Safety Regulations for Cement Industry Hazards

Abstract:
In this issue light will be thrown upon safety regulations for a cement industry. This
Cement is one of the most widely used substances on earth and its factories are one of the most

prone to hazard industries. Cement manufacturing is a resource intensive process with local and

global environmental, health and safety impacts. The cement industry is one the least advance

industry with respect to health and safety concerns. Even in this advanced technological world, a

large number of people work every day in a dusty environment. They are exposed to different

types of health hazards such as gases, fume and dust, which are risk factors in creating
occupational disease. Ensuring the healthy and safe working conditions for employees should be

at top priority.

After working for several months, in a cement plant several safety issues have been observed,

which includes Mechanical Hazards, Confined space hazards, working surfaces, and industry

hygiene hazards. All operations in cement manufacturing plant from crushing to shipment,

including any production- related off-site activities; for example the preparation, treatment,

handling and delivery of fuels and other raw materials etc. include hazards at some level.

Lets begin the technical safety issues number wise.

Quarrying is the first activity that has safety measures includes that of Mechanical Hazards :

moving parts of the bore holing machinery, material falling, crushing machinery, dust and noise.

Area surrounding explosive charges is cleared from people by tagging-out at various places.

Explosives should be handled with care away from heat and impact. Access of unauthorized

persons will be denied. After the explosives implementation check the unexploded bore holes.
Then comes the crushing phase where dust and noise is a hazard which falls under 29 CFR

1910.94(a)(1)(vi) Clean air and 29 CFR 1910.95 Occupational noise exposure to be handled

with PPE. Noise is manageable by ear plugs and dust by masks and respirators. The moving parts

of the crusher should be secured with Guards.

Milling is the next stage of which the hazards of moving parts, personnel falling, material fall,

dust, noise, hurl of mill parts. Precautions for this includes that all guards must in place to protect

from moving parts. Rails should be present for personnel fall protection. Sound level must be

assessed if noise reduction is not possible use PPE such as ear plugs. Air purification from dust

must be used like dust bag filter system. The PEL recommended limit for the ambient dust here

is 10mg/m3. The dust can cause pulmonary disorders. Appropriate PPE respirators should be

employed near the mill. During maintenance inside the mills a person is exposed to the

additional hazards of high temperature, confined space and hurling metal fragments.

Maintenance must be conducted by authorized personnel with continuous supervision and where

they acquire permits for the work. PPEs for this task are helmets with eye protector, safety belt

connected to rope, work wear and foot wear that withstand thermal load, appropriate torch and

the very important ventilation.

After this comes the clinker making process. Its hazards are fuel hazard, mechanical hazard,

heat exposure, fall from height. Additional hazards for it are ventilation, confined space, thermal

load and dust. Most of which are Serious injuries and Fatal. Check that all operators use PPEs in

the clinker production area. Check the operating procedure for access to preheater, kiln and the

cooler.
Now filtering plant will be discussed. Two types of filters used for the collection of the dust are

the electrostatic filters and the bag filters. Its common hazards are explosion due to high

concentration of CO due to coal dust, dust, asphyxiation inside the filter. Operating procedure

must be followed for securing the electrostatic filter. Appropriate PPEs must be used. During

filter maintenance the hazards are material accumulation, dust, static electricity (OSHA 1910.269

App C).

Every industry consume large quantities of fuels. In cement industry, the drying of raw materials

and the production of clinker consume large quantity of fuel that can be in the form of solid

(coal), liquid (oils), or gas (natural gas).

Fuel, heat, and oxygen are three main elements that are necessary for combustion to takes place.

In the absence of any of these three elements, the combustion does not takes place. Explosion,

fire, asphyxiation, and creation of toxic wastes are the main hazards associated with the storage

and use of fuels. Open flames near the storages, creation of hot spots during operation or

maintenance of the tanks, self ignition of hot material, and electrical discharge (thunders,

electrostatic charges, short circuits) are the basic sources of ignition. Isolation or reduction of one

the three elements necessary for combustion, is the basic preventive and protective measure for

the reduction of loss. Conform to the special safety operational instructions, adhere with the the

safety singage, disconnection of electricity prior to any maintenance work, , conditions for

explosion is removed before entering an confined tank or storage silo that previously contained

fuel, and use of PPEs are the other protective and preventive measures.

The main hazards associated with the work place in cement industry are dusty environment,

exposure to sunlight, Vibrations, fall, trip, Noise, toxic substances etc. To prevent work place
accidents provide adequate space for the activities carried out and the existence of proper

entrances and exits, operational, ergonomic and safe positioning of work places and

equipment, proper ventilation system, air conditioning, proper lighting, and appropriate PPE. To

overcome the vibration, equipment must be positioned and guarded properly. The safe work

palce play a havoc role in the prevention of accidents and occupational diseases. Elimination of

obstacles from passageways, floors and emergency exits, removal all sharp corners or edges if

any, covering of any permanent or temporary floor openings, replacement of any barriers or

guards when removed, placement of any manual/portable equipment and hand tools in safe

place, are the corrective measures to achieve safe and sound work place conditions.

Permit is required for this activity. When maintenance is taken out the working place will be

tagged-out/locked-out .