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Workplace Safety Stop, Think, Act

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A serious workplace injury or death changes lives forever – for families, friends, communities, and coworkers too. Workplace health and safety is an important and worthwhile investment.

Industrial safety standards appear to be falling in the country, much like the recently reported instant death of contracted labour on November 25, 2017, at one of the several ongoing Mumbai Metro rail projects at Goregaon. The 21-year-old contract worker Hari Om Yadav was severely injured while preparing for a ‘Pier Cap Erection’ after the crane’s rigger, that he was operating, malfunctioned.

Yadav proceeded to physically check the problem and while he was doing so his own uncle, who was manning the crane pressed the start button which set the crane in motion. The crane’s rigger hit Yadav’s head and he subsequently succumbed to his injuries. The Mumbai Metropolitan Region Development Authority’s (MMRDA’s) additional Metropolitan Commissioner issued notices to Simplex Infrastructure Ltd, the contractor who would be held accountable for the loss of human life. MMRDA officials said that around Rs 9 lakh would have to be paid to the family of the deceased worker by the contractor.

Mumbai city’s infrastructure development agency also directed the contractors to re-train all crane operators, a fact that indicates that standard operating procedures (SOPs) were not followed, thereby leading to the mishap and human fatality.

Similar instances of fatalities were reported in Mumbai even when the first Metro rail corridor (between Andheri and Ghatkopar) was being constructed in July 2011, when another worker slipped and fell off a beam he was standing upon at a height of over 50 feet. Only six days before that incident, two laborers working at the Mono-rail project also died in a construction site mishap at Chembur in eastern Mumbai. None of the three workers had donned the mandatory safety (harness) belts that would have significantly reduced the number of fatalities, probably resulting in zero deaths instead of three fatalities in the two incidents.

Same was the case at the Andheri Metro site in September 2012 when another worker was killed and 11 others injured after a slab of the under construction bridge of the Metro Rail collapsed at the arterial Andheri-Kurla road within walking distance of the international airport facility in the city.

Many such cases were also reported from across the country, be it in Chennai where on April 27, 2017 two metro water contact labourers died while separating the sewage lines from the drinking water pipelines in the Oori Salai area in April 2017.

In December 2015, a 24-year-old electrician, Anand Kumar, working at the Namma Metro’s underground station at Majestic in Bengaluru slipped and plunged 25 feet to his death. The Bangalore Metro Rail Corporation Ltd spokesperson said that Kumar was employed by Tiwary Electrical, sub-contractors to Blue Star Ltd and was conducting a survey and walking in the Environmental Control System plant room at the ‘concourse level’ when he slipped and fell down on the platform.

Is ensuring ‘zero human fatality’ while indulging in rampant industrial and infrastructural development in India, a distant dream even today, when we are set to introduce the Bullet Trains technology and thousands of kilometers of road and high speed rail networking across India?

Not so, says Maharashtra’s principal secretary for (labour) Ramesh Kumar who spoke to this journal regarding the correspondingly bad situation on account of industrial safety practiced by the 36,000 registered factories in the State (those employing over 20 workers), "We have our own machinery, including inspectors who visit individual units where accidents are reported. Zero fatality is indeed our stated objective and we are working towards it."

However, the figures of fatalities reported from these 36,000 odd registered factories suggests that a ‘zero fatality’ rate is still a long way away from accomplishment. In 2015, 145 worker deaths were reported in the State, while in 2016 this stood at 150 fatalities in industrial accidents.

In 2017, so far, 120 workers have died in mishaps reported from these registered factories. "There is the problem of many unregistered and illegal factories as well. Then there is a separate department under the Directorate of Boilers. The recent boiler room explosion reported in Uttar Pradesh at the NTPC-Unchahar facility is under probe and Dhawal Prakash Antapurkar (who holds charge as Maharashtra’s Director of Steam Boilers, Mumbai, has been co-opted onto the committee that is conducting a probe into the causes of the industrial accident reported recently in UP, where close to 29 human personnel lost their lives. His expertise will certainly help the probe and most probably also provide us with valuable learning to ensure better industrial safety in Maharashtra as well."

Sudhakar Prabhu Rathod, a mechanical engineer, is currently the Director at the Directorate of Industrial Safety and Health (Maharashtra). He says, "While 36,000 registered factories operate in the State, Mumbai would account for around 4,000 of these facilities, where more than 20 workmen are employed. Units with fewer than 20 employees, are covered under the Shops and Establishment Act and regulated by local self bodies (read municipal corporation and regional town planning authorities)."

However, he points out that his directorate is heavily understaffed. "My team of inspectors and officers visit the factories and conduct inquiries after mishaps are reported. Where violations of prescribed industrial safety standards are found to have taken place, we take action as per the rules. However, nearly 60 per cent of the posts of inspectors lie vacant in our directorate. Guidelines on industrial safety are in place and zero fatalities is an achievable target, as the compliance by factories where mishaps are reported is almost within prescribed standards."

