WORLD CEMENT

November 2014

November 2014

Siemens process control CEMAT V8.1 -

In tune with the times.
www.worldcement.com

siemens.com/cemat
 November 2014
CONTENTS
WORLD CEMENT REGULARS
09/ Comment
11/ News
19/ Keynote: Complying With Chemical
Classifications
Steve Minshall, CIH, CSP, Ash Grove Cement Company, USA, talks through the
Globally Harmonized System for Classification and Labelling of Chemicals as
it applies to Portland cement.

147/ Product News

152/ Regional Report Fact Sheet
REGIONAL REPORT: MENA
26/ Committing to Environmental Improvements
ABOUT THIS
Suez Cement Group of Companies, Egypt.

33/ Expansion Projects at Najran Cement

COVER Muayad Matar, Najran Cement Company, Saudi Arabia.

To stay competitive, operators 39/ Logistics Optimisation

have to focus on issues such Sabine Maier, FRITZ & MACZIOL, Germany, and Rachid Lahbara, CIMAT.
as process optimisation. Cemat
from Siemens is the ideal
44/ 19th Arab International Cement Conference
solution for staying competitive.
and Exhibition
Cemat, designed expressly for A preview of the exhibition and conference papers lined up for AICCE19,
the cement industry, is more than which will take place on 11 – 13 November 2014 in Marrakech, Morocco.
a software library – it stands for
a complete philosophy on how to PROCESS CONTROL AND AUTOMATION
operate a cement plant. The new 49/ Cover Story: In Tune With The Times
update Cemat V8.1 will be based
Stefan Siegel and Thomas Walther, Siemens AG, Germany.
on the newly released version 8.1
of PCS 7, Siemens’ traditional 56/ Migration: Addressing The Key Questions
distributed control system, and it KIMA Automatisierung GmbH, Germany.
will make wide use of Simatic S7
modular PLC controllers. PYROPROCESSING
65/ Natural Gas Co-Firing With Alternative Fuels
Syed Suhail Akhtar and Eric Ervin, Manufacturing Performance Center,
Holcim (US) Inc., and Shan Raza and Tahir Abbas, Cinar Ltd, UK.

www.worldcement.com

FEATURED ARTICLES
Working with and handling cement has a number
of risks. Mark Mastrangelo, Polyco, UK,
discusses the hazards workers face
and how to keep them protected.

Palladian Publications Ltd

15 South Street, Farnham, Surrey, Suez Cement Group of Companies, Egypt,
GU9 7QU, ENGLAND

26
explains how the group is working to advance

133
environmental standards at its facilities across
Egypt.

Tel +44 (0)1252 718999 Introduction

S
Let me introduce you to 39 year-old James, a
uez Cement Group of Companies, a subsidiary of the Italcementi Group – the world’s fifth biggest cement producer,
labourer working for a UK house builder. The primary duty
is one of the largest and oldest cement producers in Egypt. Its industrial network comprises five production facilities,

Fax +44 (0)1252 718992

James performs is the mixing and delivering of mortar,
which are located in Suez, Kattameya, Tourah, Helwan and El Minya.
plaster and concrete. James uses both mechanical and
All SCGC plants are ISO 9001 and ISO 14001 certified. They are also subject to comprehensive audits by the Egyptian
hand-held devices and often has to manually handle raw
Environmental Affairs Agency to ensure full compliance with local standards.
materials such as cement.
SCGC employs more than 3500 direct staff, all of whom participate in ongoing safety training and advancement programmes

Email: mail@worldcement.com
James, just like many other construction workers,
at each plant. The company follows international safety, environmental and energy policies, a philosophy that embodies the
is not necessarily aware of the hazards he is exposed
foundation of a sustainable workplace for staff as well as the communities where SCGC operates.

