Nepal Cement Saftey

Industrial Accidents in Cement
Industries of Nepal
Submitted to:
Occupational Safety and Health Project (OSHP)
Sainbu, Bhainsepati
Lalitpur
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Submitted By:
Quest Forum Pvt. Ltd.

Koteshwor, Kathmandu,
Nepal
March, 2017
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ACKNOWLEDGEMENT
Quest Forum Pvt. Ltd. would like to express its sincere thanks to the Occupational Safety and
Health Project (OSHP) and especially to the Mr, Barun Kumar Jha, Project Chief for
entrusting us for the preparation of report on Industrial Accidents in Cement Industries of
Nepal. Similarly, we are grateful to Mr. Yogeshwor Gharti, Electrical Engineer, Md.
Montassir Aalam, Engineer, Mr. Deepak Lekhak, Senior Lab Assistant and other staff from
OSHP for their valuable support during the study and preparation of this report.
Quest Forum would also like to express its sincere thanks to the Mr. Dinesh Prasad Sah, OSH
Expert a Team Leader and his Team members for successfully preparation of this study
report.
Quest Forum obliged of cement Industries who provided the accident data and its related
information for study.
Moreover, Quest Forum would like to express its kind thanks to the concerned organizations
and authors of the relevant documents, which have been consulted in the work. Without their
kind support this report would have not appeared in present form.
Quest Forum March 2017
I
A Study Report on Industrial Accident in Cement Industries
Executive Summary
At present around 59 cement industries in private sector have been registered in Department
of Industry and 2 government owned cement industries also are in operation. It is estimated
that annual gross consumption of cement in Nepal at present is around 2,500,000 MT which
can fulfilled by the domestic products. Cement has been categories as the first fundamental
constructive material. In the modern society, cement is one of the most reliable and
important constructive material. Nepal having huge deposited of limestone and also going to
self-sustained in cement production.
Cement grade Limestone, Silica reach clay and Gypsum are the main raw materials for the
cement production and coal is the main fuel for Limestone based cement industries. Clinker,
slag, fly ash and gypsum are the main raw materials for clinker based cement industries.
Cement grade Limestone and Silica reach clay are available in the country where as gypsum,
slag, fly ash and coal are imported mainly from India.
Nepal is in developing stage requiring huge infrastructural development such as roads,

highways, tunnels, hydropower development, and urbanization, which ultimately demands
the cement as one of the key development entity. Furthermore, Nepal being in between two
huge neighbors like China in the north and India in the south, if in anyway Nepal can
approach to these markets for cement; it takes no time for drastic improvements of national
economy. Hence, it is one of the potential fields to exploit the limestone and industrialize
towards cement production.
Occupational accident is such a bad-fate which any human never expects to occur. All
accidents have been traced to either unsafe acts or unsafe conditions and even unsafe
conditions can in some way be attributed to unsafe acts. According to the ILO the definition
of work accident includes accidents occurring “while engaged in an economic activity, or at
work, or carrying on the business of the employer”. Though Nepal has not yet ratified the
ILO Convention 155 on occupational Safety and Health but health and safety-related
protection measures have been included in the governing Labor Act, 1992.
Cement industries are considered as risky and dusty industries. Workers are not keen on long
years of association with these industries due to many cases of accident and ill health.
Cement industries have no clear-cut policy and plan for occupational safety and health, so it
is seen that absenteeism of workers is high and productivity of workers is low. Industries are
labour oriented and semi-automatic industries and more than one thousand three hundred
workers including 54 women workers are directly involved in ten visited cement industries.
Among from 10 visited cement industries 3 industries were visited which have limestone
based cement production system and 7 were have only grinding unit. These all visited
industries having capacity to produce more than 9500 tons per day cement.
Most of the visited cement industries having a modern technology. The overall OSH
conditions were found satisfactory in limestone based industries than the clinker based
industries. None of the industries have the safety and health committee or any standardization
of safety like OHSAS 18001. None of the industries were found the written record of
accidental data’s.
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Cement industries are in growing stage in Nepal, many new and large cement industries are
under the construction phase. It is found after interviewing of workers that due to accident
prone nature of cement industries workers have fear to work in these industries.
The data shows none of fatal accident happening in any cement industries in last 3 fiscal
years. Only few major types of accident occur most of the accident are minor in nature. The
data also represents the rate of accident are decreasing year by year, it signifying that new
upcoming industries are adopting automatic and latest technology where worker’s
involvement minimized. Most of the cement industries are newly established and well
management practiced seen during the study. Reduction of number of workers, increasing
awareness level on safety and health and some automation are the major contributor for
decreasing trend of accident in all cement industries. Remarkable improvement in awareness
of safety and health in cement industries may result the no any fatal accidents in last 3 fiscal
years in cement industries.
The following common causes were found in the cement industries for happening of
accidents:
 Workers taking Shortcuts
 Overconfidence
 Poor, or Lack of Housekeeping
 Starting a Task Before Getting all Necessary Information
 Neglecting Safety Procedures
 Mental Distractions
 Lack of Preparation
 Accident due to machineries
 Accident due to manual material handling
 Accident due to electricity
 Accident due to lack of Personal Protecting Equipment
 Accident due to occupational stress
 Accident due to lack of safety culture
 Fire
The actions needed to improve the existing conditions of Cement industries and also reduces
the rate of accidents:
 Implementation of Labour Act
 Proper training and refresher training programs should be conducted to educate the
workers as well as their supervisors particularly on occupational safety and health.
 The machinery should be regularly checked and maintained.
 All the moving drives i.e. belt drives, rollers and gear drivers should be properly
guarded or fenced.
 Adoption of good housekeeping practices by marking with yellow line will improve a
lot in Cement industries.
 Proper cable size and connection reduce the fire and electrocution.
 Introduction of scheduled and preventive maintenance will reduce many accidents.
 Introduction of tight working dress for all workers and banned to wear loose clothes
will reduce the many major and fatal accidents.
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 Proper and suitable PPE should provide to the workers.
Conclusion
It can be concluded from study that identifying hazards and their associated risk with
works, proper use of safety protection measures and enforcement of safety policy and
provisions are the major activities can be undertaken to prevent or minimize accidents
cement industries workers. There is a great need for prevention and control of risks and
hazards exposure in cement industries of Nepal. Low and no cost measures can contribute
significantly in the improvement and reduce the accident in cement industries.
IV
Table of Contents
Executive Summary............................................................................................................II
1. Background..............................................................................................................1
1.1 Introduction....................................................................................................1
1.2 Industrial Accident.........................................................................................2
1.3 Provisions of Safety and Health in National Legislation:..............................3
1.4 Objectives of Study........................................................................................4
1.5 Scope of the work..........................................................................................4
1.6 Methodology..................................................................................................5
2. Cement Sector in Nepal...........................................................................................6
2.1 Current Status of Cement Sector in Nepal.....................................................6
2.2 Problem Facing by Cement Sector................................................................8
2.3 Export Prospects of Cement...........................................................................9
2.4 Foreign Direct Investment.............................................................................9
2.5 Visited Cement Industries............................................................................10
2.6 Production Process of Cement Industries....................................................11
3. Occupational Accident...........................................................................................15
3.1 Concept of Accident:...................................................................................15
3.2 Main contributing factors for Accident........................................................17
4. Literature Review..................................................................................................18
4.1 100 Industrial Accident Cases in Nepal.......................................................18
4.2 Industrial Hazards and Accidents: Learning From Mistakes India, By Sango
Bidani:....................................................................................................................21
4.3 Accidental Cases in Cement Industries........................................................22
4.4 Major Causes of Accident in Cement Industries..........................................28
4.5 Suspended Particulate Matters in Cement Industries...................................28
4.6 Some Notable Accidents in global context..................................................30
4.7 Causes of Industrial Accident......................................................................32
4.8 Behavioral Issues in Accidents....................................................................32
5. Accidents Record in Cement Industries................................................................33
6. Causes of Accident in Cement Industries..............................................................35
7. Recommendation for Prevention and Control of Accident in Cement Industries. 38
8. Roles of Stakeholders:...........................................................................................42
9. Conclusion.............................................................................................................43
10. References:............................................................................................................44
Annex 1: Provision for Compensation:.............................................................................45
V
1. Background
1.1 Introduction
Cement has been categories as the first fundamental constructive material. In the modern
society, cement is one of the most reliable and important constructive material. Cement refers
to material which acts as a binding substance. In construction and civil engineering cement is
used to bind structural members for construction of buildings, pavements, bridges, tunnels,
roads and highways etc. Nepal having huge deposited of limestone and also going to self-
sustained in cement production.
Nepal is in developing stage requiring huge infrastructural development such as roads,

highways, tunnels, hydropower development, and urbanization, which ultimately demands
the cement as one of the key development entity. Furthermore, Nepal being in between two
huge neighbors like China in the north and India in the south, if in anyway Nepal can
approach to these markets for cement; it takes no time for drastic improvements of national
economy. Hence, it is one of the potential fields to exploit the limestone and industrialize
towards cement production.
Occupational Safety and Health (OSH) is a discipline with a broad scope involving many
specialized fields. In its broadest sense, it should aim at the promotion and maintenance of
the highest degree of physical, mental and social well-being of workers in all occupations;
the prevention among workers of adverse effects on health caused by their working
conditions; the protection of workers in their employment from risks resulting from factors
adverse to health; the placing and maintenance of workers in an occupational environment
adapted to physical and mental needs; the adaptation of work to humans (ILO).
Working condition in the majority of Nepalese industries is not satisfactory and may be
described as very poor. The workers are exposed to various risky and hazardous operations.
Workers are also exposed to excessive noise, dust/fiber, heat stress and harmful chemicals. It
has been assuming that the rate of occupational accidents and diseases are very high in
industries of Nepal which have been resulting in loss of working periods. Most industries do
not have available of basic personal protecting equipment’s (PPE’s) and ignoring the basic
safety first principles. These industries do lack adequately trained personnel and show their
reluctance to hire experts from concerned field to enhance the betterment of poor working
condition. The PPE is not available in most cases and due to low level of awareness among
the workers, even available PPE are also not used effectively. Other vulnerabilities like
housekeeping and the layout of the work places are not managed effectively.
The International Labour Organization’s (ILO) world-wide research shows that each year.
 One worker dies in every 15 seconds.
 6,300 workers die daily.
 Asbestos kills 100,000 people.
 Other hazardous chemicals and substances kill another 350,000.
 Over 2.3 million deaths occur due to occupational accidents or diseases.
 160 million workers suffer work related diseases and illnesses.
 Around 337 million workers are injured in workplace accidents.
 4% of world GDP is lost because of work related deaths, injuries or sickness.
The safety and health of the workers and their efficiency are reciprocal entities. Health and
Safety measures not only result in reduced rate of industrial accidents but also raise the work
productivity. Occupational injury denotes any personal injury, disease or death resulting from
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an occupational accident (Laurie, 1998). This has been defined as an occurrence arising out
of or in the course of work which results in: (a) fatal occupational injury, or (b) non-fatal
occupational injury. Often the term occupational accident is understood as a sudden, external
and involuntary event (Hamalainen et al., 2006: 137). In this case, Occupational injury means
death, any personal injury or disease resulting from an occupational accident. Occupational
accidents are an unexpected and unplanned occurrence, including acts of non-consensual
violence, arising out of or in connection with work which results in personal injury, disease
or death (Laurie, 1998:44); Occupational accidents and disease remain the most appalling
human tragedy of modern industry and one of its most serious forms of economic waste
(Somavia, 2004).
1.2 Industrial Accident
Modern Industrial psychologists have defined accidents in many ways:
According to Webster dictionary, accident is an event occurring by chance or arising from

unknown causes. However, yet another meaning given in the same dictionary is that accident
is an unfortunate event resulting from carelessness, unawareness, ignorance, or a
combination of various types of causes.
Lexicographically, an accident is an event that takes place without foresight and results in
some type of personal injury and/or damage to equipment and property (Ghiselli & Brown,
1948).
Hienrich (1959) views accident as an unplanned and uncontrolled even in which the action
or reaction of an object, substance, person, or radiation results in personal injury or the
probability thereof... Whereas Haddon et. Al. (1964) view it as an unexpected occurrence of
physical damage to an animate or inanimate structure.
Accident is such a bad-fate which any human never expects to occur. All accidents have been
traced to either unsafe acts or unsafe conditions and even unsafe conditions can in some way
be attributed to unsafe acts. Accidents have always been an intriguing aspect of human life
causing immense loss, pain and misery to humankind. Since accidents have been inevitable
phenomena in our daily life, our ancestors have developed the preventive measures to prevent
the accidents.
According to the ILO the definition of work accident includes accidents occurring “while
engaged in an economic activity, or at work, or carrying on the business of the employer”.
Conceptually, Occupational accidents are different from occupational diseases where
accidents are unexpected and unplanned occurrences, but occupational diseases denote the
physical and mental conditions which are “contracted as a result of an exposure over a period
of time to risk factors arising from work activity”. Similarly, a fatal accident at work is
defined as an accident which leads to the death of a victim. Where the accidents involve
multiple fatalities, they are often referred to as industrial disasters.
The need for health and safety measure for workers in Nepal is necessary due to the structure
of workforce, poor health delivery system in the country and its consequent effect on health
of workers, nature of production process and mass poverty in the country. The health services
facilities in Nepal are not symmetrically distributed. People walk for several hours to get
health services. The poor are denied access to health services because of the cost. The present
health scenario of Nepal is very bleak. The health and nutrition status of its people can only
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be described as extremely poor. It can be said without exaggeration that at any given time
almost everyone in Nepal is either ill or imminently at risk of major health problem. The
limited access to health facilities, very low level and quality of nutrition, acute problem of
sanitation are the common attributes of Nepalese health status (Nepal South Asia Center,
1998).
Poverty is common characteristics of Nepalese workers because of which they are under-
nutrient, and living in unsanitary living condition, which could lead to intermittent or prolong
bouts of illness, which in turn lead to absenteeism from work, and adversely affecting
production in enterprises. It has been argued that Nepalese entrepreneurs import machinery
and equipment without paying much attention to the quality of the machine. No one makes it
a point to see to it whether the machines are compatible to local conditions adversely skill
and capacity of worker is frequently questionable.
1.3 Provisions of Safety and Health in National Legislation:
Though Nepal has not yet ratified the ILO Convention 155 on occupational Safety and
Health, health and safety-related protection measures have been included in the governing
Labor Act, 1992. The act is much in tune with the ILO recommendation number 23 (1919)
concerning the prevention of industrial accidents, recommendation number 97 (1953)
concerning the protection of worker’s health and ILO convention number 155 (1981)
concerned with the occupational safety and health and working environment.
Considering the fact of socio-economic conditions of people and attitudes of management,

