Cement works (cement production)

1. – GENERAL SECTOR ISSUES.

According to ISTAT-ATECO’91 classification, the productive sector “Cement Production”, corresponds to activity code 26.51; this sector belongs to the “Cement, lime and plaster production” (Code 26.5) productive sector, which in turn belongs to the “Manufacture of products from the processing of non-metallic minerals” category (Code 26).

Table –ISTAT-ATECO’91 classification of the productive sector

Cement, lime and plaster production (code 26.5).

ISTAT - aTECO’91 Activity code	ACTIVITY TITLE	DESCRIPTION OF ACTIVITY
ISTAT - aTECO’91 Activity code	ACTIVITY TITLE	DESCRIPTION OF ACTIVITY
26.51	Cement production	This class includes: § production of non-pulverised cements known as clinkers and hydraulic cements, including Portland cement, aluminous cements, slag cements and superphosphate cements. This class does not include: § production of dental cement § production of cements, mortars, concretes, refractory cements, etc. § manufacture of cement products § production of ready-to-use concrete.
26.52	Lime production	This class includes: § production of quick lime, hydrated lime and hydraulic lime.
26.53	Plaster production	This class does not include: § manufacture of plaster articles.

This risk profile refers to the activities identified by ATECO’91 code for the classification of economic activities: 26.51-Cement production.

This investigation excludes activities for lime production (ATECO code ’91: 26.52) and activities for the production of plaster (ATECO ’91 code: 26.53).

The production units that produce cement are known as cement works. They are generally industrial activities that are classified as class 1 insalubrious (no. 33 B, Ministerial Decree 05.09.1994); they are activities subject to checks by the Fire brigade for fire prevention purposes, but are generally not classified as industries subject to significant industrial accident risk (Presidential Decree 175 of 1998 and subsequent amendments) unless large stocks of gas oil are present (more than 200t).

For this study, the main territorial areas to which reference was made for the identification of risk factors, damage and preventive measures are the Florence and Arezzo areas.

With regard to the main data available on sector size, production and consumption on a national and regional level, the following data have been supplied by AITEC (Italian Technical Economical Cement Association).

Italy is the European Community’s largest cement producer, a record that it has held for the past 26 years (with the sole exception of 1994). Internationally, Italy is the world’s eighth largest cement producer and eleventh largest exporter.

In 1999, cement production in Italy totalled 37,299,000 tonnes (+ 3.4% on figures for 1998, corresponding to 19.6% of the European Community’s production). This total can be broken down as follows: 73.3% Portland, 14.1% pozzuolana cement, 5.6% blast kiln cement and 7% other types.

Almost all Italian cement (97.5%) is produced using the dry or semi-dry process, whereas the wet process is adopted for only 2.5% of production.

In 1999, cement production in Tuscany amounted to 2,024,000 tonnes (+5% vis-à-vis 1998).

Cement consumption in Italy was 36 million tonnes (+4.2% on 1998).

Italian exports in 1999 amounted to 2,572,000 tonnes, representing 6.9% of domestic production (-4% on 1998), which can be broken down into 2,480,000 tonnes of cement and 92,000 tonnes of semi-processed clinker.

The main recipient countries for cement exported by Italy are the United States (23%), Albania (21%), the Netherlands (10%) and France (8%). 72% of all exports were directed to Europe, 25% to the Americas and the remaining 3% to Africa and the Middle East. The majority of exported clinker was imported by Switzerland (65%) and Croatia (34.8%). Exports, mainly by ship, were handled by ports in Southern Italy (50%) and the larger islands (23%).

The balance of trade in 1999 referring to exported and imported cement was positive to the tune of almost 900,000 tonnes.

In 1999, as in the previous year, loose cement deliveries underwent greater increases than those of bagged cement. Loose cement deliveries amounted to 27.5 million tonnes, representing 73.8% of all deliveries, whereas bagged cement deliveries totalled 9.8 million tonnes, 26.2% of the total. Bagged product is generally used in small and medium-sized works such as building renovation. Almost all cement, be it bagged or loose, is transported by road, on the basis of a compulsory tariff system.

The increase in domestic cement production and consumption was not altogether unexpected as the serious delays accumulated in recent years, especially those concerning public infrastructures, the imminent expiry of Jubilee Year and tax concessions on building renovation work all contributed to partially toning the construction industry as a whole and, as a result, the related cement market.

The number of cement-producing companies in Italy dropped from 72 in 1969 to 37 in 1996, and then dropped further to 32 in 1997, 31 in 1998 and 30 in 1999. This downsizing was due primarily to mergers and buy-outs between firms. However, the number of cement-producing companies in Italy remains far higher than that of other western countries, where concentration was much greater.

Breakdown of Italian cement production between the principal A.I.T.E.C. member firms and groups for 1999.
Company name	N° of firms	production units	production %
Italcementi	1	34	31.2
Buzzi Unicem	4	13	19.0
Colacem	4	7	11.6
Cementir	2	4	8.1
Cementi Rossi	1	4	5.8
Merone	1	4	5.8
Sacci	1	4	3.6
Lafarge Adriasebina	1	2	2.9
Barbetti	1	2	2.8
Cementizillo	1	2	2.6
Insicem	1	2	1.7
Monselice	1	1	1.6
Cementi Moccia	1	1	0.9
Cementi della Lucania	1	1	0.5
Other companies	8	8	1.9
Total	30	89	100.0

Source: A.I.T.E.C.

The 89 production units in Italy are distributed as follows: 43 in the North, 15 in Central Italy, 22 in Southern Italy and 9 on the islands.

In Tuscany there are 6 production units, of which 4 perform the entire production cycle and 2 the grinding phase only.

Research conducted by the Chamber of Commerce (Unioncamere) gave the following results:

Table - NUMBER OF LOCAL UNITS in Tuscany, year 1999.

Productive sector: Cement, lime and plaster production. ATECO’91 activity code: 26.5,

Activity code	DESCRIPTION OF ACTIVITY	total local units Tuscany region	No. of local units per province
Activity code	DESCRIPTION OF ACTIVITY	total local units Tuscany region	AR	FI	GR	LI	LU	MS	PI	PO	PT	SI
26500	Cement, lime plaster production	5	2	1				1	1
26510	Cement production	32	6	1	4	3	5	1	4		1	7
26520	Lime production	14	1	3	2	1	1	1	2		1	2
26530	Plaster production	29	1	13			7	2	1			5

(Legend table: AR = Arezzo, FI = Florence, GR = Grosseto, LI = Livorno, LU = Lucca, MS = Massa Carrara, PI = Pisa, PO = Prato, PT = Pistoia, SI = Siena)

Source: processed by A.R.P.A.T. - S.I.R.A technical sector.

Based on data supplied by the Chamber of Commerce (Unioncamere).

Table - NUMBER OF WORKERS in Tuscany in 1999.

Sector: cement production, ATECO’91 activity code: 26151,

Activity code	description of activity	total workers Tuscany region	Number of workers per province
Activity code	description of activity	total workers Tuscany region	AR	FI	GR	LI	LU	MS	PI	PO	PT	SI
26500	Cement, lime, plaster production	42	16	0				0	26
26510	Cement production	302	125	61	1	22	21	27	7		4	34
26520	Lime production	76	1	21	10	0	12	2	29		0	1
26530	Plaster production	167	3	40			46	3	3			72

(Legend table: AR = Arezzo, FI = Florence, GR = Grosseto, LI = Livorno, LU = Lucca, MS = Massa Carrara, PI = Pisa, PO = Prato, PT = Pistoia, SI = Siena)

Source: processed by A.R.P.A.T. - S.I.R.A technical sector.

Based on data supplied by the Chamber of Commerce (Unioncamere).

With regard to occupational diseases and accidents, the following data were supplied by INAIL (Italian Institute for Insurance of Occupational Accidents):

Table-Accidents reported to INAIL 1995-1999,

showing recognised and indemnified cases

Productive sector: CEMENT WORKS

ACCIDENTS-Tuscany Region
YEAR	REPORTED CASES	INDEMNIFIED			TOTAL INDEMNIFIED
		TYPE OF CONSEQUENCE
		TYPE OF CONSEQUENCE
		TEMPORARY	PERMANENT	DEATH
1995	49	45	1		46
1996	43	37	1		38
1997	52	49	1	1	51
1998	47	39	2		41
1999	45	43			43
Total 1995-1999	236	213	5	1	219
ACCIDENTS - Italy
YEAR	REPORTED CASES	INDEMNIFIED			TOTAL INDEMNIFIED
		TYPE OF CONSEQUENCE
		TYPE OF CONSEQUENCE
		TEMPORARY	PERMANENT	DEATH
1995	970	879	28	3	910
1996	929	818	27	3	848
1997	835	749	24	4	777
1998	813	699	33	7	739
1999	769	683	19	1	703
Total 1995-1999	4,316	3,828	131	18	3,977

Source: INAIL

Table-Occupational diseases reported to INAIL 1995 - 1999,

showing recognised and indemnified cases

Productive sector: CEMENT WORKS

OCCUPATIONAL DISEASES-Tuscany Region
YEAR	TYPE OF OCCUPATIONAL DISEASE			ILLNESSES REPORTED	INDEMNIFIED ILLNESSES
					TYPE OF CONSEQUENCE		TOTAL Indemnified
					Temporary	Permanent
	Code		Description		Temporary	Permanent
1995	43		Pneumoconiosis from the quarrying and treatment of silicate rocks.	2	0	0	0
	50		Hypoacusia from crushing or grinding at the mills used for cement production.	1	0	1	1
	91		Asbestosis.	1	0	1	1
	99		Non specified	5	0	0	0
	Total 1995			9	0	2	2
1996	50	Hypoacusia from hammering, boiler and tank scarfing noise.		2	0	0	0
	50	Hypoacusia from crushing or grinding at the mills for minerals and rocks.		1	0	0	0
	50	Hypoacusia from drilling with pneumatic metals.		2	0	2	2
	90	Silicosis.		1	0	0	0
	99	Not specified		1	0	1	1
	Total 1996			7	0	3	3
1997	05	Hexavalent chrome compounds.		1	0	1	1
1997	Total 1997			1	0	1	1
1998	99	Not specified.		1	0	0	0
1998	Total 1998			1	0	0	0
1999	43	Pneumoconiosis from the extraction and treatment of silicate rocks.		1	0	1	1
1999	Total 1999			1	0	1	1
TOTAL 1995-1999				19	0	7	7

Source: INAIL

With regard to energy consumption in 1999, the following data are supplied by A.I.T.E.C.

The cement industry is a high-energy use industry, with energy costs accounting for some 30-40% of total production costs. In 1999 the fuels used for the semi-processed clinker were mainly fossil fuels.

In almost all cases, cement producers were supplied by domestic dealers, supplying fossil coal from South Africa, ex-Soviet Union, Colombia, whereas petroleum coke came from the United States and Venezuela.

In 1999 the consumption of electricity used by the cement industry represented approximately 3% of total power absorbed by Italian industry and 32% of the total energy used in the construction materials industry.

In 1999 mean unit energy consumption for producing a tonne of cement, equalized to dense combustible oil, corresponded to 72 kg of fuel and 117.4 KWh, against 69.1 Kg. and 115.3 KWh in 1998.

ENERGY CONSUMPTION FOR ITALIAN CEMENT PRODUCTION IN 1999
Type	Consumption		Change % on 1998
Electricity	4,378,527,551	KWh	+ 5.3
Methane	111,272,317	m³	- 4.7
Coal	2,725,389	tonnes	+ 6.7
Dense combustible oil	314,913	tonnes	+ 10.0
Non-conventional fuels	64,371	tonnes	+ 135.8

Source: A.I.T.E.C.

In general, cement works are known as one of the industrial activities that employ waste-derived fuel (WDF). The use of CDR currently appears linked to a series of difficulties connected to Italian and EU legislation on environmental issues, economic convenience and relations between WDF producers and cement production firms.

With regard to the production of waste, the table below shows data from the processing of declarations in the “Modello Unico” tax return form.

The first column shows the PCER2 code, which indicates the class of the first two figures of the waste code according to the European code (European Waste Catalogue, which uses 6-figure codes to identify the various types of waste); P, where present, specifies a hazardous type of waste (hazardous and non-hazardous waste can belong to the same class). The two-figure code (PCER2) corresponds, as per the legend, to the description of the type of waste. The quantities are expressed in tonnes.

Table - STATISTICAL DATA ON WASTE PRODUCED (quantities expressed in tonnes)

Sector: cement production, activity code 26510, Tuscany Region, 1999.

PCER2	DESCRIPTION OF TYPE OF WASTE	Total waste produced	AR	FI	GR	LI	LU	MS	PI	PO	PT	SI
01	Waste deriving from the prospecting, quarrying, treatment and further processing of minerals and quarry materials.	4.923	1.5	3.423
06	Waste from inorganic chemical processes	195.935										195.9
06_P	Waste from inorganic chemical processes	77.762		65.88								11.88
07_P	Waste from organic chemical processes	0.182		0.182
08	Waste from the production, formulation, supply and use of coatings (paints, varnishes and glazed varnishes), sealants and printing inks.	99.092		98.79								0.3
08_P	Waste from the production, formulation, supply and use of coatings (paints, varnishes and glazed varnishes), sealants and printing inks.	0.164		0.164
09_P	Waste from the photographic industry	0.002		0.002
10	Inorganic waste from thermal processes	63.244	2.7	51.4								9.15
12	Waste from processing and superficial treatment of metals and plastic.	0.3		0.3
12_P	Waste from the processing and superficial treatment of metals and plastic	18.2		18.2
13_P	Exhaust oils (excluding edible oils 05 00 00 and 12 00 00)	0.06		0.06
14_P	Waste from organic substances used as solvents (excluding 07 00 00 and 08 00 00)	0.061		0.061
15	Packaging, absorbents, rags, filtrating materials and protective clothing (otherwise unspecified)	77.769		6.857								70.91
16	Waste not otherwise specified in the catalogue	0.6	0.6
17	Building and demolition waste (including road building)	20.17	2.4									17.82
19	Waste from waste processing plants, off-site refuse water processing plants and water industries	1.52		1.52
20	Solid urban waste and similar from retail, industry and institutions including waste from differentiated waste collection for recycling	477.291	270	12.84			123.9					70.36

Source: processed from Modello Unico declarations

Regional Waste Registry Office (A.R.P.A.T.-Regional Section of Waste Register)

The central elements on which the authorisation process for the operation of industrial plants introduced by Directive 96/61/EC “Integrated prevention and reduction of pollution)”, assimilated in Italy with Environment Ministry Decree 503 of 19.11.1997 - Law 128 of 24.04.1998-Legislative Decree 372 of 04.08.1999 “Implementation of Directive 96/61/EC concerning the Integrated prevention and reduction of pollution”, are based, include the so-called Best Available Technology (BAT). These represent one of the technical elements available to competent Administrations for determining, when issuing authorisations, the technical prescriptions and threshold values that the plant must conform to.

The Institute for Prospective Technological Studies (I.P.T.S.) of Seville, the institute appointed by the EU Commission to prepare the Reports on the best available techniques, has drafted the BREF (Best Available Techniques REFerence document) document entitled “Reference report on the best techniques available for the cement and lime industries”.

The document is available on the Internet: http://eippcb.jrc.es/pages/FActivities.htm

2.-GENERAL DESCRIPTION OF A WORK CYCLE

The work cycle of the sector’s companies is aimed at the production of cement.

Cement is a finely ground product with a flour-like appearance that forms, when a suitable quantity of water is added, a binding paste with varying degrees of fluidity and that hardens in a varying amount of time in water or air and is capable of agglomerating various materials. These properties make it suitable for use in the construction trade. It belongs to the hydraulic binder category.

There are various types of hydraulic binder, such as: Portland cement, pozzuolana cement, blast kiln cement, aluminous cement, cement agglomerates, hydraulic limes, etc.

The definitions, technical characteristics and requisites of hydraulic binders are described in articles 1 and 2 of law 595 of 25.05.1965.

For the production of cement, firms in Tuscany perform the production cycle using the dry process (this means that the raw materials, once ground and homogenised, are introduced into the kiln in a dry powdery state called perlite), or using the semi-dry process (meaning that the raw perlite is dampened, in order to form small agglomerates of perlite and water, which are introduced into the kiln for firing).

The raw materials used for cement production are essentially mineral materials (marl, plaster, limestone, etc.) and sub-products of other processes (ashes, “marmettola” or waste derived from marble processing, dross, slag).

Marl, limestone and other corrective materials are introduced into a rotating vertical cylinder mill, where they undergo an initial transformation that consists in their being crushed to form a homogeneous flour-like mixture; a second transformation then entails firing at a temperature of 1,400°C in a kiln usually fuelled by carbon powder, with combustion obtained using another type of fuel (gas oil or methane or waste-derived gas). The material obtained from firing (known as clinker) is a type of artificial rock composed of lumps of agglomerated powder. The clinker is cooled and stored in silos before undergoing a 3^rd transformation, which entails crushing by means of a rotating horizontal cylinder mill fitted with internal metal spheres.

During this operation other substances (in particular plaster), chemical additives and secondary materials are added in order to obtain powdered cement with the desired qualities. Part of the cement produced is automatically bagged in 50Kg sacks, which are then packed onto pallets and loaded onto heavy goods vehicles. The remainder is delivered loose to clients in automatic-loading tankers.

Generally speaking, cement production can be broken down into the following working phases:

- REMOVAL OF MARL FROM MINE

- MARL CRUSHING

- STORAGE AND TRANSPORTATION OF CRUSHED MARL

- STORAGE AND TRANSPORTATION OF LIMESTONE

- BLENDING OF RAW MATERIALS

- GRINDING OF UNFIRED BLEND

- HOMOGENISATION AND STORAGE OF RAW PERLITE

- PERLITE GRANULATION

- FIRING IN KILN

- STORAGE OF COMBUSTIBLE OIL FOR FUELLING KILN

- STORAGE AND GRINDING OF CARBON FOR FUELLING KILN

- COOLING OF CLINKER

- STORAGE OF CLINKER AND MIXING WITH ADDITIVES

- CEMENT GRINDING

- STORAGE AND DISPATCH OF LOOSE CEMENT

- BAGGING AND DISPATCH OF BAGGED CEMENT

- ELECTRICAL MAINTENANCE

- MECHANICAL MAINTENANCE

- MANAGEMENT OF ATMOSPHERIC EMISSIONS ABATEMENT PLANT

- CLEANING OF FACTORY YARDS

- PURIFICATION OF YARD WASHING WATER

- TECHNICAL, ADMINISTRATIVE AND SALES DEPARTMENTS

The overall surface area of a cement works can be extremely large. For example, one cement works in the province of Florence has a 50-hectare marl mine (mining concessions for 500 hectares) on the sides and top of a hill close to the factory. The factory is sited in a valley and is formed by a number of large buildings of considerable height, connected to one another by a transportation system for material being stocked and processed.

The central phases of cement production (in other words, downstream from marl quarrying and upstream from dispatch) are completely automated and the personnel present is mainly engaged in machinery monitoring operations on a patrol basis, circulating between the various productive departments with the aim of overseeing the functionality of the plant and with the task of signalling any malfunctions, maintaining constant contact with the Control Room.

Special attention must be paid, especially for large plants, during routine and occasional plant maintenance, which are often contracted out to third-party firms.

The workers involved in the 1^st, 2^nd and 3^rd transformations described above work around the clock in three eight-hour shifts. Bagging and mining staff work two eight hour-shifts per day and remaining workers work one eight-hour shift.

The diagram below gives a general outline of a work cycle.

Block diagram of the main work phases in a CEMENT WORKS

RISK ANALYSIS AND SOLUTIONS

CRUSHING OF THE COARSE MARL EXTRACTED FROM THE QUARRY

PHASE DESCRIPTION

The purpose of this work process is to crush the marl extracted from the quarry in the form of coarse pieces. In general, the crushing of the marl takes place at the foot of the quarry in order to facilitate transportation to the cement works. A special mill is used for crushing.

The transportation of crushed marl to the cement works involves conveyor belts when the quarry is downhill from the quarry or (when the distance between the quarry and the cement works does not make it possible to adopt the former solution) heavy goods vehicles.

The press and conveyor belts are remotely controlled from a centralised Control Room, thus there are no fixed workstations in this department. Workers access the department for testing, cleaning and maintenance work.

EQUIPMENT AND MACHINERY

Hammer mill

The purpose of this machine is to crush the marl extracted from the quarry until pieces with a maximum diameter of approximately 5 cm are obtained. A typical firm has a hammer mill fitted with a 500V, 184 kW electric motor, with belt transmission.

The material to be crushed is introduced into the machine using a sturdy loading hopper (for example with a capacity of 80 m³). Exiting the machine, the crushed marl is unloaded onto a discharge hopper and is taken by a conveyor belt to the covered deposits downhill or loaded onto heavy goods vehicles.

In general, the mills are fitted with dust remover systems connected to a sleeve filter for the recovery of dust and abatement of dust emission into the atmosphere.

The hammer mill undergoes maintenance by workers for: periodical replacement of the hammers, rotor, belt, shaft, control unit; repairs to the structure and its casing; testing and restoration of accident prevention devices.

Conveyor belts

These are rubber or drag-chain conveyor belts. They undergo worker maintenance for the routine replacement of the ratio motor, control unit, machine parts, rubber belt, rollers, chain elements; and the testing and restoration of the accident prevention devices.

RISK FACTORS

Exposure to noise

Description

In this sector the noise derives primarily from loading and crushing operations during the operation of the hammer mills. Personal worker exposure is limited by the fact that continuous presence near the plant is not required.

