Building Safety from the Ground Up

ICR explores how safety in the cement industry is evolving from a regulatory obligation to a strategic priority—driven by PPE compliance, digital tools, contractor management, and a safety-first mindset. Through a mix of technology, training, and behavioural change, Indian cement companies are laying the foundation for safer, more resilient workplaces.

The cement industry operates in one of the most high-risk industrial environments, where workers face extreme temperatures, high dust levels, heavy machinery, and hazardous materials. From quarrying to pyro-processing and dispatch, nearly every stage carries the potential for serious injury if not managed properly. According to the International Labour Organisation (ILO), over 2.3?million people die annually from work-related accidents or diseases worldwide, with cement manufacturing a notable contributor. In India, the Directorate General Factory Advice Service and Labour Institutes (DGFASLI) recorded over 3,000 industrial accidents in 2022, many linked to heavy-material industries like cement. Common plant hazards include mechanical failures, falls from height, electrical risks, chemical exposure, and fire or explosion threats. The Global Cement and Concrete Association (GCCA) reports that falls, machinery entanglement, and contractor-related incidents remain leading causes of fatalities globally.
Safety in cement is far more than compliance—it is a foundation of operational excellence, corporate responsibility, and worker dignity. Investment in safety equipment, training, and systems delivers measurable business value, from higher workforce retention to reduced downtime and stronger stakeholder trust. A 2021 International Finance Corporation (IFC) study found that companies with robust Environmental, Health, and Safety (EHS) frameworks had 10 to 15 per cent fewer shutdowns and up to 20 per cent higher productivity. In a capital-intensive sector with tight margins, a proactive safety culture is not a cost but a strategic asset.

Common hazards in cement manufacturing
Cement manufacturing is a complex, multi-stage process involving raw material extraction, grinding, pyroprocessing, cooling, and packaging—each phase bringing its own set of safety challenges. Workers in cement plants are routinely exposed to high levels of dust, heat, noise, mechanical hazards, heights, confined spaces, and chemical agents. For instance, dust from raw materials like limestone and clinker contains respirable crystalline silica, which can cause silicosis and other long-term respiratory issues if inhaled without proper protection. According to the Indian Council of Medical Research (ICMR), workers in dusty industrial environments are 3–5 times more likely to develop occupational lung diseases compared to other sectors.
Heat and noise exposure are especially acute in areas like kilns, clinker coolers, and grinding units, where operational temperatures can exceed 1400°C and ambient noise levels often surpass 90 decibels—well above the occupational exposure limits set by the Directorate General Factory Advice Service and Labour Institutes (DGFASLI). Extended exposure to such conditions without proper personal protective equipment (PPE) can lead to heatstroke, permanent hearing damage, and fatigue-induced errors, which increase the likelihood of accidents. A study published in the Journal of Occupational Health in 2022 noted that nearly 40 per cent of surveyed cement plant workers experienced early signs of noise-induced hearing loss, highlighting the urgent need for auditory protection and environmental noise control.
Raju Ramchandran, SVP and Head Manufacturing – Eastern Region, Nuvoco Vistas, says, “Cement manufacturing is an intense, high-temperature and operation-heavy process, where safety is paramount at every stage. Mining operations within the industry bring their own set of hazards, with strict adherence to Directorate General of Mines Safety (DGMS) guidelines being essential. Exposure to dust is another area of concern, necessitating advanced dust suppression systems and protective equipment to safeguard workers’ health. Electrical safety and proper energy isolation are also crucial, given the complexity of the equipment involved. At Nuvoco, we tackle these risks with a layered approach combining engineering controls, digital monitoring and rigorous safety protocols backed by continuous training and regular mock drills to ensure preparedness for any eventuality. Safety is an unwavering commitment to safeguarding everyone who works in and around our plants.”
Another major concern lies in working at heights, especially during equipment maintenance or installation of vertical structures such as preheaters and silos. Falls remain a leading cause of fatalities in the global cement industry, according to the Global Cement and Concrete Association (GCCA). In addition, confined spaces such as kilns, storage tanks, and maintenance tunnels pose serious risks due to restricted movement, poor ventilation, and the presence of toxic gases like CO2 or CO. Exposure to chemical hazards from fuel oils, lubricants, and additives like chromium compounds also calls for robust hazard communication and protective measures. The multifaceted nature of these risks underlines why safety in cement manufacturing must go beyond compliance—it requires a continuous commitment to hazard identification, mitigation, and a culture of proactive risk management.

