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.
Indian Cement Review (ICR) and Fuller Technologies brought industry, policy and technology leaders together to discuss how cement innovation can drive green construction at scale, writes Rakesh Rao.
India is building at a pace few countries can match. Highways, airports, housing, logistics parks, industrial corridors and urban infrastructure are reshaping the country’s economic geography. But beneath this growth story lies a difficult question: can India continue to build at scale without locking itself into a high-carbon future?
That question formed the core of an online panel discussion titled “Driving Green Construction Through Cement Innovation”, organised by Indian Cement Review (ICR) in association with Fuller Technologies as the Presenting Partner on June 25, 2026. The webinar brought together experts from cement technology, R&D, global industry platforms, building performance policy and international development cooperation to examine how low-carbon cement and material innovation can accelerate India’s green construction transition.
The discussion came at a crucial time. India has committed to achieving net-zero emissions by 2070 and reducing the carbon intensity of its economy by 45 per cent by 2030. At the same time, the country’s construction sector is expanding rapidly, driven by urbanisation, infrastructure development, housing demand and industrial growth. Cement, as one of the most widely used construction materials, sits at the heart of this transition. It is indispensable to development, but also central to the challenge of reducing embodied carbon in buildings and infrastructure.
Moderated by Nitika Krishan, Senior Urban Infrastructure and Sustainable Policy Consultant, the panel featured:
Dr Hemantkumar Aiyer, VP and Head R&D, Nuvoco Vistas Corp Ltd;
Devika Wattal, Innovation Lead, Global Cement and Concrete Association (GCCA);
Dr Sunita Purushottam, MD, GBPN India (Global Buildings Performance Network); and
Vaibhav Rathi, Senior Technical Advisor, GIZ (the German Agency for International Cooperation)
Setting the tone for the discussion, Nitika Krishan underlined the scale of the challenge before the sector. “The question before us is no longer whether we build, but how we build sustainably,” she said. She pointed out that construction accounts for nearly 40 per cent of global energy-related carbon emissions when both operational and embodied carbon are considered. Cement production, she added, remains one of the hardest industrial processes to decarbonise.
For India, this is not merely an environmental issue. It is a development issue, a competitiveness issue and increasingly, a market issue. As one of the world’s largest cement producers and among the fastest-growing construction markets, India’s material choices will influence the carbon trajectory of its built environment for decades. As Krishan observed, sustainability solutions in economies such as India must not remain limited to laboratory success. They must be scalable, commercially viable and practical at national level.
The innovation gap: From technology to market
Experts believe that there is a need to bridge the innovation gaps for making decarbonisation in cement and concrete scalable. Devika Wattal of GCCA, explained, “The starting point must be the core cement manufacturing process itself. The first and foremost is the heart of our process, the heart of cement manufacturing. How do we reduce clinker? That is always a topic where industry is working very intrinsically.”
Clinker reduction remains one of the most important pathways for lowering emissions in cement. Since clinker production is energy-intensive and chemically emits carbon dioxide, reducing the clinker factor through supplementary cementitious materials (SCMs), blended cements and new chemistries can have a significant impact. Wattal also noted that carbon capture, utilisation and storage (CCUS) will have a role, though it may not be the first lever for all markets.
However, she stressed that innovation cannot stop at technology development. A solution that works in the lab must also be adaptable to industry, scalable in production and acceptable in construction practice. “It is important for that innovation to be adaptable, to be scalable, and so that it can be executed in real time,” she said.
Wattal also called for stronger enabling systems around innovation. These include performance-based standards, product-level embodied carbon databases and clearer frameworks for evaluating green materials. Without these, low-carbon cement products may struggle to compete with conventional materials in procurement and design.
R&D must balance carbon, cost and performance
Bringing in the R&D perspective into the discussion, Dr Hemantkumar Aiyer of Nuvoco Vistas emphasised that low-carbon cement development cannot be treated as a single-variable exercise. Cement must perform in real construction conditions. It must deliver strength, durability, consistency and cost competitiveness, while also reducing carbon.
