U.S. Labor-Energy Input Survey - 2012
Confidential Plant Information
Site Name:
Company Name:
Plant Address:
City/State/Zip Code:
Plant Manager:
Plant Phone:
Submitted by:
Title:
Direct Phone:
E-mail:
Date:
A. PLANT INFORMATION – Report in U.S. Short Tons
Kiln Data
Kiln 1
Kiln 2
Kiln 3
Kiln 4
Kiln 5
Total for Plant
In-house number/name (if applicable)
Wet
Dry (No Preheater)
Dry with Preheater (No Precalciner)
Dry with Preheater & Precalciner
2012 Year-End Kiln
Practical Clinker Capacity (1)
0
(Short Tons)
(Short Tons)
(Short Tons)
(Short Tons)
(Short Tons)
(Short Tons)
2012 Total Kiln
Clinker Production
0
(Short Tons)
(Short Tons)
(Short Tons)
(Short Tons)
(Short Tons)
(Short Tons)
Total Cement Production
Portland
Masonry
Blended
Hydraulic
Other
2012 Total Plant Finished
Cement Production
0
(Short Tons)
(1)
Total
(Short Tons)
(Short Tons)
(Short Tons)
(Short Tons)
Practical Clinker Capacity = 365 days less normal down days x daily practical capacity
Please return this completed survey to the Market Intelligence Group by February 29, 2013.
(Short Tons)
2
B. LABOR DATA
Plant Function
Number of Employees
Salaried
Hourly
Contracted
Employee Hours
Total
Salaried
Hourly
Contracted
Total
Direct Labor
0
0
Indirect Labor
0
0
TOTAL LABOR
0
0
0
0
0
0
0
0
LABOR DATA DEFINITIONS
Report the number of employees and total annual hours worked for direct and indirect labor. If the number of employees fluctuated during the year, report the
number that would be considered to be typical under normal operations. Part-time employees and hours should be reported as fractional and combined to
equal full time employee count (e.g. two ½ time employees = 1 full time). Exclude vacation time, sick leave, holidays, and any other time that the employee
was paid but did not work. Some plants contract with outside firms to have work done, such as general plant maintenance, refractory work and quarrying.
Please report these workers as contracted workers by their plant function.
Report employee and employee hours for the entire plant payroll by function for hourly, salaried, and contracted labor. If time records are not kept for certain
employees, an estimate of their time should be made using 2080 hours plus overtime but minus time not worked. Report all employee hours, including
contracted employee hours, related specifically to the production of cement.
Exclude from this survey any labor such as personnel, purchasing, accounting, secretarial, sales, traffic and engineering workers, laboratory research workers,
and corporate office workers who might be at the facility but are not directly related to the production process.
Direct labor hours for salaried, hourly, and contracted labor should include labor involved in raw material handling, production, distribution and maintenance.
Indirect labor should encompass the following:
(1) general labor and mill indirect, meaning production personnel not allocated to a specific department, e.g., the plant manager, superintendent, foremen,
computer control personnel, clerks, timekeepers, watchmen, storekeepers, and other miscellaneous personnel related to the production of cement
(2) laboratory, including both salaried and hourly employee hours used at the plant by chemists and assistants involved in quality control (exclude
laboratory time allotted for research)
If employee hours are not separable by type of compensation, please indicate totals only.
Company & City:
3
C. PLANT FUEL AND POWER
SUMMARY(1)
Type
Units
Conversion factor (Btu per Unit)
(High Heat Content)
Fuel Consumption (2)
PRIMARY FUELS
(Sum should equal total for each fuel type)
Raw Material
Drying and
Grinding
Raw Material
Handling
Amount
Fuel Handling,
Drying and
Grinding
Clinkering and
Cooling
Finish
Grinding
NonProcess
Distribution
Specified by
respondent
Default value
if not specified
Gasoline
gallons
=
+
+
+
+
+
+
125,071 Btu/gal
Diesel
gallons
=
+
+
+
+
+
+
129,500 Btu/gal
Fuel Oil
gallons
=
+
+
+
+
+
+
138,690 Btu/gal
tons
=
+
+
+
+
+
+
22,565,000
Btu/ton
Residual Oil
gallons
=
+
+
+
+
+
+
149,690 Btu/gal
Natural Gas
million
cubic feet
=
+
+
+
+
+
+
tons
=
+
+
+
+
+
+
1,030,000,000
Btu/MMCF
per mm ft3
30,120,000
Btu/ton
gallons
=
+
+
+
+
+
+
85,857 Btu/gal
1,000 kilowatt
hr
=
+
+
+
+
+
+
3,412,000 Btu/
1000 kWh
Coal
Petroleum
Coke
LPG
Electricity
ALTERNATIVE FUELS (Specify alternative fuel type, units (i.e. tons, gallons, pounds), and Btu conversion factor per unit)
Units
Amount
=
+
+
+
+
+
+
Btu /
Waste Oil
=
+
+
+
+
+
+
Btu /
Solvents
=
+
+
+
+
+
+
Btu /
Tire Derived
=
+
+
+
+
+
+
Btu /
Other Solid
=
+
+
+
+
+
+
Btu /
=
+
+
+
+
+
+
Btu /
Renewable*
Type:
Type:
Other:
(1)

Fuels used for electricity co-generation should not be reported.
