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The Code on Wages 2019: Impact on cost to company

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The Code on Wages, 2019 has defined ??ages??in great detail. The same definition is quoted in the subsequent three labour codes passed by Parliament in 2020. According to Section 2 (y) of the code, ??ages” mean the entire remuneration paid to an employee while in employment and include: (i) basic pay; (ii) dearness allowance; and (iii) retaining allowance, if any.

However, ??ages??do not include:

(a) any bonus payable under any law for the time being in force, which does not form part of the remuneration payable under the terms of employment;

(b) the value of any house-accommodation, or of the supply of light, water, medical attendance or other amenity or of any service excluded from the computation of wages by a general or special order of the appropriate government;

(c) any contribution paid by the employer to any pension or provident fund, and the interest which may have accrued thereon;

(d) any conveyance allowance or the value of any travelling concession;

(e) any sum paid to the employed person to defray special expenses entailed on him by the nature of his employment;

(f) house rent allowance;

(g) remuneration payable under any award or settlement between the parties or order of a court or tribunal;

(h) any overtime allowance;

(i) any commission payable to the employee;

(j) any gratuity payable on the termination of employment;

(k) any retrenchment compensation or other retirement benefit payable to the employee or any ex-gratia payment made to him on the termination of employment.

However again, for calculating the ??ages??under this clause, if payments made by the employer to the employee under clauses (a) to (i) exceed one-half, or such other per cent as may be notified by the central government, of all the remuneration calculated under this clause, the amount which exceeds such one-half, or the per cent so notified, shall be deemed as remuneration and shall accordingly be added to the ??ages??under this clause.

This clause defines ??ages??as consisting of the basic pay, the dearness allowance and the retaining allowance if any. However, if these three components were to add up to less than 50 per cent of the total defined remuneration, then the 50 per cent figure arrived at will be regarded as ??ages??

Following the enactment of the Code on Wages, 2019, four existing Acts stand repealed. The concerned acts are: The Payment of Wages Act, 1936, The Minimum Wages Act, 1948, The Payment of Bonus Act, 1965 and The Equal Remuneration Act, 1976.

The Code on Wages, 2019 is applicable to all the employees of every establishment. This means the code applies not only to workers but to the supervisors and executives as well. The new definition of ??ages??will ensure that the minimum wages as prescribed by the the Government from time to time would strictly be complied with, while eliminating the scope for reducing the contribution to terminal benefits, because of the bifurcation method applied by employers in the past. Admittedly, once the code becomes operational, the new definition of ??ages??is likely to add to the financial burdens of several companies.

Evolution of wage structure with allowances

When I commenced my corporate career in 1970 as an Assistant Engineer with Mukand Iron & Steel Works (now called Mukand), there was nothing like the concept of cost to company (CTC). The appointment letter given to me merely carried details of the monthly basic pay, the Grade in which I was placed, and the annual increment applicable to that grade. There was also mention about the monthly dearness allowance that I would receive based on the consumer price index. In my first payslip, the total of these two items ??basic pay and dearness allowance ??amounted to a princely sum of Rs 1,050 per month.

No other allowances were payable to me, either monthly or annually, during the first two years of my service, except the annual bonus declared by the company before Diwali based on the earnings for the previous year. This pattern of monthly wages continued largely in the same manner as I moved up the organisational hierarchy by way of promotion, as well as movement from one organisation to another in my corporate career. Just to reiterate, the basic pay and for certain years the Dearness Allowance continued to be the most important components of my monthly remuneration.

In India, the concept of CTC had its origins in the information technology (IT) companies from around mid-1980??. Alongside, consulting firms began to undertake surveys of executive remuneration for providing a comparative picture of a company?? standing in respect of its compensation levels and for determination of industry wise benchmarks. Some select companies formed remuneration clubs for similar purposes, primarily for exchange of salary details and compensation practices. These new developments necessitated having to assign cash value to perquisites extended to executives especially in multinational companies. Later, when the income tax rates were rationalised and the tax-free perquisites came up for scrutiny, companies began to treat all items of compensation as taxable. This automatically led to the legitimisation of the concept of CTC.

Simultaneously, there were other developments. The practice of including dearness allowance in the monthly salary of executives was abandoned by most companies. Also, in negotiations of long-term wage settlements with trade unions, organisations tried to introduce new allowances. This was done mainly to limit the rise in basic pay and monthly dearness allowance, as these two items had an impact on several other payments such as overtime rate, annual bonus, leave encashment, contribution to provident fund and gratuity.