“The root of understanding and balancing all these aspects lies in materials, and knowing the materials,” he said.
According to Dr Aiyer, R&D teams must understand the variability of raw materials such as fly ash, slag and clinker. Different sources produce different material behaviours. This makes mix optimisation, material characterisation and processing-property relationships critical. When performance is affected, cement manufacturers must understand how strength enhancers, admixtures and other performance chemicals interact with the material system.
He also linked material science with process efficiency. Clinkerisation takes place at extremely high temperatures, around 1,400 to 1,450 degrees Celsius. Any improvement in raw mix design, process control or energy optimisation can, therefore, help reduce emissions and cost. Dr Aiyer pointed to artificial intelligence-based optimisation, Cement 4.0 tools and advanced software as important enablers for real-time process and material control.
“The more you understand the materials, the more you can control it,” he said.
LC3: The promise is proven, the sequencing is not
Limestone calcined clay cement, commonly referred to as LC3, has attracted global attention because it can reduce clinker content significantly by using calcined clay and limestone while maintaining performance in many applications. Kiranmai Sanagavarapu of Fuller Technologies said the technology itself has already moved beyond proof of concept. Fuller Technologies has worked with calcined clay technology for nearly two decades and has seen plants running in France and Ghana. These plants, she said, are meeting local and national specifications, while the economics are beginning to make sense.
“The calciner is performing, the economics is stacking up, it is making business sense to produce,” she said.
But if the technology is viable, why has adoption not scaled faster? For Sanagavarapu, the answer lies in project sequencing. Too often, clay characterisation happens after equipment is specified. This, she warned, is a backward approach because calciner design depends on clay mineralogy, kaolinite content, iron levels, reactivity, moisture and other variables.
“If you don’t know what your deposit looks like before you commit for the equipment, you are, in a way, going blind into designing,” she said.
She also identified permitting and plant integration as major bottlenecks. Environmental clearances, mining permissions and local regulatory approvals must begin early. Similarly, calcined clay must be integrated into existing grinding, blending and logistics systems from the design stage, not treated as an afterthought during commissioning.
India already has IS 18189:2023 standard for LC3, but Sanagavarapu pointed out that the standard is not yet visible enough in procurement documents. “The gap between what is technically being permitted and what the procurement is asking is the single biggest bottleneck,” she said.
In her view, successful scale-up depends on getting the sequence right: clay characterisation first, permitting in parallel, standards aligned with construction, and integration built into plant design.
India’s LC3 journey: Progress, but demand remains thin
Providing details of India’s LC3 commercialisation experience, Vaibhav Rathi of GIZ noted that JK Cement carried out the first commercial production of LC3 at its Rajasthan plant, followed by JK Lakshmi Cement three months later. These initiatives were supported by the International Climate Initiative of the Government of Germany, with IIT Delhi contributing deep institutional knowledge on LC3 research and BIS certification.
Rathi said India’s early experience has produced clear lessons. One of the biggest was the need to build capacity among regulators. While BIS certification existed, State Pollution Control Boards were unfamiliar with the technology and unsure about the approval pathway.
“The capacity building is not just needed amongst the producer and the users of the cement, but also the regulators who are working with this technology for the first time,” he said.
He also highlighted the need for better information on China clay deposits. Since China clay is currently classified as a minor mineral, centralised data on availability, quality and location is limited. If cement manufacturers are to adopt LC3 at scale, stronger mineral intelligence will be important.
The third issue is demand. LC3 has already been used in projects such as Palava City in Mumbai and Noida International Airport, but these remain limited examples. “It is in a chicken and egg situation,” Rathi said. “Cement companies are saying we need more demand, and users are saying there is not enough cement available.”
Public procurement, he suggested, could help break this cycle. If agencies such as CPWD and other public bodies begin testing, accepting and specifying LC3, it could create the market confidence needed for cement companies to invest in production and storage.
Building codes must catch up with innovation
Dr Sunita Purushottam of GBPN India argued that material choices will determine built environment emissions over the long term, but India’s current policy signals remain fragmented. Although LC3 has received BIS recognition, she pointed out that building codes, municipal bylaws, schedules of rates and sustainability codes do not yet provide uniform guidance on low-carbon cement.