However, his senior colleague in the State Secretariat, Rajesh Kumar is drawing out crystal clear plans to achieve target ‘zero’ in as far as fatalities are concerned. Says he, "We have already recommended (to Rathod) the setting up of a committee that will visit factories and submit a policy/guidelines paper for implementation. While there are existing criteria on industrial safety, the same needs to be enhanced. There has to be strong emphasis on training and creating awareness among the stakeholders involved in carrying out developmental work in a much more safe manner to bring down fatalities to zero."

He adds that Gujarat has a better track record on reducing fatalities, but stops short of providing hard data on the subject. "This is what I have been hearing for some time, about the policy and protocols being followed in Gujarat being of higher quality and closer to the objective of ‘zero fatalities’. Similarly, we are emphasising on new age technology to ensure better safety standards are employed. Better technology would surely ensure more healthy practices in the infrastructure as well as manufacturing facilities based out of Maharashtra. The distinction between hazardous (like steam boilers) or accident prone manufacturing processes and non-hazardous facilities and the commensurate emphasis required in distinct measures for both is required." He adds that once the policy paper for industrial safety (expected to be ready in another six months time) is ready, strong efforts would be made through workshops and awareness campaigns to ensure that the accent on safety becomes a habit in the entire state of Maharashtra, in turn ensuring it moves closest to the ‘zero fatality’ status.

"Already many illegal factories have started registering themselves and coming on-board the formal segment of the business industry. Improvements in safety standards, guidelines, protocols and regulation are soon to follow."

– Renni Abraham

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Concrete

India donates 225t of cement for Myanmar earthquake relief

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On 23 May 2025, the Indian Navy ship UMS Myitkyina arrived at Thilawa (MITT) port carrying 225 tonnes of cement provided by the Indian government to aid post-earthquake rebuilding efforts in Myanmar. As reported by the Global Light of Myanmar, a formal handover of 4500 50kg cement bags took place that afternoon. The Yangon Region authorities managed the loading of the cement onto trucks for distribution to the earthquake-affected zones.

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Concrete

Reclamation of Used Oil for a Greener Future

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In this insightful article, KB Mathur, Founder and Director, Global Technical Services, explores how reclaiming used lubricants through advanced filtration and on-site testing can drive cost savings, enhance productivity, and support a greener industrial future. Read on to discover how oil regeneration is revolutionising sustainability in cement and core industries.

The core principle of the circular economy is to redefine the life cycle of materials and products. Unlike traditional linear models where waste from industrial production is dumped/discarded into the environment causing immense harm to the environment;the circular model seeks to keep materials literally in continuous circulation. This is achievedthrough processes cycle of reduction, regeneration, validating (testing) and reuse. Product once
validated as fit, this model ensures that products and materials are reintroduced into the production system, minimising waste. The result? Cleaner and greener manufacturing that fosters a more sustainable planet for future generations.

The current landscape of lubricants
Modern lubricants, typically derived from refined hydrocarbons, made from highly refined petroleum base stocks from crude oil. These play a critical role in maintaining the performance of machinery by reducing friction, enabling smooth operation, preventing damage and wear. However, most of these lubricants; derived from finite petroleum resources pose an environmental challenge once used and disposed of. As industries become increasingly conscious of their environmental impact, the paramount importance or focus is shifting towards reducing the carbon footprint and maximising the lifespan of lubricants; not just for environmental reasons but also to optimise operational costs.
During operations, lubricants often lose their efficacy and performance due to contamination and depletion of additives. When these oils reach their rejection limits (as they will now offer poor or bad lubrication) determined through laboratory testing, they are typically discarded contributing to environmental contamination and pollution.
But here lies an opportunity: Used lubricants can be regenerated and recharged, restoring them to their original performance level. This not only mitigates environmental pollution but also supports a circular economy by reducing waste and conserving resources.

Circular economy in lubricants
In the world of industrial machinery, lubricating oils while essential; are often misunderstood in terms of their life cycle. When oils are used in machinery, they don’t simply ‘DIE’. Instead, they become contaminated with moisture (water) and solid contaminants like dust, dirt, and wear debris. These contaminants degrade the oil’s effectiveness but do not render it completely unusable. Used lubricants can be regenerated via advanced filtration processes/systems and recharged with the use of performance enhancing additives hence restoring them. These oils are brought back to ‘As-New’ levels. This new fresher lubricating oil is formulated to carry out its specific job providing heightened lubrication and reliable performance of the assets with a view of improved machine condition. Hence, contributing to not just cost savings but leading to magnified productivity, and diminished environmental stress.

Save oil, save environment
At Global Technical Services (GTS), we specialise in the regeneration of hydraulic oils and gear oils used in plant operations. While we don’t recommend the regeneration of engine oils due to the complexity of contaminants and additives, our process ensures the continued utility of oils in other applications, offering both cost-saving and environmental benefits.