In enterprises which have field force for supporting the sales and marketing effort, there has been a practice of negotiated tax-free daily allowance for local and out station working of the field force as the job entails travel, boarding and at times lodging expense. Here the tax-free daily allowance is normally paid without any supporting vouchers and at times higher than the normal expense. The eligible tax-free daily allowance is quite often part of a negotiated long-term wage settlement.

CTC

CTC is the nomenclature presently used by Employers while making an offer of employment to show case total remuneration. The final figure shared can be misleading as in some cases it includes items such as performance bonus payable at its maximum (for which amount limited number of persons qualify), monetary value of Subsidised snacks and meals, and gratuity (which again is payable only when an employee completes a minimum of five years of service). Many new employees get at first impressed with the CTC figures shown on the paper, but later feel disappointed when they realise that the monthly take home pay is very much lower, and not one twelfth of the CTC amount, as they had assumed that it would be.

Some companies offer an ? la carte system where employees can opt for allowances of their choice within the negotiated CTC limits. This is done for two purposes: 1) cash now as against deferred payment and 2) reduction of tax liability.

The CTC represents a company?? total annual expenditure on an employee. CTC computation includes all the payments, in cash and in kind, the direct payments and the money value of the welfare benefits and perquisites extended to an employee. Hence, to avoid any misunderstanding or subsequent disappointment, the CTC components should be explained clearly and carefully to a new joinee.

Elements of CTC

The items defined under section 2 (y) of the code fall into three categories of the CTC format in vogue among the companies. They are as follows:

A) Direct benefits to an employee ??(i) basic pay, (ii) dearness allowance, (iii) retaining allowance, (a) bonus, (d) conveyance allowance, (e) special expenses, (f) house rent allowance or reimbursement, (g) amount payable under an award, (h) over time allowance, (i) commission.

Allowances such as shift allowance, education allowance, dress allowance, and any other allowance which form part of the direct benefits but have not been defined anywhere in the Code, will have to be considered as elements of item (e) special expenses and be regarded as part of remuneration.

However, medical allowance or reimbursement, medical insurance premium and leave travel reimbursement, which are shown as part of CTC, may not have to be included in calculating the remuneration under the code.

B) Indirect Benefits to an employee include the item value of house accommodation. Which under Section 2 (y) (b) of the code is defined as: ??he value of any house-accommodation, or of the supply of light, water, medical attendance or other amenity or of any service excluded from the computation of wages by a general or special order of the appropriate Government?? House accommodation to employees plus supply of electricity, water is generally provided in the company?? township. In some cases, accommodation is provided to essential staff or persons in top management cadre. There is a method of computing the value of accommodation, if provided free, as per existing income tax laws.

There are organisations that hich provide also the following benefits: interest free loans for buying assets, food coupons in lieu of subsidised meals, payment of medical insurance premium, free transport to office and free uniform. All these items form part of indirect benefits, but they have not been defined anywhere in the Code. On the other hand, they are being shown as part of CTC by the organisations. These items stay as grey areas and there is a danger that they may become objects of arbitrary interpretation by the Labour & Employment Department.

C) Saving contribution to an employee refers to item 2 (y) (c) of the code contribution paid by the employer to any pension or provident fund, and the interest which may have accrued thereon. Organisations were including the contributions made by the Employer to the employee?? Pension and Provident Fund accounts under the existing law, in the employee?? CTC. However, the interest which may have accrued to the contribution in the year was never considered as part of CTC, as this is not paid by the employer. Be that as it may, for the first time ever, the interest accruing to the contribution has been made a part of remuneration under the new code. This is clearly a new development.

Many companies operate superannuation fund for their executives. The contribution to the superannuation fund, amounting to 15 per cent of an employee?? basic salary (plus dearness allowance, if any), is solely made by the employer. The Government of India has presently set an aggregate limit of Rs 7.5 lakh for employer contributions to the Provident Fund (PF), National Pension System (NPS) and superannuation fund (SF), any contribution beyond which is taxable for the beneficiary, otherwise this amount does not at present attract any liability. In fact, the code seems silent about SF. The SF is, no doubt, a pension fund, and the code does make a mention of pension fund. But the pension fund referred to under item 2 (y) (c) in the Code is about the pension scheme which forms part of the PF. SF does not get discussed at all in the Code.