Role of personal protective equipment
In the high-risk environment of cement manufacturing, Personal Protective Equipment (PPE) plays a frontline role in safeguarding workers from a wide range of occupational hazards. From exposure to high temperatures and airborne particulate matter to mechanical injuries and chemical contact, the need for comprehensive, head-to-toe protection is non-negotiable. Standard PPE in cement plants typically includes hard hats, earplugs, respirators, safety goggles, flame-resistant clothing, cut-resistant gloves, and safety shoes compliant with IS 15298 or EN ISO 20345 standards. According to the International Labour Organisation (ILO), proper use of PPE can reduce workplace injury and illness by up to 40 per cent, yet studies by India’s Directorate General Factory Advice Service and Labour Institutes (DGFASLI) reveal that lack of proper PPE usage or ill-fitting gear continues to be a common root cause in many reported incidents in industrial settings.
Anuj Kumar Mathur, Industry Expert and Retd. DGM – Safety, Health and Environment, Indian Oil Corporation, explains that the cement manufacturing process involves exposure to a wide range of occupational hazards including dust, noise, high temperatures, mechanical injuries and chemical exposure. The use of appropriate Personal Protective Equipment (PPE) is essential for safeguarding workers’ health and safety at every stage. PPE, however, serves as the last line of defence against occupational hazards in any industry. While engineering controls and administrative measures are essential, the proper selection, use, and maintenance of PPE can significantly reduce the risk of injury and illness.
Equally important is ensuring that PPE is not just available but also compliant with national and international safety norms. Indian Standards such as IS 2925 for helmets, IS 8519 for gloves, and IS 11226 for respiratory protection provide specific performance benchmarks tailored for heavy industries. In many leading cement plants, regular audits are now conducted to check PPE condition, fit, and user compliance. A recent report by the Global Cement and Concrete Association (GCCA) highlights that cement companies with strong PPE monitoring programs report significantly fewer recordable injuries per million man-hours. However, the challenge remains in ensuring contractor-level compliance, as outsourced workers often fall outside direct control systems. Bridging this gap through robust training, fit testing, and digital PPE tracking systems is becoming an industry best practice—and a critical component of building a truly safe and resilient cement workforce.

Fire safety in cement plants
Fire safety is a critical yet often underemphasised aspect of cement plant operations. The combination of high-temperature processes, combustible materials, heavy electrical loads, and complex machinery creates multiple ignition points across production and storage areas. Key fire risks in cement manufacturing include overheated bearings, short circuits, flammable oils and fuels, coal dust in mills, and welding or hot work activities during maintenance. According to a 2023 report by the National Fire Protection Association (NFPA), industrial fires caused an estimated $1.2 billion in direct property damage globally, with cement and mineral plants accounting for a significant share of incidents in developing economies. In India, several fire-related accidents in the cement sector have drawn attention to the urgent need for advanced fire suppression systems, periodic fire safety audits, and better-trained emergency response teams.
Priya Ajbani, Founder, Firescue, says, “High-risk industrial environments demand products that can perform under pressure literally and figuratively. In such cases, we focus on supplying robust, industrial-grade fire extinguishers, flexible sprinkler hose droppers that can be easily installed around tricky ductwork or high ceilings, and high-capacity hose reels with quality nozzles that ensure water pressure isn’t compromised. The key is to offer certified, tested equipment that meets international standards and lasts long despite heat, dust, and vibration- conditions that are typical in cement plants. At the end of the day, a good product doesn’t just save lives- it simplifies the fire safety process for the people who operate it on the ground.”
Modern fire safety in cement plants now goes beyond extinguishers and hose reels. Plants are increasingly deploying automatic fire detection and suppression systems, such as foam-based suppression in fuel storage areas, water mist systems for electrical rooms, and tube-based fire suppression for enclosed equipment like panels and conveyor belts. Fire audits, mandated under the Factories Act, 1948 and National Building Code (NBC), are conducted at regular intervals to assess readiness, check compliance, and recommend corrective actions. Additionally, leading cement manufacturers are investing in IoT-enabled hydrant systems and mobile-based emergency notification tools to improve incident response time. A 2022 study by the Indian Institute of Fire Engineers (IIFE) revealed that plants with digital fire safety systems experienced 35 per cent faster emergency response and 25 per cent lower downtime after fire-related events. As the sector moves toward more automated and sustainable operations, embedding robust fire safety frameworks remains a non-negotiable pillar for risk mitigation and operational resilience.

