Sustainability Report 2011

Transcription

The value
of knowledge
sustainability report 2011
contents
corporate sustainability
_methodology note
_corporate governance system
_stakeholders
performance indicators
_economic performance
Economic value generated and distributed
21
22
24
28
37
39
39
_environmental and social performance
Italy
Germany
Luxembourg
Netherlands
Poland
Czech Republic / Slovakia
Ukraine
Russia
usa
Mexico
46
48
66
78
88
92
100
110
120
130
144
_human rights
152
_ environmental and social performance:
charts and tables
156
gri content index
Self-declared Application Level gri g3
assurance statement
163
170
173
pany’s dedicated management has a long-term
view of the business and commitment towards
a sustainable development, supported by
high quality and environmentally friendly assets.
Buzzi Unicem pursues value creation through
lasting, experienced know-how and operating
efficiency.
vision
ready-mix concrete and aggregates. The com-
compliance declaration
“heavy-side” group, focused on cement,
Buzzi Unicem is an international multiregional,
2
the group at a glance
Key Figures
2005
Cement sales
Concrete sales
2006
2007
2008
2009
2010
2011
t / 000
32,245
33,320
34,067
32,093
25,548
26,570
28,216
cm / 000
15,649
16,542
17,096
16,996
13,893
14,379
15,066
t / 000
7,794
9,442
14,050
12,280
10,031
10,651
12,399
Sales revenue
Aggregate sales
€ m
2,951.4
3,205.0
3,496.1
3,520.2
2,671.8
2,648.4
2,787.4
Capital expenditures
€ m
243.1
254.0
527.4
853.3
389.9
268.2
156.6
Headcount at year end
no.
11,805
11,054
11,520
11,845
11,269
11,316
10,956
Sales Revenue by Line of Business
(in %)
Sales Revenue by Region
(in %)
3
8
9 10
1
7
6
2
2011
2011
5
2
1
4
3
1
Cement and clinker
61
1
Italy
20
2
Ready-mix concrete and aggregates
38
2
usa
20
Related activities
1
3
Germany
22
4
Mexico
8
5
Czech Republic and Slovakia
6
6
Poland
5
7
Russia
6
8
The Netherlands
4
Luxembourg
4
Ukraine
4
3
9
10
Sales Revenue
(in million of eur)
(in million of eur)
2005
2,951.4
2005
243.1
2006
3,205.0
2006
254.0
2007
3,496.1
2007
527.4
2008
3,520.2
2008
853.3
2009
2,671.8
2009
389.9
2010
2,648.4
2010
268.2
2011
2,787.4
2011
156.6
the group at a glance
International presence
russia
usa
the netherlands
germany
luxembourg
poland
ukraine
czech republic
s lovakia
mexico
italy
algeria
italy
Buzzi Unicem, Unical, Cementi Moccia (50 %), Laterlite (33 %), Addiment Italia (50 %)
germany
Dyckerhoff, Deuna Zement, Dyckerhoff Beton
luxembourg
Cimalux
the netherlands
Dyckerhoff Basal Nederland
poland
Dyckerhoff Polska
czech republic
and s lovakia
Cement Hranice, zapa beton
ukraine
Volyn-Cement, yugcement, Dyckerhoff Ukraina
russia
Sukholozhskcement
usa
Buzzi Unicem usa, Alamo Cement, Kosmos Cement (25 %)
mexico
Corporación Moctezuma (50 %)
algeria
Société des Ciments de Hadjar Soud (35 %), Société des Ciments de Sour El Ghozlane (35 %)
Operating structure
ita
Cement plants
of which grinding
Cement capacity
ger
lux
nld
pol cze / svk
ukr
rus
usa mex ¹
Total
no.
14
7
2
–
1
1
2
1
8
3
no.
3
2
1
–
–
–
–
–
–
–
39
6
Mio t / yr
10.8
7.2
1.4
–
1.6
1.1
3.0
3.6
9.5
6.3
44.5
558
Ready-mix batch plants
no.
160
129
–
16
30
82
6
–
78
57
Aggregate quarries
no.
14
3
–
2
–
10
–
–
6
2
37
Terminals and deposits
no.
6
–
–
–
1
–
3
–
31
–
41
ita / Italy, ger / Germany, lux / Luxembourg, nld / The Netherlands, pol / Poland, cze / Czech Republic, svk / Slovakia, ukr / Ukraine, rus / Russia,
usa / United States of America, mex / Mexico
¹ figures at 100 %
3
4
introduction
Pietro Buzzi
Michele Buzzi
In the countries in which we operate, factories have always been an important reference
point for the economic and social life of the nation. A place where the added value
originating from the transformation of material is appreciated also in terms of long-term
social aggregation. In some Western countries, the charm of hyper real products, financial assets, the concept of making money from money, may tempt some into denaturalizing the origins of our work, thus decreasing the pride associated with it.
In order to prevent this from happening, we preserve and take forward our corporate
knowledge, which we consider the base of our company’s success. The management and
passing on of the corporate know-how ensure that we always improve on what we know
how to do best.
We believe that the ability of transferring to the work group what has been learned through
the work experience constitutes a huge wealth for those leading a project, particularly
if the experience is transferred not only from project to project but also from one country
to another. This is the key to reading the Sustainability Report 2011: for our company,
“cross fertilization”, i. e. the flexibility and mutual sharing of experience, is a sign of great
professionalism and represents the desire to grow and learn together, sometimes accepting very challenging tests.
As for the past editions, we believe that this report must be viewed as a working tool
from which to draw conclusions on our working method and measure our objective of
continuous improvement.
On this point, it is worth mentioning how the investments have led to reductions in emissions per ton of clinker in the three years at group level, respectively of:
NO x − 7 %
SO x − 30 %
Dust − 25 %
Particularly important is the data from the USA, where we record a decrease of 35 % for
5
introduction
respectively, and Poland with a doubled heat replacement.
But there is more.
With improvements in mind we redesigned the structure of the report, reorganizing it to
present the data divided by country, preserving the accuracy and transparency of the
information.
We have a strong and constant commitment to optimizing our work while respecting the
SO x, Russia and Luxembourg, where we recorded a reduction in NO x of 56 % and 30 %
The Sustainability Report 2011 wishes to focus on a priceless asset: the in-house sharing
of professional experience that accompanies us in our growth, as a company and as
people.
PIETRO BUZZI
MICHELE BUZZI
chief executive finance
chief executive operations
environment and providing support to the communities which host our plants.
6
the value of knowledge
The value of
knowledge
innovation
Target: exchange know-how and
innovation.
erfahrung
The experience and solutions
consolidated inside the group
ensure long-lasting results.
costruire
Different cultures: new strengths.
інновація
The strength of team work.
experiencia
Experience, open mindedness and
sharing objectives.
строить
Build a group identity and
technological know-how.
7
8
lengerich, germany
Innovation
target: exchange know-how
and innovation
The Yugcement cement plant is near the town of Nikolaev,
in the South of Ukraine. The plant has a production
capacity of 1 m / t of cement a year. The new coal mill has
enhanced the plant and improved its competitively.
9
olshanske, ukraine
Інновація
the strength of team work
The Lengerich facility was erected in 1872 and has
belonged to the Dyckerhoff group since 1931.
The plant has a capacity of 1.8 million tons and is
among the first in Germany in terms of size and
modern facilities.
10
a perfect example
of effective and winning
teamwork at an
international level
When the spirit of cooperation among the various group sites exceeds the value of
pure technological know-how.
In 2007 I was sent to Dyckerhoff Ukraine LLC to cover the
This is an essential added value in a context where local
post of technical director, armed with thirty years of
legislation obstructs this type of project, especially
experience in the cement industry acquired as operations
with regard to environment-related aspects (e. g. using
manager and production director in Germany and Russia.
secondary fuels in the burners), and where equivalent
legislation is often completely lacking.
By working as a team on various project, it is easy to learn
from one another, making reciprocal use of the experi-
As often happens, the small steps make the difference.
ence gained by each member. However, the experience
The success of a company is not only determined by the
in Ukraine taught me that teamwork knows no limits.
use of ever newer technologies: the greatest potential
is in its human resources and intercultural understanding,
While we were installing more modern and efficient coal
in harmony with a world that is constantly growing
mills and burners in the Volyn-Cement and Yugcement
smaller.
plants, my Polish colleagues, at the site of Nowiny, were
instructing the Russian operating personnel on using
the technology necessary to operate the upgraded plants.
All the people coming from the Czech site of Hranice, the
Polish site of Nowiny and the German site of Geseke
actively contributed by providing their utmost and excellent support, despite the work overload at their own
plants. So I learned that to get results, you must also overcome the linguistic barriers and consider different cultures.
11
innovation
lengerich, germany
kiev, ukraine
small steps make the difference
The effective transfer of an assignment overseas represents
an essential component in corporate strategies.
karl-heinz kasch,
technical director,
kiev, ukraine
Joined the group in 1981 as Area Operations
Director in the plant of DeunaZement GmbH and
was operations director until 1998.
From 1998 to 2007 he was Production Director at
the plant of Lengerich and since 2007 he has
been Technical Director of Dyckerhoff Ukraine.
12
wiesbaden, germany
Erfahrung
the experience and solutions
consolidated inside the group
ensure long-lasting results
The group has been working in Mexico since 1981, through
Corporación Moctezuma. The company has 3 modern
and efficient cement plants. The first is located in the municipality of Tepetzingo, the second in the center of the country (San Luis Potosí) and the third in the state of Veracruz,
and was inaugurated at the end of 2010.
13
cerritos, mexico
Experiencia
experience, open mindedness
and sharing objectives
Established 145 years ago in Amöneburg, in the district of Wiesbaden, by Wilhelm Gustav Dyckerhoff
with his sons Rudolf and Gustav, today the building
serves as the headquarters of the Dyckerhoff group.
In Wiesbaden the employees of the entire group participate in international projects.
14
experience is nothing without
the right mental attitude
and the willingness to share.
Methodological excellence needs fine tuning to be applied to contexts other than
those already tried and tested.
In 2006 I was transferred from the German site of
cultures and mentalities cooperated (there are Mexicans,
Dyckerhoff to the Cementos Moctezuma plant in Mexico,
Brazilians, Argentinians, Italians and a German); sec-
in my capacity as technical director responsible for the
ondly because it would have been wrong to forcefully trans-
plants of Apazapan, Cerritos and Tepetzingo – all equipped
fer an organizational structure that worked perfectly
with state-of-the-art technology, including Horomill
in an individual country (in this case Germany).
mills for energy efficiency.
To find solutions that suited the Mexican plants we had
My presence was useful to optimize the production pro-
to fully collaborate, drawing from our ability to adapt
cess and the operating sequences inside the plant
and understand the mentality and proposals of the respec-
as well as to identify and solve any maintenance issues.
tive cultures.
We analyzed the organizational structures to then sensibly
Today – back in Europe as technical director and member
re-engineer them together with the colleagues. The
of the BoD of CIMALUX s. a. in Luxembourg – I am
experience gained as operations director and maintenance
aware that experience is a precious universal value that
and production director in Göllheim and Amöneburg
does not depend on the culture or type of mentality;
proved to be highly useful.
nevertheless, it is not sufficient to provide a solid contribution to the foreign sites, where an open mind and
In Göllheim, in particular, we had implemented a new
methodology that gave priority to the maintenance process,
canceling the startup times and introduced the supply of spare part materials able to increase efficiency.
However there is no handbook for modifying a different
plant. Firstly because at the Mexican plants various
lots of flexibility are also needed.
15
experience
wiesbaden, germany
combining knowledge and experience
To solve some problems, firstly it is worth using all
the experience and solutions consolidated inside
the group, benefiting from the wonderful combination
of knowledge and experience.
uwe benedikt,
technical director and board member,
esch-sur-alzette, luxembourg
After significant experience in the engineering
sector from 1996 to 2004 he was Operations
Director at the Göllheim plant. From 2004 to
2006 Production Director in Amöneburg and
from 2006 to 2011 Technical Director at Cementos Moctezuma in Mexico. Since 2012 he has
been the Technical Director and member of the
Board of Directors of Cimalux.
cerritos, mexico
16
casale monferrato, italy
Costruire
build a group identity and
technological know-how
The Suchoi Log cement plant has been part of the
group since 1994 and has always been a site
to exchange international technical know-how. The
plant is also specialized in the production of
special cement for the consolidation of oil wells.
17
suchoi log, russia
строить
different cultures: new strengths
The Buzzi Unicem group has about 11,000 employees worldwide: cultural differences and the continuous exchange of
ideas are an important growth element for the company and
a significant strength.
18
discovering russia:
intercultural relations
as a growth factor
A proposal almost made by chance that quickly turns into a business featuring
radical changes and experience.
“Good morning Sir, I often hear you talk about Suchoi
get to know the machinery of this new plant and, espe-
Log: do you need someone to go to Russia? I would like
cially, familiarize with the people who manage it: now I am
to be taken into consideration …” It all started like this,
part of an international team of Russian and German
with a sudden question to Sandro Buzzi, while he was
engineers and I work in fully cooperation, gaining their
visiting the experimental plant of Sommariva Bosco.
vast experience.
I did not get an answer straight away.
I can say that the initial objective has still not been 100 %
Tiziana and I got married on August 15, 2009, and 11
first results of my commitment, mainly thanks to all of
achieved; I think I have taken the right path to get the
months later we left for Ekaterinburg, capital of the Ural
those who live with me the reality of this project. I
mountains, in southern Siberia. And then another 120
would like to thank my wife Tiziana: without her I would
km of countryside and forests to reach Suchoi Log, where
have never found the courage to leave.
there is the cement plant with the newly built production line. We had finally arrived in Russia: what now? A
Finally, I would like to remember the answer Mr. Buzzi gave
new life for starters. A year has already gone by and
me, while, at the end of that visit in Sommariva, he
it is difficult to summarize in a few lines the stages of the
shook my hand: “Ah, Raiteri! We will talk about Russia …”.
radical change.
For a Jack London-style dreamer like me, an entire book
would not suffice. Certainly getting used to this new
situation has been very testing and has required a great
strength of character, I would say a true desire to “start
over”. I am a cement plant technician and my task was to
19
construct
casale monferrato, italy
suchoi log, russia
strengths
Build new projects, exchange experiences with
international teams, create cooperation: the strengths
of our group.
giuseppe raiteri,
quality engineer,
suchoi log, russia
Having gathered significant experience as production manager in various companies,
Giuseppe Raiteri joined the group in 2004 as
Mechanical maintenance manager at the
plant of Robilante. To date he covers the role of
Quality Engineer at the plant of Suchoi Log
in Russia.
20
21
Corporate Sustainability Process
contents
_methodology note
_the corporate governance system
_stakeholders
22
24
28
22
methodology note
Detail of the kiln, Chattanooga plant, usa
Methodology Note
fication of greenhouse-gas emissions pursuant to the
directive 2003 / 87 / CE of the European Parliament and
Council and by Resolution 14 / 2009, which establishes
The Buzzi Unicem group’s 2011 Sustainability Report
the rules for implementing the Commission’s Decision.
presents the social, environmental, and economic performance associated with the group’s activities in the vari-
Reporting system
ous countries where it operates. It follows the approach
Data collection was supported by a structured process to
established during the last few years. The Report’s
gather facts and figures based on a reporting package
content and publication schedule are in line with last year,
sent by each area head in the Corporate task force (Buzzi
based on a rationale of continuity, while in this edition
Unicem SpA) to their direct contacts in the various
the structure has been changed by integrating consoli-
countries.
dated information with the specific chapters for each
country where the group works.
Reporting process
Our 2011 Sustainability Report is the result of a structured
Relevant guidelines
process performed by a task force set up at Corporate
The 2011 Sustainability Report of the Buzzi Unicem group
HQ level and formed by various functions representing a
has been prepared according to the Sustainability Re-
cross-section of all areas connected with the group’s
porting Guidelines of the Global Reporting Initiative (GRI)
social, environmental, and economic reporting, working
g3, at application level A +. For the calculation of green-
without aid of outside advisors. Starting in November,
house-gas emissions of the group’s Italian cement factories
with official announcement by the CEO to the entire group
included in the Emissions Trading System, we applied
of the 2011 Sustainability Report project, the task
the criteria established by the Commission of the European
force defined the information approach to be used (the
Community’s Decision 2007 / 589 / CE of 07 / 18 / 2007,
Sustainability Reporting Package) and the key country
which sets out the guidelines for the monitoring and noti-
contacts to be involved for data gathering. The reporting
methodology note
packages received by individual area managers of
Balance – Data is shown objectively and systematically,
Italian and international companies were then collected
based on an information approach applied over the years
and consolidated by tasks force members for their
and steadily improved. The indicators used to show
respective areas of responsibility.
the results are based on measurements of performance in
23
The facts and figures shown in the Sustainability Report
ods.
refer to all companies included in Consolidated Accounts
on a line-by-line basis active in the production of cement
Comparability and Clarity – In order to make the report
and concrete and that have a significant social and /or envi-
simpler to read and distribute it to the various coun-
ronmental impact.
tries, we have organized it differently from last year. This
edition of the report presents the sustainability perfor-
In addition:
mance subdivided by each country where the group works.
_ All data refers to the period between 1.1.2011 and
Where relevant, this is compared with the group’s per-
31.12.2011,
_Q
uantitative environmental and social data has been
formance and the trends of previous years. Any significant
variation is also explained in the text. Tables and charts
100% consolidated and not accounting to the propor-
without comparative data refer to indicators whose com-
tionality of ownership.
parison time span is not meaningful or to new indica-
_ The economic data originates from the Annual Financial
Report.
_ The reporting boundary of the Sustainability Report
includes the subsidiary company Corporación Monte-
tors for which it was not possible to retrieve prior years’
data. Application of the Global Reporting Initiative
model also permits comparison with domestic and international organizations that use the same model.
provement or deterioration compared with previous peri-
the period regardless of whether there has been imReporting boundary
accounts. The company has been included because it
Accuracy – Data has been checked by the various area
is considered significant in terms of sustainability
managers of our Italian and international companies,
impacts as per the GRI Boundary Protocol.
who, in turn, co-ordinated the individuals involved at the
_ Any exceptions to the reporting boundary are stated in
the individual sections.
factories. The “Group Profile” and “Economic Performance” sections of the report have been prepared using
the same data forming the group’s consolidated finan-
Reporting principles
cial statements, which are prepared in compliance with
The reporting principles applied to prepare the 2011
International Financial Reporting Standards (IFRSS ).
Sustainability Report refer to the GRI guidelines mentioned
above, which are indicated below:
Timeliness – The publication timing of the 2011 Sustainability Report and of the Annual Report is aligned; both
Inclusiveness, Materiality and Sustainability Context –
documents are presented at the Annual General Meeting
For each type of Stakeholder we have identified the rela-
of Shareholders.
tionships established and engagement actions (see the
Stakeholders section). The document also illustrates the
Reliability – The Sustainability Report has been approved
group’s main social and environmental impacts relevant
by the Board of Directors and subjected to outside
for the stakeholders concerned. The information gathered
independent verification by PricewaterhouseCoopers. The
has been organized by geographic area consistently
purpose of such verification is to check compliance
with the group’s characteristic multi-regional organiza-
with the reporting principles specified in this chapter,
tional system.
including the conclusion concerning the stated level
of application of GRI G3 guidelines.
Completeness – see Reporting Boundary section.
zuma which is proportionally consolidated in group
24
the corporate governance system
Mercedes-Benz Museum, Stuttgart – Germany, created with Dyckerhoff cement
The corporate governance
system
Organization of the parent company and the subsidiary
Dyckerhoff
In compliance with Italian legislative requirements
for listed companies, the organization of parent company
Buzzi Unicem S. p. A consists of:
The corporate governance system
_ a board of directors responsible for corporate manage-
As at December 31, 2011, the Corporate Governance sys-
ment: currently the B. o. D. consists of 5 executive and
tem in the parent company Buzzi Unicem S. p. A. was
8 non executive directors, of which 5 are independent;
in line with the recommendations made by the CONSOB
in 2007 the Internal Control Committee was set up –
(the Italian securities & exchange commission) and
consisting of 3 directors, the majority of whom indepen-
oriented towards the principles contained in the Italian
dent – who are assigned the tasks envisaged by the
Corporate Governance Code for listed companies and,
Italian Corporate Governance Code;
more generally, with the best practices at national and
_ a Board of Statutory Auditors;
international level.
_ the Shareholders’ Meeting.
Voluntary instruments, such as for example the Antitrust
The Dyckerhoff subsidiary is subject to the German Stock
Code, are applied in the group companies, including
Corporation Act, by virtue of which it has a dual man-
the foreign companies. Instead the tools which refer to
agement and control structure, consisting of 4 members
the legal provisions conform to the provisions in the
of the Board of Management (B. o. D.) and 9 members
various legislative contexts.
of the Supervisory Board, of whom 6 are represented by
shareholders and 3 by employees. The Supervisory
Board has issued procedural rules for conducting business
and has set up 2 committees:
Transactions with related parties
specifically provides guidance to be followed Plant,
The Board of Directors, in compliance with the provisions
City, Country for the matters concerning accounting and
of Consob Regulation no. 17221 / 2010 and subsequent
risk management;
amendments, adopted, subject to the unanimous opinion
_ Executive Committee (consisting of the President and
expressed by a Committee of independent directors, the
another 2 members of the Supervisory Board), which
“Procedures for transactions with related parties”, aiming
handles recruitment, dismissal, pension agreements and
to ensure the substantial and procedural transparency
matters associated to the Board of Management, and
and accuracy of the transaction with related parties. These
guides the Supervisory Board concerning management
procedures are applicable to transactions planned start-
remuneration.
ing from January 1, 2011.
Internal control system
Management of confidential information
The Board of Directors holds ultimate responsibility for
The Board of Directors has approved a “Market abuse
the Internal Control system.
and privileged information manual”, aiming to create a
dossier of the procedures and the practices followed
The company has set up the Internal Auditing function
in the group with reference to the external disclosure of
with the task of checking the constant compliance of
corporate documents and privileged information.
_ Finance Committee (consisting of 3 members), which
25
established to assure a prudent and efficient manage-
Internal Dealing
ment and protection of the company assets. The Board of
The Board of Directors has adopted an Internal Dealing
Directors appointed an Internal Control Manager, in
Procedure. In compliance with the law and regulations
the person of the Internal Auditing manager, who does not
on the subject, the procedure is designed to govern opera-
report on a line basis to any operational area managers
tive procedures for the respect of notification obliga-
and reports to the directors and auditors.
tions. Such obligations are incumbent on Relevant Persons
in relation to the transactions carried out on the shares or
For international operations, in 2006 the Internal Audit
other associated instruments of the Buzzi Unicem group’s
Committee was established, consisting of Buzzi Unicem
listed companies.
and Dyckerhoff Internal Auditing managers.
Code of Business Ethics
In 2008, in the most important subholding companies
The group’s main Italian companies have each adopted
(USA, Mexico, Russia and Ukraine), we set up specific
a Code of Business Ethics that expresses the commitment
Decentralized Audit Departments (DAD) consisting of one
and ethical responsibilities in doing business, regulating
or two people.
and unifying corporate conduct on transparent and accurate standards towards the stakeholders.
These units report hierarchically to the local top management of the subholding companies but functionally
The Code of Business Ethics adopted is bought to the
answer to the Internal Audit Committee consisting of the
attention of and is applied, where compatible, to the rep-
two Internal Auditing managers.
resentatives, assignees, agents, associates, external
consultants and companies that act in the name of and on
both operational and administrative internal procedures
26
the behalf of or who receive an assignment from the com-
As part of the internal control & audit system, our cor-
pany. Buzzi Unicem’s Board of Directors, on 11.11.2011
porate risk management approach takes the concrete form
approved the adaptation of the Code of Business Ethics to
of a 6-monthly procedure of risk inventory taking con-
the new cases of offence (environmental offences) in-
trol and reporting. In the periodical reporting, the ratio is
troduced in August, in the sanction system of Leg. Decree
considered between the combination of all risks man-
231 / 01 (art.25 undecies).
aged, i. e. the residual risk amount, and the group’s shareholders’ equity, providing the creation of an overall risk
Organization, Management and Control Model
strategy, known and accepted.
Given the need to ensure accurate and transparent conditions in the conduction of the business and corporate
Antitrust Code
activities, to protect its standing and image and that of the
In 2011 the Board of Directors approved the updating
subsidiaries, the shareholders as well as its employees,
of the “Rules of Conduct for group employees to ensure
Buzzi Unicem S. p. A. deemed it useful for its corporate
compliance with antitrust regulations”.
policies to adopt the Organization, Management and
Control Model foreseen by Legislative Decree 231 / 2001.
Code of Conduct
The Model was approved by the Board of Directors in
the standards of conduct to be applied by personnel.
March 2003 and is constantly updated in order to absorb
The Board of Directors reviewed the Code and sent it in
the new presupposed offence cases and identify the
8 different languages to all the group employees.
The parent company has prepared a document spelling out
related sensitive processes.
Subsidiaries’ management has been made especially aware
The Supervisory Board was identified in the Internal Audit-
of the importance of the Code and its observance by
ing department of the parent company. This Board has
their respective organization. Observance of the code is an
the task of supervising the effective operation and obser-
essential part of the contractual obligations and of the
vance of the Model and promotes and deals with its
commitment and duty of Buzzi Unicem group employees.
updating.
The chief Italian subsidiaries adopted their own Organization Model and also identified the Internal Auditing of
the parent company as the Supervisory Board.
Risk Management
The Buzzi Unicem group has a Risk Management system
that is administered by the Internal Auditing department. The risk management system involves the Board of
Directors, management, and staff with the aim of identifying contingencies that might hit the companies, managing risk within certain limits, and therefore of providing reasonable assurance of achieving corporate objectives.
27
28
stakeholders
Workers working at the factory of Amöneburg – Germany
Stakeholders
Furthermore, orders are accompanied by a letter relating
to the Code of Business Ethics that the Supplier must
return to the l. p. d. duly signed to indicate acceptance.
Suppliers
Supplier selection takes place based on the technical and
The organizational excellence of production depends on
economic competitiveness of bids, together with the
efficiency throughout the supply chain. For this reason
reputability and soundness of the companies concerned,
we build a reciprocally supportive relationship with our
once again with a view to building long-lasting and
suppliers, based on quality, trust and duration.
legally compliant relationships.
Selection
If prospective suppliers have not been previously screened
Selecting suppliers / partners not only focuses on satisfy-
and are not present in the corporate approved supplier
ing contractual requirements but also on sharing the
register, it is l. p. d.’s task to acquire all the documentation
company values which inspire our group. This is achieved
to include them in the register, available at each Pro-
via the circulation of the Code of Business Ethics,
duction Unit / Concrete Area.
adopted by our parent company to make all internal and
external stakeholders aware that the conduct must be
After receiving a request for execution of a contractor
correct and transparent.
job, the l. p. d. screens the bids and manages commercial
negotiations with suppliers.
In Italy it is the Logistics and Purchasing Division (l. p. d.)
that informs all the Suppliers accordingly, stating in
In compliance to art. 26 of Italian Leg. Decree 81 / 2008,
each order that the Code of Ethics is available on the cor-
bids always explicitly indicate safety costs.
porate web site* and specifying that this equates to
confirming the vision by the same supplier.
The group’s philosophy has always been to pay special
ees’ awareness to environmental issues.
attention to businesses operating locally, close to the
factories. In 2011 local suppliers exceeded 35 % of the
With a view to increasingly optimizing the management
total.
of purchasing processes, at the end of 2011 a new
application was developed, called ‘I-Procurement’, which
When the supplier relationship has to be managed and
complements the ‘Purchasing’ package by ensuring
developed over time, an assessment of suppliers is per-
the opportunity for facilities to obtain supplies fully inde-
formed every two years, care of our local organizations.
pendently via electronic catalogues.
This assessment aims to select those suppliers who pro-
The implementation represents an effective production
vide added value.
environment that will bolster the strategic alliances of
the company with its suppliers, highlighting new cooper-
We also prefer companies with OHSAS 18001, ISO: 14001
ation solutions.
certificates or EMAS registration and we ask those who
do not have these to provide precise clarifications based
The new applications aim to ensure the compliance of the
on an extensive series of questions concerning environ-
corporate purchasing policy, the automation of the
mental matters and safety and quality management, en-
related processes and to develop professionalism in the
couraging them to comply with the certification require-
figures involved.
ments.
When the implementation process of the I-Procurement
In addition, we pay special attention to the use of recy-
application is completed, the indirect costs will be
clable packaging, optimization of logistics, reduction,
National and local suppliers (Italy)
2011 Spending ratio local / total
2
84.6
69.4
80
87.2
96
95
96
100
58
60
1
0
ita
8.1
22.8
20
35.2
40
usa
ger
lux
nld
pol
cze
ukr
rus
mex
1
National suppliers
64.8
63.5
2
Local suppliers
35.2
where possible, of noise pollution and building employ-
Assessment and loyalty-building over time
29
stakeholders
30
stakeholders
notably reduced for supplies through the automation of
Customers
the purchasing process and the reduction of the supplier base, through a rationalization by geographic area.
To win and retain market confidence, the group is
committed to ensuring that the quality of its products
Lastly, as the duration of the supplier relationship is very
and services meet the highest standards of excel-
important for our approved suppliers, we apply 2-year
lence, in all respects.
or 3-year contracts.
Buzzi Unicem’s customers may count on an extensive
series of activities undertaken to ensure that they are fully
and uniformly satisfied.
Besides the after-sales assistance phase described in
the UNI EN ISO 9001 2000 standard, in Italy we have introduced a further procedure designed to provide customers with a fully comprehensive and precise flow of information over time and open to dialogue and discussion.
The procedure includes data, updates, technical support,
invitations to take part in laboratory or industrial tests,
and assistance in the event of any disputes arising between
customers and end-users of their services.
In particular, for any need relating to the use of products – from practical procedures to checking on performance, and from any complaints to legally required
information – the customer has our Technical Assistance
Service at its disposal, which provides the required
support with the necessary timeframe.
In parallel, the r&d department continually identifies –
based on the suggestions from management’s direct and
constant exchange of ideas with the commercial area –
innovative and alternative solutions best suited to meet
the requirements and address the criticalities of a constantly changing market.