This is yet another grey area. It would, therefore, be advisable to include the employer?? contribution to the superannuation scheme as part of remuneration. There are companies that have stock options for certain category of employees and this could be a grey area for it to be considered as remuneration based on the Income Tax Act.

Impact on companies

The two items, that pose a problem in computing an employee?? remuneration for a financial year, are overtime and annual bonus. In the case of workers, over time earnings are a part of remuneration. However, the payments are likely to vary from month to month and the exact amount will only be known at the end of the year. Similarly, the annual bonus payable to employees could vary from year to year as the final amount is based on the available allocable surplus. Of course, it is entirely a different matter that in quite a few companies, the quantum of bonus is negotiated and settled with the trade union and is in no way related to the allocable surplus.

All organisations have to calculate the ??ages??as defined under the cde and see whether the existing basic pay, dearness allowance and retaining allowance together amount to more than 50 per cent of the remuneration for every one of their employees, whether they are executives, supervisors, workers or even contract workers. If it does, there would not be any additional financial liability to the company when the code becomes operational.

But in organisations where the ??ages??do not add up to 50 per cent of the remuneration, extra provision will have to be made for leave encashment and gratuity payments. As for the employer?? contribution towards PF, as long as the present limits are in force at ??12 per cent of the wages subject to a present wage ceiling of Rs 15,000 pm ??the additional financial impact is likely to be marginal. If, however, the wage ceiling of Rs 15,000 were to be enhanced or removed, then there is bound to be additional liability, once the code becomes operational.

Conclusion

In cases where the wages paid amount to less than 50 per cent of the total remuneration, organisations need to take corrective measures to remove the anomaly forthwith. The easiest way is to enhance the basic pay gradually while granting annual increments.

Organisations should also institute reasonable limits to leave accumulation and urge their employees to avail of their annual leave regularly. This will reduce a company?? liability considerably when it comes to leave encashment.

There is a provision in the code that the full and final settlement of a departing employee will have to be completed within two working days. This may not pose a problem in the cases of retirement, retrenchment or dismissal of an employee. However, in the cases of resignation

without advance notice, making full and final settlement of the dues within two working days can be a big challenge, as processing of the monthly payroll in most enterprises is outsourced. Hopefully, this issue can be resolved by ensuring that the departing employee has to serve the notice period.

Confusion still persists among the professionals of most companies as to which components of the CTC are to be included in computing the remuneration, to determine the quantum of ??ages?? It would hugely benefit organisations, trade unions and employees, if the Ministry of Labor & Employment, Government of India can release question and answers by sharing real life examples to explain how the ??ages??are to be calculated. This will help the organisations to duly comply with all the provisions of the new code and spare them from being harassed at a later date by government agencies for non-compliance, which, in many cases, could be merely due to ignorance or misunderstandings.

ABOUT THE AUTHOR:

Dr. Rajen Mehrotra is Past President of Industrial Relations Institute of India (IRII, Former Senior Employers??Specialist for South Asian Region with International Labor Organization (ILO) and Former Corporate Head of HR with ACC Ltd. and Former Corporate Head of Manufacturing and HR with Novartis India Ltd. E-Mail: rajenmehrotra@gmail.com

Published in April 2021 issue of Current Labour Reports.

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Concrete

Protect Your Margins

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In a research-backed article, Dr SB Hegde examines why carbon-adjusted profitability and LC3 will decide the next set of winners in cement manufacturing.

The Indian cement industry has achieved world-class operational efficiency through lower specific energy consumption, high plant utilisation and a reduced average clinker factor of approximately 67.5 per cent. These traditional measures of operational excellence remain essential. However, they are no longer sufficient. Carbon now carries a measurable financial cost under India’s Carbon Credit Trading Scheme (CCTS) and under European carbon markets. Future leadership will be defined by carbon-adjusted profitability, the ability to generate strong returns while systematically lowering the carbon intensity of every ton sold.
Limestone calcined clay cement (LC3) offers a practical, scalable pathway to achieve this dual objective. By replacing up to 50 per cent of clinker with calcined clay and limestone, LC3 can reduce CO2 emissions by 30–40 per cent while delivering comparable or superior durability performance.
This article examines the technical foundations of LC3, European industrial practices, the emerging Indian carbon market and a concrete roadmap for Indian companies to embed carbon-adjusted metrics and LC3 into daily operations, incentives and commercial strategy.