Automation and digital tools enhancing safety
As the cement industry embraces Industry 4.0, automation and digitalisation are playing a transformative role not only in improving operational efficiency but also in elevating workplace safety standards. Traditional safety practices are being augmented—and in many cases replaced—by intelligent systems such as Permit-to-Work (PTW) software, IoT-based monitoring, Behaviour-Based Safety (BBS) platforms, and real-time safety dashboards. These tools offer real-time visibility into safety compliance, worker behavior, equipment health, and hazardous conditions—enabling faster, more informed decision-making. According to a 2022 report by McKinsey & Company, industries implementing digital safety tools saw a 25 to 40 per cent reduction in recordable incidents, thanks to improved monitoring, predictive analytics, and timely intervention.
Ganesh W Jirkuntwar, Senior Executive Director and National Manufacturing Head, Dalmia Cement (Bharat), says, “At Dalmia, safety is embedded into daily work, not treated as a separate task. Integrating safety into day-to-day operations is critical to its sustainability. Every morning begins with structured toolbox talks mandatorily attended by all workforce and ‘Suraksha Vartalaps’, where teams collectively identify job-specific risks. Across units, daily safety reviews are held as part of the operations rhythm, with real-time data and feedback feeding directly into corrective actions.”
“Digital tools like the ‘KAVACH’ and ‘Boots on Ground’ platform allow supervisors to log observations, track unsafe conditions and monitor action closures with location-tagged evidence. The Permit to Work (PTW) system is fully digitised, ensuring consistent protocols and visibility for all critical jobs. These practices ensure safety is not a standalone agenda, but rather, an integral part of the operating DNA” he adds.
In the context of cement plants, these tools are particularly valuable given the scale, complexity, and inherent risks of operations. IoT sensors installed on kilns, conveyors, and high-risk zones can track temperature spikes, gas leaks, or unauthorised access to restricted areas. PTW systems ensure that only trained personnel perform critical tasks like confined space entry or hot work, reducing human error. Behaviour-Based Safety platforms use data analytics to identify unsafe acts and reinforce positive habits through coaching and alerts. Meanwhile, centralised safety dashboards provide plant managers with real-time alerts, compliance reports, and actionable insights—enabling them to proactively manage risk across multiple sites. A case study from Dalmia Cement revealed that the integration of mobile-based PTW and IoT-linked hydrant systems led to a 30 per cent improvement in emergency response time and a measurable drop in near-miss incidents. The message is clear: digital tools are no longer optional add-ons—they are now integral to building safer, smarter, and more accountable cement operations.