“The current cement regulations are largely prescriptive and favouring traditional materials,” she said. This limits the ability of alternative materials to compete on performance, durability and emissions.
Dr Purushottam also raised the issue of taxation. Cement, including LC3, currently falls under the same GST bracket as conventional cement. A differentiated tax structure, she argued, could help accelerate market adoption. “In order for the market to demand LC3, that differentiation in the GST could go a long way,” she said.
She noted that green building certifications such as IGBC and GRIHA are already creating demand for low-carbon materials by assigning points for embodied carbon and sustainable material use. However, she said large-scale adoption will require regulatory mandates, particularly through building codes and state-level notifications.
She also cautioned that low-carbon cement alone does not solve the entire building performance problem. A material may reduce embodied carbon, but the operational carbon of a building depends on thermal performance, design, insulation and energy use. “The energy part has two elements,” she said. “One is the embodied carbon of the material itself, and the other is the operational carbon.”
Collaboration is the bridge between invention and impact
Wattal said GCCA sees innovation as a strategic priority and works through platforms that connect industry with academia and start-ups. “There is no way we will decarbonise our sector without innovation,” she said.
However, she stressed that research must be connected to actual industry challenges. Innovations developed in isolation may fail when they encounter real-world barriers such as raw material variability, plant integration, cost, standards and finance. Start-ups, too, need industry mentorship and scale-up pathways.
Wattal also flagged the importance of finance. Even strong technologies may struggle to attract investment if there is no common understanding of bankability. “We have always put projects into, is this a bankable project? But the definition of a bankable project has never been defined,” she said.
For India, she saw strong potential in its academic and start-up ecosystem, but said the challenge lies in alignment and prioritisation. The country has the research base, industrial capacity and market size. What it now needs is a coordinated route from innovation to deployment.
There is a practical concern for cement manufacturers: how can existing plants be adapted for lower emissions without compromising reliability or commercial viability?
Kiranmai Sanagavarapu addressed, “The reliability risk in calcined clay retrofit is definitely real, but it is almost always self-inflicted. The risk arises when a new process is added to an existing circuit without properly redesigning grinding and blending configurations.”
Existing cement plants, she explained, can take two broad routes. The first is external sourcing of calcined clay combined with mill optimisation. This requires lower capital investment and can potentially move in 12 to 18 months if other conditions are in place. It may reduce emissions by around 20 to 30 per cent. The second route is integrated calcination on site, which requires higher capital expenditure and longer lead times, but provides greater control over quality, supply and emissions reduction potential.
For Sanagavarapu, the principle is simple: low-carbon retrofits must be designed with intent. “Design it with an intent properly from the start. Start in the market conditions where the economics are already working,” she said.
Circularity: The overlooked advantage
According to Vaibhav Rathi, fly ash and slag are already well established in cement and construction (C&D), but construction and demolition waste remains underutilised. “C&D waste is a growing business opportunity which not many have taken up,” he said. India’s continuous construction and demolition activity creates huge volumes of waste, much of which contributes to air pollution, land degradation and material inefficiency. With the right processing and standards, this waste can be converted into useful construction products.
Rathi also pointed out that LC3 has a circular economy dimension that is often overlooked. It can use low-grade kaolin-rich clay left behind after high-grade clay is extracted for other applications. “LC3 is not only a low-carbon solution, but also a circular economy solution,” he said.
At the same time, he cautioned that LC3 in India is not yet cheap because it has not reached scale. Site-specific techno-commercial feasibility studies, supported jointly by development agencies and industry, could help companies assess whether LC3 production makes technical and financial sense at a given location.
Dr Purushottam added that India must address both low-carbon cement and construction waste together. “Both low-carbon cement and C&D waste go hand in hand. India does not have an option but to work on both,” she said.
Dr Aiyer called for policy shifts from both government and industry, including preferential purchasing of sustainable materials, minimum supplementary cementitious material requirements in public and public-private projects, and faster regulatory implementation. “If we can fast-track the regulatory standards and their implementation on the ground, that is the way to go,” he said.
