integrated report - 2015 documents/integrated...26,7 million metric tons in 2015 we provide gravel...
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I N T E G R A T E D R E P O R T - 2 0 1 5
São Paulo
● Peru
Uruguay4 ● ● ● ●
BRAZIL
● Bolivia3
0.2
● ● ● ●
33.3
● ● ● Chile2/6
2.2
● ● ● Argentina1/6
2.8 0.5
OUR BUSINESSES AND MARKETS
● CEMENT37,2 MILLION METRIC TONS IN 2015
Our biggest business area and main product is still cement.
APPLICATIONS: It is the basic component of concrete and mortars. Cement is used in construction in general, for industrial, commercial and residential surfaces and floors. It is used in all types of infrastructure construction.
● CONCRETE10,2 MILLION M3 IN 2015
In Brazil, we market concrete in 15 Brazilian states through our Engemix affiliate, a well-known brand name that specializes in concrete batching centers.
APPLICATIONS: Composed of a mixture of cement, sand, aggregates and water, it is the most common construction material. It is also used for paving outdoor areas.
● MORTAR1,8 MILLION METRIC TONS IN 2015
In Brazil, we produce three ranges of mortars: the Matrix brand, which is a range of standard mortars, the Votomassa brand, a range of adhesive mortars and Decoratta brand, a fine plaster for finishing masonry.
APPLICATIONS: It is used to join blocks or bricks, finish surfaces and lay ceramic tiles.
In Brazil, which is our main market, due to the political and economic scenario, we had to react quickly in 2015, with measures that would safeguard our operations and business activities.
At the same time, we conti-nued with our long-term invest-ment plan in order to increase our geographical diversifica-tion and consolidate our posi-tion in markets with high growth potential.
The economic recovery in the United States and the improved performance of our operations in North America, Europe, Africa and Asia offset the decline in consumption in Brazil. The deva-luation of the R$/US$ exchange rate also contributed positively to our consolidated results.
We were the first Brazilian company to make a bond issue in the international capital markets in 2015, in the amount of EUR 500 million.
For our employees, we are committed to creating an incre-asingly challenging internal envi-ronment. In 2015, we invested 20 million reais in the develop-ment of our teams. For our custo-mers, we improved the average service time and our product quality index in all segments.
Sustainability is one of the main drivers of our business activities. We developed a Sustainability Strategic Plan and established a series of commitments and targets to be achieved by 2020. In 2015, we participated in the COP 21 meeting in Paris and created a new area to seek new options for Alternative Fuels and Raw Materials (AFR).
We still have much to build for this and future generations.
● ● ● ● Spain
● ● ● Morocco
3.2
1.2
Florida5 ● ●
Great Lakes ● ● ● United States/Canada
0.8
VOTORANTIM CIMENTOS LATIN AMERICA
5 2/1 6/43 1/16 1/1 4 We signed a financing agreement for the construction of a new cement plant to be constructed in Santa Cruz Province, Bolivia. In Argentina, we approved an expansion project in San Luis, which will increase its production capacity to 993 thousand metric tons/year. Also in Argentina, we invested US$ 12.6 million in the modernization of a lime factory to serve the construction market. We started up operations at an adhesive mortar plant in Uruguay, with a capacity of 25 thousand metric tons/year.
VOTORANTIM CIMENTOS BRAZIL
17 10 104 18 9 2In 2015 we inaugurated three production units: a cement plant in Edealina (GO), with a capacity of 1 million metric tons/year; a mortar plant in Camaçari (BA); and an agricultural lime production plant in Arroio Grande (RS).
1. Argentina, participation of 49% (Avellaneda) | 2. Chile, participation of 16.7% (Bio Bio) | 3. Bolivia, participation of 67% (Itacamba) | 4. Uruguay, participation of 51% (Artigas) | 5. Includes 100% of the installed annual capacity of Suwanee, which is not consolidated in VCSA's financial statements | 6. Includes 100% of the installed annual capacity of Bío Bío and Avellaneda, which are not consolidated in VCSA's financial statements
A COMPANYBUILT TO LAST
5.2
INSTALLED ANNUALCEMENT CAPACITY OF OURCONSOLIDATED OPERATIONS 55,5 MILLION
METRICTONS/YEAR
1 MILLIONMETRIC TONS
83 MARACANÃSTADIUMS=
1. United Nations Global Compact (UNGC) – This is a United Nations initiative to encourage companies to respect human rights, support decent work, protect the environment and fight corruption;
2. Cement Sustainability Initiative (CSI) – This is an international cement industry protocol, signed by the 25 largest producers of building materials in the world, to promote the adoption of best practices in the cement sector;
3. Business Pact – "In the Right Direction" Program – By signing this pact the signatories commit to combating the sexual exploitation of children and adolescents along Brazilian highways;
4. SBE-VC-RBMA Technical Cooperation Agreement – This is a partnership among Votorantim Cimentos, the Brazilian Society for Speleology (SBE), and the Atlantic Forest Biosphere Reserve (RBMA) to develop social and environmental practices that contribute to the protection of caves and the Atlantic Forest biome;
5. Global Reporting Initiative (GRI) – This is an independent international organization that helps businesses, governments and other organizations to understand and communicate their impacts on critical sustainability issues such as climate change, human rights, corruption and many others;
6. Open Letter to Brazil on Climate Change (ETHOS Institute) – This is a Brazilian business sector initiative, coordinated by the ETHOS Institute, under which the company makes a number of commitments to combat climate change.