Training and behaviour-based safety
While equipment and protocols are essential, the foundation of any truly safe cement plant lies in the behaviour and preparedness of its workforce. Training and Behaviour-Based Safety (BBS) programs are now recognised as critical components in reducing accidents, empowering employees, and fostering a proactive safety culture. Cement plants are increasingly investing in structured skill development initiatives—ranging from Emergency Response Training (ERT) and safe equipment handling to hazard identification and near-miss reporting. According to the International Labour Organisation (ILO), nearly 80 per cent of workplace incidents globally are caused by unsafe behaviours rather than unsafe conditions—highlighting the need for consistent behavioural interventions alongside technical controls.
Sujeet Kumar Singh, Founder, HSESkillEdge, says, “Contractor and worker compliance for routine activities is effectively managed through a Contractor and Logistics Safety Management System, supported by rigorous training, on-the-job observations, and active worker engagement in risk assessments. This includes regular toolbox talks, safety skits during monthly safety gate meetings, and, most importantly, positive reinforcement through public recognition, praise for safe behaviours, and continuous feedback on observations related to at-risk behaviours or opportunities for improvement (OFIs).”
“The Indian cement industry has also taken a progressive step by initiating the development of a Safety Passport System for contractors, contract workers, and drivers. This initiative, in collaboration with the Global Cement and Concrete Association (India) and the National Safety Council of India, is highly practical and focuses on hand-holding and capacity building to ensure health and safety, especially in non-routine and high-risk jobs. I am truly grateful to be part of the core team driving this initiative, alongside corporate safety heads from all GCCA (India) member companies” he adds.
In the Indian cement sector, leading companies have adopted comprehensive BBS models that combine real-time observations, peer-to-peer feedback, coaching, and performance tracking. Training modules are also being digitised using 3D animations, e-learning platforms, and simulation-based safety drills to enhance retention and engagement. A 2023 report by the Global Cement and Concrete Association (GCCA) showed that plants with active BBS and workforce training programs reported 40 to 50 per cent fewer lost-time injuries (LTIs) than those relying only on physical safety systems. Furthermore, integrating behaviour-focused audits with standard operating procedures (SOPs) ensures that safety becomes second nature rather than a checklist. In essence, when safety becomes a mindset—nurtured through daily reinforcement and skill building—it transforms from a policy into a way of life on the shop floor.

Contractor safety management
In the cement industry, a significant portion of the workforce comprises contracted or third-party workers—particularly in operations such as maintenance, loading/unloading, material handling, and logistics. This creates a complex safety challenge, as contractors often operate outside the core company’s direct control systems, making it harder to enforce uniform safety protocols. In India, the Directorate General Factory Advice Service and Labour Institutes (DGFASLI) reported that nearly 40 per cent of serious industrial accidents in manufacturing units involved contract labour, largely due to inadequate training, lack of PPE compliance, and poor safety orientation. In cement plants, where high-risk environments are the norm, the lack of contractor safety governance can have severe and sometimes fatal consequences.
To address this, leading cement manufacturers have begun implementing structured Contractor Safety Management (CSM) programs that include prequalification audits, induction training, real-time safety tracking, and accountability frameworks. Some are also deploying digital ‘worker passport’ systems, which log training history, medical fitness, and access permissions for every contractor on site. The Global Cement and Concrete Association (GCCA) recommends integrating contractors into core Behaviour-Based Safety (BBS) programs, and ensuring they are part of regular tool-box talks, emergency drills, and incident investigations. In fact, a 2023 GCCA survey showed that cement plants with dedicated contractor safety governance reported 32 per cent fewer injuries among third-party workers compared to those without. Effective contractor safety isn’t just about regulatory compliance—it’s about aligning everyone on site with a common safety culture, where accountability and awareness are universal.

Conclusion
As the cement industry evolves to meet the demands of sustainability, scale, and operational excellence, the importance of a robust safety framework has never been greater. From managing high-risk environments and enforcing PPE compliance to leveraging automation, fire safety systems, and Behaviour-Based Safety (BBS) programs, the industry is steadily moving toward a culture where safety is not just enforced—but embedded. What’s clear is that safety must go beyond audits and checklists; it must become a continuous, organisation-wide commitment that includes not just full-time staff, but also contractors, suppliers, and every individual entering the plant gate.
The integration of digital tools, advanced training, and strict contractor safety management is not just about regulatory alignment—it is about building resilient operations that protect people, reduce downtime, and drive long-term value. With increasing awareness, global benchmarks, and support from industry bodies like the GCCA and CMA, Indian cement manufacturers are now well-positioned to lead by example. By putting “safety from the heart” into action—through technology, accountability, and culture—the industry can lay the foundation not just for stronger infrastructure, but for safer, smarter workplaces across the country.

– Kanika Mathur