the Labor Act 1992 demands every employer to be responsible enough to provide adequate
health and safety services to the employers. The Act in chapter 5 has outlined a
multidimensional measure to ensure good health and safety of the workers working at the ten
or more worker employed organizations as:
 To maintain neat and clean condition in the establishment ensuring that dirt and filth
do not cause any stench.
 To ensure adequate ventilation, light and temperature in workroom.
 To arrange for the disposal and distraction of refuse, dirt and filth.
 To prevent inhalation of industrial dusts, fumes and polluted air that harms the health
of workers.
 To arrange for the protection or reduce the adverse impact of noise produce in the
work on the health of workers.
 To arrange sufficient space for the movement of workers with a view to eliminate
injury because of overcrowding at work place. In consonance with this provision, the
Act has prescribed at least 15 cubic meter of space for each worker depending on the
nature of the work.
 To arrange adequate water for drinking, flushing of toxic chemicals and extinguishing
fires.
 To arrange separate toilet for male and female.
 To declare all or any part of establishment as a non-smoking zone based on the nature
of establishment.
 To arrange for compulsory medical checkup of workers in the hazardous industry at
least once a year.
 To provide protecting equipment to protect the eyes of workers from the bad effect of
dust, particulates and radiation.
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 To make arrangement for equipment to protect workers from the harmful effects of
chemicals and the industry from fire.
 To construct fence around each part of danger machinery and equipment and timely
inspection, lubrication and adjustment by an experienced and trained adult workers.
 To prevent from the likely injury, the Act has prescribed optimum limit of load to be
lifted or moved by the workers based on age and sex. The prescribed loads for adult
male is 55 kg, 45 kg for female, 25 kg for minor male and 20 kg for minor female
aged between 16 and 18 years. It is 20 kg for the minor male and female of aged
between 14 and 16 years.
The Act also has safety provisions for the workers who work higher than atmospheric
pressure in the production process. In order to ensure safety of workers, the Labor Officer has
been authorized to issue an order to the management for necessary arrangement and provision
for health and safety of the workers and to close down the unsafe plant and machinery
(Section 34). The provision of compulsory reporting to the Labor Office by the concerned
establishment about the fatal accidents or serious accidents or occupational diseases is made
in the Act (Section 35).
The Act has also empowered the government to specify the safety standards in the country
(Section 36). The act has shown its special concerned to the protection from occupational
diseases, health hazards, injuries and accidents to the workers working the hazardous jobs
like construction, transportation.
1.4 Objectives of Study

The main objectives of the proposed study were:
a. To list out the 3 years’ data of Industrial Accident in selected cements industries of
Nepal.
b. To find out the main causes of accidents in cement industries.
c. To recommend the potential accident prevention strategy for cement industries.
1.5 Scope of the work

The scope of the work as per the TOR was as follows:
1. Collection of three Fiscal Years Industrial accidents data from 10 Cement
Industries which are in operation in Bara, Parsa, Makwanpur and Rupandehi districts
of Nepal.
2. Collection of available relevant reports and publications from concerned
organizations/agencies.
3. Collection of available relevant information from literature study and internet
search.
4. Analyze the primary and secondary data and find the industrial accident’s trend in
Cement industries.
5. Identify the potential causes of industrial accident in Cement industries.
6. Recommendation of measures and potential strategies to control the industrial
accidents in Cement industries.
7. Preparation of the Draft report with recommendation in context of Nepalese
Cement industries and submit to Occupational Safety and Health Project (OSHP) for
comment and feedback.
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8. Incorporation of relevant suggestions and feedback given by OSHP to finalize the

report and submit to DoL.
1.6 Methodology
The methodology adopted for the preparation of the report was as follow:
 The report is based on the primary and secondary available data and information.
 International norms and expert opinion is considered for the studies.
 Books, publications, reports, literature and internet sites used for the description of the
accident and Nepalese context.
 The comments and suggestions from the OSHP studied and relevant comments and
suggestions will be incorporated to finalize the report.
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2. Cement Sector in Nepal

2.1 Current Status of Cement Sector in Nepal
The cement industries are operated mostly in large scale and located mostly in urban
vicinities and Tarai region. In the earlier period, Cement industries were established by the
Government, when there was no initiative from the private sector. Himal Cement Company
Ltd. of 360 TPD capacity was established in Chobhar in the Kathmandu Valley, Hetauda
Cement Industry Ltd. of 750 TPD capacity in Lamsure, Hetauda and Udapypur Cement
Industry Ltd. of 850 TPD capacity in Gaighat of Udayapur by the Government. Himal
Cement Company Ltd. has been closed whereas Hetauda Cement Industry and Udayapur
Cement Industry are still operational.
Almost all the Cement industries possess similar technology and process. But the Cement
goods production varies industry to industry. Most of the industries mainly produces OPC
(Ordinary Portland Cement) & PPC (Portland Pozzolana Cement).
Cement grade Limestone, Silica reach clay and Gypsum are the main raw materials for the
cement production and coal is the main fuel for Limestone based cement industries. Clinker,
slag, fly ash and gypsum are the main raw materials for clinker based cement industries.
Cement grade Limestone and Silica reach clay are available in the country where as gypsum,
slag, fly ash and coal are imported mainly from India.
At present around 59 cement industries in private sector have been registered in Department
of Industry. It is estimated that annual gross consumption of cement in Nepal at present is
around 2,500,000 MT. Annual increment of demand for cement in Nepal is considered to be
around 20 percent. It is estimated that around six billion NPR of investment has been made
by private entrepreneurs in cement sector. Couples of big cement industries of 900 to 1,500
TPD based on rotary kiln technology are in pipe line and some of them will come into
operation by next couple of months. It is expected that after some years, Nepal will be self-
sufficient in Cement.
Cement production in Nepal has been growing sharply over the past few years. The industry
is among the country's most flourishing business sectors as the demand of cement is
constantly rising. The country’s cement industry has been steadily growing at 8-10 per cent
annually for the past several years. Its future looks bright if all stakeholder’s maintained self-
discipline.

The domestic cement industry has an installed production capacity of about 6 million tons
annually which is higher than the annual demand of 4 million metric tons. But the cement
industries currently operational have been able to utilize only about 50 per cent of their total
production capacity. Local production fulfils about 80 percent of the requirement and the rest
is met by imports from India. Nepal produces OPC, PPC and PSC cements. The country’s
import of cement has been dropping year after year because of the rising domestic
production. According to the Trade and Export Promotion Centre (TEPC), the rate of growth
in cement imports has declined in the last fiscal year. The decline in the import of both
cement and clinker reflects Nepal’s progress towards self-sufficiency in cement production.
Out of the 59 industries, only 12 produce clinker which is major raw material used in cement
production. As early as a decade ago, Nepal used to depend on India for 95 per cent of its
clinker requirement. However, with more industries now setting up clinker production units
after querying limestone quarries, import from India has been declining year after year.
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Today, almost 60 percent of the clinker demand is met through domestic supply. A few
industries will start producing own clinker. That will bring down the import to 20-25 per
cent.
Limestone Mining for Cement Production

Exploitation and industrialization of potential mineral resources in any country plays a vital
role in their economic development. Nepal, though endowed with a diversity of metallic and
non-metallic minerals sources, only few of them have proven potential for exploitation and
industrialization.
Mining industries are generally a high-risk job, a long-term commitment and require high
capital expenditure. Besides that, in developing countries like Nepal, such industries suffers
from lack of proper policies, weak rules and regulations, contradicting acts, rules and bylaws,
political instabilities, riots and political disturbances, local and social problems. The terms
and conditions of investment can suddenly alter because of legislation, mining and
investment laws and is often in a constant state of flux. On the other hand, the business has
also got to look into ecological factors, environmental factors, socio-economic factors and
resource management problems such as maximum resource utilization and its sustainability.
Coming to industrialization of limestone quarries, the common problems faced by the

industrialists are lack of high quality limestone deposits; cumbersome mining leasing process,
problematic land acquisition procedures, lack of infrastructure such as roads and energy,
ecological, social and environmental issues. Some other worrying aspects are the cost of
production, encroachments and attacks from external infringers, industrial safety and
compliances.
Energy Used
Main sources of energy used in the Cement industries in Nepal are electricity and coal. Coal
is mainly used in the kilns for calcination in limestone based units and in some cases also
used for electricity generation in plants having co-generation system. Approximate share of
electrical energy used in Nepal's cement industry is 9 %; thermal energy amounts to 91 %.
Baseline study undertaken by GIZ/NEEP in 2012 for the Cement sector has found the
specific energy consumption to be considerably above the regional benchmark (see table).
That means there are huge saving potentials by implementing energy efficiency and
upgrading technologies.
Source: Specific energy consumption in Nepalese Cement industries (GIZ/NEEP, 2012)
According to a baseline study in cement sector of Nepal energy cost of product value in
limestone-based cement industries is with 48 %. In clinker-based industries energy cost
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amounts to at least 5 % of product value. Energy saving potential on the product cost is
estimated to be Limestone based industry is above 19%.
In clinker based cement industries are estimated to be electricity up to 45,854 MWh could be
saved. In limestone based cement industries of Nepal saving potentials amount to 35,390
MWh electrical and 1,598,359 GJ thermal energy. By implementing energy efficiency
monetary savings in clinker-based industries and limestone-based industries amounts to about
38 Crore and 110 Crore Lakh Nepalese Rupee, respectively.
2.2 Problem Facing by Cement Sector

– Political
Nepal has recently opted to become a republic state and accordingly a new constitution along
with the legislations have been formulated. However, the new legislation is still not
implemented and there are several groups who are agitating and opposing the
implementation.
– Social
Nepal is known as living place of many ethnic groups. Industrialization culture is not seen in
our society, although it has many expectations from the large and recognized industries.
Lack of social inclusion and motivation many cement industries facing new issues from
society every day.
– Environmental
Environmental Protection Act and Regulation are the relevant legislations for taking care of
environmental issues in Nepal. Many large cement industries have fulfilled the requirement
of Environment Impact Assessment (EIA) before they go in for production. However,
environmental issues are associated with all stages of cement production i.e. mining,
transportation, transmission, construction and production. Due to ignorance of these issues,
cement industries are facing many obstacles from the government and public.
– Energy
Power shortage because of long hours of load-shedding is the biggest challenge being faced
by mining and cement manufacturers in the country. The power crisis has forced them to use
diesel power which makes each cement sack costlier.
– Import duty
The high import duty levied on raw material, mainly clinker, is another problem, according to
cement manufacturers. It has weakened the competitiveness of Nepali cement in terms of
price. “The government has been continuously increasing the customs duty on clinker
ignoring its effects on domestic cement manufacturers,” all this makes the Nepali cement
costlier than cement in any other SAARC country.

– Safety and health
Cement industries are considered as risky and dusty industries. Workers are not keen on long
years of association with these industries due to many cases of accident and ill health.
Cement industries have no clear-cut policy and plan for occupational safety and health, so it
is seen that absenteeism of workers is high and productivity of workers is low.
8
– Transportation
The syndicate system in transportation is another big problem for the domestic cement
industry. Cement industries are not getting sufficient number of trucks to supply finished
goods to the targeted location. The cost associated with transportation is also high.
Manufacturers complain that even with enough production and demand, they are unable to
supply their products to the market due to unavailability of transportation. Every commodity
has a lifespan; and in the case of cement, it is 30 days, if the cement is not used within 30
days, the desirable outcome is not achieved.
– Others
Other serious issues faced by the cement industry include: financial support by the banking
sector, clear and effective FDI policies, user group and market management, quality control,
lack of effective means of lowering production cost such as mining cost, capacity
enhancement, technological improvement etc. It lacks long-term vision for its sustainability.
2.3 Export Prospects of Cement

With the increase in production, export of Nepali cement has also risen in the past few years.
Though the size of the export is negligible compared to the import, the increasing trend
indicates the possibility of Nepali cement becoming a product of comparative advantage to
the country's export. Nepal exported cement worth Rs 3.16 million in FY 2013/14.
Nevertheless, it will take time for Nepal to become a net exporter of cement, according to
producers. "As Nepalese Cement industries are not able to fulfill the domestic demand, there
is no possibility of export currently. Most industries are selling their products within the
country. Nepalese Cement industries can think of exports once they meet the domestic
demand.
2.4 Foreign Direct Investment

Nepali cement industry has become lucrative to foreign investors in recent years. Big
international producers, namely, Dangote of Nigeria, China's Hongshi and Reliance of India
are in the process of establishing production facilities in Nepal. Lured by the infrastructure
boom in Northern India and Western China, the companies are eying to tap Nepal's vast
limestone reserves. Their products are expected to be export-oriented while also fulfilling the
domestic demand in Nepal. Dangote Group, one of the largest industrial conglomerates of
West Africa, is said to be starting the construction of cement factory in the next one year. The
company which was granted a USD 500 million FDI approval in November 2013 by the
Investment Board of Nepal (IBN) is currently looking for a local partner, according to an
informed source.

Meanwhile, the top Chinese manufacturer Hongshi Holding Group has partnered with the
Nepali company Shivam Cement to kickstart its business in Nepal. The company in March,
2015 signed a joint venture (JV) agreement with Shivam Holdings Nepal to set up a Rs 30
billion production facility. According to the agreement, Hongshi will have 70 per cent share
(Rs 21 billion) and the rest (Rs 9 billion) will be invested by Shivam. The JV which will be
named Hongshi-Shivam Cement Pvt Ltd aims to produce 120,000 sacks or 6,000 tonnes of
cement per day and has plans to start production in three years.

