Solutions for Cement Industry

Best Safety Solution for Cement Industry

Overview of Work Health and Safety in Cement Production Plants

Like other heavy industries, cement production includes large manufacturing plants with numerous complex processes.  The complexity of everyday operations causes many safety risks to arise in all production stages including mining raw materials at the quarry, grinding at the crusher, heating at the cement kilns and ovens for clinker production, cooling in cyclone towers, grinding and mixing the clinker in cement mills, storage in silos and tankers, transportation of the material across the facilities through the conveyor belt, packaging and filling cement mixer trucks.

With both open and enclosed areas to cover, safety in cement plants is traditionally hard to control and monitor. Risk elements in cement production plants include accidents involving slips and falls, chemical exposure, loss of control of equipment and lack of preparation for emergency situations

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çimento sektörü için çözümler pandemi güvenliği - pandemic safety in cement industry

Pandemic Safety

Many production stages of cement happen in small, confined spaces such as silos where workers must carry out their tasks in close proximity to each other where airborne transmissions easily occur. It is difficult to monitor social distance compliance without having personnel present and monitoring each worker at all times. It is also challenging to keep track of all contacts for filiation when there is a positive case identified within the workforce.

Safe Steps Pandemic Safety module digitalizes social distancing and contact tracing processes with BLE-powered wearable devices ergonomically designed to be used in every stage of the production process. By measuring proximity between devices and warning users when safe distance is breached, Safe Steps aims to empower workers to keep themselves and others safe from the risk of transmission. Devices also record all risky interactions, which can be viewed from the management panel by relevant personnel.

Lone Worker Safety

Cement production facilities area collection of open and enclosed spaces dispersed over a large area. Daily tasks such as fixing and maintenance of equipment and different stages in the production require workers to move across the facilities, many times without their colleagues. Due to the nature of cement production, there are also many incidents that may require lone workers to ask for assistance such as falling from rotary kilns, mills, cyclone towers and other heights. Lone workers may also need assistance in enclosed areas that are difficult to observe remotely such as silos and warehouses.

Safe Steps Lone Worker Safety module allows management to monitor the safety of lone workers wherever they are. The devices include an easy to reach panic button to be used to ask for assistance and to activate RTLS to locate the employee in need immediately. The device is also capable of automatically alerting the management panel in no movement situations or falls to make sure relevant personnel is alerted when the worker is unable to do so.

çimento sektörü için güvenlik çözümleri yalnız çalışan güvenliği - lone worker safety in cement industry
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Preparation for Facility-Wide Emergency Scenarios

Emergency preparedness is particularly important for cement production plants for many reasons. The large size of the area creates difficulties in locating and evacuating all workers in time. There are also many hazardous materials being used during the production process, which can cause incidents such as fires, explosions and chemical leaks that require a full evacuation.

Safe Steps Lone Worker module helps with evacuation situations by allowing WHS personnel and other relevant departments to monitor the process remotely through the management panel or the mobile application for more flexibility. All preestablished zones and the employees in them can be observed from a single screen on the panel to ensure all workers are evacuating and reaching the safe zone.

Safe Steps mobile application and platform aims to help businesses digitally transform their operations and rapidly adapt to the current conditions as the world emerges from lockdown and employees go back to work

Collision Avoidance

Cement production and transportation activities require the usage of large mobile vehicles such as bulk cement trucks, forklifts, AGVs and lifting equipment which may cause collisions or other vehicle-related accidents. These accidents are not only common, but can have a high risk of fatality, making it a very important safety issue to address.

 Safe Steps Proximity Warning and Collision Avoidance system uses the same IoT infrastructure to leverage connectivity for vehicle safety. The system prevents vehicle-to-vehicle and vehicle-to-pedestrian collisions by providing location awareness to workers and mobile equipment. With wearable devices for pedestrians and UWB tags installed on vehicles, pedestrians are warned when they are near a vehicle and the vehicle is automatically slowed down or stopped without driver intervention.

Forklift Collision Avoidance featured image
Cement Industry NeedsWhy Safe Steps?
Large area coverage with open and enclosed zones Safe Steps uses different communication protocols to ensure the most precise and accurate measurements. GPS, NB-IoT, Bluetooth and Ultra-Wideband can be used depending on the specific needs of the facility.
Noisy production processes (grinding units, cooling fans, compressors, cement mills etc.) Safe Steps wearable devices use light, sound and vibration to alert workers of risky situation to ensure the warning can be received in any situation.
Maintenance work requires lone worker operations across a large area Safe Steps devices include an easy to reach panic button and the ability to automatically alert the management panel in no movement scenarios to ensure all workers in need of assistance are located and helped in time wherever they are.
The use of large mobile equipment for production and transportation (bulk cement trucks, lifting equipment etc.) Vehicle to vehicle and vehicle to pedestrian collisions can be avoided even in the most complex operations with Safe Steps. When there is a risk of collision, pedestrians and vehicle operators are warned through wearable devices, while vehicles can be automatically slowed down or stopped depending on distance parameters set by the management.
Risk of fires and explosions due to chemicals being used Safe Steps can be used to manage emergency scenarios as well. For situations that require a full evacuation, panel admins can carry out a roll call through the panel to ensure all employees have reached a pre-established safe zone.
Risky zones requiring authorized entry Safe Steps smart badges can be utilized to restrict access and control entries to certain areas of the plant to prevent accidents, chemical exposure and other health hazards.
Need for training to use digital WHS platforms Safe Steps Pandemic Safety, Lone Worker Protection and Collision Avoidance modules can be bundled together for a complete WHS solution, allowing all safety processes to be managed and monitored from a single panel. Without a need for additional platforms, employees need training only for the Safe Steps platform.
Monitoring and measuring WHS performance for complex operations Safe Steps management panel offers WHS departments and company management an overall view of safety performance with rele3vant and actionable insights that can help improve processes.

safe steps work health and safety platform for cement ındustry

Find out how different features of Safe Steps solve industry specific health and safety needs. 

 
Safe Steps uses different communication protocols to ensure the most precise and accurate measurements. GPS, NB-IoT, Bluetooth and Ultra-Wideband can be used depending on the specific needs of the facility.
Safe Steps wearable devices use light, sound and vibration to alert workers of risky situation to ensure the warning can be received in any situation.
Safe Steps devices include an easy to reach panic button and the ability to automatically alert the management panel in no movement scenarios to ensure all workers in need of assistance are located and helped in time wherever they are.
Vehicle to vehicle and vehicle to pedestrian collisions can be avoided even in the most complex operations with Safe Steps. When there is a risk of collision, pedestrians and vehicle operators are warned through wearable devices, while vehicles can be automatically slowed down or stopped depending on distance parameters set by the management.
Safe Steps can be used to manage emergency scenarios as well. For situations that require a full evacuation, panel admins can carry out a roll call through the panel to ensure all employees have reached a pre-established safe zone.
Safe Steps smart badges can be utilized to restrict access and control entries to certain areas of the plant to prevent accidents, chemical exposure and other health hazards.
Safe Steps Pandemic Safety, Lone Worker Protection and Collision Avoidance modules can be bundled together for a complete WHS solution, allowing all safety processes to be managed and monitored from a single panel. Without a need for additional platforms, employees need training only for the Safe Steps platform.
Safe Steps management panel offers WHS departments and company management an overall view of safety performance with rele3vant and actionable insights that can help improve processes.

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Safe Steps mobile application and platform aims to help businesses digitally transform their operations and rapidly adapt to the current conditions as the world emerges from lockdown and employees go back to work

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