Connect with us

Concrete

Personal Protective Equipment

Published

on

Shares

Anuj Kumar Mathur, Industry Expert and Retd. DGM – Safety, Health & Environment, Indian Oil Corporation, talks about the Personal Protective Equipment (PPE) and its various applications in Cement Industries.

Personal Protective Equipment (PPE) refers to specialised clothing or equipment worn by workers to protect themselves from health and safety hazards in the workplace. In fact, PPE acts as a barrier between the worker and potential risks, such as physical injuries, chemical exposures or respiratory hazards.
PPE 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.

Key purposes of PPE are:

  • Prevent injuries from accidents (e.g., falling objects, cuts, burns)
  • Protect against harmful substances (e.g., dust, fumes, chemicals)
  • Reduce the risk of long-term health issues (e.g., hearing loss, respiratory diseases)

The process of cement industry
The process starts with the extraction of raw materials such as limestone, clay, and other additives like iron ore and bauxite from quarries. These materials are then crushed into smaller sizes for easier processing. The crushed raw materials are ground into a fine powder in mills and are proportioned carefully. This mixture is called raw meal. Accurate blending ensures the quality of the final product. The raw meal is fed into a preheater tower and then into a rotary kiln. Here, it is subjected to very high temperatures (around 1450°C). This process causes the raw meal to undergo calcination, forming clinker, the intermediate product of cement. The hot clinker coming out of the kiln is rapidly cooled using air. This sudden cooling helps maintain the desired properties of the clinker. The cooled clinker is mixed with gypsum and other materials and ground into a fine powder in a cement mill. This fine powder is cement. The final product is stored in silos and then packed in bags or transported in bulk to distributors and construction sites.

Occupational hazards in cement industry
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 PPE is essential for safeguarding workers’ health and safety at every stage.

Let’s look at the various PPEs and their application areas in cement manufacturing process:

Head protection: To protect against falling objects, head injuries from overhead equipment and impacts during maintenance work.

PPE used: Industrial safety helmets (hard hats) with chin straps.

Application areas:

  • Quarrying and raw material handling (risk of falling rocks/debris)
  • Maintenance activities in high or elevated areas
  • Construction and structural work around kilns and mills

Eye and face protection: To guard against dust, flying particles, chemical splashes and radiant heat.
PPE used: Safety goggles (for dust and chemical protection) and face shields (for grinding, welding or high-temperature zones).

Application areas:

  • Crushing and grinding units (dust and particles)
  • Clinker cooling (heat and dust)
  • Chemical handling and cement packaging areas

Respiratory protection: To prevent inhalation of dust, silica particles and harmful gases, which can cause respiratory illnesses such as silicosis or chronic obstructive pulmonary disease (COPD).
PPE used: N95/N99 dust masks (for short-term, low-dust exposure), half- or full-face respirators with particulate filters (for high dust or gas exposure), and self-contained breathing apparatus (SCBA) for confined spaces or toxic environments.

Application areas:

  • Raw material grinding, clinker grinding
  • Kiln operations and maintenance (exposure to hot gases)
  • Cement bagging and despatch zones
  • Cleaning of silos or confined spaces

Hearing protection: To prevent hearing loss from prolonged exposure to high noise levels generated by crushers, mills and rotary kilns.

PPE used: Earplugs (disposable or reusable) and earmuffs (for high-noise environments).

Application areas:

  • Ball mills, crushers, fans and compressors
  • Packing and despatch sections
  • Any location where noise exceeds 85 dB(A)

Hand protection: To protect against mechanical injuries, chemical exposure and thermal burns.
PPE used: Cut-resistant gloves (handling sharp tools or materials), chemical-resistant gloves handling additives, fuels, lubricants) and heat-resistant gloves (working near kilns or clinker).

Application areas:

  • Maintenance and repair
  • Chemical dosing and laboratory work
  • Handling hot surfaces near kilns or clinker coolers

Foot protection: To prevent injuries from heavy objects, sharp materials, slips and chemical spills.
PPE used: Steel-toed safety boots with slip-resistant soles, rubber boots (for chemical or wet areas) and heat-resistant footwear (for kiln areas).

