Concrete

Safety first!

Published

5 years ago

July 1, 2021

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Confined spaces include, but are not limited to, tanks, vessels, silos, storage bins, hoppers, pre heater tower, kiln platform, cooler ducts, quarry locations, vaults, pits, manholes, tunnels, equipment housings, ductwork, pipelines, etc.

A confined space is an area that is large enough to bodily enter and perform work, has limited means of entry or exit and is not intended for continuous occupancy. All three of these criteria must apply for an area to be classified as a confined space. Confined spaces are characterized by poor ventilation and have the potential for having a hazardous atmosphere. The configuration of a confined space may restrict rescue efforts and can often result in the injury or death of poorly prepared or trained rescuers. Based on the safety audit and past incidences it is possible to identify confined spaces in every plant and it is necessary for the plant management to have a list of such locations.

Most Common Hazards

The main hazard when working in a confined space is the atmosphere due to the presence of carbon monoxide, hydrogen sulfide, and methane gas that may result in oxygen deficiency or asphyxiation. Outside the confined space, 21 percent Oxygen is necessary to sustain life. Oxygen in confined spaces tends to go low. It might be used for rust, bacterial growth, and slime. Other gas may enter the confined space and displace the oxygen. Operations like heating will consume oxygen.

If oxygen is reduced to 12 to 16 percent, workers will increase pulse and respiration and experience loss of coordination. If the oxygen decreases to 6 to 10 percent, they will experience nausea, vomiting, loss of consciousness, and even death.

Other common confined space hazards include unguarded machinery, exposed live wires, and heat stress. Confined space accidents are a major concern in various industries due to their hazards. Confined space training; outlines the skills and protocols for safe entry to confined spaces which includes hazards, risks and precautions. Confined spaces include, but are not limited to, tanks, vessels, silos, storage bins, hoppers, pre heater tower, kiln platform, cooler ducts, quarry locations, vaults, pits, manholes, tunnels, equipment housings, ductwork, pipelines, etc. Work in confined space can kill or cause injuries in any industries, ranging from those involving complex area to simple storage. They includes not only people working in the confined space, but also for the managers, supervisors and other personal associated with confined space, who are without adequate training.

Monitor the Atmosphere

Atmospheric monitoring is the first and most critical rule, as most fatalities in confined spaces are the result of atmospheric problems. Remember, your nose is not a gas detector ??some hazards have characteristic odors and others do not. Even when you can detect the presence of a hazard, you cannot determine the extent of that hazard. Some materials may even deaden your sense of smell after short exposure, which can deceive you into thinking the problem has gone away, when in fact your ability to smell it is all that went away.

The only reliable method for accurate detection of atmospheric problems is instrument monitoring. Basic confined space atmospheric monitoring should routinely include oxygen concentration and flammable gases and vapors. OSHA regulations require the oxygen concentration to be between 19.5 and 23.5 percent and flammable vapors or gases to be below

10 percent of the lower explosive limit (LEL).

But regulatory limits provide only minimal protection. Best practices dictate that any variation from normal (20.9 percent oxygen and 0 percent LEL) should be investigated and corrected prior to entering the space.

Toxic monitoring requires an evaluation of potential atmospheric contaminants before you even determine how the monitoring will be performed. Simply put, this means you must establish what you need to look for in order to determine what equipment to use. The following digital instruments are available for common toxic contaminants:

Electrochemical sensors measure carbon monoxide, hydrogen sulfide, sulfur dioxide, ammonia, chlorine, and several other materials.Infrared sensors measure carbon dioxide and several other materials.

Photo ionization and flame ionisation detectors will measure volatile organic compounds (VOCs) at the parts per million (ppm) level. This may be required if solvent vapors are present. These vapors will exceed the limits for inhalation long before they will be detected with most LEL meters. Colorimetric tubes can be used to determine if a toxic contaminant is present in situations where no digital instrument is available.A thorough assessment of the atmospheric conditions in the space must be completed before entering the space, and should be continued during the entire entry.

Eliminate or Control Hazards

All hazards identified during the hazard assessment must be eliminated or controlled prior to entering the space.Elimination, the preferred method for dealing with hazards, means that a hazard has been handled in a way that it cannot possibly have an impact on the operation. For example, a properly installed blank eliminates the hazard of material being introduced through a pipe.

Ventilate the Space

Your approach to atmospheric problems should be to correct the condition prior to entry, and ventilation and related activities are the best options for correcting these problems.Forced-air ventilation is generally the most effective approach for confined space entry operations. This technique dilutes and displaces the atmospheric contaminants in the space. Exhaust ventilation works best when a single-point source, such as welding, is the cause of the atmospheric contaminant.

