BASIC OUTLINE OFTHE

OCCUPATIONAL SAFETY AND HEALTH

PROGRAM IN A

CEMENT
MANUFACTURING PLANT
EGAR, ENSOMO, FRANSICO, PONGASE
Cement is one of the most widely used construction
WHAT IS
material on earth. Cement is the basic material for CEMENT?
constructions which is made from a mixture of
elements that are found in natural materials such as
limestone, marl and/or clay. Because cement has been
used commonly, its health effects have become an
important issue both for employees and the
environment (koh et. Al. 2011).
Cement manufacturing is an energy and resource
WHAT IS
intensive process with both local and global CEMENT?
environmental, health and safety impacts. Because of
these impacts, ensuring healthy and safe working
conditions for employees is one of the most significant
issues for the cement industry.
 RISK ON A CEMENT
In addition to the various health hazards, cement MANUFACTURING
workers are especially exposed to dust which causes
lung function impairment, chronic obstructive lung PLANT
disease, restrictive lung disease, pneumoconiosis and
carcinoma of the lungs, stomach and colon at various
production process such as quarrying, crushing, raw
material grinding, blending, kiln burning, cement
grinding and packaging in cement industry (Meo 2004)
 SAFETY ON A CEMENT

MANUFACTURING
Therefore, ensuring healthy and safe working
conditions for employees and contractors is a PLANT
fundamental key to corporate social responsibility, and
is one of the most important issues for the cement
industry (WBCSD 2004).
 CLASSIFICATION
AND DEFINITION OF
THE HAZARDS IN
CEMENT
MANUFACTURING
• Cement manufacturing processes
including health and safety risks
were classified as follows

6
CLASSIFICATIONAND DEFINITIONOFTHE HAZARDS INCEMENT MANUFACTURING

 QUARRYING
 CRUSHING
 CLINKER PRODUCTION
 MILLING PROCESSES AT RAW MILL, CEMENT
MILLING AND COAL MILLING
 MATERIAL TRANSPORT
 FILTERING
 STORAGE
 LOADING AND DELIVERY OF FINAL PRODUCTS
 FUEL STORAGE ACTIVITIES
 USE OF HAZARDOUS MATERIAL
 GENERATING UNITS (TRIA PROJECT)

7
Main hazard factors associated with cement manufacturing processes (Cumbane 2011).
In the table shown below, main hazard factors associated with cement manufacturing processes are presented. As shown
from the table, main hazardous factors in quarrying of raw materials can be defined as dust and noise. Noise emits during
balsting, crushing and operation of conveyors in quarrying operations. Noise sources in cement manufacturing plant
mainly include milling machines, crushers, electric motors (Canfeng 2012).

Cement Manufacturing
Main Hazard Factor
Process

1. Quarrying 1. Dust, Noise

2. Raw material preparation 2. Dust, toxic gas (CO,
CO2, NOx, SO2), noise,
3. Clinker burning
heat pollution
4. Clinker cooling and
3. Dust, toxic gas, high heat
cement milling
radiation, high workload
5. Packaging, storage and
4. Auxiliary materials and
delivery
additives, dust, heat,
noise
5. Dust, high workload

8
 SAFETY ON A CEMENT

MANUFACTURING
Dust emissions are one of the most significant impacts of
cement manufacturing and associated with handling and PLANT
storage of raw materials (including crushing and grinding of raw
materials), solid fuels, transportation of materials (e.g. by trucks
or conveyor belts), kiln systems, clinker coolers and mills,
including clinker and limestone burning and packaging/bagging
activities (IFC 2007). Packaging is the most polluting process (in
terms of dust) in cement and production (Cumbane 2011).
Injuries by Causes

Typical injury causes in cement plants are defined as slips, trips and falls (29%); falling or moving objects (19%) and
lifting, overload and exertion (18%) as shown from Figure 2. Fatalities are the most serious tragedy that can
happen in the cement Industry. 79% of all fatalities arise from 3 main causes: Traffic & Mobile Plant (43%), Falls
from Heights & Items falling (21%) and Caught in Moving/Starting Equipment (15%). It was reported that
contractors and young/temporary employees are high risk categories in cement manufacturing plants (WBCSD
2004).
10
Potential hazard preventive actions in cement manufacturing plant
(Adapted from OSHA)
POTENTIAL HAZARD PREVENTIVE ACTION
Slip, Trips and Falls Good housekeeping
Sufficient lighting
Tidy work place

Identify and fix fall hazards, such as slippery surfaces,

damaged ladders and walkways

Confined areas (lack of oxygen, poisonous gas, Must be avoided entry to confined spaces
fumes or vapour, fire and explosions, dust, hot Remote cameras can be used
conditions…)
Permit-to-work
Cleaning before entry
Provision of ventilation
Testing the air
Provision of lightings
11
Potential hazard preventive actions in cement manufacturing plant
(Adapted from OSHA)
POTENTIAL HAZARD PREVENTIVE ACTION
Electric Each panel should be labelled

Safe electrical equipment should be purchased and used

Appropriate PPE

Training of personnel

Falling/Moving Objects Tidy workplace

Avoid working beneath cubed elevators, conveyor belts
PPE usage

12
Potential hazard preventive actions in cement manufacturing plant
(Adapted from OSHA)
POTENTIAL HAZARD PREVENTIVE ACTION
Fire (conveyor belts, electrical cables, fuels, Proper waste disposal
waste combustible materials…) Good housekeeping
Heat detectors usage
Fire extinguisher
Fire fighting procedures