Estimate

Noise levels higher than 90 dB(A) have been measured in the vicinity of the plant.

Expected damage

Continuous exposure to medium-high noise levels can cause hearing damage (hypacusia caused by noise) and non-hearing-related damage. The latter can also be caused by exposure to levels lower than those for which regulations prescribe particular preventive measures.

In addition to communication and occupational performance disorders, the following may also occur: cardiovascular alterations (increase in blood pressure, etc.); psychological disorders (asthenia, irritability, depression, insomnia); digestive system disorders.

As a result of the need to speak loudly for verbal communications in noisy conditions, the vocal cords may be subject to stress, which may be a contributing cause (together with exposure to an unfavourable microclimate and to dust) of throat diseases with hypophonesis.

PREVENTIVE MEASURES

- Perform regular plant maintenance.

- Soundproof the noisiest machines and separate them from other workrooms.

- Replace the oldest and noisiest machines with newer, less noisy ones.

- Organise work in such a way as to reduce worker exposure times.

- Perform noise assessments and apply the preventive measures set out in Legislative Decree 277/91, summarised in the table entitled “Noise exposure threshold values”, included in this document in the chapter entitled “General reference norms”.

reference norms

- Art. 24 “Noise and shaking” Presidential Decree 303 of 19.03.1956.

- Item IV “Protection of workers against the risks of exposure to noise during work” Legislative Decree 277 of 15.08.1991.

- Presidential Decree 459 of 24.07.1996 “Regulation for the implementation of directives 89/392/EEC, 91/368/EEC, 93/44/EEC and 93/68/EEC concerning the reconciliation of Member State Legislation on machinery” (Machinery Directive).

Exposure to dust

description

In the event of marl dust leakage from the plant, workers may be exposed during patrol checks, but above all during cleaning and maintenance work.

Expected damage

Marl is a natural rock primarily composed of limestone and clay (in turn formed by iron and aluminium silicates), with a low crystalline free silica content (1%); personal exposure to marl dust can cause irritation to the respiratory tract and pneumoconiosis from mixed dusts.

Dusty environments may also increase the risk of accidents.

preventive measures

- The entire system (especially the hoppers, mill, joints of loading and unloading points of the conveyor belts) should be closed and fitted with a localised exhaust system connected to a dust exhaust filter.

- Remove any material that has leaked from the plant as swiftly as possible, in order to prevent particular atmospheric conditions (e.g. windy days) lifting and spreading the dust.

- When removing material that has accidentally leaked from the system, it is advisable to avoid procedures that could lift the dust (such as use of shovels and/or brooms), in favour of industrial pneumatic cleaning appliances (centralised systems for extracting large quantities of dust or granular material) and road sweepers for cleaning yards. In this way, one reduces both exposure to powders and the risk of musculo-skeletal damage caused by the use of manual equipment such as shovels.

- Limit access to dusty environments and, in the event of maintenance and/or substantial accidental leakage of dust from the plant, use personal protection devices (dust-proof facemask, airtight goggles, gloves, work gear, accident prevention shoes, hard hat, ear protectors and/or plugs), if the worker wears glasses, the lenses of the dust-proof goggles must be graduated.

- Perform thorough equipment maintenance operations; it is useful to include a control device on the conveyor belts’ idle rotation rollers, connected to an automatic device that, if one belt jams for any reason, stops the other belts connected to it in order to prevent material build-ups.

- Arrange for marl powder recovery using the dust exhaust system filter in order to prevent worker exposure.

- Implement codes of conduct and hygiene: after use at the end of the work shift, filtering facemasks must be stored in a place that is uncontaminated by dust or alternatively disposed of if the disposable type is used; when performing dirty work or work involving exposure to dust or other harmful agents, both workers and partners must be permitted access to double compartment lockers for storing civilian and work clothes and must have adequate access to washing facilities (showers, wash basins, etc.) kept in a good state.

- Worker medical information, training and surveillance.

reference norms

- Consolidation Act 1265/34 and Decree of the Ministry of Health 05/09/94 (Insalubrious industries).

- Title II, Art. 9 “Airing closed workplaces” and Item II “Protection against harmful agents” of Presidential Decree 303 of 19.03.1956 “General occupational hygiene norms”.

- Legislative Decree 626 of 19.09.1994 and subsequent amendments and additions.

- Presidential Decree 336 of 1994 (Occupational diseases).

Work in the vicinity of moving mechanical parts

description

Unless adequately protected, operating parts and mill motion drive belts may entail the risks of gripping, entrapment, crushing and dragging.

Conveyor belts can pose serious risk of accidents, especially during maintenance and cleaning operations.

Expected damage

Traumatic lesions consisting in contusions and injuries.

preventive measures

The press drive belt and working parts must be shut off, for example using a fixed cover or one fitted with an interblock device, and the crushed material discharge spout must be protected in such a way as to prevent contact with operating parts.

Since the machine is controlled from a remote control room, each start-up of the plant must be preceded by a visual and acoustic signal.

The machinery must also be fitted with an emergency stop device for imminent danger situations or in the event of accidents, and a safety device that prevents untimely start-up in the event of the restoration of electricity supplies following a blackout. When internal mill cleaning or the replacement of operating parts is performed, the entire plant must be in safe conditions, as machine start-up is normally controlled from the remote control room. In particular, it is possible to implement safety procedures that, while one worker is performing maintenance work, prevent another from being able to start the machine. For this reason, before starting maintenance operations, it is possible to implement a “Block and Signal” type procedure that consists, for example, of blocking all forms of energy that can move the various parts of the machine, removing the key from the control panel and posting a notice bearing the wording “Do not switch on machinery-maintenance work in progress”.

In the event of worker intervention aimed at eliminating conveyor belt jams, accident risk is increased by the concomitance of other factors that can make work tiresome: dustiness, poor lighting, cramped and awkward work spaces and the presence of reptiles and/or insects. In other types of companies, fatal accidents have occurred due to gripping and dragging by conveyor belts, and it is therefore necessary to pay special attention to ensuring that they are in a safe state.

The heads and the rollers of the conveyor belts must be protected with fixed protection devices or protection devices fitted with interblocks. In certain stretches, the conveyor belts run at a certain height from the ground and a walkway is arranged alongside them in order to allow access for maintenance work. In this case it is advisable to install an access gate fitted with an interblock on belt functioning at the start of the walkway, with the possibility of starting the belts up again by means of a button panel only when the operator is present and step–by–step advancing, which excludes the control panel from the conveyor belt once it has been switched on.

Workers must not attempt to perform intervention of any type when the system is in movement. In order to perform adjustments and maintenance work, in addition to the above-mentioned button panel, a thread stretched along the belt’s course connected to an emergency stoppage device is sometimes used. The presence of the stretched thread for emergency stoppage alone cannot be considered sufficiently preventive, when the moving mechanical parts remain unprotected. In any case, before commencing cleaning or maintenance work, the plant must be secured following a standardised procedure of the block and signal type as described above for the mill.

Given the inconvenient working conditions, in the event of conveyor belt operations, it is advisable to schedule preventive maintenance, to be performed in safe conditions, if possible on days when the plant is closed. One solution is that of installing a control system that provides real-time information on conveyor belt motor current absorption values, which can raise the alarm when normal absorption values are exceeded. In this way it is possible to intervene using preventive maintenance, for example by replacing a bearing before it causes belt jamming.

It is recommended that the walkways that run along the conveyor belts at a certain height from the ground are of suitable dimensions to allow comfortable access and working. It is important that good lighting is available during maintenance. Before intervening for maintenance it is advisable to check that there are no insects’ nests and to use industrial pneumatic cleaning systems (centralised systems for removing large quantities of powdery or granular material).

Worker information and training are essential

reference norms

- Presidential Decree 547 of 27.04.1955 and subsequent amendments and additions.

- Legislative Decree 626 of 19.09.1994 and subsequent amendments and additions.

- Presidential Decree 459 of 24.07.1996 (Machinery Directive).

- UNI EN standards.

Work areas where vehicles transit

description

The transit of heavy goods vehicles transporting raw materials and other vehicles can entail the risk of cementwork workers being run over.

expected damage

Traumatic lesions from being run over.

prevention

Arrange and signal, both horizontally and vertically, separate lanes for pedestrians and motor vehicles, arrange signal crossing areas and position danger and limit signs (5 kmh speed limit, traffic lights, automatic bars etc.).

Worker information and training.

reference norms

- Art. 8 “Traffic lanes, hazard zones, flooring and passageways” Presidential Decree 547 of 27.04.1955.

- Legislative Decree 626 of 1994 and subsequent amendments and additions

Working at a height

description

Plant access and maintenance operations may involve the need to reach stations at a certain height from the ground, with a consequent risk of falls from above. It is also possible that others on the ground may be struck by materials and/or equipment used during maintenance operations that accidentally fall from above.

expected damage

Traumatic lesions caused by the person working at a height falling.

Traumatic lesions caused by the fall from above of material that can hit people on the ground.

These are fatal accident risks.

prevention

Arrange secure access routes to high stations with stable and non-slip steps, parapets, foothold bands, etc, as per current regulations.

Passageways must be kept free of obstacles and materials.

Periodically check that the gangways and safety parapets are in good structural conditions, especially when manufactured in metal subject to deterioration caused by atmospheric agents.

In order to keep the various gangways free of material spillage, it is advisable to install industrial pneumatic cleaning systems such as centralised systems for extracting large quantities of powdered or granular material. It should be pointed out that walking on build-ups of powder can cause falls due to slipping.

Workers who access the plant must wear non-slip safety shoes.

During maintenance operations, in certain situations it may be necessary for workers to wear a harness with a fall prevention system. Suitable hoisting systems should be used for transporting materials and equipment to a height.

Signal, demarcate, prevent access to and monitor the area on the ground corresponding to that above which operations are carried out at a height. Staff working on the ground must wear protective hard hats.

Operations must be carried out under surveillance.

Visitor access to work areas must be organised and regulated (for example, visitors should be fitted with individual protective gear, accompanied by staff, etc.).

reference norms

- Art. 386 “Safety belts” Presidential Decree 547 of 27.04.1955.

- Title II “Working environments, workplaces and passageways” Presidential Decree 547 of 27.04.1955.

- UNI EN Standards 361, 363 and 795

- Ann. IV, part B, sect. II EEC/AEEC/EC Directive 57 of 24.06.1992: “Council Directive of 24^th June 1992 concerning the minimum safety and health provisions to be implemented in temporary or mobile work sites (eighth special directive under article 16, subsection 1 of Directive 89/391/EEC)”

- Legislative Decree 626 of 1994 and subsequent amendments and additions.

Exposure to atmospheric agents and draughts

description

Work processes entail the passage and/or stoppage of workers for varying lengths of time in open or covered areas, with consequential exposure to atmospheric agents and/or draughts.

expected damage

Colds and similar disorders.

preventive measures

- Cover plant when possible.

- Correct work organisation.

- Adequate protective gear for protection against atmospheric agents supplied by the company.

- Worker information and training.

reference norms

- Legislative Decree 626 of 1994 and subsequent amendments and additions.

Night-time work

description

The workers involved in the above-mentioned processes work around the clock, in three eight-hour shifts, which therefore also include night-time work.

expected damage

Night-time work can cause alterations to the sleep-wake rhythms and the circadian biorhythms in general, unbalance eating habits, cause irritability, susceptibility to depression and possible repercussions on the worker’s family and social life. This inconvenience is made the greater by the concomitance of other risk factors that are present, in particular exposure to dust and noise.

preventive measures

It is essential that work be organised correctly in order to reduce night-time work as far as possible and implement the measures aimed at eliminating or reducing the risks of exposure to dust and noise as described above at the source.

Shifts should be organised in such a way as to minimise the number of consecutive nights worked by the same worker by organising shifts at times in accordance with biorhythms (sleep, meals, etc.) and notifying workers of the shift schedule with sufficient notice.

Night-time work regulations have recently been modified by Legislative Decree 532 of 26.11.1999, to which reference should be made for more detailed information. It should be remembered that employers are responsible for organising and funding medical visits in order to subject night-time workers to preventive, routine check-ups aimed at establishing the absence of contraindications and two yearly medical checks. If the worker is found to be unsuitable for night-time work, he/she will be guaranteed the assignment of other daytime activities or roles.

Before assigning workers to night-time work, employers must inform them and the Safety Officer of the greater risks deriving from night-time work, where present, and arrange suitable personal and collective protective measures in line with the additional risks deriving from the performance of night-time work. For example, in the case of reduced staff numbers at night, it is recommended that more than one worker be present in each department in order to guarantee assistance in the event of accidents.

reference norms

Legislative Decree 532 of 26.11.1999 “Provisions concerning night-time work, under Art. 17, subsection 2 of Law 25 of 05.02.1999”, implements in Italy the principles of European Directive 93/104/EC referring to certain aspects of working hour organisation. This Decree applies to all public and private sector employers that employ workers in night-time work services, excluding the transport sector and “junior doctors’ activities”.

OUTSOURCING

Certain cementworks rely on external firms for all, or part of, their crushed marl supplies. Certain maintenance operations, especially occasional ones, are often contracted out to external firms.

EXTERNAL IMPACT

Noise diffusion into the surrounding environment

The above-mentioned noisy work processes may cause high noise levels, and unless adequate soundproofing is supplied they may cause disturbance to the community living close to the production plant, especially since production spans the entire 24-hour period, including night-time.

Noisy machinery can be soundproofed by surrounding it with phono-insulating-absorbent structures. Atmospheric emission abatement systems should be fitted with exhaust fans, and the chimneys should have silencers.

Atmospheric emissions

The flow of dusty air, deriving from machines’ localised exhaust systems, is sent to a sleeve filter for dust recovery. Plant efficiency is required for environmental protection and especially for production reasons, since the dust recovered constitutes a resource for the cementworks.

Dust dispersion

The work processes described above may cause widespread dust dispersion, especially in the event of accidental spillage. The plant must be monitored constantly, exhaust systems should be used frequently to clean the plant and road sweepers should be used to clean the production unit yards.

Water drainage

As mentioned above, due to the possibility of dust dispersion, water used for washing yards must be collected and taken to a water purification plant prior to disposal.

Induced vehicle traffic

The number of transiting heavy good vehicles can be large.

TRANSPORTATION, GRINDING, HOMOGENISATION AND ANALYSIS OF UNFIRED MATERIALS

PHASE DESCRIPTION

The aim of this phase of the work process is to grind the unfired raw materials, in particular the mined marl and the limestone used as a corrective and provided by external suppliers. Grinding takes place in a special mill to obtain a homogeneous flour-like mixture in the quantities required for the type of cement being produced.

Mill loading takes place from the top of the tower, to which the raw materials can be taken in a variety of ways: for example, the marl can be taken directly from the quarry by conveyor belt, whereas the limestone may arrive at the factory on heavy goods vehicles that unload it into a large hopper from which, by means of conveyor belts, it passes into the storage silos and then, by means of further conveyor belts, is introduced into the grinding mill.

The raw materials introduced into the mill (marl, limestone, correctives) are dispensed by means of an automatic control system of the chemical conditions of unfired perlite leaving the mill.

The unfired perlite produced by the mill is moved by pneumatic plant, fitted with powerful air compressors, until it reaches the unfired perlite homogenisation and deposition plant.

Grinding, homogenisation and deposition of the unfired perlite take place in a large, tall building, with an open lattice-like structure formed by columns, beams and parapets, known as the unfired material crushing and pulverising tower. The various floors of the factory can be accessed by stairs and lifts. This building also constitutes the support of one of the two ends of the long, rotating semi-horizontal kiln (see firing phase), which is loaded directly by a hopper with the homogenised unfired perlite produced in the tower.

Photograph 1: top part of the unfired material crushing and pulverising tower.

In this phase of the work process, as in the previous one, there are no fixed workstations, rather personnel follow a patrol schedule for monitoring plant operation and only intervene for cleaning operations, using fixed or portable centralised exhaust units, or for maintenance work.

Monitoring and adjustment operations in the extraction sector and the dispensing and grinding of the unfired mixture are generally performed by monitoring staff using moving machinery and/or mains-connected electrical appliances. Monitoring operations also include the cleaning of using suction systems, greasing using relevant manual devices or systems devoid of manual greaser, sight and instrumental checks on electrical parts, instrumental checks on physical size detectors used for the monitoring or remote control of the centralised room.

Quality control and chemical laboratory staff are responsible for unfired perlite samples, which are taken automatically by a sampling machine and analysed by a spectrometer to measure the amount of calcium carbonate present in the perlite in order to perform adjustments on the speed of plant dispensers. Sampling and analysis is performed at intervals of approximately 20 minutes for the unfired perlite discharged from the mill and approximately every 8 hours for the unfired homogenised perlite to be introduced into the kiln for firing.

Photograph 2: lower part of the unfired materials crushing and pulverising tower.

Photograph 3: View of the top of the unfired materials crushing and pulverising tower:

- Crushed marl transportation system running from the quarry to the cement works (right side),

- Cement transportation system and storage silos (left side).

Photograph 4: conveyor belt for marl from quarry, seen from the opening of the entry at the top of the unfired material crushing and pulverising tower (protection removed in the first stretch of the belt, on the left).

Photograph 5: receipt of marl from the conveyor belt at the top of the unfired materials crushing and pulverising tower (protection removed in the last stretch of the belt).

Photograph 6: close-up of conveyor belt.

EQUIPMENT AND MACHINERY

Goods vehicle unloading hopper

This large hopper is positioned below the level of lorry transit to facilitate unloading. The material is extracted from the bottom of the hopper by conveyor belts. The inner structure, conveyor belts, control units and accident prevention devices undergo routine worker maintenance.

Unfired materials grinding plant (mill, kiln, sleeve filters, Archimedean screw conveyors, etc.)

The unfired material grinding mill has the purpose of crushing the materials introduced, until they are pulverised. The mill is usually a rotating vertical cylinder mill with a track and rollers.

The material to be ground is made to fall on the mill’s track where it is crushed by the grinding rollers and dried by hot air at approximately 200 °C.

In general, the hot air comes from the clinker cooler (see firing phase) with the supply of further hot air produced by a fuel burner kiln.

Once a given fineness is obtained, the perlite is lifted by a current of air produced by a fan and transported into the sleeve filter where it is recovered. The flow of dusty air is made to pass through tubes of porous fabric (sleeves) that have the capacity to hold the powder while the clean air passes through the sleeve before being emitted into the atmosphere via the exhaust fan and chimney. The sleeve filters used in companies in the sector can be divided into a number of compartments (for example, 3) and contain a large number of sleeves (for example, 720).

The sleeve filter is located in the open air and is connected to the plant via insulated metal tubes with intermediate interceptor shutters, and to the fan and emission chimney via another insulated tube.

The perlite captured by the internal fabric of the sleeve is recovered via a rapid and violent jet of compressed air that causes the perlite to fall into the recovery Archimedean screws. The Archimedean screws send the perlite to a pneumatic pump that sends it to the homogenisation silos.

The entire plant is regulated by an automatic temperature and depressurisation monitoring and adjustment system and by a safety system to protect against any overloads that may occur due to operating faults. Overheating in the airflow that crosses the sleeves can cause the deterioration of the material constituting them, with a consequential loss of filtering power. In the event of an overload, the system intervenes automatically on a series of motorised shutters that introduce cold air from the outside into the system before stopping the mill, excluding it from the gas cycle, introducing cold air into the sleeve filter and finally stopping the final exhaust.

In order to avoid the dispersion of dust into the environment, there are localised exhaust units on the mill’s ancillary machines and on the loading and unloading points of the conveyor belts that carry the raw materials to be ground. The flow of dusty air deriving from extraction is taken to an auxiliary sleeve filter separate from the sleeve filter described above.

In order to reduce noise diffusion, the exhaust fans are segregated by metal plates and the ventilators that create depressurisation for suction are fitted with silencers installed on the respective chimneys.

With regard to the electrical power used, we include as an example some figures for a sector company: the mill is supplied with a voltage of 500V having a power of 315 kW; final exhaust is controlled by a 355 kW variable speed motor, the other auxiliary motors of the plant are less powerful, with a power of between 3 and 15 kW.

The track and roller mill is subject to routine maintenance work, such as the replacement of rollers, grinding track, motor, hydraulic command, gear unit, separator, lubrication pumps; replacement or repair of the shell or structure; recovery of accident prevention devices.

The shutters undergo routine maintenance work such as the replacement of bearings, control unit, levers, internal blades or wear-proof plates; structural repairs; recovery of accident-prevention devices.

The sleeve filters and the Archimedean screws undergo routine maintenance work, such as periodical replacement of sleeves and Archimedean screw parts (gear box, control unit, internal elements); structural repairs, check and recovery of accident prevention devices.

The top part of the sleeve filter is accessible, for example, by means of a flight of metal steps with grid rungs and various intermediate floors from which it is possible to access the interception shutters of the connection tubing to the filter; the flight of stairs proceeds as far as a concrete floor slab, and then on to a pneumatic sleeve shaking area and from here to the cover. On the chimney there is a station for taking samples for monitoring emissions into the atmosphere.

The exhaust fan is subject to routine maintenance work such as: the replacement of the motor, joints, rotor or blade and relative supports, capacity adjustment gear unit; structural repair; recovery of accident-prevention devices.

The motor and fan control equipment, command and signalling equipment of the centralised room and the physical size measurement instruments are all enclosed inside lockers positioned in an electrical cabinet room, closed and fitted with forced ventilation systems in order to maintain a slight overpressure in relation to the external environment in order to prevent the entry of dust inside.

