Concrete

Personal Protective Equipment

Published

10 months ago

August 11, 2025

admin

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.

Up Next

Our campaigns reinforce premiumisation

Don't Miss

We view safety as a core value

Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

Published

3 days ago

June 1, 2026

admin

The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.

Concrete

Burnpur Cement Reports Standalone Net Loss Of Rs 207.4 Million

Standalone net loss of Rs 207.4 mn in March 2026 quarter

Published

3 days ago

June 1, 2026

admin

Burnpur Cement reported a standalone net loss of Rs 207.4 million (Rs 207.4 million) for the quarter ended March 2026. The company said the loss reflects its financial performance for the period and will be reflected in its results filed with regulators. The announcement followed routine quarterly reporting by the listed cement manufacturer. Burnpur Cement is a cement manufacturer operating in India and serving construction markets, with operations spanning production, distribution and sales across the domestic construction sector.

The March 2026 quarter result marks a weakening in profitability for Burnpur Cement as market conditions in the sector remained challenging. The company attributed the outcome to operational and market factors, while outlining measures to manage costs and working capital. The reported standalone loss of Rs 207.4 million will be central to assessments by analysts and investors, which will be weighed alongside sector trends and company guidance. Management indicated continued focus on stabilising operations and optimising production efficiency.

No further numerical details were included in the initial summary, and consolidated figures were not disclosed in the brief notice, constraining immediate analysis of underlying drivers. The firm reiterated that it will provide comprehensive results and explanatory notes in its annual filing and investor communications. Analysts will assess the full disclosures when detailed financial statements become available. The timing of those detailed filings will determine how soon stakeholders can access full data.

Investors and stakeholders were advised to review the filings and the company’s releases for complete information, including cash flow and segmental performance, before drawing investment conclusions. The company’s operations and future guidance will determine recovery prospects in subsequent quarters. Regulatory disclosures and investor communications will guide market interpretation of the quarter and inform analyst forecasts. Burnpur Cement remains subject to the regulatory reporting process applicable to listed entities.

Concrete

Ramco Cements Campaign Wins Six Kyoorius Honours

Hard Worker campaign wins Grand Prix for Eco Plaster film

Published

6 days ago

May 29, 2026

admin

The Ramco Cements Limited’s Hard Worker campaign has achieved a major milestone at the prestigious Kyoorius Creative Awards, winning six honours including the coveted Grey Elephant Grand Prix for the Eco Plaster film. The awards were announced and presented at the Kyoorius Creative Awards Night 2026 held on 23rd May 2026 at the Jio World Convention Centre, Mumbai.

Competing alongside some of the country’s leading brands and agencies, the campaign received recognition across multiple creative categories, reaffirming the power of authentic storytelling rooted in the lives of hardworking people. The Eco Plaster commercial, which highlighted the importance of water conservation through innovative construction solutions, emerged as the campaign’s biggest winner, securing most of the honours.

The campaign’s wins include:
Grey Elephant (Grand Prix) – Eco Plaster
Blue Elephant – Best Film – Eco Plaster
Blue Elephant – Best Direction – Eco Plaster
Blue Elephant – Best Music – Eco Plaster
Baby Elephant – Best Direction -Tortoise & Hare
Baby Elephant – Best Use of Humour – Eco Plaster

Established in 2014, the Kyoorius Creative Awards recognise and celebrate creative excellence across India’s advertising, marketing and communications industries. Presented by Zee Entertainment Enterprises and powered by the USA-based The Clio Awards, the awards are regarded among the country’s most respected creative honours.

Known for their ethical and neutral judging process, the Kyoorius Creative Awards evaluate work purely on merit through a non-hierarchical awards structure, without Gold, Silver or Bronze distinctions. The iconic Elephant symbolises memorable work that leaves a lasting impact on the industry.

The Hard Worker campaign by The Ramco Cements Limited was conceived around the insight that true strength and progress are built through everyday hard work. Through emotionally resonant storytelling, distinctive craft and culturally rooted narratives, the campaign connected strongly with audiences across markets. The integrated campaign was rolled out across television, digital platforms, outdoor media and extensive on-ground activations, helping strengthen the brand’s connect with consumers, engineers, masons and trade communities alike.

Commenting on the achievement, A V Dharmakrishnan, CEO of Ramco Cements, said: “Winning at the Kyoorius Creative Awards is a proud moment for all of us. The Hard Worker campaign was created as a tribute to the spirit of hardworking people who form the backbone of our industry and our nation. These recognitions reaffirm our belief that authentic, meaningful storytelling has the power to create a deep and lasting connection with people.”

Balaji K Moorthy, Executive Director – Marketing, Ramco Cements, added: “The Hard Worker campaign was built on a simple but powerful insight – that hard work deserves recognition and respect. We wanted the communication to feel rooted, emotional and culturally relevant while also pushing creative boundaries. Winning six honours, including the Grey Elephant Grand Prix, is a tremendous validation of the idea, the craft and the collaborative effort of everyone involved in the campaign.”