Working at height Usage of appropriate ladder and scaffolder

Usage of fall protection system
Usage of appropriate PPE

13
Potential hazard preventive actions in cement manufacturing plant
(Adapted from OSHA)
POTENTIAL HAZARD PREVENTIVE ACTION
Hot/cold surfaces (hot surface burns...) Usage of appropriate PPE

Noise and Vibration Technologies of noise attenuation, adsorption

and insulation
Appropriate hearing protection

14
Potential hazard preventive actions in cement manufacturing plant
(Adapted from OSHA)
POTENTIAL HAZARD PREVENTIVE ACTION
Excavation sites All excavations in the plant should be surrounded
with a handrail

Vehicles Avoid overloading

Make sure back-up alarms on all vehicles are
functioning
Be sure that trucks and other vehicles are in good
working order, including audible back-up warning
signals, before operating them

15
Potential hazard preventive actions in cement manufacturing plant
(Adapted from OSHA)
POTENTIAL HAZARD PREVENTIVE ACTION
Safety guards of machines Those parts must be provided with safety guards
or devices
Usage of appropriate guards (interlocking,
automatic, self-adjusting, two hand control
devices…etc.)
Maintaining of conveyor belt systems

Manual handling Must be looked out for sharp edges, splinters and
nails
When lifting heavy objects, legs should be used
as much as possible to save back muscles

16
Potential hazard preventive actions in cement manufacturing plant
(Adapted from OSHA)
POTENTIAL HAZARD PREVENTIVE ACTION
Tag out – Lock out (electrical or process Electrical isolation switches must be turned off
isolation)

Dust Usage of automated packing machines

Usage of enclosed conveyors
Storage of crushed raw materials in closed bays
Appropriate respiratory protection should be
worn
Cement dust Usage of respirator to minimize inhalation of
cement dust
Usage of soap and water avoid skin damage

17
 All people working on our sites have a right
to expect safe and healthy work conditions
and the duty to contribute to such conditions
with responsible behaviour. We regard H&S
as core business values being integrated in
the overall business performance Every injury
HEALTH & SAFETY or case of ill health resulting from
employment is avoidable with appropriate
POLICY systems of work, equipment, substances,
training and supervision 9 Cement
GUIDING PRINCIPLES Sustainability Initiative Effective H&S
management includes risk assessment from
the initial plant design and construction
stage, commissioning and overall planning for
organisation of work and maintenance All our
operations must continually improve their
H&S performance
18
 Management processes shall be in
place to ensure risks are adequately
identified, controlled and managed.
The analysis is regularly updated,
notably during the installation of new
HEALTH & SAFETY equipment, changes in the
organisation, etc. Employees,
POLICY Contractors and customers shall be
informed of the risks and the measures
RISK ANALYSIS taken to eliminate or minimise them. A
monitoring and alert system shall be in
place that puts risk control at
appropriate management level
depending on its seriousness.

19
 Workshop audits and inspections are
planned and take place on a regular
basis. They are reported and give rise
to corrective and preventative actions,
which are managed in the same way as
HEALTH & SAFETY injury analysis. These inspections and
audits are conducted by the line
POLICY management, trained for that purpose,
including the Top Management.
SAFETY AUDITS AND INSPECTIONS Personnel are involved as much as
possible in these audits and
inspections. In addition to these
internal audits there are crossed audits
between different sites, which use the
so-called “fresh view” technique.

20
 New installations are designed
and built taking into account the
safety of operating and
PREVENTION AND maintenance personnel. The
installations and mobile
CONTROL OF RISKS equipment shall be effectively
maintained and where
FIXED AND MOBILE EQUIPMENT appropriate, examined and
inspected. Those subject to
regulatory controls are
monitored.

21

PREVENTION AND
CONTROL OF RISKS
PERSONAL PROTECTION EQUIPMENT
Personal protection equipment
for work shall be identified, the
circumstances in which it
should be worn defined, and
suitable arrangements made
including training &
supervision to ensure it is
worn (See appendix for
datasheet on PPE usage)
22
 Instructions, rules and
procedures are designed so
work may be performed safely,
without risk to health, and in
PREVENTION AND accordance with risk
assessment. They shall be:
CONTROL OF RISKS Written Up-dated In line with
regulations Realistic 11
INSTRUCTIONS, RULES AND PROCEDURES
Cement Sustainability Initiative
Known and understood by all
parties involved Followed and
respected

23
• x Any person working on equipment
with moving parts must personally
ensure the equipment is de-energized,
isolated and locked/tagged out

• x No person may disable or bypass a

process safety interlock - either

•
mechanical or electrical

x Any person working from a position

Life saving rules
with the potential for a fall of 1.8 meters
or more must use fall protection

• x Any person doing flame welding,

cutting or brazing up to 6 meters from
any flammable material must obtain a
proper hot work permit and apply the
requirements

24
• x Any person entering a confined space
must obtain a proper confined space
entry permit and apply the
requirements
• x Prescribed PPE shall always be worn
when exposed to open processes or
systems (e.g. clearing material
Life saving rules
blockages, electrical work, etc …)
• x Using illegal drugs is strictly forbidden
on any site - use of alcohol or other legal
drugs that can effect personal
concentration is discouraged

25
Group 3
MEMBERS

Michael Margaux Renz

Fransisco Ensomo Pongase

Narfred
Egar

26
THANK YOU

27