The electric panels undergo routine maintenance work such as: the replacement of electrical or electronic parts, panel elements, condensers, rheostats, transformers, end-of-stroke devices, field sensors; the recovery of accident-prevention devices.

Routine maintenance work on all the machines present in the plant also entails assembly and dismantling operations, using hoisting equipment and/or rented truck cranes, electrical or oxyacetylene welding, use of electric or pneumatic utensils (grinders, drills, etc.), portable ladders, scaffolding. For these operations, refer to the “mechanical maintenance” phase.

Photograph 7: lower part of the unfired material grinding mill, at the foot of the crushing and pulverising tower.

Unfired perlite homogenisation and deposition plant

The unfired perlite obtained from the unfired material grinding mill, is sent by pneumatic pumps to a special homogenisation plant. It is formed by a series of medium-sized silos (for example, three 200 tonne-silos) and one large deposit silo (for example, one 2,000 tonne-silo).

Homogenisation takes place by loading, alternately, the smaller silos and at the same time taking the perlite from the bottom of them via special conduits that take it to the conveyor system (usually chain bucket elevators) that transports the perlite to the top part of the department, where two Archimedean screws are loaded that recycle the same perlite, re-introducing it into the small silo, in which the mill pump is engaged at that time, and partly in the large storage silos. From here, through discharge spouts that are introduced cyclically and automatically, the desired quantity of perlite is discharged in two spirals that transport it to a pneumatic pump that sends the homogenised perlite to the firing kiln’s loading hopper.

All the transport machinery is in a depressurised state and the powder is recovered via the sleeve filter. The system is controlled by automatic adjusters that regulate the quantity of perlite in circulation, on the basis of automatic silo level measurements and a series of sensors that check the functioning of the machinery.

Machines are started up automatically from the centralised command and control room.

The system is subject to routine maintenance. In greater detail: pumps undergo substitution of the internal air tubes and substitution and/or repair of external elements; elevators undergo replacement of the motor, gear unit and wear rings, structural repairs and the recovery of accident prevention devices; for other machines, see matters raised previously for the unfired material grinding system.

Photograph 8: hopper for loading perlite into kiln, positioned on the crushing and pulverisation tower. Note the small compressors for the pneumatic clearing localised at various points of the hopper.

Kiln loading hopper

This is essentially a large metal funnel that has the purpose of allowing the loading of the unfired perlite into the kiln; the hopper is fitted with small air compressors at various points, which are activated in order to create impulsive jets of air when it is necessary to clear the hopper.

Pressurised appliances

The department also contains a number of pressurised appliances:

- Pneumatic pumps;

- Compressed air tanks;

- Compressed air dryers, formed by a pressurised tank, in which the air to be dried is introduced, which contains a coil in which Freon gas supplied by a refrigeration system circulates.

Photograph 9: air compressor (separated by closed cabin) used for the pneumatic movement of material.

Spectrometer

This is a radiogenic machine employed in laboratory analysis that uses a radioactive source for functioning. Given the importance of the instrument for the monitoring and adjustment of the production process, some sector firm laboratories have two spectrometers (one as a reserve).

Lifts and hoists

These are the means used to transport the workers and work equipment used for maintenance to the structure’s various floors.

Photograph 10: area in front of the lift-hoist opposite the kiln loading hopper, in the crushing and pulverising tower. Note the safety signs.

RISK FACTORS

Below we consider the main risk factors to which workers may be exposed during the normal operation of the plant they access to perform monitoring and cleaning activities. With regard to routine and occasional maintenance, see the “mechanical maintenance” phase.

Exposure to noise

description

In this department, the majority of noise is caused by the grinding and homogenisation plants.

ESTIMATE

With the plant operating, the following levels of noise are generally produced:

- in the vicinity of the track and roller mill with relative hot air abduction kiln: greater than 90 dB(A).

- in the vicinity of the unfired blend homogenisation plant : approximately 87 dB(A).

- in the areas around the belts and extractors, in the vicinity of the sleeve filter: lower than 85 dB(A).

- in the electric panel room: lower than 80 dB(A).

It should be pointed out that in some firms access to areas where noise levels are lower entails crossing the mill department, where noise levels are higher.

Expected damage

Continuous exposure to medium-high noise levels can cause hearing damage (hypacusia caused by noise) and non-hearing related damage. The latter can also be caused by exposure to levels lower than those for which regulations prescribe special preventive measures.

In addition to communication and professional performance disorders, the following may also occur: cardiovascular alterations (increase in blood pressure, etc.); psychological disorders (asthenia, irritability, depression, insomnia); digestive system disorders.

As a result of the need to speak loudly for verbal communications, in noisy conditions, the vocal cords may be subject to stress, which may be a contributing cause (together with exposure to an unfavourable microclimate and to dust) of throat diseases with hypophonesis.

PREVENTIVE MEASURES

- Perform regular plant maintenance.

- Soundproof the noisiest machines and separate them from other workrooms.

- Replace the oldest and noisiest machines with newer and less noisy ones.

- Organise work in such a way as to reduce worker exposure times.

- Perform noise assessment and apply the preventive measures set out in Legislative Decree 277/91, summarised in the table entitled “Noise exposure threshold values”, given in this document in the chapter entitled “General reference norms”.

reference norms

- Art. 24 “Noise and shaking” Presidential Decree 303 of 19.03.1956.

- Item IV “Protection of workers against the risks of exposure to noise during work” Legislative Decree 277 of 15.08.1991.

- Presidential Decree 459 of 24.07.1996 “Regulation for the implementation of directives 89/392/EEC, 91/368/EEC, 93/44/EEC and 93/68/EEC concerning the reconciliation of member state legislation on machinery” (Machinery Directive).

Work in raised positions

description

Access to the plant and maintenance operations may make it necessary to operate in raised positions, with a consequential risk of falls from a height. It is also possible that other people on the ground may be hit by materials and/or equipment used for maintenance that accidentally fall from above.

expected damage

Traumatic lesions caused by falls from above of person performing working at a height.

Traumatic lesions caused by the fall of materials from above that may hit people on the ground.

These are fatal accident risks.

prevention

Arrange safe access to the stations at a height with stable, non-slip steps, parapets, foothold bands, level platforms, etc. as prescribed by current regulations.

Passageways must be kept free from obstacles and materials.

Periodically check the good structural state of the platforms and safety parapets, especially when manufactured in metal, which can be subject to deterioration caused by atmospheric agents.

In order to keep the various platforms free from material spillage, it is recommended that industrial pneumatic cleaning systems such as centralised systems for extracting large quantities of powdery or granular material be used. It should be pointed out that walking on build-ups of powder may also cause falls due to slipping.

Workers that access the plant should wear non-slip safety shoes.

In the event of maintenance operations, according to the various situations, it may be necessary to wear a safety harness to prevent falls from above. In order to take materials and equipment to a height, suitable lifting systems should be used.

Signal, close off, prevent access and monitor the ground level area below which operations from above are performed. Staff on the ground should wear safety helmets.

Operations must take place under the surveillance of a supervisor.

Visitor access to activity areas should be organised and regulated (example: visitors should be given personal protection devices and accompanied by staff, etc).

reference norms

- Art. 386 “Safety belts” Presidential Decree 547 of 27.04.1955.

- Title II “Working environments, work places and passageways” Presidential Decree 547 of 27.04.1955.

- UNI EN standards 361, 363, 795

- Annex IV, part B, section II EEC/AEEC/EC Directive 57 of 24.06.1992: “Council Directive of 24^th June 1992 concerning minimum health and safety prescriptions to be implemented in temporary or mobile worksites (eighth special directive under article 16, subsection 1 of Directive 89/391/EEC)”

- Legislative Decree 626 of 1994 and subsequent amendments and additions.

Exposure to dust

description

In the event of marl and limestone powder leakage from the plant, workers may be exposed during patrol checks, but above all during cleaning and maintenance work.

Expected damage

Marl is a natural rock composed primarily of limestone and clay (in turn formed by iron and aluminium silicates), with a low crystalline free silica content (1%). The limestone used in cement production is in practice composed of almost pure calcium carbonate (CaCO₃) with traces of iron, aluminium and magnesium oxide. Personal exposure to marl powders can cause irritation to the respiratory tract and pneumoconiosis from mixed dusts.

Dusty environments may also increase the risk of accidents.

preventive measures

- The entire plant (especially the hoppers, mills, joints of loading and unloading points of the conveyor belts) must be closed and fitted with a localised exhaust system connected to a dust exhaust filter.

- Remove any material that has leaked from the plant as swiftly as possible in order to prevent particular atmospheric conditions (e.g. wind days) favouring the lifting and spreading of the dust.

- When removing material that has accidentally leaked from the system, it is advisable to avoid procedures that could lift the powder (such as use of shovels and/or brooms), in favour of industrial pneumatic cleaning appliances (centralised systems for extracting large quantities of powder or granular material) and road sweepers for cleaning yards. In this way one reduces both exposure to powders and the risk of musculo-skeletal damage caused by the use of manual equipment such as shovels etc.

- Limit access to dusty environments and, in the event of maintenance and/or substantial accidental leakage of dust from the plant, use personal protection devices (dust-proof facemask, airtight goggles, gloves, work gear, accident prevention shoes, helmet, ear protectors and/or ear plugs), if the worker wears glasses, the lenses of the dust proof goggles must be graduated.

- Perform thorough equipment maintenance operations. It is useful to include a control device on the conveyor belts’ idle rotation rollers, connected to an automatic device which, if the belt jams for any reason, stops other belts connected to it, in order to prevent material build-up.

- Personal protection equipment must be worn during cleaning and maintenance operations and when taking samples of the unfired perlite to be analysed.

- Implement codes of conduct and hygiene: after use at the end of the work shift, filtering facemasks must be placed in a place uncontaminated by dust, or alternatively disposed of if the disposable type is used; when performing dirty work or work including exposure to powders or other harmful agents, workers and partners must be permitted access to double compartment lockers for storing civilian and work clothes and must have access to adequate washing facilities (showers, wash basins, etc.) kept in a good state.

- Worker health information, training and surveillance.

reference norms

- Consolidation Act 1265/34 and Decree of the Ministry of Health 05/09/94 (Insalubrious industries).

- Title II, Art. 9 “Airing closed workplaces” and Item II “Protection against harmful agents” of Presidential Decree 303 of 19.03.1956 “General norms for occupational hygiene”.

- Legislative Decree 626 of 19.09.1994 and subsequent amendments and additions.

- Presidential Decree 336 of 1994 (Occupational diseases).

Work in the vicinity of moving mechanical parts

description

The moving parts of the machinery pertaining to the unfired material transportation, grinding and homogenising plant can cause accidents due to gripping and dragging.

expected damage

Traumatic lesions.

preventive measures

- Make hazardous machinery areas inaccessible, using fixed shields or guards fitted with interblock devices.

- Do not perform maintenance work on machinery in movement.

- Do not oil the gears of machines in movement, unless using oilcans with suitably long nozzles in a frangible material in order to allow the worker to remain at a safe distance. The safety distance can be guaranteed, for example by a metal grid, either fixed or fitted with an interblock device, positioned at a sufficient distance from the hazard area.

- Do not wear voluminous garments that could be caught up and dragged by the moving parts of the machinery.

- Activate a visual-acoustic signal before starting the system.

- The subsequent return of the electricity supply after blackouts must not entail automatic restarting of the machine.

- The machinery must be installed, used, maintained, repaired and adjusted in conformity with Manufacturer’s instructions, especially with regard to old machinery that does not bear CE markings.

- Adopt standardised maintenance procedures.

- Worker information and training.

With regard to conveyor belts, see also the previous section on “marl crushing”.

reference norms

- Presidential Decree 547 of 27.04.1955 and subsequent amendments and additions

- Legislative Decree 626 of 19.09.1994 and subsequent amendments and additions

- Presidential Decree 459 of 24.07.1996 (Machinery directive)

- UNI EN standards.

Presence of methane or LPG or combustible oil-fuelled plant

description

Special fuel burners are used to produce the hot air required to dry the material in the mill during grinding (integrating the hot air recovered from the clinker cooler). For example, one Sector firm has a burner with a nominal power of 2.5 million Kcal/h using a methane gas-fuelled burner with a 0.5 bar mains pipe. This mains pipe is fuelled by its own stainless steel sheet decompression chamber positioned outside the department. The burner can function using combustible oil and is therefore fitted with the thrust pump unit and the conditioning and measuring unit for oil burner assembly.

There is a risk of methane gas leaks, with the subsequent formation of explosive mixtures and accidental leakage of combustible oil, exposure to combustion gas.

expected damage

Explosion-fire, burns and intoxication.

preventive measures

- Installation on the gas pipe of an interception solenoid valve controlled by a gas detector positioned inside the room.

- Ensure that electrical installations are suitable for high-risk areas in the event of fire.

- Observance of the necessary requirements for the issuance of a Fire Prevention Certificate by the Fire Brigade.

- Presence of suitable extinguishers that are tested and routinely inspected by specialist firms.

reference norms

- Legislative Decree 626 of 1994 and subsequent amendments and additions

- UNI-CIG standards.

- Ministerial Decree of 31.03.1984 applies for fixed LPG tanks with capacities of up to 5 m³, and Ministerial Decree of 13.10.1994 applies for capacities exceeding 5 m³.

Presence of pressurised equipment

description

The pneumatic shaking for the cleaning of sleeve filters, activating of pneumatic shutters and the other above-mentioned uses of compressed air entail the use of air compressors fitted with compressed air tanks, which entail the risk of explosions.

expected damage

Traumatic lesions due to the violent movement of metal parts during the explosion and falls.

preventive measures

Said devices undergo type approval checks by ISPESL (Italian Institute for Prevention and Safety at work) that enforce the following manufacturing and operating standards:

- M collection ,for the characteristics of the materials to be used in pressurised equipment;

- VSR collection, for pressurised container stability testing;

- VSG collection, for steam generators stability testing;

- PIVG Code, for the various standards concerning the operation of steam generators and pressurised containers.

As things currently stand, under the provisions set out in the PIVG Code, routine checks on pressurised plants must be performed annually by technicians belonging to the Prevention Department of the Local Health Units.

The following are also required:

- Presence of the necessary protective devices.

- Manoeuvring and maintenance by specialised staff only.

- Worker information and training.

reference norms

- Law of 21.11.1972 “Standards for the manufacture of pressurised equipment” (authorising the A.N.C.C.-now I.S.P.E.S.L.-to issue technical regulations and standards).

- Title IV, Item XIII, Art. 167 “Compressors” Presidential Decree 547 of 27.04.1955.

- Title VI, Item II, Art. 241 “Suitability and resistance requisites” Presidential Decree 547 of 27.04.1955.

- UNI EN Standards1012/1, 1012/2.

Exposure to atmospheric agents and draughts

description

Work processing entails the passage and or stationing of workers in covered or open areas for varying lengths of time, with consequential exposure to atmospheric agents and/or draughts.

The forced ventilation system in the electrical panel room can cause exposure to draughts to workers who are present for monitoring and maintenance work.

expected damage

Colds and similar.

preventive measures

- Cover plant when possible.

- Correct work organisation.

- Gear supplied by the company suitable for protection against atmospheric agents.

- In the electric panel room, the air introduction grids are sufficiently distant from operating areas and the ventilation system is not such that it exposes workers to bothersome draughts.

- Worker information and training.

reference norms

- Legislative Decree 626 of 1994 and subsequent amendments and additions.

Exposure to radiating heat, warm microclimates and work near hot surfaces

description

Warm air tubes used for drying from the mill and those for the transportation of unfired perlite can be hot and therefore generate radiating heat. Worker exposure to warm microclimates is greater during maintenance work, and the disturbance can worsen during the summer. Patrol staff may be exposed to temperature changes between one department and another, especially during the winter.

expected damage

Burns are possible from accidental contact with heated surfaces; breathing disorders, thermal stress and bone and joint disorders caused by unfavourable microclimates. Temperature changes can be the cause of colds and bone and joint disorders.

preventive measures

- Insulate hot surfaces, especially those with which workers may come into contact.

- Wear Personal protection equipment (heat-proof gloves and suitable garments).

- Air-conditioned cabins and refectories

- Worker health information, training and supervision.

reference norms

- Art. 9 “Air change”, Art.11 “Temperature” and Art.13 “Humidity” Presidential Decree 303 of 19.03.1956.

- Art. 240 “Protection of external walls at high temperatures” Presidential Decree 547 of 27.04.1955.

- Art. 378 “Clothing” and Art. 379 “Protective gear” Presidential Decree 547 of 27.04.1955.

- UNI EN standard 563 (see 6.1.26)

Work entailing the use of radiogenic machinery

description

The spectrometer used for the analysis performed on the unfired perlite functions using a radioactive source, which if used incorrectly, could cause worker exposure to ionised radiation. In certain firms there may also be reserve spectrometers to those usually used. For example, a sector firm may have two, with a total quantity of radioactive substances equal to 20,000 microcuries, lower than that indicated in point 1 of Ministerial Decree 14.07.1970.

expected damage

Exposure to ionising radiation can cause tumours.

preventive measures

- Inform the competent Local Health Unit and Provincial Labour Bureau about the holding of radiogenic machinery.

- Routinely check devices used for protection against ionising radiation.

- Perform exposure evaluation every 2 years.

- Worker health information, training and surveillance.

reference norms

- Presidential Decree 185 of 13.02.1964

- Ministerial Decree of 14.07.1970

- Legislative Decree 230 of 1995

- Legislative Decree 626 of 1994

Night-time work

description

The workers involved in the above-mentioned processes work around the clock, in three eight-hour shifts, therefore entailing night-time work.

expected damage

Night-time work can cause alterations to the sleep-wake rhythms and the circadian biorhythms in general, unbalance eating habits, cause irritability, susceptibility to depression and possible repercussions on the worker’s family and social life. These inconveniences are increased by the concomitance of other risk factors that are present, in particular exposure to powder and noise.

preventive measures

It is essential to organise work correctly in order to reduce night-time work as far as possible and implement measures aimed at eliminating or reducing the risks of exposure to powder as described above at the source.

Night-time work regulations have recently been innovated by Legislative Decree 532 of 26.11.1999, to which reference should be made for more detailed information. It should be remembered that employees are responsible for organising and funding medical visits in order to subject night-time workers to preventive, routine check-ups aimed at establishing the absence of contraindications and two yearly medical checks. If a worker is found to be unsuitable for night-time work, he/she will be guaranteed the assignment of other daytime activities or roles.

Before accepting workers for night-time work, employees must inform them and the Workers’ Safety Officer of the greater risks of night-time work, where present, and arrange suitable personal and collective protective measures. For example, if staff numbers are reduced at night, it is recommended that more than one worker be present in each department in order to guarantee assistance in the event of accidents.

reference norms

Legislative Decree 532 of 26.11.1999 “Provisions concerning night-time work, under Art. 17, subsection 2 of Law 25 of 05.02.1999” implements in Italy the principles of the European Directive 93/104/EC referring to certain aspects of working schedules. The Decree applies to all public and private sector employers that employ workers with night-time work services, excluding the transport sector and “junior doctors’ activities”.

OUTSOURCING

This phase is not usually contracted out to external firms. The transportation of materials is sometimes contracted out to external firms.

EXTERNAL IMPACT

Noise diffusion into the external environment

The above-mentioned noisy work processes may cause high noise levels and, unless adequate sound proofing is supplied, the community living close to the production plant may be disturbed, especially as production involves the entire 24 hour period, including the night.

Noisy machinery can be soundproofed by surrounding it with phono-insulating-absorbent structures. Atmospheric emission abatement systems should be fitted with fans, and the chimneys should have silencers.

Atmospheric emissions

The flow of dusty air from machines’ localised exhaust units is sent to a sleeve filter for dust recovery. Plant efficiency is required for environmental protection and especially for production reasons, since the powder recovered constitutes a resource for the cementworks.

Induced vehicle traffic

The number of heavy good vehicles transiting can be large.

Dust dispersion

Water drainage

As described above, due to the possibility of powder dispersion, water used to wash yards must be collected and taken to a water purification plant prior to disposal.

Photograph 11: road sweeper in the yard in front of the unfired materials grinding mill (clinker silos in the background).

FIRING THE BLEND IN THE KILN

PHASE DESCRIPTION

Firing is the central phase of the entire cement production process. Starting from the unfired perlite, a fired, granular product known as clinker is obtained.

In cement production plants that employ the dry process, the unfired perlite is introduced into a rotating kiln by means of a hopper into which it is fed by a pneumatic pump. The firing process comprises three phases: preheat, sintering (at a temperature of approximately 1,400°C, the perlite becomes a pasty mass and then agglomerates into granules as it advances along the kiln).

In cement production plants employing the semi-dry process with Lepol grate, unfired perlite is extracted and lifted by an elevator, dispensed and wetted with water in a granulator plate where rounded agglomerations of water and perlite form that are then transported on a belt into the Lepol grate where the material is pre-fired before being introduced into the kiln.

The inside walls of the Lepol grate used for pre-firing are covered with a refractory material, and must be scaled weekly using high-pressure water.

In both production processes pre-heating is usually through the hot gases of kiln combustion; clinker cooling is through cold air from a special grid cooler with walls covered with a refractory material, inside which the temperature of the clinker drops from approximately 1000°C when it leaves the kiln to approximately 100°C before being stored in special warehouses or silos by means of metal grill conveyors.

The entire plant is placed under exhaust systems and the airflow polluted by dusts and combustion fumes is sent to an emission abatement plant with dust recovery.