Buzzi Unicem market capitalization (ordinary and savings
downward trend and in any many cases reaching new
shares) as at December 31, 2011 was tangibly lower
lows. At the beginning of the year the market seemed to
than at the close of 2010 (– 23.8 %). In the same period,
have started to rally; however, the positive signs were
the main index of the Milan Stock Exchange, the FTSE
short lived, overwhelmed by fears concerning the sover-
MIB, featured a similar trend, with a decrease of 25.2 %.
eign debt crisis and the strength of the euro zone. The
The volumes traded dropped (– 19 % on the previous
price of Buzzi Unicem shares was therefore affected, espe-
year). The average trading value was expected at 8.40 euro
cially in the second half, by the slowdown in global
per ordinary share (8.97 euro in 2010) and 4.70 euro
trade, the cooling of the production activities, particular-
per saving share (5.41 euro in 2010). In the first months
ly in the euro area, and the growing uncertainties for
of 2012 the listing of our stock began to grow with a
economic development, caused by the consolidation of
good pitch; we are sure it is a trend based on more solid
the public spending and the difficulties in supplying
recovery prospects and not a technical blip. The com-
credit to the economy by the banking sector.
pany, as already in the previous two years, deemed it important to ensure a minimum level of remuneration to
From an operational point of view the year featured a
its shareholders in the form of dividend. In 2011 the insti-
two-speed development: accelerated cement consumption
tutional investors holding a percentage of shares ex-
in Central Europe and especially in Eastern Europe on
ceeding 2 % increased their weight within the share cap-
the one side, the prolonged slow recovery in the USA and
ital. The majority shareholder also increased its per-
the sudden drop in Italy on the other.
centage in the capital of Buzzi Unicem. At year end 25 %
Price trend of Buzzi Unicem shares
(Base January 2004 = 100)
380
360
340
320
300
280
260
240
220
200
180
160
140
120
100
80
60
40
20
2005
2006
2007
2008
2009
Ordinary
2010
Savings
2011
ftse Italia All-Share index
In the financial markets pessimism prevailed and the
2011 was another volatile year for share prices, with a
Shareholders
31
stakeholders
32
stakeholders
Trading in Buzzi Unicem shares
Ordinary shares
Savings shares
Ordinary shares
Number
Number
€ mn
€ mn
85,769,049
28,311,046
1,045.5
252.9
Annual period of reference
2005
Savings shares
2006
100,899,098
32,479,343
1,850.5
398.8
2007
168,024,567
21,128,085
3,635.8
319.3
2008
217,560,057
31,688,570
3,194.2
321.5
2009
278,784,704
53,467,061
2,960.0
308.9
2010
365,608,536
31,748,299
3,277.7
171.9
2011
303,044,199
20,525,035
2,546.1
96.4
of the ordinary capital was held by foreign investors.
To encourage frequent contact with small shareholders,
financial analysts and institutional investors, the
group uses an Investor Relations office. There are many
communication channels that often involve the top
Key per-share data
2005
2006
2007
2008
2009
2010
2011
Basic eps (ordinary)
1.31
1.77
2.23
1.92
0.67
(0.31)
0.12
Diluted eps (ordinary)
1.26
1.71
2.23
1.92
0.67
(0.31)
0.12
Cash flow per share
2.67
3.14
3.64
3.39
1.90
1.68
1.44
Shareholders’ equity per share
9.67
10.63
10.95
12.14
12.16
12.48
13.81
10.1x
12.1x
8.5x
6.0x
16.8x
n / a
56.3x
euro
Price / earnings ratio
Price at year-end
ordinary shares
13.16
21.45
18.93
11.58
11.28
8.62
6.75
savings shares
9.17
14.56
12.51
6.57
7.24
5.36
3.37
ordinary shares
0.32
0.40
0.42
0.36
0.18
–
0.05
savings shares
0.34
0.42
0.44
0.38
0.20
0.03
0.05
ordinary shares
2.4 %
1.9 %
2.2 %
3.1 %
1.6 %
–
0.7 %
savings shares
3.8 %
2.9 %
3.5 %
5.8 %
2.8 %
0.6 %
1.5 %
Dividend per share ¹
Yield
¹ 2011: proposed to shareholders at the Annual General Meeting
on site meetings, periodic presentations to the financial
community, road shows at the main financial stock
exchanges.
Main shareholders
at 31 December 2011
Ordinary
shares
% of total
share capital
% of ordinary
share capital
Presa S.p.A. (Buzzi family)
79,200,000
38.44
47.90
Fimedi S.p.A. (Buzzi family)
17,750,000
8.61
10.73
ubs ag ¹
4,842,536
2.35
2.93
Platinum Investment Management Limited
3,344,212
1.62
2.02
¹ of which 4,769,311 shares in the capacity of lender without voting rights.
management of the company: telephone conferences,
33
stakeholders
below:
March
Roadshow – Cheuvreaux
Paris
April
Institutional Investors Meeting – Unicredit
Milan
May
Annual General Shareholders’ Meeting
Casale Monferrato
May
Roadshow – Deutsche Bank
Frankfurt
July
Building Seminar – Credit Suisse
London
September
Roadshow – Mediobanca
Stockholm and Copenhagen
October
Pan European Building Conference – BoA Merrill Lynch
London
November
Roadshow – Equita
New York
December
Institutional Investors Meeting – Fidentiis
Milan
The main events taking place in 2011 are summarized
34
stakeholders
Local communities and their environment
Staff
We dedicate a significant portion of our resources
In this edition we aimed to value the aspects that are
to integrate our activities with the areas and communi-
usually tackled in the previous editions, subdivided
ties surrounding our production sites, in order to
by individual country where we work.
constantly and increasingly reduce the social and environmental impact of our business.
Hence, the management of diversity, the balance between
work and family life, staff incentive programs, career
The particular type of activities carried out in our facto-
training and development, employee participation, safety
ries means that Buzzi Unicem has a direct relationship
in the workplace and collective bargaining, has been
with the surrounding area and environment, the respect
analyzed nation by nation.
of which, over the years, had gradually changed from
being an obligation to become a strategic asset.
In short, we may say that in Europe the practices are
homogeneous with attention on the family problems, favor-
The entire life of a plant, from its construction to full oper-
ing part-time formulas, especially at headquarters and
ation, features extensive use of all technologies avail-
administrative offices and time flexibility, in particular for
able to mitigate and offset its environmental impact, being
female staff.
mindful that the aim of this effect, over time, is to
achieve a positive return in terms of participation in local
Training is valorized throughout the group, with Russia
social and economic life.
and Ukraine recording the highest average number of
training days (18 Russia and 5 Ukraine with a group aver-
Thus the group works hard to:
age of 4 days pro capita between external and internal).
_ stimulate management of the various establishments to
exploit our background of globally shared know-how,
Also safety in the workplace with no fatal event in the
making itself available to support all worthwhile initia-
group in 2011 and intensive and pervasive training pro-
tives having constructive and socially supportive aims.
grams are a priority.
_ Maintain a continuous dialogue with all stakeholders,
particularly institutions, opinion groups, trade unions
Concerning collective bargaining, in Europe (all) it is ex-
and the civil community.
tended and frequent to all the levels of the cement
_ Support the social life of manufacturing locations with
focused actions that enables communities to gain
industry, almost absent in the concrete sector, in particular in the Czech Republic and Slovakia.
tangible benefits from Buzzi Unicem’s presence in their
area.
Also in the USA it is frequent and articulated in Buzzi
Unicem USA, totally absent in Alamo, Texas.
The “Portland” section of our website www.buzziunicem.it
illustrates the relationship between the group, the
environment and local communities in greater depth.
stakeholders
35
36
37
contents
_e conomic performance
39
_environmental and social performance
Italy
Germany
Luxembourg
The Netherlands
Poland
Ukraine
Russia
usa
Mexico
46
48
66
78
88
92
100
110
120
130
144
_human rights
152
_e nvironmental and social performance:
charts and tables
156
Performance indicators
38
economic performance
Cement Plants Location
as of December 31, 2011
europe
lengerich
geseke
deuna
amöneburg
neuss
neuwied
esch-sur-alzette
rumelange
rivne
göllheim
riva del garda
trino
robilante
vernasca
hranice
cadola
sorbolo
settimello
manfredonia
barletta
caserta
siniscola
hadjar soud
nikolajev
travesio
guidonia
sour el ghozlane
nowiny
augusta
russia
usa / mexico
stockertown
selma
pryor
maryneal
greencastle
cape girardeau
chattanooga
suchoi log
san antonio
cerritos
tepetzingo
apazapan
Cement plants
Grinding plants
39
Dyckerhoff HQ, Wiesbaden – Germany
Economic performance
The creation of sustainable value for the stakeholders is a daily objective in each country
where the group carries out industrial activity. Therefore listed below are the 2011
economic performance indicators obtained thanks to the commitment and cooperation of
all the subjects interacting with the company (Shareholders, Providers of funds, the
Community and the Environment, Public administration and Institutions, Human Resources
and Corporate System).
Economic value generated and distributed
that Italy is experiencing, basically entering into recession.
In 2011 the main emerging markets maintained high
growth rates, while more mature economies have still not
In the various markets we are present in, 2011 was char-
started a sufficiently solid recovery. Investments in
acterized by highly differentiated operating conditions.
construction, which the demand for cement and concrete
In Italy, the weakening in internal demand and the effect
depends on in the areas where the group works, have
on the income available for the public finance correc-
shown a notable expansive trend in Eastern Europe and
tive measures have contributed to worsening the economic
an improvement above expectations is confirmed in
situation of consumption and investments, especially
Central Europe; on the other hand, the industry is still
from the third quarter onwards. The economies of Central
penalized by the persisting weakness in residential
Europe, structurally more solid, have maintained the
building in the USA and the difficult economic situation
benefits deriving from the dynamism of the foreign trade
40
and the mild climate that characterized the first and
showed the highest characteristic profitability within the
last quarter of the year. Eastern Europe witnessed a double
group.
digit growth in deliveries, a sign that the product of
the construction industry is returning to pre-crisis levels
Italy
( 2007 – 2008). In the US, the demand linked to residen-
After the first half of the year when the fall in demand in
tial building did not show signs of recovery. Non residen-
the construction industry seemed to stop and weak but
tial building continued to suffer due to the reduction
comforting signs of improvement were being seen, since
in private investments, and public investments in infra-
July, with the intensification of the financial tension on
structure were limited due to the high levels of debt
the public debt, the labored deficit containment measures
in many States of the union. Finally Mexico, where the
and the slowdown in international trade, a sharp slow-
country’s growth rate stayed positive and in line,
down took place. Investments in construction worsened
important construction and renewal infrastructure proj-
overall by more than 2 % over the previous year. Com-
ects provided suitable support to the investment in
pared to the peak of the last expansion cycle, new residen-
construction.
tial building dropped by more than 45 %. The plan to
expand residential buildings did not start. The non-resi-
The improvement in volumes was driven by Russia, the
dential segment, which also had showed some positive
Czech Republic, Ukraine, Luxembourg, Mexico, Germany
signals in the service and industrial segment, has now an
and Poland respectively. The USA recorded a business level
unsold portion that is staring to cause concerns. Among
slightly lower than 2010, while in Italy a notable drop
the few favorable signals, noteworthy is the strong growth
in demand took place. The characteristic profitability ben-
of investments in the sector of the renewable energy
efited from the recovered volumes and the strengthen-
sources, stimulated by a questionable incentive scheme.
ing of the prices in Eastern Europe, remaining stable at
In the segment of public infrastructures, the scarcity of
interesting levels also in less dynamic countries (the
resources affected the medium-small work programs and
Czech Republic and Poland). In Central Europe and in
caused additional delays for large works. Our sales of
Mexico the improvement was consequent to the volume
hydraulic binders and clinkers, including the volumes for
effect and concerned the absolute values rather than the
export, dropped to levels unseen since the beginning
values related to the turnover. In the USA, due to an
of the 1990s. The commercial policy focused mainly on
additional drop in prices, accompanied by the under uti-
improving sales prices; the recovery obtained was nota-
lization of production capacity and a certain pressure
ble but this effort must continue in the future to align the
on the cost side, the characteristic profitability probably
intrinsic value of our product to that of the market.
reached the minimum point of the cycle. The volume
effect was very unfavorable in Italy, where the good recov-
Germany
ery in sales prices could not offset the increase in unit
The construction industry, which already in the second
production costs, due to both the increase in energy fac-
half of 2010 had began to recover, during the year
tors and the modest level of factory activity. Interesting
recorded a growth of 5.4 %, benefiting from the expansive
signs of improvement in production efficiency were seen
economic phase of the country and the particularly
in the countries where we recently concluded impor-
good weather conditions in the winter. The residential
tant investment projects. In Ukraine, after two very diffi-
market, driven by renewal and modernization invest-
cult years, EBITDA returned to be positive; Russia
ments in existing buildings, further increased the strength
41
Composition and distribution of added value
Production value (€ m)
Stakeholders (%)
64 Human Resources
1
1
Production cost, other income & expenses, amortization and depreciation
2
Net added value
2,195
680
already shown in the previous year, reporting progress
Poland
of 5.9 % on the previous year. For the non-residential seg-
Poland’s and Ukraine’s hosting of the next European
ment, previously stagnant, the positive change reached
soccer championship and the consequent creation of the
6.6 %. Only the growth rate in public works recorded a
necessary infrastructure works gave the construction
slowdown. Our deliveries of cement recorded an im-
industry with an additional push which, together with the
pressive development compared to last year, in a context
good performance of the residential and commercial
were prices unfortunately remain weak.
segments, resulted in an increase in investments equal
to 12.9 %. The total quantity of cement sold by the
Luxembourg
group in Poland increased, with a high level of used pro-
In 2011 no important changes took place in the local
duction capacity. The same can be said for ready-mix
building market, while the demand coming from exports
concrete. The prices expressed in local currency rose.
sustained our level of activity. Sales of hydraulic binders and clinkers, including quantities for export, were up,
against a slight drop in unit average revenues.
The Czech Republic and Slovakia
The construction industry, which in 2008 began to slow
down, unfortunately confirmed its persisting difficulties,
The Netherlands
dropping by about 6 %. Cement consumption in the coun-
Spending in private investments showed a strong recov-
try remained almost unchanged. Nevertheless our
ery, also bolstered by positive data relating to employment.
group managed to increase sales by taking advantage of
After two consecutive years of recession, investments
the vertical integration in the country and by increasing
in construction recorded a 3.7 % increase. Sales of ready-
exports to Poland and other neighboring countries. Aver-
mix concrete slightly increased, while net revenues
age prices, expressed in the local currency, suffered
were down due to the weak price level.
from the competitive pressure from nearby Slovakia and
felt the higher distribution costs. The ready-mix con-
Shareholders
Providers of funds
Community
Public Institutions
Corporate System
2
14
6
8
6
2
42
crete sector, which also includes Slovakia, recorded an
Mexico
overall positive trend, with sales up and prices dropping.
The building industry is driven, among other things, by
some important public projects to build and upgrade
Ukraine
infrastructures and for residential construction, confirm-
The construction market grew by 11.1 % compared to
ing its driving role. Grey cement consumption in the
the year before. Cement consumption in the country
country began to increase. The associate company Cor-
increased and thus our sales volumes for cement and
poración Moctezuma, thanks to the contribution of the
ready-mix concrete rose considerably. The average
new production site in Apazapan (Veraccruz), ended the
sales prices in local currency, driven by the high demand,
year with increasing sales volumes and rising prices.
maintained a constant positive pitch. Significant improvements were obtained in production efficiency, thanks to
The value of production increased (+ 5 %) consequently to
the commissioning of the new plants for the use of coal
the recovered volumes, sustained in several geographic
in place of natural gas in both production sites.
areas also by the growth in sales prices. Production costs
affected some group business areas more than others,
Russia
especially concerning the surge in energy factors. The abil-
The construction industry benefited from the favorable
ity to generate Added Value (the difference between
economic situation, up by 4.8 %, recording an accelera-
the value of production and the consumption of goods and
tion compared to the stagnant situation of last year.
services, hereafter AV) strengthened (i. e. the wealth
Cement consumption in the country consequently regis-
created in favor of the various stakeholders).
tered a considerable positive change. Sales of cement
were very impressive. Sales prices in the local currency
began to strengthen only in the second part of the year.
Added-value Reclassified Income Statement
In addition to the favorable trend in volumes and prices,
worth mentioning are the improvements in efficiency
deriving from the new dry-process production line.
United States
Cement consumption in the country remained at 2009
2009
2010
2011
2,795.8
2,732.8
2,875.6
– 1,783.0
– 1,863.3
– 1,958.3
13.9
13.2
6.6
millions of euros
Value of production
Intermediate production
costs
Other income and
expenses
Gross added value
1,026.7
882.8
923.9
were slightly lower, and also the production of ready-
Amortization / depreciation
and impairment
– 218.7
– 386.7
– 243.5
mix concrete stagnated. The weak demand continued to
Net added value
808.0
496.1
680.4
and 2010 levels. The sales volumes generated by the group
affect the cement sales prices in local currency, while
those of ready-mix concrete had a more favorable trend.
The AV generated by our group’s business activities
Prolonged limited capacity utilization, the increases in
increased by 37 %.
fuel and distribution made it impossible to improve perunit manufacturing costs.
The portion of AV supporting the “Community and the
2009
2010
2011
Current assets
1,646.6
1,385.4
1,616.3
Non-current assets
4,412.9
4,469.9
4,312.6
Invested capital
6,059.5
5,855.3
5,928.9
Short-term debt
910.4
665.6
942.9
Long-term debt
2,436.7
2,385.9
2,141.2
millions of euros
Environment” remained almost constant, confirming
the company’s efforts and commitment in the social and
Equity
2,712.4
2,803.7
2,844.8
Sources of invested capital
6,059.5
5,855.3
5,928.9
environmental field.
The remuneration of the ordinary and savings shares
increased.
The percentage of AV relating to “Public administration
and Institutions” increased from – 8 % to + 8 %. The neg-
Restatement of the consolidated balance sheet and income
ative figure of the previous year was due to the entry
statement based on sustainability criteria permits quan-
of deferred tax assets as an effect of the impairment of
tification and allocation of these benefits – based on their
Oglesby assets (Illinois).
economic, environmental and social form – to the group’s
many different stakeholders.
In Italy, in the period 2000 – 2011 we made production
investments for the development of under-utilized
national areas (mainly Sicily, Sardinia and Apulia) total-
Distribution of Net Added Value
2010
2011
Corporate system
17
– 9
– 6
Human Resources
52
88
64
Public administration and
institutions
10
– 8
8
about 11 % of the total investments made in Italy in the
period and have all been completed. To date incentives
in %
Shareholders
Community and the
environment
5
0
2
11
21
14
5
7
6
granted by the Economic Development Ministry under
Italian Law 488 / 92 and from investment incentives
recognized as tax credits, for a total of approximately
€ 11 million. These assisted investments account for
and benefits for more than € 10 million have been credited to us. During the year we did not receive any new
loans and / or investment subsidies in the other geographic
areas included the reporting boundary.
The breakdown and YoY change of AV shows a substantial
change in the portion going to the corporate system,
Lastly, there was a big increase in the percentage of AV
which moved from the negative result of 2010 ( – 9 %) to
going to “Human Resources”. Staff remuneration is
a positive one of + 8 %.
mainly fixed. The company, however, has an incentive and
loyalty-building plan for Italian managerial staff featur-
The percentage of AV going to “Providers of Funds”
ing payments in the form of savings shares depending on
dropped also because of the decrease in the debt position,
the objectives achieved (MBO system). Savings shares
which the company wants to maintain well within the
are granted to beneficiaries either by means of reserved
prudent limits that have always distinguished our business
capital increases or use of treasury shares. The cost
policy.
corresponding to the shares transferred – equal to their
fair value on grant date – forms part of staff costs.
ing some € 67 million, benefiting from facilitations
2009
Providers of funds
Balance Sheet
43
44
Employee benefits go beyond direct remuneration during
and salary). They may be unfunded or wholly / partially
the employment relationship, extending also into the
funded by contributions paid by the company, and some-
post-employment period. More specifically, such benefits
times by its employees, to an entity or fund legally
primarily consist of pension plans, life insurance,
separate from the employer which in turn pays out the
healthcare plans and severance indemnities. Support for
benefits to employees. The defined-benefit pension
the wellbeing and health of employees thus remains a
plans that the group has in Germany and, to a lesser extent,
distinctive features of Buzzi Unicem’s corporate concept.
in Luxembourg, are mostly unfunded. Conversely, pen-
It translates into tangible effects on employees’ quality
sion plans in the USA are almost totally funded, whereas
of life and enables us to attract and retain the most tal-
healthcare plans are, by nature, unfunded. The defined-
ented staff and assure long-lasting motivation and pro-
benefit pension plan of companies operating in Mexico
fessional satisfaction.
is largely funded. Employee severance indemnities
(Italian acronym = TFR) are considered equivalent to an
The way in which the benefits are assured varies from
unfunded defined-benefit plan. The provision is extin-
country to country, depending on the legal, tax and eco-
guished at the time of retirement, and in special cases can
nomic conditions of each area where the group oper-
be partially paid out in advance. The “Other” item is
ates. Obligations refer both to in-force employees and retir-
comprised of loyalty bonuses accorded to employees upon
ees. The following table details our employee benefit
achievement of a given tenure, and generally paid
obligations:
out when an employee ends his / her employment with the
company. In particular, in Mexico we note the existence
2011
2010
thousands of euros
of a system called “prima de antiguedad” which is similar
to the Italian TFR system. Payment of these benefits is
a certainty (i. e. once minimum requirements have been
met), whereas the exact timing of payment is not defined.
By category
Post-employment benefits
Pension plans
171,310
173,405
The scope of our operations covers different social envi-
Healthcare plans
109,886
107,133
ronments. Differences range from the strong presence
25,480
27,671
155
123
8,960
9,670
315,791
318,002
Employee severance indemnities
Others
Other long-term benefits
system in Italy, to a situation of more advanced plans
and policies in the USA and Germany. In these two countries there is a high degree of flexibility for arranging
assistance consistent with the employee’s needs based
By geographic area
Italy
of state social security agencies governing the pension
26,396
28,584
Central Europe
175,857
179,906
usa and Mexico
113,538
109,512
315,791
318,002
on future life expectancy.
The Czech Republic and Poland provide a state pension
system, similar to the Western model, partly funded
by employees with the remainder funded by employers.
Defined-benefit plans are those that calculate the amount
This cost is included in the income statement under
of pension benefits earned by retirees, usually accord-
the “Staff costs” heading. In these countries, pension
ing to one of more factors (age, years of company tenure
funds also exist into which employees can contribute
part of their salary as a form of supplemental pension provision, benefiting from tax relief. The Russian and
Ukrainian pension systems are solely state-funded. But
they are often inadequate and employees are not
obliged to retire at a set age. Given this situation, in certain cases we facilitate employees wishing to leave the
company by giving them employee-reduction incentives.
45
given tenure. In this case, the carrying value of the obligation in the balance sheet reflects the likelihood and
probable duration of effective payment. Such plans are
unfunded. In the USA a deferred compensation plan
( DCP ) is provided for certain employees. Sums withheld
are set aside in a trust and trust profits accumulate for
the benefit of DCP participants.
benefits”, generally paid out upon achievement of a
The group also accords its employees “Other long-term
46
environmental and social performance
Wind generator at the Franeker plant – the Netherlands
Environmental and social performance
The Sustainability Report, now in its ninth edition, is a transparent, detailed
and exhaustive reporting tool of strategic worth for an international group
such as ours.
The 2011 Sustainability Report quantifies the economic,
provides companies and organizations with a complete
environmental and social impact of the business, pro-
framework to draw up the sustainability reports used
viding management and all the staff with valuable support
worldwide).
to plan future strategies, following a logic of continuous
improvement.
The description reflects the positive and negative aspects
in a balanced manner, in order to effectively and con-
To confirm the importance of the document for the entire
sistently assess the overall performance.
group, the 2011 Sustainability Report – as has happened for several years now – considers all the “core” in-
In this section the group’s environmental and social im-
dicators envisaged by the guidelines of the GRI (Global
pacts are dealt with; this year subdivided by nation. The
Reporting Initiative, a non-profit organization that promotes
Sustainability Report does not include the associates Addi-
economic, environmental and social sustainability and
ment, Premix, Elma and the subsidiary Cementi Moccia.
The new structure was introduced with the purpose of
giving the right importance to the characteristics of each
country and, especially, to facilitate the consultation of
the various data by putting it into context within the reference country. This important working tool is also beneficial for local use.
The graphs at the end of each chapter show a complete
47
data referring to the entire group: the time interval considered always covers the last three years, with the purpose of providing a suitable level of comparison.
All the environmental data presented here concerns, in
particular, the consumption of natural, energy and water
resources, the production of waste, emissions into the
atmosphere, water discharges, transportation and green-
picture of the individual country in comparison with the
For the environmental data, the impacts of the cement industry are discussed such as: consumption of natural,
energy and water resources, production of waste, atmospheric emissions, water discharge, packaging, transportation and greenhouse gases.
Also the investments and expenses concerning the environment and safety are indicated. The performance indicators related to production were used since they describe in a synthetic, uniform and comparable manner
the performance, the indicators relating to the burning
line refer to a ton of clinker produced, while, to ensure
uniformity and comparability of the data among various
countries and different years, the impacts generated
along the entire production cycle refer to a ton of equivalent cement. The social data refers to staff management and the community in general.
Finally, also the investments and expenses concerning
the environment, health and safety are indicated.
house gases.
48
Italy
cadola
riva del garda
trading conditions
cement business
travesio
trino
robilante
Volumes
Prices
Mkt share sorbolo
vernasca
settimello
– 10.5 %
8.4 %
16 %
guidonia
manfredonia
barletta
siniscola
caserta
Cement plants
Grinding plants
Ready-mix concrete plants
Affiliated ready-mix concrete plants
augusta
Italy
At the end of 2010, the preliminary procedure relating
Environmental indicators
rial (78,500 t / y) was started in Guidonia, which would
Natural resources
allow, at full operation, a significant rise in the quantity
The recovery of waste, raw and secondary raw materials
of alternative materials recovered.
to the increased recovery of non-hazardous waste as mate-
in 2011 is equal to 272,416 t and shows a substantially
constant and rather limited quantitative trend (12 %) com-
Energy resources
pared to the authorized limits. The actual substitution
Thermal and electric energy consumption accounts for
percentage of natural raw materials equals 3.1 % (3.4 %
the highest percentage of cement production costs and,
in 2009).
therefore, regardless of external effects, has been moni-
The maximum substitution of natural raw materials is
years in particular, Buzzi Unicem has pursued this prior-
recorded in Settimello (18.6 %), Siniscola (16.2 %), thanks
ity objective of technological optimization leading to
to the use of airborne ash from thermoelectric plants
an approximate 20 % reduction in unitary energy con-
in the production cycle, Vernasca (7.8 %), Riva (7.6 %),
sumption for clinker burning kilns, the heart of the
tored and optimized for several years. In the last 20
Sorbolo (9.5 %). Trino (3.3 %) and Barletta (2.8 %).
technological cycle, with progressive systems and managerial modifications.
The other production sites of Augusta, Guidonia, Cadola
and Travesio, as well as Robilante, (while increasing
Also the IPTS report of Seville acknowledged the notable
the use of residual materials in percentage terms) recorded
improvement in thermal efficiency of the Italian Cement
an annual balance ranging between 0.7 % and 1.7 %,
Industry, with specific indicators among the lowest in Eu-
thus, lower than the group’s average.
rope, also showing the absence of additional acceptable
reduction margins, economically unsustainable in relation
11 / 10
var %
mc /000
4,106
4,638
– 11.5
t / 000
2,503
2,884
– 13.2
k / c Ratio
– 10.5
100
Sales revenue
€ m
568.1
614.2
– 7.5
83.3
€ m
22.4
30.8
– 27.3
66.6
no.
1,886
1,963
– 3.9
50
numbers & facts
Cement production capacity 10.8 million tons, 14 plants,
6 terminals / deposits, 160 ready-mix concrete plants,
14 aggregate quarries.
2009
2010
2011
6,480
33.3
16.6
0
Ratio between clinker used and cement produced
ita
bu
to the modest benefits achievable and the business objec-
ness and the k / c ratio requested by the mix of cements
tives, subordinated to the conventional “capital inten-
currently produced.
sive” and “energy intensive” needs, which are known to
characterize our production sector.
The amount of heat replacement, chargeable to the ener-
The thermal energy requirement of clinker burning lines
kilns, proved to be equal 11.6 %, compared to 10.4 % in
is 3,622 MJ / t of clinker, equal to the values of the pre-
2010.
gy recovery of alternative fuels in the clinker burnwing
vious two years, despite a tendential increase in 2009,
2010 and 2011 and certainly also attributable to the
In 2011, an increase of 0.8 % was recorded in quantita-
non continuous and regular use of the clinker burning lines,
tive terms, with the co-incineration of 99,838 t of waste
subject to numerous starts and stops.
(CDR-p, CDR, plastic, rubber, oil emulsions, meat and bone
meal).
The lower production of clinker also meant a general
decrease in the consumption of fossil fuels (– 7.4 % of
The thermal contribution of fuel waste reaches 21.5 % in
coal and petcoke) and methane (– 23 %), plus an addi-
Robilante (55,791 t, with 25.6 % of annual average sub-
tional reduction (– 17 %) in the consumption of dense fuel
stitution for kiln 3 and 15.7 % for kiln 2), 32.6 % in Bar-
oil.
letta (29,295 t), 21 % in Travesio (12,386 t) and 2 % in
Vernasca, respectively (2,365 t of meat and bone meal),
Concerning the specific consumption of electric energy,
with average monthly levels up to 38 % in Barletta and
the most important activities include coal grinding, ce-
Robilante.
ment grinding and grinding and burning of meal. The indicator confirms an average of 103 kWh / t of cement,
The energy valorization of waste has led to a conse-
a figure whose substantial stability is also due to the fine-
quently lower provision of about 59,300 t of petcoke.
Aggregate sales
5,799
Concrete sales
t /000
73.7
79.7
Cement sales
74.3
79.8
2010
74.1
79.9
2011
49
50
In addition, the co-incineration of 90,900 t of waste with
the environment and the landscape. For many years Buzzi
biogenic content allows us to account for about 89,700 t
Unicem has been applying a process of impact assess-
of CO credits.
²
ment that, via in-depth studies and analyses, permits exhaustive evaluation of the effects. Finally, the analytical
In Robilante, the co-incineration authorization for CDR
process allows the preparation of the project or develop-
up to 110,000 t / year was recently issued. In Barletta, Au-
ment plan and the environmental recovery project. The
gusta and Siniscola, additional administrative proce-
first assesses the application of the best techniques to opti-
dures were started, which will favor a notable increase in
mize quarry development, while the second evaluates
the heat replacement from non conventional fuels in
those which provide the best re-establishment of the orig-
the future.
inal landscape.