Regeneration process
Our regeneration plant employs state-of-the-art advanced contamination removal systems including fine and depth filters designed to remove dirt, wear particles, sludge, varnish, and water. Once contaminants are removed, the oil undergoes comprehensive testing to assess its physico-chemical properties and contamination levels. The test results indicate the status of the regenerated oil as compared to the fresh oil.
Depending upon the status the oil is further supplemented with high performance additives to bring it back to the desired specifications, under the guidance of an experienced lubrication technologist.
Contamination Removal ? Testing ? Additive Addition
(to be determined after testing in oil test laboratory)

The steps involved in this process are as follows:
1. Contamination removal: Using advanced filtration techniques to remove contaminants.
2. Testing: Assessing the oil’s properties to determine if it meets the required performance standards.
3. Additive addition: Based on testing results, performance-enhancing additives are added to restore the oil’s original characteristics.

On-site oil testing laboratories
The used oil from the machine passes through 5th generation fine filtration to be reclaimed as ‘New Oil’ and fit to use as per stringent industry standards.
To effectively implement circular economy principles in oil reclamation from used oil, establishing an on-site oil testing laboratory is crucial at any large plants or sites. Scientific testing methods ensure that regenerated oil meets the specifications required for optimal machine performance, making it suitable for reuse as ‘New Oil’ (within specified tolerances). Hence, it can be reused safely by reintroducing it in the machines.
The key parameters to be tested for regenerated hydraulic, gear and transmission oils (except Engine oils) include both physical and chemical characteristics of the lubricant:

  • Kinematic Viscosity
  • Flash Point
  • Total Acid Number
  • Moisture / Water Content
  • Oil Cleanliness
  • Elemental Analysis (Particulates, Additives and Contaminants)
  • Insoluble

The presence of an on-site laboratory is essential for making quick decisions; ensuring that test reports are available within 36 to 48 hours and this prevents potential mechanical issues/ failures from arising due to poor lubrication. This symbiotic and cyclic process helps not only reduce waste and conserve oil, but also contributes in achieving cost savings and playing a big role in green economy.

Conclusion
The future of industrial operations depends on sustainability, and reclaiming used lubricating oils plays a critical role in this transformation. Through 5th Generation Filtration processes, lubricants can be regenerated and restored to their original levels, contributing to both environmental preservation and economic efficiency.
What would happen if we didn’t recycle our lubricants? Let’s review the quadruple impacts as mentioned below:
1. Oil Conservation and Environmental Impact: Used lubricating oils after usage are normally burnt or sold to a vendor which can be misused leading to pollution. Regenerating oils rather than discarding prevents unnecessary waste and reduces the environmental footprint of the industry. It helps save invaluable resources, aligning with the principles of sustainability and the circular economy. All lubricating oils (except engine oils) can be regenerated and brought to the level of ‘As New Oils’.
2. Cost Reduction Impact: By extending the life of lubricants, industries can significantly cut down on operating costs associated with frequent oil changes, leading to considerable savings over time. Lubricating oils are expensive and saving of lubricants by the process of regeneration will overall be a game changer and highly economical to the core industries.
3. Timely Decisions Impact: Having an oil testing laboratory at site is of prime importance for getting test reports within 36 to 48 hours enabling quick decisions in critical matters that may
lead to complete shutdown of the invaluable asset/equipment.
4. Green Economy Impact: Oil Regeneration is a fundamental part of the green economy. Supporting industries in their efforts to reduce waste, conserve resources, and minimise pollution is ‘The Need of Our Times’.

About the author:
KB Mathur, Founder & Director, Global Technical Services, is a seasoned mechanical engineer with 56 years of experience in India’s oil industry and industrial reliability. He pioneered ‘Total Lubrication Management’ and has been serving the mining and cement sectors since 1999.

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Concrete

Charting the Green Path

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The Indian cement industry has reached a critical juncture in its sustainability journey. In a landmark move, the Ministry of Environment, Forest and Climate Change has, for the first time, announced greenhouse gas (GHG) emission intensity reduction targets for 282 entities, including 186 cement plants, under the Carbon Credit Trading Scheme, 2023. These targets, to be enforced starting FY2025-26, are aligned with India’s overarching ambition of achieving net zero emissions by 2070.
Cement manufacturing is intrinsically carbon-intensive, contributing to around 7 per cent of global GHG emissions, or approximately 3.8 billion tonnes annually. In India, the sector is responsible for 6 per cent of total emissions, underscoring its critical role in national climate mitigation strategies. This regulatory push, though long overdue, marks a significant shift towards accountability and structured decarbonisation.
However, the path to a greener cement sector is fraught with challenges—economic viability, regulatory ambiguity, and technical limitations continue to hinder the widespread adoption of sustainable alternatives. A major gap lies in the lack of a clear, India-specific definition for ‘green cement’, which is essential to establish standards and drive industry-wide transformation.
Despite these hurdles, the industry holds immense potential to emerge as a climate champion. Studies estimate that through targeted decarbonisation strategies—ranging from clinker substitution and alternative fuels to carbon capture and innovative product development—the sector could reduce emissions by 400 to 500 million metric tonnes by 2030.
Collaborations between key stakeholders and industry-wide awareness initiatives (such as Earth Day) are already fostering momentum. The responsibility now lies with producers, regulators and technology providers to fast-track innovation and investment.
The time to act is now. A sustainable cement industry is not only possible—it is imperative.

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