EQUIPMENT AND MACHINERY

Semi-horizontal rotating kiln

Semi-horizontal rotating kilns are formed by long steel cylinders covered inside by refractory material, fed by coal with gas oil ignition (sometimes methane or waste derived fuel is used instead of coal). This type of kiln is very large, for example, one sector firm has a kiln with a diameter of 3 metres and a length of 30 metres. The kiln is fitted with a resting base with rolling rings and rollers, usually positioned at the ends and in the middle.

The kiln requires routine maintenance, especially with regard to the repair and recoating of the inner refractory layer, by demolishing the old refractory and the slag that can form on it. This operation requires the plant to be shut down and the workers to go inside the kiln in order to demolish the refractory and de-scale the kiln using manual equipment, in particular pneumatic hammers.

Photograph 12: semi-horizontal rotating kiln. Clinker deposit in the background.

Photograph 13: semi-horizontal rotating kiln seen from the top of the crushing and pulverising tower (production plant using dry process). Note the central ring that rests on the rolling support and, to the left of the kiln, the base of the chimney connected to the electro-filter for the abatement of emissions into the atmosphere.

Photograph 14: end of the rotating kiln from the crushing and pulverising tower side (production plant employing dry process). In the background, the chimney for releasing emissions into the atmosphere.

Photograph 15: clinker deposits.

Photograph 16: end part of the rotating kiln, with conveyor and clinker deposits (to the right), coal storage (in the background on the left), seen from the crushing and pulverising tower.

RISK FACTORS

Exposure to gas, fumes and dust

description

During the firing of the perlite in the kiln (fed by coal with gas oil ignition), combustion fumes and dust may diffuse, to which workers may be exposed. The main polluting substances that can develop are nitrogen oxide (NO_x), carbon oxide (CO), etc.

Substantial worker exposure may occur during maintenance operations, in particular during the de-scaling and demolition of kiln refractory.

expected damage

Exposure to gas, fumes and dust in this phase of the work process can cause irritation to the respiratory tract and the mucous membranes, lung diseases and oxycarbonism, especially in the case of scarce efficiency of the exhaust system on the kiln. Additional risks are present if waste fuel, used tyres or other objects are introduced inside the kiln.

preventive measures

- Evaluation of the danger posed by the combustion products of the materials introduced into the kiln.

- Equip the kiln with adequate exhaust system.

- Prepare standardised procedures for the maintenance of the firing plant, in particular for the demolition and replacement of the refractory.

- Use personal protection equipment (filtering masks, goggles, overalls).

- Implement codes of conduct and hygiene.

- Health information, training and monitoring of workers exposed.

- For further indications, refer to the “mechanical maintenance” phase.

reference norms

- Presidential decree 547 of 1955 and subsequent amendments and additions

- Presidential Decree 303 of 1956 and subsequent amendments and additions

- Legislative Decree 626 of 1994 and subsequent amendments and additions

Exposure to noise

description

The noise created in this operational phase derives primarily from kiln burners, the rotating of the kiln and the material subject to firing inside the kiln.

Maintenance workers may be particularly exposed to noise, in particular during de-scaling and the demolition of the refractory using pneumatic hammers inside the kiln.

estimate

The noise at kiln level is generally higher than 85 dB(A) and lower than 90 dB(A). For example, in one sector firm an Leq of 88.4 dB(A) was measured. Personal exposure is mitigated by the fact that this area does not entail fixed workstations.

Demolition operations inside the kiln using pneumatic hammers cause very high noise levels (higher than 90 dB (A)).

expected damage

Continuous exposure to medium-high noise levels can be the cause of hearing damage (hypacusia caused by noise) and non-hearing related damage. The latter can manifest also for exposure levels lower than those for which regulations prescribe preventive measures.

In addition to communication and professional performance disorders, the following may also occur: cardiovascular alterations (increase in blood pressure, etc.); psychological disorders (asthenia, irritability, depression, insomnia); digestive system disorders.

As a consequence of the need to speak loudly for verbal communications in noisy conditions, the vocal cords may be subject to stress, which may be a contributing cause (together with exposure to an unfavourable microclimate and to dust) of throat diseases with hypophonesis.

PREVENTIVE MEASURES

- Perform regular plant maintenance.

- Soundproof the noisiest machines and separate them from other workrooms.

- Replace the oldest and noisiest machines with newer and less noisy ones.

- Organise work in such a way as to reduce worker exposure times.

- See the “mechanical maintenance” phase for further indications.

reference norms

- Art. 24 “Noise and shaking” Presidential Decree 303 of 19.03.1956.

- Item IV “Protection of workers against the risks of exposure to noise during work” Legislative Decree 277 of 15.08.1991.

Exposure to radiating heat, warm microclimates, work near hot surfaces

description

Warm air tubes used for drying can be hot and therefore generate radiating heat. Worker exposure to warm microclimates is greatest during maintenance work and the disturbance can worsen during the summer. Maintenance work on the kiln, such as the renewal of the refractory layer, must take place when the cementworks is not operative, however minor repairs may expose workers to radiating heat. Patrol staff may be exposed to temperature changes between one department and another, especially during the winter.

expected damage

preventive measures

- Insulate hot surfaces, especially those with which workers may come into contact.

- Wear Personal protection equipment (heat-proof gloves and suitable garments).

- Air-conditioned cabins and refectories.

- Health information, training and supervision for workers.

reference norms

- Art. 9 “Air changes”, Art.11 “Temperature” and Art.13 “Humidity” Presidential Decree 303 of 19.03.1956.

- Art. 240 “Protection of external walls at high temperatures” Presidential Decree 547 of 27.04.1955.

- Art. 378 “Clothing” and Art. 379 “Protective gear” Presidential Decree 547 of 27.04.1955.

- UNI EN standard 563 (see 6.1.26)

Work in the vicinity of moving mechanical parts

description

Kiln rotation can cause gripping and dragging, especially in the case of maintenance operations performed nearby.

expected damage

Traumatic injuries.

preventive measures

- Make hazardous machinery areas inaccessible, using fixed guards or guards fitted with interblock devices.

- Do not perform maintenance work on machinery in movement.

- Do not oil the gears of machines in movement, unless using oilcans with suitably long nozzles in frangible material in order to allow the worker to remain at a safety distance. The safety distance can be guaranteed, for example by a metal grid, either fixed or fitted with an interblock device, positioned at a sufficient distance from the hazard area.

- Do not wear voluminous garments that could be caught up and dragged by the moving parts of the machinery.

- Activate a visual- acoustic signal before starting the system.

- Black outs and subsequent returns of electricity supply must not entail automatic restarting of the machine.

- The machinery must be installed, used, maintained, repaired and adjusted in conformity with Manufacturer’s instructions, especially with regard to old machinery that does not bear CE markings.

- Adopt standardised maintenance procedures.

- Worker information and training.

reference norms

- Presidential Decree 547 of 27.04.1955 and subsequent amendments and additions.

- Legislative Decree 626 of 19.09.1994 and subsequent amendments and additions.

- Presidential Decree no459 of 24.07.1996 (Machinery directive).

- UNI EN standards.

Exposure to vibrations

description

The use of pneumatic hammers for the scaling and demolition of the refractory of the kiln entails exposure to vibrations of the hand-arm system.

estimate

This type of vibration is considered as significant with regard to both amplitude and frequency.

expected damage

Exposure to vibrations can cause damage to the circulatory system, nerves and joints (Raynaud’s syndrome). The onset of this pathology is related to the duration and extent of exposure. Cigarette smoke and excess cold worsen circulatory damage caused by vibrations.

preventive measures

Pneumatic hammers with low vibration levels and lower vibrational impact must be used. Use vibration-dampening handles and reduce the duration of exposure by alternating work between a number of workers, wear suitable clothing, inform workers of the greater risks of exposure to vibrations in the case of smokers or workers regularly exposed to low temperatures for long periods of time, train staff to employ correct working practices and subject them to medical check-ups.

reference norms

- Decree of the Employment Ministry 18.04.1973 “List of diseases for which reporting of occupational accidents and professional diseases is compulsory”

- Art. 46, Item I, Title III “Machinery shaking and vibrations” Presidential Decree 547 of 27.04.1955.

- Art. 24, Item II, Title II “Noise and shaking” Presidential Decree 303 of 19.3.1956

- 9.9.3 EEC/AEEC/EC Directive 663 of 22.12.1986: “Council Directive of 22nd December 1986 for the harmonisation of Member State Legislation concerning self-propelled trolleys for handling”.

- 1.5.9 EEC/AEEC/EC Directive 392 of 14.06.1989: “Council Directive of 14^th June 1989 concerning the reconciliation of Member State legislation on machinery “.

- 1.5.9 “Field of application and definitions” and 3.2.2 “harmonised norms and equivalent provisions” Presidential Decree 459 of 24.07.1996

- EC notice of 22^nd March 1997 (22nd March 1997) (CEN-EN 1032): “Commission notice within the framework of the application of Council Directive 89/392/EEC of 14^th June 1989, concerning machinery, amended by Council Directives 91/368/EEC, 93/44/EEC and 93/68/EEC”.

- UNI-EN standard 30326-1 of 01.04.1997 (see 6.1.38): “Mechanical vibrations-Laboratory method for the evaluation of vibrations on vehicle seats-Basic requirements”.

- Ministerial Decree 30.05.1997 (UNI-EN 1033, 1997) “List of harmonised standards adopted under subsection 2 of art. 3 of Presidential Decree of 24^th July 1996 459 (2): “Regulation for the implementation of Council Directives 89/392/EEC, 91/368/EEC, 93/44/EEC and 93/68/EEC concerning the reconciliation of Member State legislation”

- EC notice of 04.06.1997 (CEN-EN 1299, 1997): “Commission notice within the framework of the application of Council Directive 89/392/CEEC of 14^th June 1989 on machinery, amended by Directives 91/368/EEC, 93/44/EEC and 93/68/EEC”.

Awkward work in restricted spaces

description

Operators involved in de-scaling and replacement of the kiln’s refractory coating work inside the kiln, therefore in a particularly awkward environment, where they are also exposed to dust, noise, vibrations, microclimate (as described above) all of which are factors that contribute to increasing awkwardness during work and the risk of accidents.

expected damage

Injuries and contusions caused by blows and falls. Alienation to work and stress.

preventive measures

- Prepare standardised maintenance procedures.

- Maintenance workers who work inside the kiln must operate under the close surveillance of a work colleague outside the kiln.

- Work must be divided into shifts, alternated by breaks.

- Workers must be adequately informed and trained on both current work procedures and first aid measures.

Night-time work

description

The workers involved in the above-mentioned processes work around the clock, in three eight-hour shifts, therefore entailing night-time work.

expected damage

Night-time work can cause alterations to the sleep-wake rhythms and the Circadian biorhythms in general, unbalance eating habits, cause irritability, susceptibility to depression and possible repercussions on the worker’s family and social life. This inconvenience is made greater by the concomitance of other risk factors that are present, in particular exposure to dust and noise.

preventive measures

Night-time work regulations have recently been innovated by Legislative Decree 532 of 26.11.1999, to which reference should be made for more detailed information. It should be remembered that employees are responsible for organising and funding medical visits in order to subject night-time workers to preventive, routine check-ups aimed at establishing the absence of contraindications and two yearly medical checks. If the doctor finds that the worker is unsuitable for night-time work, he/she will be guaranteed the assignment of other daytime activities or roles.

Before accepting workers for night-time work, employees must inform them and the Workers’ Safety Officer on the greater risks relating to night-time work, where present, and arrange suitable personal and collective protection measures in line with the additional risks deriving from the performance of night-time work. For example, in the case of reduced staff during the night, it is recommended that more than one worker be present in each department in order to guarantee assistance in the event of accidents.

reference norms

Legislative Decree 532 of 26.11.1999 “Provisions concerning night-time work, under Art. 17, subsection 2 of Law 25 of 05.02.1999”, implements in Italy the principles of European Directive 93/104/EC referring to certain aspects of work schedule organisation. The Decree applies to all public and private sector employers that employ workers with night-time work services, excluding the transport sector and “junior doctors’ activities”.

OUTSOURCING

This work phase is not contracted out to external firm, as it is the central phase of the entire production process.

EXTERNAL IMPACT

Atmospheric emissions

The fumes and dust originating from the exhaust system at the mouth of the kiln are sent to a reprocessing tower and from there to an electro-filter, before being sent to a chimney.

Photograph 17: reprocessing tower for the fumes from the kiln before being introduced into the electro-filter.

Noise diffusion into the surrounding environment

Noisy machinery can be soundproofed by surrounding it with phono-insulating-absorbent structures. Atmospheric emission abatement systems should be fitted with fans and the chimneys should have silencers.

Production of waste

The powder recovered from the electro-filter is primarily formed by sodium and potassium sulphates; it is totally reused for grinding cement and hydraulic lime (see the clinker grinding and mixing with additive phase).

COAL STORAGE AND GRINDING

DESCRIPTION OF THE PHASE

As described previously, during the firing of the blend in the kiln phase, the main fuel used to fire the kiln is a pulverised solid fuel (coal), composed primarily of free carbon with the presence of carbon compounds containing hydrogen and oxygen, sulphur, inorganic substances that, after combustion, remain as ashes and water constituting its humidity.

The coal is transported to the production plant in bulk on lorries and is unloaded into a special unloading hopper, from which it is removed by conveyor belts or a bridge crane with grab jaw and introduced into a storage silo. Before being used as a fuel, the coal is ground and simultaneously dried by a mill ventilated with hot air, which makes it possible to obtain coal powder with the fineness and dryness required for regular combustion in a kiln.

Coal deposition is an activity subject to fire prevention checks by the Fire Brigade.

EQUIPMENT AND MACHINERY

Goods vehicle unloading hopper

This large hopper is positioned beneath the lorry transit level in order to facilitate coal unloading. The material is extracted from the bottom of the hopper by conveyor belts or by a bridge crane with grab jaws. The internal casing, conveyor belts, control units and accident prevention protection devices undergo routine maintenance by workers.

Mill ventilated with hot air for coal grinding

This is a tubular or vertical belt and roller or belt and sphere type mill, identical to those described for the grinding of perlite. Discharge air temperature is approximately 70-80°.

RISK FACTORS

Exposure to noise

description

Noise derives primarily from the coal-grinding mill.

estimate

Noise levels in the vicinity of the mill are generally higher than Leq 95 dB(A).

Personal exposure is mitigated by the fact that there are no fixed workstations.

Expected damage

In addition to communication and professional performance disorders, the following may also occur: cardiovascular alterations (increase in blood pressure, etc.); psychological disorders (asthenia, irritability, depression, insomnia); digestive system disorders.

As a result of the need to speak loudly for verbal communications, in noisy conditions, the vocal cords may be subject to stress, which may be a contributing cause (together with exposure to an unfavourable microclimate and to dust) of throat diseases with hypophonesis.

PREVENTIVE MEASURES

- Perform regular plant maintenance.

- Soundproof the noisiest machines and separate them from other workrooms.

- Replace the oldest and noisiest machines with newer and less noisy ones.

- Organise work in such a way as to reduce worker exposure times.

reference norms

- Art. 24 “Noise and shaking” Presidential Decree 303 of 19.03.1956.

- Item IV “Protection of workers against the risks of exposure to noise during work” Legislative Decree 277 of 15.08.1991.

- Presidential Decree 459 of 24.07.1996 “Regulation for the implementation of directives 89/392/EEC, 91/368/EEC, 93/44/EEC and 93/68/EEC concerning the harmonisation of the legislation of member states on machinery” (Machinery Directive).

Exposure to radiating heat, warm microclimates and work near hot surfaces

description

The warm air tubes used for drying from the mill and coal transportation can be hot and therefore generate radiating heat. Worker exposure to warm microclimates is greatest during maintenance work, and the inconvenience can be greater during the summer season. Patrol workers can be exposed to changes in temperature between one department and another, especially during the winter.

expected damage

Burns due to accidental contact with hot surfaces may occur; breathing disorders, thermal stress, bone and joint disorders due to unfavourable microclimates. Changes in temperature can cause illnesses from colds and bone and joint disorders.

preventive measures

- Insulate hot surfaces, especially those with which workers may come into contact.

- Wear individual protective gear (heatproof gloves and adequate clothing).

- Air-conditioned refectories and cabins.

- Worker health information, training and surveillance.

reference norms

- Art. 9 “Change of air”, Art.11 “Temperature” and Art.13 “Humidity” Presidential Decree 303 of 19.03.1956.

- Art. 240 “Protection of external walls at high temperatures” Presidential Decree 547 of 27.04.1955.

- Art. 378 “Clothing” and Art. 379 “Protective Gear” Presidential Decree 547 of 27.04.1955.

- UNI EN 563 standard (see 6.1.26)

Exposure to coal dust

description

During coal grinding and handling, the entire plant is depressurised for productive reasons (the dust is a resource and as little as possible should be lost). Nevertheless, it is possible that dust may be diffused, resulting in worker exposure, especially in the event of accidental leakage and maintenance.

The TLV - MAC value for coke coal dust is 15 mg/m³.

expected damage

Exposure to coal dust can cause irritation to the respiratory tract and lung diseases.

preventive measures

In order to reduce exposure, adequate exhaust systems must be positioned in the points where dust may spread; in the case of manual handling, dust-proof masks must be worn (as well as protective gear such as overalls, gloves, etc.)

The above-mentioned hygiene standards must be followed (cleanliness of rooms, showers, changing rooms, lockers, etc.). Worker health information, training and surveillance are essential.

reference norms

- Presidential decree 547 of 1955 and subsequent amendments and additions

- Presidential Decree 303 of 1956 and subsequent amendments and additions.

- Legislative Decree 626 of 1994 and subsequent amendments and additions.

Work in the vicinity of moving mechanical parts

description

The moving parts of the machinery, comprising the coal transportation, grinding, and drying systems, can cause accidents due to gripping and dragging.

expected damage

Traumatic lesions

preventive measures

- Make hazardous machinery areas inaccessible, using fixed guards or guards fitted with interblock devices.

- Do not perform maintenance work on machinery in movement.

- Do not oil the gears of machines in movement, unless using oilcans with suitably long nozzles in frangible material in order to allow the worker to remain at a safe distance. Safety distances can be guaranteed, for example by a metal grid, either fixed or fitted with an interblock device, positioned at a sufficient distance from the hazard area.

- Do not wear voluminous garments that could be caught up and dragged by the moving parts of the machinery.

- Activate a visual-acoustic signal before starting the system.

- Blackouts and subsequent returns of electricity supply must not entail automatic machine restarting.

- The machinery must be installed, used, maintained, repaired and adjusted in conformity with Manufacturer’s instructions, especially with regard to old machinery that does not bear CE markings.

- Adopt standardised maintenance procedures.

Worker information and training.

With regard to the conveyor belts, see also the matters mentioned previously for the “marl crushing” phase.

reference norms

- Presidential Decree 547 of 27.04.1955 and subsequent amendments and additions

- Legislative Decree 626 of 19.09.1994 and subsequent amendments and additions

- Presidential Decree 459 of 24.07.1996 (Machinery Directive).

- UNI EN standards.

Storage of combustible material

description

The large quantity of coal stored constitutes a considerable fire hazard. The material is usually stored at a humidity of approximately 8%, however the action of sunrays for long periods (for example during the summer months) could cause the drying out of the material, with a consequential rise in the risk of fire and dust dispersion.

expected damage

Fire with consequential possible intoxication, burns and traumatic lesions.

preventive measures

- Correct storage of the coal in a closed, covered storage cell in order to remove the deposited material from the action of sunlight and wind.

- Routine checks on the humidity of the stored coal.

- Implementation of the safety measures foreseen for the issuance of the Fire Prevention Certificate, in particular with regard to trigger risks (ban on smoking and naked flames and use of relative signs, electric system suitable for the hazard classification of the place in which it is installed), automatic fire detection, emergency exit routes (clear pathways, correct door opening direction, panic bars, etc.), emergency lighting, signals, fire-resistance of structures, extinguishers, water reserves for extinguishing fires and relevant drive system.

- Preparation of a fire-prevention safety plan.

- Worker training on handling emergency situations.

- Worker information and training.

reference norms

- General fire prevention standards.

- Legislative Decree 626 of 1994 and subsequent amendments and additions.

Night-time work

description

The workers involved in the above-mentioned processes work around the clock, in three eight-hour shifts, therefore entailing night-time work.

expected damage

Night-time work can cause alterations to the sleep-wake rhythms and the circadian biorhythms in general unbalance eating habits, cause irritability, susceptibility to depression and possible repercussions on the worker’s family and social life. These inconveniences are made greater by the concomitance of other risk factors that are present, in particular exposure to powder and noise.

preventive measures

Night-time work regulations have recently been innovated by Legislative Decree 532 of 26.11.1999, to which reference should be made for more detailed information. It should be remembered that employees are responsible for organising and funding medical visits in order to subject night-time workers to preventive, routine check-ups aimed at establishing the absence of contraindications and two yearly medical checks. If a worker is found unsuitable for night-time work, he/she will be guaranteed the assignment of other daytime activities or roles.

Before accepting workers for night-time work, employees must inform them and the workers’ safety Manager on the greater risks deriving from night-time work, where present, and arrange suitable personal and collective protection measures in line with the additional risks deriving from the performance of night-time work. For example, in the case of reduced staff during the night, it is recommended that more than one worker be present in each department in order to guarantee assistance in the event of accidents.

reference norms

Legislative Decree 532 of 26.11.1999 “Provisions concerning night-time work, under Art. 17, subsection 2 of Law 25 of 05.02.1999”, implements in Italy the principles of the European Directive 93/104/EC referring to certain aspects of working hour organisation. The Decree applies to all public and private sector employers that employ workers with night-time work services, excluding the transport sector and “junior doctors’ activities”.