From green ambition to green construction
Cement innovation is no longer only about chemistry. It is about systems. Low-carbon cement will scale only when technology, standards, procurement, finance, regulation, education and construction practice move together.
LC3 and other low-carbon technologies have shown promise. India has early commercial examples, strong research capability and growing market interest. But mainstream adoption will depend on whether demand can be created, regulators can be capacitated, standards can be embedded in procurement, and manufacturers can see a clear business case.
For a country building at India’s scale, the opportunity is enormous. Cement will continue to be central to infrastructure and urban development. The challenge now is to ensure that the cement used in India’s growth story carries a lower carbon burden.
Rakesh Rao
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Specialised rail logistics will move fly ash from power plants to infrastructure industries.
New Delhi
Indian Railways is planning a large-scale green logistics initiative to transport fly ash from thermal power plants to industries where it can be reused in infrastructure and construction activities.
The initiative was discussed during a review meeting chaired by Union Minister for Railways Ashwini Vaishnaw. Union Ministers of State for Railways V Somanna and Ravneet Singh Bittu were also present.
India generates nearly 340 million tonnes of fly ash every year from thermal power plants. The proposed initiative aims to create an efficient rail-based transport system using specialised containers and dedicated logistics arrangements to move fly ash safely from power plants to end-use industries.
Fly ash is widely used in road construction, cement manufacturing, brick production, concrete, blocks and boards. By improving its movement through the railway network, the initiative is expected to support better utilisation of this industrial by-product while reducing environmental concerns linked to storage and disposal.
The move also aligns with India’s circular economy goals by converting waste from thermal power generation into a useful raw material for the construction and infrastructure sectors. Wider availability of fly ash can help reduce material costs in areas such as bricks and cement, supporting more affordable infrastructure and housing development.
Through this initiative, Indian Railways aims to provide a cleaner, safer and more organised transport solution for fly ash, turning an environmental challenge into an infrastructure resource.
Gears, drives, and motors have evolved from essential mechanical components into strategic enablers of reliability, efficiency, and sustainability in modern cement plants. ICR explores how advanced motion technologies, predictive maintenance, digitalisation, and intelligent drive systems are helping cement manufacturers reduce downtime, optimise energy use, and build future-ready operations.
As the Indian cement industry prepares for another phase of capacity expansion, the focus is shifting from merely increasing production volumes to improving operational efficiency, reliability, and sustainability. According to industry estimates, India is expected to add nearly 160–170 million tonnes of cement capacity between FY26 and FY28, driven by infrastructure investments, urbanisation, and housing demand. In this environment, gears, drives, and motors have emerged as critical enablers of productivity, forming the backbone of every major process from raw material extraction and grinding to clinker production and cement dispatch. Motors alone account for nearly 60 per cent to 70 per cent of industrial electricity consumption globally, according to the International Energy Agency (IEA), while rotating equipment failures remain among the leading causes of unplanned downtime across heavy industries. In cement plants, where equipment operates under high loads, extreme dust conditions, elevated temperatures, and continuous-duty cycles, the performance of gears, drives, and motors directly influences energy consumption, maintenance costs, plant availability, and overall profitability. As digitalisation and Industry 4.0 technologies gain momentum, these systems are evolving from passive mechanical components into intelligent assets capable of delivering real-time operational insights.
