projects in thepast eiht months. www.meaowvalley.com

32 ceMStOne /MeNdOTA HeiGHTS, MiNN.Oers reay-mix, ecorative concrete, hih-per-ormance concrete, areates, concrete block,brick, an ecorative stone. Spplie ecorativeconcrete or the Minnesota Twins new TaretFiel. www.cemstone.com

33 LattIMOre MaterIaLS /MCKiNNey, TexAS

Fone in 1961. With acilities locatethrohot the state, LMC is a major concreteprocer in Texas; owns more than 400reay-mix an hal trcks. www.lmctx.com

34 VaLMOnt InduStrIeS /OMAHA, NeB.

Steel an spn concrete tility poles acconteor a thir o Valmonts 2009 revene. Saleswere own 13%, partly e to lower speninon transmission strctres by North Americantilities. www.valmont.com

35 gate cOnStructIOn MaterIaLSgrOuP /JACKSONViLLe, LA.The olest non-petrolem ivision o gatePetrolem proces prestresse concreteor inrastrctre, commercial, an instrialprojects throhot the Sotheast u.S.www.ateprecast.com

36 a&a ready MIxed cOncrete /NewPORT BeACH, CALi.

Alon with A&A Concrete Spply, the Caillieramily rns Associate Reay Mixe ConcreteInc. an Cemak Trckin Inc. They alsospecialize in onsite, portable batch plants.www.aareaymix.com

37 new enterPrISe StOne and LIMe /New eNTeRPRiSe, PA.

By mi-2009, NES&L an its sbsiiariesreceive nearly $34 million in eeral stimlsprojects. The rop perorme almost $9 milliono the work rin Jne an Jly. www.nesl.com

38 cOncrete SuPPLy cO. /CHARLOTTe, N.C.

In the past ecae, this procer has rownby acqisition an now has a stake in sevenlocal reay-mix an prestress procers. Nowoperates more than 30 plants in the Carolinas.www.concretespplyco.com

39 nebcO Inc. /LiNCOLN, NeB.Bean as the Abel Constrction Co. in 1908an expane to make reay-mixe concrete,concrete pipe, an block. The procer now hasan accont on LinkeIn. www.nebcoinc.com

40 cretex cOMPanIeS /eLK RiVeR, MiNN.Cretex Concrete Procts grop rew in Jne2010 when it acqire Concrete Procts oWyomin, a procer o reinorce concrete pipe

an precast procts. www.cretexinc.com41 aLLey-caSSetty brIck & bLOck /NASHViLLe, TeNN.

The concrete block procer bean as a smallretail coal bsiness in the 1880s; still operatesa commercial an instrial coal ivision, an atrckin ivision. www.alley-cassetty.com

42 hIgh cOncrete grOuP /deNVeR, PA.This precast procer promotes moresstainable precast, inclin the CarbonCastline o C-gRId carbon ber reinorce proctsan ECast with weiht-savin areates.www.hihconcrete.com

43 harPer InduStrIeS /PAduCAH, Ky.Operates in Kentcky, Tennessee, an Texas.Presient Billy Harper is a proessional racecarriver on the National an International Hot Ro

Association circits. www.harper1.com

44thOMaS cOncrete InduStrIeS /ATLANTA

Has or concrete laboratories an more than40 plants in georia an the Carolinas. Everyemployee mst complete Thomas Concrete

Acaemy, an in-hose concrete basic trainin.www.thomasconcrete.com

45 tIndaLL cOrP. /SPARTANBuRG, S.C.The precast/prestresse procers Conley,ga., plant receive a 2009 Enery Champion

Awar rom the u.S. department o Enery;one o only 47 plants in the u.S. to receive thereconition. www.tinallcorp.com

46 hOLLIday rOck /uPLANd, CALi.In 2009, spplie concrete or a $165 mil-lion San Bernarino I-10 restoration project.The procers rapi-set mix esin alloweserviceability within or hors o placement.www.holliayrock.com

47 ernSt enterPrISeS /dAyTON, OHiOThir-eneration, amily-owne reay-mix

procer also sells constrction materials

inclin nishin tools, rebar an wire mesh,

expansion joints, an concrete cres an seal-ers. www.ernstconcrete.com

48 fabcOn Inc. /SAVAGe, MiNN.Earne a saety awar in 2009 or operatin an

entire year withot a sinle workay lost e to

employee injry or illness in its Ohio operations.

Also has plants in Minnesota, Pennsylvania, an

Iniana. www.abcon-sa.com

49 cOntInentaL MaterIaLS cOrP. /

CHiCAGO

Holin company operates in two instries:

Constrction Procts an HVAC. Its Concrete,

Areates, an Constrction Spplies ivisionincles Castle Concrete an Transit Mix Concrete

in Colorao. Sol denver-base sbsiiary, Rocky

Montain Reay Mix Concrete, in Jly 2009.

50 Schwab InduStrIeS /dOVeR, OHiOOlcastle Materials boht Schwabs reay-

mix, block, an areates acilities in 2010:

Twin Cities Concrete, Qality Block an Spply,

an Meina Spply in Ohio an Schwab

Reay-Mix an Eastern Cement in Floria.

51 angeLLe cOncrete /JeNNiNGS, LA.Fone in 1947, Anelle has ry-batch plants

an cement terminals in soth-central Loisi-ana. Also operates as delta Concrete an SothLoisiana Cement. www.anelleconcrete.com

$51 Million To $100 Million

52 cLark PacIfIc /weST SACRAMeNTO, CALif.

The procers enineers an precast experts

specialize in architectral precast systems,

esin/bil parkin soltions, seismic tech-

noloical avances, an cstom architectral

nishes. www.clarkpacic.com

fabconinc.

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