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HEALTH AND SAFETY IN CEMENT INDUSTRY

Preprint · June 2022

DOI: 10.13140/RG.2.2.26400.87045

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HEALTH AND SAFETY IN CEMENT
INDUSTRY

Group Members
M Hassaan Yousaf
M Kashif Khan
Muhammad Nazim

Submitted to Dr Afshan Naseem

Abstract
Most individuals in the twenty-first century work in a dusty atmosphere daily. They are exposed to several
health risks, such as smoke, fumes, and dust, all of which are risk factors for occupational illness
development. The primary goal of this research was to determine the health hazards connected with
workers who work in cement plants. Cement manufacture employs them to study potential health risks.
Only a limited number of cement mill employees were studied in this research. Data was collected after
the staff completed a list of conventional style questions in google forms. The data reveal that working
conditions have a major influence on employees' health, and that health issues are on the rise throughout
the summer. The goal of this study is to gather information on the health effects of cement dust and to
decrease health risks for cement mill operators by informing them about the hazards of cement dust.
Key words: Cement, cement dust, cement manufacturing, occupational health, and safety

INTRODUCTION
Cement dust is a significant source of air pollution. It includes dangerous components such alkaline
compounds (lime), which rust in human tissues, silica, which accumulates in the skin and causes lung
damage (silicosis), and chromium, which may induce allergies (pulmonary and skin). Cement dust often
affects three primary organs: the eyes, lungs, and skin, resulting in a range of respiratory, skin, and eye
issues. Given the above, it was determined to investigate possible work interruptions for cement industry
employees exposed to cement dust. The cement business is a major contributor to worldwide economic
development. Portland cement is commonly given to Joseph Aspin, who received a patent for this
combination of limestone and clay in 1824. Because it resembles a natural stone from the Isle of Portland,
the concrete used to make it is named "Portland." Lime is an alkali-based component that damages human
cells, silica hurts the skin and may cause lung damage (silicosis), and chromium can induce allergies
(pulmonary and skin). Cement dust often affects three primary organs: the eyes, lungs, and skin, resulting
in a range of respiratory, skin, and eye issues. Given the above, it was determined to investigate possible
work interruptions for cement industry employees exposed to cement dust. Workers in cement plants are
exposed to a variety of occupational hazards that can lead to illness and injury, but a concerted effort
involving exchanges of ideas from many organizations both inside and outside the cement industry is
attempting to emphasize the importance of improving employee health and safety. Safety and health are
important to us at JSPL, and they are an inherent element of our operations. The firm has put in place a
sophisticated safety management system with the Occupational Health and Safety Policy, which includes
standard operating procedures, instructions, workplace safety initiatives, and a work permit system.The
major objectives of this literature study are to identify specific hazards in the cement production process
and to investigate health and safety issues.
CEMENT MANUFACTURING PROCESS
Cement is a fine powder made up of calcium silicates, aluminates, and aluminoferrites, which are all
hydraulic cement components. There are 30 unripe components in all, divided into four categories
(calcium, silica, alumina, iron). These fundamental elements are shown in the form of

Table 1 fundamental elements in Cement Industry

SAFETY ISSUES

Table 2 Safety issues in cement factory

One of the most essential processes is dust removal, which is connected to the processing and storage of
immature materials (including crushing and milling), solid fuels, transportation (e.g., trucks or conveyor
belts), heating systems, clinker coolers, and mills, and activities. Cementing has a major impact. packaging
/ packing bags, as well as burning clinker and limestone A phase in the manufacturing process is the
packing of highly contaminated (dust) cement. The emission of nitrogen oxide occurs when a cement
furnace is heated to a high temperature (NOX). Carbon dioxide, often known as greenhouse gas, is
predominantly generated by mineral combustion and limestone dissolution.
The cement manufacturing system faces both fundamental and unique hazards, including the following:

• Safe behavior
• Work equipment
• Safety labeling
• Personal protective equipment (ppe)
• Manual load handling
METHDOLOGY
The separate and cross-shift tests comprised 100 production teams from the crusher and packing sectors,
as well as 20 guard controls. All chosen personnel were evaluated for "ideal" dust levels in their respiratory
tracts before and after the changeover, as well as a high flow rate (PEF). At the conclusion of the day shift,
severe respiratory difficulties were noted. Breathing dust in cement-making locations is typically
significantly greater than on building sites, particularly during cleaning. Residents in the cement dusty
region suffer from respiratory issues, stomach disorders, and other maladies. A few workers were given
the questionnaire, and interviews were done based on the operations of a few companies. Workers in the
cement industry were given a questionnaire, and the responses of 10% of the workforce were recorded
and disseminated. Following that, there were negotiations. Below is a collection of questions and
interview questions in different formats.