Introduced air must be fresh. Use caution to avoid introducing hazards such as having the inlet of the ventilation setup too near the exhaust of a vehicle. Sufficient volume for the size of the space must be used. The length of duct and the number of bends in the duct can significantly reduce airflow and must be considered.

Use Proper Personal Protective Equipment

Proper personal protective equipment (PPE) should be the last line of defense. Elimination and control of hazards should be done whenever possible. PPE is essential when the hazards present cannot be eliminated or controlled through other means. PPE that meets the specific hazard must be readily available to the work crew. And personnel must be trained and competent in the proper use of the equipment. It is equally important that supervisors insist on proper use.

Isolate the Space

Isolation of the space should eliminate the opportunity for introducing additional hazards through external connections. This includes lockout of all powered devices associated with the space, such as electrical, pneumatic, hydraulic, and gaseous agent fire control systems. Piping isolation may be completed with blanks, by disconnecting piping, or with a double block-and-bleed arrangement. A single valve is not adequate isolation.

Know the Attendant?? Role

An outside attendant must be present to monitor the safety of the entry operation, to help during an emergency, and to call for assistance from outside if that becomes necessary. The attendant?? role is primarily to help ensure that problems do not escalate to the point where rescue is needed. If an entrant does get injured or overcome, the attendant is to call for help and use external retrieval if available. This attendant must never enter the space during emergencies ??multiple fatality incidents in confined spaces usually result from people attempting rescue.

Be Prepared for Rescues

Any equipment required for rescue must be available to those who are designated to use it. External retrieval equipment that may be used by the attendant must be in place when appropriate. More advanced rescue equipment for entry-type rescues must be available to the designated rescue crew.You must ensure that the rescue crew is properly equipped to handle rescue for the particular situation. For example, if the rescue crew for your facility has self-contained breathing apparatus (SCBA) and your spaces do not have large enough openings for the SCBA to pass through, the rescue crew will not be able to perform effectively. In this case, they should be equipped with airline breathing apparatus with escape cylinders.

Use Good Lighting

Lighting is important for two primary reasons: You cannot safely perform in environments where you cannot see adequately, and lighting failure can cause fear. Anyone who is uncomfortable inside a well-lit confined space may become afraid if the lighting fails, and fear can cause people to behave irrationally and injure themselves or others.The entrant should always have at least one backup source of lighting, so if cord lights are used, the entrant should also carry a flashlight.

Plan for Emergencies

You must assume you will have emergencies. While your efforts to prevent them need to be constant, odds are good that you will have to deal with at least a minor emergency if you engage in confined space entry over a long enough period.Emergencies may not even have anything to do with the confined space, but if the entrant is in the space at the time of the emergency, prompt and effective action is required. If your entry crew is prepared for this emergency, it may be handled without a problem. If preparationsare not adequate, the emergency may easily turn into a fatal incident.

Emphasize Constant Communication

Effective communications are critical to safe operation and are the string that ties all the other activities together. Communication must be maintained between entrants and the attendant. The attendant must also be able to contact the entry supervisor and call for emergency help.None of these steps is complex or difficult, but they still provide the layout for a basic, safe approach to confined space entry. Be aware that the next time you read about a confined space fatality, at least one of these general rules was probably violated. And do your best to ensure that I won?? ever read about one of your entries.

Contractors

Health and Safety regulations apply equally to Contractors and their employees working onsite; contracts with Contractors should specify the rights and duties of each party in this respect. The contracted party?? ability to work safely should be a major selection criterion.Health and safety shall be effectively managed on work sites. This shall include where appropriate suitable, regular safety audits of the work undertaken by the contractor.Contractors are actively assisted/ supported in safety matters. It will be ideal to rate the contractor on safety parameters and these safety records are taken into account before awarding any new work. Poor safety performance shall not be tolerated and to result in early termination.

Training

The training on safety should be top driven so that it will have wide acceptance and importance. Proper record of safety training should be maintained with HR department and to be taken into account before promotion. Safety training of new recruits, temporary workmen, and casual employees is as important as that of normal employees.

Communication

Communication is an important factor of the safety initiative. This shall include information on the site?? safety plan, provide feedback on performance and actions taken,learning points to prevent injuries. It encourages a free flow of information.

– VIKAS DAMlE

Concrete

ABB Extends Drive Lifespan at ACC Cement Plant Without Production Shutdown

Published

4 hours ago

November 12, 2026

admin

ABB reconditions 25 drives at ACC’s Jamul cement plant, avoiding 16 tonnes of CO₂ emissions while improving reliability through predictive maintenance.
Chhattisgarh

ABB has signed a multi-year Motion OneCare service agreement with ACC Limited, part of the Adani Group, to modernise ageing industrial drives at its Jamul cement plant in Chhattisgarh, improving operational reliability while avoiding approximately 16 tonnes of carbon dioxide (CO₂) emissions without disrupting production.