Water resources
With regard to the environmental reclamation project,
The consumption of water resources for the conditioning
Buzzi Unicem strives to return the site to its natural state.
of gases discharged from kilns and the cooling in a closed
In doing so, we implement all the measures necessary
cycle of the mechanical parts is on average 248 l / t cem
to restore the natural landscape to the entire site often
(– 4.3 % compared to 2010), with indicators substan-
going beyond the mere maintenance of stabilizing quar-
tially in line with the previous three years and with a value
ry walls and masking the excavated areas. Therefore, the
of about 110 l / t cem for the best production sites.
interventions aim to encourage the target species in a
general context of increasing biodiversity.
A significant generalized decrease is recorded in specific
consumption of process water in Settimello (– 95 %:
Re-naturalization of a quarried site can take considerable
32 l / t cem which can be correlated to the stoppage of the
time because of the slow pace of the natural processes
raw material grinding systems and the clinker burning
involved. In fact, environmental reinstatement techniques
line), Robilante (– 14 %: 295 l / t cem) and Sorbolo (– 30 %:
act as starters, guides and accelerators of the process
13 l / t cem), which can be correlated to the adaptation
which might not otherwise take place without them.
and correct management of the water meters on the pumping system and the actions to recover and recycle in-
For example, a wood or a meadow is not established
dustrial water and groundwater drainage.
simply by planting trees or sowing grass. All the basic elements have to be reconstructed, starting from the soil
A notable increase is recorded in Cadola (+ 45 %: 210 l / t
and morphology of surroundings and progressing onto the
cem), Siniscola (+ 36 %: 178 l / t cem), Barletta (+ 20 %),
composition of flora and landscape.
Vernasca (+ 19 %) and Augusta (+ 9 %). These increases
can be correlated to the particular production structure
Because of its attention to the environment, Buzzi Uni-
recorded during the year. Values well above the average
cem is proud to say that we have three active min-
group level still characterize Trino and Riva.
ing sites in internationally famous natural locations in Italy,
which are recognized by national control entities.
Biodiversity
The environment recovery work is in line with the devel-
The development of quarries and mines inevitably chang-
opment process which is carried out each year.
es the areas they are located in, with impacts on both
Worth mentioning in 2011:
51
_ The start of the conversion project of the industrial
attributable to the improved energy efficiency (less
site of Magreta in the municipality of Sassuolo (Mo)
thermal energy consumed by the kiln and auxiliary ser-
which is in line with the modern needs of multi func-
vices) and, especially, the credits deriving from co-
tionality and management of suburban areas. In an area
incineration of combustible waste, with biogenic content.
of about 10 hectares, woods and meadows are being
created, together with a Soft air field (recreational target
shooting) and a small handcraft area.
_ The activation of a convention with the National Research
Council (CNR-ISPAAM) of Sassari for the use of plant
matter of local origin at ecotypical level for the technical
grassing is carried out in the quarry of Sas Funtanas
di Siniscola (Sardinia).
Greenhouse gases
In 2011 the total direct emissions of CO² equaled 3,814,380 t,
with a decrease of about 6 % which correlates to the
corresponding decrease in clinker production. The specific emission factor, equal to 626 kg CO² / t of cement,
shows a decrease of 1.7 %, compared to 634 kg CO² / t of
clinker in 2008. A containment in direct CO² emission
factors took place thanks to the reduction of about 1.5 %
in CO² from decarbonation (univocally correlated to
the k / c ratio) and about 6 % in CO² from combustion,
The subdivision between direct and indirect CO² emissions is respectively equal to 62 % for decarbonation and
38 % for combustion.
Start of environmental recovery at the top portion of the quarry in Sas Funtanas – Italy
52
Vich quarry, Ponte nelle Alpi, Belluno – Italy
Atmospheric emissions
by 19 % in Robilante, with an average heat substitu-
Modern continuous monitoring systems control the emis-
tion of 21.5 %, thanks to the important contribution from
sions deriving from the clinker burning line. In partic-
unconventional fuels.
ular, the emission factors relating to sulphur oxides equals
1.73 kg NO² / t clk, with an additional reduction compared to 1.78 kg NO² / t clk in 2010.
The emission factor equals 0.08 kg SO² / t clk in 2011,
Except for the increased emission factor recorded in Cad-
in the emission level, which has always been minimal over
ola and Guidonia, a general reduction and / or leveling
the years, is in contrast with the value of Travesio, de-
with a reduction of about 40 % compared to the average
value equal to 0.11 kg SO² / t clk in 2010. This decrease
is recorded for the other cyclone furnaces, with percent-
spite the drop, which can be correlated to the presence
ages ranging between – 17 % in Barletta, – 7 % in Ver-
of sulphides in the marl.
nasca, – 6 % in Travesio, – 4 % in Augusta, – 2 % in Robilante, attributable to the growing sensitivity and focus
Thanks, especially, to the replacement of electrofilters with
on the operation of the burning kiln towards the formation
bag filters, the growing efficiency of the technical con-
of NOx, and, the benefits connected to the energy recov-
trols and the particular attention in the management of
ery of waste (with lower content of molecular sulphur), the
the filtering units installed on the clinker burning lines,
implemented cooling the flame head and the optimized
Robilante, Vernasca and Guidonia record a content of emit-
management of SNCR systems, also correlated to a reduced
ted dust between 3 and 5 g PTS / t clk.
urea consumption (– 8 %).
Waste
The burning line in Barletta, occasionally supplemented
The quantity of special waste generated in the produc-
by the activation of the SNCR plant, records the lowest
tion process is always low, with an average of 788 g / t cem.
level of all the UP. Likewise, urea consumption dropped
Moreover, significant and general percentage variations
quantitative levels increasing in Sorbolo, Barletta, Ca-
ment because of the contractual status.
dola and Trino, whereas a decrease is recorded in Settimello, Travesio, Vernasca, Guidonia, Robilante and
For full-time staff, the HQ adopts flexible working hours,
Siniscola.
which enable staff to work their contractual hours in a
very broad timespan.
About 76 % of the waste produced is predisposed for recovery in other production sectors, whereas 17 % (319
Staff incentive programs
t / year) is represented by hazardous waste, disposed of by
A profit-sharing bonus (called the performance bonus) is
authorized companies.
provided for all staff in the cement sector. The terms
Social Indicators
tiated with national trade unions and workers’ trade
Workplace diversity
unions representatives, based on productivity and profit-
of each performance bonus last for 3 years and are nego-
Both the cement and concrete sectors feature a tradi-
ability indicators. In 2009, due to the adverse overall
tional employment structure, a rather low turnover and
economic conditions, the performance bonus agreement
only a small percentage of non-EU employees.
expiring on 31 December 2008 was extended. With the
collective labor agreement signed on 18 February 2010,
Furthermore, active policies do not exist that actively
the performance bonus agreement was extended to 31
promote minorities as there is no specific need to do so
December 2010, and then extended again by a year (31
yet, although the few cases of non-EU employment that
December 2011) with the industry agreement stipulated
have occurred so far have been examples of perfect inte-
on 9 March 2011.
gration.
A second-level agreement for the concrete sector is negoThe number of women in significant positions of responsi-
tiated by trade unions and local business associations
bility is also somewhat limited. This is mainly because
without the participation of either the company or repre-
women tend to be employed in central departments (ad-
sentatives of the workers.
ministration, marketing / communication), where a few
cover positions responsible for coordinating sections or
Management staff are granted free savings shares upon
entire offices / services or have excelled in managerial
achievement of objectives set as part of a management
or highly specialized roles.
by objectives (MBO) incentive program based on corporate
and individual indicators.
Work-Life balance
Cement production requires constant coverage of the
For sales staff in the cement segment specific incentive
production process by operators. Given this, it is difficult
plans are envisaged. These incentives are separate from
to assure policies favoring part-time work at the factory
the MBO plan already in place for managerial personnel.
sites.
Part-time workers (23 of which are female out of a total
of 24 and 50 % of which are employed at the HQ) are in
no way discriminated against in terms of career advance-
are recorded among the various Production units, with
53
54
Training / career progress
The present collective labor agreement for the cement
Notwithstanding the severe ongoing economic crisis of
sector was renewed on 18 February 2010 and lasts 3
the last three years, training and development activities
years.
for all employees continued, with specific attention to technical aspects (safety and environment).
In the Emilia-Romagna region, regarding the personnel
More specifically, the “Objective = Safety” training proj-
manently closed at the end of 2008, Buzzi Unicem and
from the site in Santarcangelo (province of Rimini), perect initiated in 2008 (co-financed by Fondimpresa [the
the relevant local trade-union organizations signed at the
inter-professional training fund] saw additional modules
end of the year a 6-month agreement to extend the un-
develop in 2011 (only for the year in question, 1,622
employment subsidies and benefits and support retrain-
workers involved and 5,640 hours of training supplied) and
ing. Thus far, these agreements have permitted – on
at the end of the year the signing of a national agree-
the date of drafting this document – the activation of an
ment for additional action plan focusing on the concrete
additional 30 months of extraordinary subsidized tem-
sector, with the aid of remote modules for 2012 and
porary lay-off (on an exceptional basis) before implemen-
the involvement of 837 workers.
tation of the agreements signed in 2008 concerning
At the end of 2011, in parallel with the inevitable rational-
consequence of the definitive closure of the plant.
termination of individual employment relationships, as a
ization of the concrete sector, a training course was
started for all the sales staff of the sector called v. i. p. (Ven-
At the site of Calenzano – Settimello (province of Flor-
dere, Imparare, Presentare [Sell, Learn, Present]).
ence), in Tuscany, after a year of extraordinary subsidized
Staff participation
extraordinary subsidized temporary lay-off period was
There is a works council at all the Buzzi Unicem sites.
started for unexpected and sudden events, aimed at
These representatives have frequent meetings both
temporarily suspending the burning activities.
temporary lay-off due to the market crisis, in 2011 an
with factory management and central HR managers. Meetings are conducted constructively and with the utmost
In total, 22 employees out of 64 of the initial structure
transparency. This dialogue makes it possible – notwith-
have left the company, most of whom opted for the non-
standing the difficulties of the period – to continue ef-
oppositional national “soft landing” collective dismissal
forts to minimize, as much as possible, the painful adverse
procedure, 2 found definitive employment in Unical, 4
impact on employment levels caused by the severe crisis.
temporary employment or in Unical or in other sites of
the Cement industry, 21 are workers at the current mill-
Collective bargaining
ing center, the remainder is suspended in extraordi-
In 2011 the work of the European Works Council contin-
nary subsidized temporary lay-off.
ued, which meets in plenary session once a year (in
2011 at Robilante) and in select sessions (at Executive
At the end of the extraordinary subsidized temporary lay-
Committee level) twice a year (at Wiesbaden).
off (February 2012) resorting to the extraordinary subsidized temporary lay-off is foreseen on an exceptional
basis until the end of 2012.
2011
2010
2009
total workforce
1,872
1,950
2,028
Men
1,725
1,796
1,866
147
154
162
1,809
1,888
1,971
tinued in 2010, with the non-oppositional termination of
30 employment contracts within the first half of 2011,
at the end of the year – also due to the worsening of the
credit situation in the construction industry – it was
necessary to resort to a more painful and incisive nation-
Women
al rationalization plan which will be completed by 2012
Open-end contracts
and which envisages disposing of a total of 22 plants (from
Fixed-term contracts
63
62
57
the initial number of 160) and a maximum of 50 lay-
Full-time
1,848
1,924
2,002
offs, through extraordinary subsidized temporary lay-off
Part-time
24
26
26
interventions regarding about 80 employees during all
Total hires
44
29
114
5.62
of 2012.
%
2.35
1.49
Total terminations
122
107
145
%
6.52
5.49
7.15
Employment
Of which, resignations
26
40
105
In 2011 the global economic crisis which had started at
Due to retirement
25
26
0
the beginning of 2008 continued and intensified, leading
Of which, dismissals
(individual, collective)
71
41
40
to the first round of layoffs.
The Italian headcount (Buzzi Unicem, Unical) dropped from
Without Cementi Moccia, Addiment, Elma and Premix, which are not
consolidated
1950 people in 2010 to 1872 people at 31 / 12 / 2011.
There were 122 (71 due to staff reduction) terminations
Labor relations
in the period, almost all of them as part of Buzzi Unicem’s
A national collective labor contract is applied to all cate-
non-oppositional mobilization plan. There were 44 new
gories of employees.
recruitments.
For the cement sector – excluding managers – the national
collective labor contract for the cement industry is applied (and lasts 3 years starting in 2010 ). The contract –
in negotiation of which Buzzi Unicem participates directly – signed by Federmaco (the Italian federation of
producers of basic construction materials) and relevant
national trade unions. The renewal agreement was signed
on 18 February 2010.
For the concrete sector – excluding managers – the
national collective labor contract for employees of building and similar companies is applied (once again lasting for 3 years starting in 2010). It is signed by ANCE (the
tion that involved about 40 employees in 2009 and con-
Total employee workforce by contract type
and rate of turnover
In the concrete segment, after a first year of rationaliza-
55
56
national association of building companies) and by rel-
If the company and trade unions fail to reach agreement
evant national trade unions.
within 75 days, the company can proceed with dismissals,
but has to pay higher social security charges (triple)
All managers (with the Italian contractional grade of
for the employees dismissed.
“dirigenti”) are covered by the national collective contract
for companies producing goods and services. It is
2011 featured the continuation of extraordinary subsi-
signed by Confindustria (the confederation of Italian Indus-
dized temporary lay-off (on an exceptional basis) for the
try) and by Federmanager (the national federation of
factory of Santarcangelo Romagna (province of Rimini)
managers).
which definitively ceased operation toward the end of 2008.
For all categories of works – excluding managers – nation-
Having covered all the positions envisaged by the frame-
al collective bargaining agreements are joined by
work with the national trade union organizations to
“Level 2” bargaining. In the case of the cement sector, this
encourage non-oppositional “soft-landing” up to a maxi-
is at company level, whereas for the concrete sector it
mum of 67 employees, in October 2011 another was
is at provincial level (i. e. negotiated by local business as-
signed up to an additional maximum of 50 employees, valid
sociations with relevant local trade unions).
until 31 December 2013.
The Buzzi Unicem Level 2 contract (concerning perfor-
The recent Pension Reform (December 2011 effective from
mance bonuses) was extended until 31 December 2011.
1 January 2012), which substantially annulled seniority
pensions, made the tool negotiated with the trade union
Minimum notice period concerning
organizations less appealing. In fact, since January
organizational changes
2012 only the regime of old-age pensions with 66 years
The obligation to inform work councils is envisaged and
of age applies or, alternatively, the possibility of early
regulated by two legislative measures.
retirement with at least 42 years of work performed (in this
case economic disincentives are also foreseen with an
Italian legislative decree 18 / 2001 establishes that, in
effect on the amount of the pension).
cases of mergers and acquisitions, companies with more
than 15 employees must inform work councils of the
The urgent legislative intervention therefore made it
project 25 days before the definitive merger or acquisition
more complicated to manage the employment crisis, also
deed is signed. In doing so, they must provide details
economically, due to the raise in the average pension
about the business plan, impact on the manning level and
age by 4 / 5 years.
contractual obligations.
In February 2012 the extraordinary subsidized tempoBased on Italian Law 223 / 1991, in cases of redundancies
rary lay-off for the 22 employees in Calenzano – Settim-
involving more than five dismissals, there is a manda-
ello (FI) ended and it was extended on an exceptional
tory procedure that requires the company to inform work
basis for an additional 10 months for 17 workers. Unfor-
councils and trade union leaders in a thorough and
tunately, as already mentioned, it was necessary to pro-
detailed manner about the reasons for redundancies and
ceed with an additional rationalization plan for the con-
identification of the criteria to select staff for redundancy.
crete activities, involving a maximum of 83 workers
57
suspended in extraordinary subsidized temporary lay-off,
In this light, in 2008 the management launched “Objec-
for 50 of which dismissal is foreseen. The extraordi-
tive = safety ”, an internal communication campaign
nary subsidized temporary lay-off program, signed in De-
constructed on simple and clear messages, able to speak
cember 2011, lasts for all of 2012 and mainly involves
to everybody in a way that everybody can make it their
Emilia Romagna, Tuscany and Lazio.
own; the utmost attention is paid to the awareness and involvement of all the staff, as it emerges from the ambi-
Occupational Health and Safety
tious slogan of the initiatives that says: “only thanks to
The risk analysis and assessment pursuant to Leg. Decree
everybody’s commitment and awareness can we really
81 / 2008, represented an important process to raise
be safe”.
awareness and gain the continuous attention of the corporate structure on safety and hygiene at work. The
In 2011 additional refresher courses were held for about
absorption of the EU regulatory provisions and the imple-
600 workers on manual handling of loads and using cat-
mentation of modern managerial systems, conforming
egory III DPI and to managers and h&s managers the risks
with standards UNI EN ISO 14001 and BSI-OHSAS 18001,
for work-correlated stress and the fulfillments of the
led to the spreading of a new approach to the problems
provisions of reach and clp regulations. Specific modu-
of safety, turning them into important parameters for the
lar courses were held for various company departments
purpose of assessing the efficiency and productivity of
such as: h&s managers, managers, mechanical mainte-
the company. Buzzi Unicem considers the competence of
nance staff, electricians, operators driving operating
its staff and their constant technical-professional up-
machinery, fire-fighting teams and asbestos management,
grading as fundamental, as well as the continuous search
pressure vessels, designing of electric systems, contract-
for the indispensable motivational stimuli that allow
ed works and “Machinery” Directive, which in total con-
them to evolve “from the obligation of sharing”.
cerned 935 workers.
Technical worksite assistant – Italy
Lost-time injury rate
1.25
10
0
2009
2010
ita cem
bu cem
0.75
0.50
0.25
0
2011
ita cls
1.00
2009
2010
bu cls
ita cem
Injury frequency rate = number of injuries × 1,000,000 ⁄ hours worked
0.53
0.23
0.34
0.53
20
14.0
8.4
7.3
30
11.1
10.9
8.3
20.5
40
24.7
1.50
50
28.92
60
0.31
0.31
0.36
0.52
Injury frequency rate
0.6
0.43
0.3
0.57
15.3
16.1
10.1
58
2011
ita cls
bu cem
bu cls
Lost-time injury rate = lost days × 1,000 ⁄ worked hours
The assessment of the data relating to accidents and sta-
For the concrete segment an additional improvement
tistical indexes, since 1981, shows how the statistical
is recorded in the accident indicators, limited to seven, four
distribution of values is variable within the normal param-
of which were caused by road accidents.
eters of acceptability.
The absentee rate rose slightly from 2.99 % in 2010 to
Firstly, worth mentioning is the gratifying result obtained
3.09 % in 2011.
by the cement plant in Augusta, six years without an
accident; also the production sites of Barletta, Riva, Trino,
There were three national strikes: in May and September
Sorbolo, Manfredonia, Ravenna and the Research
of only one trade union against the Government’s eco-
Center in Guidonia did not have any accidents in 2011.
nomic policy, and in December against the Pension Reform.
In 2011, the values of the Indexes of Severity were respec-
With reference to professional illnesses reported during
tively equal to 14 and 0.53, recording a slight worsen-
2011, seven were recorded (3 hearing impairment, 1
ing compared to 2010 and in line with the performance
illness from vibrating tools, 1 back pain, 1 bronchopathy,
levels related to 2009.
1 asbestosis), compared to the 2 cases of hearing impairment reported in 2010.
These statistical indexes are in any case substantially in
line with the average recorded in the Italian Cement
Segment, and with the trend for the main European Countries.
59
Average injury duration
gg
120
100
80
38
28
47
21
25
28
29
2010
ita cem
2011
ita cls
bu cem
bu cls
Average injury duration = lost days / number of injuries
Occupational Health & Safety training and
Anomalous situations may lead to a rating of the restrict-
prevention programs
ed ability to do a job, or to a change of job to reduce
Besides checking employees’ exposure to chemical agents,
the possible onset of any clinical disorders.
physical agents (noise and vibrations) and biological
agents via environmental and personal assessment, the
Also in 2011 the “Objective = Safety” training project
company, working with the relevant labor physicians,
continued, co-financed by Fondimpresa (the Inter-profes-
monitors personnel’s state of health. This is done by means
sional training fund) initiated in 2008, involving 1,622
of a series of in-depth tests, the frequency of which var-
workers for a total of 5,640 hours of lessons.
ies depending on jobs and medical check-ups. These tests
are recommended by the labor physicians based on
The Project will also continue in 2012.
preparation of a healthcare protocol. In addition to the medical examinations typical of occupational medicine, a
Training
normal healthcare protocol includes spirometry tests (lung
Of the total training days provided in 2011 (4,648, of
function tests), hearing tests, chest x-rays, electrocar-
which 2,632 external and 2,016 internal, compared to the
diograms, and functional assessment of the spinal cord.
1,375 external and 2,541 internal in 2010) more than
2,000 total days (1,710 external and 343 internal) were
The results are summarized by the labor physician and
dedicated to safety in the workplace and more than
discussed – ensuring protection of the worker’s privacy –
1,200 to technical training.
during the periodic meeting required by current legislation and during top management review, if the OHSAS
Priority was also given to studying languages, in particular
18001 standard is applied.
English but also German and Spanish.
2009
0
28
25
30
20
20
43
40
60
60
Local hiring procedures and percentage of
In May the Vernasca plant was visited by a group of 32
local senior management
mechanical engineering students from Delft University,
Although the group does not yet have a global policy as
in Holland. The group showed huge interest during the
such, it is common practice to recruit staff – above all,
company presentation and the visit to the plant.
blue-collars, foremen and white-collars working at the factories – giving priority, in the face of equal conditions
Donations
and professional skill, to local resources in order to main-
In Italy, at the Sicilian site of Augusta, set directly on the
tain and enhance relations with local communities. Ce-
coast, donations were made to the Stella Maris Associ-
ment and concrete producers are typically of a regional
ation, which performs important reception and support
nature. Given this, it is important to know local market
activity for sailors in transit in the port of Augusta.
conditions and the local social environment.
The production site of Guidonia sponsored the sidewalk
In all countries it is corporate policy to encourage the
resurfacing works of Via della Pietrara (street next to
training / hiring of managers of the respective nationalities
the site) for an amount of € 250,000.00 + VAT.
concerned – therefore linked to the life of the community where the company is active.
Every year the production site in Riva del Garda donates
€ 20,000 to the Cooperativa Sociale Agricola Giovanni,
This does not, however, preclude the possibility for the
whose purpose is to protect the general interest of the
group’s managers and professionals to enhance their ex-
community and promote the human and social inte-
perience at other sites outside their respective national
gration of citizens. The cooperative carries out activities
borders. This can involve handling, for example, special
aiming to find work for disadvantaged people, espe-
projects or the start-up phase of new equity invest-
cially those who are about to return to a normal social life
ments or businesses.
after spending time at the Mondo X community, a
26 % of Italian managers (13 out of a total of 49 at
nationally.
charitable association known for assisting the public
31 / 12 / 2011) work away from their region of birth or residence.
Furthermore all the production sites have donated cash
or cement to religious organizations, sports, cultural
Activities for local communities
and social aggregation associations, schools, non-profit
Voluntary beneficial initiatives
charities and local entities.
Buzzi Unicem created the “technological park”, in the
public gardens that surround the group’s headquarters in
The Buzzi Unicem Foundation
Casale Monferrato. The park’s purpose is to provide
The Buzzi Unicem Foundation was established in 2003 in
information on old unused machinery by creating an inter-
Casale Monferrato, Italy, by Buzzi Unicem SpA, with
esting “industrial archeology” route that does not only
the mission of promoting and sustaining interventions
go through the company’s history but also the industrial
aiming to improve the diagnosis and treatment of
activity that has characterized the territory for more
malignant mesothelioma, a particularly aggressive tumor
than a century. During 2011 the park was visited by vari-
linked to the environmental and professional exposure
ous groups, parties, associations and two school classes.
to asbestos.
61
This disease is a social phenomenon with worrying
In addition, the Foundation offers its support to Entities
effects in the Casale area, where asbestos was manufac-
and Institutions that care for terminal patients.
tured in the past.
The a.s.p.h.i. Foundation
There has unfortunately been an increase in the disease
The group supports the a. s. p. h. i. Foundation (Association
at a global level also to the extent that it has exceeded
for Professional Development of the Handicapped in
the threshold based on which it was considered a purely
the IT field), a non-profit organization. Its mission is to
local phenomenon.
promote integration of the disabled in school, work,
and society via use of ICT (Information Communication
The Foundation finances the project of researchers in Uni-
Technology). Thanks to a. s. p. h. i, hundreds of young
versities, Research centers and Health authorities con-
people have entered the world of work, demonstrating
cerning:
that handicaps can be overcome.
_ Applied scientific research into preventive and immunotherapy systems,
_ Direct work on patients aimed at early diagnosis and
treatment.
anfass non-profit Association
Buzzi Unicem supports the non-profit Association Anfass
(National association for the families of the intellectually
and /or Relationally disabled), a large association of par-
The Foundation work with the public sector, channeling
ents, family members and friends of people with dis-
funds to projects which best share ideas, experience
abilities that is now present throughout the country.
and suitable resources to facilitate the routes that lead to
the right clinical solutions; an ideal junction between
science and patients.
Anfass works mainly on a voluntary basis, it is non-profit
organization and only pursues solidarity and social
promotion purposes mainly in favor of disadvantaged peo-
Employee and family day at the Robilante factory – Italy
62
ple in situations of intellectual and / or relational disabil-
In relation to the new offences, risk analyses were car-
ity and their families to guarantee the right to a free and
ried out for all the companies and the relevant models are
protected life that is independent in so far as possible,
planned to be amended during 2012.
while respecting their dignity.
The constant verification of the application of the Code
Group support for art
of Ethics allows important transparency objectives to be
The “Consulta”, an organization for the enhancement of
pursued: in agreement with suppliers, for example, a
artistic and cultural heritage of Turin, has several mem-
termination clause was inserted in case of not complying
bers, including Buzzi Unicem. The company is also a cor-
with the principles contained therein.
porate golden donor (a supporter of day-to-day activity)
of the FAI – Fund for the Italian Environment (which safe-
Corruption
guards the Italian heritage).
During 2011 no incidents of corruption were reported.
Buzzi Unicem also supports the Santa Caterina non-prof-
Position and participation in public policy and lobbies
it association set up to restore the church of St. Catherine
Buzzi Unicem SpA is an active member of AITEC, the
(in Casale Monferrato) and its choir.
Technical and Economic Trade Association of Italian
cement manufacturers, and of Cembureau, the European
Group support for Culture
Association based in Brussels.
Buzzi Unicem supports “Cement in the identity of Monferrato Casalese” a non-profit cultural association aiming
In the AITEC, Buzzi Unicem contributes to the exchange of
to raise awareness on, protect and value the heritage
opinions between the industry and institutions, social
of all the assets related to the local binder industry (cement
parties, entities and public and private organizations, while
and lime).
also promoting awareness of the technical and eco-
Transparency of business conduct
how and decades of experience acquired by the industry
nomic potential of its products. Through AITEC, the knowSince 2005 the Code of Conduct has been sent to the em-
are available to all those who, for personal, educational or
ployees of all the companies that are at least 50 %
professional reasons, are interested in better under-
owned by the parent company: maintaining a business
standing the world of cement.
conduct based on the principles stated in the Code
allows us to pursue the objective of transparency. Since
Cembureau is the spokesperson of the cement industry
2003 the company has adopted the Organization,
towards the European Parliament and other EU public
Management and Control Model pursuant to Legislative
authorities. Through the association it is possible to com-
Decree 231 / 2001. In 2011 Buzzi Unicem’s Board of
municate our vision of the community policy develop-
Directors approved the adaptation of the Code of Ethics
ment on issues related to the environment, energy, prod-
to the new cases of offence (environmental offences)
uct regulations and sustainability.
introduced, in August, in the sanction system of Leg.
Decree 231 / 01.
63
Italy
50
20
40
15
30
10
20
5
0
3.0
7.4
25
3.2
6.3
60
3.4
6.2
30
2009
2010
2011
ita
10
0
11.6
17.5
(in %)
10.4
18.4
Heat substitution
(in %)
10.6
18.1
Natural raw materials substitution
2009
2010
2011
bu
ita
4
120
90
2
60
1
30
2009
2010
0
2011
ita
Greenhouse gas
bu
(g / t of clinker)
3,000
626
697
750
2,400
1,800
300
1,200
150
600
2009
2010
0
2011
ita
bu
1,728
1,759
634
681
3,600
0
2011
ita
900
450
2010
bu
NO X
(kg / t of cement)
600
2009
bu
1,779
1,831
0
1,788
1,764
3
3.6
4.0
150
3.6
4.0
180
5
3.6
4.0
6
103
118
(kWh / t of cement)
107
120
Specific electricity consumption
(gj / t of clinker)
111
120
Kiln-specific consumption
626
681
64
2009
2010
2011
ita
bu
Dust
600
160
450
120
300
80
2009
2010
2011
ita
184
147
0
10
0
40
9
150
2009
2010
2011
bu
ita
Water consumption
Waste generation
(l / t of cement)
(g / t of cement)
bu
100 %
3,000
83.3 %
66.6 %
2,400
50.0 %
1,800
33.3 %
1,200
16.6 %
600
600
600
2009
Truck
2010
Train
Ship
76
186
231
bu
ita
bu
115
79
127
261
ita
2
595
129
bu
3
90
53
184
ita
156
15
0
2011
Truck
Train
400
200
0
18
38
800
648
800
654
1,000
200
2011
ita
bu
ita
2009
Ship
Truck
bu
% recycled ita
ita
bu
2010
Train
Ship
365
181
150
(km / t of cement)
350
130
179
Transport – Outbound
(km / t of cement)
238
Transport – Inbound
400
788
1,039
2010
ita
1,000
2,726
76
2,921
66
2009
% rainwater ita
16.6 %
0
15
17
bu
50.0 %
209
2011
ita
327
164
184
2010
0
204
2009
0
66.6 %
33.3 %
13
45
0
3.1
1.7
75
2.4
150
804
355
274
225
259
287
300
2,709
80
3,600
83.3 %
366
100 %
366
450
375
bu
2011
Truck
Train
Ship
200
750
197
240
84
253
900
112
237
(g / t of clinker)
147
357
(g / t of clinker)
15
SO X
65
66
Germany
trading conditions
cement business
Volumes Prices
Mkt share lengerich
neuss
geseke
12.8 %
– 1.5 %
14 %
deuna
neuwied
göllheim
amöneburg
Cement plants
Grinding plants
Germany
covered by synthetic gypsum deriving from desulfurization plants.