Similarly, Reliance Cement Industries of India has also received endorsement from the IBN
to establish a cement factory in the country. Though much is not known about the progress
9
after the approval of its investment proposal last year, the company has pledged Rs 40 billion
in FDI and aims to produce 2.3 million tonnes of cement annually. Collectively, the three
foreign companies have received project approvals worth USD 1.2 billion which has been
marked among the largest FDI commitments in the Nepali industrial sector for the time
being. Likewise, two other foreign companies have also recently expressed their interests to
invest in the country's cement industry, according to a source close to the matter.
2.5 Visited Cement Industries

Cement industries are labour oriented and semi-automatic industries and more than one
thousand three hundred workers including 54 women workers are directly involved in ten
visited cement industries. The all 10 visited industries are located in terai region of country.
The 3 industries were visited which have limestone based cement industries and 7 were have
only grinding unit. These industries having capacity of more than 9500 tons per day cement.
Most of the visited cement industries having modern technology. The overall OSH
conditions were found satisfactory in limestone based industries than the clinker based
industries. None of the industries have the safety and health committee or any standardization
of safety like OHSAS 18001. None of the industries were found the written record of
accidental data’s.
Table: Visited Cement Industries
Number of Workers Capacity,
Name of Cement Industries Location
M F Total TPD
Ambe Cement Pvt. Ltd. Lipni Birta, Parsa 53 0 53 1000
Arghakhanchi Cement Pvt. Ltd. Mainahiya,
202 2 204 1100
Rupandehi
Brij Cement Industries Pvt. Ltd. Gonaha, Rupandehi 137 0 137 1200
Nepal Ambuja Cement Udhyog Kamhariya-3,
38 3 41 725
Rupandehi
Narayani Cement Udhyog Pvt.
Lipnimal, Bara 50 0 50 1050
Ltd.
R.M.C. Cement Pvt. Ltd. Bajni, Simra, Bara 15 0 15 300
Relaince Super Cement Pvt. Ldt. Gadhimai, Bara 20 2 22 1400
Siddhartha Cement Udhyog Gonaha, Rupandehi 150 15 165 750
Shivam Cement Industries Hetauda,
220 25 245 1250
Makwanpur
Hetauda Cement Industries Hetauda,
493 7 500 800
Makwanpur
Total 0 0 0 0
2.6 Production Process of Cement Industries

2.6.1 Process Flow Chart
Figure 1: Clinker Based Cement Plant
Input Process Hazards


10
Clinker Clinker Dust

 
Fly ash Storing Fly ash Dust
Gypsum Gypsum Dust
clinker  fly ash
Gypsum(from
Storing
store)  Crushed Dust
Electricity Crushing  (Master 
Gypsum  Spillages
Manpower Hopper)
Electricity
Manpower

Storing
Electricity (Raw Dust emission
 
Manpower Material Spillages
Hopper)

Electricity Storing
Dust emission
Manpower  (Mill 
Spillages
Hopper)

Cement dust
Electricity emission
Cement
Water (for cooling)   Noise
Milling
Compressed air Water (warm)
Dust in collector

Electricity Storing
  Dust emission
(Silo)

Poly bag Weighing Spillage (Reused)

Electricity/Compressed air  and  Damaged bags
Manpower Packing Dust emission
 Cement in Bag
11
Figure 2: Process Flow Chart of Limestone Based Cement Plant

Input Process Hazards

Lime Stone Boulder Lime Stone Crushing Dust Emission

Electricity  Primary & Spillage
Manpower Secondary Noise

Dust Emission
Electricity 
 Lime Stone Blending LS Spillage
Manpower
Noise

Clay From Ore
Dust Emission
Electricity
 Raw Meal Grinding  Spillage
Hot Air from Kiln
Noise
Manpower

Dust Emission
Electricity 
 Homogenization Dust Spillage
Manpower
Noise

Dust Emission
Hot air from Kiln
Preheating & Dust Spillage
Electricity  
Calcinations Noise
Manpower
Heat Radiation

Coal Dust
Hot Air emission Coa Dust Emission
Coal l
From Kiln   Rejected Sintering  Hot air to raw mill
Grinding dust
Electricity Coal Hot Heat Radiation
Manpower Noise air

Hot air to coal mill &
Electricity
 Cooling  raw mill
Manpower
Dust emission

Electricity Dust emission
 Storing & Stabilizing 
Manpower Rejected Clinker

Gypsum Dust Emission
Electricity  Cement Grinding  Cement Spillage
Manpower Noise

Packing bags Dust Emission
Electricity  Packing  Cement Spillage
Manpower Damaged bags
 Cement ready for Dispatch
12
2.6.2 Process Description

Crushing:
Firstly, the line major component in the composition of cement Calcium Oxide (CaO) is
obtained from the quarries is crushed to seven inch during primary crushing and 25mm
during secondary crushing. All the crushed materials are checked for calcium carbonate,
lime, alumina, ferrous oxide and silica contains. This process is done repeatedly as there may
be some variations in composition of limestone obtained from same quarries. If the
composition of limestone does not meet the required or the desired quality, then some
limestone having good composition is mixed.
Raw mill:
The raw mill is the equipment used to grind raw material into raw mix during the
manufacture of the cement. The raw mill stays of the process effectively defines the
chemistry of the finished cement and has the large effect upon the efficiency of the whole
manufacturing process. The raw minerals are fed to raw mills by the means of conveyer and
proportioned with the help of weight feeder which are adjusted as per chemical analysis done
on the raw materials. The raw materials are ground to the desired finest in the raw mill. The
resulting fine powder is blown upward where it is collected in cyclones. The fine powder is
fed to the large size continues blending and storage by use of aero pole. The mineral from the
blending silo is dropped by gravity.
Clinkersation:
Material is increased in stages from 60C to 850C with the help of hot gases having the
temperature of 1000C. The pre heater is a sloped kiln in which well- proportioned raw
material is fed from top. There being slop the material automatically comes at the lower end
of the pre heater. The raw mixture is heated in a cement kiln, a slowly rotating and sloped
cylinder, with temperatures increasing over the length of the cylinder up to a peak
temperature of 1400-1450 °C. A complex succession of chemical reactions take place (see
cement kiln) as the temperature rises. The peak temperature is regulated so that the product
contains sintered but not fused lumps. Sintering consists of the melting of 25-30% of the
mass of the material. The resulting liquid draws the remaining solid particles together by
surface tension, and acts as a solvent for the final chemical reaction in which alite is formed.
Alite is the name for Tricalcium Silicate Ca3SiO5. It is the characteristics mineral in the
Portland cement. Too low a temperature causes insufficient sintering and incomplete
reaction, but too high a temperature results in a molten mass or glass, destruction of the kiln
lining, and waste of fuel. When all goes to plan, the resulting material is clinker.
Grinding:
In order to achieve the desired setting qualities in the finished product, a quantity (2-8%, but
typically 5%) of calcium sulfate (usually gypsum or anhydrite) is added to the clinker and the
mixture is finely ground to form the finished cement powder. This is achieved in a cement
mill. The grinding process is controlled to obtain a powder with a broad particle size range, in
which typically 15% by mass consists of particles below 5 μm diameter, and 5% of particles
above 45 μm. The measure of fineness usually used is the "specific surface", which is the
total particle surface area of a unit mass of cement. The rate of initial reaction (up to 24
hours) of the cement on addition of water is directly proportional to the specific surface.
Typical values are 320–380 m2·kg−1 for general purpose cements, and 450–650 m2·kg−1 for
"rapid hardening" cements. The cement is conveyed by belt or powder pump to a silo for
storage. Cement plants normally have sufficient silo space for 1–20 weeks production,
13
depending upon local demand cycles. The cement is delivered to end-users either in bags or
as bulk powder blown from a pressure vehicle into the customer's silo. In developed
countries, 80% or more of cement is delivered in bulk, and many cement plants have no bag-
packing facility. In poor countries bags are the normal mode of delivery.
Packing of cement
Cement are generally packed in jute bags conventionally and this is also used in packing of
cement in Nepal because of its low cost. But jute has many draw backs listed below
 Jute bags when emptied contains some cement which is wasted and because of this
wastage full quantity does not reach the concrete mixture.
 The handling of jute bags proves harmful to the health of labourer as they inhale a
considerable amount of cement during loading and unloading.
 The quality of cement is affected due to entry of moisture from the atmosphere.
14
3. Occupational Accident
The most recent estimates available from the ILO suggest that around 2.2 million people die
due to work-related accidents or illness each year. 350,000 of these deaths are due to
accidents and the rest are due to occupational illnesses and diseases. On top of this, the ILO
estimates that there are 264 million non-fatal accidents each year that result in a 3+ day
absence from work, and 160 million people with work-related illnesses. The ILO believes
that the cost of work-related ill health and accidents costs the world 4% of the global GDP or
$1.25 trillion US dollars.
Accidents, however, are thought to account for only 19% of global work-related deaths, the
remainder being due to illnesses and diseases. The biggest killers, along with accidents, are
cancer, circulatory diseases and communicable diseases.
Many workplace accidents have relatively minor repercussions, which could result in just a
paper cut or scratch, others can have more serious and potentially fatal consequences. For
instance, there are some industries in which individuals are more exposed to occupational
hazards than others, such as the construction and metal industries which had the highest rate
of fatal injuries out of all other industry sections. In construction falls accounted for 51% of
construction injuries resulting in death.
It was revealed that slips, trips or falls were responsible for more than 50% of serious injuries
to employees. Furthermore, the majority of incidents that resulted in employees taking more
than three days off work – or affected their ability to perform their usual duties over this
period – were caused by handling accidents.
3.1 Concept of Accident:

Depending upon the circumstances or purpose, accidents have been defined in various ways.
Heinrich defines an accident as an unplanned and uncontrolled event in which the action or
reaction of an object, substances, person, or a radiation results in personal injury, or the
probability thereof. It is pertinent to point here that some industrial psychologists have
attributed accidents to error. But as in the case of other types of error, accidents do not just
happen. Rather, they can be considered as being brought about by certain preceding
circumstances and events, some of which may be associated with human beings, other by
situational factors, many times referred to as mechanical factors. There are, as in
mathematics, theorems in accident occurrence, as, for example:
A personal injury occurs as result of an accident.

 An accident occurs only as the result of a person or mechanical hazards
 Person or mechanical hazards exist only because of the personal faults.
 Faults of person are inherited or acquired by environment.
The implication of this theorem may be explained in the form that an injury cannot possibly
occur unless there has been a personal unsafe act / or exposure to an unsafe mechanical
condition. To minimize accidents, then, systematic efforts will have to initially depend upon
the availability of knowledge regarding unsafe act and mechanical conditions. These efforts
will lead to knowledge that would help in g performing appropriate corrective action. The
tendency to error is a pervading human trait. Errors of various kinds can affect not only the
quality of work that people do but also contribute to injuries and fatalities. Human errors in
15
work activities are so pervading that in every post facto analysis an accident can be traced to
a lapse on the part of the human element.
From aircraft accidents to minor accidents human error has always played a decisive role.
According to a study conducted by Boeing Company, 60-80% of aircraft accidents worldwide
can be attributed to human error. The findings were that 74% of the accidents were due to
crew error, 12% due to mechanical failure, 5% due to lack of maintenance, and 3% accidents
were attributed to other reasons. Similarly, the Directorate of rail safety of India has stated
that 68% of all rail accidents are due to failure of railway staffs. For the road accident also the
majority of injury and fatality can be attributed to reckless road behavior. It analysis is even
true with industrial accidents, too.
Despite all these successes of medical and social sciences, man, woman and children
continue to suffer from injuries sustained in the home, at play and at the work. Though a
continual watch and record is kept of work accident and these are analyzed at regular
intervals by Government departments, safety organizations, and individuals having expertise
in safety, accidents continue to happen. The nature and incidence of accident depend on many
factors but attitude and mental status are usually critical.
Major issue in an accident remains the human error. It may be because it happens to be a
controllable component. The basic question arises is what really constitutes an error. An
operational definition of human error has been proposed by Peters as follows: Any deviation
from a previously established, required or expected standard of human performance that
results in unwanted or undesired time delay, difficulty, problem, incident, malfunction, or
failure.
As pointed out by Rook, human error is somewhat synonymous with poor workmanship.
Since workmanship frequently can be considered as varying along some continuum, it may
be necessary to characterize that degree of workmanship that is considered unacceptable in
terms of some appropriate standard. Sometimes, however, the consequences of an error are so
clear that there is no question of degree. If it is possible to characterize errors in a situation, it
is useful to determine the human behavior and the situational variables associated with the
type of error in question.
Accidents are usually attributed to some physical causes in the environment or to a number of
items related to the human factors. Classic studies were carried out to identify the major
causes of accidents and various physical aspects of accidents were identified. Another major
study was carried out for identifying the contributing human factors in accidents. An
interesting aspect in this study was to indicate that faulty attitude was an important cause of
accidents. This study as well as many similar studies that precluded it led to the interesting
finding that a relatively small group of people was involved in a large percentage of all
reported accidents. Thus working under similar condition one can find a large number of
people whose accident record is excellent, while a small group share the most numbers of the
accidents. This finding apparently confirmed statements of psychologists and psychiatrists
that accidents don’t distribute themselves by chance rather they happen frequently to some
people and infrequently to others due to a combination of circumstances. There are
individuals who because of certain mental, psychological or physical defects fall to an
accident when it arises, while there are those with the necessary physical and mental
requirements who show little susceptibility to accident. These findings however focused
16
accidents as an individual problem and could be reduced by studying individuals who met the
accidents.
A majority of work on the concept and causes of accidents have been done in the western
context. In 1931, H.W. Heinrich noted that there are two basic factors leading to accidents:
unsafe mechanical or physical conditions and unsafe acts of persons, or the human factor.
3.2 Main contributing factors for Accident