Website: www.worldcement.com 26\ /27 /133

Volume 45: Number 11

November 2014 ISSN 0263 6050 November 2014
World Cement
/3
CONTACT
DETAILS
Editorial
Managing Editor: James Little
james.little@worldcement.com
95 “ARM Cement
Ltd, one of the
major East
African cement
Editor: Katherine Guenioui
katherine.guenioui@worldcement.com
Assistant Editor: Louise Fordham
louise.fordham@worldcement.com producers, has
Editorial Assistant: Rosalie Starling
rosalie.starling@worldcement.com selected HGH’s
Contributing Editor:

Design
Paul Maxwell-Cook
KILNSCAN
Production:  Sophie Awcock
sophie.awcock@worldcement.com
to operate
Sales the thermal
Advertisement Director:
rod.hardy@worldcement.com
Rod Hardy
monitoring of
Advertisement Manager:
ian.lewis@worldcement.com
Ian Lewis
the kiln shell at
Advertisement Executive:
paul.heyworth@worldcement.com
Paul Heyworth
its Kaloleni plant
Website near Mombasa.”
Website Editor: Callum O’Reilly
callum.oreilly@worldcement.com
Website Manager: Tom Fullerton
tom.fullerton@worldcement.com
Digital Editorial Assistant: Katie Woodward
katie.woodward@worldcement.com

Marketing
Circulation Manager: Victoria McConnell
victoria.mcconnell@worldcement.com
Subscriptions Manager:  Laura Cowell
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Office Administrator: Jo Repton
jo.repton@worldcement.com
Reprints:
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Nigel Hardy

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Printed in the UK.

 November 2014
CONTENTS
71/ Preventing Brick Hydration
Kamol Tanchotikul, Nichapat Patchararungruang, Thanapa Wongwichakorn
and Suchaya Amornkittimatee, Siam Refractory Industry Co., Ltd, Thailand.

77/ Improving Brick Performance

Ma Shulong, Li Yanjing, Gao Changhe, Zhang Jili, Zhan Huasheng,
Feng Yunsheng and Li Ping, Beijing Tongda Refractory Technologies Co. Ltd,
China.

83/ Moveable Anchor Systems

Silicon, the Netherlands.

89/ Magnesia-Spinel Brick for Severe

Environmental Conditions
Eduardo M. Reis and Wagner M. Silva, Magnesita.

95/ Adapting to Complex Configurations

Gildas Chauvel, HGH Infrared Systems, France.

MATERIALS HANDLING
100/ Worldwide Coverage
Melanie Saxton, Geometrica, Inc., USA.

107/ Raw Materials Handling, Storage and

Homogenisation
Saswat Kumar Sahu, Tenova TAKRAF, India.

CRUSHING, GRINDING & ADDITIVES

111/ Appropriate Dosing of Chromate Reducers
Dr Armin Schneider, KRONOS INTERNATIONAL, Inc., KRONOS ecochem,
Germany.

113/ Dedusting the Cement Industry

J. Bogerd, Mapei SpA, Italy.

117/ Chemical Activation of Flyash Cements

Josephine Cheung, Riccardo Stoppa and Richard Sibbick, W. R. Grace, USA.

129 124/ Coal Milling Upgrade in Nigeria

Jean-Roch Licari, SNEF Group, Romania.

HEALTH & SAFETY

129/ Prioritising Employee Health
Steve Tagg, Human Resources Director at Aggregate Industries, Europe.

133/ Effective Hand Protection

Mark Mastrangelo, Polyco, UK.

135/ OH&S News

GENERAL INTEREST
141/ Zinc Industry Byproduct for Gypsum
Substitute
M. M. Ali, S. K. Agarwal and Ashwani Pahuja, National Council for Cement
and Building Materials, and T. N. Suresh Kumar, Binani Zinc Limited, India.