Announced on 27 October 2026, the agreement combines scheduled drive reconditioning, digital condition monitoring and energy appraisals to extend equipment lifespan, improve plant uptime and optimise maintenance costs. The initiative marks a shift from conventional equipment replacement towards a more resource-efficient approach to industrial asset management.

The first phase, completed in April 2026, involved the on-site reconditioning of 25 ABB ACS800 variable speed drives without a major plant shutdown. By retaining the existing cabinets and restoring the drive modules rather than replacing entire panels, ABB helped ACC preserve capital investment, minimise material consumption and avoid approximately 16 tonnes of CO₂ emissions.

A second phase, covering an additional 25 ACS800 drive modules, is scheduled for the fourth quarter of 2026. The programme is designed to improve long-term equipment reliability while allowing maintenance activities to be aligned with the plant’s operational schedules.

The ACS800 drives, installed at Jamul in 2010, had delivered more than a decade of near-continuous service in demanding cement manufacturing conditions. However, ageing electrical components and changing fault patterns had begun to affect their ability to meet the plant’s reliability requirements.

Rather than opting for complete equipment replacement, ACC engaged ABB’s certified engineers to conduct a comprehensive asset health assessment. The evaluation found that the existing cabinets and enclosures remained structurally sound, making targeted reconditioning a technically viable and cost-effective alternative to full replacement.

Drawing on nearly two decades of experience with ACC’s equipment and operating requirements, ABB developed a maintenance framework tailored to the plant’s shutdown windows, budget cycles and production priorities.

The Motion OneCare agreement incorporates planned equipment restoration, condition-based monitoring and energy assessments, enabling ACC to adopt a more systematic approach to maintaining critical electrical infrastructure.

As part of the programme, ACC has implemented ABB Ability™ Digital Powertrain Insights to monitor drive performance and identify emerging operational issues before they result in equipment failures.

The digital platform provides continuous visibility into parameters such as temperature, current, vibration and fault patterns. These insights allow maintenance teams to detect early signs of equipment deterioration, schedule interventions more effectively and reduce the likelihood of unexpected downtime.

Amit Gupta, Local Division Manager, Motion Services, ABB India, said: “We know what unchecked wear costs over time: a small inefficiency that eats away at ROI for years. At Jamul, the evidence pointed clearly to assets with productive life still in them.”

“Our job was to restore them properly and give the team the tools to stay ahead of the next problem. At ABB, we don’t just fix what fails. We want to protect what works.”

The initiative also demonstrates the growing relevance of circular economy principles in cement manufacturing, where extending the service life of existing industrial equipment can reduce capital expenditure, material consumption and the environmental impact associated with manufacturing replacement components.

According to ABB, drive reconditioning can reduce lifecycle emissions by 50 to 80 per cent compared with complete equipment replacement. By preserving functional components and restoring critical modules, the process helps retain the economic and material value of existing industrial assets.

The addition of energy appraisals in subsequent phases will further expand the programme beyond equipment restoration, enabling ACC to assess drive performance, identify energy-saving opportunities and improve operating efficiency.

For cement manufacturers, variable speed drives play an important role in controlling motors and optimising energy consumption across production processes. Maintaining their reliability and efficiency is essential for minimising operational disruptions and managing electricity costs.

Vinod Bahety, CEO – Cement Business, Adani Group, said: “Moving from reactive firefighting to a structured maintenance plan was exactly what this operation needed. That kind of peace of mind doesn’t come easily. It comes from a partner that understands how your business runs.”

“We didn’t need a full system overhaul; we needed expert support, actionable insights, and a plan we could execute around our schedule. That’s what we got.”

The project supports ACC’s broader strategy to improve manufacturing efficiency through digital transformation, preventive maintenance and sustainable asset management.

ACC, a subsidiary of Ambuja Cements and part of the Adani Group, operates 20 cement manufacturing facilities and 119 ready-mix concrete plants across India. The company has been advancing initiatives focused on renewable energy, circular economy practices and technology-driven operational improvements.

Alongside Ambuja Cements, ACC is part of a large-scale building materials business committed to achieving net-zero emissions by 2050, with near-term and net-zero targets validated by the Science Based Targets initiative (SBTi).

The Jamul initiative aligns with these sustainability objectives by demonstrating how equipment life extension and digital monitoring can contribute to resource efficiency without requiring large-scale replacement of existing infrastructure.