The following factors can be taken in accident happening in Cement industries:
 Lack of organization health and safety policy, structure, work involvement and
management system
 Poor safety culture
 Lack of knowledge and lack of awareness of information sources
 Lack of, or poor, government policies, legislation, enforcement and advisory system
 Lack of incentive-based compensation system
 Lack of, or poor, occupational health services
 Lack of research and proper statistics for priority-setting
 Lack of effective training and education
17
4. Literature Review
Some relevant literature related to accident and cement industries hazards and risk reviewed.
4.1 100 Industrial Accident Cases in Nepal

“According to findings of Mishra el al on 100 Industrial Accident Cases in Nepal found out
followings”:
Establishment of industries in Nepal has become supportive to grow the national economy
and has provided better job opportunities for many people living in poverty with different
kinds of unemployment. In this study on 100 cases of industrial accidents that were occurred
in the different industries of Nepal. It shows that more than 86% of the workers were
working in different industries in the hope of a better life. Besides other industrial hazards,
industrial accidents are one of the major health problems among industrial workers.
We have identified that 66% of the injured workers in our study due to wood, furniture, and
the carpet industries. The risk factor for accidents in these industries is statistically
significant. Likewise, 83% males of the 16 to 35 year age group were in the top list of
injured. . Different factors like carelessness, over-activeness and more exposure to machinery
in this sex group may be responsible for the accidents. Though the minimum recruitment age
in 70% of the industries was pegged at 15 years, child labour, which is forbidden by law, was
an open secret. The numbers of workers below 15 years old were 9.5%.
One of the major contributing factors for the injuries was lack of proper training for the
workers. Percentage of unskilled workers in the industries and injured among them was
recorded at 82.5 and 96 percentages respectively. The risk factor for accident is significantly
higher in unskilled and semi-skilled workers belonged to laborer group.
Though injuries also happened to workers who worked for less than two hours every day,
31% of the injuries were continuously working for more than five hours on the day of the
accident. Continuous work increases the risk of accident. This may be due to lethargy or to
extreme fatigue thus leading to less concentration. Fifty-one percent of the accidents occurred
at odd hours.
Inadequate safety precautions, ignorance, and human errors have been reported to
significantly contribute to injuries. All industries included in this study had no work schedule.
The machinery was not checked and was not properly maintained. Only 52% of the workers
were taught safety measures. None of the industries undertook proper preventive measures to
prevent work related accidents. Only 20% of the industries were noted to have good working
conditions
The health status of the workers was never considered in the time of recruitment in most
industries. There have been legal provisions for regular health services, health insurance and
compensation for the victims in developed countries. In this study, regular health services and
health insurance were not provided in 92.5% of the workers.
Sixty one percent of the workers had at least one work related accident. The average rate of
accidents both minor and major was 21.7 per year. In this study only 55% of the industries
had first aid kit and none of them were properly used. It is suggestive that first aid
management of the injured cases was negligible in Nepalese industries.
Age and Sex wise distribution of the workers and injured:
18
Two third (63.5%) of the workers belonged to 16 to 35 years of age. Majorities (83%) of the
injured workers were from this age group. Among them result shows that 9.5% of the
workers were less than 15 years of age. Most of the injured (96%) were male. Male female
ratio of the workers was 1.2:1. The odd ratio of 2.48 signifies that workers of younger than 35
years are in higher risk of accident. The odd ratio for sex wise accident risk was calculated to
be 7.58 suggesting that male is more prone to accident.
Type of industry and number of accidents:

Most of the injuries (66%) took place in carpet and wood &furniture industries. The odd ratio
of 7.76 signifies that working in wood &furniture and carpet industries has higher risk of
accident.
Training and accidents

The control group workers and the injured were classified into unskilled, semi-skilled, and
skilled on the basis of their working experience of less than 6 months, 6 months to 5 years,
and more than 5 years respectively. Of the 100 injured workers 24% were unskilled, 57%
semi-skilled and 19% were skilled. The workers of the industries were inquired whether they
had any training related to their work; 82.5% them did not have proper training. 96% of the
injured workers did not have any formal training before being employed. The odds ratio of
0.20 signifies that training and industrial accidents are inversely related. 58% of the injured
were laborers, which includes non-professionals working without training.
Age distribution of the workers and the injured

Age Group % of total workers No. of injured
<15 years 9.5 4
16-25 years 39.0 55
26-35 years 24.5 28
36-45 years 17.5 8
>45 years 9.5 5
Time of accidents
56% of the injuries occurred during day time and the remaining 44% had the injury during
odd hours. Among 44 percentages, about 14% (6/44) sustained the injury at around 2.00 am.
Continuous work increases the risk of accident

Among the 100 injured workers 18% were working continuously for more than 7 hours
without taking any rest. However, 19% of the injured were working for less than 1 hour, 25
% for 1-2 hours, 26 % for 3-4 hours and 12 % for 5-6 hours.
Industry wise distribution of injured workers and types of injury
Industry Soft tissue Close fracture Open fracture Total
Carpet 11 2 15 28
Wood & Furniture 17 3 18 18
Rice & Oil 0 0 3 3
Printing Press 1 1 5 7
Motor workshop 3 0 2 5
Garment 3 0 1 4
Iron and Grill 4 0 0 4
Shoes and Slipper 1 0 1 2
Others 5 1 3 9
19
Industry Soft tissue Close fracture Open fracture Total

Total 45 7 48 100
The phenomena like known disease, medication, alcohol consumption and addiction to elicit
drugs did not cause the accidents: Most of the injured workers except one did not have any
known disease before or at the time of the accident. In addition, all workers except one were
not under the influence of alcohol at the time of the accident. None of the workers were illicit
drug users.
Types of injury
Among 100 cases included, 45% of them had soft tissue injuries and 55% had bone injuries.
Furthermore, seven of the bone injury cases had simple fracture and 48 had compound
fractures.
Health Care, First Aid services, and Health Insurance

Only 7.5% of the industry workers were getting health check-up service and it was regular
only in 25.5 percentages of the industries. First-aid kits were found only in 55% of the
industries and none of them had sufficient necessary contents. Majority i.e. 62% of the
workers had never even seen such kind of medical kits. Health insurance was not provided
for 92.5% of the industry workers in 75% of the industries. None of the injured in our series
had health insurance.
Frequency of Industrial accidents:

Sixty one percent of the workers had experienced at least one accident while working.
Therefore, on an average, there were 21.7% accidents per industry per year.
Working condition of the industry:

In contrast to the opinion of the industry authorities, 73% of the workers concluded that they
had poor working condition. Only 20% of the industries had good ventilation, lighting and
working condition in terms of cleanliness around the industry.
Work without meal and during illness increases the risk of accident
Thirty-seven percents of the workers often used to work without meal and 16% used to work
even during illness. They considered illness only when they were bed ridden and could not do
their work.
Preventive measures:
None of the industries had regular servicing and none of them provided protective wearing to
the workers. Only about i.e. 52% of the workers were taught about the safety measures. Only
63.5% of the workers used to check the machines before use.
4.2 Industrial Hazards and Accidents: Learning From Mistakes India, By Sango
Bidani:
With new technologies evolving every day and few people knowing how to use these
technologies industrial accidents and hazards have become the order of the day. This
dangerous trend has high prevalent in the developing countries, and developed countries
have to also equally address the issue to sensitize its stakeholders. India has been receiving
end of industrial hazards since the 1980s. It all started with the tragic Bhopal Gas Tragedy
20
and then the oleum gas leak in Delhi caused by Sriram Industries. Unfortunately, we have not
learnt lessons from these tragic incidents, in contrast even today we continue to face
industrial hazards like the recent gas leaks in Mumbai and Bengal’s Durgapur district, not to
forget the equally tragic situation of people affected by the Mayapuri radioactive scrap deal.
In this article, we will first try to understand the definition of industrial hazard, then go on to
talk about each industrial hazard mentioned above and in what way we can prevent such
incidents from taking place in the future. It should be clear to that industrial hazard come
under technological hazards and they are different from social hazards like terrorism, which
is the most prominent one. Now, an industrial hazard is a hazard, which occurs when one
strives for commercial gains in quick time and mostly industrial hazards happen in an
industrial area which is making harmful substances like dyes, chemicals and radioactive
materials. These industrial hazards have disastrous environmental repercussions as well as
fatal casualty to the human habitation in the industry and around it.
After understanding the dynamics of industrial hazard, we proceed to look at some of India’s
biggest industrial accidents and the way they affected the lives of people and intended
solutions to prevent such kinds of disaster to occur in the future. The first and foremost
incident that comes to mind when we talk of industrial accidents was caused due to a
hazardous stored chemical called Methyl Isocyanate, which is notoriously called as the
Bhopal Gas tragedy where many innocent people had lost their lives. The gas escaped into
the air leading to many people having breathing problems, eyesight loss, and nausea and
vomiting. The reason for the escape of the gas into the air was poorly maintained and there
had been no safety norms followed scientifically. The incident could have claimed much less
number of lives if the hazardous chemical industry had been set up where human habitation
had been lesser. Unfortunately, this was not the case with tragic Bhopal gas accident.
The second major industrial accident which was caused due to use of hazardous chemicals
was in New Delhi. It was in the year of in 1986 where leak of oleum gas into the air has taken
the life of a person. After this incident that the Supreme Court in a landmark judgment
mentioned that any industry involved in the manufacture of inherently dangerous chemicals
or hazardous chemicals will have to indemnify all those who suffer on account of the
carrying on of such hazardous or inherently dangerous activity regardless of whether it is
carried on carefully or not. So this clearly means that the onus is completely on the enterprise
which makes the hazardous chemical.
The third incident was in the Mayapuri industrial area, Delhi, where industrial hazard like
radioactive scraps were found to the people who were selling the scrap material. In the
process, six people were admitted because of skin discoloration and other defects as a result
of working with these hazardous materials, a person has lost his life after he had multiple
organ failure and others continue to battle for life even as their blood platelet level continues
to fall down pathetically. Apparently, these scrap dealers claim that this radioactive source
came from Delhi University’s Chemistry department which had been l proved true later on,
but the question that continues to puzzle the layman is that how such an industrial hazardous
mechanism could be flourishing for such a long time? Investigations are still uncertain
regarding causalities regarding this industrial hazard and other potential sources from which
they get hazardous chemicals.
The most recent industrial hazardous chemicals were released causing many people fell sick
was occurred in Mumbai. In this incident, more than a 100 people fell sick after they inhaled
the hazardous chlorine gas that leaked into the atmosphere and creating shocking effects. This
21
is not the first time that chlorine gas leakage has been reported in Mumbai. In fact, there had
been the cases occurred in the years of 2003 and 2007.
The hazardous chemical which forced 28 people to get sick after gas leaked from the
scrubber area of Blast Furnace 2 in Durgapur, West Bengal. So, what can we do to ensure
that such incidents don’t take place in the future? The first thing that we have to ensure is that
when an industry is being set up it should have a clearance which shows that the industry
going to open is not an industrially hazardous one and similarly, the production activity of
such industry is not going to harm the environment. This kind of environmental clearance
should be kept with the industry or industry owner. Secondly, if any industrially hazardous
industry has to be set up it should be set up in an area where there is less human habitation.
Similarly, it should be the responsibility of the industry or industry owner to aware the people
who are working in the industry about alternative routes to escape in case if a gas leak does
take place accidentally.
4.3 Accidental Cases in Cement Industries