Why gears, drives, and motors are the backbone of cement plant operations Every major process in a cement plant depends on the seamless operation of gears, drives, and motors. Raw mills, vertical roller mills, crushers, kiln drives, conveyor systems, fans, and clinker coolers all rely on rotating equipment to maintain continuous production. A failure in any one of these systems can disrupt entire process chains, highlighting their strategic importance. Modern cement plants process thousands of tonnes of material daily, requiring equipment capable of transmitting enormous torque while maintaining precision and reliability. Kiln drives and grinding systems, in particular, operate under some of the highest mechanical loads found in industrial manufacturing. The ability of gears and motors to withstand these conditions directly impacts plant throughput and production stability. Satish Maheshwari, Chief Manufacturing Officer, Shree Cement says, “Effective lubrication management remains one of the most critical factors in extending the lifespan of cement plant drive systems. Proper lubrication, supported by regular oil analysis, vibration diagnostics, and condition monitoring, helps minimise wear, prevent unexpected failures, and maintain the integrity of critical components such as gearboxes, motors, and drive assemblies. By identifying potential issues at an early stage, plants can move from reactive maintenance to a more proactive and reliability-focused approach.” “Smart motors, intelligent drives, and next-generation gearboxes are set to redefine cement plant maintenance and performance. Equipped with embedded sensors, IoT connectivity, digital twins, and AI-driven diagnostics, these technologies enable real-time condition monitoring, predictive maintenance, and seamless digital integration. As the industry embraces Industry 4.0, smart drive systems will play a pivotal role in improving energy efficiency, reducing downtime, and optimising asset performance across the cement manufacturing value chain” he adds. Industry studies suggest that rotating equipment accounts for a significant proportion of maintenance expenditure in process industries. Effective design, selection, and maintenance of gears, drives, and motors therefore have a direct influence on asset utilisation, operational efficiency, and total cost of ownership.
The cost of downtime: reliability challenges in rotating equipment Unplanned downtime remains one of the most expensive challenges facing cement manufacturers. Industry estimates indicate that a major failure involving a critical gearbox, kiln drive, or grinding mill can result in production losses running into lakhs of rupees per hour, depending on plant capacity and operating conditions. Sanjeev Arora, President – Motion Business & IEC LV Motors Division, ABB India says, “One of the most significant shifts taking place in industrial decision-making today is moving away from evaluating equipment based solely on upfront capital cost toward understanding total cost of ownership (TCO). In a typical motor system, the purchase price often represents only a small fraction of the total lifecycle cost however energy consumption, maintenance requirements, downtime and operating efficiency account for the vast majority of long-term operational expenses. For cement manufacturers operating in highly competitive markets, this distinction is critical.” “A high efficiency motor paired with an appropriately configured variable speed drive may require a higher initial investment, but the long-term benefits are substantial. Reduced electricity consumption, lower maintenance needs, longer service intervals and improved process stability can deliver faster payback and stronger profitability over time” he adds. Cement plants present a particularly challenging environment for rotating equipment. Dust ingress, thermal fluctuations, shock loads, vibration, shaft misalignment, and lubrication contamination contribute significantly to equipment degradation. Studies by SKF indicate that nearly 50 per cent of bearing failures are linked to lubrication issues and contamination, while improper alignment and vibration-related problems remain leading causes of gearbox and motor failures.
Energy-efficient motors and drives: unlocking operational savings Energy is one of the largest operating expenses for cement manufacturers, often accounting for 25 per cent to 35 per cent of total production costs. Grinding operations alone can consume nearly 60 per cent to 70 per cent of a plant’s electrical energy, making energy-efficient motors and drives a strategic investment. According to the International Energy Agency, high-efficiency motors combined with Variable Frequency Drives (VFDs) can reduce energy consumption by 20 per cent to 30 per cent in suitable applications. By matching motor speed and torque to actual process requirements, VFDs minimise unnecessary power consumption while reducing mechanical stress on equipment, improving both efficiency and reliability.