Limits of traditional operational excellence
For many years, plant performance has been judged primarily by five indicators: specific heat consumption, specific power consumption, kiln and mill utilisation, clinker factor and overall equipment effectiveness. These metrics drove continuous improvement and helped the industry reduce energy use and increase the share of blended cement. Three structural changes have rendered them incomplete as sole measures of success.
First, carbon now carries a real or opportunity cost. Plants that improve volume or lower cash cost while raising or stagnating emissions intensity create a hidden liability that will surface as CCTS trading matures and as green procurement expands.
Second, lower-carbon products such as LC3 and high-performance blended cements are creating differentiated market segments. Customers in infrastructure, real estate and export-oriented construction are beginning to specify embodied-carbon limits.
Third, investors and lenders increasingly treat carbon intensity as a financial risk factor. Traditional KPIs can mask the divergence between short-term cash profit and long-term carbon-adjusted value.

What is carbon-adjusted profitability?
Carbon-adjusted profitability evaluates normal profit after explicit adjustment for carbon performance. A practical expression is:
Carbon-Adjusted EBITDA = Conventional EBITDA – Carbon Cost + Green Premium Income
Carbon cost may be an internal carbon price, the actual cost of purchasing Carbon Credit Certificates under CCTS, or the opportunity cost of high emissions relative to peers. Green premium income arises when customers pay more for verified lower-carbon cement or when the company sells surplus credits. Tracking both conventional and carbon-adjusted profit side-by-side gives management a clearer picture of value creation under evolving market rules.

Table 1. Traditional KPIs versus Carbon-Adjusted Leadership Metrics
Traditional Focus New Leadership Metric Why It Matters
Specific energy consumption Emissions intensity (kg CO2/t cement) Directly linked to future CCTS and CBAM costs
Kiln utilisation Carbon-adjusted contribution margin Reveals true value of incremental volume
Clinker factor Share of lower-carbon products sold (incl. LC3) Measures commercial success of the transition
Power cost per tonne Effective carbon cost per tonne sold Expose hidden liabilities
Absolute EBITDA Carbon-adjusted EBITDA + green premium Aligning profit with future market reality

LC3: Technical foundations and performance advantages
LC3 is a ternary blended cement that typically combines approximately 50 per cent clinker, 30 per cent calcined clay, 15 per cent limestone and 5 per cent gypsum (the classic LC3-50 formulation). The decisive technical advantage is that clay is calcined at 700–850 °C, far below the 1,450 °C required for clinker production. This lower temperature, together with the substantial reduction in clinker content, delivers CO2 reductions of 30–40 per cent relative to ordinary Portland cement (OPC).
Chemistry is synergistic. Calcined kaolinitic clay (metakaolin) reacts with calcium hydroxide from clinker hydration and with limestone to form additional C-A-S-H gel and carboaluminate phases. These phases densify the microstructure, reduce porosity and improve durability.
Field experience shows superior resistance to chloride ingress, sulphate attack and alkali–silica reaction. Early-age strength can match OPC with high-reactivity clays; later-age strengths routinely meet 42.5 and 52.5 grade requirements.
Importantly, LC3 does not require high-purity kaolin. Clays with 40 per cent or even lower kaolinite content can be activated successfully, expanding raw-material availability across India. Calcination can use adapted rotary kilns or dedicated flash calciners, making the technology compatible with existing plant infrastructure and far less capital-intensive than carbon capture.
Economic analyses show that LC3 can be produced at equal or lower cost than OPC in many locations because of reduced energy demand and cheaper clay. Life-cycle assessments consistently report 30–40 per cent lower embodied CO2 per tonne of cement.
Table 2. Comparative profile: OPC versus LC3-50
Parameter OPC LC3-50
Typical clinker content ~95 per cent ~50 per cent
CO2 emissions (relative) Baseline (≈0.85 t CO2/t cement process + fuel) 30–40 per cent lower
Clay calcination temperature Not applicable 700–850 °C
Key hydration products C-S-H, portlandite, ettringite C-A-S-H + carboaluminates
Chloride & sulphate resistance Good Superior
Production cost potential Baseline Equal or lower in most locations
Infrastructure compatibility Existing High (minor adaptations)

