Concrete

Personal Protective Equipment

Published

11 months ago

August 11, 2025

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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.

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Concrete

Nuvoco commissions Surat grinding unit

Nuvoco posts 20 per cent rise in Q1 PAT

Published

2 hours ago

July 14, 2026

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Nuvoco Vistas Corp. has announced its financial results for the quarter ended June 30, 2026, reporting growth in volumes, earnings and profitability while advancing its expansion plans in western India.

The company inaugurated a 2-million-tonnes-per-annum (MTPA) grinding unit at its Limla Cement Plant in Surat on July 11, 2026, ahead of schedule. The facility, part of the Vadraj Cement assets, is expected to strengthen Nuvoco’s presence in western India while freeing up capacity at its Rajasthan plants to cater to demand in northern markets.

Progress at the Kutch project remains on track, with phased commissioning scheduled to begin in the third quarter of FY27. The company has also commenced work on a bulk cement terminal at Viramgam, Sachana, Gujarat, featuring a dedicated railway siding. The terminal is expected to become operational by the second quarter of FY28 and will support distribution across Gujarat. These projects form part of Nuvoco’s capacity expansion programme, which is expected to increase its total cement capacity to 35 MTPA by FY28.

During Q1 FY27, the company recorded cement sales volumes of 5.3 million tonnes, up 5 per cent year-on-year. Consolidated total income rose 9 per cent to Rs 31.29 billion, while EBITDA increased 7 per cent to Rs 5.72 billion, marking the company’s highest-ever first-quarter EBITDA. Profit after tax grew 20 per cent year-on-year to Rs 1.60 billion.

Commenting on the results, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp., said the company delivered improved business performance despite macroeconomic and geopolitical challenges. He attributed the results to disciplined execution, cost optimisation and operational efficiencies, while highlighting the early commissioning of the Surat grinding unit as a key milestone in the company’s expansion strategy.

He added that the company remains focused on prudent procurement, supply chain efficiency and cost discipline while monitoring geopolitical developments that could affect industry supply chains and input costs.

Concrete

Cement Sector Faces Sluggish Growth in First Half of FY27

April Price Hikes Unlikely To Offset Margin Decline

Published

1 day ago

July 13, 2026

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Nuvama Institutional Equities has warned that India’s cement industry is expected to record subdued volume growth in the first half of fiscal year 2026-27 before a recovery in the second half. The brokerage assessed that price increases implemented in April 2026 will be insufficient to offset an overall decline in sector profitability. It attributed the outlook to weak demand and fresh capacity additions scheduled during fiscal years 2026-27 and 2027-28 that are likely to keep prices under pressure.

The report noted that demand was sluggish in April and May 2026 owing to global uncertainty, labour shortages, heatwaves, constraints in raw materials and unseasonal rainfall. Producers raised prices across regions in April to mitigate rising petcoke costs and higher packaging expenses, but the increases proved short lived. Nuvama reported that standard petcoke prices rose to USD153/t, around USD41/t higher than in the third quarter of fiscal year 2025-26.

Price correction followed weaker demand, limiting the net increase to about Rs 10-12 per bag by the end of the quarter. Imported petcoke prices have since fallen to USD132/t from a recent peak of USD168/t, although they remained roughly USD20/t higher quarter on quarter. The brokerage expected the higher input cost impact to begin reflecting from late quarter one of FY27 and to continue into early quarter two.

Nuvama also estimated that crude linked increases were likely to raise packaging costs by about Rs 120-150/t and to exert upward pressure on freight. It warned that soft demand combined with significant new supply coming on stream in FY27-28 would keep pricing under strain and constrain near term margin recovery. The report concluded that volume growth was likely to be sluggish in the first half of FY27 before recovering in the second half.

Concrete

Nuvoco Vistas launches Limla cement plant, expands Gujarat footprint

Published

1 day ago

July 13, 2026

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Nuvoco Vistas opens a 2 MMTPA grinding unit at Limla, entering Gujarat and advancing its target of 35 MMTPA capacity by FY 2028.

Surat (Gujarat)

Nuvoco Vistas Corporation Ltd, a part of Nirma Group and one of India’s leading building materials company, has inaugurated the Limla Cement Plant in Surat (Gujarat), one of Vadraj Cement Limited’s (VCL) principal manufacturing facilities. The commissioning represents a key milestone in Nuvoco’s acquisition and restoration of VCL, while supporting the company’s expansion across the Western Indian cement market.

