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Putting Safety ahead of Production

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Preventive OSH is gaining popularity among cement companies, as that proves to be a business case for them when huge costs and reputation are at stake on the flipside.

Focus on occupational safety and health (OSH) is increasing in India, while it is at a long way to go before it reaches the global best practices. However, cement industry in India, being a highly organised industry, is much ahead of several other sectors, though it is yet to catch up with the best.

Though big organisations are doing better or willing to do even better in safety aspect, the challenge lies in bringing the organisations and enterprises at the bottom of the pyramid – micro, small, and medium enterprises, where awareness of critical importance of occupational safety and health is very low.

International Labour Organization (ILO) Director – General Guy Ryder said during the opening ceremony of the XXI World Congress on Safety and Health at Work on September 3, 2017, at the global level, the impact of not investing in Safety nearly equals to the combined gross domestic product of 130 poorest countries in the world.

ILO also unveiled estimates showing that, worldwide, 2.78 million workers die each year as a result of occupational injuries and illnesses. Of those, approximately 2.4 million are linked to work-related disease. The total cost of illnesses, injuries and deaths was 3.94 per cent of the global GDP, or $2.99 trillion. According to another estimate, the figure is 10-20 per cent of their GDP for Asian nations.

Exposure to dust and high temperatures, contact with allergic substances, and noise exposure can be defined as hazards associated with health; while falling/impact with objects; hot surface burns; and transportation, working at height, slip/trips/falls can be defined as hazards associated with safety.

Manufacturing hazards
While the stages of core processes of cement manufacturing are mining of limestone, limestone crushing/grinding, fuel preparation, burning of raw meal, cement grinding, material handling, packing and transportation of raw material and finished goods, Sanjay Joshi, Chief Manufacturing Officer, Nuvoco Vistas Corp Ltd, classified major hazardous areas into five – Mining of limestone, material handling and rushing/grinding, clinkerisation process, coal handling in clinkerisation process, and uncontrolled fire. (See interview in the following pages)Concrete manufacturing process has its own areas of potential hazard – Inside the concrete plant, where concrete is manufactured; during transport of concrete by "transit mixers" from plant to various construction sites; and at the construction sites where the concrete is delivered by static or mobile pumps, says Prashant Jha, Chief Concrete and Aggregates, Nuvoco Vistas Corp. Ltd.

If one has to classify potential hazards in cement and concrete industries based on the severity of impact, dust emissions are one of the most significant impacts of cement manufacturing and associated with handling and 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. Packaging is the most polluting process (in terms of dust) in cement production, says Vinay Pathak, Senior General Manager & Subject Matter Expert – APAC Region, Personal Safety Division, 3M India Ltd.

Harmful gases and vapours, wet concrete, and high heat & thermal effects, particularly in raw mill and preheater tower, hot clinker, precipitator and bypass dust and hot cement, follow dust emissions in these manufacturing processes, besides several physical hazards occurring in the process of movement of goods.

Remedial measures
Given the huge cost OSH accidents or events in manufacturing plants can cause and reputation risk involved, cement manufacturers are taking preventive measures by adhering to compliance measures meticulously to safeguard their employees’ safety and health.

"All the areas in the plants are surveyed and signages have been displayed about the hazard and a safety manual is also provided to the employees. Workers carry out a daily cleaning procedure along with changing of bag filters as per OEMs manual. As a protocol, plant personnel need to wear PPEs, PPS-2 nose mask, earmuffs at high noise areas and aluminium suits in hot zones before carrying any process," says Ujjwal Batria, Chief Operating Officer, Dalmia Cement (Bharat) (See interview) Dalmia cement has also built green zones across the plant vicinity and at different points to minimise the impact on the environment. Water cooler points with rest shelters are provided across all plants and ORS is provided during summer season. Effective control measures help us to achieve our mission of zero harm, Nuvoco claims, while listing the measures they have taken to avoid or control various hazards in mining and transportation, burn injury during clearing of blocked cyclone, and in coal shop, fine coal bin and bag houses. Its concrete plants are established considering engineering and administrative control of all hazards.

As an effective hazard prevention and management strategy, "health and safety policy should be adapted with other policies of the company. Additionally, risk management policy of company should be developed, and risk assessment should be performed regularly and efficiently," says Pathak. 3M is a leading personal protection equipment (PPE) manufacturer for cement and concrete manufacturing plants as well.