November 2014
World Cement
/5
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 November 2014
EDITOR’S
COMMENT

Katherine Guenioui, Editor

katherine.guenioui@worldcement.com

Policy makers more responsive private enterprise is able to be than

government bodies (when they so choose). Naturally,
are slow. commercial companies are driven by profit. The global
panic and media frenzy surrounding the Ebola epidemic
Anyone following the climate no doubt makes a vaccination look a lot more desirable
change talks over the last now, profit-wise, than it did when the virus first appeared
several years will be more than 40 years ago; at that time there was simply no financial
aware of that. There’s a lot of incentive for pharmaceutical companies to respond.
speechifying about ‘playing our Likewise, carbon capture and storage sounds like a
part’, ‘working together’, a lot of calls for action and finance. potential solution to the greenhouse gas problem,
In comparison to the strong words, the pace of actual while carbon capture and utilisation is the ‘holy grail’, as
change feels glacial. One could similarly look at the Ebola Victor K. Der, adviser to the Global CCS Institute, told the
epidemic and accuse governments and institutions like the New York Times.* SkyMine® will convert the CO2 captured
World Health Organisation of dragging their feet. There has from the cement production process into usable products:
been a lot of talk, but on 17 October UN Secretary General bleach, hydrochloric acid and bicarbonate of soda that
Ban Ki Moon reported that the trust fund set up to tackle can be sold to the market. Skyonic has stepped up with
the epidemic had a balance of just US$100 000. Shortly enthusiasm and an entrepreneurial spirit where many
thereafter it was reported that the philanthropic arm of the other companies have seen only obligation and expense.
global furniture store, IKEA, had donated more money to Trying to bring profit to a sector that is traditionally
the cause than the governments of Spain, Luxembourg and thought of as not-for-profit (or frankly unprofitable) is
Norway combined. No doubt it’s easier to dole out armfuls certainly one means of generating a response.
of cash when you don’t have to answer to voters – and of For the cement industry, this means finding the
course, when you have the cash to spend in the first place. commercial value in change. Switching to alternative fuels
Many governments do not. is already widely recognised as one means of improving
With that and the now accelerated efforts by big a plant’s environmental impact and lowering fuel costs.
pharma to come up with a vaccination, reported within Blended cements are another. What is the next step change
days of the official opening of Skyonic’s SkyMine® – a for our sector and how do we embrace it while protecting
carbon capture and utilisation plant at the Capitol our existing profit margins? Who will lead the industry
Aggregates cement plant in San Antonio (there’s a link, towards this change? All answers gratefully accepted at
I promise!) – it got me to thinking about how much katherine.guenioui@worldcement.com.

Authors from Holcim (US) and Cinar Ltd present

Muayad Matar outlines the
33/ Expansion Projects at Najran Cement. 65/ a study on Natural Gas Co-Firing with
Alternative Fuels.
KIMA Automatisierung walks us through Steve Tagg focuses on physical and mental
56/ Migration: Addressing the Key 129/ health at work in Prioritising Employee
Questions. Health.

*http://www.nytimes.com/2014/10/17/business/energy-environment/
texas-plant-to-capture-and-then-reuse-carbon.html?_r=0
November 2014
World Cement
/9
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 November 2014
WORLD NEWS
Dominican Republic  Cemex announces Canada  Exhibitor registration now open
launch of solar power plant for the 2015 IEEE-IAS/PCA Conference
Cemex Dominican Republic has announced the launch Exhibitor registration is now open for the 57th Annual
of a solar plant that will provide renewable energy for IEEE-IAS/PCA Cement Industry Technical Conference, which
its cement plant in San Pedro de Macorís. The plant will be held in Toronto, Canada, from 26 – 30 April 2015.
comprises 5040 panels with inverters that capture the During the conference, attendees will visit St Marys’
sunlight and convert it into energy. Bowmanville facility, the largest cement plant in Canada.
“The contribution represents 1.5 MW that will allow “This year’s conference technical content is shaping up
us to produce 2.2 million kWh/y, equivalent to the amount to be one of the best ever,” said 2015 Conference Chairman,
of energy consumed by 2000 homes,” said Jesús García Martin Vroegh of St Marys Cement. “No other conference
Cárdenas, Director of Operations at the plant. brings this level of technical knowledge to the industry.”
The solar plant, which is Cemex’s first in the Caribbean, Tutorials will be held on 27 April 2015 and are open
is in line with the group’s sustainability strategy, which to all conference registrants. There will also be new
aims to reduce the carbon footprint of its operations and professional training sessions and general session
mitigate their environmental impact. Cemex plans to presentations. Attendee registration will be open soon.
continue to explore other sustainable energy solutions, Exhibitors can register on the conference website:
such as wind and hydropower. www.cementconference.org.