4.3.1 Mine Safety and Health Administration blames management of Ash Grove
Cement for fatal accident at Midlothian plant in 19 December 2016.
US: The Mine Safety and Health Administration (MSHA) has blamed the management of
Ash Grove Cement’s policies, procedures and controls for the death of a worker at its
Midlothian cement plant in May 2016. Roderick Barnes, a maintenance worker aged 46
years, died from a fall from the top of a slurry tank. In its report on the incident the MSHA
said that the cement producer failed to provide protection around openings through which
workers could fall and that that it failed to use fall prevention and protection devices. The
MSHA has issued five citations for violations of the Mine Act is relation to the event.
4.3.2 Four workers injured at ACC cement plant in Sindri in 18 July 2016
India: Four contract workers have been injured by an explosion at an ACC cement plant in
Sindri, Jharkhand. Sindri deputy superintendent of police Vikash Kumar Pandey told the
Hindustan Times that a cylinder in the fine coal crusher plant exploded, probably due to extra
pressure generated by the hot air generator attached to the crusher. The injured workers have
been taken to Bokaro General Hospital where their conditions are said to be critical. ACC has
stopped production at the plant to conduct a internal inquiry into the incident.
4.3.3 Silo collapses at Fauji Cement plant in Pakistan in 01 June 2016
Pakistan: A raw meal silo has collapsed at the Fauji Cement Company plant at Tehsil Fateh
Jang, Punjab. The structure containing 25,000t of raw material collapsed on 29 May 2016
also causing damage to the coal mill area of second production line. The company reported
no casualties.
Fauji Cement has shut down its 7200t/day second production line following the incident. It
expects that the line will remain closed for approximately five to six months. However,
dispatches out of stock will continue as the plant’s cement mills are operating normally. The
plant’s 3700t/day first production line is currently undergoing planned maintenance and will
resume production soon.
4.3.4 Worker killed in fall at Midlothian Ash Grove Cement plant in 16 May 2016
22
US: A worker has died from a fall at the Midlothian Ash Grove Cement plant in Texas on 10
May 2016. The worker, Roderick U Barnes, was a maintenance mechanic at the plant
according to the Waxahachie Daily Light newspaper. Barnes had been working on the top of
a concrete mixing tower. The Mine Safety and Health Administration and Ash Grove Cement
are conducting investigations into the cause of the accident.
4.3.5 Four killed in scaffold collapse at Sinai Cement plant in 07 January 2015
Egypt: Four workers were killed and at least 35 others were injured on 27 December 2014 when a
scaffold collapsed in the Sinai Cement plant in central Sinai. Sinai Cement denied that it had a
connection with the accident in a statement.
4.3.6 Worker dies at Shayona Cement plant in Malawi in 03 December 2014
Malawi: One worker has died and three others have been injured at the Shayona Cement
Factory in Kasungu. Hot clinker caused the injuries due to an open door at the plant
according to local media. Three of the injured workers, including the deceased worker, were
from Malawi. The fourth worker was from India.
"When they switched on the furnace, the cement stone busted from the clinker and produced
hot ashes which covered them. One died in the process of receiving treatment, while the other
three are in critical condition," said local police.
4.3.7 Worker dies in freak accident in cement factory in 12 May 2014
India: A worker was killed on 10 May 2014 while cleaning the belt of a crusher in Jaypee's
cement plant in Chhijwar, Madhya Pradesh.The incident took place when the worker, Gulab
Patel, who was cleaning the crusher belt got trapped in the machine. The victim was rushed to
Rewa's Sanjay Gandhi Hospital but he died on the way.
Patel's family have alleged that he was killed inside the plant and that the management failed
to inform them about the incident. The family said that they came to know about the incident
only through other workers. The plant management has agreed to pay compensation of
US$16,753, provide a job to a family member and also provide free training to the son of the
deceased.
4.3.8 Fire at Jammu & Kashmir Cement plant in 04 December 2013
India: A fire broke out at the government run Jammu & Kashmir Cement plant in the
Pulwama district of south Kashmir on 3 December 2013. No one was hurt and damage was
caused to "a few machines like motors, diesel oil tank, hot air generator and coal mill," said a
police spokesman. Fire and emergency services responded swiftly and put out the fire in an
hour. The cause of the fire remains unknown.
4.3.9 Cement Australia and subsidiary fined over US$170,000 for worker death in 14
August 2013
Australia: Cement Australia and Cement Australia (Kandos) (CA Kandos) have been fined a
total of US$172,843 for the death of Colin David Fuller at the Kandos cement plant in 2009.
Fuller was fatally injured when he was crushed between two hydraulic rams while working at
the factory on 13 September 2009, according to the Mudgee Guardian.
23
The North South Wales (NSW) Industrial Relations Commission found that CA Kandos and
Cement Australia had breached the Occupational Health and Safety Act 2000, by failing to
install fixed guarding along the entire length of a feeder and conveyor system as required by
Australian safety standards and failing to provide adequate supervision and instruction to
Fuller. In the judgement Commissioner J Backman found that the systems in place at the time
of Fuller's death were comprehensive but defective in a number of respects.
4.3.10 One dead in Dangote accident in 02 August 2013
Nigeria: One worker was killed on 31 July 2013 at the Dangote Cement Gboko plant when
he was hit by falling limestone, according to the All Africa Media Group. The deceased
labourer, Solomon Ashir, was killed instantly.
Ashir was from the local community, which reacted angrily towards Dangote following his
death. Many were of the opinion that health and safety measures at the plant had been
deficient.
Bonfires were lit on the roads used to access the plant in the hope of trapping key staff
members in the plant and Ashir's body was even carried into the office of the local Assistant
General Manager (AGM) in charge of mines. He had fled the office in fear for his life before
the protesters arrived.
Local media reported that Dangote representatives took the body to the local hospital after the
protesters had vacated the office. Dangote's community relations manager could not be
reached for comment.
Meanwhile, Benue State Police Public Relations Officer, Daniel Ezeala, confirmed that the
incident had taken place and said that an investigation into the cause of the incident was
underway.
4.3.11 Two cement workers killed in Central African Republic strife in 03 April 2013
Central African Republic: Two cement plant builders have been killed accidentally by
French troops in Bangui in Central African Republic (CAR). The bodies of one Indian and
one Nepalese national have been sent to Gabon in a French Military aircraft for repatriation,
according to Indian media. In addition, six injured Indian nationals, who were flown to Chad,
have been reported as stable.
The dead workers were employed by MIs Jaguar Overseas to build a cement plant in the
capital of CAR. A release from the company said that about 100 employees of the company
were currently stationed at the plant. It stated that the regional stabilisation force in Bangui,
as well as the French forces, had been visiting the plant to reassure employees of their safety.
The release added that there had been visible improvement in the situation, with local staff
returning to work and utilities restarted.
4.3.12 Cement industry safety in India in 06 February 2013
A stark reminder came this week of the thankfully rare but potential risks of working in the
cement industry. Five deaths were reported at Ambuja Cement's Bhatapara cement plant in
India on 31 January 2013.
24
According to a press release Ambuja issued, the steel construction supporting a fly ash
hopper located on top of a building, and connected to the cement mill, collapsed at the
Bhatapara plant. Further details in local press reports added that about 200t of fly ash fell
from a height of 15m. Five labourers and plant employees working at the site were buried
under the debris and subsequently died. Four officials from the company have since been
arrested and the plant closed while investigations are conducted.
Previously in January 2013 burn injuries were reported as another Ambuja cement plant, this
time at Darlaghat. Eight workers received burns after a blast from a boiler unit.
However, despite these incidents the safety figures for Ambuja Cement and the other major
Indian producers are high. In Ambuja Cement's 2011 sustainability report it recorded that its
lost time injury frequency rate (LTIFR) was 1.04 for total employees and supervised workers.
Its LTIFR has been dropping steadily since 2008, when it was 3.18.
This compares to other major Indian cement producers as follows. UltraTech Cement
reported that its LTIFR for permanent employees was 0.82 in 2011-2012, a consistent drop
year by year since 2008-2009. ACC reported that its LTIFR for its own and subcontracted
employees was 0.31 in 2011. Shree Cement reported a LTIFR of 0.91 in 2010-2011 for
employees and contractors. For international comparison the Mineral Products Association
set a LTIFR target of 1.79 or lower for 2014 in the UK. Lafarge's global LTIFR in 2011 was
0.63 and Holcim's was 1.6.
An Ambuja's plant in Rajasthan picked up two national awards from the Government of India
for Safety Performance in mid 2012. One was for first place for outstanding performance in
Industrial Safety based on 'Lowest Average Frequent Rate'. The second was a runners-up
prize for the category 'Accident Free Year'. Lafarge India, UltraTech, ACC and the other
major producers all hold similar accolades. Sadly, any safety record is only as good as the
shift that has just finished.
4.3.13 Four officials arrested at Ambuja Cement following deadly accident in 06
February 2013
India: Four officials at Ambuja Cement have been arrested following an accident with five
fatalities at the company's cement plant at Rawan in Chhattisgarh.
"Vice President of Ambuja Cement Sanjay Kumar Badopadhyay, DGM Production K Venkat
Stayanarayan Murty, DGM Mechanical Rajendra Singh Kurmi and GM electrical Sanjay
Kumar Mishra have been arrested in connection to the Ambuja cement factory (incident),"
said a police officer to the Press Trust of India. They were booked under IPC sections 287
(negligence with machinery), 337 (endangering life or personal safety) and 304A (causing
death by negligence).
Five workers were killed on 31 January 2013 when a fly ash container crashed into the
mixing unit of the plant at Rawan village. A case has been registered against Ambuja Cement
management and the labour department has ordered a halt to factory operations until an
investigation into the incident has been completed.
Chief Minister Raman Singh has directed the factory management to provide compensation
of US$18,800 to the kin of each victim and a job to one member of their families. A six-
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member panel headed by additional collector of Balodabazar district has also been formed to
conduct magisterial probe into the incident, which has been asked to submit its report in one
week.
4.3.14 Cement quarry explosion kills ten in China in 29 August 2012
China: An accidental explosion at a quarry supplying a cement plant in southern China has
killed ten people and left 18 with confirmed injuries.
Workers were in the process of unloading 13t of explosives from three trucks at a quarry of
the Longshan Cement Company in Yingde city in Guangdong Province when some of the
explosives ignited on 27 August 2012. Of the 18 injured, nine are workers from the cement
company and the others are residents in the nearby town of Yinghong, which is separated
from the quarry by a river.
At least nine people living in a nearby town were also injured in the blast when windows
shattered. Among the dead were quarry workers and others who transported and unloaded the
explosives.
An investigation team has been set up and sent to the site of the accident to search for
evidence and handle the remains of the explosives. A probe into the cause of the blast is
underway.
Longshan Cement Company, a subsidiary of Anhui Conch Cement, employs 950 people,
including 240 who work at the quarry.
4.3.15 Worker killed at Cemex plant in Rugby in 18 January 2012
UK: A worker was killed in an industrial accident at the Cemex plant in Rugby in the early
hours of this morning.
A spokesman for the plant confirmed that a man working for a sub-contractor was killed at
the plant and emergency services attended the scene. Police officers and the Health and
Safety Executive are currently at the site investigating what happened. Another man suffered
a broken arm in the incident and had to be taken to hospital for treatment.
Cemex community affairs manager Ian Southcott said, "Regrettably one person has died and
our thoughts and sympathies are with their family and friends. Cemex is cooperating fully
with all of the investigations taking place." Southcott refused to reveal any more details about
the accident while investigations are on-going.
The cement plant is currently in its annual shutdown period for regular maintenance. There
are a number of contractors working on the site as a result. In December 2011 Cemex was
fined for a worker's death in 2008 at the same plant.
4.3.16 Cemex fined for worker’s death at cement plant in 2008
UK: Cemex UK has been fined Euro230,000 following the death of a worker in an explosion
at its Rugby cement plant. The UK Health and Safety Executive (HSE) prosecuted Cemex
after the death of 28-year-old Peter Reynolds on 15 January 2008.
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Leamington Spa Crown Court heard that Reynolds was treating waste cement dust in the
bypass dust plant at the company's Rugby Cement Works. While he was clearing a blockage
in the lower mixer, there was a violent explosion of steam and dust from inside the machine.
The force of the explosion blew Reynolds out through the side of the building onto the road
ten metres below. He was pronounced dead at the scene.
HSE's investigation into the incident found that Cemex had recognised the potential for
blockages to cause explosions as steam pressure built up within the mixer but it took no
action to prevent them. The court also heard the company had failed to review its risk
assessment following a previous incident in May 2006, when another man was injured using
the same machine. This explosion bent a metal-cladded external wall, pushing it out by 50cm.
Speaking after the hearing, HSE Principal Inspector Neil Craig said, "This was an entirely
avoidable tragedy, which has left a young family without a husband and a father. If Cemex
had investigated the previous incident properly, Mr Reynolds would still be alive today."
"Cemex's protection against the build up of pressure was for the plant to be continuously
vented when processing waste cement dust, but it frequently blocked. These blockages then
caused steam to build up to a high pressure."
"The company could have made a number of changes to the mixer to reduce the flow of dust
and improve the venting and cooling systems, or devised a new system of work. However, no
action was taken and employees were expected to operate this dangerous piece of
machinery."
Cemex UK pleaded guilty to breaching Section 2(1) of the Health and Safety at Work etc Act
1974. The company was fined Euro230,000 and ordered to pay Euro200,000 costs.
4.4 Major Causes of Accident in Cement Industries

(as per the published document entitled “Health and safety in the cement industry: Examples
of good practice”, World Business Council for Sustainable Development)
Fatality Analysis 2000 - 2003 As fatalities are the most serious tragedy that can happen in the
Cement Industry, TF3 set about gathering all statistical data available, and analysed it
thoroughly to derive the best possible fatality prevention strategy. Data from a number of CSI
members was collated and analysed as follows: x There was a total of 389 Fatalities in
~300,000 employed over last 4 years x The Contractor Fatality
Ratio, where available, was 8 times that of Employees x The
combined overall ratio (for Employees & Contractors) was
2.67 for that study. CSI Company Fatality Causes Analysis by
cause shows that 79% of all fatalities arise from
3 main causes x Traffic & Mobile Plant
(43%) x Falls from Heights & Items falling (21%) x
Caught in Moving/Starting Equipment
(15%).
Typical Injury Causes & Types
27
Main causes are Slips, Trips and Falls (29%), Falling or Moving Objects (19%) and Lifting,
Overload and Exertion (18%). These three causes account for 66% of the total accidents.
4.5 Suspended Particulate Matters in Cement Industries

This sector of industries produces a large quantity of dust and dust emission. Dust is
generated during the loading, unloading and handling of raw materials and semi products, in
different process as: mining, crushing staking and reclaiming, raw meal grinding,
homogenizetion, calcinations, clinkerization, cooling, cement grinding, packing and, loading
processes. Dust generated during most of the processes settles down within the industrial
premises. Little quantity of dust emission from most of the processes may go out of the
premises. Dust emitted from the kiln stack, if it is not controlled properly, pollutes wide areas
around the industry, which is really a big head ach from such industries. If the dust collecting
systems of the different units are not properly maintained, dust emission may be quite high
making tremendous economic loss to industry, health problems to workers and environmental
degradation to society.
Dust Emission from Crushing Operation

The generation of dust and particulate materials during the crushing operation is inherent and
the emissions are most apparent at feeding and discharge points. The quantity of emission
depends on the condition and quality of the crushing materials used and stages of operation
and operating practices greater. The greater reduction in size, the higher the emissions are.
Emissions from Material Handling

In the material handling process, various handling devices like feeders, belt conveyors,
bucket elevators, screw conveyors and vibrating conveyers are used to transport different
materials from one point to another. Particulates are emitted from any of the material
handling operations. Most of the emissions occur at transfer points. Since transport of
material on the conveyor causes little disturbance of air and emissions that occur due to the
wind are judged to be minimum. The transfer points include transfers from a conveyor on to
another, into a hopper and on to a storage pile. The amount of uncontrolled emissions
depends on the size distribution of the material handled, the belt speed and the free fall
distance.
Emissions from Raw Materials and Cement Grinding

In the raw materials and cement grinding process along with all types of conveying systems
bag filters are used to catch the dust particles. If the conveying systems and bag filters are not
maintained properly immense quantity of fine products and semi products leaks out or splat
all over the units polluting the surrounding area.
Emissions from Clinkerization

