Lafarge’s Exshaw-based plant is known for its ability to provide cement for construction projects and with a major expansion project underway, it has also made Bow Valley history.
Over the weekend of July 6-7, a foundation pour of concrete to see Lafarge’s operations expand by 60 per cent saw 2,500 cubic metres go into the ground.
Officials with the company say they believe the single pour, which lasted 31 hours, could be the largest in Bow Valley history.
“As far as we know, we believe it is the largest continuous pour in the Bow Valley in recent memory,” said Ron Braun, Lafarge’s vice-president of major projects. “What it was specifically, is it is the foundation underneath the new pre-heater tower, so that’s the tall structure that supports the process vessel – it is a foundation that will support that tower.”
To put it in perspective, Braun said 2,500 cubic metres is equivalent to the amount of concrete used in 100 new homes. It took 280 cement truckloads back to back with 18 trucks working continuously and 150 people working in shifts over the weekend to complete the task.
“It is kind of a delicate ballet,” Braun said about organizing the various aspects of the pour. “We are pleased all the concrete was sourced locally and the cement, of course, came from the Exshaw plant.”
Nearby competitor Burnco was brought in to assist in supplying the concrete, with their staff also working around the clock to get the massive pour completed.
Norm Kuntz with Burnco said the company was happy Lafarge asked them to get involved in supplying part of the job.
“It is not that unusual; in several markets where something of a large scope happens we have managed to work out arrangements to co-partner on the project, or have one company support another company,” Kuntz said. “Whenever there is something that challenging that one company just can’t quite chew it off all on their own, it is not that uncommon for us to co-operate in that fashion.”
He said according to staff in the company’s Bow Valley operations, the continuous pour is believed to be the largest in its history. It was also a challenging job because it had to be done continuously and work started at 3 a.m. with extra staff being brought in and overnight shifts worked.
Canmore-based Walker Plant Construction co-ordinated and oversaw the pour as the concrete forming, pump and finish contractor for the first phase of the expansion. Owner Alistair Liley said it is the biggest single continuous pour his company has been involved with.
“I think it is important to realize it is a local crew doing this and that was the biggest pour we have ever done,” Liley said, adding both Burnco and Lafarge ready mix concrete operations worked “flat out to get this thing done.”
“There is a horrendous amount of organization – organizing aggregate and coordinating the cement trucks so there is no hiccup through the pour.
“We are very proud to have been the local guys able to get this work. It was a huge undertaking and I think you will find it was the biggest single pour of the entire valley.”
Braun said the pour is the biggest scheduled for the expansion project, which is expected to be complete in the spring of 2015.
It went forward even though the surrounding community of Exshaw was still in a state of emergency due to flooding that occurred at the end of June.
“We were very fortunate we only had light impacts from the flooding. We lost a few construction days and that’s it, so we remain on schedule for the startup,” Braun said.