Conclusion
There is no doubt that benefits outweigh monetary cost and reputation risk for companies and physical pain and disruption in life of employees. So, it is imperative that companies embrace safe working practices and the mindset shift should happen from "Production first, Safety later" to "Safety-first productivity".

Though the willing bigger companies have mastered the art of internal communication relating to potential hazards, reporting of hazards by companies is yet to be streamlined. To evolve appropriate strategies in OSH, reasonable amount of data is necessary. Regulatory mechanism needs to be tightened to ensure this happens. About a year back, the then Director General, National Safety Council, VB Sant said at a seminar "If you take a scale of 1-10 and if your goal is to achieve 10, I think we are between two to three only, if one is being honest about it and in the light of measures adopted in advanced countries."

Sant had urged that OSH targets should be linked to various government schemes for building a robust safety culture in corporate entities as part of promoting "Make in India" (MII) scheme. MII was launched in September 2014 to make the country a global manufacturing hub. MII can be made successful only by ensuring that manufacturing is also "Safe in India".

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Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

Dalmia Bharat Acquires Jaiprakash Associates Cement Assets for ₹2,850 Crore

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Dalmia Cement executed a Business Transfer Agreement with Jaiprakash Associates and Adani Infra, to acquire 5.2 MnTPA of cement capacity across Madhya Pradesh and Uttar Pradesh.

Dalmia Cement (Bharat) announced on May 22, 2026 that it had signed a Business Transfer Agreement with Jaiprakash Associates Limited and Adani Infra (India) Limited for the acquisition of cement plants located at Rewa in Madhya Pradesh and Churk, Chunar and Sadwa in Uttar Pradesh. The deal was struck at an enterprise value of ₹2,850 crore and is expected to close within two weeks of execution.

The acquired assets from Jaiprakash Associates include 5.2 MnTPA of cement capacity and 3.3 MnTPA of clinker capacity. The package also covers 99 MW of thermal power capacity and railway sidings at Rewa, Chunar, and a common siding at Churk. This infrastructure gives the acquisition immediate operational utility beyond just production tonnage.

The transaction has a long backstory. Dalmia Cement had originally entered into a framework agreement with Jaiprakash Associates in December 2022, covering the sale of these business assets along with a long-term clinker supply arrangement. However, before the deal could be completed, Jaiprakash Associates was admitted to insolvency proceedings under the Insolvency and Bankruptcy Code. The earlier agreements could not be consummated as a result.

In an official statement, Puneet Dalmia, Managing Director & CEO, Dalmia Bharat, said, “I am very excited about addition of these assets in our portfolio. This serves as a great strategic fit for Dalmia. It helps us move forward in our journey to be a pan India player and provide a strong head start to serve the high potential markets in Central region. I am optimistic that the expansion potential of these assets along with close proximity with Dalmia’s captive mines will help us create a capacity hub for the future”.

Following the approval of Adani Group’s resolution plan for Jaiprakash Associates under the IBC framework, Dalmia approached the new management to revive discussions. The fresh Business Transfer Agreement was executed to settle all pending disputes, legal proceedings, and arbitration matters arising from the original framework agreement with Jaiprakash Associates.

Expanding market reach

Dalmia added, “Our familiarity with these assets under the earlier tolling arrangement gives us a deep understanding of the facilities and helps us establish strong connect with channel partners and vendors. We believe that this will help us in faster ramp up of capacities and quicker inroads into the market. As we look forward, I am very confident that we will be able to leverage the strengths of Dalmia to operate these assets in a manner where we can maximise value creation for all our stakeholders.”

With the addition of these plants, Dalmia Bharat’s total installed cement capacity will rise to 54.7 MnTPA upon consummation. The company has further expansion projects underway at Belgaum, Pune, and Kadapa, which are expected to take overall capacity to 66.7 MnTPA by Q2 to Q3 FY28.

The Central India location of the Jaiprakash Associates plants gives Dalmia Bharat faster access to markets in Madhya Pradesh and Uttar Pradesh than a greenfield build would have allowed. The company also cited debottlenecking and brownfield expansion as near-term opportunities at the acquired sites. Dalmia Bharat said the assets were expected to contribute positively to EBITDA and overall returns, given the pricing environment in the region and the company’s cost structure.

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