In Clinkerization process of the limestone based cement industries, exothermic chemical
reactions takes place in the kiln emitting immense quantity of exhaust gas and dust particles,
which come out from the kiln’s chimney stack. Such emission of such cement industries is
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the main trouble maker. To minimize the dust emission from kiln stacks different types of
dust collecting devices such as dust collecting chambers, cyclones and wet-scrubbers are used
in VSK system whereas in rotary kiln system conditioning tower and Electro-static
Precipitators (ESP) are used. When such devices do not function properly, dust emission
from the kiln stack will be extremely high.
Emissions from Packing and Dispatch

During cement packing into the bags cement spreads out from the cement nozzles. That
spreaded cement should be sucked by dust collecting system. As in raw mill and cement mill
units bag filters are used to catch the dust particles. If the conveying systems and bag filters
are not maintained properly immense quantities of cement leaks out or splat all over the
packing units polluting the surrounding area.
Total four Cement Industries (2 Grinding and 2 Clinker making and Grinding) were selected
and visited namely Hetauda Cement Industries Ltd., Hetauda; Shivam Cement Industries Pvt.
Ltd., Hetauda-21, Makwanpur; Narayani Cement Udhyog Pvt. Ltd., Lipnimal, Bara and
Ambe Cement Pvt. Ltd, Lipni Birta-6, Parsa
Table 1 General Information of Cement Industries

Trees
Dust
Production Compound Inside and
Dust Cleaning
Name of MT/day Wall Road Greener
Types control System
Industry y
system
Y/ Height ,
Capacity Actual
N ft
Clinker
Hetauda Multi Slab
750 375 and Y 8 Water Yes
Cement Cyclone Casted
Grinding
Clinker
Multi Blackto
Shivam 1200 1100 and Y 6 Water Yes
Cyclone p
Grinding
Grinding
Multi
Ambe 1000 800 (Close Y 10 Metallic Water Yes
Cyclone
Circuit)
Grinding
Multi Slab
Narayani 1050 400 (Close Y 11 Water Yes
Cyclone Casted
Circuit)
4.6 Some Notable Accidents in global context

Bangladesh Building Collapse
Bangladesh earns 80 percent of its income from its 5,000 garment industries and is the second
largest apparel exporter after China eight-storey garment industry complex was collapsed in
April 24th 2013 which has claimed 1,038 lives to date. Another 2,500 workers were rescued
from the industrial area 30 kms out of Dhaka, many of the victims are suffering serious
injuries even in present days.
The tragedy was apparently caused when generators were functional during a blackout. The
owners have been accused of using shoddy building materials, violating safety measures in
29
the building, and not obtaining necessary clearances. It has been noticed that cracks had
appeared in the building the day before.
The architect who designed the building said it had not been designed to run industries using
heavy machinery and he further mentioned that “We designed a six-storey building... There
was no way the building was designed to be extended to 9 or 10 floors”.
Huge Poison Gas Leak in Bhopal, India Poison Gas Leak in Bhopal, India (1984): During
the night of December 2-3, 1984, a storage tank containing methyl isocyanate (MIC) at the
Union Carbide pesticide plant has leaked the gas into the densely populated city of Bhopal,
India. It was one of the worst industrial accidents in history.
Union Carbide India, Ltd. built a pesticide plant in Bhopal, India in the late 1970s in an effort
to produce pesticides locally to help increase production on local farms. However, sales of
pesticide did not materialize in the numbers, adversely; the plant was soon losing money. In
1979, the industry began to produce large amounts of the highly toxic methyl isocyanate
(MIC), because it was a cheaper way to make the pesticide carbonyl. To reduce the
production costs, training and maintenance in the industry were drastically curtailed. Workers
in the industry complained about the dangerous conditions and warned of possible disasters;
however, management did not take any action.
The Union Carbide company claims that a saboteur placed the water inside the tank, although
it was not evident. It might be also possible that once the tank began to overheated, workers
poured water on the tank, not realizing the fact that it might be more hazardous. On the
morning of December 3, 1984, around 12:15 am, MIC fumes were leaking out of the storage
tank. Although there should have been six safety features that would have either prevented
the leak or contained it, unfortunately that night all six features were not working properly. It
was estimated that 27 tons of MIC gas escaped out of the container and spread across the
densely populated city of Bhopal, India, which had a population of approximately 900,000
people. Although a warning siren was turned on, it was quickly turned off again, so as to not
cause panic.
Most of the residents in Bhopal were sleeping during the gas had been leaked. Many woke up
after they heard the coughing of their children or found themselves choking on the fumes. As
people jumped up from their beds, they felt their eyes and throat burning. Some choked on
their own bile. Others fell to the ground in contortions of pain.
People started to run here and there without identifying any destination. Families were split
up in the chaos situation. Many people fell to the ground unconsciously and then trampled
upon. Estimates of the death toll vary drastically. Most of the sources have mentioned that at
least 3,000 people died from immediate exposure to the gas, while higher estimate went up to
8,000. In last two decades, including the night of the disaster, approximately 20,000
additional people have lost their lives due to the fatal consequences of the leaked MIC gas.
Another 120,000 people are coping their life with enormous sufferings that has been created
by the side effects of the leaked gas like blindness, extreme shortness of breath, cancers, birth
deformities, and early onset of menopause. Chemicals from the pesticide plant and leaked gas
have infiltrated the water system and the soil near by the old industry and thus continue to
cause poisoning in the people who are living nearby.
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Just three days after the disaster, the chairman of Union Carbide, Warren Anderson, was
arrested. Later on he was released on bail, however he fled from India. Although his
whereabouts were unknown for many years, recently he was found living in the Hamptons in
New York. Extradition procedures have not started because of political issues. Anderson is
one of the “wanted” criminals in India for culpable homicide for his role in the Bhopal
disaster.
One of the worst parts of this tragedy is actually, although Union Carbide has paid some
restitution to the victims, the company claimed that they are not liable for any damages
because they blamed a saboteur for the disaster, and further claimed that the industry was in
good working order before the gas leak. The victims of the Bhopal gas leaked received very
little compensation. Many of the victims are living with l ill health and remain unable to
work.
4.7 Causes of Industrial Accident

The British Safety Council wishes to highlight the number of work-related deaths, injuries
and cases of ill-health that occur worldwide each year, with a view to promote higher
standards of health and safety risk management.
The International Labour Organisation (ILO) considers that only one third of its member’s
report reasonably reliable accident figures. Though the reporting of accidents is criticized but
the situation in relation to cases of ill-health is far worse. Even those countries with a better
reporting mechanism are under-reporting the incidence of deaths due to ill health. In order to
understand the full scale of the problem, the reporting of work related accidents and cases of
ill health needs to be improved considerably.
Major Causes of Work-related Deaths

Causes Global Total
Cancer 609,677
Circulatory System Diseases 519,254
Accidents and violence 355,049
Communicable diseases 320,471
Respiratory System diseases 146,176
Digestive System diseases 22,565
Mental disorders 20,341
Diseases of the genitor-urinary system 8,479
Source: Decent Work-Safe Work, Dr. J. Takala, ILO
4.8 Behavioral Issues in Accidents

This Sanskrit Mantra from Vishnu Puran can be read thus: .
Akal Mrityu Haranam, Sarva Vyadhi Vinashanam,

Vishnu Padodakam Pitwa, Punarjanmo Na Vidyate.
(Vishnu Purana)
Paraphrasing this means, I must be rid of accidental death and all sickness; as I drink this
holy liquid that washes the feet of Lord Vishnu, I seek freedom from the cycle of rebirth.
Fear from accidents has always been there in human mind and avoiding accidents has always
been a major aim in worshiping the different gods and the nine planets known as. NAUGRAH
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in the Hindu religious nomenclature. The Hindu religion recognizes three causes of misery,
which are called Adhidaivik, Adhivautic and Adhyatmik of which the first two pertain to
natural disasters and unforeseen event like accidents. Thus man has always been wary of
accidents and has sought freedom from it be it through divine grace or modern techniques of
science.
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5. Accidents Record in Cement Industries

During the study 10 industries were visited to collect the data of accident happened in last 3
fiscal years. Among the 10 visited cement industries 3 were lime stone based industries and 7
were clinker based industries. Cement industries considered as an accident prone industries
but during the study record of the accident not found in systematic manner in any industries.
The most common accident is the squeezing off of a single joint of a finger or the whole
finger. Losing half or a whole hand, an arm, etc. in the machinery are seen minimum. The
working conditions were not seen as practiced of safety first principle. None of the industries
were found safety committee and any safety and health certification. The following accident
records were found in visited cement industries.
Table: Accident Records in Cement Industries

Cement FY 2070/71 FY 2071/72 FY 2072/73
Industries Minor Major Fatal Total Minor Major Fatal Total Minor Major Fatal Total
Ambe Cement 26 0 0 26 28 1 0 29 26 0 0 26
Arghakhanchi
30 0 0 30 28 0 0 28 30 3 0 33
Cement
Brij Cement
4 0 0 4 3 0 0 3 5 0 0 5
industries
Hetauda
110 0 0 110 105 0 0 105 85 0 0 85
Cement
Narayani
Cement 12 1 0 13 10 0 0 10 8 0 0 8
Udhyog
Nepal Ambuja
20 0 0 20 25 0 0 25 24 0 0 24
Cement
R.M.C.
5 0 0 5 4 0 0 4 5 0 0 5
Cement
Reliance Super
0 0 0 0 0 0 0 0 3 0 0 3
Cement
Shivam
35 0 0 35 46 0 0 46 45 0 0 45
Cement
Siddhartha
60 0 0 60 50 0 0 50 60 1 0 61
Cement
Total 0 0 0 0 0 0 0 0 0 0 0 0
Accident in Three Fiscal Years

350
302 303 299 300 291 295
300
250
200
150
100
50
0
FY 070/71 FY 071/72 FY 072/73
Minor Major Fatal Total
Result and Discussion:
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The above collected data not represent as an actual data because most of the accidents are not
recorded by the industries. None of the Cement industries have management system for
occupational safety and health. These data were provided by the industries management.
Cement industries are in growing stage in Nepal, many new and large cement industries are
under the construction phase. It is found after interviewing of workers that due to accident
prone nature of cement industries workers have fear to work in these industries.
The above data shows none of fatal accident happening in any cement industries in last 3
fiscal years. Only few accidents are major types of accident and almost all accident are minor
accidents. The above data also represents the rate of accident decreasing year by year, it
signifying that new upcoming industries are adopting automatic and latest technology where
worker’s involvement minimized. Most of the cement industries are newly established and
well management practiced seen during the study. Reduction of number of workers,
increasing awareness level on safety and health and some automation are the major
contributor for decreasing trend of accident in all cement industries. Remarkable
improvement in awareness of safety and health in cement industries may result the no any
fatal accidents in last 3 fiscal years in cement industries.
Cement industries are also less fire sensitive industries. Least fires happening in last three
fiscal years in all Cement industries but no any fire disaster were happened in any cement
industries. No any explosion potential found in cement manufacturing industries.
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6. Causes of Accident in Cement Industries

In the cement industries accident rate is found low as compare to its accident prone nature of
industries. The reasons are of various natures. Most of the recorded accident found are minor
in nature. Only few accidents are in major in nature. Most of the accident were found were in
vehicle movement and material handling.
The following common causes were found in the cement industries for happening of
accidents:
Workers taking Shortcuts
Humans are notoriously lazy, so taking shortcuts is a rather common practice in all walks of
life, not necessarily work alone. However, when workers take shortcuts at work, especially
when they are working around dangerous machinery, they are only exposing themselves to a
potential catastrophe. Simply put, shortcuts that are taken on the job are not actually
shortcuts. They are simply increasing risk of injury, or worse, death.
Overconfidence
Confidence is always a great thing to have, but there is also such a thing as too much
confidence. When workers walk into work everyday with the attitude that, “It will never
happen to me”, they are setting an attitude that leads to incorrect procedures, methods, and
tools while working. Be confident, but remember that you are not invincible.
Poor, or Lack of Housekeeping
Whenever someone walks through your workplace, they can get a pretty good idea of attitude
towards workplace safety by just looking at how well workers kept up their working area.
Housekeeping is one of the most accurate indicators of the company’s attitude towards
production, quality, and worker safety. A poorly kept up area leads to hazards and threats
everywhere. Not only does good housekeeping lead to heightened safety, but it also sets a
good standard for everyone else in the workplace to follow.
Starting a Task Before Getting All Necessary Information
The quickest way to get a job done is to do it right the first time. To do it right the first time,
you need to make sure that you have any and all pertinent information relating to the task you
will be performing. Workers who begin a job with just half the information, or half the
instructions, are essentially doing the job while blind.
Neglecting Safety Procedures
This is probably the worst thing that any employee at any level in the organization can do.
Deliberately neglecting set safety procedures in the workplace doesn’t just endanger, but it
endangers the workers around as well as the company as a whole. Casually following safety
procedures doesn’t work either.
Mental Distractions
Everyone has a life outside of the workplace, and sometimes life can take dips and turns that
affect your emotions and your mood negatively. However, as harsh as it sounds, workers
cannot let mental distractions from their personal lives affect their performance at work. Not
only will they become less aware of their surroundings and less safe, but they will also
become less productive, costing the company time and money.
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Lack of Preparation
Job Hazard Analysis (JHA) is an effective method of figuring out the best way to work safely
and efficiently. When workers begin a task without thinking through the process beforehand,
or hastily start without any type of planning, they are setting themselves up for failure. Make
sure industry plan for workers work, then workers plan work.
There are several reasons why workplace accidents happen, but these 7 are the most common,
and sadly, the most overlooked, causes. It really comes down to awareness and focus. Lazy
workers are not as effective and they are not as safe as their aware and focused counterparts.
On top of this, lazy workers immediately become a direct threat to everyone around them.
There needs to be a conscious effort each and every day in the workplace to make sure that
these 7 causes don’t happen.
Some of the specific and technical causes of accidents in cement industries:
Accident due to machineries

Most of the machines and technology were seen new. Lots of maintenance activities always
going on in the all cement industries. Moving drives like gear and belt drives were not
properly guarded in all machines. Some of the accidents recorded during loading, unloading
and maintenance works.
Accident due to manual material handling