Natural resources
Confirming these objectives, the content of clinker in
The production of clinker requires natural resources such
cement produced in Germany in the last 3 years has con-
as limestone, clay or its natural mix, calcareous marl-
stantly dropped, until reaching a value of 70.1 % dur-
stone. About 1.6 – 1.8 t of these raw materials are nec-
ing 2011. Furthermore, the replacement of natural raw
essary to produce 1.0 t of cement clinker.
materials is continuously growing reaching an impressive 14.1 % result compared to the group’s average, which
Currently, the cement industry is committed to increasing
was 7.4 % in 2011.
the amount of substances other than clinker in cement.
It is a measure aiming to affect the properties of the pro-
Energy resources
duct, to improve the cost / effectiveness ratio of the
The production of cement clinker absorbs a large part of
production process, preserve the natural resources and
the thermal energy from fuel transformed at the plant.
recycle substances from other types of processes in
A small part of this is also used for drying the raw mate-
an advantageous way while respecting the environment,
rial. From the middle of the 1970s, the traditional fuels
by complying with German legal provisions on the
used in the cement industry were raw coal, lignite and pe-
management of commercial and industrial waste. In Ger-
troleum. Already back in the 1990s, a significant amount
many, the iron slag and calcareous stone play an im-
of coal was replaced by petcoke.
portant industrial role as potential substitutes of cement
clinker. Natural gypsum and / or anhydrite cover about
During the last few years, the use of alternative fuels in
70 % of the added sulphate demand, used to adjust the
the clinker burning process has assumed an ever greater
working properties of the cement. The remainder is
importance in Germany, among these: pneumatic re-
2011
2010
11 / 10
67
k / c Ratio
12.8
3,170
27.5
100
t /000
649
467
39.0
83.3
Sales revenue
€ m
636.6
548.5
16.1
66.6
€ m
29.0
26.6
9
50
no.
1,822
1,756
3.8
Aggregate sales
numbers & facts
129 ready-mix concrete plants, 3 aggregate quarries.
2009
2010
2011
33.3
16.6
0
ger
bu
jects, other solid fuels with a high heat power (“fluff”),
Electric energy is mainly used for the pretreatment of
residual sludge, oils and exhausted solvents.
raw materials (about 35 %), the burning and cooling of
In two of the German cement plants, residual sludge is
(about 38 %).
clinker (about 22 %) and the grinding of the cement
used as secondary fuel and secondary raw material for the
kiln, a reuse of energy and complete and combined
The consumption of electric energy is about a tenth of the
material.
total energetic consumption.
At the plant in Geseke, a chlorine bypass system was set
The main cause for the slight increase in the electric
up in 2011, which increases the amount of secondary
energy consumption lies in more and more demanding
fuel without needing frequent stops caused by excessive
technical specifications in terms of product quality and
incrustation in the furnace.
the stricter measures to protect the environment.
The heat substitution from alternative fuels has constant-
The German Electric Energy Mix (see 2010) was consti-
ly grown over the years, reaching 50.7 % in 2011. It
tuted of renewable energy: 14.8 % (solar, biomass, wind,
may be stated that more than half of the energy require-
water), 22.6 %, (nuclear), 57.9 % (fossil).
ment is provided by the co-incineration of alternative
fuels, with a notable saving in terms of the environment,
economically speaking.
This result is particularly encouraging in the cement
plant of Geseke, where a heat substitution is recorded
equaling 68.2 %, the best result of the entire group.
4,797
4,043
5,409
t /000
mc /000
70.1
79.7
Concrete sales
71.3
79.8
Cement sales
72.5
79.9
var %
68
Recovery of the copse woodland near Lengerich – Germany
Water resources
At the quarry of the plant in Lengerich, a flock of sheep
Most of the water used in a cement production plant
owned by the company grazes regularly in a way to pre-
is required for cooling and as process water in the condi-
serve the flora of the quarry.
tioning tower during the bypass operation of the kiln.
Greenhouse gases
If possible, rain collected at the plant site or in the quarry
During the clinker burning process, greenhouse gases
is reused. In the German plants, the consumption of
are released into atmosphere. CO represents the majori²
ty of these gases. Other harmful gases from a climatic
water is minimized by using closed-circuit cooling systems.
point of view are released only in very small quantities.
During 2011, this use grew until reaching 38 % of the total
water consumption, equaling 178 l / t cement.
The emissions deriving from the processing of raw materials are produced during the decarbonation of the cal-
Biodiversity
careous stone (CaCO3 –> CaO + CO2) and represent about
Protecting the environment also implies the reintegration
60 % of all CO emissions. The emissions correlated to
²
energy are produced directly through the combustion of
of quarries in the territory via re-naturation or a return
to cultivation after the closure, as well as the reuse, as
fuel and indirectly through the consumption of electric
much as possible, of the materials deriving from the
energy.
production and application of the cement, such as dust,
concrete and discharge water containing cement.
Recovery of the copse woodland near Lengerich. The
use of waste with a high heat power as a secondary fuel
While extending a quarry at the plant of Göllheim, all
in the cement production plants is a direct method to
the measures available were adopted to allow Eurasian
reduce emissions of CO .
²
Eagle-Owls (Bubo Bubo) to nest within the quarry again.
antee the lowest environmental impact possible through
All the Dyckerhoff AG and Deuna Zement GmbH cement
reuse or disposal.
plants have SNCR (Selective Non-Catalytic Reduction)
systems installed in them to reduce NOx. These second-
The ratio between waste which comes from other factories
ary measures are required to respect the extremely
and which is recovered in the production cycle as fuel
restricted NOx emission limits foreseen in Germany based
or raw materials, and waste produced in the plant is 400 / 1,
on the average values recorded every 30 minutes of
confirming the sustainability of the cement production
every day. With respect to these limits, which are record-
cycle.
69
New agreement on environmental safety and the
environment and on the energy policy in Germany
“Safety in the workplace, health and environmental pro-
The constant use of this technology allowed us to reach
tection, as well as an effective use of energy, are essen-
emission factors lower than 1 kg NO x / t clinker, one of the
tial elements of the corporate strategy of the Buzzi Unicem
best results of the group.
group, and are as important as the other key objectives,
Also concerning the emissions of dusts and SO from the
²
burning line, the modern abatement systems such as
were repeated and signed by the Board of Directors
bag filters and the use of reducing agents allow us to reach
GmbH during the first week of November last year.
such as profitability and product quality”. These intentions
and the Work Council of Dyckerhoff AG and Deuna Zement
a value well below the legislative limits and the average
group values.
Since 2009 and in conformity with OHSAS 18001 and ISO
14001, all the German cement production plants have
The SO indicator (g / t clinker) decreased by 46 % from
²
2010 to 2011 mainly due to the use of raw materials
implemented management systems for environmental safe-
with a lower sulfur content in the Lengerich and Geseke
of the “Sicher mit System” seal of quality, and which were
plants.
certified by external bodies. Today, this system has
Waste
pliance with DIN EN 16001 / ISO 50001.
ty and the environment which meet the requirements
been enhanced to include energy management in comThe plants for the production of cement do not generate
specific waste correlated to the type of production; the
Among other things, it requires the definition of parame-
dust collected in the filters is used in the cement produc-
ters which may be assessed in a standardized manner,
tion process. In the cement plants there is only waste
methodical inspections of existing plants, including aux-
typical of large machinery, such as transmission parts, mills,
iliary services, and the adaptation of the most effective
rotary kilns, etc. (exhausted oil and grease) and waste
existing alternatives. Other key elements are documenta-
coming from maintenance.
tion and communication, since the data collected at a
certain plant may be used by other factories. As a result
This waste is collected and recycled (if possible) by com-
of these various aspects, solutions are under develop-
panies specializing in waste treatment, in order to guar-
ment for energy savings in every sector, as well as in production.
an ammonia solution at a well defined temperature range
in the discharge gases of the furnace.
ed in very short time intervals, it is necessary to inject
70
The Dyckerhoff team at the JP Morgan Corporate Challenge, 2011 – Germany
The Board of Directors and the Dyckerhoff management
spectives and constitutes an additional value in terms of
team appointed the people who will have the task of
marketing policies, staff recruitment and corporate image.
implementing the energy improvements, providing them
with all the information and resources necessary to
carry out their work.
Both management and staff are aware of the issue and
in any case all the operational companies respect the
national provisions, overall very similar one to the other
The energy management system will be controlled inter-
as they all derive from community regulations.
nally and externally. Suitable measures and follow-up
plans will be developed to optimize the improvements ob-
Work-Life balance
tained. An energy management system was already
Although the majority of production staff are shift work-
activated in the “pilot plant” in Geseke in August 2011, as
ers, the company systematically seeks to reconcile work
well as subject to an internal control in December 2011
requirements with the needs of individuals.
and an external control at the beginning of February. In
line with international regulations, the energy manage-
ment system will be implemented and certified in all the
No stock granting or stock option programs are envisaged.
other German systems by the end of 2012.
However, for all employee categories, part of their compensation is variable and is based on the company’s prof-
Social Indicators
itability. The average variable portion is about 5 % of
Workplace diversity
the gross annual salary for staff and 14 % for management.
Despite no policy having still been introduced to encourage diversity, this value is considered a source of ben-
Starting from 2011 the variable remuneration for the
efit by both the company and staff, since it expands the
management includes the accident frequency indicator
analysis of opportunities by considering different per-
as managerial parameter, to the tune of 10 % of the
value.
2011
2010
2009
total workforce
1,822
1,756
1,647
Men
1,563
1,502
1,405
259
254
242
1,656
1,623
1,503
German law. Cases not expressly coming within the
scope of the law protecting intellectual properties are rewarded on the basis of collective bargaining.
Women
Training aimed at the development of individual skills, also
Open-end contracts
in terms of career advancement, is promoted in a cus-
166
133
144
tomized manner, considering the potential of the candidate
Full-time
1,704
1,634
1,526
and the corporate need for personnel with respect to
Part-time
118
122
121
the characteristics of the candidate.
Total hires
211
223
132
8.01
On a broader level, HR regularly organizes training courses focusing on subjects of specific interest for the company, such as cement and concrete technology, Project
Management, basic IT skills.
As part of the “Zukunft Personal” (Personnel of the Future)
11.58
12.70
Total terminations
%
145
114
138
%
7.96
6.49
8.38
73
63
70
Due to retirement
22
12
10
50
39
58
Including 136 apprentices (60 white collars and 76 blue collars)
project, an initiative was already launched in 2009 to
refocus the HR development area, with the redefinition of
leadership principles, creation of a skill model and iden-
In Germany, collective bargaining takes place at three
tification of benchmark profiles for individual roles. The
levels: between trade unions and business associations, at
Project was implemented at the beginning of 2010 and
company level and at site level.
continued in 2011: it is intended to strengthen staff’s skills
on an ongoing basis, while building staff loyalty and
At federal level, contractual minimum pay is the main item
motivation. Each individual should be enabled to use his /
handled. Dyckerhoff is represented in the business de-
her capabilities in the best possible way thus contribut-
legations where it is geographically present in terms of
ing to the company’s success. The intention is also to adapt
factories. At present Dyckerhoff is applying some 40
staff qualifications to a constantly changing world of
collective agreements of this type.
work, while also ensuring succession plans at all levels.
At company or site level, the items of operational interest
Staff participation
are negotiated directly by management with the rele-
According to German company law, 3 out of 9 seats on the
vant workers’ representatives. The topics recurring most
Supervisory Board are held by workers’ representatives.
often are:
_ management of safe working practices;
At the factory level, staff are represented by the Works Coun- _ procedures for employees’ improvement proposals;
cil which takes part in the decision-making process in
compliance with regulatory requirements, ranging from
mere information to consultation, up to the right of veto.
_ employee loan programs.
inventions based on a precise framework established by
Cash incentives and bonuses are envisaged for staff’s
71
1.50
50
1.25
0
2009
ger cem
0.25
0
2011
ger cls
bu cem
2009
2010
bu cls
ger cem
To date, some 65 company agreements are in force at
Dyckerhoff.
0.15
0.50
7.3
8.1
2010
0.75
0.16
0.57
0.36
0.52
24.7
1.00
20.5
8.3
10
12.9
30
37.8
28.92
40
20
47.7
60
1.03
0.34
0.53
0.17
0.82
0.3
0.57
15.6
20.1
10.1
72
2011
ger cls
bu cem
bu cls
In compliance with the reference legislation, the mini-
Employment
mum notice period to implement organizational changes
The structure of the German businesses grew to 1,822
is 4 weeks.
employees from 1,756 in 2010, mainly due to an increase
in staff of 37 employees in the concrete segment.
The OHSAS 18001 methodology (the Occupational Health
There were 211 new recruits and 145 terminations, of which
73 resignations, 22 retirements, 50 dismissals.
and Safety Assessment Series – the international standard that sets requirements for systems managing and safeguarding worker health and safety) was recently at all
Labor relations
German factories and the head office. It has been audited
83.6 % of staff (blue-collar and white-collar) are covered
by an accredited certification agency and achieved 100 %
by a collective agreement, whereas directors and man-
certification of German factories.
agers are not.
2010 marked the start of the “Safety first” information
Since Germany is a federation, there is no national col-
campaign, the purpose of which is to heighten the daily
lective labor agreement concerning German businesses.
attention paid by all management and staff to on-the-
Collective agreements are stipulated between the busi-
job safety. In addition to periodic meetings of the “Occu-
ness organization and the trade union, which also includes
pational Health & Safety” task force, the issue is also
representatives of relevant works council.
discussed at all meetings; in particular, there is an in-depth
review of the circumstances that may occur in contractors, or during the start-up of new plants.
73
gg
120
100
80
47
21
19
2010
ger cem
2011
ger cls
bu cem
bu cls
The German sites also take part in a nationwide competi-
Education & Training
tion relating to occupational health and safety orga-
The training days carried out in Germany in 2011 totaled
nized by the German association of cement manufacturers
4,110 (1,729 external training days and 2,381 of inter-
(this year’s data is not yet available). Of note is that no
nal training; absolutely in line with the data of 2010, with
injuries occurred in 2011 at the Geseke site.
4,022 days of which 2,008 external and 2014 internal).
The absentee rate rose slightly from 4.56 % to 5.07 %. No
The highest number of training days was dedicated to dif-
professional illnesses were recorded in 2011.
ferentiated training (635 days, relating to management
and employees, dedicated to specific conferences on con-
Accidents
crete technology, technical training on technology and
During 2011 15 accidents were recorded in the cement seg-
on the chemistry of cement organized by the German trade
ment, for a total of 286 days of work lost. The Geseke
association, updating IT and managerial systems – SAP)
cement plant has an excellent result (0 accidents). This re-
and professional training (456 days, relating to foremen
sult led to a notable reduction in the accident indexes,
and workers, dedicated to the production scheduling
with the Frequency Index equal to 8.1 (– 37 %) and the
and manager training) since it concerns the external train-
Index of Severity equaling 0.15. Both the indexes are
ing and differentiated training (for 780 days, detailed
among the lowest recorded in the whole Buzzi Unicem
training for member of the works council, for PAs, updates
group.
within the HR management following the organizational
modifications introduced, project management, sales
On the contrary, the concrete segment recorded a slight
techniques) concerning internal training. Also significant
increase in the accident indexes, with a Frequency
is the safety training with about 800 days in total be-
Index equaling 47.7 and an Index of Severity equal to
tween external and internal.
1.03, due to the 55 accidents recorded in the year.
2009
0
22
20
11
41
30
20
40
12
15
43
25
60
74
Employee and family day in the quarry of Amöneburg – Germany
road race of 2011 which saw the highest number of
participants. In addition to being a reason for corporate
As regards function heads at the central corporate unit
cohesion, this initiative also serves a noble purpose:
level, plant or area managers in the concrete segment, and
the registration fees were donated to the “German Sport
in the office functions, 20 % of management is local
Aid Foundation”, a charitable body that promotes sport
and 80 % inter-regional / national.
among diversely-abled students.
In factories in the cement segment 30 % of plant manage-
Donations
ment is local and 70 % inter-regional / national.
Dyckerhoff AG donated two life size statues of human
In the concrete segment 80 % of plant management is
Wiesbaden.
figures made of high-spec white concrete to the city of
local and 20 % inter-regional / national.
Group support for the environment
Dyckerhoff AG supports the Teutoburger Wald e. V. Asso-
ciation, founded in 1998 and joining Dyckerhoff repre-
In Germany, an event is held once a year to display the
sentatives and volunteers. Its purpose is to develop com-
productions sites’ activities and particularly the use
mon projects for the forest of Teutoburg in Lengerich
of alternative fuels, and the re-naturalization of quarries.
aimed at wildlife, landscape and people, including hikes,
conferences and activities to protect the copse wood-
Dyckerhoff participated with a team of 58 athletes / employ-
land. In 2011, thanks to the help of 11 Dyckerhoff appren-
ees coming from the entire country in the 19th edition
tices, 500 beech trees were planted.
of the JP Morgan Corporate Challenge in Frankfurt, the
All of the Dyckerhoff group’s activities are subject to
fraud risk analysis, as part of the annual integrated system
of internal control.
According to the Code of Conduct, the offers, payments,
requests and acceptance of cash in any form are unacceptable. The Dyckerhoff’s groupwide effective Internal
75
vide information directly to the Corporate Audit, including
any type of fraud and any case of corruption.
Corruption
For the cement industry, Dyckerhoff is part of the
Audit Standard provides for all the group’s units to pro-
ber of Cembureau.
For the concrete industry, Dyckerhoff is member of the
Union of Concrete Producers.
Cement Manufacturers Association (VDZ), former mem-
Heat substitution
(in %)
(in %)
50
20
40
15
30
2011
ger
17.5
12.3
2010
18.4
2009
18.1
2009
2010
2011
10
0
bu
ger
4
120
90
2
60
1
30
2009
2010
0
2011
ger
Greenhouse gas
bu
(g / t of clinker)
3,000
581
697
750
1,800
300
1,200
150
600
2009
2010
0
2011
ger
bu
999
1,759
2,400
1,831
600
681
3,600
0
2011
ger
900
450
2010
bu
NO X
(kg / t of cement)
600
2009
bu
2010
2011
1,764
0
883
3
3.8
4.0
150
3.9
4.0
180
5
3.8
4.0
6
116
118
(kWh / t of cement)
114
120
(gj / t of clinker)
111
120
2009
894
0
20
7.4
5
6.3
10
45.6
25
14.1
60
11.1
6.2
30
48.9
50.7
Germany
603
681
76
ger
bu
Dust
600
160
450
120
300
80
2009
2010
2011
ger
184
147
0
18
0
40
15
64
150
2009
2010
2011
bu
ger
Water consumption
Waste generation
(l / t of cement)
(g / t of cement)
bu
83.3 %
66.6 %
2,400
50.0 %
1,800
33.3 %
1,200
16.6 %
600
2,709
57
2010
0
bu
ger
bu
ger
bu
2009
Truck
2010
Train
Ship
2011
Truck
Train
0
ger
bu
762
ger
2009
Ship
% recycled ger
754
350
130
179
ger
200
246
168
76
186
231
400
59
24
45
600
400
79
127
261
600
73
24
106
800
90
53
184
800
69
69
84
1,000
bu
Truck
bu
ger
2010
Train
Ship
365
181
150
(km / t of cement)
728
(km / t of cement)
0
2011
ger
200
682
702
2009
% rainwater ger
1,000
50.0 %
33.3 %
269
134
2011
bu
66.6 %
16.6 %
0
327
164
184
2010
ger
671
146
2009
0
235
148
0
8.1
123
150
178
225
75
38.5
355
37.9
300
2,726
65
100 %
3,000
2,921
68
3,600
83.3 %
366
100 %
366
450
375
bu
2011
Truck
Train
Ship
200
750
197
240
17
253
900
32
237
(g / t of clinker)
357
(g / t of clinker)
12
SO X
77
78
Luxembourg
trading conditions
cement business
Volumes Prices Mkt share 22.3 %
– 1.8 %
na
esch-sur-alzette
rumelange
Cement plants
Grinding plants
Luxembourg
The replacement of natural raw materials with waste
and / or products in 2011 increased notably, until reaching
Natural resources
23.5 %.
Calcareous stone and marl are necessary for the production of cement clinker. The extraction of these mate-
Energy resources
rials causes interference with the environment such
The operation of burning the cement clinker absorbs most
that to produce 1.0 ton of cement clinker, about 1.55 tons
of the thermal energy consumed in the production pro-
of material are needed. Raw materials may be replaced
cess. A smaller amount of thermal energy is used for dry-
with other substances with a similar chemical composi-
ing the raw materials and other cement components.
tion: airborne ash, iron slag and industrial residues
from the aluminum recycling industry containing alumi-
Currently, alternative fuels are an important source of en-
num oxide are replacement components of marl and
ergy for the cement industry and contribute to the re-
clay; gypsum, or a mixture of gypsum and anhydrite, is
duction of the volume of fossil fuels used and the emis-
added to the cement mill to check the setting of the
sions of CO . In 2011, in the plant of CIMALUX, alterna²
tive fuels absorbed 29.1 % of the total consumption of fuel
cement.
energy: reject tires, other solid fuels (“fluff”), puriCalcareous stone and granulated iron residues are espe-
fication sludge and solvents were used.
cially industrially important as potential substitutes of
cement clinker. The second are a by-product from
The total consumption of fuel at the plant of CIMALUX
hot metal production and are used in the production of
equaled 2,738,991 GJ and the total electric energy amount-
Portland cements of slag and blast-furnace cement.
ed to 128,849 MWh. Fuel energy is mostly necessary
79
k / c Ratio
1,319
1,079
22.2
83.3
€ m
112.8
92.3
22.2
66.6
€ m
2.2
8.0
– 72.5
50
no.
157
156
0.6
numbers & facts
Cement production capacity 1.4 million tons, 2 plants.
2009
2010
2011
33.3
16.6
0
lux
bu
for the burning of clinker (91.3 %), while electric energy
oration in the cooling tower are to be compensated. In
is mainly used for the pre-treatment of the raw mate-
the grinding plant, the water is used in ball mills to cool
rials (about 14.7 %), for the burning and cooling of clin-
the cement. The improvements to the process made
ker (about 20.3 %) and for cement grinding (about
in the Cementmill VIII plant reduced consumption con-
50.5 %).
siderably.
The more and more demanding specifications in terms of
product quality and the measures aiming to improve
Biodiversity
environmental protection were the main cause of the ever
Cement production is based on using natural resources.
growing trend in electric energy consumption during
Calcareous stone and marl are obtained from a quarry
the last decades.
situated near the plant in Rumelange and the extraction
process means a substantial change in the natural con-
Water resources
formation of the environment: trees are cut down but the
Most of the water used in cement production plants is
top soil is removed from the original location and stored
required to cool the mechanisms and the large-sized ma-
for the reforestation that will be carried out at the end of
chinery. It is also used as process water in the kiln con-
the mining operations, while new structures are created
ditioning towers.
to offer the fauna and the flora more diversified scenarios.
Thus, the new environment is ready to be quickly repop-
The water used in the plants is collected in a gallery of
an old disused chromite mine. The consumption of water
is minimized, thanks to the use of closed-circuit cooling
systems, in a way that only the water losses and the evap-
ulated by new species of birds and amphibians.
t /000
Sales revenue
Cement sales
100
69.6
79.7
11 / 10
var %
69.9
79.8
2010
71.3
79.9
2011
80
Rail transportation, Esch-sur-Alzette – Luxembourg
Greenhouse gases
During the clinker burning process, gases are released
The measurement, monitoring and signaling of emissions
with an important climatic impact. CO represents the
²
majority of these gases. Emissions correlated to raw mate-
improvement of the environmental performance of cement
contribute to the understanding, documentation and
rials are produced during the decarbonation of the cal-
production plants. In 2007, the factory of CIMALUX in-
careous stone and represent about 66 % of the total emis-
vested in new equipment to continuously monitor the
sions of CO . The emissions correlated to energy are
²
produced directly through the combustion of fuel, and in-
emissions of dusts, NO x, SO , TOC and CO in correspon²
²
dence with the chimney, while the remaining parame-
directly through the use of electric energy.
ters, important for environmental pollution laws, are mea-
In 2011, 561 kg of CO per ton of equivalent cement
²
were released. By substituting raw materials with decar-
controlled by the national government authorities of Lux-
sured in a discontinuous manner. All the emissions are
embourg.
bonated iron slag it will be possible to reduce the emissions of CO in the future.
²
We recorded a reduction in NO x emissions in 2011 com-
The use of waste with a high heat power as a secondary
ing the entrance for fuels. This allowed us to reduce the
fuel in the cement production plants is a direct system
speed of the gas and improve the combustion of shred-
to reduce emissions of CO since most of these fuels con²
tain a percentage of biogenic carbon.
to the kiln significantly reduced the emissions of NO x.
pared to 2010. In 2010, the kiln was modified by widen-
ded tires. The combustion of shredded tires at the entrance
Therefore, we put a new main burner into operation with
CO emissions from plants are not measured but cal
²
culated on the basis of the production of clinker and the
with the tire feeding system which we fixed at the start of
fuels used.
2011. The addition of shredded tires meant a signifi-
low emissions of NO x. In 2010, we had some problems
cant reduction in NO x emissions.
81
environmental excellence that testifies to the optimal
performance in terms of reusing waste.
phuric compounds, so that our emissions are normally far
below measurable levels. In the second half of the year,
Social Indicators
we used slag cement to economize on natural raw mate-
Workplace diversity
rials and the consumption of energy while containing
Despite no policy having still been introduced to encour-
the emissions of CO .
²
age diversity, this value is considered a source of ben-
This new material contains a high percentage of sulphur,
which explains the increase in SO emissions.
²
Waste
efit by both the company and staff, since it expands the
analysis of opportunities by considering different perspectives and constitutes an additional value in terms of
marketing policies, staff recruitment and corporate
image.
The management of a cement production plant does not
necessarily mean the production of typical waste. It is
Both the management and staff are aware of the issue and
important to only eliminate the waste produced from main-
tenance and project works. The plant in CIMALUX par-
ticipates in a national initiative to eliminate these small
quantities of waste. For recycling, when possible, or for
the elimination of small quantities of waste and hazardous
products, the project ‘Super-DrecksKëscht fir Betrieber’
follows the rules of sustainable development. After successfully passing the annual review by ‘SDK fir Betrieber’, the two plants in CIMALUX were awarded a seal of
Our emissions of SO are very low, due to the type of raw
²
materials we use. Our raw materials are very low in sul-
0
2010
bu cem
0
2009
2010
bu cls
2011
lux cem
0.34
0.53
1.02
0.25
2011
lux cem
0.75
0.3
0.57
28.5
20.5
2009
1.00
0.50
7.3
10
8.3
20
10.1
30
23.8
40
0.36
0.52
1.25
24.7
1.50
50
28.92
60
0.98
0.33
34.5
82
bu cem
bu cls
Work-Life balance
of general interest such as cement and concrete technol-
Although the majority of production staff are shift workers,
ogy, safety at work, project management, languages,
the company systematically seeks to reconcile work
office automation and managerial systems.
requirements with the needs of individuals.
In addition, Luxembourg labor laws foresee additional
The collective bargaining works directly between the com-
leave for training purposes.
pany and the trade unions concerning employment contracts, while more operational issues are negotiated at fac-
tory level.
No stock granting or stock option programs are envisaged.
On the other hand, it is possible to activate variable
Employment
remuneration forms in consideration of the corporate
The structure is substantially stable with 157 employees
performances.
(one more than in 2010), with 10 recruitments record-
period.
ed compared to 9 resignations recorded in the reference
Training aiming to develop personal skills and promoting
career advancement is provided in a customized manner, in consideration of the company needs and the potential of the candidate.
On a wider scale, the specific HR departments of the individual countries organize training programs on subjects
83
gg
120
100
80
2010
2011
lux cem
bu cem
bu cls
Labor relations
2011
Two separate collective contracts are applied, one for
2010
2009
white-collar and one for blue-collar, with an application
rate of 88.58 % of the personnel. Both are negotiated
total workforce
157
156
152
Men
147
147
143
10
9
9
155
154
150
2
2
2
Full-time
153
153
149
Part-time
4
3
3
Total hires
10
15
8
6.37
9.62
5.26
9
11
6
5.73
7.05
3.95
2
0
2
Due to retirement
7
10
4
Women
Open-end contracts
%
Total terminations
%
Including 2 apprentices (white collars)
directly by the company with the most representative trade
unions.
There are no notice obligations before implementing organizational changes.
The reference regulation is Directive 2002 / 14 / EC, absorbed by the legal system of Luxembourg on 9 May 2008,
which imposes the notice to and consultation with the
relevant workers regarding business development, employment progression and significant organizational changes.
0
47
21.5
34
25
30
20
2009
1
0
The absentee index is 6.26 %, up compared to 5.74 % in
2010 due to an increase in absences for accidents.
0
10
20
43
40
43
60
84
Living cement – concrete house in Schengen – Luxembourg
Accidents
Training
In 2011, 9 accidents were recorded, 2 more than the 7 in
There were 205 external and internal (170 + 35) training
2010. As a consequence, the Frequency Index rose by
days mostly focused on technical training and occupa-
20 % and is the highest among the group’s cement seg-
tional safety.
ment. Therefore it is necessary to raise staff’s awareness in order to reduce the occurrence of accidents and
especially those linked to behavioral faults. The Index
of Severity equals 0.98, practically constant compared to
Substantially all the management, including senior man-
2010, also among the worst of the group, with accidents
agers, is local, though without having adopted any for-
lasting 34 days on average.
mal specific policy.
Occupational Health & Safety training and
Corruption
prevention programs
Informative seminars for all the personnel and periodic
inspections for workers are envisaged, according to the
healthcare protocol drawn up by the labor physician. The
Cimalux actively supports Fedil, the “Luxembourg Busi-
company offers a voluntary flu shot program.
ness Federation”, and Cembureau.
Compulsory prophylaxis is provided against hepatitis B
and tetanus for risky activities such as handling industrial sludge.