In India, commercial adoption has begun in earnest. JK Cement commenced the first commercial production of LC3 in the Indian subcontinent at its Mangrol plant in Rajasthan in 2025 under BIS standard IS 18189.
By early 2026, approximately 2,000 tonnes had been produced and sold, avoiding an estimated 500 tonnes of CO2. JK Lakshmi Cement followed with commercial launch of its Green PRO LC3 grade from the Jaykaypuram plant. As of mid-2026, two producers are supplying LC3 to the market. The first large-scale infrastructure application is the Noida International Airport (Jewar), where LC3 was used in the runway and a building complex, demonstrating full constructability and performance under demanding conditions. These early volumes are still small relative to national cement demand, but they mark the critical transition from pilot to commercial reality. Companies that scale capacity now will be positioned to capture both CCTS credits and emerging green-procurement demand.

Why the shift is accelerating
According to the World Bank’s State and Trends of Carbon Pricing 2026, direct carbon pricing now covers nearly 30 per cent of global greenhouse-gas emissions and generated more than US$107 billion in public revenue in 2025. The average global carbon price stands at approximately US$21 per tonne, although regional prices vary widely.
In Europe, the EU ETS price has traded near €80–85 per tonen in mid-2026. Free allocation for cement is being withdrawn in parallel with CBAM. European producers therefore face a clear signal: every tonne of avoided CO2 improves both compliance and competitiveness. Holcim has scaled calcined-clay production, including Europe’s first dedicated line at Saint-Pierre-la-Cour (France) and a second line in the Czech Republic (2026). Heidelberg Materials, Cementir (FUTURECEM) and others have commercialised low-clinker calcined-clay blends across multiple markets, showing that carbon-adjusted profitability is already reshaping capital allocation in the world’s most mature carbon market.India’s CCTS is now operational. Binding emission intensity targets apply to 186 cement facilities for FY 2025–26 and FY 2026–27. Average required reductions for integrated plants are modest (around 2.7 per cent by FY 2027), yet the direction is clear.
Trading of Carbon Credit Certificates is expected in the second half of 2026, with early prices likely in the `800–1,500 per tonne range. Plants that outperform targets can sell credits; those that underperform must buy them or face compensation. Cement is well positioned to be a net supplier of credits if clinker factor continues to fall through LC3 and other low-clinker systems.

Way forward for India
India starts from a strong baseline, world-class energy efficiency and a clinker factor already lower than the global average. The next competitive frontier is the deliberate reduction of process emissions through clinker substitution at scale. LC3 is uniquely suited to Indian conditions because suitable clays are widely distributed, the technology fits existing kiln and grinding infrastructure, and the resulting product can meet the performance demands of both infrastructure and building construction.
A practical national pathway contains five interlocking elements:

  1. Standards and acceptance: Accelerated finalisation and promotion of BIS specifications for calcined-clay and limestone–calcined-clay cements will remove a key barrier to commercial uptake. Alignment with European practice (EN 197-5) can facilitate knowledge transfer and export readiness.
  2. Supply-chain development: Investment in flash calcination capacity and systematic characterisation of regional clay deposits will secure reliable, low-cost feedstock. Existing rotary kilns can be adapted for initial volumes while dedicated calciners are built.
  3. Incentive alignment: Part of variable compensation for plant managers, sales teams and senior leadership should be linked to emissions intensity reduction and to the volume of lower-carbon products (including LC3) sold. Without this link, traditional volume and cost targets will continue to dominate behaviour.
  4. Product-level carbon accounting: Reliable measurement of emissions intensity at the individual cement grade level, supported by third-party verification where required, is essential for both CCTS compliance and credible green claims.
  5. Demand-side pull: Green public procurement policies that specify maximum embodied-carbon thresholds for major infrastructure projects will create a predictable market for LC3 and other low-carbon cements, accelerating scale and cost reduction.
    Companies that treat LC3 as a strategic product line rather than a niche offering will be better positioned to generate surplus Carbon Credit Certificates, capture any emerging green premium, and protect margins as carbon costs rise.

Organisational changes required
Technical capability alone is insufficient. Three organisational shifts are required.
Daily management: Emissions intensity must appear on the same daily and monthly dashboards as heat consumption, power consumption and utilization. Plant reviews should examine both conventional and carbon-adjusted results.
Incentives: A meaningful portion of bonuses for plant heads, technical teams and sales leadership should be tied to lower emissions intensity and successful commercialisation of LC3 and other low-carbon grades.
Commercial approach: Sales teams need clear volume and pricing targets for lower-carbon products, supported by technical service that helps customers specify and place the material correctly. Without commercial pull, excellent technical performance remains under-utilised.