Cement Industries production layout seems very congested in all visited cement industries.
During the materials and machines handling risk of accident is high. Uneven surface
congested working place and manual works are the main causes of accident.
Accident due to electricity

Short circuit and electrocution are the major effect of electrical hazards in any workplace.
Electrical distribution and installation seems unmanaged in many Cement industries. Cable
size plays vital role for the cable heating and ignition of fire but during the study none of the
industries have the drawing and design of cabling system. Loose connection was seen many
places of the industries.
Accident due to lack of Personal Protecting Equipment

Personal Protecting Equipment (PPE) is the last control techniques for the prevention of
accident. Cement industries are the labor intensive industries. Most of the workers in this
industry coming from agriculture and most of them are unskilled and semiskilled. Very
limited workers were only sustaining for longer years in cement industries mainly due to
hazardous in nature. Most of the Cement industries are facing the problem of unavailability
of workers. During the study it was found that some workers were very new to the cement
industries. No any working dress introduced to the cement industries resulting female were
working with wearing of sarees and loose clothes and male also wears loose clothes. Many
major and major accidents were happened due to trapping of loose clothes in moving drives.
No any scientific based PPE seen in any Cement industries. Lack of proper and suitable PPE
many accidents were happening.
Accident due to occupational stress

Workers working in cement industries were not seen as a prime objective of them, most of
them worked mainly due to near to home, lack of other opportunity, coming with friends, and
not skilled required. Most of the workers not encourage to makes their carrier in cement
36
industries. High Noise and dust exposure are main factors to make workers annoying and
uncomfortable. Most of the workers were seen as working in stress. While anybody working
in stress may do the wrong decision in many times so, risk of accident is very high.
The worker’s attitude towards various types of stresses is a new concept in the studies of the
working class. The employer and sometimes the worker consider the stress as a part of work
and day-to-day life. The individual worker has been asked to give his opinion about various
problems faced in the work place which are causing different kind of physical discomforts
(i.e. stresses). The workers generally relate the discomforts and the causes behind them.
Accident due to lack of safety culture

Although most of the cement industries are new in Nepal but safety culture practice not found
in these industries. Lack of strong legislative provision and implementation of OSH
provisions and lack of management willingness for safety and productivity safety culture not
developed in this sector. Uneducated, unskilled and agriculture based workers are other
causes to not develop safety culture. Many accidents are happening due to lack of safety
culture practices.
Fire
As a generality, there are few combustible materials in the process equipment in a cement
plant, with the exception of conveyor belts. Several cases of significant conveyor belt fires
have arisen, where belt misalignment and/or friction caused heat build-up and subsequent
ignition. Thereafter the fire can spread in minutes to the entire conveyor, typically resulting in
toxic smoke emission and severe damage to the conveyor gantry. In employee health and
safety terms it is therefore vitally important that there are safe exit routes for rapid exit at
both ends of the conveyor. Heat detectors may be used at conveyor tension stations, and belts
may be purchased made of less/noncombustible material, to lessen the risk of fire.
37
7. Recommendation for Prevention and Control of Accident in Cement

Industries
7.1 Implementation of Labour Act
Good health is fundamentally important for human life. Thus, the Labor Act has incorporated
certain provisions for the health and safety of workers including neat and clean workplace
with adequate ventilation, light and sufficient space for movement of workers. The Act has
also focused to arrange for a compulsory medical examination, at least once a year, of the
workers in the hazardous job. The facilities of adequate water for drinking and washing, toilet
facilities, constructing fence around each part of the hazardous machines as well as the
restriction of overload carrying are covered in the Act to make the work environment healthy
and protective and prevent workers from the problem of occupational and communicable
diseases and incidence of industrial accidents and injuries. So, strictly implementation of
Labour Act provisions will be improved a lot in safety and health of the Cement industries
workers.
7.2 Administrative and Engineering Recommendations

Besides the implementation of Act, the Implementation of following recommendation may
help to reduce the rate of accident in Cement industries.
 Proper training programs should be conducted to educate the workers as well as their
supervisors particularly on occupational safety and health.
 The machinery should be regularly checked and maintained.
 All the moving drives i.e. belt drives, rollers and gear drivers should be properly
guarded or fenced.
 Adoption of good housekeeping practices by marking with yellow line will improve a
lot in Cement industries.
 Proper cable size and connection reduce the fire and electrocution.
 Introduction of scheduled and preventive maintenance will reduce many accidents.
 Introduction of tight working dress for all workers and banned to wear loose clothes
will reduce the many major and fatal accidents.
 Proper and suitable PPE should provide to the workers.
 Fire prevention plan and fire extinguishing system should be compulsory to the all
Cement industries.
 Workers should provide the stress management program. Management should listen
and solve the workers views and problem.
 All Cement industries should make No Smoking zone for whole premises.
 Compulsorily introduce induction training for all new workers.
 Emergency preparedness system should introduce in all Cement industries.
 Regular health check-ups and health awareness programs should be conducted for the
workers.
 Appropriate work schedules should be developed and the workers should be assured
of their job.
 Health and accidental insurance for the workers should be provided.
 Provision of first aid must be compulsory in all industries.
 Treatment in the hospitals must be efficient.
 The working condition in the industries should be made more scientific and concerned
government authorities should regularly check the standard.
38
7.3 Effectiveness of Safety Measures:

Depending on the cause, nature, severity and longevity, the Labor Act 1992 specifies that
some of them are financially compensable and some are compensable by paid leave and some
are simply the injury required medical treatment only. The amount of compensation
(including paid leave) in Nepal is specified in the Labor Act as mentioned in the section IV of
the study or and bilateral agreement between workers and management. Depending on the
nature, severity and longevity of illness, an injury (accident) occurred during the work place
because of genuine cause is known as compensable injury. Thus, on-the-job injuries caused
by defective machinery, fires or explosions at work, lifting of heavy equipment or material or
slipping on an oily floor surface at work are some of the example of compensable accident.
Similarly, some of the illnesses are also compensable in Nepal. However, no all accidents are
considered fully compensable in Nepal.
7.4 Good Practices in Safety

The following good practice in safety in cement plants will reduce the accidents:
7.4.1 Mobile Plant

Common hazards associated with the heavy plant (e.g. dumper trucks, front loading shovels,
fork lift trucks) used in quarrying and bulk material transport include vehicle impact and
twisted ankles during embarking and disembarking. Vehicle impact has the potential for
particularly high severity incidents, both in quarries and on the manufacturing sites. Incidents
can be reduced by improved driver training, increasing awareness of the people working
alongside these vehicles, and by using dedicated routes and crossings to help keep vehicles
and pedestrians apart. Modern vehicles also offer improved visibility, helping further reduce
the risks as the older equipment is replaced.
7.4.2 Working at Height

Controls relating to working at height or in confined areas (e.g. Permit-to-work, task risk
assessment) are effective in reducing injuries by raising awareness of the hazards and
ensuring the correct work methods are followed and that the proper precautions are taken.
Mandatory use of safety equipment (harnesses, safety nets) to properly protect workers from
falls, posting of permits, and regular inspections of the job site are commonly employed
techniques.
7.4.3 Plant Isolation/Lock-Out
Plant Isolation is one of the most important areas of plant safety, with improvements in the
technology in the industry, these procedures become more however effective systems which
fully isolate machinery from all energy sources are essential.
Any isolation of energy systems; mechanical, electrical, process, hydraulic and others, cannot
proceed unless:
 the method of isolation and discharge of stored energy are agreed and executed by a
competent person(s)
 any stored energy is discharged
 a system of locks and tags is utilized at isolation points
 a test is conducted to ensure the isolation is effective
 isolation effectiveness is periodically monitored
7.4.4 Slips, Trips and Falls
39
Slips, trips and falls are another common cause of injuries in the industry. These can arise
from the uneven surfaces in the quarries and roads and from lapses in good housekeeping
within the manufacturing plants. As borne out in the injury analysis, Slips, Trips and Falls
cause almost 30% of all injuries. (See appendix for Slips, Trips and falls Prevention Policy)
Slips, trips and Falls can be minimized through following simple housekeeping procedures:
 Keep work places tidy
 Use the scrap and dirt bins where provided
 Tidy stacking and tidy layout prevents injuries
 Good housekeeping leads to greater safety
 Pile material so that it is stable and steady
 Put tools and other equipment where they cannot possibly fall or be knocked on to
someone below.
 Clearly mark, fence or cover all openings in floor, roof or ground.
 Keep gangways, paths, roads and stairways clear of obstacles
 All excavations in the plant should be surrounded with a handrail
 Provide all scaffolds and platforms with toe boards and railings.
 When working overhead remove all loose material such as bolts, screws, tools,
timbers, fittings, etc. when the job is finished.
 Never throw tools or materials, always pass them from hand to hand.
 A nut or bolt falling from a height can kill a person.
7.4.5 Manual Handling

Due to the repetitive nature of some of the tasks related to cement production, it is very
important to ensure that the correct training in given to employees in relation to manual
handling. (See appendix for Manual Handling Procedures)
Size up the job first. If you think it is too heavy, get help – or use a crane or fork lift.
 Look out for sharp edges, splinters and nails.
 Pull out or knock down projecting nails before you pass material on or throw it out for
scrap
 Don’t try to carry a load you cannot see over.
Remove obstructions before lifting.

 Stack goods carefully and tidily on trucks and trailers
 When lifting heavy objects, use your legs as much as possible to save your back
muscles.
 Get a good grip of the articles
 Keep your back straight and chin in
 Slacken and bend your knees
 Take up a firm stand, lift steadily and do not twist your body
 When lifting or guiding pieces of equipment, watch for nipping points.
7.4.6 Fire
Firefighting procedures must also be in place. Electrical cables may also cause or transmit a
fire, also with emission of highly toxic smoke. For that reason, cable tunnels can present a
40
significant safety hazard in case of fire, and it is very important to have defined routes for
rapid personnel exit. Storage of fuels of all types must of course be in accordance with local
fire regulations and good practice. This applies also to external stockpiles of coal, pet-coke,
tyres and the like, where appropriate fire precautions will be required, particularly in hot dry
weather. It goes without saying that storage of waste combustible materials will create a fire
hazard. Proper waste disposal and good housekeeping is the best form of prevention.
7.4.7 Electrocution
As cement plants are very energy intensive, there will be significant power distribution
equipment in all plants. Electrical maintenance must be conducted on a professional basis not
to present safety hazards. Isolation/Lock-out procedures must be rigorously adhered to. Due
cognizance must be given to the possibility of back-feed due to looped systems or
energization in reverse direction: the electrical supervisor must manage these issues.
It goes without saying that non-competent or unauthorized persons should not open up or
attempt to work on electrical equipment, even if intended as part of plant isolation
procedures. If such persons need to access inside electrical equipment (for example to re-set
overload trips), then they must be protected against injury by contact with live terminal and
busbars (such as by covering these in plastic housing).
The other main electrical hazard to be considered is accidental contact by high vehicles or
equipment touching overhead wires. If such overhead wires exist, then appropriate warning
signs and “gates” will be required to prevent contact. It will also be beneficial to provide
instruction, in case of such an incident, in jumping clear without simultaneous vehicle to
ground contact.
7.4.8 Machine Guarding
Where there is a risk of physical contact with moving parts of work equipment which could
lead to injuries, those parts must be provided with guards or devices to prevent access to
danger zones.
7.4.9 Heat Burns
Incidents and injuries resulting in burns arise from contact with hot clinker or cement
powder. Hazards are particularly associated with hot cement kiln dust (CKD), and dust on
preheater systems. Chemical (alkali) burns may also result from contact with CKD. During
normal operation the hot raw, intermediate and final products are contained or highlighted.
There is far greater risk when contact is possible during abnormal operation of the plant,
when clearing blockages, carrying out maintenance or in emergency situations. It is not
always obvious when something is hot, the risks include personal injury – severe burns and
fire – from contact with combustible materials; oils, scaffold boards, ladders, electrical
cabling, etc.
41
8. Roles of Stakeholders:
Maintaining the health and safety in cement industries is not only the matter of concern of the
victims but also the role of other stakeholders, because the poor health and accident of
industrial workers bring many problems in the society as a whole. Thus, this section of the
study focuses the role to be played by the government, management and trade unions
considering as the prime concerned parties in the issue.
8.1 Role of Government

The government, as an actor of industrial relations system, can play crucial role in reducing
the incidents of industrial accidents and the problem of occupational health by formulating
appropriate labor laws. Government is only that actor in industrial relations system, which
controls relationship between other two actors, employers and employees and maintains
harmonious industrial relations in the country. The government renders the task of regulating
standard of health and safety measures in enterprises by using the authority mentioned in the
concerned laws formulated as guided along by the constitution, ILO conventions and
recommendations, labor policies and labor movements.
8.2 Role of management

The sound health and safety measures not only result in reduced rate of industrial accident,
absenteeism, and turnover, physical and mental, strain of workers and wastage of resources
but also raise efficiency in production, boost moral team spirit and the sense of belongingness
among the employees. The poor health and hazardous work cause suffering and distress to
workers and their families. They also represent an important mental loss to the industry in
particular and society in general. Hence, it is a prime responsibility of every management to
ensure about good health and safe environment in the industry.
8.3 Role of trade union