Vadraj Cement Limited is a subsidiary of Nuvoco Vistas Corporation Limited and has installed cement capacity of 6 MMTPA across its assets. The Limla inauguration therefore represents the first operational step in the acquired platform’s wider revival, while the Kutch facilities provide clinker supply, mineral security and coastal logistics support for the western business.

Nuvoco completed its acquisition of Vadraj Cement Limited, then under the Corporate Insolvency Resolution Process, after paying a consideration of Rs 1,800 crore in June 2025. VCL’s asset portfolio comprises a clinker unit at Kutch and a grinding unit at Limla in Surat. It also includes high-quality captive limestone reserves and a captive jetty at Kutch, supporting more efficient logistics. Following the takeover, Nuvoco began an extensive programme of restoration, refurbishment and expansion at both locations, leading to the commissioning of the Limla plant.

The Limla Cement Plant is expected to support a phased increase in sales volumes across Gujarat. It will also help Nuvoco supply neighbouring markets in Western Maharashtra and release cement capacity from its northern plants, which can consequently be redirected towards markets in North India. The plant will manufacture a full portfolio comprising Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. It will additionally produce the complete Nuvoco Duraguard range, including the premium Nuvoco Duraguard Microfibre product. The acquisition is also expected to generate operational synergies with Nuvoco’s existing plants at Nimbol and Chittorgarh in Rajasthan, improving logistics optimisation and market reach across important regional markets.

The grinding unit at the Limla Cement Plant was completed ahead of schedule, with 2 MMTPA of capacity now inaugurated to expand Nuvoco’s operating scale and customer reach. After Vadraj Cement’s assets become fully operational, plants in North and West India are expected to account for nearly 40 per cent of Nuvoco’s total cement capacity. This will broaden the company’s manufacturing network, strengthen access to high-growth markets and support its plan to increase consolidated cement capacity to 35 MMTPA by FY 2028, reinforcing its longer-term growth strategy.

Commenting on the development, Jayakumar Krishnaswamy, Managing Director, Nuvoco Vistas Corp Ltd, said: “The inauguration of the Limla Grinding Unit in Surat is an important milestone in Nuvoco’s growth journey and demonstrates our commitment to disciplined, value-accretive expansion. Gujarat is strategically significant for Nuvoco, with substantial opportunities arising from infrastructure investment, industrial growth, rapid urbanisation and continuing demand from the housing and construction sectors. The facility strengthens our regional footprint, improves operational flexibility and increases our ability to serve customers across northern and western markets with greater reliability and efficiency.”

He added: “Through the Vadraj acquisition, we have refurbished and restarted a strategically important asset, returning it to operations in record time through strong execution and collaboration between teams. The achievement demonstrates our ability to create value from acquired assets, fulfil our commitments and retain the confidence of stakeholders. It also highlights the strength of our project delivery capabilities and our continued focus on building sustainable, profitable growth over the long term.”

Nuvoco Vistas Corporation Limited is a building materials company whose vision is to build a safer, smarter and more sustainable world. It is among the leading players in East India and has a significant presence across North and West India. Nuvoco began operations in 2014 with a greenfield cement plant at Nimbol, Rajasthan. It later acquired Lafarge India Limited, which had entered India in 1999, followed by Emami Cement Limited in 2020 and Vadraj Cement Limited in April 2025. The company has also announced an expansion in eastern India through a new grinding mill at the Arasmeta Cement Plant, supported by several debottlenecking programmes involving equipment upgrades, process improvements and internal capacity initiatives. These developments place Nuvoco on track to achieve total cement capacity of approximately 35 MMTPA. The company reported total income of Rs 11,362 crore in FY 2025-26, reflecting its continuing growth trajectory.

Nuvoco operates a diversified portfolio across three segments: Cement, Ready-Mix Concrete and Modern Building Materials. Its cement portfolio includes Concreto, Duraguard, Double Bull, PSC, Nirmax and Infracem, covering Ordinary Portland Cement, Portland Slag Cement, Portland Pozzolana Cement and Portland Composite Cement. Its pan-India RMX business provides value-added products under Concreto for performance concrete, Artiste for decorative concrete, InstaMix for ready-to-use bagged concrete, X-Con covering M20 to M60 grades, and Ecodure for specialised green concrete. Nuvoco has supplied materials to projects including the Mumbai-Ahmedabad Bullet Train, Birsa Munda Hockey Stadium in Rourkela, Aquatic Gallery at Science City in Ahmedabad, and metro railway projects in Delhi, Jaipur, Noida and Mumbai.