Application areas:

  • Quarry and crushing areas
  • Grinding, kiln and cooler zones
  • Cement packaging and warehouse

Body protection: To shield against chemical splashes, radiant heat, dust exposure and sharp edges.
PPE used: Coveralls or long-sleeved flame-retardant clothing, high-visibility vests for mobile equipment zones and chemical-resistant aprons (in labs or dosing areas).

Application areas:

  • Entire plant, especially dusty or hot zones
  • Maintenance tasks, welding and hot work
  • Quality control labs and chemical dosing

Fall protection: To prevent falls from heights during inspection, cleaning or maintenance.
PPE used: Full-body safety harness with lanyards, lifelines and fall arrest systems

Application areas:

  • Kiln maintenance, silo inspection and conveyor systems
  • Working on platforms, ladders or scaffoldings

Regular training for use of PPEs and audits
for use of PPEs should be conducted to ensure compliance and worker safety across all stages of cement production.

New-age safety monitoring tools
AI-enabled tools are transforming safety protocols in industries by turning passive protection into active prevention. These smart systems use AI-powered cameras and sensors to monitor workers in real time, instantly detecting missing gear, improper usage or unsafe proximity to hazardous zones.
Unlike traditional use of PPE, which relies solely on human compliance, AI-enhanced equipment adds an intelligent layer of oversight—alerting supervisors and workers the moment a potential risk is identified. This fosters a culture of continuous awareness. As the industry embraces digital transformation, AI-enabled safety monitoring gadgets are emerging as a crucial tools in the mission toward Zero Loss, blending technology with accountability to keep every shift safer.

PPE Matrix: PPE and its application areas

PPE Item Purpose / Protection Typical Application Areas in Cement Industry
Hard Hat (Safety Helmet) Head protection from falling debris and impacts Quarries, crushing units, conveyor systems, maintenance zones near mills and kilns
Safety Goggles / Glasses Eye protection from dust, particles, chemical splash Raw material handling, grinding areas, packaging, chemical dosing
Respirators / Dust Masks Protection from cement dust and silica exposure Grinding, clinker handling, kiln areas, silos, packing zones
Ear Protection (Earplugs/Earmuffs) Hearing conservation from loud machinery noise Crushers, ball mills, fans, conveyors
Gloves (Cut resistant / Chemical / Heat resistant) Protect against mechanical injury, chemical burns, heat Raw handling, maintenance, chemical dosing, kiln and cooler zones
Safety Boots (Steel toe, Slip resistant) Foot protection against falling objects, slips, chemical contact Quarry areas, material handling, storage, dispatch docks
High Visibility Clothing Ensures visibility around moving vehicles and machinery Logistics, dispatch zones, mobile equipment areas
Coveralls / Full Body Protection Protect against dust, cement burns, static discharge Clinker grinding, dust intensive zones, chemical labs, kiln maintenance

About the author:
Anuj Kumar Mathur is a result-driven professional with 36+ years of experience in the petroleum industry across India and Kuwait. He has successfully led fire and safety departments in two Indianoil refineries, demonstrating strong teamwork and managerial skills. He is well-versed in safety inspections, accident investigations and safety audits.

Concrete

FORNNAX Appoints Dieter Jerschl as Sales Partner for Central Europe

Published

on

By

Shares

FORNNAX TECHNOLOGY has appointed industry veteran Dieter Jerschl as its new sales partner in Germany to strengthen its presence across Central Europe. The partnership aims to accelerate the adoption of FORNNAX’s high-capacity, sustainable recycling solutions while building long-term regional capabilities.

FORNNAX TECHNOLOGY, one of the leading advanced recycling equipment manufacturers, has announced the appointment of a new sales partner in Germany as part of its strategic expansion into Central Europe. The company has entered into a collaborative agreement with Mr. Dieter Jerschl, a seasoned industry professional with over 20 years of experience in the shredding and recycling sector, to represent and promote FORNNAX’s solutions across key European markets.

Mr. Jerschl brings extensive expertise from his work with renowned companies such as BHS, Eldan, Vecoplan, and others. Over the course of his career, he has successfully led the deployment of both single machines and complete turnkey installations for a wide range of applications, including tyre recycling, cable recycling, municipal solid waste, e-waste, and industrial waste processing.