Worldwide  CSI releases updated co-processing guidelines

The Cement Sustainability Initiative (CSI) has stakeholder expectations in recent years, as well as
released an updated version of its Guidelines for to include the CSI members’ collective expertise and
Co-Processing Fuels and Raw Materials in Cement experience in co-processing since the document’s first
Manufacturing. These guidelines provide a technical publication in 2005.
overview of key issues and guiding principles relating Utilisation of alternative fuels and raw materials
to the responsible selection and use of fuels and raw in cement manufacturing can reduce the use
materials. of conventional fuels and virgin raw materials,
The CSI has also published a companion document thereby reducing the quantity of natural resources
to the guidelines, which describes the impacts of necessary for cement production and the overall
co-processing on society. This document details how environmental impact of cement operations, while also
the cement sector can engage with regulators as part contributing to a more sustainable, efficient waste
of their stakeholder engagement around the use of management system. The CSI guidelines provide a
alternative fuels and raw materials. practical reference for cement companies and their
The technical guidelines were revised in view of stakeholders, helping them understand and identify
technology developments, the changing nature of responsible and sustainable approaches to the
alternative fuels and materials, and the evolution of selection and use of fuels and raw materials.

News
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Highlig

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WORLD CEMENT XX ThyssenKrupp secures another To read more
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XX CEMBUREAU concerned about go to:
climate and energy targets

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XX Skyonic opens commercial-scale
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November 2014
World Cement
/11
November 2014
WORLD NEWS

Dominican Republic  XXXI Technical Congress FICEM round-up

On 8 – 11 September 2014, cement producers from addition to the four keynote speakers. The presentations
Latin America and the Caribbean, industry experts, were scored by attendees, resulting in four winners:
and technology and service providers from around the • 1st prize: ‘A disciplined approach to ensuring
world gathered in Santo Domingo for the XXXI Technical the success of major halts’ by Fran Jiménez,
Congress FICEM. Over the course of the event, the Cementos Cibao, Dominican Republic.
345 delegates had the opportunity to catch up with • 2nd prize: ‘Increase of resistance-enhancing additives
the latest equipment developments and advances in Type I cement’ by Cesar Trujillo, Cementos Argos,
in engineering at an exhibition that brought together Colombia.
international suppliers for the worldwide cement industry. • 3rd prize: ‘Green taxes, threat or opportunity for
Running concurrently with the exhibition, the congress co-processing’ by Ricardo Pareja, Cementos Mélon,
featured a conference programme spanning the cement Chile.
production process, occupational health and safety, • Supplier prize: ‘Vertical Roller Mill drive COPE’ by
maintenance and the environment. This year’s congress Guillermo Benjumea and Peter Boiger, Loesche
kicked off with words of welcome from Gabriel Restrepo, America, Inc. and Renk.
FICEM Chairman, and Carlos Emilio González, Chairman
of the Dominican Cement Producers Association, as well The principal aim of Technical Congress FICEM is to
as an inauguration panel that included José del Castillo, provide a forum for the exchange of best practice and
Minister for Industry and Trade, Pelegrín Castillo, Minister expertise in the cement production process, whilst also
for Energy and Mining, and Jean Alaín Rodríguez, Director demonstrating innovative technologies and initiatives that
of the Centre for Exports and Investment in the Dominican can enhance the sustainability of the industry. Building
Republic. on this tradition of knowledge sharing, a three-day course
The technical programme began with keynote on cement chemistry was launched for the first time this
presentations from international sustainability experts. year, running in parallel with the congress.
Philippe Fonta, Managing Director of the WBCSD-CSI, The event concluded with a tour of Domicem’s Sabana
outlined the CSI’s Responsible Sourcing Scheme for Grande de Palenque plant. Participants were shown
the cement and concrete industry and the aims of around the site and invited to take a closer look at the
the upcoming Concrete Sustainability Council. The plant’s quarry, laboratory and control room. Delegates
International Finance Corporation’s Kristtian Rada were treated to some excellent displays of Dominican
and Luis Alberto Salomón discussed programmes to hospitality, whether it be the ocean side lunch following
support the development of sustainable cities and the Domicem plant tour or the gala dinner, which
greater uptake of waste heat recovery systems in the marked the end of the congress and included traditional
cement sector, before architect Luis De Garrido gave his dancing, a live merengue band and some spectacular
unique perspective on the role of concrete in ecological carnivalesque costumes.
architecture. In all, 43 high quality papers were presented, Photos of the event can be found on World Cement’s
22 by cement manufacturers and 17 by suppliers, in Facebook page: www.facebook.com/worldcement.