Table 3. Three-stage roadmap to carbon-adjusted profitability
Time Horizon Priority Actions Expected Outcome
Next 12 months Add emissions intensity to plant dashboards; establish internal carbon price; initiate LC3 pilot production and customer trials Visibility and early organisational learning
12–24 months Revise incentive systems; scale LC3 and other low-carbon grades to key accounts; secure third-party verification capability People and sales aligned with carbon goals
24–36 months Embed carbon-adjusted metrics in board reporting and capital allocation; expand calcined-clay capacity Full system integration and competitive advantage

Questions senior leaders should ask
Boards can accelerate the transition by insisting on answers to a short list of questions:
• Is our carbon-adjusted profit improving, stable or declining relative to conventional EBITDA?
• Did recent volume growth improve or worsen our emissions intensity?
• What share of sales already comes from lower-carbon products, including LC3, and what is the trajectory?
• How exposed is our capital expenditure plan to rising carbon costs under CCTS and potential CBAM-related requirements?
• Do our incentive systems still reward only volume and cost, or have they been updated to include carbon performance?
Treating carbon with the same seriousness as energy cost or kiln utilization does not diminish operational excellence; it expands the definition of excellence to match the new competitive reality.

Looking ahead
By 2030 the gap between leading and lagging cement companies will not be decided by who records the lowest specific heat consumption. It will be decided by who delivers the strongest carbon-adjusted profits.
Absolute emissions may still rise as national production grows. That is not the issue. Companies that reduce intensity year after year and successfully sell cleaner products will pull ahead in both domestic and export markets. Those that do not will fall behind, even if their traditional efficiency numbers look strong.
Operational excellence built the Indian cement industry. It remains the foundation. It is no longer the complete picture. Carbon-adjusted profitability is the clearer measure of success.
LC3 is not a distant technology. It is available now. It cuts CO3 by 30–40 per cent, works with existing plants, and is already in commercial production in India. Companies that treat it as a strategic product, not a pilot, will protect their margins and generate tradable credits.
Leaders who act now will place carbon metrics on daily dashboards, link incentives to intensity reduction and LC3 sales, invest in calcined-clay capacity, and build commercial capability to sell lower-carbon products. They will shape the next chapter of the industry.

References

  1. World Bank. (2026). State and Trends of Carbon Pricing 2026. Washington, DC: World Bank Group.
  2. International Carbon Action Partnership (ICAP). (2026). India Carbon Credit Trading Scheme – Status and Coverage. Berlin: ICAP.
  3. Ministry of Environment, Forest and Climate Change / Bureau of Energy Efficiency. (2025). Greenhouse Gases Emission Intensity Target Rules, 2025. New Delhi: Government of India.
  4. Scrivener, K., Martirena, F., Bishnoi, S., & Maity, S. (2018). Calcined clay limestone cements (LC3). Cement and Concrete Research, 114, 49–56.
  5. RMI. (2024). The Business Case for LC3. Rocky Mountain Institute.
  6. European Commission. (2026). EU Emissions Trading System – Allowance Price Data and Free Allocation Phase-out Schedule. Brussels.
  7. Holcim. (2025–2026). Scaling Calcined Clay for Sustainable Building – Corporate Updates on European and Latin American Capacity. Zurich: Holcim Ltd.
  8. LC3 Project / EPFL. (2026). LC3 – A Guide to Best Practices for Scalable, Affordable and Sustainable Low-Carbon Building. Lausanne: École Polytechnique Fédérale de Lausanne.
  9. Business Today / Industry Reports. (2026). First Large-Scale LC3 Application at Noida International Airport, Jewar. New Delhi.
  10. NITI Aayog / Industry Analyses. (2026). Roadmap and Baseline Performance Indicators for the Indian Cement Sector. New Delhi.
  11. Springer / Innovative Infrastructure Solutions. (2026). LC3 Systems: A Review of Chemistry, Performance, Durability and Sustainability toward Market Adoption.
  12. Cementir Holding / Industry Sources. (2025–2026). FUTURECEM and Related Low-Clinker Technologies in Europe.
  13. Climate Risk Horizons & Independent Analyses. (2026). Assessment of Emission Intensity Targets under India’s CCTS for Cement and Other Hard-to-Abate Sectors.
  14. GCCA / TERI. (Various years). Decarbonization Roadmaps for the Indian Cement Industry.
  15. EN 197-5:2021. Cement – Part 5: Portland-composite cement CEM II/C-M and Composite cement CEM VI. European Committee for Standardization.