Speaking about the partnership, Mr. Jerschl said,
“I’ve known FORNNAX for over a decade and have followed their growth closely. What attracted me to this collaboration is their state-of-the-art & high-capacity technology, it is powerful, sustainable, and economically viable. There is great potential to introduce FORNNAX’s innovative systems to more markets across Europe, and I am excited to be part of that journey.”

The partnership will primarily focus on Central Europe, including Germany, Austria, and neighbouring countries, with the flexibility to extend the geographical scope based on project requirements and mutual agreement. The collaboration is structured to evolve over time, with performance-driven expansion and ongoing strategic discussions with FORNNAX’s management. The immediate priority is to build a strong project pipeline and enhance FORNNAX’s brand presence across the region.

FORNNAX’s portfolio of high-performance shredding and pre-processing solutions is well aligned with Europe’s growing demand for sustainable and efficient waste treatment technologies. By partnering with Mr. Jerschl—who brings deep market insight and established industry relationships—FORNNAX aims to accelerate adoption of its solutions and participate in upcoming recycling projects across the region.

As part of the partnership, Mr. Jerschl will also deliver value-added services, including equipment installation, maintenance, and spare parts support through a dedicated technical team. This local service capability is expected to ensure faster project execution, minimise downtime, and enhance overall customer experience.

Commenting on the long-term vision, Mr. Jerschl added,
“We are committed to increasing market awareness and establishing new reference projects across the region. My goal is not only to generate business but to lay the foundation for long-term growth. Ideally, we aim to establish a dedicated FORNNAX legal entity or operational site in Germany over the next five to ten years.”

For FORNNAX, this partnership aligns closely with its global strategy of expanding into key markets through strong regional representation. The company believes that local partnerships are critical for navigating complex market dynamics and delivering solutions tailored to region-specific waste management challenges.

“We see tremendous potential in the Central European market,” said Mr. Jignesh Kundaria, Director and CEO of FORNNAX.
“Partnering with someone as experienced and well-established as Mr. Jerschl gives us a strong foothold and allows us to better serve our customers. This marks a major milestone in our efforts to promote reliable, efficient and future-ready recycling solutions globally,” he added.

This collaboration further strengthens FORNNAX’s commitment to environmental stewardship, innovation, and sustainable waste management, supporting the transition toward a greener and more circular future.

 

Continue Reading

Concrete

Budget 2026–27 infra thrust and CCUS outlay to lift cement sector outlook

Published

on

By

Shares

Higher capex, city-led growth and CCUS funding improve demand visibility and decarbonisation prospects for cement

Mumbai

Cement manufacturers have welcomed the Union Budget 2026–27’s strong infrastructure thrust, with public capital expenditure increased to Rs 12.2 trillion, saying it reinforces infrastructure as the central engine of economic growth and strengthens medium-term prospects for the cement sector. In a statement, the Cement Manufacturers’ Association (CMA) has welcomed the Union budget 2026-27 for reinforcing the ambitions for the nation’s growth balancing the aspirations of the people through inclusivity inspired by the vision of Narendra Modi, Prime Minister of India, for a Viksit Bharat by 2047 and Atmanirbharta.

The budget underscores India’s steady economic trajectory over the past 12 years, marked by fiscal discipline, sustained growth and moderate inflation, and offers strong demand visibility for infrastructure linked sectors such as cement.

The Budget’s strong infrastructure push, with public capital expenditure rising from Rs 11.2 trillion in fiscal year 2025–26 to Rs 12.2 trillion in fiscal year 2026–27, recognises infrastructure as the primary anchor for economic growth creating positive prospects for the Indian cement industry and improving long term visibility for the cement sector. The emphasis on Tier 2 and Tier 3 cities with populations above 5 lakh and the creation of City Economic Regions (CERs) with an allocation of Rs 50 billion per CER over five years, should accelerate construction activity across housing, transport and urban services, supporting broad based cement consumption.

Logistics and connectivity measures announced in the budget are particularly significant for the cement industry. The announcement of new dedicated freight corridors, the operationalisation of 20 additional National Waterways over the next five years, the launch of the Coastal Cargo Promotion Scheme to raise the modal share of waterways and coastal shipping from 6 per cent to 12 per cent by 2047, and the development of ship repair ecosystems should enhance multimodal freight efficiency, reduce logistics costs and improve the sector’s carbon footprint. The announcement of seven high speed rail corridors as growth corridors can be expected to further stimulate regional development and construction demand.