OUTSOURCING

The phase is not usually contracted out to external firms.

EXTERNAL IMPACT

This operating phase entails the following environmental impact factors:

Noise diffusion into the surrounding environment

The above-mentioned noisy work processes may cause high noise levels and, unless adequate soundproofing is supplied, the community living close to the production plant may be disturbed, especially as production involves the entire 24 hour period, including the night.

Atmospheric emissions

The fumes and dust from the exhaust system on the grinding mill and coal drying systems are sent to an abatement plant before being released into the atmosphere. Plant efficiency is required for environmental protection, above all for productive reasons, since the powder recovered constitutes a resource for the cementworks.

Dust dispersion

The work processes described above may cause widespread powder dispersions, especially in the event of accidental spillage. The plant must be monitored constantly, the suction systems should be used frequently to clean the plant and road sweepers should be used to clean production unit yards.

The coal storage cell must be closed and covered in order to protect the deposited material from the action of the wind and sunlight.

Water drainage

As described above, due to the possibility of powder dispersion, water used for yard washing must be collected and taken to a water purification plant prior to disposal.

In this operating phase the following environmental risk factors are present:

Fire

In the event of fires, in addition to possible damage to workers and structures and loss of resources (coal, water), considerable quantities of combustion fumes may be released into the environment and the water used for extinguishing fires may be released, with consequential pollution of the air, soil and water.

The above-mentioned fire prevention measures for worker protection mentioned in the combustible material storage subsection must be implemented and an adequate system for the collection of water used to put out fires must be prepared.

CLINKER GRINDING AND MIXING WITH ADDITIVES

DESCRIPTION OF THE PHASE

The aim of this operating phase is to finally obtain cement by means of the grinding of the Clinker, which constitutes the basic semi-processed product, to which other materials are added according to the type of cement one intends to produce. In general, the correctives marl and limestone are added, which, in addition to plaster, when introduced in doses of 3-7%, act as a setting retardant in the preparation of all qualities of cement.

Plaster is primarily composed of bihydrate calcium sulphate and is delivered to the cement works in bulk by lorries that unload it into special hoppers, from which it is extracted by conveyor belts or a grab jaw bridge truck in order to be placed inside the storage silos.

The grinding of the clinker together with the plaster, correctives and additives, takes place in special mills, known as fired product grinding mills.

Inside the mill, in the production of certain types of cement, liquid additives that act as accelerator-fluidifiers are introduced. In some cement works hydraulic lime is also produced, and for this a specific additive that acts as an airer-water retainer is used. The additives are delivered to the cementworks in tankers that unload the liquids in storage tanks using pumps installed on the tankers.

For the production of certain types of cement the product discharged from grinding is mixed together with the dust recovered from the firing kiln’s atmospheric emission abatement electro-filter.

The cement obtained appears as a fine powder, whose principal constituents are calcium ferrides, silicates, and aluminates.

In this phase too there are no fixed workstations, however the workers perform patrols in order to monitor the functioning of the plant and intervene only for cleaning by means of a fixed or mobile centralised exhaust system and/or for maintenance work.

Monitoring and adjustment operations inside the department are generally performed by monitoring staff using motor vehicles or electrical equipment. Monitoring operations include cleaning using exhaust systems, machinery lubrication using the relevant manual appliance or lubrication of systems devoid of automatic lubricating devices, visual and instrumental checks of the electrical parts and instrumental checks on the parts for the detection of physical values used for remote commanding and control from the centralised control room.

Quality control and chemical laboratory workers take care of solid material sampling, performed automatically by a special sampling machine, for the necessary laboratory tests. Product sampling occurs every 2-3 hours.

Liquid additive samples are taken by the workers from special taps, using manual equipment.

EQUIPMENT AND MACHINERY

Goods vehicle unloading hopper

This large hopper is positioned beneath the goods vehicles’ transit plane, in order to facilitate plaster unloading. The material is extracted from the bottom of the hopper, by conveyor belts. The inner structure, conveyor belts, control units and accident prevention devices undergo routine worker maintenance.

Grab jaw bridge truck

This hoisting device is used to extract bulk material from the unloading hoppers of the goods vehicles and introduce it into the grinding system’s loading conveyor. The grab jaw bridge truck is usually a bridge crane composed essentially by a bridge that shifts sideways and a trolley, which is also mobile, that houses the controls and winding drums of the grab jaw manoeuvre. The machine is controlled by a worker who operates levers from inside a cabin.

The bridge truck is subject to maintenance for routine checks and if necessary the replacement of the hoisting cables, the opening-closing device of the grab jaw or the grab jaw itself; replacement of motors, gear boxes, cable drums, rails, electrical parts; metal carpentry repairs and testing and restoration of safety devices.

Fired product grinding and cement storage system

The material to be ground is extracted from the hoppers and taken to a height by an elevator in order to be introduced into the grinding mill.

Any liquid additives used in the production of the various types of cement are extracted from the storage tanks by piston dispensing pumps and sent into the mill.

In the same way as the unfired material grinding system, in this case too the system is a closed cycle, where the grinding mill is connected to a process filter for the collection of the material produced in powder form. The filter is of the fabric sleeve type (for example 350-700 sleeves) and is fitted with ancillary machines for the collection and transportation of the material produced (elevators, transportation Archimedean screws, pneumatic pumps, etc.).

These are usually horizontal rotary cylinder mills, covered internally with steel alloy casing; inside there are steel spheres (whose diameter may vary from 2.5 and 9 cm), which act as grinding bodies, rolling around the cylinder as it rotates on its axis. This procedure causes the pulverisation of the product and at the same time causes the gradual wear of the steel spheres and internal casing of the cylinders. On discharge from the mill, there is a perforated disk, known as the diaphragm, through which the ground material passes, facilitated by the depressurisation to which the plant is subjected by the process filter fan.

Some firms have dual chamber mills, separated by a perforated diaphragm, where the first chamber contains spheres with a diameter of 70-90 mm that perform the coarser grinding and in the second there are spheres with a diameter of 25-60mm, for finer grinding. One firm often has both types of mill (single and dual chamber).

The powdered product exiting the mill through the diaphragm falls into an elevator that takes it to a separator.

The separator used for the material discharged from the single chamber mills is generally formed by a metal case containing two hoppers (one inner and one outer), a rotating plate and a certain number of metal plates with adjustable lengths known as valves. The powdered product falls onto the rotating plate and under centrifugal force moves towards the outside of the inner hopper, while the current of air, created by the process filter fan and the blades of the rotary plate, permits the passage from the inner hopper to the outer hopper of material of a given fineness only. What passes into the outer hopper is the finished product that falls, together with the dust recovered from the sleeve filter, into a pneumatic pump, which sends it to the cement storage silos.

Another type of separator, used in general for the material discharged by dual chamber mills, consists of a perforated drum that rotates at a variable speed, affected by the current of air produced by the sleeve filter fan. This allows the dust that has reached a certain fineness only to reach the recovery filter, depending on the speed of drum rotation.

In both types of separator the coarser material that remains inside is transported once more to the grinding mill entrance together with the new feed material.

For the production of certain types of cement the dust recovered from the kiln’s electro-filter, which is stored in special metal silos from where it is extracted by intubated propellers of variable speeds, then weighed on weighing slides, is introduced directly by pneumatic pumps, via metal tubes, into the separators. The storage silos for the dust recovered from the kiln’s electro-filter and the extraction system are depressurised by means of a dust exhaust sleeve filter.

The cement produced is stored in various silos by means of pneumatic pumps. The choice of silos depends on the type of cement produced, and the operation entails a suitable connection of the mill pump with metal tubing that leads to the chosen silo by means of motorised deviators controlled by the control and command room. The silos of cement produced are robust structures in reinforced cement and the dust is removed by sleeve filters.

Sleeve filters are fitted with automatic compressed air systems for shaking the sleeves. The dust is recovered by the Archimedean screws to be reused in the production plant, whereas the air purified by the sleeves is introduced into the atmosphere by a chimney.

The entire plant undergoes routine maintenance, in the same way as that described for the unfired material grinding plant.

RISK FACTORS

Exposure to noise

description

Noise mainly derives from the clinker grinding mill.

estimate

The noise level in the vicinity of the mill is generally higher than Leq 95 dB(A). Personal exposure is mitigated by the fact that there are no fixed workstations.

In a sector firm, inside the cabin of a bridge truck a noise level of 75 dB(A) was recorded, however in order to leave or access his/her workstation, the operator must transit areas where noise levels are greater than 85 dB(A).

Expected damage

In addition to communication and professional performance disorders, the following may also occur: cardiovascular alterations (increase in blood pressure, etc.); psychological disorders (asthenia, irritability, depression, insomnia); digestive system disorders.

As a consequence of the need to speak loudly for verbal communications, in noisy conditions, the vocal cords may be subject to stress, which may be a contributing cause (together with exposure to an unfavourable microclimate and to dust) of throat diseases with hypophonesis.

PREVENTIVE MEASURES

- Perform regular plant maintenance.

- Soundproof the noisiest machines and separate them from other workrooms.

- Replace the oldest and noisiest machines with newer and less noisy ones.

- Organise work in such a way as to reduce worker exposure times.

reference norms

- Art. 24 “Noise and shaking” Presidential Decree 303 of 19.03.1956.

- Item IV “Protection of workers against the risks of exposure to noise during work” Legislative Decree 277 of 15.08.1991.

Work in the vicinity of moving mechanical parts

description

The moving parts of the clinker and additive transportation and grinding plant can be the cause of accidents due to gripping and dragging.

Another possible risk factor is the bridge truck’s radius of action (where present for the handling of bulk to be ground), which could interfere with the vehicle and personnel transit zone, with the risk of blows and being run over.

expected damage

Traumatic lesions.

preventive measures

- Restricting personnel and vehicle access to the area affected by the bridge truck’s radius of action. For example, in one sector firm, this has been implemented by intercepting the entrance and exit of goods vehicles to the goods shed using automatic bars and relative traffic lights; the opening of the bars that permit the transit of the goods vehicle is conditioned by various sensors that control the relative position of the bridge crane and the vehicle. There is also an automatic acoustic-visual signalling system that signals to the worker operating the bridge crane the entry of a vehicle into the area of the bridge crane’s radius of action.

- Make hazardous machinery areas inaccessible, using fixed guards or guards fitted with interblock devices.

- Do not perform maintenance work on machinery in movement.

- Do not oil the gears of machines in movement, unless using oilcans with suitably long nozzles in frangible material in order to allow the worker to remain at a safe distance. Safety distances can be guaranteed, for example, by a metal grid, either fixed or fitted with an interblock device, positioned at a sufficient distance from the danger zone.

- Do not wear voluminous garments that could be caught up and dragged by the moving parts of the machinery.

- Activate a visual-acoustic signal before starting the system.

- Blackouts and subsequent returns of electricity supply must not entail automatic restarting of the machine.

- The machinery must be installed, used, maintained, repaired and adjusted in conformity with Manufacturer’s instructions, especially with regard to old machinery that does not bear CE markings.

- The working environment must be sufficiently well lit and fitted with emergency lighting. The bridge crane cabin must also be fitted with both normal and emergency lighting.

- Adopt correct working practices, for example, the worker operating the crane-bridge crane should avoid performing abrupt manoeuvres, or multiple manoeuvres that may cause dangerous oscillations of the load and prevent the sideways movement of the bridge with the load in front of the control cabin.

- Adopt standardised maintenance procedures (see mechanical maintenance phase).

- Worker information and training.

For conveyor belts refer also to the matters raised previously for the “marl crushing” phase.

For the bridge crane see also the matters raised in the “mechanical load handling”.

reference norms

- Presidential Decree 547 of 27.04.1955 and subsequent amendments and additions

- Legislative Decree 626 of 19.09.1994 and subsequent amendments and additions

- Presidential Decree 459 of 24.07.1996 (Machinery Directive).

- UNI EN standards.

Work in areas where vehicles transit

description

The transit of goods vehicles carrying raw materials (in this phase, primarily plaster) and other vehicles can involve the risk of cementwork workers being run over.

expected damage

Traumatic lesions caused by being run over by goods vehicles.

Prevention

Arrange and signal, both horizontally and vertically separate lanes for pedestrians and motor vehicles, signal crossing areas, position danger signs and regulations (5kmh speed limit, traffic lights, automatic bars etc.).

Worker information and training

reference norms

- Art. 8 “Traffic lanes, hazard zones, flooring and passageways” Presidential Decree 547 of 27.04.1955.

- Legislative Decree 626 of 1994 and subsequent amendments and additions.

Exposure to dust

description

During the grinding and manoeuvring of clinker, additives and cement, the entire plant is depressurised for productive reasons (the dust is a resource and as little as possible should be lost). Nevertheless, the dust may be dispersed, resulting in worker exposure, especially in the case of accidental spillage and maintenance.

One workstation that requires particular evaluation of the exposure to dust is the bridge truck operator cabin, where dust could enter and is unlikely to leave, thus causing a very dusty environment.

expected damage

Exposure to clinker, additive and cement dust can be the cause of irritation to the respiratory tract and lung disease.

preventive measures

In order to reduce exposure adequate exhaust systems should be localised in the points of the additive mixing and grinding plant from which dust may escape; in the case of maintenance work or accidental spillage, dust-proof masks should be worn (as well as protective gear such as overalls, gloves, etc.) and material that has leaked should be removed using industrial exhaust systems.

In order to prevent the bridge truck’s operator cabin from accumulating dust, an airtight cabin is usually used, manufactured in an iron structure with double glazing and airtight window and doorframes, fitted with a conditioning plant that keeps it at a pressure slightly higher than that of the external environment. The cabin thus allows a reduction in exposure to noise (especially if it is fitted with soundproof covering), and in order to facilitate communication between the worker operating the bridge truck and his fellow workers the cabin has a telephone connected to the company’s switchboard. The air conditioning system is also able to guarantee the operator’s microclimatic comfort both in the summer and the winter by cooling or heating the interior of the cabin.

The above-mentioned hygiene standards must be respected (cleanliness of rooms, showers, changing rooms, lockers, etc.) and worker health information, training and surveillance must be performed.

reference norms

- Presidential decree 547/1955 and subsequent amendments and additions.

- Presidential decree 303/1956 and subsequent amendments and additions.

- Legislative decree 626/1994 and subsequent amendments and additions.

Exposure to vibrations

description

One workstation that can cause exposure to vibrations is the bridge truck’s operator cabin, due to the normal manoeuvres of the bridge truck’s motors.

estimate

This type of vibration is usually considered slight, with regard to both amplitude and frequency.

expected damage

Exposure to vibrations can cause damage to the circulatory system, nerves and joints (Raynaud’s syndrome). The onset of this pathology is related to the duration and extent of exposure. Cigarette smoke and excessive cold worsen circulation damage caused by vibrations.

preventive measures

- The bridge truck is fitted with an anatomical seat capable of absorbing vibrations.

- The bridge truck’s manoeuvre levers are fitted with grips that dampen vibrations.

- Perform regular bridge truck maintenance in order to eliminate any anomalies that may cause greater vibrations.

- Air-condition and heat the bridge truck’s cabin.

- Inform workers about the greater risks of exposure to vibrations if they are smokers or are frequently exposed to low temperatures for long periods of time.

- Worker training on correct work practices.

reference norms

- Decree of the Employment Ministry 18.04.1973 “List of the diseases for which reporting of occupational accidents and professional diseases is compulsory”

- Art. 46, Item. I, Title III “Machinery shaking and vibrations” Presidential Decree 547 of 27.04.1955.

- Art. 24, Item II, Title II “Noise and shaking” Presidential Decree 303 of 19.3.1956

- 9.9.3 EEC/AEEC/EC Directive 663 of 22.12.1986: “Council Directive of 22^nd December 1986 for the harmonisation of Member State Legislation concerning self-propelled trolleys for handling”.

- 1.5.9 EEC/AEEC/EC Directive 392 of 14.06.1989: “Council Directive of 14^th June 1989 concerning the harmonisation of Member state legislation on machinery “.

- 1.5.9 “Field of application and definitions” and 3.2.2 “harmonised norms and equivalent provisions” Presidential Decree 459 of 24.07.1996

- EC notice of 22nd March 1997 (22^nd March 1997) (CEN-EN 1032): “Commission notice within the framework of the application of Council Directive 89/392/EEC of 14^th June 1989, concerning machinery, amended by Council Directives 91/368/EEC, 93/44/EEC and 93/68/EEC”.

- UNI-EN standard 30326-1 of 01.04.1997 (see 6.1.38): “Mechanical vibrations-Laboratory method for the evaluation of vibrations of vehicle seating-Basic requisites”.

Contact with chemical products

description

The fluidifier-accelerator used for the production of certain types of cement is formed by a blend in aqueous solution of inorganic salts and organic nitrogen derivatives with a limited addition of acetic acid as a clarifier.

The additive used as an airer-water retainer for the production of hydraulic lime is formed by an aqueous solution based on sulphated surfactants.

Workers may come into contact with these products in the case of accidental leakage or during plant maintenance work or when taking samples for laboratory tests.

Possibility of falls caused by slipping in the case of personnel transiting on floorings made slippery by spilt liquids.

Failure to label tank taps, tubes and containers used for material transfers or for the conferral of samples for laboratory tests can raise the risk of ingestion. In companies belonging to other sectors, numerous fatal accidents have occurred for this reason.

expected damage

Expected damage depends on the specific composition of products, shown on the product safety sheets, and on methods of use.

Possibility of injuries due to slipping.

preventive measures

- Evaluate the dangers posed by the products used and the possibility of replacing them with other less hazardous ones.

- Follow the indications given on the product safety sheet and wear suitable personal protection equipment.

- Prevent the possibility of spillage or leakage, for example: install double-bodied safety storage tanks; basins for the limitation-collection-neutralisation of any spillage; grated flooring with collection basins and/or grated containers (in suitable material) to be positioned underneath the taps and in points where spillage or leakage could occur; perform regular pump maintenance; use suitable means for taking liquid samples from tank taps using sealed safety containers with spring-loaded re-closure caps.

- Respect standards for the colouring and labelling of tanks, tubes, taps and containers (including those used for short transfers for laboratory tests).

- Prepare standardised maintenance procedures.

- Worker information and training.

reference norms

- Presidential Decree 547 of 27.04.1955 and subsequent amendments and additions

- Presidential Decree 303 of 19.03.1956 and subsequent amendments and additions

- Legislative Decree 626 of 19.09.1994 and subsequent amendments and additions

- Presidential Decree 336 of 1994 (Occupational diseases).

- Law 256 of 29.05.1974 “Classification and discipline of packaging and labelling of hazardous substances and preparations”.

- Presidential Decree 927 of 24.11.1981 “Implementation of European Community Council Directive 79/831/EEC of 18.09.1979, bringing the sixth amendment of Directive 67/548/EEC, on the classification, packaging and labelling of hazardous substances and preparations”.

- Legislative Decree 52 of 03.02.1997 “Implementation of Directive 92/32/EEC concerning the classification, packaging and labelling of hazardous substances”.

- Decree of the Ministry of Health of 04.04.1997 “Implementation of art. 25, commas 1 and 2, of Legislative Decree 52 of 03.02.1997, concerning the classification, packaging and labelling of hazardous substances, concerning product safety sheets”.

- Decree of the Ministry of Health of 28.04.1997 “Implementation of Art. 37, commas 1 and 2, of Legislative Decree 52 of 03.02.1997, concerning the classification, packaging and labelling of hazardous substances”.

- Legislative Decree 90 of 25.02.1998 “Amendments to Legislative Decree 52/1997”

- Legislative Decree 285 of 16.07.1998 “Implementation of Community directives concerning the classification, packaging and labelling of hazardous preparations, under Art. 30 of Law 128 of 24.04.1998”.

Night-time work

description

The workers involved in the above-mentioned processes work around the clock, in three eight-hour shifts, therefore entailing night-time work.

expected damage

Night-time work can cause alterations to the sleep-wake rhythms and the circadian biorhythms in general, unbalance eating habits, cause irritability, susceptibility to depression and possible repercussions on the worker’s family and social life. These inconveniences are made greater by the concomitance of other risk factors, in particular exposure to powder and noise.

preventive measures

It is essential to organise work correctly in order to minimise night-time work and implement measures aimed at eliminating or reducing the risks of exposure to powder as described above at the source.

Shifts should be organised in such a way as to minimise the number of consecutive nights worked by the same worker, by organising shifts at times in accordance with biorhythms (sleep, meals, etc.) and notifying workers of the shift schedule with sufficient notice.

Night-time work regulations have recently been innovated by Legislative Decree 532 of 26.11.1999, to which reference should be made for more detailed information. It should be remembered that employees are responsible for organising and funding medical visits in order to subject night-time workers to preventive, routine check-ups aimed at establishing the absence of contraindications and two yearly medical checks. If the doctor finds that a worker is unsuitable for night-time work, he/she will be guaranteed the assignment of other daytime activities or roles.

Before accepting workers for night-time work, employees must inform them and the Workers’ Safety Officer on greater risks deriving from night-time work, where present, and arrange suitable personal and collective protective measures. For example, in the case of reduced staff during the night, it is recommended that more than one worker be present in each department in order to guarantee assistance in the event of accidents.

reference norms

OUTSOURCING

This phase is not generally contracted out to external firms, as it forms the central phase of the production process.