Voluntary commitmentsWe are signatories of the following voluntary global and national pacts and initiatives:
● AGGREGATES26,7 MILLION METRIC TONS IN 2015
We provide gravel and sands of different grain sizes for the construction industry, to meet the needs of the market segments for concrete producers, industries, infrastructure, paving and retail.
APPLICATIONS: Materials used mainly for the manufacture of concrete but also for: asphalt, pre-cast slabs, reinforced concrete structures, pre-cast concrete artifacts, cyclopean concrete, and materials for landfills, drainage, base and sub-base of highways and paved areas.
LIME
HYDRATED LIME A material with a plasticizing capability, used in construction and mortars.
LIME PAINT Economically attractive material, used to paint large areas at a lower cost.
● AGRICULTURALLIMESTONE
Used in agriculture and in animal husbandry in order to: correct soil acidity, neutralize aluminum toxicity, increase the efficiency of fertilizers and improve nutrient availability. Due to the high levels of calcium and magnesium in its composition it also provides these macro-nutrients for crop development.
Tunísia ● ●
Turkey ● ● ●
India ●
China ●1.8
3.0
1.2
5.9
VOTORANTIM CIMENTOS NORTH AMERICA
4/1 2 103/18 43Expansion of our Charlevoix plant in Michigan, United States. The production capacity of the plant will be increased from 1.3 to 1.9 million metric tons/year. Our plant in Bowmanville, Canada, received its first long-term government authorization to use low-carbon fuels.
VOTORANTIM CIMENTOS EUROPE, ASIA AND AFRICA
14 8 104 21 2 Expansion of our cement factory in Sivas, Anatolia, Turkey. The new production line, which has a planned capacity of 1.2 million metric tons/year, is expected to begin operations in early 2017. This investment, amounting to EUR 140 million, is the largest ever made by Votorantim Cimentos outside the Americas.
CementPlants
GrindingMills
Concrete BatchingCenters
AggregatesPlants
MortarPlants
LimePlants
NUMBER OF UNITS / NUMBER OF PARTICIPATIONS
KEY ACTIVITIES
KEY ACTIVITIES
KEY ACTIVITIES
PERFORMANCE INDICATORS
Community engagement
Reduction in emissions of NOx and SO2
Use 30% of alternative fuels
Security (fatality rate)
Water and biodiversity
Ethical business practices (conduct code)
AFR - Alternative fuels target
EBITDA
Sustainability in the supply chain
Reduction of CO2 emissions
Global Environmental Policy and Green Rules
Cash Cost process
Clinker / Cement Factor
IQP processes
Commercial NPS
OEE - Productivity and Quality
Tmac - Customer Service
Index of engagement
H
C
C
C K L
C NM OK L
C K L
ME
O QE
I
P
P
P
F G
A D
E B
IMPACTS BY ACTIVITY
SOCIALGeneration of Employment and IncomeModernization of Public Administration
Overloading of local infrastructureTruck traffic
ENVIRONMENTALSocial and environmental education
Archaeological and paleontological protectionRehabilitation of degraded areas
Removal of vegetationNoise
Emissions of particulate matterImpacts (soil, biodiversity and communities)
Biodiversity managementWaste
Co-processingCO
2 emissions
Other emissions (NOx,SO2,etc.)