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Concrete

More Oversight Makes Cement Plants Less Safe

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Dijam Panigrahi makes a counterintuitive but data-backed argument that routing every sensor alert through human approval does not make cement plants safer.

India’s cement industry has spent the last two years wiring kilns, mills and coolers with sensors and automated control systems, and the safety case for doing so is strong on paper. Contract workers still make up the majority of the industry’s workforce, and fatal accidents remain a recurring problem. The Indian National Cement Workers Federation has noted that around 83 per cent of workers in the sector hold precarious positions, a fact that resurfaced after an oxygen cylinder explosion killed three contract workers at a plant in Chhattisgarh.
Industry tallies compiled by IndustriALL found cement plants recorded at least seventeen accidents in one year with 21 workers killed, and ten accidents the following year with nine killed, most of them contract staff. Automated monitoring, in theory, closes that gap. A sensor never gets complacent and never skips a check because a shift is short staffed.
However, plants that respond by routing every anomaly reading to a person for approval are quietly building a system that fails the same way understaffing does. When operators receive dozens of flagged deviations a shift, most of them minor, they learn a simple lesson: the fastest way through the queue is to approve without reading closely. The safety benefit disappears, not because the technology failed, but because the humans supervising it adapted to the volume.

Why alerts get ignored
A study cited by manufacturing technology publisher Applied SmartFactory found more than 95 per cent of alarms in a semiconductor fab were low priority, and only about 4 per cent ever triggered an action, with just 100 out of 5,000 alarms accounting for 70 per cent of all alarm activity. The mechanism is the same whether the trigger is a vibration sensor or an AI model flagging a kiln temperature swing. Once the ratio of noise to signal crosses a threshold, workers stop treating the system as a decision aid and start treating it as a formality to clear.
The scale of AI deployment underway makes this more than a theoretical risk. Stanford’s 2026 AI Index Report found organisational adoption of AI has reached 88 per cent, even as documented AI incidents rose to 362 in 2025, up sharply from 233 the year before, according to analysis of the report. The Index also found only about a third of organisations have adopted a formal governance framework, with NIST’s AI Risk Management Framework cited by 33 per cent and ISO/IEC 42001 cited by 36 per cent.
Most manufacturers are deploying monitoring systems faster than they are building the judgment for when a flagged event actually needs a person’s attention. In India, plants run by JK Cement have begun pairing CCTV feeds with AI to define safe zones around heavy machinery, a promising direction that still depends on operators trusting and reading the alerts the system generates.

A three-tier model for cement plant
The fix is not less monitoring or more monitoring. It is classifying decisions by risk and by novelty, rather than treating human oversight as a single switch that is either on or off. A workable model sorts factory floor events into three tiers.
The first tier, proceed, covers deviations the plant has seen before that fall within known safe bounds, such as a kiln feed rate adjustment within an established range. These should run without a stop for approval, because routing them to a person only trains that person to click through.
The second tier, pause, covers events that are unusual but not yet dangerous, such as a vibration reading trending toward a limit or a fuel blend shifting outside its typical mix. These warrant a brief human check before the system proceeds, giving an operator the chance to apply judgment the model does not yet have.
The third tier, escalate, covers events that are both high risk and unfamiliar, such as a pressure reading combined with a temperature spike that has no close precedent in the plant’s history. These should stop the process entirely and require a decision from someone with the authority to shut down a line.

Who should set the threshold
Where these tiers get drawn matters as much as the framework itself. Threshold setting is frequently handed to the vendor supplying the monitoring software or to a plant’s IT department, both of which understand the technology but not the specific tolerances of a given kiln, mill or line. Operations staff, who know that a particular grinding unit runs hotter under monsoon humidity or that a calciner behaves differently after a refractory reline, are better positioned to calibrate what counts as routine on their own equipment.
Handing threshold ownership to operations does not remove IT or vendors from the process, but it puts the calibration decision closest to the people who live with its consequences on the floor.