24 – 26 November 2014 25 – 28 November 2014 19 – 24 January 2015

ICCMATS Bauma China 2014 BAU 2015
Johannesburg, South Africa Shanghai, China Munich, Germany
www.iccmats-wits.co.za www.bauma-china.com www.bau-muenchen.com

21 – 24 April 2015
2 – 6 February 2015 26 – 30 April 2015
24th AFCM Technology Symposium &
World of Concrete IEEE-IAS/PCA Conference
Exhibition
Las Vegas, USA Toronto, Canada
Hanoi, Vietnam
www.worldofconcrete.com www.cementconference.org
cemass@fpt.vn

November 2014
12\ World Cement
Consistent-quality cement without wasting a watt.

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mills, fans and pumps used throughout your cement plant. ABB’s ACS 2000 medium
voltage variable speed drive could be the answer. For motor-driven applications,
the general-purpose drive replaces traditional throttling or damping devices saving
energy, lowering emissions, reducing maintenance costs and improving process
performance. The drive is extremely easy to install and commission and can be
operated without an input isolation transformer with line voltages from 4.0 to 6.9 kV,
saving capital cost and floor space. To learn more about the ACS 2000 medium
voltage drive, visit: www.abb.com/drives
November 2014
WORLD NEWS

Colombia  Argos builds

new Innovation Center
New Zealand  Holcim
Cementos Argos is constructing
holds ground-breaking
a new Innovation Center in
ceremony for new import Medellín, Colombia. The project
terminal is being developed alongside
EAFIT University and will
Holcim New Zealand has carried become a new meeting place for
out the official ground-breaking for Argos employees, researchers,
its new $50 million cement import academics and the community.
terminal in Timaru. The old silos The Innovation Center will contribute to the cement
have already been demolished and concrete industry’s technological and sustainable
by PrimePort and the site is clear development and address the industry’s biggest
for construction to begin, with challenges, as well as those of the construction sector
approvals already in place. The site and the world in general, which can be divided into
should be fully operational by the two main categories: experimental development and
first quarter of 2016. research.
The ground-breaking ceremony was attended by the The first category will work on new material
Member of Parliament for Rangitata, Hon Jo Goodhew, who and product technologies (the development of
planted a tree to celebrate the occasion as a symbol of the new materials with better characteristics in terms
care and value Holcim places on environments in which it of performance, quality, aesthetics, functions,
operates. eco-efficiency and sustainability). The second
Holcim New Zealand’s Managing Director, Jeremy category will be focused on new process technologies
Smith, says the investment can be taken as a sign of the (better production processes aimed at reducing energy
company’s confidence in the strength of the New Zealand consumption, increasing productivity and improving
market, particularly in rebuilding following the Christchurch environmental performance).
earthquake. “The Port of Timaru terminal provides effective Activities at the Innovation Center will cover
access to the major market of Christchurch, utilising the different fields of knowledge across the following
new $5 million silo capacity completed in January 2014 key processes: chemical and physical processes,
at the Lyttleton Port of Christchurch,” said Smith. “This thermal processes, biotechnological processes, energy
terminal also provides effective distribution to the whole of processes, experimental processes, materials tests
the South Island market and the lower North Island as well.” and applications, the development of construction
Holcim New Zealand had previously announced plans systems, knowledge management, the technical
to move out of manufacturing in New Zealand, changing supervising and monitoring of innovation systems
instead to a strategy of importing and distributing bulk and incubation processes, and the development of
cement. In addition to the investment in Timaru, the technology-based businesses. For these activities, it
company is also building a 30 000 t import terminal will count on a variety of teams with highly developed
in Auckland. Construction is scheduled to begin in analytical skills and experience in the different
December 2014. fields of interest, and the most advanced technology
The new cement import terminal in Timaru will consist for the different laboratories and each of the key
of two berthing facilities, one for 35 000 t (handy-sized) processes mentioned above (e.g. electronic field
vessels and one for smaller coastal distribution vessels. emission microscopes, X-ray diffractometers and X-ray
The site will also include a shore-based ship unloading fluorescence testers, as well as other equipment used
facility, a 30 000 t capacity cement storage dome, for materials analysis).
ship-loading for domestic distribution, a load-out facility The Innovation Center will be located on the main
for bulk cement trucks and ancillary building facilities. In campus of EAFIT University and will be open to the
the future, cement may also be distributed by rail. Initially, complete innovation ecosystem, setting a precedent
domestic shipments (via coastal vessel) are expected to be for the development of the relationship between
1 – 2 shipments per week. universities, companies and the state in Colombia.