Biomass, Biofuels, Wind, etc.
(2)
See Appendix for Descriptions
Company & City:
4
D. Kiln Fuel and Power Summary (1) (Skip if only 1 kiln operation.)
(Sum of kilns should equal total amount for each fuel type provided in Section C)
Type
Units
Amount
(Total)
Kiln 1
Kiln 2
Kiln 3
Kiln 4
Kiln 5
In-house kiln number/name (if applicable)
Gasoline
Gallons
=
+
+
+
+
Diesel
Gallons
=
+
+
+
+
Fuel Oil
Gallons
=
+
+
+
+
Tons
=
+
+
+
+
Residual Oil
Gallons
=
+
+
+
+
Natural Gas
Million
cubic feet
=
+
+
+
+
Tons
=
+
+
+
+
LPG
Gallons
=
+
+
+
+
Electricity
1,000
kilowatt
hr
=
+
+
+
+
Coal
Petroleum Coke
Alternative
Fuels
Specify alternative fuel type and units (i.e., short tons, gallons, pounds, etc.)
=
+
+
+
+
Waste Oil
=
+
+
+
+
Solvents
=
+
+
+
+
Tire Derived
=
+
+
+
+
Other Solid
=
+
+
+
+
=
+
+
+
+
Renewable*
Type:
Type:
Other:
(1)

Fuels used for electricity co-generation should not be reported.
Biomass, Biofuels, Wind, etc.
Company & City:
5
APPENDIX
Raw Material Handling - Raw material handling should encompass all energy used at the plant to quarry, crush, preblend, and store all raw materials including limestone,
shale, clay, gypsum, etc.
Raw Material Drying and Grinding - This begins at the discharge from raw material storage and ends at the kiln feed inlets. Dry-process plants should report all energy
used to operate drying equipment, conveyors, grinding mills, classifiers, dust collectors, homogenizers, blending silos, and kiln feed storage equipment. Wet-process plants
should report energy used to operate proportioning equipment, grinding mills, pumps, classifiers, mixers, and agitators.
Fuel Handling, Drying and Grinding - Fuel handling, drying and grinding category encompasses the energy required to process the fuel from storage location to injection
into the kiln.
Clinkering and Cooling - Clinkering and cooling starts at the kiln-feed inlet and ends at the inlets to finish grinding mills. Plants should report all energy used to operate the
kilns, clinker coolers, dust collectors, conveyors, and coal mills.
Finish Grinding - Finish grinding should include all energy required to operate finish grinding mills, classifiers, dust collectors, conveyors, cement coolers, and pumps.
Distribution - Distribution includes the energy required to operate the plant's cement storage facilities, pack houses, bagging, and palletizing equipment and bulk loading
equipment. Include only the fuels consumed at the plant site for distribution. The energy used to operate company-owned trucks, boats, barges, or train engines should be
excluded.
Non-Process - The energy required for facility heating, ventilation, and air conditioning; also lighting and facility support.
If you have questions or comments, please contact:
Market Intelligence Group
5420 Old Orchard Road
Skokie, IL 60077
Main: 847.966.6200
Fax: 847.972.9049
www.cement.org
Edward J. Sullivan
Dave Zwicke
Michael W. Howard
Andrew Moss
Joseph T. Chiappe
Brian Schmidt
Karen Arneson
Vice President & Chief Economist
Senior Regional Economist
Senior Economist
Senior Market Intelligence Analyst
Senior Market Intelligence Analyst
Market Intelligence Analyst
Market Intelligence Specialist
Thank you for your prompt and accurate response.
847.972.9006
847.972.9192
847.972.9188
847.972.9068
847.972.9310
847.972.9042
847.972.9048