Advances in gearbox design and power transmission technologies Modern gearbox technology has evolved significantly in response to the increasing demands of cement manufacturing. Advanced materials, case-hardened gears, optimised tooth profiles, improved surface finishing, and enhanced lubrication systems are helping reduce friction, wear, and thermal loading. Girish Hanchate, Director – Industrial Market, India SKF India (Industrial) says, “Smart diagnostics are significantly improving the lifecycle of gears, motors, and other rotating equipment by enabling a shift from reactive maintenance to condition-based asset management. Hidden issues such as vibration anomalies, bearing defects, misalignment, and temperature fluctuations can quietly reduce plant throughput by 10 per cent to 20 per cent while increasing energy consumption long before a breakdown occurs. By leveraging advanced sensors, predictive analytics, machine learning, and real-time monitoring of vibration, temperature, and motor current, cement manufacturers can detect developing faults early, optimise maintenance schedules, and prevent costly secondary damage. This not only improves reliability but also supports energy efficiency and sustainability objectives.” “The next major evolution in drive and bearing technology lies in the development of fully integrated smart mechanical ecosystems that combine high-performance bearings, advanced lubrication management, and digital intelligence. Sensor-enabled condition monitoring embedded directly within bearings and drive systems allows operators to capture critical operational data at the source, enabling predictive maintenance and real-time performance optimisation. Innovations such as SKF’s VA9A1 Spherical Roller Bearing series, engineered specifically for demanding cement applications such as crushers and kilns, demonstrate this trend. By increasing internal bearing space and optimising lubricant flow, these designs improve grease retention, reduce wear, minimise downtime, and create more resilient, energy-efficient rotating equipment systems for the future of cement manufacturing” he adds. Manufacturers are increasingly focusing on compact, high-torque gearbox designs capable of delivering higher power density while maintaining service life. Innovations such as condition-monitored gear systems, improved sealing technologies, and modular gearbox architectures are simplifying maintenance while enhancing operational reliability.
Predictive maintenance, condition monitoring, and asset health management The shift from reactive to predictive maintenance is transforming asset management across the cement industry. Technologies such as vibration monitoring, thermography, oil analysis, ultrasound testing, and motor current signature analysis are enabling operators to identify potential failures before they occur. Research by Deloitte suggests that predictive maintenance can reduce breakdowns by up to 70 per cent and lower maintenance costs by 25 per cent. In cement plants, where shutdown windows are limited and equipment operates continuously, predictive maintenance offers a powerful tool for improving reliability and extending asset life. Digitalisation, industry 4.0, and the rise of intelligent drive systems Industry 4.0 technologies are redefining the role of gears, drives, and motors. Smart sensors embedded within motors, bearings, and gear systems can continuously monitor temperature, vibration, load, lubrication condition, and energy consumption. Girish Hanchate says, “As the industry embraces automation, sustainability, and digital transformation, the importance of intelligent motion technologies will continue to grow. The convergence of advanced engineering, predictive maintenance, and Industry 4.0 solutions is creating a new generation of cement plants where reliability, efficiency, and sustainability work together to deliver long-term value. For cement manufacturers navigating increasing production demands and environmental expectations, investing in smarter gears, drives, and motors is no longer optional—it is a business imperative.” Cloud-based monitoring platforms and Industrial Internet of Things (IIoT) architectures enable maintenance teams to access equipment health data remotely, improving visibility across geographically dispersed operations. Advanced analytics and artificial intelligence are further enhancing fault detection capabilities, enabling more accurate maintenance planning. The emergence of digital twins represents another significant development. By creating virtual replicas of physical assets, operators can simulate operating conditions, predict failures, optimise maintenance schedules, and improve lifecycle management decisions. These technologies are helping transform rotating equipment into intelligent assets that actively contribute to operational decision-making.
Building future-ready cement plants through smart motion technologies The future of cement manufacturing will depend heavily on the ability to integrate mechanical reliability with digital intelligence. Smart motion technologies combine high-efficiency motors, intelligent drives, condition monitoring systems, and automation platforms to create more responsive and efficient operations. Sustainability goals are also accelerating investment in advanced motion technologies. Reduced energy consumption, improved equipment efficiency, and extended asset life contribute directly to lower carbon emissions and reduced resource consumption. These benefits align closely with the industry’s decarbonisation objectives. As capacity expansions continue across India, future-ready cement plants will increasingly prioritise reliability, flexibility, and data-driven decision-making. Organisations that successfully integrate smart motion technologies into their operations will be better positioned to reduce costs, improve productivity, and maintain a competitive advantage in a rapidly evolving market.
Conclusion Gears, drives, and motors are no longer viewed solely as mechanical components; they have become strategic assets that influence every aspect of cement plant performance. Their reliability affects production continuity, their efficiency impacts operating costs, and their digital capabilities increasingly shape maintenance and operational strategies.