November 2014
14\ World Cement
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WORLD NEWS
France  Haver & Boecker wins Lafarge Worldwide  Industry appointments
Global Supplier Award 2014 Holcim Ltd
On 17 September, Lafarge hosted the Global Supplier Urs Bleisch, Corporate Functional Manager and a
Awards 2014 at its headquarters in Paris, which member of Senior Management of Holcim Ltd, has been
recognised the best initiatives of its global suppliers in nominated to be a member of the Holcim Executive
seven categories, including: Health & Safety, Sustainability, Committee. He will keep his current responsibilities for
Performance, Product Development, Emerging Market, Holcim Technology Ltd, Holcim Group Services Ltd, and
Logistics, and Strict Working Capital or Financing the project management office of the Holcim Leadership
Solutions. Journey.
Haver & Boecker came top in the Sustainability Alain Bourguignon, currently Area Manager in charge
category for its ADAMS® technology, which is used for of Canada, UK and the USA, and a member of Senior
filling powder-type products into watertight PE bags. The Management of Holcim Ltd, will be seconded to the joint
technology was developed together with Lafarge in a Divestment Committee that was established by Holcim
mutual cooperation project. Lafarge Tarmac had identified and Lafarge in the context of their planned merger. He will
a significant customer issue: the wastage of cement be supported by Marc Soulé, currently Lafarge’s Senior
from damaged paper packed cement, for which PE bags Vice President Performance Management.
were an excellent solution. The combination of Lafarge In their new roles, they will conduct management
Tarmac’s customer and solutions-led focus with H&B’s presentations to potential buyers of the assets Holcim
technical expertise has resulted in PE bags being a very and Lafarge proposed for divestment. They will also
successful innovation in the UK packed cement market. prepare the option of divesting these assets, including the
Read more about the HAVER ADAMS® technology on option of separating these out in a single package, either
page 149. in Europe or worldwide. In this specific context, should
managerial resources be required, Alain Bourguignon
would be proposed for the future CEO role and Marc Soulé
for the future CFO role.
Holcim and Lafarge have previously announced their
intention to make substantial divestments in connection
with the overall merger process. Different options for how
South Africa’s Competition Commission has granted these divestments should be executed are currently being
approval for the LafargeHolcim merger on the considered and discussed with the regulatory authorities
condition that Holcim divests its stake in Afrisam and with potential buyers. Any option considered will be
within the three years following final approval of the subject to the approval of regulatory authorities and the
merger. completion of the proposed merger between Holcim and
Lafarge, and will be carried out in the framework of the
Two new technical committees (Natural Pozzolans relevant social processes and ongoing social dialogue
and Nanotechnology of Concrete) were formed at the with the employee representatives’ bodies.
2014 ACI Technical Activities Committee Summer As a consequence, Roland Köhler, member of the
Meeting in Waimea, Hawaii. The committees will Holcim Executive Committee currently in charge of
allow for better focus and alignment of projects that Continental Europe, will also take over responsibility
specifically apply to each topic. for the UK. The enlarged region will be named ‘Europe.’
Andreas Leu, member of the Holcim Executive Committee
Jim Rushworth, Co-Chair of the CSI Task Force 5 currently in charge of Latin America, will in addition
on Biodiversity & Land Stewardship, presented the assume responsibility for USA and Canada. The enlarged
BMP Guidance at the CSI Forum 2014. The guidance region will be named ‘Americas.’
presents the six crucial stages in biodiversity
management and explains the connection between 4B Components
operations and healthy ecosystems. 4B Group has announced the appointment of Johnny
Wheat as President of 4B Components Limited, with
Carbolite has published the first issue of its customer responsibility over North, Central and South America.
magazine, “the sample”, presenting instruments and “In his role as President, Wheat’s challenge will be
applications from the field of heat treatment and to continue the growth of the company and its brand
providing insight into customer-specific solutions on throughout the region,” said Nicholas Braime, 4B Group
a laboratory and industrial scale. Chairman & Managing Director.