Signals that oversight is actually working
A few concrete indicators reveal whether a monitoring setup is functioning as intended or simply providing the appearance of safety. The escalation rate over time is the first: a rate that stays flat or climbs slowly as operations mature is healthy, while one that spikes and then falls sharply often means operators have started overriding the system rather than engaging with it. Time to resolution is the second: escalations that take progressively longer to close suggest fatigue or confusion about ownership, not diligence. The third, and most telling, is how accurate the system’s own uncertainty estimates turn out to be, meaning whether events flagged as high risk actually correlated with real incidents, and whether events waved through stayed incident free. A system whose escalations do not track with actual outcomes trains operators toward the same complacency that unmonitored equipment produces.
None of this argues against automation in Indian cement manufacturing, where a labor structure built on contract work and a track record of serious accidents make better monitoring an urgent need. It argues for treating human oversight as a design problem with three distinct settings, rather than a single
dial turned up whenever a plant wants to look safer on paper.

About the author:
Dijam Panigrahi, Co-founder and COO, GridRaster, is a spatial computing platform for industrial enterprises and manufacturers.

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Concrete

The biggest gap arises from inconsistent leadership

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Anuj Kumar Mathur, Safety Consultant, stresses on the importance of closing the enduring gap between what safety systems say on paper and what actually happens on the plant floor.

Robust safety manuals, certified PPE and digital monitoring systems mean little if the culture on the plant floor does not enforce them. Safety Consultant Anuj Kumar Mathur has spent enough time in high-risk operations to know precisely where that gap opens and why it persists. In this exclusive interaction, he suggests feasible ways to strengthen the safety culture at a manufacturing unit.

Having led safety across high-risk fuel operations, what lessons can the cement industry adopt to strengthen its safety culture beyond regulatory compliance?
Beyond regulatory compliance, the cement industry should embed visible leadership commitment, proactive risk assessment, process safety management, strong contractor control, near-miss learning, and employee engagement to build a resilient safety culture that prioritises prevention, operational discipline and continuous improvement over mere compliance.

As cement plants become increasingly automated and digitally connected, how should organisations redefine their approach to process safety and operational risk?
As cement plants become increasingly automated, organisations should integrate process safety with digital risk management by strengthening cybersecurity, real-time monitoring, predictive maintenance, management of change and workforce competency to ensure safe, reliable and resilient operations.

What are the most common gaps between having robust safety systems on paper and achieving consistent safety performance on the ground?
The biggest gap arises from inconsistent leadership commitment on ground, weak safety culture, inadequate supervision, poor risk communication, insufficient workforce engagement specially, ineffective training and failure to translate procedures into disciplined execution, accountability and continuous monitoring at the operational level.

How can cement manufacturers better integrate contractor safety, leadership accountability and workforce behaviour to build a truly zero-harm workplace?
Manufacturers can achieve a zero-harm workplace by enforcing uniform safety standards for employees and contractors, strengthening leadership accountability, promoting proactive hazard reporting, enhancing competency through continuous training and fostering a culture where safe behaviour is recognised, expected and consistently practiced

What emerging technologies and safety practices do you believe will have the greatest impact on risk prevention in cement manufacturing over the next decade?
Artificial intelligence, IoT-enabled monitoring, predictive analytics, digital twins, wearable safety devices, drones, robotics and advanced process automation will significantly enhance hazard detection, predictive maintenance, real-time risk management, and worker protection, enabling safer and more resilient cement manufacturing.
IoT-enabled monitoring is the use of interconnected sensors and smart devices to continuously collect, transmit and analyse real-time data from equipment, processes and the work environment. This enables early detection of unsafe conditions, equipment failures, or abnormal operating parameters, allowing timely intervention before incidents occur.
In cement manufacturing, IoT-enabled monitoring can be used for:
• Monitoring kiln, crusher, and mill temperatures, pressures, and vibrations.
• Detecting overheating of bearings and motors to prevent failures.
• Monitoring dust concentration, gas leaks (CO, SO2, NOx), and oxygen levels.
• Tracking conveyor belt alignment and condition.
• Monitoring structural health of silos and
storage facilities.
• Tracking worker location and exposure to hazardous environments using wearable devices.
• Providing real-time alerts and predictive maintenance recommendations.


Benefits:
• Early hazard detection
• Reduced equipment downtime
• Improved process safety and reliability
• Lower maintenance costs
• Enhanced regulatory compliance
• Better decision-making through real-time data and analytics
In simple terms, IoT-enabled monitoring transforms periodic manual inspections into continuous, real-time surveillance of plant safety and equipment health.

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