EXTERNAL IMPACT

In this phase the following environmental impact factors may be present:

Noise diffusion into the surrounding environment

The above-mentioned noisy work processes may cause high noise levels and, unless adequate soundproofing is supplied, the community living close to the production plant may be disturbed, especially as production involves the entire 24 hour period, including the night.

Atmospheric emissions

The flow of dusty air from the machines’ localised exhaust units is sent to a sleeve filter for dust recovery. Plant efficiency is required for environmental protection, above all for production reasons, since the powder recovered constitutes a resource for the cementworks.

Dust dispersion

The work processes described above may cause widespread dust dispersion, especially in the event of accidental spillage. The plant must be monitored constantly, suction systems should be used frequently to clean the plant and road sweepers should be used to clean factory yards.

Water drainage

As described above, due to the possibility of powder dispersion, water used for yard washing must be collected and taken to a water purification plant before being discharged.

In this phase the following environmental risk factors may occur:

Accidental spillage of chemical products

Storage tanks, dispensing pumps and liquid additive tubes may cause accidental spillage and leakage that may cause pollution to the soil and any surface or underground water system elements near the cement works.

Suitable measures should therefore be adopted in order to avoid occasional or continuous spillage or leakage, such as, for example, installing double-bodied safety storage tanks, basins for the limitation, collection and/or neutralisation of any spillage, performing regular pump maintenance, using suitable means for taking liquid samples from the tank taps, using sealed safety containers, with spring loaded re-closure caps, preparing emergency handling teams, training workers assigned to this task and informing and training workers.

WATER DRAINAGE TREATMENT

DESCRIPTION OF THE PHASE

This phase entails purification of refuse water from the thermal station, civilian services and washing of the various machines, plants and workroom floors.

Generally speaking water purification is performed outside the factory using a conventional active mud aerobic plant, but in some cases drainage water is sent to a consortium-run purification plant.

The plant is basically consists of homogenisation tanks, primary and secondary sedimentation tanks, aeration tanks, final mud dehydration treatment and the plant for dispensing reactants, which are generally positioned aboveground where ladders are provided to access stations at a height.

The reagents generally used in the purification plant are listed in the table below:

*Reagents used in wastewater treatment plants*
PRODUCT	PHYSICAL CONDITIONS	FEED MODE
Aluminium polychloride 18%	Aqueous solution	From tanks by pumps
Aluminium sulphate 27%	Aqueous solution	From tanks by pumps
Super-aerated white lime	Powder	Sacks added manually

RISK FACTORS

The workers assigned to plant operation are subject to risks deriving from exposure to dust, vapours, handling of chemical products, manual load handling, working in raised positions and transiting in slippery environments. Special attention must be paid during plant maintenance and cleaning operations, where there are further risks of accidents and intoxication due to the stagnation of toxic or asphyxiating gas and biological risks.

Exposure to chemical products

description and expected damage

In the event of manual picking up, transportation and dispensing, workers are exposed to contact and inhalation of the various chemical products to be added to the water treatment tanks. The following expected damage can be highlighted for the various substances:

Aluminium polychloride

Contact with aluminium polychloride solutions can cause skin irritation and can be caustic when it comes into contact with the eyes.

Aluminium sulphate

Contact with aluminium sulphate concentrate solutions may cause eye injuries.

Super-aerated white lime

Exposure to lime powder can cause skin, eye and respiratory tract irritation. Can be caustic for contact with skin and eyes.

prevention

In order to reduce exposure to the chemical products used, the possibility of substituting the more dangerous ones with less toxic formulations and the adoption of automatic closed cycle dispensing and blending machinery must be carefully considered.

For the picking up, transporting and manual dispensing of hazardous products, it is necessary to use equipment aimed at avoiding leakage, spillage and diffusion of vapours, such as, for example, self-closing taps for drums, transfer pumps, airtight closure safety containers with self-closing spring-loaded cap and flexible discharge spout.

During preparation and usage, workers must also wear suitable personal protection devices, such as gloves, aprons, eye and respiratory tract protective gear, and they must be informed about potential risks and damage following exposure, trained on correct work practices for working in safe conditions; they must be provided with suitable hygienic services: double compartment lockers for separating work clothes from civilian wear, wash basins, showers, eyebaths, etc.) and finally they must receive adequate health check-ups.

reference norms

- Title VIII “Dangerous and harmful products and materials” Presidential Decree 547 of 27.04.1955.

- Title II, Art. 9 “Aeration of closed work places” and Item II “Protection against harmful agents” of Presidential Decree 303 of 19.03.1956 “General standards for occupational hygiene”.

- Art. 3 “General protection measures” of Legislative Decree 626 of 19.09.1994.

- Art. 4 “Obligations of employers, managers and workers” Legislative Decree 626 of 19.09.1994.

- Title IV of Legislative Decree 626 of 19.09.1994 “Use of Personal protection devices”.

- UNI EN standards 626/1, 626/2, 1093/4, UNI 9293.

- Presidential Decree 336 of 1994 (Occupational diseases).

Manual load handling

description and expected damage

Manual handling of sacks of lime can cause damage to the musculo-skeletal system, and in particular to workers’ spines.

prevention

Where possible, suitable mechanical aids such as hoisting equipment should be used in manual handling. However, the most suitable solution is the adoption of automated systems for the dispensing, blending and transportation of products.

reference norms

- Title V and Ann. 6 of Legislative Decree 626 of 10.09.1994.

- UNI ISO standard 938

Work in raised and slippery positions

description and expected damage

During plant operation, workers may have to access workstations that entail risk of falls from above. This risk is worsened if the flooring surface is slippery.

prevention

The areas that can be transited around the tanks must be fitted with parapets in order to prevent workers from falling inside and fitted with footholds. Stairs and walkways in work areas must also be non-slip types and they must also have parapets and foothold bands. Fixed ladders must have fall-prevention protection cages. The workers must wear suitable footwear.

reference norms

- Title II “Working environments, work places and passageways” Presidential Decree 547 of 27.04.1955.

- UNI EN standards 361, 363, 795

Exposure to asphyxiating gas

description

During the routine maintenance of water purification tanks, when the machinery is deactivated, even for short periods of time, stagnation of carbon dioxide may occur, to which workers can be exposed if they go inside the empty tanks.

expected damage

Carbon monoxide intoxication, risk of asphyxia due to lack of oxygen.

prevention

The cleaning and maintenance or depositing operations or the treatment of water plant are sometimes assigned to external firms and in that case the safety of these operations must be co-ordinated by the company’s prevention and protection service. In particular, prior to granting workers access to the tanks, the absence of dangerous gas must be verified using suitable equipment (oxygen detectors). For the preliminary emptying and washing operations, external air must be blown into the tanks by air blowers, otherwise the workers must be fitted with breathing apparatus. In the event of the risk of the presence of dangerous gases or lack of oxygen, the worker inside the tanks must be fitted with a harness connected to a system that guarantees his recovery by another person overseeing from outside. If ladders are used they must be of an adequate length, well anchored and stable.

It is important for workers to receive training on specific risks and on operating sequences for working in safety.

reference norms

- Art. 236 “Work inside tubes, channels, containers and similar that may contain toxic or asphyxiating vapours and gas” Presidential Decree 547 of 27.04.1955.

- Title VIII “Dangerous and harmful materials and products” Presidential Decree 547 of 27.04.1955.

- Title II, Art. 9 “Airing of closed workplaces” and Item II “Protection against harmful agents” of Presidential Decree 303 of 19.03.1956 “General standards for occupational hygiene”.

- Art. 3 “General protection measures” of Legislative Decree 626 of 19.09.1994.

- Art. 4 “Employer, management and supervisor obligations” Legislative Decree 626 of 19.09.1994.

- Title IV of Legislative Decree 626 of 19.09.1994 “Use of Individual Protection Device”.

- UNI EN standards 626/1, 626/2, 1093/4, UNI 9293.

- Presidential Decree 336 of 1994 (Occupational diseases).

Exposure to biological risk

description

Workers assigned to water purification plant maintenance may be exposed to biological risks.

estimate

The greatest risk derives from exposure to aerosols, especially those from open tanks used in the initial wastewater treatment phases where they are subject to aeration by means of moving mechanical parts (stirrers).

expected damage

Possible infection by pathogens.

prevention

Worker vaccination: anti-tetanus, anti-hepatitis A, anti-typhoid and anti-leptospirosis.

Hygiene standards: do not put dirty hands in mouth; do not drink, eat or smoke during work; change work clothes and have a shower at the end of work shifts; dual compartment lockers for separating working clothes from civilian clothes.

Wear respiratory tract protection masks designed especially for aerosols, in case of transit or stoppage near the tanks where aerosols may be produced; protective goggles with lateral shield for protection against splashes.

Information, training and medical check-ups for those exposed.

reference norms

- Legislative Decree 626/1994 and subsequent amendments and additions.

EXTERNAL IMPACT

The main environmental impact factors of this phase are:

Waste production

The main waste produced by this phase of the production cycle consists of dehydrated muds from the purification plant.

Diffusion of unpleasant odours

The water purification plant may emanate unpleasant odours into the surrounding area. In particular, the presence of considerable quantities of highly biodegradable substances in the muds can cause unpleasant odours. This calls for a complete and prolonged oxidation treatment, correct and suitable temporary storage that avoids contact with the ground and rainwater, as well as frequent sending to definitive disposal sites.

The main environmental risk factors of this phase are as follows:

Water drainage

Bad plant management may lead to spillage onto the ground or inside drainage parts and an emergency tank must therefore be provided.

Spillage of chemical products on the ground

The chemical products used in the wastewater treatment plant, such as white lime, aluminium polychlorate and aluminium sulphate, may cause spillage onto the soil, both during filling from tanks to the tankers and in the case of breakages or collapses. In the case of spillages it is possible to verify the pollution of the soil with possible penetration into the ground water and the emission of vapour into the atmosphere. Therefore there must be limiting basins of chemically resistant material in order to prevent dispersion into the soil in the event of spillage and emergency neutralisation measures must be available.

MECHANICAL PLANT MAINTENANCE

DESCRIPTION OF THE PHASE

Every sector firm performs its own production cycle using complex machinery and installations and mechanical equipment and devices of various sizes. The plants requiring maintenance are chiefly: mill, transporters, silos, hoppers and sheet metal structures.

Lift trucks are used to transport work equipment.

RISK FACTORS

Typical metalwork operations are performed for the mechanical maintenance of cementwork plants. Below is some general information, provided by similar research conducted on other productive sectors, see the risk profile for that work process for further specific information.

The main risk factors potentially present in this work phase are the following:

Working at a height

description

For brief operations carried out at a height from the ground, manual ladders and scaffolding are sometimes used. This entails the risk of falls from heights of the operators that working at a height, for example due to slipping, contact with hot surfaces, presence of insects, pain, etc, which may cause a loss of balance and grip.

Moreover, there may be a risk of falling materials and equipment used or present at a height, which could hit workers on the ground.

expected damage

Traumatic lesions caused by the fall of the worker working at a height; traumatic lesions to workers on the ground hit by material falling from above. These are fatal accident risks.

prevention

- Use portable ladders only to reach the position in which work is to be carried out and not to perform operations that require demanding work performed on the ladder.

- It is forbidden to move the portable ladder when there is a worker on it.

- Portable ladders must have suitable non-slip grips at either end; the rungs must be integral and be built in to the uprights.

- Scaffolding must have parapets with footholds.

- Perform the assembly and dismantling of scaffolding in safe conditions (using harnesses against the risk of falling from above, etc.), under the direct surveillance of a supervisor.

reference norms

- Title II “Working environments, workplaces and passageways” Presidential Decree 547 of 27.04.1955.

- Art. 386 “Safety belts” Presidential Decree 547 of 27.04.1955.

- Legislative Decree 626 of 1994 and subsequent amendments and additions

- UNI EN standards 361, 363, 795.

Exposure to noise

description

Exposure to noise may take place due to the use of portable electrical tools (drills, grinding machines, screwdrivers, etc.). Indirect exposure is also possible for operations near noisy machinery.

expected damage

In addition to communication and professional performance disorders, the following may also occur: cardiovascular alterations (increase in blood pressure, etc.); psychological disorders (asthenia, irritability, depression, insomnia); digestive system disorders.

Exposure to noise during maintenance work may also be a concomitant factor that favours the occurrence of accidents.

prevention

In order to reduce exposure, noise must be reduced at source and preventive measures should be implemented on the basis of personal exposure levels and threshold values; preventive maintenance should be performed and scheduled for days when the plant is shut down to avoid indirect exposure; tools that are least noisy should be chosen; wear personal protection devices (ear protectors, ear plugs, etc.), inform and train workers and perform medical checks on them.

For personal exposure levels higher than 80 dB(A) the prevention measure established by Legislative Decree 277/91 must be applied, as summarised in the “Noise exposure threshold values” table given in this document in Chapter “General reference standards”.

reference norms

- Art. 24 “Noise and shaking” Presidential Decree 303 of 19.03.1956.

- Item IV “Protection of workers against the risks of exposure to noise during work” Legislative Decree 277 of 15.08.1991.

Exposure to vibrations

description

Maintenance operations using portable tools (drills, grinders, screwdrivers, etc.) are the cause of exposure to vibrations to the hand-arm system.

expected damage

Continuous exposure to vibrations can cause an occupational disease known as Raynaud’s Syndrome (also known as the white finger phenomenon), a vasoplastic alteration of microcirculation of the hand caused by exposure to vibrations and facilitated by exposure to low temperatures and cigarette smoke.

The onset of this pathology is related to the duration and degree of exposure.

prevention

In order to reduce exposure to vibrations localised in the hand-arm system it is necessary to use tools characterised by low vibration levels or lower vibrational impact, use hand grips that dampen vibrations, heat work environments during the winter, reduce exposure times by rotating the workers. Worker health information, training and surveillance are important.

reference norms

- Ministry of Employment Decree 18.04.1973 “List of diseases for which the reporting of occupational accidents and occupational diseases is compulsory”

- Art. 46, Item I, Title III “Machinery shaking and vibrations” Presidential Decree 547 of 27.04.1955.

- Art. 24, Item II, Title II “Noise and shaking” Presidential Decree 303 of 19.3.1956

- 9.9.3 EEC/AEEC/EC Directive 663 of 22.12.1986: “Council Directive of 22nd December 1986 for the harmonisation of Member State Legislation concerning self-propelled trolleys for handling”.

- 1.5.9 EEC/AEEC/EC Directive 392 of 14.06.1989: “Council Directive of 14th June 1989 concerning the reconciliation of Member state legislation on machinery “.

- 1.5.9 “Field of application and definitions” and 3.2.2 “Harmonised norms and equivalent provisions” Presidential Decree 459 of 24.07.1996

- EC notice of 22nd March 1997 (22^nd March 1997) (CEN-EN 1032): “Commission notice within the framework of the application of Council Directive 89/392/EEC of 14th June 1989, concerning machinery, amended by Council Directives 91/368/EEC, 93/44/EEC and 93/68/EEC”.

- UNI-EN standard 30326-1 of 01.04.1997 (see 6.1.38): “Mechanical vibrations-Laboratory method for the evaluation of vibrations on vehicle seating-Basic requisites”.

- EC communication of 04.06.1997 (CEN-EN 1299, 1997): “Commission Communication within the framework of the application of Council Directive 89/392/CEEC of 14^th June 1989 on machinery, amended by Directives 91/368/EEC, 93/44/EEC and 93/68/EEC”.

Exposure to dust

description

On-site maintenance operations expose mechanics to the inhalation of the dust dispersed in the air due both to the dustiness of the machinery on which they operate (marl, limestone, cement dust, etc.) and the grinding work and that for repairs/maintenance in particular places with portable equipment (drills, grinding machines, etc). Such work processes may expose the mechanical repairs workers to dust from metals and the abrasive materials of the grinding machines

expected damage

Irritation of the respiratory tract, lung disease, skin irritation.

prevention

It is important to examine the product safety sheets of the abrasive compounds of the grinding machine and evaluate replacement of the most dangerous products with less dangerous ones.

Before intervening on machinery, they must be cleaned to remove dust using a pneumatic exhaust system (which can be centralised or by means of portable aspiration units that can be transported on site by lift trucks).

During work involving tools that may cause dust diffusion, it is advisable to use portable aspiration units with flexible arms (trunks) for capturing the polluting agent as close as possible to the source and when necessary, wear suitable personal protection devices to protect the respiratory tract from dust (filtering masks, sealed goggles) and suitable garments (overalls, gloves).

It is important to observe hygiene norms, such as not eating, drinking or smoking during work and providing workers with adequate washing and changing facilities: when performing dirty work or work involving exposure to dust or other harmful agents, all workers, including partners, must have access to double compartment lockers for storing civilian clothes and work gear separately; installations and furnishing destined for refectories, changing rooms, toilets, bathrooms and rest rooms must be kept clean, well-aired and heated during the winter; showers must be sufficiently numerous and well-equipped in order that all the workers that desire to do so may wash immediately after the end of their work shift. Depending on the type of work activity, workers may be obliged to shower after work in the interests of their own health depending on the risks they are exposed to.

The medical information, training and surveillance of those exposed are important.

reference norms

- PRESIDENTIAL DECREE 303/1956 and subsequent amendments and additions

- PRESIDENTIAL DECREE 626/1994 and subsequent amendments and additions

Exposure to welding fumes

description

Workers may be required to carry out welding work when performing repairs in poorly aired environments.

Welding work can expose workers to welding fumes, which differ in nature according to the metal to be welded, its coating and the type of welding iron used.

expected damage

Exposure may cause irritation to the respiratory tract or more serious damage according to the nature of the fumes.

prevention

During welding work, workers must use portable localised exhaust units with flexible arms and filters suitable for the type of pollutant inhaled; wear personal protective devices (filtering masks suitable for protecting the respiratory tract from welding fumes, overalls, sealed goggles). Localised extraction must be performed so that the worker is not positioned between the extraction device and the point of emission. For welding performed in the open air, the worker must remain upwind. Before starting welding work, as much coating as possible must be removed by scaling any paint present. Other people not required for the work should be sent away from the area. The electrode manufacturer’s safety sheet should be read carefully, use electrodes suitable for the type of welding and inform workers on the nature of the electrode and the pieces to be welded and on the risks to which they are exposed; workers must also be properly trained with regard to correct working procedures and undergo medical surveillance.

reference norms

- Presidential decree 303/1956 and subsequent amendments and additions

- Presidential decree 626/1994 and subsequent amendments and additions

Exposure to infrared and ultraviolet radiation

description

Workshop operations that require welding expose workers to infrared and ultraviolet radiation.

expected damage

Eyesight damage

prevention

In this case, for maintenance operations it is advisable to shield emission sources and wear personal protection devices (dark glasses specifically designed for radiation protection).

Worker medical information, training and surveillance (eye checks) are important.

reference norms

Exposure to white hot sparks

description

Welding work can cause exposure to the projection of white hot material.

expected damage

Burns, eye injuries.

prevention

Workers must receive adequate information and training and must wear gloves, overalls and protective visors.

reference norms

- Presidential Decree 626/1994 and subsequent amendments

Work in the vicinity of moving mechanical parts

description

Maintenance operations and workshop work in general, including electromechanical works, can entail the risk of gripping, dragging, blows and crushing.

expected damage

Traumatic lesions such as contusions, injuries and amputations.

prevention

Firstly one must ensure that the machinery conforms to safety standards. The machinery and installations must be fitted with emergency stop devices and devices that prevent the immediate starting up of machines when electricity supplies come back on after blackouts. Mechanical workshop workers must know in advance which part of the machinery or plant they will be handling by consulting safety use and maintenance manuals. The company must therefore provide its staff with all the necessary information, as well as that dictated by daily experience and practices.

It is also important to prevent the untimely starting up of the machine by a worker while another is performing maintenance work. For this reason, prior to starting maintenance operations, it is possible to implement a “block and signal” type procedure, which may consist, for example, in blocking all forms of energy that can move the various parts of the machine, take possession of the control panel key and label it with a sign bearing a caption such as “Do not start up the machine - maintenance work in progress”.

Intervention on the machine while it is in motion with the protective devices removed must be forbidden unless devices that guarantee the same level of safety are used (such as man-present button panels that only permit advancing by pulses and that, once switched on, excludes the machine’s control panel).

Machine gear lubrication must not be performed when the machine is in movement, unless using spouts made with frangible material and of a length such as to allow the operator to keep a safe distance. The safety distance can be guaranteed for example by a metal grate that is fixed or fitted with an interblock device positioned a suitable distance from the hazard area.

Workers must wear suitable clothing, i.e. not loose-fitting clothes that could become tangled and consequentially lead to gripping and dragging by moving mechanical parts. For this reason, overalls are more suitable than aprons, and sleeves should be closed at the cuff.

Worker information and training is of the utmost importance.

reference norms

- Art. 6 “Workers’ duties” Presidential Decree 547 of 27.04.1955.

- Art. 41 “Machine protection and safety” Presidential Decree 547 of 27.04.1955.

- Title III, Item III “Transmissions and gears” Presidential Decree 547 of 27.04.1955.

- Art. 68 “Protection of working parts and machine operation areas” Presidential Decree 547 of 27.04.1955.

- Art. 72 “Block of protection devices” Presidential Decree 547 of 27.04.1955.

- Art. 73 “Machine feeding and discharging apertures” Presidential Decree 547 of 27.04.1955.

- Art. 76 and 77 “Control units for the starting up of machinery” Presidential Decree 547 of 27.04.1955.

- Art. 81 “Command with multiple blocking device “ Presidential Decree 547 of 27.04.1955.