Effluents
ECONOMICTaxes on contracted services
Taxes on mineral exploration (CFEM)Taxes on the acquisition of goods and services
Taxes on the sale of products and services
Positive impacts Negative impacts
VALUE PROPOSITION
Brand credibility and legacy Process improvement and bureaucracy reduction
Investments in sustainability Customer relations
Quality and variety of the product range Technical expertise and safety at work
MANAGEMENT OF PROJECTS AND INDICATORSAdvocacy
1RESEARCH* PLANT
CONSTRUCTION
2MINING
3PRODUCTION
4
INBOUND/OUTBOUNDLOGISTICS
5COMMUNICATION SALES
Services
7
OTHER STAKEHOLDERS
Shareholders
Investors
Financial institutions
Employees: own and third-party contract staff
Society
Local community
Class associations
REAL ESTATE Construction companiesINFRASTRUCTUREInfrastructure constructioncompanies
B2C
B2B
INDUSTRIALConcrete batching centersPrecast concrete industryConcrete artifacts industryFiber cement industryMortar industry
CUSTOMERSEGMENTS
MATERIALITY
Financial Capital
Human Capital
Social and relationship Capital
Natural Capital
A Ethics, transparency and integrity
B Occupational health and safety
C CO2 emissions
D Anti-corruption practices and compliance with the competition laws
E Regulatory risks
F Supply chain management
G Contribution to local development
H Economic performance: economic value generated and distributed
I Community relations
J Government relations
K Energy efficiency
L Alternative sources of electricity and fuels
M Air emissions (Particulate Matter, NOx and SO
2)
N Management and re-use of civil construction waste and reverse logistics for used cement bags
O Water consumption
P Customer satisfaction
Q Biodiversity conservation
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
STRATEGIC DRIVERS
CustomerFocus
SustainablePractices
OperationalExcellence
EmpoweredPeople
Water
Firewood
Gas
Infrastructure
Vehicle fleet and concrete mixers
People
Concrete batching centers
Distribution centers
Technology center
Fuel
Energy
Plants
Inputs
Machinery/equipment
Media and marketing
Mines
Investment capacity
Natural resources
IT
MAIN RESOURCES
PARTNERSHIPS ANDSTRATEGIC ALLIANCES
IG
AFTER-SALESSERVICEMine closure
8
● Community/Social license● Universities● Training Schools● Environmental Institutes● Government entities● Trade Unions● Government● Class Associations● Banks ● Suppliers● Equipment Suppliers● Coke Suppliers (fuel and additives)● Supplier of alternative fuels ● Co-processing services● Transport companies and independent truck drivers● Brazilian Army (explosives)● Cementitious products companies● Opinion leaders/influencers● Customers/promoters● Newspapers, magazines, TV and websites● Customers ● Key accounts (Large construction companies and Home Centers) ● Technical Laboratories
RETAILDistributors: smallretailers, home centers
* Geological research, Research and Development (R&D) and Market research
6
ECONOMIC PERFORMANCE
EBITDA R$ MILLION
1. Figures have changed since 2014 they now include China2. Includes R$ 117 million of derivative transactions
201412013 2015
2,679
3,483
414
302
8891
74
3,231
2,709
1,916
3,512
741373
483356
NORTH AMERICA
CONSOLIDATED
BRAZIL
LATIN AMERICA
EUROPE, ASIA AND AFRICA
AMORTIZATION PROFILE EXTENDED
We were able to accessfinancing lines at attractiveterms and interest rates,which enabled the companyto extend its debt profile,thus ensuring greater liquidity and reducing refinancing risk.
We were the firstBrazilian company tomake a bond issue in the global capital markets in 2015. We raised EUR 500 MILLIONwith a maturity date of2022 and an interest rateof 3.5% per year.
19,497 GROSS DEBT
4,734 CASH + FINANCIAL INVESTMENTS
14,6462
NET DEBT
DEBT ANDLEVERAGE ATYEAR-END 2015R$ MILLION
BRAZIL – In 2015 the economic and political crisis accelerated significantly, requiring a fast reaction on our part. We adapted our business structure to the new market conditions by focusing on operational excellence and cost optimization. According to the National Cement Industry Union (SNIC), the apparent cement consumption decreased by 9.5% in 2015 compared to 2014. The main factors causing the fall in consumption were increased unemployment, reduced credit availability and a deceleration in construction sector activity.
NORTH AMERICA – The recovery of the North-American market, combined with the devaluation of the R$/US$ exchange rate, helped us to offset the decline in our business in Brazil. The operating performance for the year was the best since our acquisition in 2001. According to the United States Geological Survey (USGS) and the Canadian Cement Association (CAC), the cement consumption in the Great Lakes Region, Florida and Ontario grew by 6.3%, 8.1% and 4.3% respectively.