POTENTIAL HAZARDS PREVENTIVE ACTIONS

Potential Hazard Preventive Action
Slip, Trips & Falls The home must be kept in good condition.
Lighting that is adequate
Workplace that is spotless
Identify and fix hazards including slick surfaces,
broken staircases, and potholes.
Confined areas (Lack of oxygen, Poisonous gas, It should be avoided at all costs. limited access
fumes or vapour, Fire and explosions, dust, hot to restricted regions
conditions…) Remote cameras are a possibility.
Cleaning before the working permit arrives a
source of air
After an air check, lights is provided.
Electric Each panel must be labeled separately.
Purchase and utilize only electrical equipment
that are safe to use.
PPE (Personal Protective Equipment) that is
appropriate for the work
Falling/Moving Objects Workplace that is spotless
When working near cuber elevators and
conveyor belts, use PPE (Personal Protective
Equipment).
Fire (conveyor belts, electrical cables, fuels, Proper housekeeping and garbage removal are
waste combustible materials…) essential.
Heat detectors are used.
A fire extinguisher is a device that is used to put
out a fire. Firefighting regulations must be
followed at all times.
Working at height PPE (Personal Protective Equipment) is used
while using a suitable ladder and scaffolding to
implement the Fall Prevention Program.
Hot/cold surfaces (hot surface burns…) Personal Protective Equipment (PPE) is used.
Noise and Vibration Technology for noise reduction, absorption,
and installation
Hearing protection is essential.
Excavation sites All of the minerals in the plant should be
surrounded by a wall.
Vehicles At all means, overcrowding should be avoided.
Check to see that all backup alarms on all cars
are operational.
Make sure trucks and other vehicles are in
excellent operating condition before utilizing
them, including sound warning signals that
assist backup.
Safety guards of machines In certain situations, security guards or
equipment should be established.
Use of skilled security personnel (connected,
automatic, automatic, two hand control
systems, etc.)
Maintenance of the conveyor belt system
Manuel handling Nails, splinters, and sharp edges should all be
avoided.
When lifting heavy items, the legs should be
utilized as often as possible to keep the back
muscles in good shape.
Tag Out - Lock Out (Electrical or Process The power separator switches must be
isolation) switched off.
Dust/ Cement dust Packaging equipment that is automated is
utilized.
Conveys that are closed are utilized.
Closed chambers are used to store crushed
crumbs.
Wearing a suitable respirator is required.
To lessen the smell of cement dust, use a
ventilator.
Using soap and water to clean your skin might
help you prevent skin damage.
Avoid cement dust to avoid bronchitis and
silicosis.

Table 3 Potential Hazards Preventive Actions

 RESULTS AND DISCUSSION

After gathering information on the health of cement workers, we discovered that the risk of harm is
dependent on the time, quantity of exposure, individual age, and sensitivity, as previously stated. During
the investigation, personnel were discovered to have a variety of ailments, including skin irritation,
respiratory irritation, eye irritation, nose and throat irritation, raised blood pressure, heart disease, and
chest and stomach distress. It has been estimated that the cement sector affects 80 percent of the
population. Rashes and dry skin, as well as red eyes, stiff nails, and a dry cough, seemed to be widespread
among employees with five years of experience. A substantial number of persons have complained dry
cough, respiratory issues, nasal congestion, asthma, skin rash, and irritability. Similar results were
reported among lime crusher employees. Employees who have worked for a long time have been proven
to be impacted by a variety of occupational illnesses (double, triple, or multiple) based on their age and
sensitivity. Occupational illnesses such chronic bronchitis, dry cough, eye difficulties, and skin and skin
allergies are often connected to the pollution caused by the cement industry and other comparable
resources. Six percent of the patients in the research had high blood pressure or blood clots, but none of
them developed lung cancer. Air pollution has been demonstrated to affect asthmatics' lungs, as well as
raise blood pressure, cause blood clots, and increase the risk of heart disease and stroke. Common eye
problems including tears, redness, irritation, and myopia were found in great numbers in this research (56
percent). Quarry workers are also susceptible to these forms of vision disorders.

CONCLUSIONS
Construction of cement is a labor-intensive industry that employs potentially hazardous industrial
procedures. As a consequence, the cement industry places a premium on the health and safety of its
workers, contractors, end users, and those who live near its activities. Health dangers include dust and
harsh temperatures, contact with allergens, and noise exposure, while safety hazards include falls /
collisions with objects, tropical heat, walking, working at higher elevations, and slips / trips / falls. The
importance of fostering a workplace culture of health and safety cannot be overstated. As a result, the
health and safety policy must adhere to all corporate policies. Furthermore, the company's risk
management plan should be recorded, and risk assessments should be performed on a regular basis.

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