ABB, a global technology company specialising in electrification and automation, brings more than 140 years of industrial expertise and employs approximately 110,000 people worldwide. Its Motion Services business supports industrial customers through equipment maintenance, modernisation, digital monitoring and lifecycle management solutions.

The agreement also reflects a wider shift in industrial maintenance practices, with manufacturers increasingly adopting predictive technologies to improve equipment availability, manage costs and reduce unplanned shutdowns.

With 25 drives already reconditioned and another 25 scheduled for restoration, ABB’s collaboration with ACC illustrates how targeted modernisation, digital monitoring and circular maintenance practices can extend the operational life of critical equipment while supporting more efficient and sustainable cement production.

Concrete

ABB Drives Digital Transformation at TCI MAX Cement Plant in J&K

Published

5 hours ago

November 12, 2026

admin

ABB deploys advanced process control at TCI MAX’s Srinagar cement plant to improve clinker quality, energy efficiency and sustainable manufacturing.

Kashmir

ABB has deployed its advanced process control technology at TCI MAX Cement’s Srinagar facility in Jammu and Kashmir, marking the region’s first reported implementation of advanced process control (APC) in cement manufacturing and strengthening efforts towards more efficient, digitally enabled production.

Announced on 5 November 2026, the deployment of ABB Ability™ Expert Optimizer at the facility, operated by Trumboo Industries Pvt. Ltd., aims to improve process stability, clinker quality, energy efficiency and overall plant productivity. The implementation forms part of TCI MAX’s strategy to modernise its manufacturing operations through automation and digital technologies.

Following the integration of ABB’s advanced process control solution and supporting IT infrastructure, TCI MAX has reported improvements in operational productivity, product quality and sustainability-related performance indicators. The technology focuses on optimising the cement pyro process, a critical stage of production involving high-temperature processing and clinker formation.

Waseem Ahmed Trumboo, Director, Trumboo Industries Pvt. Ltd., said: “Introducing advanced process control at TCI MAX is an important step in how we are evolving our operations. Our focus is on improving the stability and efficiency of our processes while maintaining consistent clinker quality. We have been encouraged by the performance of the solution during commissioning and by the support from the ABB team, and we look forward to realizing its full potential.”

ABB Ability™ Expert Optimizer combines advanced process control, model predictive control (MPC) and artificial intelligence (AI) to continuously monitor and optimise manufacturing operations. By analysing process conditions, predicting operational behaviour and automatically adjusting key parameters, the system enables more consistent production while reducing process variability.

In cement manufacturing, maintaining stable pyro-processing conditions is essential for achieving uniform clinker quality and optimising thermal energy consumption. Fluctuations in operating parameters can affect fuel efficiency, production output and product consistency.

The deployment is designed to address these challenges through real-time process optimisation, helping operators maintain more stable kiln operations while improving the utilisation of fuel, electricity and raw materials.

Kapil Agarwal, Senior Vice President and Local Division Manager, Process Industries Division, ABB India, said: “Cement producers are increasingly looking to adopt digital technologies to achieve greater consistency and efficiency while addressing their sustainability priorities. ABB Ability™ Expert Optimizer brings advanced process control and deep cement process expertise together to help operators make their processes more stable and efficient. We are pleased to support TCI MAX as it takes this important step in its digital transformation.”

The technology also supports sustainability objectives by optimising fuel consumption, improving electrical energy efficiency and minimising process waste. More stable operations can contribute to lower energy intensity and reduced emissions associated with cement production.

For TCI MAX, the investment represents a move towards data-driven manufacturing, where automated control systems complement operator expertise to improve production performance and operational reliability.

The implementation is particularly significant for Jammu and Kashmir’s cement industry, as it introduces advanced process optimisation technology to a regional manufacturing facility. Its deployment could demonstrate the potential for wider adoption of digital automation across cement plants seeking to modernise their operations.

The project builds on ABB’s experience in delivering advanced process control solutions to cement manufacturers worldwide. Through the integration of industrial automation, predictive technologies and process engineering expertise, the company supports manufacturers in improving resource efficiency and maintaining consistent production quality.

As cement producers face increasing pressure to manage energy costs, improve productivity and reduce their environmental footprint, technologies such as AI-enabled process control and predictive optimisation are becoming important components of plant modernisation strategies.

ABB’s Expert Optimizer provides a platform for addressing these priorities by enabling automated adjustments based on changing process conditions, reducing reliance on manual intervention and supporting more efficient plant operation.

ABB, a global technology company specialising in electrification and automation, has more than 140 years of industrial experience and approximately 110,000 employees worldwide. Its Automation business employs around 26,000 people and provides technologies and services across process, hybrid and maritime industries.