EUROPE, ASIA AND AFRICA – In Europe, Asia and Africa, we have different dynamics for each market. The highlights of the year were the economic recovery in Spain, the high rate of capacity utilization registered in our operations in North Africa and Turkey, and the impact of the devaluation of the R$/EUR exchange rate on the consolidated results. At year-end we consolidated the results of our operations in China, due to IFRS requirements. Previously, since 2012, these assets had been accounted for as assets for sale. However, we have no intention to hold these assets in China and will continue to seek buyers.
LATIN AMERICA – We only consolidate the results of our operations in Bolivia and Uruguay. All these countries, especially Bolivia, are emerging markets that have growth potential. According to estimates published in The Global Cement Report, the consumption for Bolivia and Uruguay in 2015 increased by 7.9% and 4.3% respectively.
NET REVENUE R$ MILLION
14,046
7,831
3,544
2,308
405
+7%
-8%
+55%
+17%
+19%340
13,130
8,545
1,974
2,290NORTH AMERICA
GLOBAL
BRAZIL
LATIN AMERICA
EUROPE, ASIA AND AFRICA
20141 2015
Our long-term strategy, which focuses on geographic diversification, commitment to improve operational excellence and financial discipline (cost reduction, divestiture of non-strategic assets, extended debt profile and an adequate level of liquidity), demonstrates the company's capacity to adapt to any scenario, including, principally, unfavorable situations, such as that experienced in Brazil. These actions enabled us to maintain our leadership position in the Brazilian market and to consolidate our position in other countries where we operate, without impacting the investors' confidence in the company.
TOTAL EMPLOYEES * Figures have changed since 2014 they now include China
16,756 15,779 15,288*
WOMEN EMPLOYED 11.7% 10.5% 12.3%
EMPLOYEES OVER 50 YEARS OLD * Figures do not include China
9.9% 17.9% 19.9%*
ENGAGEMENT INDEX BRAZIL - 73% 76%
SOCIAL PERFORMANCE
ENVIRONMENTAL PERFORMANCE
FOR EVERY R$ 1.00 INVESTED IN SOCIAL PROJECTS INTHE COMMUNITY, VOTORANTIM CIMENTOS GENERATED A RETURN OF R$ 4.54.Result of a study on the return on social investment at our cement plant in Primavera (PA), using the Return on Investment (ROI) methodology.
ENVIRONMENTAL CAPEX AND OPEX – R$ MILLION 2013 2014 2015
CAPEX Environmental investments 79 67.8 93.1
OPEX Environmental expenses 51.2 41.6 33.3
SPECIFIC CO2 EMISSIONS – kg CO
2 /METRIC TON OF CEMENTITIOUS PRODUCT
GROSS 657.1 657.3 659.3
NET 649.6 646.8 647
OTHER AIR EMISSIONS – METRIC TONS/YEAR
NITROGEN OXIDES (NOX) 65,407 61,005 56,997
SULFUR DIOXIDE (SO2) 22,665 20,735 22,149
PARTICULATE MATTER 3,302 3,126 1,977
CLINKER FACTOR – TARGET 2020 - 72% 76.1% 74.7% 73%
SPECIFIC CONSUMPTION OF ELECTRICITY kWh PER TON OF CEMENTITIOUS PRODUCT
109.4 112.2 109.1
PRODUCT LIFE-CYCLE ASSESSMENTS
We prepared five environmental product
declarations for existing products selected
from the cement, concrete, and mortar
product ranges. We used the methodology
defined by ISO 14025 (EPD) and ISO 14040
(LCA), and a software package developed
by the Cement Sustainability Initiative
(CSI). These declarations are of particular
interest to companies seeking certification
under the Leadership in Energy and
Environmental Design (LEED) standard.
ENVIRONMENTAL PRODUCT DECLARATIONS
We created a new business unit focused on Alternative Fuels and Raw Materials (AFR), aimed at increasing co-processing and the use of alternative fuels to replace fossil fuels. At a global level we increased our rate of utilization of alternative fuels from 7.8% in 2014 to 8.9% in 2015. This was an important initiative for reducing carbon dioxide emissions.
In a year which saw a sharp downturn in the Brazilian market, we revised our organizational structure, with the challenge of seeking a balanced budget and at the same time, preserving the knowledge base and maintaining the company in a state of preparedness for an upswing in the economy. We recorded a significant improvement in our Organizational Climate Survey indicators, in several countries, as a result of the strengthening of our corporate image as a global company.
1. Eco-efficiency of the cement produced on Rio
Branco unit (PR) (2005 to 2014) - In a comparative
analysis, the cement produced in 2005 is more ecoefficient
than the 2014, however, the performance of our product
has improved in the last few years, being necessary 9%
less cement for the same cubic meter of concrete. The final
results put the 2014 concrete in a more ecoefficient position
than the 2005 concrete. Besides that, the production cost
of Rio Branco's cement in 2014 is lower compared to 2005.
2. The environmental and economic
performance of a rigid concrete pavement
and a flexible asphalt pavement for the
construction and maintenance of a highway
over a period of twenty years. The rigid concrete
pavement, which is currently used in only 4%
of Brazil's highway network, is 53% more
eco-efficient and costs 54% less, considering
the costs of construction and maintenance.
We conducted two studies to assess the environmental performance of our products, considering the impacts throughout their life cycles, from the extraction of natural resources to their final disposal or recycling.
SOCIAL INVESTMENTS – R$ MILLION
OWNTHE VOTORANTIM INSTITUTE +THIRD-PARTY FUNDS +TAX INCENTIVES
2014 2015
6.87.6
7.58.4
LOST TIME RATE FRENQUENCY 0.74 (number of injuries with lost time compared to millions of man-hours worked, included injuries to third parties. We recorded the lowest global injury frequency rates in the last ten years.
NUMBER OF SOCIAL PROJECTS – 2015
BUDGETED
EXECUTED
112110
NUMBER OF FATALITIES VCBRCement, aggregates and concrete*
CONTRACT STAFF 9 7 3
THIRD PARTIES 8 3 1
EMPLOYEES 3 1 0
2013 2014 2015
2013 2014 2015
OUR TARGETS FOR 2020
SAFETY
To ensure the effective adoption of the Global Health and Safety Policy and the Life Saving Rules.
To implement sustainable supply chain standards.
Promote healthy working conditions and zero harms environment for all our employees. To reach zero fatalities and a LTI* Rate for direct employees of less than 0.4.
ETHICS AND COMPLIANCE
Ethical Business Practices: to ensure that all of our operations are carried out in an ethical manner and in conformity with the Votorantim´s Code of Conduct.
ECO-EFFICIENCY AND INNOVATION
Environmental Policies: to ensure the implementation of our Global Environmental Policy and Green Ruless.
Supply chain standards: to promote sustainable supply chain standards by way of our business units.
Non-fossil fuels: to use 30% non-fossil fuels in our cement plants.
Sustainable products and services: to promote the implementation of new sustainable solutions, products, services and innovation – achieve a clinker/cement factor of 72%.
CO
2 emissions: to reduce our CO
2
emissions per ton of cement by 25% compared to 1990 levels.
PM NOx SO
2
Air emissions: to reduce particulate matter, NOx and SO
2 emissions per ton
of clinker to 65g, 1950g and 750g / ton of clinker, respectively.
Water and biodiversity: to implement water management plans for scarcity areas in our business units.
Water and Biodiversity: to ensure that all of our quarries have rehabilitation and biodiversity management plans for local and sensitive biodiversity regions.
COMMUNITY ENGAGEMENT
To ensure the implementation of a community engagement plan in communities where we operate that have a high degree of social vulnerability.
MAIN R&D AND QUALITY
PROJECTS
ACTIVATED POZZOLANProduction of activated pozzolan from
the calcination of kaolin clay and
limestone, aimed at improving cement
quality and reducing costs.
ZERO LOSS I Aims to re-use concrete by the
addition of stabilizers.
MANGANESE SLAGManganese slag is used to improve
cement quality and reduce costs.
NEW PRODUCTS
COST REDUCTION
DECORATTA Development of a surface finishing
product, aimed at a practical form of
application and a fast drying time. Up to
30% reduction in the application time.
PERVIOUS CONCRETE Development of a concrete with a high
degree of porosity for use in pavements,
that has a a number of benefits.
Target achieved Target on schedule Target behind schedule
Sustainability is inherent to our business approach and activities. It is also one of the main drivers of our strategic plan. To highlight its importance and to stimulate a change of attitude in our employees, encouraging them to constantly pursue sustainability and innovation in doing business, we established our Sustainability Commitments for 2020.
DOWNLOAD THE COMPLETE VERSION OF THIS REPORT AT: www.votorantimcimentos.com/pt-BR/sustainability/Paginas/Integrated-Report.aspx
Period of analysis for this report: January to December 2015.
E-MAIL FOR CONTACTS: [email protected]
* (LTI Lost-time injury) is defined as an occurrence which results in a fatality, permanent disability or lost time at work for a shift or more.