Greening its operations is a business imperative for cement group AfriSam, which is currently successfully using alternative raw materials to fire the kiln at its Ulco plant, in the Northern Cape.

“Conventionally, coal is used to fire kilns to the intense temperatures required. In using alternative fuels and alternative raw materials, instead of some conventional raw materials, AfriSam aims to reduce coal consumption and find alternative uses for industrial by-products or waste,” says AfriSam environmental manager Claudene Moorgas.

Further, the company has also complied with the rigorous demands laid down by government for the use of alternative fuels and raw materials. The company is currently awaiting a decision on an environmental-impact assessment that was carried out at its Dudfield plant, in Lichtenberg, in the North West province, where it plans to use a range of alternative fuels.

“AfriSam is focused on every aspect of its activities to conserve and reduce consumption of natural resources, seek alternative fuel and raw material sources, rehabilitate mined and quarried areas and reduce emissions,” explains Moorgas. “This is a full and demanding agenda by any standards, with results which remain unequalled in the industry.”

She points out the company benefits from its alliance with Swiss stakeholder Holcim, which is continually innovating and has assisted AfriSam in keeping abreast of global best practices and trends.

“This is particularly true in the case of alternative fuel and raw materials technology and implementation. Extensive research and development has been invested in the drive to promote the use of alternative fuel and raw materials internationally by Holcim, as well as locally by AfriSam. Many of Holcim’s technologies have already been implemented in other parts of the world.”

Further, Moorgas points out that the company has been implementing measures to reduce water consumption, which include reusing and recycling water and reducing any wastage, long before recent warnings of a potential water crisis in South Africa.

“However, as with all Afri-Sam’s environmental strategies, it is constantly streamlining existing solutions and examining new possibilities,” she says.

The company also uses a series of by-products from other industries, such as the energy, chemicals and steel industries, to extend the cements it produces and, in so doing, significantly reduce the carbon dioxide (CO₂) emissions associated with its cement products.

To reduce diesel consumption, AfriSam has improved operational efficiencies on mines by designing the shortest haul routes to successfully decrease CO_{2 emissions in the process.}

Probably one of the most well- known environmental initiatives by the company is its Eco Build Cement, launched to industry acclaim in May 2010. This product halved the global average carbon footprint for cement without compromising on the quality required by the South African Bureau of Standards for cement in this strength class.

“The cement is extended by using slag, which has a far lower carbon footprint than CO₂-inten- sive clinker,” Moorgas explains. AfriSam is also introducing Eco Readymixed Concrete.

In 2010, the company was accredited with the Nedbank Green Mining Award in the environmental category for this initiative and for its CO_{2 reductions over the years. “Since 2000, the company has invested over R1-billion to decrease its emissions,” she continues.}

Since 2009, AfriSam has been implementing a CO_{2 measurement system on all its cement products, assessing the ongoing carbon footprint of all 40 readymix operations and its 16 aggregate plants. This was a world first in the industry, says Moorgas.}

“Particulate emissions are decreased by using bag house filters, with the plant at Dudfield being the first in the industry to implement this solution. These filters will also be installed at Ulco in the near future,” she explains.

Rehabilitation of land affected by AfriSam’s mining activities is not just a legal requirement, but also a moral obligation, states Moorgas. “In many cases, alternative uses are found for the land, such as turning it into reservoirs, dams, or picnic and recreational facilities or integrating the land into various commercial or community facilities.”

With this intent, AfriSam has established a Rehabilitation Trust Fund to ensure that future rehabilitation projects are adequately funded.

In one exceptional case, when the company discovered significant archaeological and palaeontological finds at its quarry near Sterkfontein, in Gauteng, it took the business decision to cease all mining operations there in the interest of preserving human heritage.