- Art. 82 “Machine standstill position blockage” Presidential Decree 547 of 27.04.1955.

- Art. 233 “Control and handling parts” Presidential Decree 547 of 27.04.1955.

- Title IX “Maintenance and repairs” Presidential Decree 547 of 27.04.1955.

- Art. 4 “Employee, Management and Worker obligations” Legislative Decree 626 of 19.09.1994.

- Title III “Use of work equipment” Legislative Decree 626 of 19.09.1994.

- Presidential Decree 459 of 24.07.1996 (Machinery Directive).

- UNI EN standards 291/2, 291/2, 614/1, 294, 349, 811, 418, 1037, 1088, 574, 982, 983, 1012/1, 1012/2

Mechanical and manual load handling

description

Mechanical repair and maintenance phases can sometimes require the hoisting and transportation of large system components (fans, hoppers, mechanical parts, or the machines themselves) with the consequential risk of accidents from blows and crushing with consequential lesions and contusions. The rupture of a harness or the harnessed structure is also possible.

expected damage

Lesions such as contusions, lesions and amputations.

prevention

Consult the safety indications given in the specific phase on “Mechanical load handling”. We should remember, in particular, the importance of checks on hoisting systems and wearing safety footwear and hard hats. Hard hats are essential system and composite system accessories, in fact in such movements, system parts with considerable weights may fall, which could accidentally be poorly fixed.

During manual metal sheet manoeuvring cut injuries may occur, and therefore suitably resistant gloves must be worn.

Manual handling of work equipment (toolboxes, welding irons, etc.) may cause musculo-skeletal disorders and the use of tool trolleys or trolleys for welding cylinders is therefore recommended.

Work organisation and worker training and information are fundamental.

reference norms

- Title V and All. 6 of Legislative Decree 626 of 10.09.1994.

- UNI ISO standard 938.

- Art. 8 “Traffic lanes, hazard areas, floorings and passageways” Presidential Decree 547 of 27.04.1955.

- Art. 11 “Workstations, passage ways and outdoor work areas” Presidential Decree 547 of 27.04.1955.

- Title X, Item III, Art. 381 “Head protection” Presidential Decree 547 of 27.04.1955.

- Title V “Hoisting, transportation, and storage appliances and equipment” (Item I “General Provisions”, Item II “Cranes, winches, hoists and similar”, Item III “Lifts and hoisting systems”, Item V “Mechanical transportation vehicles and equipment”) Presidential Decree 547 of 27.04.1955.

- Art. 10 “Natural and artificial workplace lighting” Presidential Decree 303 of 19.03.1956.

- Title II, Item V “Lighting” Presidential Decree 547 of 27.04.1955.

- All. 1 “Essential safety and health requisites concerning the planning and construction of safety machinery and components” Presidential Decree 459 of 24.07.1996.

- UNI standards 9288, 9289, 9290, 9291, 9292, 9293, UNI EN standards 281, 614/1, UNI ISO standards 1074, 2328, 2330, 2331, 3287, 3691, 5053, 5767, 6055.

Work in the vicinity of electrical parts

description

It is possible that maintenance work also entails work on electrical parts, and therefore there may be a risk of direct or in direct contact with electrically supplied parts.

expected damage

Electrocution.

prevention

Firstly one must ensure that the plant conforms to safety standards. Work must be performed on machines/systems when they are disconnected from the mains supply and only by specialised staff trained to intervene in safe conditions in the specific cases required by work.

Every time they are used, portable electrical appliances (drills, flexible grinding machines, electrical welding irons) should be inspected to ensure that supply cables are in good conditions.

reference norms

- Law 791 of 18.10.1977 “Implementation of the European Community Council Directive (no. 72/23/EEC) concerning guaranteed safety that electrical materials destined for use within certain voltage limits must have”.

- Title VII of Presidential Decree 547/1955 “Systems, machinery and miscellaneous equipment”

- Decree of the Ministry of Industry of 13.03.1987 “Publication of the summarised list of harmonised standards together with the implementation and publication of further (4^th group) Italian texts of the corresponding harmonised IEC standards, under Art. 3 of Law 18 October 1977, 791, on the implementation of Directive 73/23/EEC concerning safety guarantees for electrical materials”

- Ministerial Decree (Industry) 12.02.1996 “Publication of the summarised list of harmonised norms together with the implementation of further publications (4th group) Italian texts of the corresponding harmonised IEC standards, under Art. 3 of Law 18th October 1977, 791, on the implementation of Directive 73/23/EEC concerning the guaranteed safety of electrical materials”.

- Legislative Decree 626 of 25.11.1996 “Implementation of Directive 93/68/EEC, concerning CE markings of electrical material destined to be used within certain voltage limits “.

- Legislative Decree 277 of 31.07.1997 “Amendments to Legislative Decree 25th November 1996, 626 (2), comprising the implementation of Directive 93/68/EEC concerning the CE marking of electrical materials destined for use within certain voltage limits”

- Decree of the Ministry of Industry of 13.06.1989 “List of the organisations and models of marks of conformity, publication of the summarised list of harmonised norms, together with the implementation and publication of further (5th group) Italian texts of IEC standards in application of Law 791 of 18^th October 1977, on the implementation of Directive 73/23/EEC, concerning the guaranteed safety of electrical materials”.

- Art. 5, 6, 7 section II; Art. 9 section III, of EEC/AEEC/EC directive 656 of 30.11.1989: “Council Directive of 30th November 1989 concerning minimum safety and health requirements for use by workers of personal protection devices during work (third particular directive under article 16, subsection 1 of directive 89/391/EEC)”.

- Law 46 of 05.03.1990 “Standards for plant safety “

Use of the oxyacetylene torch

description

The use of oxyacetylene torch for welding may raise various risks to exposed workers.

expected damage

Burns due to contact with the flame and hot surfaces; traumatic lesions, in the case of cylinder explosions, whose consequences for workers could be fatal; damage to eyesight caused by exposure to radiating heat and luminous radiation; intoxication and damage to the respiratory tract from exposure to combustion fumes.

prevention

The oxyacetylene appliance must be fitted with safety valves applied as close as possible to the torches, in such a way as to prevent blow-back and the flow of oxygen or air into the combustible gas tubes, to make it possible to monitor its efficiency at all times and to prevent the possibility of an explosion due to blow-back.

In order to reduce exposure to combustion fumes, localised fixed or portable exhaust systems are required.

Workers must be adequately informed and trained about correct working practices and the use of personal protection devices (overalls, gloves, filtering mask, goggles and visor) and must also be subjected to medical check-ups.

reference norms

- Title VIII “Hazardous or harmful materials and products” Presidential Decree 547 of 27.04.1955.

- Title II, Art. 9 “Airing of closed workplaces” e Item II “Defence against harmful agents” of Presidential Decree 303 of 19.03.1956 “General standards for occupational hygiene”.

- Art. 3 “General measures of protection” of Legislative Decree 626 of 19.09.1994.

- Art. 4 “Employer, management and supervisor obligations” Legislative Decree 626 of 19.09.1994.

- Title IV of Legislative Decree 626 of 19.09.1994 “Use of Personal Protection Devices”.

Storage and handling of cylinders for oxyacetylene torches

description

The storage of cylinders for oxyacetylene torches may entail the risk of gas leaks and explosions, due to the fact that dissolved acetylene can break down into hydrogen and carbon. The activation energy of the acetylene decomposition reaction is relatively low, for example prolonged exposure to heat and/or a harsh blow to the cylinder can be sufficient. The composition reaction can last for several hours, and explosions may even take place a day after the container has been dealt the blow; in other productive sectors there have been fatal accidents caused by the explosion of acetylene cylinders and attention must therefore be paid to the storage, handling and use of acetylene cylinders. Deposits with quantities greater than or equal to 75kg must undergo compulsory fire prevention checks (Decree of the Ministry of Industry of 16. 02. 1982) .

expected damage

Traumatic lesions in the event of cylinder explosions; possible muscolo-skeletal disorders in the event of manual handling.

prevention

The cylinders must be fitted with the prescribed labelling and must be stored in a separate place that is well-aired, sheltered from the elements and away from sources of heat. Signs informing about the ban on smoking and the use of naked flames must be posted in the storage room. The electric system must be suitable for the dangerous place classification according to IEC standards and fire prevention standards must be observed. It is recommended that emergency procedures be established if acetylene cylinders are suspected of having suffered blows or other circumstances that may cause explosions.

Suitable anchorage systems (such as chains) should be used to prevent accidental falls of the cylinders during both storage and usage. If the cylinders are placed on trolleys, they must be stable and conform in such a way as to prevent the risk of being overturned.

Specific trolleys (see also subsection on manual handling) should be used to prevent muscolo-skeletal disorders).

Workers must be informed and trained.

reference norms

- see “explosion - fire” subsection.

- Legislative Decree 626/1994 and subsequent amendments

OUTSOURCING

Generally speaking, all maintenance work, be it preventive or otherwise, is scheduled by the company and performed by special maintenance teams, which are sometimes formed by external firms that work in the cementworks.

EXTERNAL IMPACT

The main environmental impact factors in this working phase are as follows:

Atmospheric emissions

The dust, fumes and vapours that develop during mechanical repairs on systems can diffuse into the external environment. These emissions occur occasionally, as they are caused by maintenance and repair work and are not directly connected to the production cycle. In general, they are diffuse emissions (in other words they are not channelled) and when localised portable extraction units are used the filtered air is reintroduced back into the working environment.

Noise diffusion to the surrounding area

Certain work processes, especially those requiring the use of manual equipment (such as hammers) and electrical tools (grinding machines, drills, etc) can cause noise diffusion into the outside environment with consequent disturbance to the surrounding population. Solutions consist firstly of reducing noise at source, performing the noisiest work processes during the day and using soundproofing shields.

Waste production

The main types of waste produced during this phase are:

- Sheet metal and mechanical parts deriving from the replacement and/or demolition of machine parts and mechanical systems.

- Exhausted mineral oils used for machine lubrication, replaced during maintenance.

Resource consumption

The main consumption during this phase is concerned with mineral oils for machine lubrication, materials for welding (electrodes, gas for oxyacetylene torches), sheet metal and metal parts. There is also consumption of electrical energy for powering fixed or portable machine tools.

The main environmental risk factors during this processing phase are as follows:

Spillage

During maintenance operations and in particular mechanical part dismantling and replacement there may be spillages of the chemical products used in the systems (washing solutions, etc.). Moreover, there can be spillages of mineral oils during replacement in machines and systems.

The spillage of these pollutants can cause pollution of the ground or water, and therefore organisational, procedural and system measures are required to restrict and collect any spillage and for the correct disposal of recovered products.

Explosions - Fires

The storage of oxyacetylene cylinders and welding activities can cause fire and explosion risks that can spread to the entire company, with consequent pollution due to the emission into the atmosphere of combustion products and the risk of the spreading of the waters used for putting out fires.

MECHANICAL LOAD HANDLING

DESCRIPTION OF THE PHASE

In the work phases described above, we have often encountered the use of aids for the mechanical handling of loads, such as lift trucks and bridge cranes.

The use of these appliances and machines is described in the respective work phase.

MACHINERY AND EQUIPMENT

Lift trucks

These are electrically powered fork-lift trucks. Sometimes diesel powered lift trucks may be used in outdoor yards.

Bridge trucks

These are conventional bridge trucks.

RISK FACTORS

The main potential risk factors in this phase are as follows:

MECHANICAL LOAD HANDLING WITH LIFT TRUCKS

description

During handling operations the lift truck may overturn if the load is not properly balanced and/or due to excessive unevenness and rises/drops in the ground or too small a turning circle. Should the lift truck overturn, the worker could be thrown out of his driver’s seat and be crushed under the truck.

Other workers could also be run over by the truck or the material transported on it. In one sector company a worker was recently run over by a reversing lift truck.

When stacked incorrectly, the material may fall and hit workers.

expected damage

During the above-mentioned operations, workers may suffer serious traumatic lesions.

recorded damage

In the event of accidents occurring in various productive sectors (in other words in companies that are not cementworks) lesions occurring due to accidents during this work phase were recorded as being serious or fatal.

prevention

The risks listed above can be limited by guaranteeing the following conditions:

· Arranging or equipping lift trucks in such a way as to reduce the risk of overturning; to this end, art. 7, letter b), point 1.4 of Legislative Decree 359 of 04.08.1999, lists a series of potential measures, for example possible solutions that can be adopted, such as:

- Driver cabin;

- Structure designed in such a way as to leave sufficient space between the ground and certain parts of the truck for the worker(s) on board in the event of overturning;

- Structure that fastens the worker onto the driver’s seat in order to prevent him from becoming tangled in truck parts should it overturn.

· Driver holding equipment in the driver’s seat of test engines, in order to eliminate the risk of being bounced out, in the case of overturning.

· Flooring devoid of holes, protrusions and faults.

· Vehicle routes devoid of tight bends, without excessive overhangs, preferably one way only, or wide enough for two loaded trucks to pass one another.

· Restriction of interference between the routes used by vehicles and those used by pedestrians.

· Pedestrian routes and places where workers may remain stationery protected against the risk of being hit by stacked material.

· Protection of the exits from rooms or other areas attended by workers when they intersect with vehicle routes.

· Good lighting of routes and walls of workrooms painted in light colours.

· Parabolic mirrors where necessary; in special cases evaluate the possibility of installing traffic lights, signals and, if necessary, protection against any obstacles along the lift truck’s path

· Identification of transport line crossing areas that allows the passage of people without the danger of being run over.

· Spatial and/or temporal organisation of the warehouse in such a way as to minimise the interference between loading and unloading of the warehouse.

· Suitable anchorage, cables and harnessing when intervention at a height is called for.

· Products entering must bear the indication of their weight for workers to verify that the truck and gripping system have adequate capacities.

· Acoustic and luminous vehicle manoeuvre signals.

· Guaranteed visibility from the vehicles’ driver’s seat, including correct positioning of the load transported, which must however be positioned as low as possible in such a way as to guarantee vehicle stability; in exceptional cases in which the bulk of the load is such as to obscure the field of vision, the truck must be preceded by another worker who helps the truck driver in manoeuvres and warns any other workers present in the surrounding area of the presence of the vehicle.

· Preference for the purchase of vehicles with pedals positioned in the same way as those of motor vehicles.

· Limitation of the speed of the vehicles in relation to the characteristics of the route, even with any adjustable devices that limit speed.

· Protection of control units against accidental start-up.

· Protection of the driver’s seat against the danger of being run over by objects falling from above.

· Regular maintenance and routine overhauls of the mechanical vehicle and all its various parts.

· The driver must proceed with caution, with all limbs inside the driving cabin, pay particular attention when reversing, drive the truck within the routes outlined on the ground, interrupt work if anyone is within the vehicle’s radius of action, engage the brake before leaving the truck parked.

· Post signs announcing the prohibition on transporting people on hoisting forks.

· Timely information and training of workers on correct and safe use of the vehicles in the various usage conditions. For example, the worker must know how to act if the vehicle should accidentally overturn, in other words: not to jump out of the vehicle, but rather hold on firmly to the steering wheel, dig in feet and lean in the opposite direction from that of overturning.

reference norms

- Art. 8 “Traffic lanes, hazard zones, floorings and passageways” Presidential Decree 547 of 27.04.1955.

- Art. 11 “Workstations, passageways and outdoor work places” Presidential Decree 547 of 27.04.1955.

- Title X, Item III, Art. 381 “Head protection” Presidential Decree 547 of 27.04.1955.

- Title V “Hoisting, transportation and storage vehicles and equipment” (Item I “General Provisions”, Item II “Cranes, winches, hoists and similar”, Item III “Lifts and hoists”, Item V “Mechanical transport vehicles and equipment”) Presidential Decree 547 of 27.04.1955.

- Art. 10 “Natural and artificial lighting in workplaces” Presidential Decree 303 of 19.03.1956.

- Title II, Item V “Lighting” Presidential Decree 547 of 27.04.1955.

- Ann. 1 “Essential health and safety requirements for the planning and manufacturing of machinery and safety elements” Presidential Decree 459 of 24.07.1996.

- UNI standards 9288, 9289, 9290, 9291, 9292, 9293, UNI EN standards 281, 614/1, UNI ISO standards 1074, 2328, 2330, 2331, 3287, 3691, 5053, 5767, 6055 (see 6.1.37).

Working near moving mechanical parts

description

The moving mechanical parts of the lift truck or bridge crane can be the cause of gripping, entrapment and shearing.

Another possible risk factor is given by the bridge crane’s radius of action, which could interfere with the transit areas of vehicles or workers, with the possibility of blows or being run over.

expected damage

Temporary or permanent lesions due to blows, grip, dragging, cutting, amputation and crushing of limbs.

preventive measures

- Restrict the access of people and vehicles to the area affected by the bridge crane’s radius of action. In one sector company for example this has been put into practice by intercepting the entry and exit of heavy goods vehicles with automatic bars and traffic lights; the opening of the various sensors that control the position of the bridge crane or vehicle. There is also an automatic acoustic-visual signalling system that signals to the operator assigned to the bridge crane the entry of a vehicle into the area within the bridge crane’s radius of action.

- To make the hazardous machinery areas inaccessible, using fixed shields or those fitted with interblock devices.

- Do not perform maintenance work on machinery in movement.

- Do not lubricate machine gears while in movement, unless using oilcans with spouts in frangible material and with a length such as to consent the operator to keep a safe distance. Safety distances can be guaranteed for example by a metal grate, either fixed or fitted with an interblock device, positioned at a sufficient distance from the hazard area.

- Do not wear loose-fitting garments that could be caught up and dragged by moving machinery parts.

- Activate a visual-acoustic signal before starting up the system.

- The interruption and subsequent return of energy must not entail automatic machine start up.

- The machine must be installed, used, maintained, repaired and adjusted in accordance with the manufacturer’s instructions, especially old machinery without CE markings.

- Adopt standardised intervention procedures for maintenance work.

- Worker information and training.

reference norms

- Art. 6 “Workers’ rights” Presidential Decree 547 of 27.04.1955.

- Art. 41 “Machinery protection and security” Presidential Decree 547 of 27.04.1955.

- Title III, Item III “Transmissions and gears” Presidential Decree 547 of 27.04.1955.

- Art. 68 “Protection of working parts and areas in which machines operate” Presidential Decree 547 of 27.04.1955.

- Art. 72 “Blockage of protection devices” Presidential Decree 547 of 27.04.1955.

- Art. 73 “Machine feeding and discharge apertures” Presidential Decree 547 of 27.04.1955.

- Art. 76 and 77 “Control units for starting up of machinery” Presidential Decree 547 of 27.04.1955.

- Art. 81 “Control using multiple blockage device “ Presidential Decree 547 of 27.04.1955.

- Art. 82 “Blockage of machine standstill position “ Presidential Decree 547 of 27.04.1955.

- Art. 233 “Control and handling parts” Presidential Decree 547 of 27.04.1955.

- Title IX “Maintenance and repair work” Presidential Decree 547 of 27.04.1955.

- Art. 4 “Employer, manager and supervisor obligations” Legislative Decree 626 of 19.09.1994.

- Title III “Usage of work equipment” Legislative Decree 626 of 19.09.1994.

- Presidential Decree 459 of 24.07.1996 (Machinery Directive).

UNI EN standards 291/2, 291/2, 614/1, 294, 349, 811, 418, 1037, 1088, 574, 982, 983, 1012/1, 1012/2

Work in the vicinity of hanging loads

description

The use of winches, cranes and bridge cranes entails the risk of loads falling from above. Moreover, especially when a manoeuvre involves more than one worker, there is a risk of hands getting caught up in the chains and of being hit by the load due to oscillations during handling.

expected damage

Traumatic lesions caused by blows, being run over and crushing.

prevention

In order to reduce the risk of being hit or crushed by the load, it is necessary to manoeuvre it in such a way as to reduce oscillations. Moreover, both the person driving the crane (crane driver) and the worker that harnesses the load must avoid standing between the object to be lifted and any fixed obstacles.

The crane hook must be fitted with a safety catch or formed in such a way as to guarantee the impossibility of accidental load fall. In companies in other sectors, there have been a number of fatal accidents caused by the lack of this simple safety device.

When not in use, the hook should never be left at man-height in order to avoid collisions.

The rail on which the bridge crane runs must be fitted with a suitable end-of-stroke device.

The hoisting equipment must be of a suitable capacity in relation to the weight of the object to be hoisted and must be subject to preventive and routine checks on the equipment as a whole and on its various parts, such as cables. The results of checks must be recorded in the company log. In particular, if the capacity is higher than 200kg, the system is subject to a preventive plant visit by ISPESL, annual checks by the Local Health Authority in order to verify mechanical and sliding devices and quarterly checks by technicians assigned by the company with regard to the metal cables used for hoisting loads (to be recorded in the respective logbook).

The hoisting system must only be used by specially trained staff wearing PPE (safety shoes with toecaps, gloves, hard hats).

reference norms

- Art. 8 “Traffic lanes, hazard zones, floorings and passageways” Presidential Decree 547 of 27.04.1955.

- Art. 11 “Workstations, passageways and outdoor work places” Presidential Decree 547 of 27.04.1955.

- Title X, Item III, Art. 381 “Head protection” Presidential Decree 547 of 27.04.1955.

- Art. 10 “Natural and artificial lighting in workplaces” Presidential Decree 303 of 19.03.1956.

- Title II, Item V “Lighting” Presidential Decree 547 of 27.04.1955.

- Ann. 1 “Essential health and safety requisites concerning the planning and manufacturing of machinery and safety components” Presidential Decree 459 of 24.07.1996.