85
Luxembourg
Heat substitution
(in %)
(in %)
60
25
50
23.5
30
2010
2011
lux
0
2009
120
3.2
90
2
60
1
30
2010
0
2011
lux
2011
lux
bu
(g / t of clinker)
750
3,000
561
697
3,600
300
1,200
150
600
2009
2010
0
2011
lux
bu
1,122
1,759
1,800
1,445
1,831
2,400
1,609
1,764
587
681
900
0
2010
bu
NO X
(kg / t of cement)
450
2009
bu
Greenhouse gas
600
116
118
4
4.0
150
3.6
4.0
180
5
3.8
4.0
6
104
120
(kWh / t of cement)
108
120
2009
2011
lux
(gj / t of clinker)
0
2010
bu
3
25.4
17.5
2009
10
18.4
0
7.4
20
5
6.1
6.3
10
5.4
6.2
30
30.2
40
15
21.9
18.1
20
625
681
86
2009
2010
2011
lux
bu
Dust
600
160
450
120
300
80
0
2009
2010
2011
60
147
184
34
0.4
150
40
0
lux
2009
2010
2011
bu
lux
Water consumption
Waste generation
(l / t of cement)
(g / t of cement)
bu
83.3 %
66.6 %
2,400
225
50.0 %
1,800
150
33.3 %
1,200
16.6 %
600
2011
2,709
74
2010
2,066
(km / t of cement)
2009
Truck
lux
2010
Train
Ship
bu
2011
Truck
% recycled lux
Train
0
lux
bu
lux
2009
Ship
Truck
bu
lux
2010
Train
Ship
365
181
150
16
0
200
0
0
bu
350
130
179
lux
257
bu
86
lux
76
186
231
0
103
18
400
79
127
261
600
400
8
600
90
53
184
800
35
49
59
800
200
bu
1,000
0
0
2,042
(km / t of cement)
16.6 %
0
2011
lux
1,000
572
832
2009
% rainwater lux
50.0 %
419
bu
66.6 %
33.3 %
327
164
184
lux
0
312
2010
0
669
66
355
2009
0
0
0
100
0
75
123
300
2,726
77
100 %
3,000
2,921
82
3,600
83.3 %
366
100 %
366
450
375
bu
2011
Truck
Train
Ship
200
750
197
240
0.7
253
900
0.1
237
(g / t of clinker)
357
(g / t of clinker)
47
SO X
87
88
The Netherlands
nieuwegein
The Netherlands
A bonus is foreseen for good economic and financial
In the case of the Netherlands no environmental indi-
results for the top management.
cators are provided since the company does not actively
produce cement in this country.
Training aiming to develop personal skills and career ad-
Social indicators
vancement is provided in a customized manner, in con-
Workplace diversity
sideration of the company needs and potential of the can-
Despite no policy having still been introduced to encour-
didate.
age diversity, this value is considered a source of benefit by both the company and staff, since it expands the
On a wider level, HR organizes training courses on sub-
analysis of opportunities by considering different per-
jects of general interest such as cement and concrete
spectives and constitutes an additional value in terms of
technology, safety at work, project management, office
marketing policies, staff recruitment and corporate
automation and managerial systems.
image.
Staff participation
Both the management and staff are aware of the issue and
At company level the employees are represented by the
Works Council which, depending to the subjects being
dealt with, has information, consultation or even in certain
cases veto powers.
2011
2010
89
11 / 10
mc / 000
947
914
3.6
t /000
3,290
3,737
– 12.0
Sales revenue
€ m
109.7
113.2
– 3.0
€ m
2.3
2.2
4.5
no.
287
287
0.0
Aggregate sales
numbers & facts
Collective bargaining takes place between the trade
2011
unions and entrepreneurial organizations where Dycker-
2010
2009
hoff Basal Netherlands is represented and between the
company and trade union representatives, with more operative competences.
total workforce
287
287
296
Men
263
263
269
24
24
27
269
268
270
Women
In 2011 a new collective contract was signed.
Open-end contracts
Staff assistance programs
Full-time
18
19
26
256
259
269
In 2011 telecommuting was revitalized. Staff may also
Part-time
31
28
27
resort to a collective healthcare policy (corporate).
Total hires
24
14
12
8.36
4.88
4.05
24
23
13
8.36
8.01
4.39
In addition it is possible to stipulate an insurance policy
for third party liability for personal vehicles with (more
advantageous) corporate tariffs.
Employment
The headcount stood at 287 employees, with 24 recruitments against 24 terminations. Of the 24 terminations,
20 were dismissals.
%
Total terminations
%
17
19
5
Due to retirement
3
2
8
4
2
0
Concrete sales
var %
1.25
0
2009
2010
0
2011
nld cls
2009
2010
bu cls
0.53
0.25
0
0.50
0
10
0.75
0.52
20
1.00
0.03
12.7
30
20.5
40
24.7
1.50
50
28.92
60
0.57
0.04
3.6
90
2011
nld cls
bu cls
Labor relations
Corruption
Collective bargaining is applied to 94 % of employees
and 4 weeks are required before implementing substantial
organizational changes.
Since July 2011 Dyckerhoff Basal has gone back to
being part of VOBN (Dutch concrete association), which
The absentee index (5.58 %) remained unchanged over-
it had left at the end of 2010.
all compared to the previous year (5.54 %) and no professional illnesses were recorded for the year in question.
Training
In total 260 days of training were supplied, with particular
importance given to occupational safety (100 days).
In the Franeker plant, a wind farm is being built which will
supply most of the energy required for the activities
of Dyckerhoff Basal in the northern region of the country.
Thanks to this project CO emissions into the atmo²
sphere will be greatly reduced.
91
gg
120
100
80
21
0
25
2
2010
2011
nld cls
bu cls
2009
0
20
20
12
40
60
92
Poland
trading conditions
cement business
Volumes Prices * Mkt share 7.8 %
0.8 %
9 %
nowiny
* in local currency
Cement plants
Terminals
Poland
Water resources
Potable water is obtained from groundwater wells owned
by the company, two wells pump water from the Devon
Natural resources
geological stratus. Potable water is used for hygienic pur-
In 2011, the quantity of raw materials used for the pro-
poses.
duction of cement was very similar to the previous years.
The specific consumption of water is estimated at around
The value, equal to 14.6 % (twice the group average), is
186 l / t equivalent cement, constant compared to 2010,
among the highest recorded in 2011.
and equal to about 50 % of the group’s average consumption.
Energy resources
The specific consumption, equal to 120 kWh / t equivalent
Greenhouse gases
cement, is in line with the group’s average, with an
In 2011 the total emissions of the Polish Dyckerhoff
increase of 10 % from 2010. This is due to a greater use
cement plant were 921,933 t, sufficient to meet the pro-
of alternative fuels thanks to an increase in the fluff dos-
duction needs of the facility.
age. A less fine clinker requires more energy consumption
for the grinding.
The emission factor from calcination showed a slight re-
The use of alternative fuels, such as tires and used oils,
duction (0.41 t co / t cement) while the emission factor
²
from combustion slightly increased (0.24 t co / t cement).
²
allowed us to recover 72,314 t of waste, with a consequent
heat replacement of 35.7 % (43 % more compared to
2010).
2011
2010
1,614
1,497
11 / 10
93
k / c Ratio
871
17.1
83.3
144.0
129.3
11.4
66.6
€ m
2.2
2.3
– 4.3
no.
389
411
– 5.4
numbers & facts
Cement production capacity 1.6 million tons, 1 plant,
1 terminal, 30 ready-mix concrete plants.
2009
2010
2011
50
33.3
16.6
0
pol
bu
Waste
Dust emissions from rotary kilns, together with those
In 2011, the cement plant produced a lower quantity of
of NO x and so , are measured continuously. The emission
²
of dust from the cooler is measured periodically.
waste compared to 2010 (– 98 % per t equivalent cement). Since 2010, refractory waste has not been replaced
every two years.
Thanks to the use of bag filters throughout the entire
technological process, the emission of dust during 2011
In 2011, 2.58 t of bag filters were burned in the Polish
was kept at an extremely low level and was significant-
kilns. The remaining waste was sent to external companies.
ly lower than the quantities defined in the integrated authorization.
Social Indicators
Work-Life balance
The emission factor for nitrogen oxides was 965 g / t of
In Poland, flexi-time is permitted to all the personnel who
clinker, with a reduction compared to 2010 of 24 %. Also
do not work shifts.
the value of the dust emissions recorded a drop, equal
to 31 %. On the other hand, the emission factor for sul-
This type of organization and the frequent open days
phur oxides, equaling 845 g / t of clinker, is the highest
or initiatives such as company outings and carnival cele-
recorded in the group (+ 22 % compared to 2010). This
brations, help strike a balance between work, recreation
is due to the greater content of sulphur in the raw ma-
and family time.
terials and fuels.
1,020
€ m
mc / 000
Sales revenue
100
74.3
79.7
7.8
74.9
79.8
Concrete sales
t /000
74.2
79.9
var %
Cement sales
1.25
0
2009
2011
pol cls
bu cem
0.25
0
2009
2010
bu cls
In Poland a participation bonus is connected to the eco-
2011
pol cem
0.08
0.34
0.53
2010
pol cem
0.75
0
10
1.00
0.50
0
2.8
7.3
20
20.5
30
3.1
7.6
8.3
40
24.7
1.50
50
28.92
60
0.76
0.21
0.36
0.52
0.12
0.40
0.3
0.57
6.0
13.1
10.1
94
pol cls
bu cem
bu cls
2011
2010
2009
total workforce
389
411
423
Men
314
327
337
75
84
86
336
354
343
nomic results. This ranges between 3 % and 5 % of the
gross annual salary.
Staff participation
Staff are represented by the Trade Unions and the factory
delegates, as established by law.
Women
Open-end contracts
Full-time
53
57
80
389
411
423
Collective bargaining takes place at factory level. The col-
Part-time
0
0
0
lective contract lasts several years but does not have
Total hires
22
17
25
5.66
4.14
5.91
44
29
21
11.31
7.06
4.96
8
9
9
Due to retirement
6
2
1
30
18
11
direct economic repercussions. There is a second collective contract, negotiated each year, that serves the exclusive task of financial adjustment.
Employment
The headcount dropped from 411 employees in 2010
to 389 in 2011, mainly due to the transfer of 3 concrete
plants and the closure of a fourth.
%
Total terminations
%
95
249
gg
120
100
80
47
21
28
0
25
28
2010
pol cem
2011
pol cls
bu cem
bu cls
Labor relations
Training
Practically all the staff (387 employees out of 389) have
569 external and 16 internal training days were held
a collective contract.
(compared to 699 and 28 in the previous year).
The minimum notice period to make organizational
Most of the training was of a professional nature. For the
changes, which were not recorded in the year in question,
managerial and white-collar personnel it focused on
is 12 weeks.
taxation, antitrust, accounting and legal updates. Training
new certificates by the personnel to work on mechanical
for blue-collar personnel concerned the acquisition of
The absentee rate of 2.05 % notably reduced from the
and electrical systems. The new certifications last 5 years
already low one of 2010 (2.83 %).
whereas the previous ones did not have an expiry date.
Accidents
Corruption
To reconfirm the good result achieved in 2010, when 1
accident in 249 days was recorded, in 2011 the excellent
result of “0 accidents” was achieved.
Dyckerhoff Polska is present in various associations, such
Also in the concrete segment encouraging results were
as the “Polish Cement Association”, the “Polish Associ-
obtained, given that during 2011 only 1 accident was
ation of Ready Mixed Concrete Producers” and the “Polish
recorded lasting 28 days.
German Chamber of Commerce & Industry”.
2009
0
20
30
30
20
20
43
40
60
96
Nowiny Plant – Poland
Sanctions and fines received for non compliance with
laws and regulations
In 2009 Dyckerhoff Polska received a sanction for about
€ 15 million for not complying with Polish law on competition, for which an appeal has been filed, still awaiting
definition.
97
Poland
Heat substitution
(in %)
(in %)
20
40
15
30
14.5
6.3
7.4
14.0
2009
2010
2011
5
pol
10
0
2009
2010
2011
bu
pol
4
120
90
2
60
1
30
2009
2010
0
2011
pol
Greenhouse gas
bu
(g / t of clinker)
3,000
647
697
750
1,800
300
1,200
150
600
2009
2010
0
2011
pol
bu
2009
2010
1,759
2,400
1,279
1,831
643
681
3,600
0
2011
pol
900
450
2010
NO X
(kg / t of cement)
600
2009
bu
1,764
0
981
3
3.9
4.0
150
3.6
4.0
180
5
3.5
4.0
6
113
118
(kWh / t of cement)
108
120
(gj / t of clinker)
105
120
bu
965
0
20
6.2
10
17.5
50
25.0
18.4
25
17.0
18.1
60
14.6
30
35.7
629
681
98
2011
pol
bu
Dust
240
2010
2011
0
pol
2009
2010
25
253
2009
40
36
237
0
197
80
150
41
120
357
300
160
147
557
600
450
200
689
750
2011
bu
pol
Water consumption
Waste generation
(l / t of cement)
(g / t of cement)
bu
83.3 %
66.6 %
2,400
50.0 %
1,800
33.3 %
1,200
16.6 %
600
2,709
542
2010
(km / t of cement)
0
pol
bu
76
186
231
400
47
18
0
600
400
79
127
261
600
39
21
0
800
90
53
184
800
33
20
0
1,000
pol
bu
pol
bu
2009
Truck
2010
Train
Ship
2011
Truck
Train
200
0
350
130
179
(km / t of cement)
43
27
0
200
2011
pol
1,000
pol
bu
Truck
bu
pol
2009
Ship
28
5
2009
% rainwater pol
16.6 %
% recycled pol
bu
pol
2010
Train
0
Ship
365
181
150
bu
50.0 %
46
21
0
2011
pol
0
327
164
184
2010
0
66.6 %
33.3 %
47
28
0
2009
0
0
0
0
75
12
186
184
150
203
225
207
355
300
2,726
75
100 %
3,000
2,921
3,600
83.3 %
366
100 %
366
450
375
bu
2011
Truck
Train
Ship
900
(g / t of clinker)
845
(g / t of clinker)
184
SO X
99
100
trading conditions
cement business
Volumes Prices *
Mkt share 26.2 %
– 11.5 %
16 %
hranice
* in local currency
Cement plants
in 2011 equaled 27.1 % of thermal energy, equivalent
to 33,678 tons.
Czech Republic environmental indicators
Natural resources
The primary fuels used are coal and methane. In detail,
The Hranice plant owns two quarries: Černotín, 5 km
the latter for the production of thermal energy is in turn
away, which extracts 10 % of the annual requirement
used to heat the buildings and the water.
and, Skalka, located at the plant, which extracts 90 %.
The Hranice cement plant participates in the production
The content of clinker in the cement produced in the
of electric energy from renewable sources to pay for the
Czech Republic in recent years is constantly dropping,
MWh consumed, based on the prices set by the Energy
until reaching, during 2011, a value equal to 79.4 %.
Regulation Office. 20 % of the normal price of the MWh
Furthermore, the replacement of natural raw materials is
is allocated to renewable energy.
continuously growing, reaching 13.5 %. Used in particular are the airborne ash originating from the power plants,
Water resources
iron slag coming from the foundries and iron oxide from
The water used for industrial purposes is obtained from
steel production. In 2011 consumption was 207.507 tons.
two sources: river stagnation basins and a collection tank
located in the lower part of the Skalka quarry, where
Energy resources
the water of the quarry is collected.
The cement plant in Hranice obtained the permit to use
selected material and burn selected waste in 2009. During the clinker burning process, alternative fuels are
used, like biomass, plastics and tires, whose contribution
Water consumption is subdivided into:
2011
2010
11 / 10
101
k / c Ratio
12.2
100
t /000
1,575
1,530
2.9
83.3
Sales revenue
€ m
172.0
159.4
7.8
66.6
€ m
3.0
5.2
– 42.3
50
no.
871
908
– 4.1
Aggregate sales
numbers & facts
Cement production capacity 1.1 million tons, 1 plant,
2009
2010
2011
33.3
16.6
0
_ a Roman well with spring water provided by the public
cze
bu
The company undertakes efforts to ensure the regular
water supply network: all the used water is discharged
monitoring of the renaturalization work and is presently
to the municipal water treatment plant;
carrying out maintenance works as well as compensa
_ the water used for the closed-circuit cooling process:
tory woodland planting. The areas where extraction has
57.972 m³ of water are added to the surface water due
already taken place may be redeveloped during future
to the evaporation caused by the cooling.
mining activities based on the approved general project
for territorial redevelopment and renaturation, which
Biodiversity
is obligatory.
The protected species in this location is a jersey tiger moth
(Callimorpha quadripunctaria). The border of the location
Greenhouse gases
corresponds to the border of the mining area in Hranice.
At the plant the clinker factor is being reduced, and
The extraction activity in the area bordering the pro
consequently so are the emissions of CO² – using iron slag
tected site was interrupted and the soil is being renaturalized.
as a substitute. To be able to produce a type of cement
with a greater content of iron slag and therefore less clinker, the main components (clinker and iron slag) are
Mining and renaturation activities in the locations men-
ground separately and the terrestrial materials are treat-
tioned are permitted and monitored by the authorities
ed with a common separator.
entrusted by the public administration pursuant to current
legislation. The permits must consider the measures for
the prevention of the negative effects of mining and the
The emissions of CO², calculated according to national
legislation, were 612,062 t. Of these about 66 % may be
renaturalization in the protected areas.
attributed to the decarbonation phase, while the remainder may be attributed to combustion. The 28 % increase
26.2
760
1,529
959
1,715
79.4
79.7
t /000
mc /000
82.6
79.8
Cement sales
Concrete sales
82.0
79.9
var %
1.25
0
2009
2011
cze / svk cls
bu cem
0.25
0
2009
2010
bu cls
cze cem
cze / svk cls
0.34
0.34
0.53
2010
cze cem
0.75
0.03
10
1.00
0.50
3.5
5.7
7.3
20
20.5
30
3.4
4.2
8.3
40
24.7
1.50
50
28.92
60
0.32
0.14
0.36
0.52
0.22
0.48
0.3
0.57
9.8
7.7
10.1
102
2011
bu cem
bu cls
in clinker production means an inevitable increase in
Waste
the emissions of greenhouse gases, partly mitigated by
The ratio between waste which is recovered in the produc-
the reduction in the clinker / cement ratio, down by 3 %,
tion cycle as fuel or raw materials, and waste produced
while the specific consumption of the burning line re-
in the plant is 200 / 1, confirming the sustainability of the
mained constant. As a consequence the emission factor,
cement production cycle.
equaling 622 kg / t of equivalent cement, recorded a reduction of 4.6 %, placing it among the lowest of the entire
Czech Republic social indicators
group.
Work-Life balance
The shift system applied in the cement segment was con-
sidered as the best to best combine professional com-
The emission factors recorded in 2011 were respectively
mitment with rest, free-time and family activities. Also or-
equal to 12 g / t clinker for the dust, 1,219 g / t clinker
ganized are corporate events in favor of families and
for NO x and 56 g / t clinker for SO x. All the emission fac-
employees’ children, to promote a sense of belonging and
tors are notably lower than the group average. For dust
satisfaction at work.
and sulphur oxides, in particular, the emission factor is
10 % lower than the group’s average.
Also in the concrete segment, part-time is encouraged
for young mothers and numerous maternity leave con-
The dust indicator (g / t clinker) decreased by 24 % from
tracts are being stipulated to favor parental leave. The
2010 to 2011 due mainly to greater, more stable pro-
headquarter and administrative activities are particu-
duction of clinker. No technical modifications were made.
larly suitable for these kind of substitutions or to start parttime contracts or tele-commuting.
The SO indicator (g / t clinker) doubled with respect to
²
2010 due mainly to the use of raw materials with high sul-
These measures increase staff loyalty and the sense of
fur content.
belonging.
103
gg
120
92
100
2009
47
21
10
34
43
25
2010
cze cem
2011
cze cls
bu cem
bu cls
one of the three members of supervisory board is ap-
In the cement sector salaries may be increased by a
pointed by the employees and stays in office for two years.
portion upon reaching some previously negotiated financial results.
Communication at factory level takes place between management and the workers’ representative.
In the concrete sector, individual management performance plans based on the profitability of the company
Occupational Safety
are not envisaged, notwithstanding exceptions.
In the cement sector, each year an Intervention Plan
is drawn up and all the activities are carried out and mon-
On the other hand, each year a prize is awarded to the
best concrete plant.
Contributions are also envisaged to support the stipulation of life insurance policies for the full-time personnel.
Training courses implemented in the concrete segment
concern technical development on systems, health and
safety, the environment, accounting and English.
Staff participation
In the cement segment, according to Czech corporate law,
itored according to the Standard OHSAS 18001.
0
30
20
20
22
40
60
62
60
80
104
The Zapa locomotive leaves the Hruba Voda quarry – Czech Republic
In the cement segment, a collective contract is applied,
2011
2010
2009
total workforce
727
746
744
Men
631
647
643
96
99
101
721
binding for the parties and renegotiated annually, while
there are no collective contracts – except one – in the concrete segment.
Employment
Women
The headcount decreased from 746 employees in 2010
Open-end contracts
702
722
to 727 in 2011, substantially due to a rationalization pro-
25
24
23
gram in the concrete segment. In total 32 new recruits
Full-time
716
732
729
Part-time
11
14
15
Total hires
32
37
42
4.40
4.96
5.65
were recorded against 51 terminations.
%
Total terminations
51
35
52
7.02
4.69
6.99
30
25
39
Due to retirement
12
4
5
9
6
8
%
Also for the concrete segment the assistance programs
The situation is heavily differentiated according to the in-
are only limited to employees according to the healthcare
dustrial sector: in the cement sector a CCNL (national
protocol drawn up by the labor physician.
collective labor agreement) is applied to 100 % of personnel, while in the concrete segment only one company
applies one; on average, the Czech coverage level is 27 %.
Training
In 2011, 1,525 days of training were held (1,414 external,
111 internal compared to 2,118 provided in 2010).
Also concerning the organizational changes, the situation is differentiated between the cement segment, where
The notable fall (460 days less in the cement segment
8 weeks of notice are required prior to their implemen-
and 109 in the concrete segment) is due to the fact that
tation, and the concrete segment where 6 weeks are suf-
Czech legislation imposes professional training for spe-
ficient.
cific tasks each 2 / 3 years (cement segment) and intensive
repeated (in the concrete segment).
courses for plant operators (for new recruits) were not
The work absentee index, equaling for 2011 2.59 % is substantially unchanged compared to 2010 (2.54 %).
Most of the training provided was linguistic (274 days),
professional (469 days) and technical (503 days).
Labor relations
105
In the Hranice cement plant, following a single accident
Local hiring procedures and percentage of local senior
recorded in 2011, lasting 10 days, the Frequency Index
management
is constant compared to 2010, while the Index of Severi-
All the management is local.
ty, equaling 0.03 (– 89 % compared to 2010) is among
the lowest of the group, confirming the outstanding results
recorded in previous years.
At the Hranice production site, during 2011, the works
Regarding the concrete segment both Czech and Slovak,
were finished to reduce the impact of the floods in the
the 8 accidents recorded, lasting an average of 60 days,
areas next to the plant.
generated a Frequency Index equal to 7.26 and an Index
of Severity equal to 0.43, both lower than the industry
average.
Cement Hranice organized the 49th edition of the “cement
dance”. This initiative – which each year about 400
employees, commercial partners and authority represen-
Occupational Health & Safety training and prevention
tatives take part in – as well as being one of the most
programs
awaited social events in the city, is also a chance to collect
For the cement segment medical assistance is provid-
funds for Caritas of the Czech Republic. These funds
ed in the form of periodical checkups, rehabilitation pro-
support the activities of those volunteers who take care of
grams, shots and vitamins against various diseases.
the elderly, the sick and the disabled.
Accidents
106
Slovakia
For several years ZAPA Beton has been investing in upgrading the quarry of Hruba Voda to reduce noise pol-
Social Indicators
lution and the emission of dust, thus improving environ-
Workplace diversity
mental conditions. ZAPA Beton’s contribution was also
There are no specific programs targeting an improved
essential for the renovation of bridges and transit routes.
management of diversity.
Today in the quarry there are isolated areas where
amphibians, reptiles and other protected species live under
Work-Life balance
the control of experts. Despite the increase in the activ-
Professional collaborations, part-time work, maternity
ities carried out inside the quarry, the impact on the envi-
leave contracts and tele-commuting are favored to encour-
ronment and the inhabitants is notably less compared
age a balance between corporate and family needs.
to the past. Most of the work that has led to this result was
volunteered by the employees of ZAPA Beton.
Individual performance management plans based on
the results of the company are not envisaged. notwith-
Periodic staff training is carried out on corruption, and all
standing exceptions.
the employees were informed on Buzzi Unicem’s Code
of Conduct. The concrete industry is regularly checked for
On the other hand, each year a prize is awarded to the
the risks correlated to corruption.
best concrete plant.
Training on ethics and transparencya
Contributions are also envisaged to support the stipula-
Training on the subject of anti-corruption was provided
tion of life insurance policies for the full-time personnel.
to 25 people, with classroom lessons.
Corruption
The training courses implemented concern technical
development on systems, health and safety, the environment, accounting and English.
ZAPA Beton is part of the Czech “Cement Manufacturers
Association”, which is also a member of Cembureau.
There are no collective contracts at present.
There are no formal personnel assistance programs, even
though the approach of the Zapa Beton Group is very
informal and an attempt is being made to cater for any
family needs of individuals.
Employment
The headcount reduced from 162 employees in 2010 to
programs
144 in 2011, mostly due to the turnover not being reached,
The assistance programs are only limited to employees
with 7 new recruits against 25 terminations, of which
according to the healthcare protocol drawn up by the
17 dismissals were due to market fluctuations and limit-
labor physician.
ed restructuring.
Training
In 2011, 130 days of training were held (116 external and
2010
2009
total workforce
144
162
170
Men
122
134
144
Women
Open-end contracts
22
28
26
137
155
161
7
7
9
Full-time
144
158
166
Part-time
0
4
4
Total hires
%
Total terminations
%
7
7
8
4.86
4.32
4.71
25
15
20
17.36
9.26
11.76
15
8
16
Due to retirement
2
1
3
8
6
1
Labor relations
No employee has a collective contract.
Concerning organizational changes, 8 weeks of notice are
required prior to their implementation.
The work absentee index, equaling for 2011, 1.96 %, is
up slightly from 1.35 % in 2010, getting close to the
group average (2.76 % in 2010 against 2.89 % in 2011).
management
All the management is mainly local.
The activities of the ZAPA group are regularly subject to
risk analysis linked to corruption.
Corruption
14 internal) compared to 97 provided in 2010.
2011
107
Czech Republic
Heat substitution
(in %)
(in %)
40
15
30
12.1
2009
2010
2011
7.4
20
6.3
0
11.8
5
6.2
10
27.1
17.5
20
33.1
50
18.4
25
18.1
60
13.5
30
40.0
2009
2010
2011
cze
10
0
bu
cze
4
120
90
2
60
1
30
2009
2010
0
2011
cze
Greenhouse gas
bu
(g / t of clinker)
3,000
622
697
750
2,400
1,800
300
1,200
150
600
2009
2010
0
2011
cze
bu
1,219
1,759
652
681
3,600
0
2011
cze
900
450
2010
bu
NO X
(kg / t of cement)
600
2009
bu
1,197
1,831
0
1,057
1,764
3
3.4
4.0
150
3.4
4.0
180
5
3.4
4.0
6
120
118
(kWh / t of cement)
126
120
(gj / t of clinker)
123
120
639
681
108
2009
2010
2011
cze
bu
Dust
600
160
450
120
300
80
2009
2010
2011
0
cze
184
147
40
2009
12
0
26
53
150
2010
2011
bu
cze
Water consumption
Waste generation
(l / t of cement)
(g / t of cement)
bu
83.3 %
66.6 %
2,400
50.0 %
1,800
33.3 %
1,200
16.6 %
600
200
0
cze
bu
cze
bu
cze
bu
2009
Truck
2010
Train
Ship
2011
Truck
Train
200
0
cze
bu
2,726
78
cze
2009
Ship
Truck
bu
% recycled cze
bu
cze
2010
Train
Ship
365
181
150
400
76
186
231
600
400
28
26
0
600
79
127
261
800
31
22
0
800
90
53
184
1,000
35
27
0
1,000
350
130
179
(km / t of cement)
152
27
0
16.6 %
0
2011
cze
(km / t of cement)
33.3 %
589
2010
50.0 %
43
0
2009
% rainwater cze
66.6 %
263
2011
bu
524
73
2010
cze
0
327
164
184
2009
0
192
0
113
132
75
30.3
150
32
0
225
359
355
67.1
300
2,709
83
100 %
3,000
2,921
83
3,600
83.3 %
366
80.5
100 %
366
450
375
bu
2011
Truck
Train
Ship
200
750
197
240
56
253
900
25
237
(g / t of clinker)
357
(g / t of clinker)
15
SO X
109
110
Ukraine
trading conditions
cement business
Volumes Prices * Mkt share rivne
24.0 %
16.8 %
18 %
nikolajev
* in local currency
Cement plants
Terminals
Ukraine
Energy resources
Most of the energy consumption in the Ukraine cement
plants derives from the fuel used to burn the clinker and
Natural resources
the electricity consumed to produce the raw materials
In the two Dyckerhoff cement plants in Ukraine, most of
and cement. Prior to 2010, the only fuel consumed was
the raw materials are extracted for production from
methane. In 2010 both plants commissioned coal plants.
owned natural resources. In the Yugcement plant, calcar-
At present, about 98 % of coal is used and only 2 % of
eous stone and clay are mined from the quarry located
methane gas to burn the clinker. Alternative fuels are
about 3 km from the plant. In the Volyn-Cement plant,
not yet employed due to their availability on the market.
marlstone is extracted from a quarry located about 5 km
In 2011 the Volyn plant signed an agreement for the
from the plant, and clay at a quarry about 40 km from the
supply of alternative fuels near Ryvne, a city of 300,000
plant. Gypsum and kaolin, as natural raw materials,
inhabitants, finding a partner which stipulated an agree-
are purchased from various suppliers. In addition to these
ment with the municipal administration to collect all do-
materials, iron minerals are used, originating from
mestic waste. According to the programs, this company
various sources, and materials deriving from the produc-
should treat the waste and then sell it to the Volyn facto-
tion of steel and aluminum. In both the plants, iron
ry and the material, after treatment, may be used as a
slag is used as a by-product from steel processing. The
secondary fuel. Another method to reduce the consump-
amount of raw materials varies slightly each year. The
tion of fuel lies in maintaining careful control of the
2011 average production of cement required the use of
moisture of the raw materials, as a way of ensuring the
about 3.5 million t of raw materials, of which 11 %
optimization of the heat exchange in the kilns and
deriving from non natural sources. This figure, which is
adding iron slag to the kilns to save energy on the decalci-
lower than in 2010, is significantly higher than the
fication and evaporation of water. Already a few years
group’s average.
back the plant of Volyn-Cement made notable progress,
111
k / c Ratio
2011
2010
11 / 10
1,902
1,534
24.0
100
83.3
37.9
66.6
€ m
14.4
46.2
– 68.8
50
no.
1,617
1,653
– 2.2
numbers & facts
3 terminals, 6 ready-mix concrete plants.
2009
2010
2011
33.3
16.6
0
ukr
bu
while the Yug plant had already started to add iron slag
Also concerning water consumption, the technology
to its kilns in 2010.
used for the burning line requires a considerable amount
The main fuel used is coal, which during recent years has
11 %, though remaining the worst of the Buzzi Unicem
almost completely replaced the use of methane. The
group.
of water. The specific consumption has dropped by
specific consumption of the burning line, directly linked
to the technology used, remains the highest of the en-
Biodiversity
tire group. Various optimization activities will provide a
In the territories where our companies operate there are
further fall, more than that recorded in 2011.
no protected areas like natural reserves. There is only
Water resources
zone no activity is carried out. The quarries are areas
At the Yugcement plant, the process water used to cool
with a high biodiversity potential and, in general, extrac-
the compressors, bearings, the technological and pro
tion operations regard a part of them, while the rest of
one very close to the quarry of Volyn-Cement, but in this
duction equipment (course or normal grain) is powered
the area is already exploited and reclaimed for agriculture.
by two pumps drawing from the river Yuzhniy Bug.
For this reason, it is necessary to increase stocks and
Rain water and run-off water is not used and is taken to
use the natural reserves at the same time. Once the extrac-
a lake on the slope of a hill. There is a closed-circuit
tion work is completed, the Commission for Forestry
water feeding plant with inverted water feeding, the pump-
deals with the new cultivation at the expense of the site.
ing station of which adjusts the overall consumption
On the one side, when natural reserves are affected,
with the aid of pumps. In the Volyncement plant, process
there is an inevitable impact on the biodiversity although,
water is used from the Ustia river while the drainage
on the other side, the recultivated areas are very inter
water in the quarry is used for production.
esting since the entire region is void of them.
23.0
81.5
135
112.5
166
€ m
82.5
79.7
mc / 000
Sales revenue
Concrete sales
82.0
79.8
t /000
81.8
79.9
var %
Cement sales
112
“Our Kids” project – The center for homeless children in Kiev – Ukraine
Greenhouse gases
Regarding the atmospheric emissions of the burning line,
Since 2005, a Joint Implementation Project has been
it is especially worth noting a worsening of 27 % of the
aiming to reduce the emissions of greenhouse gases,
nitrogen oxide emissions. Concerning dusts and sulphur
which relies on the replacement of natural and
oxides, on the other hand, there was an improvement
high-moisture materials with ground iron slag in kilns.
equal to 15 % and 26 % respectively.
The specific values of the calcination remained stable
Waste
(437 kg / t of cement in 2011 against 435 kg / t of cement
Waste from semi-finished products, gypsum in pieces
in 2010). The production of CO² from combustion per
ton of cement increased from 340 to 470 kg / t of cement
that are greater than acceptable, and plaster flakes from
following the increase in coal consumption from about
roads. The reject products unsuitable for other uses (e. g.
60 % in 2010 to about 100 % in 2011.
neon bulbs, dead batteries, exhausted oils and motor
rous metals, used tires, fire bricks) are then disposed
An additional fall in emissions, especially in NOx, is dif
of by specialized subcontractors.
demolition activities are used to construct the quarry
oil, filtering materials, iron and steel rejects and non-fer-
ficult to obtain in the wet kilns due to the technological
obstacles. The kiln output temperature is too low to
The factor relating to the production of waste has dropped
allow a reduction in nox with ammonia solution. Instead,
by 46 % compared to 2010. All the waste produced is
concerning emissions of dust, significant improvements
sent to recovery sites.
were obtained with the installation of new filters in the Yugcement factory.
113
Social Indicators
Workplace diversity
Due to its peripheral position with respect to the main
Even without having implemented specific policies, all
scientific and economic trends, Ukraine has suffered a
the staff management procedures in Ukraine directly and
real brain drain in the last fifty years.
indirectly fight any type of discrimination.
For this reason the company also encourages individual
In compliance with Ukrainian law, a certain number of
training proposals from personnel.
disabled people have been hired, mainly on IT systems.
In addition the female personnel was increased at mana-
Staff participation
gerial level.
In Ukraine trade unions and workers’ representatives only
have consultation powers.
The challenge of the near future will be to replace the
over-fifties who will retire with a younger workforce.
Collective bargaining works at a national industrial level
(for the definition of contract minimums) and at corpo-
A new MBO (Management By Objectives) incentive pro-
rate level (for the awarding of participation prizes or non
gram for personnel was recently started in Ukraine
monetary benefits).
based on company and individual indicators. The program
addresses the management of production sites and
the HQ and may allow us to obtain very good results upon
achieving the objectives set with the relevant manager.
Youngsters of the Our Kids center in Kiev supported by Dyckerhoff Ukraina – Ukraine
1.25
0
2009
2010
0
2011
ukr cem
bu cem
2009
0.34
0.53
2011
ukr cem
The headcount in 2011 was 1,617 employees, down com-
0
2010
bu cls
Employment
0.36
0.52
0.25
0.08
20.5
0.75
0.50
7.3
10
1.00
0
20
2.0
10.1
30
8.3
40
24.7
1.50
50
28.92
60
0.3
0.57
0.01
0.4
114
bu cem
bu cls
2011
2010
2009
total workforce
1,617
1,653
1,672
Men
1,197
1,217
1,209
420
436
463
1,616
1,616
1,619
pared to 2010 (1,653), substantially due to the hiring
freeze and to an individual termination program as part
of a rationalization program regarding the maintenance
segment in Volyn (147 recruits against 183 terminations,
of which 179 dismissals).
Women
Open-end contracts
Full-time
1
37
53
1,602
1,636
1,639
Part-time
15
17
33
Total hires
147
141
116
%
9.09
8.53
6.94
Total terminations
183
160
226
11.32
9.68
13.52
136
101
152
43
53
56
4
6
18
%
Due to retirement
115
gg
120
100
80
2011
ukr cem
bu cem
bu cls
Labor relations
The coverage rate is complete.
programs
The minimum notice period for organizational changes
Staff participate in seminars, training and professional
to Trade Unions is 9 weeks.
courses (illustrated in detail in the indicator concerning
training) to implement the professional skills.
Protecting occupational safety is one of the pillars of the
In addition, as part of a training plan for employees’ chil-
Ukrainian employment system. Healthcare insurance is
dren, the assistance program for employees may also
available to all the staff who have passed the trial period.
cover university education, with a commitment of remain-
In case of serious disease, the company reimburses the
ing employed by the company for five years at the end
cost of healthcare treatment.
of the course.
The absentee index in 2011 was 2.53 % (notably down
Training
compared to 3.14 % in 2010).
In 2011, 1,325 external training days were held (of
which 355 professional training days in Yugcement, among
Accidents
which in particular plant management and mechanical
During 2011 there were no work accidents in the 2 Ukrain-
and electrical maintenance) and 7,093 internal training
ian cement plants, notably improving the result of 2010.
days, almost 6,000 of which were for technical refresher
Furthermore, the concrete segment had no accidents for
courses on the plants (of which 5,670 in Volyn requested
the third year running.
also by local legislation for tasks defined “at risk” and
for the introduction of coal driven plants, in particular concerning the defrosting of incoming coal).
21
47
2010
0
43
25
39
2009
0
30
20
20
15
40
60
116
Volyn-Cement factory, Dyckerhoff Ukraina – Ukraine
Corruption
Donations
Dyckerhoff Ukraine supports the “Our Kids” project, in
the context of which a private German Association has
built a center in Kiev for homeless children. To date the
Dyckerhoff Ukraine is a member of the ”European
center has grown and from the 12 children who lived
Business Association”, the “American Chamber of Com-
there at the end of 2008, there are now 35 and the number
merce” and the “Italian Chamber of Commerce for
continues to rise, making the construction of a second
Ukraine”. This involvement is aimed at promoting legis-
building necessary. Dyckerhoff Ukraine, which has already
lative progress and legal reforms to fight corruption
contributed to the center’s construction, assisted “Our
and bureaucracy in the country, and build a community
Kids” in the creation of a second building by donating the
of western and local business to improve the economic
concrete and some pallets of cement in bags.
environment.
Group support for Socialization
During 2011 the plant in Volyn celebrated its 135th anniversary. The celebrations took place in the city of
Zdolbunov, in the “DKZ” Dim Kulturi Zementnikiv (cultural
home for the employees of the plant). The ceremony
featured the polyphonic choir of DKZ, mostly comprising
employees from the plant, which contributed to the
success of the evening, demonstrating the importance of
aggregation places where it is possible to spend your
free time while enhancing your talent.
117
Ukraine
Heat substitution
(in %)
(in %)
60
25
50
20
40
15
30
2009
(kWh / t of cement)
5.9
60
1
30
2009
2010
0
2011
ukr
17.5
0
2011
ukr
bu
(g / t of clinker)
907
3,600
3,000
697
2,400
600
2009
2010
0
2011
ukr
bu
1,528
1,759
1,200
150
1,199
1,831
300
1,764
1,800
2009
2010
2011
909
750
775
681
900
0
2010
NO X
(kg / t of cement)
450
2009
bu
Greenhouse gas
600
121
118
90
131
120
120
121
120
6.0
180
2
0
bu
150
4.0
3
4.0
5.7
4.0
4
2011
ukr
(gj / t of clinker)
5
2010
bu
6
18.4
0
0
2011
ukr
18.1
2010
10
0
2009
20
11.1
7.4
6.3
0
6.2
5
12.0
10
13.2
30
595
681
118
ukr
bu
300
80
0
2009
2010
bu
ukr
(g / t of cement)
50.0 %
1,800
150
33.3 %
1,200
16.6 %
600
2011
2009
(km / t of cement)
(km / t of cement)
ukr
bu
bu
Ship
bu
2011
Truck
Train
322
350
130
179
0
0
0
200
75
76
186
231
ukr
2010
Train
0
6
79
127
261
ukr
2009
Truck
0
6
0
5
90
53
184
400
221
600
400
0
% recycled ukr
800
600
200
bu
1,000
2,248
1,722
800
16.6 %
0
2011
ukr
1,000
33.3 %
2010
% rainwater ukr
50.0 %
ukr
bu
ukr
2009
Ship
Truck
bu
ukr
2010
Train
Ship
365
181
150
bu
66.6 %
0
ukr
0
83.3 %
482
2010
0
bu
100 %
62
2009
0
0
0
0
75
2,709
225
386
2,400
2,921
66.6 %
300
1,491
3,000
1,370
1,370
366
3,600
83.3 %
1,537
355
100 %
1,471
366
450
375
100
Waste generation
(l / t of cement)
100
Water consumption
2,726
ukr
2011
208
2011
87
2010
327
164
184
2009
546
0
40
74
188
150
bu
2011
Truck
Train
Ship
120
160
450
1,154
600
147
200
184
750
20
253
240
28
237
900
357
(g / t of clinker)
1,363
Dust
(g / t of clinker)
2,442
197
SO X
119
120
Russia
trading conditions
cement business
Volumes Prices * Mkt share 33.7 %
6.6 %
4 %
suchoi log
* in local currency
Cement plants
Russia
consumption was 139 kWh / t (– 6 % compared to 2010).
The fuel used for the production of clinker, the drying of
corrective agents, and the heating of buildings is meth-
Natural resources
ane, provided by an independent gas company through
At the factory of Suchoi Log, the stone from cement is
the transportation system of the body in charge. Com-
extracted with explosives from the deposit in Kurnarsky;
pared to 2010, the energy consumption deriving from
the sandstone is extracted from the deposit in Novo
methane increased by 2,587,139 GJ due to the rise in
Suckholozhsky; gypsum comes from Kuryinsky. The anhy-
production volumes (clinker). The reduction in emissions
dride stone is purchased at PJSC “Ural-Gypsum”, gran
per ton of clinker (– 4 %) is correlated to the produc-
ulated iron slag at PJSC “Svyatogor” and at PJSC “mmk”.
tion of clinker through the new line no. 5, which uses the
In 2011, the replacement of natural raw materials stood
ton of clinker compared to the four wet-process kilns.
dry method and records a lower fuel consumption per
at 5.4 %, identical to 2010 and slightly lower than the
group average.
Water resources
In 2011, the consumption of water increased by 311,334
Energy resources
m³ (compared to 2010) due to the rise in the produc-
The electrical power of the PJSC “Sukholozhskcement”
tion of cement and clinker. Rain water is absorbed entire-
plant is provided by the substations of “Kunarskaya” and
ly by the ground. In winter, snow is removed from the
“Anna”, and, as reserve contribution, from the substa-
road network and taken to green spaces where in spring
tion of “Sukhoi Log”. In 2011, the total energy consump-
it melts into the ground. The reduced water consump-
tion increased by 78,415 MWh compared to 2010 due
tion factor is due to the start of the kiln line for dry-pro-
to the increase in cement production, while the specific
cess production in 2011.
121
k / c Ratio
2,434
1,820
33.7
83.3
€ m
175.5
124.1
41.4
66.6
€ m
36.8
76.2
– 51.7
no.
1,049
1,190
– 11.8
numbers & facts
Cement production capacity 3.6 million tons, 1 plant.
2009
2010
2011
50
33.3
16.6
0
rus
bu
Greenhouse gases
ants into the air. The control is carried out by the accred-
In 2010 the Russian Sberbank informed the Sukholozhsk-
ited industrial hygiene and ecology laboratory based
cement factory of having accepted an offer for the joint
on the programs and control plans approved and agreed
implementation project for the “Construction of produc-
with the authorities in charge. In 2011, 1,090 tons of
tion line no. 5” based on article 6 of the Kyoto protocol.
dust and 3,043 tons of sulphur dioxide were released into
Currently, PJSC Sukholozhskcement is waiting for the Min-
the atmosphere.
istry for Economic Development of the Russian Federation to communicate whether or not it approved the project.
The value of NO² is not stable during the year even if the
kiln works continuously. In Russia continuous measure-
The direct CO² emission factor was 739 kg / t cement, with
ured are discontinuous.
to the reduction in the clinker content of cement and a
The industrial inspections did not show deviations of
lower specific consumption of the new burning line.
the current emissions from the maximum values admis-
ments are not taken during the year, since the values measa reduction equal to 3.5 % compared to 2010, linked
sible. In order to reduce the negative impact on the enAtmospheric emissions
vironment, the plant started an investment plan for the
According to the provisions of the Federal Law on Environ-
reconstruction and replacement of obsolete and dated
mental Protection, at the plant of Sukholozhskcement
bag filters.
an industrial environmental control is regularly carried
out as part of the Environmental Protection project,
Waste
which includes the monitoring of the conformity to the
Waste such as cement dust and ash deriving from com-
maximum standards allowed for the emission of pollut-
bustion plants is included in the production process
t /000
Sales revenue
Cement sales
100
88.7
79.7
11 / 10
var %
89.9
79.8
2010
88.0
79.9
2011
122
Olympics of the Suchoi Log plant – Russia
through systems reusing dusts for the production of
pany also runs a Hall of Fame; on holidays and special
clinker and cement. As for raw materials, iron slag and
occasions diplomas are awarded to worthy employees.
reject products from other industries are also used.
Staff participation
Other waste like scrap iron, wooden pallets and general
Staff are represented by the Trade Unions and the factory
waste are taken to the plant and then sent to authorized
delegates, as established by law.
companies.
The disposal of waste is carried out by the company
The current collective contract (2010 / 2012) lasts three
based on its license to collect, use, transport and dispose
years and is recognized as one of the best in the area for
of waste.
the additional benefits it attributes to employees.
Social Indicators
Staff assistance program
Work-Life balance
The company provides partial reimbursement for day-
In Russia, on Fridays the day staff stops work one hour
care. Facilitated terms are applied by the “oCK Sosnovyi
early, making up for it during the working days from
Bor” structure.
Monday to Thursday.
Employment
Incentive programs
The total headcount reduced from 1,190 employees in
Also in Russia there is a variable remuneration system.
2010 to 1,049 in 2011, mostly due to the deconsolidation
In addition, special acknowledgements are attributed
company with 97 employees as at 31 December 2010.
of the company OOO Sukhlocemremont, a maintenance
during events like Builder’s Day or Women’s day; the com-
123
The orphanage of Suchoi Log supported by colleagues of Dyckerhoff ag – Russia
In addition to this 155 people were hired and 199 people
left the company, of which 112 for staff reduction (95
in Suchoi Log, 16 in the company specialized in Cemtrans
2011
2010
2009
1,279
transportation and in a start up in Akbulak).
total workforce
1,049
1,190
Men
820
942
999
Women
229
248
280
1,041
1,177
1,259
8
13
20
1,049
1,189
1,273
Open-end contracts
Full-time
Part-time
0
1
6
155
103
155
14.78
8.66
12.12
199
192
425
18.97
16.13
33.23
53
74
70
Due to retirement
34
27
89
112
91
266
Total hires
%
Total terminations
%
1.50
50
1.25
28.92
60
0
2009
2010
bu cem
2009
2010
bu cls
2011
rus cem
0.34
0.53
0.10
0.36
0.52
0.14
0.25
0
2011
rus cem
0.50
0.3
0.57
7.3
24.7
10
0.75
3.4
20
8.3
20.5
10.1
30
1.00
4.3
40
0.17
1.9
124
bu cem
bu cls
Labor relations
Should other work positions not be available, at this point,
Collective bargaining is applied to 96.6 % of the workforce
the employment contract is reapplied.
and the contract is usually negotiated at site level between the manager in charge and the workers’ represen-
In the presence of an economic crisis, the company, after
tative. The content of the contracts is very comprehen-
hearing the opinion of the Works Council (workers’ rep-
sive and arranged along the structure of the collective con-
resentatives), may impose a partial work schedule up to
tracts in general existing in Western Europe.
a maximum of six months, if personnel reductions may
emerge from the situation. If the worker does not accept,
In compliance with article 74 of the Employment Code of
the employment contract may be withdrawn.
the Russian Federation, in case of technological or organizational changes, when the terms and the conditions
contained in the employment contract may not be pro-
Each year a trade union meeting is held on the subject,
tected, these may be changed, excluding the task of the
from which a programmatic accord arises concerning
worker.
the corrective measures to be made, the economic allocations and the deadlines.
The company is obliged to inform the worker about any
change to the individual contract at least two months
The Work absentee index is 3.18 %, in line with the
beforehand. If the worker refuses the new conditions pro-
rest of group (even if worse by 1 percentage compared
posed, the employer is obliged to offer him / her any
to 2010).
other position available that is professionally and health-
In 2011 three new cases of occupational illness were
wise compatible, even if of a lower professional content.
reported for lung issues.
125
gg
120
80
88
100
47
21
30
43
25
2010
2011
rus cem
bu cem
bu cls
Accidents
Professional training with a total of 12,000 days stands
In 2011, 6 accidents were recorded, 2 less than in 2010,
out, focused on specific task training (plant operators,
with a consequent reduction in the related Frequency
maintenance, chemists, overhead crane operators, rail
Index. The average duration of these accidents, equal to
material conductors) and for safety with 3,600 days in
30 days, led to an Index of severity equaling 0.1 (– 29 %
total.
compared to 2010).
programs
Dyckerhoff set up a non-profit association to assist the
Preventive medical intervention programs are envisaged
orphans from an institute in Suchoi Log. To date, thanks
such as anti-flu and meningitis shots, dental visits, pre-
to the association, it has been possible to replace the
ventive medical visits, a regeneration medicine program
windows and doors of the building, the plumbing and
for staff and their families at the Sanatorium, a pro-
drainage system have been upgraded and a nurse is
gram specifically designed for employees, called ‘mother
now on hand. Also created was a sports program for kids
and child’, an alcohol and tobacco prevention program.
with the purchase of tracksuits and ice-skates for every-
Training
with an educational trip to St. Petersburg.
body. Stays were also funded at a summer camp, together
As always, Russia is in pole position for training with
18,670 training days in total (11,563 external and 7,107
Group support for Socialization
internal) with almost 18 training days per capita annu-
During 2011, at OAO Sukholozhskcement, the second
ally (compared to the 14 of the previous year).
edition of the “olympic games” was held with the participation of about 300 company employees. The sports
event is inspired by the real Olympics with an opening
2009
0
33
20
30
20
40
60
126
Track and field event organized by oao Sukholozhskcement – Russia
ceremony, lighting of the torch and awarding of medals
to the winners. The success of these first two editions convinced the management to transform them into an
annual event.
The supply agreements are always concluded based on
the bids received from not less than three suppliers;
products are sold at the prices set in the price list and
discounts are granted only after agreement with the
company’s top management are reached.
Corruption
127
Russia
50
20
40
15
30
10
20
0
2009
2010
2011
rus
10
0
2009
2010
2011
bu
rus
(gj / t of clinker)
(kWh / t of cement)
1
30
2009
2010
0
2011
rus
Greenhouse gas
148
2011
rus
bu
1,800
300
1,200
150
600
2009
2010
0
2011
rus
bu
2,734
2,400
450
1,831
3,000
739
697
750
767
681
3,600
3,095
(g / t of clinker)
900
0
2010
NO X
(kg / t of cement)
600
2009
bu
1,764
0
139
118
60
120
90
2
120
120
4.0
4.0
3
5.2
5.5
5.8
4.0
4
150
157
180
6
5
bu
2009
2010
1,366
1,759
5
5.4
7.4
25
5.4
6.3
60
6.5
6.2
30
0.0
17.5
(in %)
0.0
18.4
Heat substitution
(in %)
0.0
18.1
773
681
128
2011
rus
bu
120
300
80
197
147
0
rus
1,200
16.6 %
600
355
366
2009
0
0
0
0
75
2010
0
2011
rus
bu
0
2009
2010
% rainwater rus
(km / t of cement)
(km / t of cement)
0
bu
rus
bu
2009
Truck
2010
Train
Ship
2011
Truck
Train
0
1,029
rus
bu
bu
rus
2009
Ship
16.6 %
Truck
bu
rus
2010
Train
0
% recycled rus
0
rus
350
130
179
bu
0
rus
200
26
76
186
231
200
10
130
0
400
79
127
261
600
400
11
120
0
600
90
53
184
800
13
89
0
800
33.3 %
1,059
1,000
50.0 %
2011
rus
1,000
66.6 %
Ship
365
181
150
1,800
33.3 %
97
50.0 %
150
83.3 %
0
225
bu
100 %
1,194
2,400
2,967
2,709
66.6 %
300
99
3,000
2,921
3,600
83.3 %
366
100 %
1,704
1,038
881
(g / t of cement)
1,367
Waste generation
(l / t of cement)
450
2011
bu
Water consumption
375
2010
2,726
rus
2009
957
2011
149
2010
99
2009
327
164
184
0
40
119
25
150
bu
2011
Truck
Train
Ship
160
450
600
489
200
774
750
13
253
240
18
237
900
357
(g / t of clinker)
941
Dust
(g / t of clinker)
184
SO X
129
130
usa
trading conditions
cement business
Volumes Prices * Mkt share selma
greencastle
– 1.6 %
– 5.3 %
9 %
stockertown
cape girardeau
pryor
maryneal
chattanooga
* in local currency
san antonio
Cement plants
usa
Energy resources
The energy consumption of firing the kilns was slightly
lower in 2011 than in 2010 (4.09 GJ / t compared to
Natural resources
4.16 GJ / t). Most of the plants recorded a reduction in fuel
The production facilities of Alamo, Greencastle, Cape
energy consumption, except for a small increase at
Girardeau, Festus and Chattanooga showed a significant
the Maryneal facility and a more significant increase at
increase in the percentage of substitution for natural
the Stockertown facility. At Stockertown, the increase
resources thanks to the use of synthetic gypsum, with
was due to a combination of operational problems related
a consequent savings of more than 180,000 tons of
to the startup of the tire systems and production cur
natural gypsum. This resulted in a 10 % reduction in
tailments for inventory control.
the quantity of natural gypsum extracted, extending
the lifespan of the natural gypsum reserves by the same
Overall consumption of electric energy in 2011 remained
amount. During the last half of 2012, the Alamo facil-
substantially unchanged compared to 2010, amounting
ity plans on investing in changes to finish mill no. 1 sys-
to about 158 kWh / t. Most of the plants recorded a normal
tem that will allow 100 % substitution of synthetic
variability. The most significant changes were a reduc-
gypsum. The Greencastle and Alamo facilities significant-
tion at Maryneal and an increase at Pryor. The reasons for
ly increased the use of water treatment residues such
the changes in power consumption are most likely at-
as filter cake and residual sludge generated by automo-
tributed to efficiencies related to production levels. Pryor
bile component manufacturers. Cape Girardeau and
saw a significant decrease in production and Maryneal
Festus used about 3,700 tons of alternative raw materials.
had improved performance in 2011. In the USA, the fuel
The substitution percentages from alternative raw ma-
for firing the kilns consisted of 38 % coal, 36 % pet-
terials increased from 5.7 % in 2010 to 6.6 % in 2011,
coke, 2 % natural gas and 24 % alternative fuel.
with significant increases at the Festus facility (10.4 %)
and Chattanooga facility (9.6 %).
2011
2010
11 / 10
131
k / c Ratio
– 1.6
2,222
– 1.4
100
t /000
4,267
1,758
142.7
83.3
Sales revenue
$ m
776.6
796.6
– 2.5
66.6
$ m
33.6
46.9
– 28.4
50
no.
2,290
2,410
– 5.0
Aggregate sales
numbers & facts
Cement production capacity 9.5 million tons, 8 plants, 31 terminals, 77 ready-mix concrete plants, 6 aggregate quarries.
2009
2010
2011
33.3
16.6
0
usa
bu
The total substitution percentage for alternative fuels in
the entrance of cold air. In 2011 an operational change
2011 was 25.3 % compared to 23.5 % in 2010. Cape
was implemented to reduce the electric consumption in
Girardeau and Greencastle continued to utilize very high
the kiln draft fans., water sprays for cooling the gases
quantities of alternative fuel, with a substitution per
was employed which more than doubled the amount of
centage exceeding 50 %. Cape Girardeau was able to re-
water used. In August of 2011, Festus completed test-
place 53.2 % of their fossil fuel with alternative fuel
ing to set a higher temperature for regulatory compliance
and Greencastle was slightly less with 52.6 % replace-
which will allow reduced water consumption for the
ment. Both Maryneal and Pryor use only tire feeding
future and return to 2010 levels.
systems and are limited to lower levels of fuel substitution. Stockertown began operation of their non-hazard-
The Greencastle facility is a semi-wet-process plant
ous alternative fuel system in July 2011. The system was
and the quantity of water consumed is the highest among
commissioned using tire derived fuel mainly on kiln
the Buzzi Unicem USA plants (about 48 % of the total).
no. 3. The facility was able to achieve 3.1 % substitution
The increase in the quantity of water used per ton of ce-
for the year.
ment is mainly due to the greater water requirement
linked to the treatment of the kiln dust, which increased
Water resources
by more than 250 %.
The Festus, Missouri facility was the most efficient in
using water resources with the specific consumption of
In 2011, at Pryor and Greencastle, about 78 % and 98 %
water equal to 0.136 cubic meters per ton of equiva-
respectively of the water consumed was rain water.
lent cement in 2011. However, this was a significant increase from 2010 levels. The Festus facility has a reg
In 2011, the Chattanooga factory significantly increased
ulatory obligation to maintain discharged gases from the
the use of tire rejects as fuel. This led to a 37 % increase
kiln system below a certain temperature. To accom-
in the process water consumed in the kiln.
plish this, the temperature was mainly controlled through
6,275
2,192
6,177
t /000
mc / 000
93.7
79.7
Concrete sales
93.1
79.8
Cement sales
93.1
79.9
var %
132
Open-air laboratory near the plant in Stockertown – usa
Biodiversity
Greenhouse gases
In the US, the Federal Endangered Species Act and the
The EPA (US environmental protection agency) is imple-
Clean Water Act deal with the protection of flora and
menting a series of provisions introduced in 2010 which
fauna at risk, the related habitats and other sensitive eco-
include the adoption of a regulatory program for each
systems. Furthermore the governments of the various
new industrial source, or any existing source which intro-
states apply separate laws aiming to protect and restore
duces a change resulting in an increase in GHG. The
sensitive natural resources, such as lakes, rivers and
facility must identify and implement the best control tech-
creeks. To conform to these programs, Buzzi Unicem USA
nology available (BACT) to reduce greenhouse gases.
must undertake to respect the protected species and
Since the Buzzi Unicem USA plants were existing facili-
environments and guarantee minimum industrial impacts
ties when these regulations were drawn up and have
on the environment.
not introduced changes responsible for significant increases in greenhouse gas emissions, they are not subject
The plants of Festus and Cape Girardeau are on the Mis-
to the BACT requirements.
sissippi River and use barges to receive materials and
ship products. Based on the studies carried out, the sec-
At the moment, the only formal programs to reduce green-
tions of the river where the plants are located repre-
house gases continue to be implemented by various
sent the ideal habitat for the Pallid sturgeon to feed and
Regional Bodies, including the Midwestern Regional Green-
reproduce. The Pallid sturgeon is a protected species
house Gas Reduction Accord (MRGHGRA), an organiza-
at risk of extinction. Nevertheless, in 2011, no hazard for
tion encompassing several states (including Illinois) em-
these habitats was reported in correlation with the ac-
ployed to establish a multi-sectorial system of “limits
tivities of the plants.
and exchange”.
USA plants must inform the EPA of the greenhouse gas
plant increased the CKD (Cement Kiln Dust) removal rate,
emissions for all the non-mobile fuel sources at the plants,
thereby removing the sulfur from the kiln system and
using a continuous monitoring system to record CO² emis-
reducing the quantity of sulfur available for the formation
sions or prescribed calculations.
of SO². Greencastle also realized an increase in the use
In normal conditions, the specific CO² emission factor for
this plant is on average equal to 0.87 t CO² / cement.
fuels in the kilns for the production of clinker reduces
the emissions of NO x and SO².
of non-hazardous alternative fuels. The use of alternative
There are two main reasons for the increase in emissions:
the amendment of the assessment system in some
The Pryor plant showed an important reduction in the
plants, passing from the calculations of the World Business
volumes of specific emissions of NO x compared to 2010,
Council for Sustainable Development (WBCSD) to CO²
measurement through monitoring and less effective oper-
at the same time showing an increase in the volume of
ations from a fuel point of view.
specific emissions of SO². Due to the persistent American
economic crisis, in 2011 only Kiln no. 3 was operational, creating a 31 % reduction in the production of clinker.
Based on the tests carried out on the emissions, Kiln
A SNCR and ammonia injection are commonly used to
3 showed results of NO x notably better compared to Kiln
control emissions of NOx in the kiln discharge stacks below
1 (with a reduction of 60 %).
the regulatory limit.
The plant in Stockertown achieved a reduction equal
In 2011 the Buzzi Unicem USA plants reported total esti-
to about 34 % of the volumes of specific emissions of NO x
mated emissions equal to 10,000 tons of NO x, 2,400 tons
and about 35 % of the volumes of specific emissions
of SO² and 250 tons of particulate matter attributed to
kilns, clinker coolers and raw mills. Under normal condi-
of SO². The reduction in NO x emissions took place thanks
to two reasons. Firstly, in 2011 stricter state regulations
tions, the average values of the specific emissions of
were introduced for the first time, which led to a reduction
the plant are 1.85, 0.45, and 0.05 kg / t clinker respective-
in permitted emissions. Secondly, the plant started
ly for NO x, SO² and dust.
burning tires to obtain fuel to be used in both its kilns,
thus contributing to the reduction in the quantity of NOx
Compared to 2010, in 2011 the overall specific emission
produced. The practice above also contributed to reduc-
values of NO x, SO² and particulate matter were lower
respectively by 5 %, 15 % and 30 %.
ing SO² emissions. Furthermore, the Stockertown plant
replaced part of the petcoke (traditionally 100 % used)
with coal, containing a lower quantity of sulfur.
The changes recorded for these values compared to 2010
are the result of various factors. The Greencastle plant
Buzzi Unicem USA estimates reaching similar levels of
managed to obtain greater operational stability of the kilns
emissions in all its plants in 2012. The site, which more
compared to 2010. A stable operation of the kiln helps
than any other has the potential to improve its emis-
to reduce the concentrations of NO x and SO² in the dis-
sions of NOx and SO², is the one in Stockertown, which con-
charge gases. In addition, in 2011, the Greencastle
In compliance with national regulations, the Buzzi Unicem
133
134
tinues to make improvements to its fuel plant based on
oils and lubricants are reused to replace new oil in
the use of tire rejects with the purpose of increasing its
open lubrication systems such as chain conveyors or input
consumption of alternative materials.
seal mechanisms on the kiln where possible.
Waste
On-site reuse can involve reintroduction of used mate
The Buzzi Unicem USA plants generated about 18 %
rials such as spent refractory as alternative raw materials
more waste in 2011 compared to 2010, with CKD (Cement
where product quality allows.
Kiln Dust) being the predominant waste generated.
Buzzi Unicem USA expects waste generation in 2012 to
About 82 % of the total waste produced and is generated
return to about the same waste production volumes as
by three of the eight US cement facilities operating. CKD
in 2010. Since the US economy is not excepted to recover
generation varies from one plant to another based on the
significantly in 2012, the plants will remain at reduced
production capacity and quality. Dust is removed from
production. In 2011, the ratio between the waste gener-
the kilns for the purpose of reducing alkali, sulfur or chlo-
ated and the waste recovered for beneficial reuse in the
rine and avoid operating problems.
production cycle was 1 / 12.
The CKD removed from the kilns may be disposed of in
Social indicators
on-site landfills or sold for beneficial reuse such as a
Workplace diversity
lime substitute. Buzzi Unicem USA has an ongoing pro-
Starting from the second half of the last century, in the
gram to minimize the generation of waste through the
USA a highly detailed legislation was developed with
improvement of control mechanisms where possible and
the aim of eliminating discrimination at worksites. Among
if dust is generated to find outlets for a beneficial reuse.
other things, it requires the sending to the Commission
for Equal Opportunities of an annual report on the com-
The increase of CKD generation in 2011 may related to
position of the personnel employed.
higher alternative fuel usage resulting in higher chlorine
volumes in the kiln system and the need to increase the
removal of dust.
The situation is differentiated.
Non-CKD waste materials are also managed to minimize
Buzzi Unicem USA has an incentive program for the
generation and disposal. Each Buzzi Unicem USA facil-
management and one for the rest of the staff linked to the
ity makes every effort to minimize the production of waste
profitability of the company.
and undertakes to recycle any wastes materials gener
ated on site. When the material cannot be recycled on
Alamo does not provide any stock granting / option plan
site, recycling alternatives are looked for offsite. Only
or profit-sharing bonus.
in cases where recycling on or off site is not available or
feasible, are the waste streams disposed. E. g., used
At Buzzi Unicem USA there are training programs to
fluctuates from 8 % at Alamo Cement, to 12 % at Buzzi
bridge any individual gap or for career progression. In
Unicem USA up to a peak of 38 % at Alamo Ready Mix,
specific and more limited cases, university fees paid
mostly caused by the disturbance in the labor market for
to attend courses of interest for the company are refunded.
drivers, due to an increase in oil exploration in southern Texas.
In Buzzi Unicem USA collective contracts or agreements
are in place at the sites specified in the chart below.
2011
2010
2009
total workforce
2,290
2,410
2,186
Men
2,112
2,226
2,004
178
184
182
2,289
2,410
2,183
Site:
Trade union organization:
Cape Girardeau Plant,
Paducah & Nashville Terminal
PACE * (now a.k.a. usw)
Festus Plant
Boilermakers
Women
Cape Girardeau Alternate Fuels
PACE * (now a.k.a. usw)
Open-end contracts
Greencastle, Pryor, Oglesby
Plants & Bonner Springs,
Milwaukee Terminals
Boilermakers
Stockertown Plant
Teamsters (Transport)
Maryneal Plant & Dallas
Terminal
Steelworkers
Memphis Ready Mix
Teamsters (Transport)
Full-time
*P
ACE – now also known as USW following the merger with United Steel
workers’ of America – is the United Steel, Paper and Forestry, Rubber,
Manufacturing, Energy, Allied-Industrial and Service Workers International
Union.
0
3
2,398
2,176
Part-time
12
12
10
Total hires
329
332
344
14.37
13.78
15.74
449
411
402
19.61
17.05
18.39
223
204
129
62
47
46
164
160
227
%
Total terminations
%
Due to retirement
Employment
1
2,278
Dorsett Rmc subsidiary recorded in Alamo from April 2010 for 303 units.
The headcount in the USA recorded a notable decrease,
with 120 employees less equally divided between Buzzi
Unicem USA and Alamo (from a total of 2,410 employees
Labor relations
at the end of 2010 to 2,290 at the end of 2011).
The situation is differentiated and depends on the company and the geographic location.
Regarding Buzzi Unicem USA, the reduction was due to
the hiring freeze as well as to a certain number of dis-
In Buzzi Unicem USA the personnel covered by collective
missals by the operational personnel involved in tempo-
bargaining totals 60.1 %. Trade unions vary depending
rary layoffs programs.
on the factory and the geographic location; overall there
are four trade unions which the company interacts with
The turnover ratio, which is on average equal to 20 %,
135
0
2009
2010
usa cem
0.25
0
2011
usa cls
bu cem
bu cls
2009
0.58
0.34
0.53
0.75
1.05
24.7
7.3
10
1.00
0.50
15.2
20
10.1
30
13.2
24.8
8.3
20.5
28.92
40
0.59
0.36
0.52
1.25
43.7
1.50
50
49.4
60
1.21
0.3
0.57
0.74
0.76
16.2
136
2010
usa cem
2011
usa cls
bu cem
bu cls
(Teamsters = Transport, Boilermakers = Boilers, Steelwork-
the staff from May 2011 and at the time of preparing these
ers = Steel, PACE = steel, paper, forestry, rubber, manu-
financial statements has some workers still suspended.
facturing and energy component of the allied-industrial
and service workers international).
At Alamo Cement Company no employee has a collective
Unicem USA sustainable development strategy, in 2011
contract.
various programs were implemented concerning occupa-
Based on the continuous improvement plan and Buzzi
tional safety and industrial hygiene.
Minimum notice period concerning organizational
changes
The work absentee index in 2011 was 1.92 % slightly but
In the case of closure, even temporary, of a plant the Work-
appreciably down compared to 2010 (2.20 %).
er’s Adjustment and Retraining Notification Act (w.a.r.n.)
provides for any company that employs a minimum of
No professional illnesses were reported.
100 employees to communicate in writing and at least
60 days in advance, any reduction of staff for the defini-
Accidents
tive closure or the suspension, also temporary, of the
During 2011, 35 accidents were recorded in the 8 US
production activities at a plant exceeding six months,
cement plants, with days of absence totaling 2,788. Both
should there be a loss, even temporary, of work for at
these values are worse than in 2010. The same can be
least 50 employees for each period of thirty days within
consequently said for the frequency index, equal to 15.23
the abovementioned six-month period.
(+ 15 %), and the index of severity 1.21 (+ 15 %). The
average duration of the accidents was 80 days, identical
In 2011 temporary suspensions lasted one to two months,
excluding Pryor, Oklahoma, which suspended part of
to 2010.
137
gg
120
80
80
80
100
47
21
13
43
2010
usa cem
2011
usa cls
bu cem
bu cls
On the other hand in the concrete sector an increas
For a very limited number of workers a contribution was
ingly higher Frequency index is recorded, equal to 43.7,
acknowledged to attend university courses or non-uni-
against an industrial average equal to 24.7.
versity professional courses directly or potentially pertaining to the corporate role held or to be held in the fore-
seeable future.
programs
Buzzi Unicem USA, in addition to the Healthcare Assis-
The main goal is to show that attending the course will
tance Program for employees, provides a healthcare assis-
notably improve the performance of the user or will
tance program for staff and their families.
develop his / her professional skills in light of growing responsibilities within the company.
In 2011 flu shots and informative seminars on various
diseases were offered.
In 2011, four employees attended university courses,
three to attain a first degree and one to attain a Master’s
Training
degree.
1,146 external and 3,601 internal training days were
provided, with more than 90 % of the courses supplied
concerning health and safety in the workplace.
management
In Buzzi Unicem USA at plant manager level and the
Currently Buzzi Unicem USA has suspended the Repay-
level of managers’ direct reference people, the percent-
ment Program for the expenses incurred for University
age of locals and people not living in the neighboring
fees.
areas is varied; in fact it often happens that to advance
2009
0
25
20
24
40
45
15
30
20
60
138
ieee / pca delegation visit to the Festus plant – usa
careers, employment is offered, at certain levels, for
In Texas, Alamo Cement Co. sponsored the 16th “Alamo
professional growth at other sites.
Annual Golf Tournament” to raise funds for religious
people took part in the event and 3,900 dollars were
raised for the Special Olympics of South Texas Charity
and non-profit organizations in South Texas. About 143
Buzzi Unicem USA organized the collection of used tires at
and 3,900 dollars for the Casey Wells Scholarship
the production sites that use them as fuel to produce
Fund, a fund offering college scholarships to high school
energy for kilns. In addition, collection programs for recy-
students.
cling of computers, toner cartridges, cell phones, paper,
aluminum cans and batteries were implemented.
In 2011 the plant in Stockertown received the PCA
The Pryor site organized a food collection which meant
Sustainable Manufacturing Award for Outreach for the
about 450 kg of food were donated to the local food
promotion of greater environmental awareness among
bank.
local schools and organizations, as well as for the creation
of an open-air laboratory to improve student’s learning
Donations
opportunities. Before creating a space for students and
Buzzi Unicem USA participates in various initiatives
the local population, it was necessary to redevelop the
(donations, fund collections) to support the local commu-
area and especially restore the flora and ensure safe access.
nities where it works and assists various charitable
About 70 trees, 100 plants and 1.6 km of clover were
organizations that take care of less fortunate children, the
planted. In addition, entrance routes, parking lots, paths
most important being “The United Way”. It also sup-
and stairways were arranged for the most uneven parts.
ports The American Heart Association and The American
The plant transformed an unused and difficult area into a
Cancer Society.
139
flourishing area, full of life which is now available to
Also Alamo Cement Co. dealt with these subjects by pro-
students and locals.
viding specific training concerning the “Basic Principles
ulation Statues” to 78 employees, including managers
of u.s. Antitrust Law and Basic Antitrust and Trade RegThe legal office periodically informs Buzzi Unicem USA
and sales reps. Provided was also specific training on the
of the potential risks for the sales area. Furthermore,
methods through which it is possible to recognize viola-
the sales, purchases, finance, marketing and government
tions, using video presentations and distributing suitable
affairs areas are periodically monitored to ensure
illustration materials.
that the company acts in compliance with the laws of the
United States FCPA (US Foreign Corrupt Practices Act)
Corruption
and RICO (Racketeer Influenced and Corrupt Organization
Act).
Alamo Cement Co., which works in an environment
Buzzi Unicem USA is a member of the Portland Cement
where the total risk of corruption is low, adheres to the
Association (PCA), and is represented in various com-
already mentioned RICO federal law.
mittees of the PCA, such as the Environment and Energy
Committee (e & e), National Emissions Standards for
Training on ethics and transparency
Hazardous Air Pollutants (neshap) and Climate Change
Buzzi Unicem USA organized a training course also cov-
Policy (cpp), which work towards legislation which
ering anti-corruption matters. 44 people took part.
fairly implements the greenhouse-gas reduction objectives.
Fishing competition at the factory of Pryor – usa
140
Creation of a totem pole at the entrance to the Festus plant, mo – usa
Alamo Cement Co. is a member of Alamo Area Council of
For the violation of the safety rules, about 61,500 dollars
Government (AACOG), an organization where local,
have been paid, while the sum due for non compliance
state and national matters are discussed to provide suitable
with laws and tax payment schedules is about 14,300
suggestions to the competent bodies, in particular con-
dollars.
cerning the environment.
At the Stockertown production site, 31,394 dollars had to
The company actively participates in the South Central
be paid for violating the CEM (Continuous Emission
Texas Cement and Lime Manufactures (SCTC / LM),
Monitoring).
consisting of four cement manufactures and one lime manufacturer. At state level, Alamo Cement Co. is involved
in the Texas Association of Business (TAB), which deals
with subjects concerning the environment, human
resources and legislation. It is also a member of the Texas
Cement Producers Group (TCPG) and the Portland
Cement Association (PCA).
Sanctions and fines received for non compliance with
laws and regulations
Two administrative procedures have been opened against
Buzzi Unicem USA for the violation of state and federal
laws concerning emissions and safety in the mines.
141
The Sunken Gardens obtained from the first quarry in Alamo – usa
usa
25
50
20
40
15
30
10
20
7.4
2010
2011
usa
10
0
2009
2010
2011
bu
usa
(gj / t of clinker)
(kWh / t of cement)
60
1
30
2009
2010
0
2011
usa
Greenhouse gas
158
usa
bu
872
3,000
697
2,400
1,800
300
1,200
150
600
2009
2010
0
2011
usa
bu
1,854
1,759
801
681
841
3,600
450
0
2011
(g / t of clinker)
900
600
2010
NO X
(kg / t of cement)
750
2009
bu
1,956
1,831
0
118
90
2
1,986
1,764
3
120
120
120
4
4.1
4.0
150
4.2
4.0
180
5
4.2
4.0
6
160
bu
158
6.3
5.7
6.2
2009
5
0
6.6
60
5.8
30
23.5
17.5
(in %)
25.3
18.4
Heat substitution
(in %)
22.6
18.1
681
142
2009
2010
2011
usa
bu
Dust
750
200
0
(g / t of cement)
50.0 %
1,800
33.3 %
1,200
16.6 %
600
384
366
47.3
53.8
366
84.0
231
75
0
2009
2010
0
2011
usa
bu
2009
2010
% rainwater usa
usa
bu
usa
bu
2009
Truck
2010
Train
Ship
2011
Truck
Train
0
365
181
150
bu
34
152
74
usa
200
327
164
184
76
186
231
0
84
44
118
200
79
127
261
400
89
50
155
600
400
90
53
184
600
113
19
117
800
usa
bu
usa
bu
usa
bu
2009
Ship
% recycled usa
34
143
203
(km / t of cement)
bu
350
130
179
(km / t of cement)
16.6 %
0
32
135
189
800
50.0 %
2011
usa
1,000
66.6 %
33.3 %
0
1,000
83.3 %
21
2,400
bu
100 %
27
66.6 %
9,986
3,000
53
3,600
83.3 %
2,921
100 %
388
355
450
375
10,806
Waste generation
150
48
68
usa
(l / t of cement)
225
2011
bu
Water consumption
300
2010
11,743
usa
2009
2,726
2011
40
2,709
2009
48
253
2010
150
0
80
237
357
300
120
449
450
147
160
532
600
Truck
2010
Train
Ship
2011
Truck
Train
Ship
240
900
197
(g / t of clinker)
697
(g / t of clinker)
184
SO X
143
144
Mexico
trading conditions
cement business
Volumes Prices *
Mkt share 13.6 %
5.9 %
12 %
cerritos
apazapan
tepetzingo
* in local currency
Cement plants
Mexico
kilns consisted of 99.1 % petcoke, 0.84 % dense fuel oil
lubricates, and lubricant soaked fibers along with discard-
Natural resources
ed rubber materials generated by maintenance oper
During 2011, a total of 8,744,868 tons of raw materials
ations.
and 0.05 alternative fuels. The latter included used
were used at the plants in Tepetzingo, Cerritos and
Apazapan.
Water resources
The specific consumption of water in 2011 was on aver-
The Apazapan plant began using iron slag as an alterna-
age equal to 195 l / t of equivalent cement.
tive raw material at the end of the year, contributing
about 1 % replacement of raw materials. The facility plans
Within the group, the plant in Cerritos recorded the most
on increasing usage of the slag material through 2012.
efficient use of water, consuming only 70 liters per ton
of equivalent cement.
The Tepetzingo and Cerritos facilities were not able to
utilize alternative raw materials in 2011 but continue to
search for feasible materials to be used.
The cement plants of Tepetzingo, Cerritos and Apazapan are equipped with water treatment systems that allow
waste water to be used reused to irrigate green areas.
Energy resources
Thanks to this system, no waste water is discharged into
2011 equaled 3.38 GJ / t of clinker. The consumption of
the local lakes, rivers and water courses.
electric energy in 2011 remained constant from 2010 at
88 kWh / t of equivalent cement. The fuel used in the
2011
2010
11 / 10
145
k / c Ratio
13.6
1,800
– 2.7
100
t /000
230
550
– 58.1
83.3
Sales revenue
$ m
662.3
565.8
17.1
66.6
$ m
56.3
102.0
– 44.8
50
no.
1,174
1,164
0.9 Aggregate sales
numbers & facts
2009
2010
2011
33.3
16.6
0
mex
bu
Biodiversity
Greenhouse gases
The main impact on biodiversity lies in the loss of habitat
As members of the National Cement Chamber (CANACEM),
due to the removal of the vegetation and the use of the
an initiative supported by the national authorities is
territory as a consequence of the extraction work in the
currently underway, aimed at quantifying the CO² emissions produced by the cement industry throughout the
quarries.
country. Precise objectives have been set for the next 10
The plant in Cerritos has a nursery where species be-
to 20 years and the initial goal is to focus on the reduc-
longing to the local flora are cultivated; these plants are
tion of the clinker percentage in cement, and to increase
then used for the reforestation of the quarry which to
the use of alternative fuels.
date the period in question, concerned has involved more
than 97,802 m² of land.
Since a minimal percentage of alternative fuel is current-
Programs are in place for the protection and transfer
ly being used, federal law does not impose using a con-
of plants and animals safeguarded by environmental reg-
tinuous monitoring system; nevertheless, there is an obli-
ulations at national and global level. More than 6,174
gation to carry out annual analyses of the emissions at
examples of flora, and about 52 of fauna, including mam-
each of the three plants. Emision sources are fitted with
mals, reptiles and birds, have been saved during the
dust particle mitigation systems such as bag filters or
period.
electrostatic precipitators. In addition, tank trucks peri-
In addition there are buffer zones where the original
eliminate dust emissions. The emissions of specific dust
vegetation is maintained and acts as habitat for the vari-
during 2011 were 42 g / t of clinker, therefore lower
odically pour the water on the roads of the quarry to
ous species.
4,904
1,752
5,570
t /000
mc / 000
78.6
79.7
Concrete sales
78.4
79.8
Cement sales
78.0
79.9
var %
146
Tepetzingo plant – Mexico
than in 2010, when this value was 117 g / t of clinker. The
drop is due to the maintenance of the bag filters in the
Special conditions are envisaged for entry and career
Cerritos plant.
advancement (foreman / manager) for those holding degrees and diplomas from agreed institutes.
Waste
In the three cement plants waste management plans are
Staff participation
adopted for the management, storage and final des
Though there is no regulation concerning the participation
tination of any reject materials produced in the plants.
of the staff in the corporate bodies, normally weekly
production and maintenance meetings are held where var-
The 3 factories follow a planned hierarchy envisaged for
ious issues are tackled with the contribution of the work-
managing of waste. First an attempt is made to prevent
ers.
and minimize the production of wastes and, if this is not
feasible, to reuse or recycle it. Furthermore, attempts
to recover as much energy as possible are made. If none
Cementos Moctezuma recognizes benefits to employees
of these options are applicable, the waste is disposed
that go beyond the legal provisions; in particular: the
of with authorized companies.
canteen with discounted prices, supplementary pension
funds that are not compulsory either by law or by col-
Social Indicators
lective bargaining, healthcare insurance for major inven-
tions, life insurance and general accident insurance for
A bonus is provided based on the profitability parameters,
all the staff.
whereas shares are not granted to employees.
147
Worker at the quarry at Tepetzingo – Mexico
Employment
The Mexican headcount has remained substantially sta-
2011
2010
2009
total workforce
1,174
1,164
1,055
Men
1,038
1,035
933
136
129
122
1,155
1,133
999
ble with an increase of 10 employees (from 1,164 people
at 31 / 12 / 2010 to 1,174 people at 31 / 12 / 2011).
Women
Open-end contracts
Full-time
Part-time
Total hires
%
Total terminations
%
Due to retirement
19
31
56
1,174
1,164
1,055
0
0
0
197
271
190
16.78
23.28
18.01
187
162
231
15.93
13.92
21.90
146
116
138
5
1
2
36
45
91
Including 15 apprentices (10 white collars and 5 blue collars)
1.50
54.8
60
0
2009
2010
mex cem
0
bu cem
2010
bu cls
mex cem
0.10
0.78
0.34
0.53
1.13
2009
0.36
0.52
0.25
0.09
0.50
0.15
0.75
2011
mex cls
1.14
1.00
0.3
0.57
26.5
7.3
32.8
20.5
3.4
10
8.3
20
10.1
30
5.4
40
24.7
1.25
28.92
50
3.9
148
2011
mex cls
bu cem
bu cls
Labor relations
Also regarding the severity of these accidents, on average
The collective bargaining coverage is 45.8 % and is gen-
lasting 28 days, the index of severity fell 38 % com-
eralized for all the operational personnel both in the
pared to 2010, confirming excellent values, about a third
cement and concrete segment. The minimum period to
of the segment’s value.
apply organizational changes set by regulations is 2
weeks.
On the other hand it is a different story for the concrete
sector, where 45 accidents were recorded, which led
to an Index of Severity equal to 26.5 and a Frequency
Various programs are implemented such as, for example,
Index equal to 0.78. Both the indicators are slightly
the protection of airways and hearing, training on the
higher than the average values of the concrete segment.
use of personal protection equipment, handling of hazardous materials, first aid and fire fighting courses.
Training
In total in Mexico 3,552 training days were held, all
The absentee rate at the Mexican sites was 1.34 %
external, of which 540 training days focused on safety.
against 0.61 % in 2010 and 0.62 % in 2009. No professional illnesses were recorded.
management
Accidents
Generally, at supervisor and middle management level,
While at the cement plants of Tepetzingo and Cerritos
local personnel prevails.
no accidents were reported, in Apazapan there were 10.
The high number of working hours in any case kept
Also 80 % (8 out of 11) of the Top management is Mex-
the Frequency Index in Mexico at excellent values (equal
ican.
to 3.4 for a decrease of 37 % compared to 2010).
149
gg
120
100
80
47
21
28
29
2010
mex cem
2011
mex cls
bu cem
bu cls
soccer team for students aged 13 to 17 to become part
of which a good average must be kept at school.
In Mexico various training courses are held; in Tepetzingo
the program called “Selva Nuestra” continued, with the
aim of building environmental awareness in children and
In the accounting period, various audits were conducted
teens aged 6 to 15 in the local community. In Cerritos
in several areas, considering in particular those exposed
an apprenticeship program and professional qualification
to the possible risk of corruption and conflicts of interest.
courses for young people and adults are in place. Still
in Cerritos the “environment day” was celebrated, during
Currently being assessed is the implementation of a
which an attempt was made to raise awareness in stu-
Complaint Mailbox, where employees and stakeholder may
dents from nearby communities on environmental issues.
report any act of corruption that affects them or that
they are aware of.
In Apazapan the support necessary to repair some streets
near the plant was provided.
Corruption
At the production sites of Tepetzingo and Apazapan the
health fair was held during which free medical assistance
was provided to a host of people.
Moctezuma is a member of the National Cement Chamber.
All three plants support students in the local communities
by donating school material and assigning scholarships
to deserving students. In order to encourage young people
to study, the production site in Tepetzingo sponsors a
2009
0
28
35
43
25
20
24
21
30
20
40
60
Mexico
50
20
40
15
30
10
20
2009
2010
2011
bu
mex
(gj / t of clinker)
(kWh / t of cement)
4
120
60
1
30
2009
2010
0
2011
mex
Greenhouse gas
2011
mex
bu
(g / t of clinker)
750
3,000
659
697
3,600
659
681
900
2,400
450
1,800
300
1,200
150
600
0
2010
NO X
(kg / t of cement)
600
2009
bu
2009
2010
0
2011
mex
bu
2009
2010
2,987
1,759
0
85
90
2
2,441
1,764
3
3.4
4.0
150
3.3
4.0
180
5
3.4
4.0
6
120
bu
118
mex
0
88
2011
120
2010
88
2009
2,755
0
10
1,831
5
0.1
7.4
25
0
6.3
60
0
6.2
30
0.1
17.5
(in %)
0.1
18.4
Heat substitution
(in %)
4.0
18.1
656
681
150
2011
mex
bu
200
600
160
527
0
2010
2011
2009
80
80
42
150
253
357
300
120
291
237
450
40
0
mex
2009
2010
2011
bu
mex
Water consumption
Waste generation
(l / t of cement)
(g / t of cement)
bu
100 %
3,000
83.3 %
66.6 %
2,400
50.0 %
1,800
33.3 %
1,200
16.6 %
600
bu
mex
2009
Truck
bu
mex
2010
Train
Ship
bu
2011
Truck
Train
0
mex
bu
mex
2009
Ship
% recycled mex
Truck
bu
mex
2010
Train
Ship
365
181
150
350
130
179
200
0
0
0
0
0
mex
76
186
231
400
107
76
600
400
79
127
261
600
70
87
800
90
53
184
800
83
85
1,000
0
2011
bu
1,208
(km / t of cement)
1,288
(km / t of cement
1,000
2,726
55
263
2010
mex
200
580
2,921
74
2009
% rainwater mex
16.6 %
0
79
1
2011
bu
50.0 %
1,248
2010
mex
0
66.6 %
33.3 %
327
164
184
2009
0
44
0
0.0
0
0.3
178
0.0
75
171
150
195
225
310
355
300
2,709
81
3,600
83.3 %
366
100 %
366
450
375
bu
2011
Truck
Train
Ship
750
147
240
197
900
583
(g / t of clinker)
Dust
(g / t of clinker)
117
184
SO X
151
152
human rights
Human Rights
of human rights in contracts for the supply of plants or
for equity investment. The company, in fact, operates almost exclusively in countries that cannot be considered
Group personnel have received our Code of Conduct
to be specifically at risk in this respect, and that mostly
and understand its rationale and the common values on
already signed the relevant UN and ILO conventions
which our business activity is based.
concerning human rights.
Buzzi Unicem is committed to complying with national
legislation in all the countries where it is active.
Significant suppliers subjected to human
rights screening
The company works in countries that have ratified the fundamental OIL / ILO (International Labor Organization)
In Italy, the Code of Business Ethics – drawn up to ap-
conventions abolishing forced labor and under-age labor
ply Italian Legislative Decree 231 / 2001 – is sent to our
and have mostly integrated them into the respective
main partners and is an integral part of the supply
domestic legislation.
agreement.
For this reason Buzzi Unicem believes that compliance
The current edition includes a section concerning trans-
with domestic legislation in the various countries where
national crimes, thus transposing the Convention and re-
it works is a sound means of ensuring full respect of
lated application protocols approved by the General
human rights, with non-discrimination and assurance of
Assembly of the United Nations on November 15, 2000.
the absence of under-age and forced labor as part of
It also considers, among other things, potential exploita-
the group’s sphere of responsibility.
tion of illegal immigration. The parent company’s Code of
Business Ethics, even though it does not explicitly envis-
In this scenario, all management staff and staff with human
age clauses for the protection of human rights – which
resources management responsibility have been fully
are already regulated by the original legislation of the
informed on and trained in, compliance with the local qual-
countries were we operate – expressly governs exploita-
ity employment legislation.
tion of illegal immigration as one of the crimes that
could potentially be committed by third parties in connection with the various contractual relationships.
Human rights protection clauses in
significant investments
As this has been included in the Code of Business Ethics
– which is indicated as an integral part of the general
The global economic crisis caused a slowdown in the
conditions of supply – in the unlikely event of non-appli-
various strategic investments that were not yet at an ad-
cation of this and other contractual clauses by the sup-
vanced phase.
plier, the contract is terminated for contractual default. In
the rest of Europe, no supply agreement of the Dycker-
As the company reached the conclusion that no real risks
hoff subholding company’s investee companies presently
existed in terms of the failure to respect human rights,
features specific human rights clauses.
it was unnecessary to include clauses for the protection
153
Shipping department, Cerritos factory – Mexico
This is because the group’s sphere of action concerns
Alamo does not perform human rights-screening.
human rights
ventions and (b) whose specific domestic regulations
already independently outlaw acts against the protection
Discrimination incidents reported
of human rights.
No episodes of discrimination were reported in any
United States of America
countries in which the group operates, with the excep-
Buzzi Unicem USA does not formally screen suppliers or
tion of the USA where 4 new cases occurred.
contractors with regard to matters concerning the safeguarding of human rights.
Of these, two appeals are still suspended in the courts.
General condition of supply, however, require scrupulous compliance with all federal and state regulations –
Risks for freedom of trade union association
consequently also with requirements concerning human
rights protection.
As highlighted in the foreword to the Human Rights indicators, in our companies based in European Union coun-
Conversely, preferential suppliers are screened at central
tries there are no risks of discrimination against trade
level by Buzzi Unicem USA and then referred to facto-
unions or against employees’ desire to join them or to be
ries as, in addition to providing goods and services, they
represented by them in negotiations with the company.
also provide added-value features, such as, design,
training, inventory control and special supply. Because of
This is also testified to by the rate of collective bargain-
this they are widely used at the overall level and
ing coverage, as well as by the good general level of
account for a significant percentage of purchases.
labor relations achieved (for example, with creation in
2008 of the European Works Council).
countries (a) that have ratified the main UN and ILO con-
154
human rights
Employees at work, Intesa San Paolo skyscraper – Italy
Even so, the Russian and American businesses merit
interfering with these rights by, for example, giving pref-
further detail.
erence to one trade union at the expense of another,
by punishing an employee who has sued the company for
Russia
unfair labor practices, or by refusing to negotiate with
Adoption of most company measures have to be submit-
a trade union. Likewise, the Act also prohibits trade un-
ted for consultation with the company trade union repre-
ions from forcing a worker to join, from forcing an em-
sentatives. Without such consultation, these measures
ployer to take retribution against workers, from refusing
cannot be implemented.
to negotiate in good faith and fairness, from engaging
in boycotts, from forcing a company to negotiate when an-
With respect to the right to strike, if the proclamation
other trade union has already been recognized as the
of a strike is consistent with established law, the right is
counterparty, and from calling a strike over jurisdictional
guaranteed and not subject to any time limits.
disputes between trade unions.
United States of America
In practice, Buzzi Unicem USA has company policies and
There are no sites where exercising the right of associa-
practices to ensure compliance with relevant regula-
tion with trade union is at risk. The First Amendment to
tions and laws. There are monthly meetings at all sites
the United States Constitution, in fact, safeguards citi-
with workers’ local representatives.
zens’ right of association. In addition, various federal and
state laws, particularly the 1935 National Labor Rela-
In addition to the scheduled meetings, Buzzi Unicem
tions Act, establish that personnel are provided the free-
USA adopts an “open-door” policy, allowing staff to free-
dom of association, free to organize and set up trade
ly express opinions and comments.
unions and free to enter into collective agreements. The
National Labor Relations Act prohibits employers from
155
Risk of adolescent labor incidents
Careful and thorough analysis conducted by all foreign
branches has shown that no branch identified real and
concrete risks of incidents involving unlawful adolescent
(15 / 18 years old) labor.
In addition, an analysis of exposure to hazardous activities for juvenile personnel showed that no employed
juvenile is exposed to hazardous activities.
Risk of compulsory labor
A meticulous and detailed analysis of all foreign branches has shown that no branch have identified any real and
tangible risks of compulsory labor, as defined in the
applied reporting criteria.
Triathlon at the quarry of Domelaar of Dyckerhoff Basal Nederland – the Netherlands
human rights
156
Environmental and Social Performance: Charts and Tables
hse management systems
Cement plants
Italy
Augusta
Barletta
Cadola
Guidonia
Robilante
Siniscola
Travesio
Vernasca
Sorbolo
Germany
Amöneburg
Deuna
Geseke
Göllheim
Lengerich
Neuss
Neuwied
Mexico
Czech Republic
Luxembourg
Tepetzingo
Hranice
Esch-sur-Alzette
Rumelange
Concrete plants Italy
Settimello
Castelfiorentino
Monsummano
Barberino Val d’Elsa
Venturina
Orbassano
Cagliari
Santena
Terminals
Italy
Ravenna
en iso 14001
ohsas 18001
epd
Environmental
anagement system
m
Occupational
health & safety
management system
Environmental
Product Declarations
157
usa
ger
mex
ukr cze / svk
pol
bu
Concrete production
cm 4,106,275 2,192,130 3,919,357 1,756,686
Concrete plants
no.
170
81
129
57
6
82
30
16
571
Plants using fly ash
no.
51
78
126
10
0
67
30
16
378
t
42,608
116,024
166,452
1,620
0
95,492
52,495
28,000
502,692
Total fly ash used
Fly ash used per m³
of concrete
165,630 1,713,312 1,014,798
nld
912,579 15,780,766
kg/cls
10
53
42
1
0
56
52
31
32
Plants with water / aggregate separation system
no.
40
12
124
1
6
14
28
7
232
Plants with process
water recycling system
no.
170
5
126
0
0
14
26
17
358
Plants with rainwater
treatment systems
no.
80
5
121
0
0
16
30
0
252
ita
usa
ger
mex
ukr
rus
cze
lux
pol
nld
Health & Safety
2.555
0.053
0.016
0.178
0.368
0.099
0.276
0.108
0.015
0
Environment
2.963
0.511
7.640
0.006
0.212
1.128
0.217
0.409
0.132
0
Health & Safety
0.934
0.644
1.138
0.138
0.350
0.594
0.207
0.226
0.234
0.070
Environment
5.833
2.337
23.058
0.260
0.399
0.911
1.223
0.266
0.592
0
hse investments and spending
ita
Concrete
Investments
Spending
The company made significant efforts in 2011 to guarantee the Ecology, Environment and Safety improvement process in place,
as shown for each country in the table above.
Indirect co²
ita
usa
ger
mex
ukr
Electricity
44.9
84.7
59.9
36.4
44.1
Transport
26.2
17.0
27.3
62.1
80.7
rus
cze
lux
pol
2011
51.0
71.1
32.2
101.9
57.3
44.8
10.9
30.6
6.2
34.8
kg co2 / t of cement
€ millions
158
Percentage of employees covered by collective bargaining agreements
Total workforce 2011
No. of employees covered by
collective bargaining agreements ccnl
% of total employees
ger
lux
nld
cze
svk
pol
rus
ukr
usa
1,872
1,822
157
287
727
144
389
1,049
1,617
2,290
1,013
1,617
822
538
8,378
96.57 100.00
35.90
45.83
72.68
1,872
1,524
139
270
196
–
387
100.00
83.64
88.54
94.08
26.96
0.00
99.49
Absentee rate (illness, injuries, other causes)
Absentee rate
(%)
’09
’10
Of which for strikes
(%)
’11
’09
’10
’11
Occupational
diseases
’09
’10
’11
Deaths
’09
’10
’11
ita¹
3.56
2.99
3.09
0.03
0.08
0.07
1
2
7
0
0
0
ger
4.18
4.56
5.07
0
0
0
0
0
0
0
0
0
lux
3.69
5.74
6.26
0
0
0
0
0
0
0
0
0
nld
4.74
5.54
5.58
0
0
0
0
0
0
0
0
0
csz
2.55
2.54
2.59
0
0
0
0
0
0
0
0
0
svk
2.19
1.35
1.96
0
0
0
0
0
0
0
0
0
pol
2.62
2.83
2.05
0
0
0
0
0
0
0
0
0
rus
2.36
2.18
3.18
0
0
0
3
5
3
0
0
0
ukr
3.53
3.14
2.53
0
0
0
0
0
0
0
0
0
usa
2.31
2.20
1.92
0
0.10
0
3
5
0
0
0
0
mex
0.62
0.61
1.34
0
0
0
0
0
0
0
0
0
Total
2.92
2.76
2.89
0.01
0.03
0.01
7
12
10
0
0
0
¹ Excluding managers
mex
Total
ita
1,174 11,528
159
483
2,237
8,397
122
48
324
1,235
163
391
485
2,411
141
125
25
0
918
0
468
98
0
139
1,342
lux²
nld
cze
svk
pol
rus
ukr
1,486
1,016
90
39
460
91
364
1,529
602
Technical training
199
94
14
18
84
0
51
281
hse training
779
67
8
3
22
2
54
437
Vocational training
180
140
18
0
83
3
203
Foreign language training
260
47
8
0
236
86
Managers, office supervisors,
and white-collars
Management training
54
33
34
12
6
0
32
107
54
19
114
465
Other
14
635
8
6
29
0
24
95
40
0
1,175
2,026
205 10,034
1,146
713
80
151
954
25
723
663
1,315
16,009
Technical training
124
83
9
96
380
8
50
380
161
123
284
1,698
hse training
931
85
56
49
63
2
64
159
167
537
55
2,168
91
456
0
0
369
15
66
9,277
395
3
0
10,672
0
4
11
0
38
0
0
0
0
0
0
53
Management training
0
0
4
6
0
0
4
58
0
0
58
130
21
160
0
0
918
1,288
569 11,563
1,325
1,146
3,552
24,406
Foremen and blue-collars
Vocational training
0
85
0
0
104
0
Country total
2,632
1,729
170
190
1,414
116
Number of managers, office
supervisors and white-collars
1,054
876
73
65
199
34
167
289
374
757
276
4,164
Average per-head
t raining days
1.41
1.16
1.23
0.60
2.31
2.68
2.18
5.29
1.61
0.64
8.11
2.02
Number of foremen and
blue-collars
818
810
82
222
528
110
222
760
1,243
1,533
883
7,211
Average per-head
training days
1.40
0.88
0.98
0.68
1.81
0.23
0.92
13.20
0.58
0.43
1.49
2.22
1,872
1,686
155
287
727
144
389
1,049
1,617
2,290
1,159
11,375
1.41
1.03
1.10
0.66
1.94
0.81
1.46
11.02
0.82
0.50
3.06
2.15
Other
Total workforce
Average per-head
training days
¹ Germany: excluding 136 apprentices
² Luxembourg: excluding 2 apprentices
³ Mexico: excluding 15 apprentices (10 white-collars, 5 blue-collars)
The term “External training” refers to training activity provided to the company employees by third party.
Total
ger¹
usa mex³
ita
Number of training days provided to:
Days of external training provided to employees
160
Days of internal training provided to employees
ita
ger¹
lux²
nld
cze
svk
pol
rus
ukr
1,143
1,687
28
7
70
4
8
776
832
usa mex³
Total
589
0
5,144
Number of training days provided to:
Managers, office supervisors, and white-collars
Technical training
587
30
0
0
6
0
0
0
539
24
0
1,186
hse training
186
311
3
6
51
4
8
600
117
502
0
1,788
Vocational training
166
0
10
0
13
0
0
121
0
11
0
321
0
417
0
0
0
0
0
34
130
0
0
581
168
149
0
0
0
0
0
0
0
52
0
369
36
780
15
1
0
0
0
21
46
0
0
899
873
694
7
63
41
10
8
6,331
6,261
3,012
0
17,300
Technical training
337
110
0
0
33
0
0
540
5,752
42
0
6,814
hse training
157
420
0
50
4
10
8
3,014
501
2,902
0
7,066
Vocational training
371
0
0
0
4
0
0
2,766
0
0
0
3,141
0
0
0
0
0
0
0
0
8
0
0
8
Management training
0
14
0
0
0
0
0
0
0
0
0
14
Management training
Other
8
150
7
13
0
0
0
11
0
68
0
257
Country total
2,016
2,381
35
70
111
14
16
7,107
7,093
3,601
0
22,444
Number of managers, office
supervisors and white-collars
1,054
876
73
65
199
34
167
289
374
757
276
4,164
Average per-head
training days
1.08
1.93
0.38
0.11
0.35
0.12
0.05
2.69
2.22
0.78
0.00
1.24
Number of foremen and
blue-collars
818
810
82
222
528
110
222
760
1,243
1,533
883
7,211
Average per-head
training days
1.07
0.86
0.09
0.28
0.08
0.09
0.04
8.33
5.04
1.96
0.00
2.40
1,872
1,686
155
287
727
144
389
1,049
1,617
2,290
1,159
11,375
1.08
1.41
0.23
0.24
0.15
0.10
0.04
6.78
4.39
1.57
0.00
1.97
Other
Total workforce
Average per-head
training days
¹ Germany: excluding 136 apprentices
² Luxembourg: excluding 2 apprentices
³ Mexico: excluding 15 apprentices (10 white-collars, 5 blue-collars)
The term “Internal training” refers to training activity provided by and to the company employees.
161
lux
nld
cze
svk
pol
rus
ukr
usa
mex
Total
1,054
936
75
65
199
34
167
289
374
757
286
4,236
Men
916
690
65
52
123
19
105
175
214
617
181
3,157
Women
138
246
10
13
76
15
62
114
160
140
105
1,079
63
138
9
2
11
2
12
60
69
35
52
453
30 / 50 year olds
658
492
32
37
126
18
99
177
215
518
177
2,549
Over 50s
333
306
34
26
62
14
56
52
90
204
57
1,234
0
0
0
0
0
0
0
0
0
111
0
111
818
886
82
222
528
110
222
760
1,243
1,533
888
7,292
809
873
82
211
508
103
209
645
983
1,495
857
6,775
9
13
0
11
20
7
13
115
260
38
31
517
68
141
16
11
47
10
16
123
211
128
200
971
Under 30s
Minorities
Men
Women
Under 30s
30 / 50 year olds
454
390
46
116
317
63
130
428
727
1,006
600
4,277
Over 50s
296
355
20
95
164
37
76
209
305
399
88
2,044
Minorities
0
0
0
0
0
0
0
0
0
573
0
573
Country total
1,872
1,822
157
287
727
144
389
1,049
1,617
2,290
1,174
11,528
Managers, office super
visors and white-collars
ger
ita
Breakdown of personnel by category, gender and age
162
163
gri Content Index
164
gri content index
g3 content index
Profile
Disclosure
Description
Cross-reference
Note
I. Profile Disclosures – 1. Strategy and Analysis
1.1
Statement from the most senior decision-maker of the organization.
1.2
Description of key impacts, risks, and opportunities.
2.1
Name of the organization.
2.2
Primary brands, products, and / or services.
2.3
Operational structure of the organization, including main divisions,
operating companies, subsidiaries, and joint ventures.
Pages 4 – 5
Website: Sustainability
I. Profile Disclosures – 2. Organizational Profile
Cover page, page 1
2.4
Location of organization’s headquarters.
2.5
Number of countries where the organization operates, and names
of countries with either major operations or that are specifically
relevant to the sustainability issues covered in the report.
2.6
Nature of ownership and legal form.
2.7
Markets served (including geographic breakdown, sectors served,
and types of customers / beneficiaries).
Pages 1 – 3
Page 3
Pages 24 – 26
Website: about us
Page 3
Pages 24 – 26
Pages 31 – 33
Website: investor relations
Page 3
Page 30
2.8
Scale of the reporting organization.
2.9
Significant changes during the reporting period regarding size,
structure, or ownership.
Not available There were no significant changes in
the size, structure,
or ownership in the
reporting period.
Pages 2 – 3
2.10
Awards received in the reporting period.
Not available
3.1
Reporting period (e. g., fiscal / calendar year) for information
provided.
I. Profile Disclosures – 3. Report Parameters
Pages 22 – 23
3.2
Date of most recent previous report (if any).
Pages 22 – 23
3.3
Reporting cycle (annual, biennial, etc.).
Pages 22 – 24
3.4
Contact point for questions regarding the report or its contents.
Website: contacts
3.5
Process for defining report content.
Pages 22 – 23
3.6
Boundary of the report (e. g., countries, divisions, subsidiaries,
leased facilities, joint ventures, suppliers). See gri Boundary
Protocol for further guidance.
Pages 22 – 23
3.7
State any specific limitations on the scope or boundary of the
report (see completeness principle for explanation of scope).
Pages 22 – 23
3.8
Basis for reporting on joint ventures, subsidiaries, leased facilities,
outsourced operations, and other entities that can significantly
affect comparability from period to period and / or between organizations.
Pages 22 – 23
3.9
Data measurement techniques and the bases of calculations, including assumptions and techniques underlying estimations applied
to the compilation of the Indicators and other information in the
report. Explain any decisions not to apply, or to substantially
diverge from, the gri Indicator Protocols.
Pages 22 – 23
3.10
Explanation of the effect of any re-statements of information provided in earlier reports, and the reasons for such re-statement
(e. g.,mergers / acquisitions, change of base years / periods, nature
of business, measurement methods).
Pages 22 – 23
3.11
Significant changes from previous reporting periods in the scope,
boundary, or measurement methods applied in the report.
Pages 22 – 23
3.12
Table identifying the location of the Standard Disclosures in the
report.
gri Content Index
(Pagina 163 – 169)
Did not receive
awards / prizes during the
reporting period.
gri content index
165
g3 content index
Profile
Disclosure
Description
Cross-reference
3.13
Policy and current practice with regard to seeking external
assurance for the report.
4.1
Governance structure of the organization, including committees
under the highest governance body responsible for specific tasks,
such as setting strategy or organizational oversight.
Pages 24 – 26
Corporate Governance
Relation 2011 (page 12)
4.2
Indicate whether the Chair of the highest governance body is also
an executive officer.
Pages 24 – 26
4.3
For organizations that have a unitary board structure, state the
number of members of the highest governance body that are independent and / or non-executive members.
Pages 24 – 26
4.4
Mechanisms for shareholders and employees to provide recommendations or direction to the highest governance body.
4.5
Linkage between compensation for members of the highest governance body, senior managers, and executives (including departure arrangements), and the organization’s performance (including
social and environmental performance).
4.6
Processes in place for the highest governance body to ensure conflicts of interest are avoided.
Pages 24 – 26
Code Ethics (page 4)
4.7
Process for determining the qualifications and expertise of the
members of the highest governance body for guiding the organization’s strategy on economic, environmental, and social topics.
4.8
Internally developed statements of mission or values, codes of
conduct, and principles relevant to economic, environmental, and
social performance and the status of their implementation.
Pages 24 – 26
4.9
Procedures of the highest governance body for overseeing the organization’s identification and management of economic, environ
mental, and social performance, including relevant risks and opportunities, and adherence or compliance with internationally agreed
standards, codes of conduct, and principles.
Pages 24 – 26
4.10
Processes for evaluating the highest governance body’s own performance, particularly with respect to economic, environmental,
and social performance.
4.11
Explanation of whether and how the precautionary approach or
principle is addressed by the organization.
4.12
Externally developed economic, environmental, and social charters, principles, or other initiatives to which the organization subscribes or endorses.
Pages 24 – 26
4.13
Memberships in associations (such as industry associations) and /
or national / international advocacy organizations in which the
organization: * Has positions in governance bodies; * Participates
in projects or committees; * Provides substantive funding beyond
routine membership dues; or * Views membership as strategic.
Pages 62, 75, 84, 90, 95,
106, 116, 140, 149
4.14
List of stakeholder groups engaged by the organization.
4.15
Basis for identification and selection of stakeholders with whom to
engage.
4.16
Approaches to stakeholder engagement, including frequency of
engagement by type and by stakeholder group.
Pages 28 – 34
4.17
Key topics and concerns that have been raised through stake
holder engagement, and how the organization has responded to
those key topics and concerns, including through its reporting.
Pages 28 – 34
Website: Chart of values
Note
Pages 22 – 23
Website: Chart of values;
Guiding Principles
Pages 28 – 34
stakeholders
Pages 28 – 34
The Board of Directors
makes an annual selfassessment of the size,
composition and functioning of the Board itself and
its committees.
Pages 24 – 26
I. Profile Disclosures – 4. Governance, Commitments, and Engagement
166
gri content index
g3 content index
Profile
Disclosure
Description
Cross-reference
II. Disclosures on Management Approach
dma ec
Disclosure on Management Approach ec
Guiding Principles
Pages 39
dma en
Disclosure on Management Approach en
Pages 46 – 47
dma la
Disclosure on Management Approach la
Guiding Principles
Pages 46 – 47
dma hr
Disclosure on Management Approach hr
Guiding Principles
Pages 152 – 155
dma so
Disclosure on Management Approach so
Guiding Principles
dma pr
Disclosure on Management Approach pr
Guiding Principles
ec1
Direct economic value generated and distributed, including revenues, operating costs, employee compensation, donations and
other community investments, retained earnings, and payments to
capital providers and governments.
ec2
Financial implications and other risks and opportunities for the
organization’s activities due to climate change.
Pages 50, 68, 79, 101,
111, 132, 145 Consolidated
Annual Report 2011
(page 59)
ec3
Coverage of the organization’s defined benefit plan obligations.
Pages 44 – 45
Consolidated Annual
Report 2011 (page 87)
ec4
Significant financial assistance received from government.
ec6
Policy, practices, and proportion of spending on locally-based suppliers at significant locations of operation.
Page 28 – 30
ec7
Procedures for local hiring and proportion of senior management
hired from the local community at significant locations of operation.
Pages 60, 75, 84, 105,
107, 138, 148
ec8
Development and impact of infrastructure investments and services
provided primarily for public benefit through commercial, in-kind,
or pro bono engagement.
Pages 60 – 62, 75, 90,
105 – 106, 116,
125 – 126, 138 – 140, 149
en1
Materials used by weight or volume.
Were used 47,691,419 t of
raw materials, of which:
44,167,706 t natural raw
materials and 3,523,713 t
non-natural raw materials
en2
Percentage of materials used that are recycled input materials.
Pages 48, 64, 66, 76, 78,
86, 92, 98, 100, 108, 110,
118, 120, 128, 130, 142,
144, 150
en3
Direct energy consumption by primary energy source.
Pages 48, 64, 66, 76, 78,
86, 92, 98, 100, 108, 110,
118, 120, 128, 130, 142,
144, 150
en4
Indirect energy consumption by primary source.
Pages 48 – 50, 64, 66 – 67,
76, 78, 86, 92, 98, 100,
108, 110, 118, 120, 128,
130, 142, 144, 150
en8
Total water withdrawal by source.
Pages 50, 65, 68, 76, 79,
87, 92, 99, 100, 109, 111,
119, 120, 129, 131, 143,
144, 151
III. Performance Indicators – Economic
Pages 39 – 45
Page 44
III. Performance Indicators – Environmental
Note
gri content index
167
g3 content index
Profile
Disclosure
Description
en10
Percentage and total volume of water recycled and reused.
en11
Location and size of land owned, leased, managed in, or adjacent
to, protected areas and areas of high biodiversity value outside
protected areas.
Pages 50, 68, 79, 101,
111, 132, 145
en12
Description of significant impacts of activities, products, and services on biodiversity in protected areas and areas of high biodiversity value outside protected areas.
Pages 50, 68, 79, 101,
111, 132, 145
en16
Total direct and indirect greenhouse gas emissions by weight
(co2, ch4, n2o, hfcs, pfcs, sf6).
en17
Other relevant indirect greenhouse gas emissions by weight.
en19
Emissions of ozone-depleting substances by weight.
en20
nox , sox , and other significant air emissions by type and weight.
en21
Total water discharge by quality and destination.
en22
Total weight of waste by type and disposal method.
en23
Total number and volume of significant spills.
en26
Initiatives to mitigate environmental impacts of products and services, and extent of impact mitigation.
en27
Percentage of products sold and their packaging materials that are
reclaimed by category.
Cross-reference
Note
Pages 53, 64 – 65, 69,
76 – 77, 80, 86 – 87, 93,
98 – 99, 102, 108 – 109,
112, 118 – 119, 121,
128 – 129, 133 – 134,
142 – 143, 145, 150 – 151
In 2011, water discharges
of the Group amount to
approximately 11 million
cubic meters
Pages 52 – 53, 65, 69, 77,
81, 87, 93, 99, 102, 109,
112, 119, 122, 129, 134,
143, 146, 151
In 2011 there were no significant spills. The main
overground tanks, containing dangerous substances, are provided with
suitable containment
basins in order to avoid
unpleasant emergencies.
Pages 48 – 50, 66 – 67, 78,
92, 100, 110, 120, 130,
144,
Website:
Sustainability – Certifications
The need for packaging is
reduced to a minimum
level, because the quantity
of sold packed-cement is
nearly 20 %. This trend is
confirmed in all the countries, except for Mexico,
where such percentage is
slightly less than 48 %. The
other product are sold
unpacked, whilst packedcement is sacked into bags
which are placed onto
wooden pallets, properly
covered with a polyethylene film.
Page 157
There are no other significant emissions
Pages 51, 64, 68, 76, 80,
86, 92, 98, 101, 108, 112,
118, 121, 128, 132 – 133,
142, 145, 150,157
Pages 50, 65, 68, 76, 79,
87, 92, 99, 100, 109, 111,
119, 120, 129, 131, 143,
144, 151
The society has used
1,532,081 cubic meters of
rainwater.
168
gri content index
g3 content index
Profile
Disclosure
Description
Cross-reference
en28
Monetary value of significant fines and total number of non-monetary sanctions for non-compliance with environmental laws and
regulations.
Pages 96, 141
Consolidated Annual
en29
Significant environmental impacts of transporting products and
other goods and materials used for the organization’s operations,
and transporting members of the workforce.
en30
Total environmental protection expenditures and investments by
type.
la1
Total workforce by employment type, employment contract, and
region.
Pages 55, 73, 82, 89, 94,
104, 107, 114, 123, 135,
147, 161
la2
Total number and rate of employee turnover by age group, gender,
and region.
Pages 55, 73, 82, 89, 94,
104, 107, 114, 123, 135,
147
la4
Percentage of employees covered by collective bargaining agreements.
Pages 55 – 56, 73, 83, 90,
95, 105, 107, 115, 124,
136, 148, 158
la5
Minimum notice period(s) regarding significant operational changes, including whether it is specified in collective agreements.
Pages 56, 73, 83, 136
la7
Rates of injury, occupational diseases, lost days, and absenteeism,
and number of work-related fatalities by region.
Pages 57 – 58, 73 – 74, 83,
90, 95, 105, 107, 115,
124 – 125, 137, 148, 158
la8
Education, training, counseling, prevention, and risk-control
programs in place to assist workforce members, their families,
or community members regarding serious diseases.
Pages 59, 83, 105 – 107,
115, 125, 137 – 138
la10
Average hours of training per year per employee by employee
category.
Pages 59, 74, 84, 90, 95,
105, 107, 115, 125, 138,
148, 159 – 160
la13
Composition of governance bodies and breakdown of employees
per category according to gender, age group, minority group
membership, and other indicators of diversity.
Page 161
la14
Ratio of basic salary of men to women by employee category.
Page 158
hr1
Percentage and total number of significant investment agreements
that include human rights clauses or that have undergone human
rights screening.
Page 152
hr2
Percentage of significant suppliers and contractors that have
undergone screening on human rights and actions taken.
Page 152
hr4
Total number of incidents of discrimination and actions taken.
Page 153
hr5
Operations identified in which the right to exercise freedom of
association and collective bargaining may be at significant risk,
and actions taken to support these rights.
hr6
Operations identified as having significant risk for incidents of
child labor, and measures taken to contribute to the elimination of
child labor.
Page 155
hr7
Operations identified as having significant risk for incidents of
forced or compulsory labor, and measures to contribute to the
elimination of forced or compulsory labor.
Page 155
so1
Nature, scope, and effectiveness of any programs and practices
that assess and manage the impacts of operations on communities,
including entering, operating, and exiting.
so2
Percentage and total number of business units analyzed for risks
related to corruption.
Pages 65, 77, 87, 99, 109,
119, 129, 143, 151
Page 157
III. Performance Indicators – Labor Practices and Decent Work
III. Performance Indicators – Human Rights
Pages 153 – 154
III. Performance Indicators – Society
Pages 60 – 62, 75, 90,
105 – 106, 116, 125 – 126,
138 – 140, 149
Pages 62, 75, 106, 107,
126, 139, 149
Note
gri content index
169
g3 content index
Cross-reference
so4
Actions taken in response to incidents of corruption.
Pages 62, 75, 84, 90, 95,
106, 107, 116, 126, 140,
149
so5
Public policy positions and participation in public policy development and lobbying.
Pages 62, 75, 84, 90, 95,
106, 116, 140, 149
so8
Monetary value of significant fines and total number of non-monetary sanctions for non-compliance with laws and regulations.
Pages 96, 141
Consolidated Annual
pr1
Life cycle stages in which health and safety impacts of products and
services are assessed for improvement, and percentage of significant products and services categories subject to such procedures.
pr3
Type of product and service information required by procedures,
and percentage of significant products and services subject to
such information requirements.
Website: Products – Safety charts Website:
Quality Certification
pr6
Programs for adherence to laws, standards, and voluntary codes
related to marketing communications, including advertising, promotion, and sponsorship.
Website:
Quality Certification
pr9
Monetary value of significant fines for non-compliance with laws
and regulations concerning the provision and use of products and
services.
Note
Pages 106, 140
III. Performance Indicators – Product Responsibility
Website: Sustainability – Certifications
Website: Products – Safety charts
Pages 96, 141
Consolidated Annual
Percentage of employees trained in organization’s anti-corruption
policies and procedures.
Description
so3
Profile
Disclosure
self-declared application
Self-declared Application
Level gri g3
The Buzzi Unicem group Sustainability Report 2011 has
been prepared according to the Sustainability Reporting Guidelines issued by Global Reporting Initiative (GRI)
g3, application level A + (self declared).
output
output
g3 Performance
Indicators
& Sector
Supplement
Performance
Indicators
Report on a minimum
of 10 Performance
Indicators, at least one
from each of: Economic, Social and Environmental.
b
b +
Report on all criteria
listed for Level C plus:
1,2
3,9, 3,13
4,5 – 4,13, 4,16 – 4,17
Management
Approach Disclosures
for each
Indicator Category
Report on a minimum
of 20 Performance
Indicators, at least one
from each of Economic, Environmental,
Human rights, Labor, Society, Product
Responsibility.
a
a +
Same as requirement
for Level B
Management
Approach Disclosures
for each
Indicator Category
Report on each core g3
and Sector Supple
ment* Indicator with
due regard to the
Materiality Principle by
either: a) reporting
on the Indicator or b)
explaining the reason for its omission.
report externally assured
Report on:
1,1
2,1 – 2,10
3,1 – 3,8, 3,10 – 3,12
4,1 – 4,4, 4,14 – 4,15
Not Required
g3 Management
Approach
Disclosures
c +
c
g3 Profile
Disclosures
output
report application level
standard disclosures
170
self-declared application
171
172
173
Assurance Statement
174
assurance statement
assurance statement
175
176
assurance statement
assurance statement
177
178
_buzzi unicem s.p.a.
Via Luigi Buzzi, 6
15033 Casale Monferrato (al)
Telephone + 39 0142 416.111
www.buzziunicem.it
_coordination and graphic design
Heisters & Partner
Büro für Kommunikationsdesign,
Mainz / Germany
_editing
Mercurio S.r.l.
Milano
This Sustainability Report has been completed
in accordance with gri A + standards
buzzi unicem s.p.a.
via luigi buzzi, 6
casale monferrato (al)
italy
telephone + 39 0142 416.111
www.buzziunicem.it

Sustainability Report 2011

Transcription

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