Commenting on the budget, Parth Jindal, President, Cement Manufacturers’ Association (CMA), said, “As India advances towards a Viksit Bharat, the three kartavya articulated in the Union Budget provide a clear context for the Nation’s growth and aspirations, combining economic momentum with capacity building and inclusive progress. The Cement Manufacturers’ Association (CMA) appreciates the Union Budget 2026-27 for the continued emphasis on manufacturing competitiveness, urban development and infrastructure modernisation, supported by over 350 reforms spanning GST simplification, labour codes, quality control rationalisation and coordinated deregulation with States. These reforms, alongside the Budget’s focus on Youth Power and domestic manufacturing capacity under Atmanirbharta, stand to strengthen the investment environment for capital intensive sectors such as Cement. The Union Budget 2026-27 reflects the Government’s focus on infrastructure led development emerging as a structural pillar of India’s growth strategy.”

He added, “The Rs 200 billion CCUS outlay for various sectors, including Cement, fundamentally alters the decarbonisation landscape for India’s emissions intensive industries. CCUS is a significant enabler for large scale decarbonisation of industries such as Cement and this intervention directly addresses the technology and cost requirements of the Cement sector in context. The Cement Industry, fully aligned with the Government of India’s Net Zero commitment by 2070, views this support as critical to enabling the adoption and scale up of CCUS technologies while continuing to meet the Country’s long term infrastructure needs.”

Dr Raghavpat Singhania, Vice President, CMA, said, “The government’s sustained infrastructure push supports employment, regional development and stronger local supply chains. Cement manufacturing clusters act as economic anchors across regions, generating livelihoods in construction, logistics and allied sectors. The budget’s focus on inclusive growth, execution and system level enablers creates a supportive environment for responsible and efficient expansion offering opportunities for economic growth and lending momentum to the cement sector. The increase in public capex to Rs 12.2 trillion, the focus on Tier 2 and Tier 3 cities, and the creation of City Economic Regions stand to strengthen the growth of the cement sector. We welcome the budget’s emphasis on tourism, cultural and social infrastructure, which should broaden construction activity across regions. Investments in tourism facilities, heritage and Buddhist circuits, regional connectivity in Purvodaya and North Eastern States, and the strengthening of emergency and trauma care infrastructure in district hospitals reinforce the cement sector’s role in enabling inclusive growth.”

CMA also noted the Government’s continued commitment to fiscal discipline, with the fiscal deficit estimated at 4.3 per cent of GDP in FY27, reinforcing macroeconomic stability and investor confidence.

Continue Reading

Concrete

Steel: Shielded or Strengthened?

CW explores the impact of pro-steel policies on construction and infrastructure and identifies gaps that need to be addressed.

Published

on

By

Shares

Going forward, domestic steel mills are targeting capacity expansion
of nearly 40 per cent through till FY31, adding 80-85 mt, translating
into an investment pipeline of $ 45-50 billion. So, Jhunjhunwala points
out that continuing the safeguard duty will be vital to prevent a surge
in imports and protect domestic prices from external shocks. While in
FY26, the industry operating profit per tonne is expected to hold at
around $ 108, similar to last year, the industry’s earnings must
meaningfully improve from hereon to sustain large-scale investments.
Else, domestic mills could experience a significant spike in industry
leverage levels over the medium term, increasing their vulnerability to
external macroeconomic shocks.(~$ 60/tonne) over the past one month,
compressing the import parity discount to ~$ 23-25/tonne from previous
highs of ~$ 70-90/tonne, adds Jhunjhunwala. With this, he says, “the
industry can expect high resistance to further steel price increases.”

Domestic HRC prices have increased by ~Rs 5,000/tonne
“Aggressive
capacity additions (~15 mt commissioned in FY25, with 5 mt more by
FY26) have created a supply overhang, temporarily outpacing demand
growth of ~11-12 mt,” he says…

To read the full article Click Here

Continue Reading

Trending News

SUBSCRIBE TO THE NEWSLETTER

 

Don't miss out on valuable insights and opportunities to connect with like minded professionals.

 


    This will close in 0 seconds