- UNI standards 9288, 9289, 9290, 9291, 9292, 9293, UNI EN standards 281, 614/1, UNI ISO standards 1074, 2328, 2330, 2331, 3287, 3691, 5053, 5767, 6055 (see 6.1.37).

Photograph 19: safety hook.

Manual load handling.

description

The replacement of test engine batteries requires their being handled.

expected damage

Manual handling may cause muscolo-skeletal disorders and damage.

prevention

The risks associated with the manual handling of loads can be reduced by using mechanical battery hoisting equipment.

Test engine batteries can also be charged, leaving them on-board the machine itself. In this case, the battery charger is positioned inside a special chamber while the vehicle is parked under a canopy in the yard, in the vicinity of the external wall of the room housing sockets and plugs for electrical connection; this solution also limits exposure to electrical accumulators and explosion-fire risks.

Manual handling requires a risk evaluation according to the measures of Legislative Decree 626/94 that can be put into practice, and workers must be adequately informed and trained.

reference norms

- Title V and Ann. 6 of Legislative Decree 626 of 10.09.1994.

- UNI ISO standard 938

Exposure to diesel combustion products

description

Should diesel lift trucks be used, workers may be exposed to combustion products, composed primarily of: non-combusted hydrocarbon particles, nitrogen oxide (NO, NO₂), sulphur dioxide (SO₂), carbon oxide (CO), formaldehyde (HCHO), aromatic and aliphatic hydrocarbons, volatile organic substances.

expected damage

Exposure to the above-mentioned pollutants can cause lung disease, oxycarbonism, irritation of the cephalic extremities, bronchial asthma, blood disorders, liver disease, neuropathies, kidney disorders, myocardiopathies and dermatitis. Formaldehyde is also suspected to be a carcinogen.

recorded damage

Surveys conducted in other productive sectors show that workers exposed to gas from the exhaust of diesel-powered trucks have complained of conjunctivitis and irritation of the respiratory tract.

prevention

In order to restrict exposure to this risk factor, diesel lift trucks should be fitted with catalytic exhaust pipes (valid for both NO₂ and CO) or water ones (for the particulate) and their use must be restricted to outside working environments (in the yard in front of the factory), whereas electrically-driven test engines must be used inside. The market currently offers electrical lift trucks whose capacity is sufficient for the sector’s productive needs.

reference norms

- Title II, Art. 9 “Airing closed workplaces” and Item II “Protection against harmful agents” of Presidential Decree 303 of 19.03.1956 “General occupational hygiene standards”.

- Art. 3 “General safeguarding measures” of Legislative Decree 626 of 19.09.1994.

- Art. 4 “Employer, Management and Supervisor obligations” Legislative Decree 626 of 19.09.1994.

- Title IV of Legislative Decree 626 of 19.09.1994 “Use of Personal Protection Devices”.

- Title VII of Legislative Decree 626/94 “Protection against carcinogens”, as amended by Legislative Decree 66 of 25.02.2000.

- Presidential Decree 336 of 1994 (Occupational diseases).

- Legislative Decree 66 of 25.02.2000 “Implementation of Directives 1997/42/EC and 1999/38/EC, that amend directive 90/394/EEC, on worker protection against risks from exposure to carcinogens or mutagens during work”.

Exposure to noise

description

When driving mechanical vehicles (lift trucks), workers can be exposed to noise due to noise generated by the vehicle and direct exposure if the vehicle is introduced into departments where noisy work processes are performed.

Expected damage

In addition to communication and professional performance disorders, the following may also occur: cardiovascular alterations (increase in blood pressure, etc.); psychological disorders (asthenia, irritability, depression, insomnia); digestive system disorders.

prevention

Exposure evaluation and the adoption of respective preventive measures and above all careful vehicle maintenance are required. The possibility of replacing diesel lift trucks (sometimes used in outdoor yards) with quieter electrical trucks should be evaluated.

In cases where personnel exposure levels exceed 80 dB(A), the preventive measures established by Legislative Decree 277/91, summarised in the “noise exposure threshold values” given in the “General Reference norms” chapter of this document shall apply.

reference norms

- Art. 24 “Noise and shaking” Presidential Decree 303 of 19.03.1956.

- Item IV “Protection of workers against the risks of exposure to noise during work” Legislative Decree 277 of 15.08.1991.

Exposure to vibrations

description

Driving mechanical vehicles (lift trucks) can be the cause of exposure to vibrations.

expected damage

Continuous exposure to vibrations can cause an occupational disease known as Raynaud’s Syndrome (also known as the white finger phenomenon), a vasoplastic alteration of the microcirculation in the hands due to exposure to vibrations and favoured by exposure to low temperatures and cigarette smoke.

prevention

Use low vibration vehicles with low vibratory impact, and perform careful maintenance on them.

reference norms

- Decree of the Employment Ministry 18.04.1973 “List of diseases for which the reporting of occupational accidents and professional diseases is compulsory”

- Art. 46, Item I, Title III “Machinery shaking and vibrations” Presidential Decree 547 of 27.04.1955.

- Art. 24, Item II, Title II “Noise and shaking” Presidential Decree 303 of 19.3.1956

- 9.9.3 EEC/AEEC/EC Directive 663 of 22.12.1986: “Council Directive of 22^nd December 1986 for the harmonisation of Member State Legislation concerning self-propelled trolleys for handling”.

- 1.5.9 EEC/AEEC/EC Directive 392 of 14.06.1989: “Council Directive of 14^th June 1989 concerning the harmonisation of Member state legislation on machinery “.

- 1.5.9 “Field of application and definitions” and 3.2.2 “harmonised norms and equivalent provisions” Presidential Decree 459 of 24.07.1996

- EC communication of 22^nd March 1997 (22^nd March 1997) (CEN-EN 1032): “Communication of the Commission within the framework of the application of Council Directive 89/392/EEC of 14^th June 1989, concerning machinery, amended by Council Directives 91/368/EEC, 93/44/EEC and 93/68/EEC”.

- UNI-EN standard 30326-1 of 01.04.1997 (see 6.1.38): “Mechanical vibrations-Laboratory method for the evaluation of vibrations on vehicle seating-Basic requisites”.

Handling of mineral oils

description

Lift trucks, like machines in general, require mineral oils as lubricants for mechanical parts.

expected damage

Mineral oils are a class of compounds that entail acute (allergies, dermatitis) or chronic (tumours) risks to workers.

The IARC subdivides oils into two macro-categories:

- Non-severely refined: classified certainly carcinogenic for humans (Group 1).

- Severely refined: classified among the substances for which it is not possible to express a judgement on their carcinogenic properties (Group 3).

The European Union, on the other hand, in classifying products deriving from petrol oil and coal (including mineral oils) followed criteria different from refinement as such - the blends of substances derived from petrol oil and coal are considered substances to which univocal CAS identification number and a univocal CE index number is assigned, thus classifying approximately 600 substances as carcinogenic (R45) unless the manufacturer is able to demonstrate that they contain (Presidential Decree 52/97):

- Less than 0.1% weight/weight of 1.3-butadiene

- Less than 0.1% weight/weight of benzene

- Less than 3% of Dmso (Dimethylsulphoxide) extract according to IP 346 measurement

- Less than 0.005% weight/weight of benzopyrene

Or, if the producer is aware of the entire refinement process, he can demonstrate that the substance from which the product is derived is not carcinogenic.

Therefore, in this case too, it is fundamental that the label and the safety sheet be read carefully and correctly filled in.

prevention

Use less dangerous mineral oils (severely refined oils) and avoid fouling, especially when removing exhausted oils. Workers must therefore use Personal Protection Devices (gloves, overalls, aprons, goggles) and avoid keeping rags or used gloves impregnated with oil in the pockets. Adequate information, training and worker health check-ups are important.

reference norms

- Title VIII “Dangerous or harmful materials and products” Presidential Decree 547 of 27.04.1955.

- Art. 3 “General protection measures” of Legislative Decree 626 of 19.09.1994.

- Art. 4 “Employer, management and supervisor obligations” Legislative Decree 626 of 19.09.1994.

- Title IV of Legislative Decree 626 of 19.09.1994 “Use of Persona Protection Devices”.

- Title VII of Legislative Decree 626/94 “Protection against carcinogens”, as amended by Legislative Decree 66 of 25.02.2000.

- Presidential Decree 336 of 1994 (Occupational diseases).

- Legislative Decree 66 of 25.02.2000 “Implementation of directives 1997/42/EC and 1999/38/EC, that amend Directive 90/394/EEC, on worker protection against risks deriving from exposure to carcinogens or mutagens during work”.

Exposure to electrical accumulator acids

description

During electrically driven truck recharging, workers can be exposed to the acids contained in the batteries.

expected damage

Chemical irritation and burns of the skin and mucous membranes they come into contact with.

prevention

The inhalation of acid vapours present in electrical accumulators is limited by recharging in separate, adequately aired rooms. If natural aeration is insufficient an extraction system should be used. Alternatively, closed recharging equipment can be used and placed under an exhaust unit.

One further solution can be that of charging the test engine battery by leaving it on the vehicle. In this case the battery charger is placed beneath a canopy in the yard near the outer wall of the above-mentioned room; this solution avoids the problem of handling loads for battery replacement

In order to avoid contact between the acids and the skin, during handling operations for battery replacement, caps must be closed and workers must wear acid-proof gloves. The addition of demineralised water to battery elements can be performed automatically with retainer valves that prevent the leakage of the acidic solution.

reference norms

- Title VIII “Dangerous or harmful materials and products” Presidential Decree 547 of 27.04.1955.

- Title II, Art. 9 “Airing of closed workplaces” and Item II “Protection against harmful agents” of Presidential Decree 303 of 19.03.1956 “General Occupational Hygiene Norms”.

- Art. 3 “General Protection Standards” of Legislative Decree 626 of 19.09.1994.

- Art. 4 “Employer, Management and Supervisor Obligations” Legislative Decree 626 of 19.09.1994.

- Title IV of Legislative Decree 626 of 19.09.1994 “Personal Protection Device Usage”.

- UNI EN standards 626/1, 626/2, 1093/4, UNI 9293.

- Presidential Decree 336 of 1994 (Occupational diseases).

Development of substances capable of creating explosive mixtures with the air

description

Recharging accumulators of electrically driven trucks entails a fire-explosion risk. In fact, during recharging, the passage of electrical current causes electrolysis, with the development of hydrogen. There is also a partial evaporation of the strong acids contained in the battery. Therefore, in the absence of suitable airing, it is possible to reach a level of environmental saturation that can cause the formation of an explosive mixture.

Should there be an explosion, it may also include the projection of strong acids contained in the battery.

expected damage

In the event of a fire/explosion workers may suffer severe burns, traumatic lesions and intoxication. If hit by splashes of battery acid, they may suffer skin burns and eye injuries.

prevention

In order to reduce risks deriving from the recharging of electrical accumulators, this operation must be performed in separate well-aired areas. The electric system must conform to standards for rooms with greater fire risks (IEC 64-8). This room should not contain other flammable material. If the recharging is performed under localised aspiration, the geometrical parameters of the extraction system must be suitably sized in relation to the speed of extraction in order to prevent an explosive mixture with air forming.

Fire prevention measures must also include the presence of type-approved powder extinguishers at least. In the event of higher risks, it may be advisable to install an automatic extinguishing system (such as the CO₂type).

A detailed evaluation of fire risks on the basis of the provisions of Ministerial Decree of 10.03.98 is required.

reference norms

- Art. 19 “Separation of harmful areas” Presidential Decree 303 of 19.03.1956.

- Art. 20 “Protection of the air against pollution with harmful products” Presidential Decree 303/56.

- Art. 303 “Electrical accumulators” Presidential Decree 547 of 27.04.1955.

- Decree of the Ministry of Industry of 01.03.1989 “Implementation of Directive EEC/88/571, on the upgrading of methods of protection of explosion-proof electrical material”

- Legislative Decree 626 of 19.09.1994 and subsequent amendments and additions

EXTERNAL IMPACT

The main environmental impact factors of this working phase are as follows:

Atmospheric emissions

These are formed by emissions from diesel-powered vehicles and the vapours of acids emitted during battery recharging. These emissions have a relatively low environmental impact.

Production of waste

The main waste products produced during this phase are the used oils and batteries from lift trucks. This waste is collected by specialist firms (see subsection 4.1).

Used oil is stored in a suitable way, prior to collection by the appointed firm, under conditions that ensure safety to both workers and the environment. Suitable containers should therefore be used in order to eliminate the risk of breakage and spillage. Containers suitable for this purpose must obey precise rules and in particular they must be fitted with:

· Suitable closure devices for preventing leakage of the content;

· Accessories and devices for performing filling and emptying in safety conditions;

· Containment basin in the event of breakage or spillage;

· Gripping means for making handling operations safer.

The containers must be arranged in such a way as to minimise the risk of accidental collision and other serious inconveniences.

On nearing the maximum capacity of the used oil container, call the Compulsory Used Oils Consortium and pass the oil on to them in safe conditions (non-polluted conferral to the used oils consortium is free of charge), paying the utmost attention to handling containers and to the work situation around liquid transfer operations.

Used lead batteries are dangerous for human beings and for the environment as they contain 60-65% of their weight in lead and 20-25% in diluted sulphuric acid. The lead interferes with vital biological processes and its action attacks the liver, nervous system and reproductive system, sulphuric acid causes burns and contaminates water. Sulphuric acid is classified by the ACGIH as a suspected carcinogenic agent.

Used batteries must be handed over to a COBAT (Compulsory Consortium for Exhausted Lead Batteries and Lead Products) approved collector.

The main environmental risk factors during this work phase are as follows:

Spillage of sulphuric acid and contamination of the ground with lead.

In the event of battery breakage during handling, acid spillage may occur; spillage is also possible during battery recharging and during temporary storage of used batteries awaiting collection by the disposal firm. Spillage may lead to pollution of the ground and the waters. Used lead batteries are hazardous to mankind as they contain 60-65% of their weight in lead and 20-25% in sulphuric acid. The lead interferes with vital biological processes and its action attacks the liver, nervous system and reproductive system, sulphuric acid causes burns and contaminates water. Sulphuric acid is classified by the ACGIH as a suspected carcinogenic agent.

Demineralised water may be added to battery elements using an automatic system, with retainer valves that prevent the leakage of acid; during handling for battery replacement the caps must be closed.

Recharging sites must be configured in such a way as to prevent spillages, for example a special collection channel can be arranged, covered with a grate in acid-proof material and fitted with an accumulation and neutralisation well; the acid collected in the well can be neutralised and removed.

Workers must be suitably trained for dealing with accidents with regard to both safeguarding the environment and health and safety standards.

Until such time as the used batteries are collected by COBAT-approved collection firms, they should temporarily be stored in portable containers made of acid-proof material and have the following characteristics (decision of the inter-ministerial Committee 27^th July 1984)

· fitted with suitable closure devices in order to make handling safe and easy;

· use accessories and devices for performing filling and emptying operations in safety;

· the sides must be at least 20 cm higher that the maximum height of foreseen accumulation;

· labelled with visible labels or plates fixed to the containers or placed in the storage areas;

· containers that have contained batteries and are not reused for the same type of waste must be subject to reclamation treatment suitable for further uses. They must never be used for containing foodstuffs.

Spillage of mineral oils on the ground or into water

The replacement of the used oils in the test engines and the topping up of oil must be performed in conditions of the utmost safety and hygiene in order to prevent inadequate operations or technical means from producing spread and spillage onto the ground and into water, therefore the utmost professionalism and caution is required to perform the work correctly.

It is therefore essential that employers provide adequate instructions to employees and apprentices for the correct management of used oils for environmental protection, without neglecting health and hygiene provisions for the protection of health and safety: oils are a source of risk (slipping, fire, intoxication) that must be evaluated according to the standards specified in the provisions of respective legislative decrees 626/94 and 242/96.

Fire - explosion

Fire-explosion of the battery recharging room can cause structural damage and may also affect other parts of the building, as well as causing the spread of the fire to adjacent rooms.

Almost all Italian cement (97.5%) is produced using the dry or semi-dry process, whereas the wet process is adopted for only 2.5% of production.

In 1999, cement production in Tuscany amounted to 2,024,000 tonnes (+5% vis-à-vis 1998).

Italian exports in 1999 amounted to 2,572,000 tonnes, representing 6.9% of domestic production (-4% on 1998), which can be broken down into 2,480,000 tonnes of cement and 92,000 tonnes of semi-processed clinker.

The balance of trade in 1999 referring to exported and imported cement was positive to the tune of almost 900,000 tonnes.

Source: A.I.T.E.C.

The 89 production units in Italy are distributed as follows: 43 in the North, 15 in Central Italy, 22 in Southern Italy and 9 on the islands.

In Tuscany there are 6 production units, of which 4 perform the entire production cycle and 2 the grinding phase only.

The cement industry is a high-energy use industry, with energy costs accounting for some 30-40% of total production costs. In 1999 the fuels used for the semi-processed clinker were mainly fossil fuels.

In almost all cases, cement producers were supplied by domestic dealers, supplying fossil coal from South Africa, ex-Soviet Union, Colombia, whereas petroleum coke came from the United States and Venezuela.

In 1999 the consumption of electricity used by the cement industry represented approximately 3% of total power absorbed by Italian industry and 32% of the total energy used in the construction materials industry.

There are various types of hydraulic binder, such as: Portland cement, pozzuolana cement, blast kiln cement, aluminous cement, cement agglomerates, hydraulic limes, etc.

The definitions, technical characteristics and requisites of hydraulic binders are described in articles 1 and 2 of law 595 of 25.05.1965.

EXTRACTION OF MARL FROM THE MINE

CRUSHING OF THE COARSE MARL EXTRACTED FROM THE QUARRY

EQUIPMENT AND MACHINERY

Hammer mill

In general, the mills are fitted with dust remover systems connected to a sleeve filter for the recovery of dust and abatement of dust emission into the atmosphere.

In addition to communication and occupational performance disorders, the following may also occur: cardiovascular alterations (increase in blood pressure, etc.); psychological disorders (asthenia, irritability, depression, insomnia); digestive system disorders.

As a result of the need to speak loudly for verbal communications in noisy conditions, the vocal cords may be subject to stress, which may be a contributing cause (together with exposure to an unfavourable microclimate and to dust) of throat diseases with hypophonesis.

reference norms

reference norms

reference norms

Colds and similar disorders.

reference norms

Night-time work

Induced vehicle traffic

TRANSPORTATION, GRINDING, HOMOGENISATION AND ANALYSIS OF UNFIRED MATERIALS

Photograph 3: View of the top of the unfired materials crushing and pulverising tower:

- Crushed marl transportation system running from the quarry to the cement works (right side),

Unfired materials grinding plant (mill, kiln, sleeve filters, Archimedean screw conveyors, etc.)

Unfired perlite homogenisation and deposition plant

This is essentially a large metal funnel that has the purpose of allowing the loading of the unfired perlite into the kiln; the hopper is fitted with small air compressors at various points, which are activated in order to create impulsive jets of air when it is necessary to clear the hopper.

Pressurised appliances

Spectrometer

These are the means used to transport the workers and work equipment used for maintenance to the structure’s various floors.

In addition to communication and professional performance disorders, the following may also occur: cardiovascular alterations (increase in blood pressure, etc.); psychological disorders (asthenia, irritability, depression, insomnia); digestive system disorders.

As a result of the need to speak loudly for verbal communications, in noisy conditions, the vocal cords may be subject to stress, which may be a contributing cause (together with exposure to an unfavourable microclimate and to dust) of throat diseases with hypophonesis.

reference norms

reference norms

preventive measures

Traumatic lesions due to the violent movement of metal parts during the explosion and falls.

Colds and similar.

reference norms

Exposure to radiating heat, warm microclimates and work near hot surfaces

reference norms

Night-time work

Induced vehicle traffic

FIRING THE BLEND IN THE KILN

EQUIPMENT AND MACHINERY

Exposure to gas, fumes and dust

estimate

In addition to communication and professional performance disorders, the following may also occur: cardiovascular alterations (increase in blood pressure, etc.); psychological disorders (asthenia, irritability, depression, insomnia); digestive system disorders.

reference norms

Exposure to radiating heat, warm microclimates, work near hot surfaces

reference norms

Exposure to vibrations

Night-time work

The fumes and dust originating from the exhaust system at the mouth of the kiln are sent to a reprocessing tower and from there to an electro-filter, before being sent to a chimney.

COAL STORAGE AND GRINDING

EQUIPMENT AND MACHINERY

RISK FACTORS

In addition to communication and professional performance disorders, the following may also occur: cardiovascular alterations (increase in blood pressure, etc.); psychological disorders (asthenia, irritability, depression, insomnia); digestive system disorders.

reference norms

Exposure to radiating heat, warm microclimates and work near hot surfaces

reference norms

Storage of combustible material

Fire with consequential possible intoxication, burns and traumatic lesions.

Night-time work

Atmospheric emissions

CLINKER GRINDING AND MIXING WITH ADDITIVES

EQUIPMENT AND MACHINERY

Grab jaw bridge truck

Fired product grinding and cement storage system

In addition to communication and professional performance disorders, the following may also occur: cardiovascular alterations (increase in blood pressure, etc.); psychological disorders (asthenia, irritability, depression, insomnia); digestive system disorders.

reference norms

Worker information and training

reference norms

Contact with chemical products

Night-time work

Storage tanks, dispensing pumps and liquid additive tubes may cause accidental spillage and leakage that may cause pollution to the soil and any surface or underground water system elements near the cement works.