The TCI MAX deployment reinforces ABB’s growing role in the digital transformation of cement manufacturing in India, where improving process efficiency and reducing energy consumption remain critical to the industry’s long-term sustainability.

With the advanced process control system now implemented at its Srinagar facility, TCI MAX aims to build on the initial operational improvements and further optimise production efficiency, clinker consistency and environmental performance.

Concrete

Ramco Cements’ Hard Worker Wins Eight Awards at ‘Love of Advertising Awards 2026’

Published

5 hours ago

November 12, 2026

admin

Ramco Cements’ Hard Worker brand wins eight awards for excellence in advertising, packaging and brand identity at the Love of Advertising Awards 2026.

Hyderabad

The Ramco Cements Limited’s construction chemicals brand, Hard Worker, has secured eight awards at the Love of Advertising Awards 2026, recognising its creative excellence across television, digital advertising, packaging design and brand identity.

Organised by the Advertising Club of Trivandrum, the awards were presented at a ceremony held at The Leela Raviz, Kovalam, on 24 October 2026. The recognition highlights Hard Worker’s integrated marketing strategy and its efforts to establish a distinctive presence in India’s competitive construction chemicals market.

The eight awards span multiple creative categories, reflecting the brand’s approach to combining product-focused communication with engaging storytelling, humour and innovative design. Through its campaigns, Hard Worker has sought to simplify technical product benefits and make construction chemicals more accessible and relatable to consumers and construction professionals.

Built around the philosophy of “Hard-working products for hardworking people”, the brand focuses on communicating practical product advantages through memorable advertising narratives while maintaining a consistent identity across different marketing platforms.

Its campaigns for Ramco Hard Worker Eco Plaster and Tile Fix have been central to this approach. The Eco Plaster campaign highlights water conservation through the product’s self-curing properties, positioning it as a solution that supports more efficient construction practices. Meanwhile, Tile Fix promotes specialised tile-fixing solutions by presenting their practical benefits through relatable situations and creative storytelling.

Beyond advertising, Hard Worker has invested in distinctive packaging and brand identity development to improve product recognition and maintain consistency across customer touchpoints. This integrated approach has helped the brand differentiate itself in a category where marketing communication has traditionally focused on technical specifications and functional performance.

A V Dharmakrishnan, CEO, Ramco Cements, said, “Winning eight awards at the Love of Advertising Awards is a proud moment for Ramco Cements and the Hard Worker team. We believe that building a strong brand requires not only quality products but also the ability to communicate their value in a compelling and differentiated manner. Hard Worker’s journey reflects our commitment to combining product performance with innovative marketing to create meaningful connections with our customers and strengthen our presence in the construction chemicals market.”

The recognition comes as building materials manufacturers increasingly focus on brand differentiation, product awareness and customer engagement to strengthen their position in the construction chemicals segment.

By using humour and storytelling to explain product applications and benefits, Hard Worker aims to bridge the communication gap between technical construction solutions and the practical requirements of contractors, applicators and end-users.

Balaji K. Moorthy, Executive Director – Marketing, Ramco Cements, said, “Hard Worker was conceived to bring a fresh perspective to the construction chemicals category, where product communication has traditionally been functional and technical. Our endeavour has been to break through the clutter with distinctive ideas, humour and storytelling, while keeping the product proposition at the heart of every campaign. The recognition across TV and digital advertising, packaging design and brand identity design demonstrates our integrated approach to building the brand. These eight awards are an encouraging recognition of the creative thinking and collaborative effort behind Hard Worker’s marketing initiatives.”

The awards add to Hard Worker’s growing portfolio of creative recognitions and reinforce Ramco Cements’ emphasis on integrating product innovation with strategic marketing.

The brand’s communication initiatives also reflect a wider shift in the construction materials industry, where manufacturers are increasingly adopting consumer-focused marketing strategies to improve product understanding and strengthen relationships with construction professionals.

With its portfolio of construction chemicals, Hard Worker aims to address evolving requirements for durability, application efficiency and construction quality. Its marketing efforts seek to complement these product attributes by building stronger awareness and encouraging the adoption of specialised construction solutions.

Ramco Cements, one of India’s established cement manufacturers, operates across cement and allied building solutions. Through Hard Worker, the company is expanding its presence in the construction chemicals segment with products designed to enhance performance, quality and durability in modern construction applications.

The latest recognition strengthens Hard Worker’s brand visibility and underscores the growing importance of creative communication in promoting technical building materials. Ramco Cements intends to continue combining product development with distinctive marketing initiatives to support the brand’s growth in India’s construction chemicals market.