As the source protection of the rights and interests of the members, trade unions can help
enterprise for effective implementation of the legal provisions made for the prevention,
promotion and development of health and safety measures for workers at workplace. Unions
can pressurize government for the enactment of health and safety friendly labor laws and
management to implement it effectively.
42
9. Conclusion
Good health is fundamentally important for human life. Thus, the Labor Act has incorporated
certain provisions for the health and safety of workers including neat and clean workplace
with adequate ventilation, light and sufficient space for movement of workers. Labor Act, the
magnitude of industrial accident and the problems of occupational health are not reduced at
satisfactory level in Nepal, since there is always a demand from the side of workers in their
charter of demands about the maintenance for health and safety in their workplace. Therefore,
the Act has to make a special provision of multipartite committee, instead of the present
safety committee in enterprises, to determine standard of work and criteria for health and
safety measures at the workplace, representing management, trade unions, labor office and
experts in order to reduce the magnitude of industrial accidents and the problems of
occupational health in Nepalese industries.
Cement Industries considered as a hazardous and accident prone industries. Exposures of

high dust, Noise are the major hazards along with mechanical and electrical hazards in
Cement industries. Besides these hazards risk of the accident and fire are also very in this
industry. None of the industries have the system adapted to manage safety and health in
Cement industries. New, unskilled workers are mainly victim of accidents in Cement
industries. Awareness and training regarding safety and health were in very poor stage.
43
10. References:
– Accident in Manufacturing industries in Nepal, OSHP, 2011
– Baseline Study Report for Cement Industries in Nepal, ESPS/DANIDA 2004
– FNCCI (various years). Nepal and the World: A Statistical Profile. Kathmandu:
Federation of Nepalese Chambers of Commerce and Industry (FNCCI).
– FNCCI. (1997). Survey Report on Wages, Working Condition in Manufacture
Industries in Nepal. Kathmandu: FNCCI.
– Global Estimates Of Occupational Accidents – Hamalainen, Takala, Saarela – 2005.
– Global Estimates of Occupational Accidents – Sixteenth International Conference of
Labour Statistician (1998) –
(http://www.ilo.int/public/english/protection/safework/accidis/globesti.pdf)
– Hamalainen, P. Takala, J. and Saarela, K. L.( 2006). “Global Estimates of
Occupational Accidents”. Safety Science, Vol. 44 .pp. 137–156.
– Karl Marx - "Capital", Vol.1, Progress Publishers, Moscow, 1984, p – 474
– Labor Act 1992. Kathmandu: The Law Book Management Committee.
– Labour Rules 1993. Nepal Gazettee, Nov. 8 1993,
– Laurie, Andrina (1998). Statistics of Occupational Injuries: Report III of the Sixteenth
International Conference of Labor Statisticians held in Geneva from 6 - 15 October.
Geneva: International Labor Office.
– Nepal South Asia Centre (1998). Nepal Human Development Report 1998, Nepal
South Asia Centre, Kathmandu.
– Park, J.E. and Park, K. (1991). Park's Textbook of Preventive and Social Medicine,
13th edition, Jabalpur: Banarsidas Bhanot, Jabalpur.
– Pun, Khumraj (2011). Occupational Safety and Health Situation in Industrial Sector in
Nepal. Http:// www.scribd.com/doc/50002585/Occupationalsafety-and-health-in-
industrial-sector-in-nepal . Accessed on 6 August 2011.
– Somavia, J. (2004). Global strategy on occupational safety and health – conclusions
adopted by the international
– www.hse.gov.uk/statistics/industry/manufacturing/manufacuring.pdf
– (http://www.ilo.org/public/english/protection/safework/cops/english/download/e9109
72.pdf)
– (http://www.who.int/oeh/OCHweb/OCHweb/OSHpages/OSHDocuments/WHOOSH
Documents/WHOOCHDocuments.htm)
– Japan International Centre for Occupational Safety and Health (JICOSH), Guidelines;
(http://www.jicosh.gr.jp/english/guideline/index.html)
44
Annex 1: Provision for Compensation:

The Labour Act 1992 and the Labour Rules 1993 have made the following provision of
compensation to the workers in case of ill health and accidents during the work.
Labour Rules, 2050 (1993)

Publish in Nepal Gazettee 2050.7.23 (Nov. 8, 1993)
In exercise of the powers conferred by Section 86 of the Labour Act, 2048 (1991),
Government of Nepal has framed the following Rules.
Section 15. Compensation against injury:

(1) In case a worker or employee is injured while doing a work designated by Enterprise, the
whole amount incurred on his/her treatment, shall be paid by the Proprietor, as compensation,
to such worker or employee on the recommendation of the medical practitioner recognized by
Government of Nepal.
(2) In case of a worker or employee, after being injured in course of doing the works
designated by the Enterprise, is unable to work and is required to undergo treatment staying
at home or Hospital, the Proprietor shall have to provide the full remuneration in case of
treatment in the Hospital; half of the remuneration in case of treatment undergone at home for
that period, in addition to the compensation to be provided pursuant to Sub-rule (1). Provided
that, the Proprietor need not to provide any remuneration for the period for more than One
year in case the treatment has to be undergone for more than that period.
Section 16. Compensation in case of grievous hurt resulting in physical disability:

(1)In case a worker or employee is grievously hurts leading to the physical disability while
doing the works designated by the Enterprise, then such a worker or employee shall be paid
by the Proprietor a lump sum amount equivalent to his/her Five years remuneration at the rate
of his/her current remuneration, if the disability of the worker or employee is of Hundred
percent, which being determined on the basis of percentage of disability as mentioned in the
Schedule.
(2)While paying compensation for the injury leading to the disablement, by the Proprietor to
the concerned worker or employee pursuant to this Rule, and compensation amount payable
equivalent to the percentage of his/her disablement as mentioned in Schedule assuming Five
years of remuneration amount for the Hundred percent disablement.
Section 17. Compensation in case of death:

If any worker or employee dies immediately or during treatment as a result of an accident
while doing the works designated by the Enterprise, compensation equivalent to the amount
of Three years of remuneration of the deceased shall be provided by the Proprietor, in lumps
to the nearest heir of the deceased worker or employee.
Section 18. Determination of the percentage of disablement:

In case any worker or employee is injured leading to physical disablement as a result of an
accident while working in the Enterprise, the Industry Inspector after getting determined the
percentage of disablement of such worker or employee as mentioned in schedule (Attached as
an Annex) from the medical practitioner recognized by Government of Nepal shall get the
compensation paid to such worker or employee by the Proprietor pursuant to Rule 16.
Provided that, the determination of percentage of disablement of worker or employee shall
not be more than Hundred percent.
45
Section 19. Circumstance not receiving compensation:

In case a worker or employee dies or succumbs to injury leading to physical disablement, due
to natural calamities while working the work designated by the Enterprise, the heir of such
worker or employee shall not be entitled to the compensation pursuant to these Rules.
Section 20. Double compensation shall not be received:

In case any Enterprise has procured any sorts of insurance of its workers or employees, then
such worker or employee shall get only either the compensation amount pursuant to these
Rules or the compensation amount of insurance whichever is greater.
Section 21. May be terminated from service awarding compensation and gratuity:
In case any worker or employee gets injured as a result of an accident while working in the
Enterprise and does not get recovered even after treatment up to One year or is certified by a
medical practitioner recognized by Government of Nepal that he/she is unable to work due to
disablement caused by accident, then such worker or employee may be terminated from
service by the Proprietor by providing compensation pursuant to Rule 16, in addition to the
gratuity under these Rules.
Section 22. Priority to be given for occupation:

The members of the dependants of family of the worker or employee, who is terminated from
service of Enterprise pursuant to Rule 21 or has died as a result of accident while working in
Enterprise, shall be given priority for job according to their qualification in case a post falls
vacant.
Specifying the degree of Disablement
S. No. Particulars of the Injury Disablement in percentage
1. Loss of two limbs 100

2. Loss of two hands or loss of all fingers
Along with palm 100
3. In case of loss of total sight 100
4. Total paralysis 100
5. In case of permanent sickness as a result of
Injury 100
6. In case of loss of other eye of one eyed
Person 100
7. In case of loss of other arm who had had
only one arm 100
8. In case of loss of other foot of one footed
Person 100
9. In case of loss of one foot and one arm 100
10. In case of total and permanent incompetency
due to any other hurt 100
11. In case of total deaf 70
Condition of amputation of one Arm

12. Amputation of Shoulder Joint 80
13. In case the arm is amputed from the middle
46
of Shoulder and elbow 70

14. In case of loss of arm from elbow 70
15. In case of loss of arm from the middle of
elbow and wrist 70
16. In case of loss of hand from wrist 60
17. In case of loss of four fingers and along with
thumb of one hand 60
18. In case of loss of four fingers except thumb
of one hand 40
19. In case of loss of two flanks of the thumb 30
20. In case of loss of one flanks of the thumb 20
21. In case of loss of three flanks of the pointing Finger 14
22. In case of loss of two flanks of the pointing Finger 11
23. In case of loss of one flank of the pointing Finger 9
24. In case of loss of three flanks of the middle Finger 12
25. In case of loss of two flanks of the middle Finger 9
26. In case of loss of one flank of the middle Finger 7
27. In case of loss of three flanks of fourth and fifth finger 7
28. In case of loss of two flanks of fourth and fifth finger 6
29. In case of loss of one flank in both the fourth and fifth
finger 5
30. In case of additional loss in first or second meta carpal 5
31. In case of additional loss in third, fourth or fifth meta carpal
Condition of amputation of any one or of both the legs

33 In case both the thigh are amputed from the middle
or in case the leg is amputed from the middle of one
thigh leading to the loss of leg of other side or the
organ is amputed below from both the knees 100
33. In case the legs are amputed 5 inch below from both
the knees 100
34. In case the leg is amputed 5 inch below from
one knee leading to the loss of another foot 100
35. In case there are only stump knees and are
bearing only after both the feet are amputed 100
36. In case there is amputation from upper joint
of metal rsophelongial joint of both feet 90
37. In case there is loss in all the fingers below
metarsophelongial join of both the feet 80
38. In case there is loss upon all fingers of both
the feet form the proximal of interphelongial join 40
39. In case there in only loss in lower part from
proximal interphelongial joint of all the
fingers of both the feet 20
40. In case there is amputation from middle of
hip joint 90
41. In case there is amputation downwards to hip
joint, but if the stump of remaining leg is less
than 5 inch from troancter joint 80
42. In case the let is amputed not reaching below
47
the middle of the thigh in a way that there is

stump below the hip joint which is 5 inch
more than the trocanter joint 70
43. In case there is amputation in below from
middle of the thigh up to knee in a way not
being more than 3 1/2 inch 60
44. In case there is amputation in leg below knee
and the stump below the knee is of between
3 1/2 inch to 5 inch 50
45. In case there is amputation in leg below the
knee and the stump is 5 inch long below
from the knee 50
46. In case there is stump for aid bearing after
total amputation in one leg 40
47. In case there is amputation in one leg only
from proximal metatarsophelongial joint 40
48. In case all the fingers of one leg are amputed
from proximal metatarsophelongial joint or
are amputed from middle of metatarsophelongial joint 20
49. In case of loss of both the flanks of the toes
of the feet 10
50. In case of loss of one flank of one toe of feet 3
51. In case of loss of some portion of toe including its bone 3
52. In case of loss of finger other than toe 3 (each)
53. In case of loss any portion of any finger of
feet including bone other than toe 1
Other Specific injuries

54. In case of loss but not complicated, to
another eye, when one eye was in normal condition 40
55. In case of loss in sight or loss in retina of
other eye when one eye's sight was in normal condition 30
56. In case of loss of hearing power of one ear 20
Total recovery to be created in limbs and joints after injury

57. Spine 30
58. Shoulder joint 40
59. Elbow 40
60. Wrist 30
61. Proximal and distal radio ulnar joint 30
62. Thumb (First Metacarpal flanks joint) 63
63. One joint of any one finger other than of thumb 3
64. All the joints of any one finger other than of Thumb 10
65. All the joints of all fingers including of thumb 40
66. Hip Joint 40
67. Knee 19
68. Ankle 19
69. Joint below tails bone 19
70. Toe (First Meta flanks joint) 19
71. Joints of other fingers of feet other than toe 10
48
Paralysis of limbs or only of any part of body after injury

72. Total paralysis as a result of injury in spinal Chord 100
Total paralysis of the following limbs

73. Brachial Plexus 70
74. Radial Nerve 50
75. Median Nerve 40
76. Ulnar Nerve 40
77. Syatic Nerve 70
78. Medial Paplitial Nerve 40
79. Lateral Paplitial Nerve 30
49

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Limestone Mining for Cement Production

Coming to industrialization of limestone quarries, the common problems faced by the

Source: Specific energy consumption in Nepalese Cement industries (GIZ/NEEP, 2012)

2.2 Problem Facing by Cement Sector

2.3 Export Prospects of Cement

2.4 Foreign Direct Investment

2.5 Visited Cement Industries

2.6 Production Process of Cement Industries

Input Process Hazards

Clinker Clinker Dust

Poly bag Weighing Spillage (Reused)

Figure 2: Process Flow Chart of Limestone Based Cement Plant

2.6.2 Process Description

3.1 Concept of Accident:

A personal injury occurs as result of an accident.

3.2 Main contributing factors for Accident

4.1 100 Industrial Accident Cases in Nepal

Age and Sex wise distribution of the workers and injured:

Type of industry and number of accidents:

Training and accidents

Age distribution of the workers and the injured

Continuous work increases the risk of accident

Industry Soft tissue Close fracture Open fracture Total

Health Care, First Aid services, and Health Insurance

Frequency of Industrial accidents:

Working condition of the industry:

4.3 Accidental Cases in Cement Industries

4.3.3 Silo collapses at Fauji Cement plant in Pakistan in 01 June 2016

4.3.6 Worker dies at Shayona Cement plant in Malawi in 03 December 2014

4.4 Major Causes of Accident in Cement Industries

Typical Injury Causes & Types

4.5 Suspended Particulate Matters in Cement Industries

Dust Emission from Crushing Operation

Emissions from Material Handling

Emissions from Raw Materials and Cement Grinding

Emissions from Clinkerization

Emissions from Packing and Dispatch

Table 1 General Information of Cement Industries

4.6 Some Notable Accidents in global context

4.7 Causes of Industrial Accident

Major Causes of Work-related Deaths

4.8 Behavioral Issues in Accidents

Akal Mrityu Haranam, Sarva Vyadhi Vinashanam,

5. Accidents Record in Cement Industries

Table: Accident Records in Cement Industries

Accident in Three Fiscal Years

Minor Major Fatal Total

Result and Discussion:

6. Causes of Accident in Cement Industries

Some of the specific and technical causes of accidents in cement industries: