The Bayer Stone Cottonwood Quarry in Chase County, Kansas has historically been a dependable and durable source of limestone for well over 100 years. Local Kansas landmarks such as the Kansas State Capitol and the Chase County Courthouse utilizes limestone excavated from this region. The first Bayer Stone Cottonwood quarry began operation in 1962 and the current location was opened in 1983, at that time Bayer Stone had 5 quarries in Riley County and the Onaga quarry in Pottawatomie County.

Ron Boeckman is the overall Facilities Superintendent and Field Trainer. Residing in McFarland, Kansas, Ron has been traveling 75 miles each way to work for over 16 years and worked his way up from a loader operator when he was 25 years old.

Boeckman says the process of removing the stone is an extremely interesting one. Even though the quarry is in operation year round, we begin exposing the ledge about the 1st of February. The "Stripping" phase removes 35,000 cubic yards of ground cover exposing 440 feet by 115 feet of Cottonwood Limestone 6 foot thick good for a half a years production.

Next we prep the area with water reclamation and storage tanks. We then set in place and situate the belt saw on its 120 foot track. The belt saw will cut 5 1/2 inches a minute or about 250 feet a day just enough to keep ahead of the loader removing the blocks for separation. Normally sections are cut from 3 to 6 foot widths depending on the order. This process continues until the ledge is cleared and then reclaiming of the land begins.

By the end of November dirt is brought back to fill in the hole to settle for 2 years. After that any sink holes are filled and top soil is laid over the top. The area is then re-seeded back to natural prairie grass. The environment is top priority, no chemicals or explosives are used. The lime residue is left in the quarry, not allowing runoff to fields or streams. Boeckman enjoys the relationship he has with Bayer Stone. He says everything starts here, if we don't get the stone cut, they can't do their job up there (St. Marys fabrication plant). It takes a tremendous amount of pride and every day's a little different.

Running the "Staging Area" is Steve Thompson with 10 years experience. He handles the separation of all the stone blocks and loads the trucks for transport. When he first started working at the Cottonwood quarry, Thompson was surprised with the quantity of rock stock piled out in a season and how many different sizes and varieties there are. The stone blocks at the site stretch well over a mile. In any given day, 6 to 10 trucks are loaded and shipped out to the Bayer Stone Fabrication facility in St. Marys and up to 16 trucks have been loaded for outsourcing. Each truck will carry 330 cubic feet or 46,500 pounds. Thompson says its refreshing to work at a place you really enjoy and that is exceptionally well organized.

Even though Bayer Stone fabricates its own stone, many blocks and slabs are sent to companies that don't have their own quarry but do have the fabrication capabilities. Quite simply, customers request the Cottonwood limestone. The ledge in Chase County that is currently being quarried has been estimated, at current production levels to last 200 years.