November 2014
16\ World Cement
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 November 2014
KEYNOTE

Complying
with Chemical
Classifications
Steve Minshall, CIH, CSP / Ash Grove Cement Company,
USA, talks through the Globally Harmonized System for
Classification and Labelling of Chemicals as it applies to
Portland cement.

While most companies have grown accustomed to

complying with the original 1983 OSHA hazard
communication standard, the revised version is more
complex than it appears on the surface.

T
he Globally Harmonized System for important to cement manufacturers: 16-section
Classification and Labelling of Chemicals, SDS; hazard statements; precautionary statements;
also known by the mercifully short acronym pictograms; labels.
GHS, has been imposed upon industry since
the Occupational Safety and Health Administration History of HCS and OSHA’s alignment with
(OSHA) issued a final rule revising its Hazard GHS
Communication Standard (HCS) to align with The HCS became federal law in 1983 and in
GHS (HCS-GHS). While the cement manufacturing 1987 OSHA revised it to expand coverage to all
industry is largely regulated by the Mine Safety and industries; additional modifications were adopted
Health Administration, Portland cement products in 1994. As its name implies, the HCS is meant to
are sold into general commerce and therefore the inform workers about the hazards of the chemicals
revised HCS-GHS rule also affects the cement sector. with which they work. The original HCS mandated
While most companies have grown accustomed hazard determinations, labelling and detailed
to complying with the original 1983 OSHA hazard information in material safety data sheets, a written
communication standard, the revised version is more programme and employee training.
complex than it appears on the surface. The revised HCS that adopts GHS improves
After a review of the history of GHS, this article on the original standard by providing more
delves into five areas of the HCS-GHS rule that are detailed criteria for classifying chemical hazards;

November 2014
World Cement
/19
November 2014
KEYNOTE
standardising signal words, pictograms, hazard and Is it possible that OSHA will already have an
precautionary statements on labels; and requiring a update to the revised HCS-GHS standard before the
standardised format for the newly re-named safety final deadline of 1 June 2016? We will all have to
data sheet or SDS. OSHA’s HCS-GHS standard is wait and see.
focused on standardisation and the presentation of
uniform information to workers. In fact, OSHA calls it Why GHS now?
a ‘uniformity standard’. The answer to this question is ‘it’s in the numbers’:
OSHA did not recently conclude that aligning with 43 – 521 – 250 – 507 - 201.
the GHS was the right thing to do at this moment. Unfortunately, these numbers are not the key to
The process started in 1992 when the United Nations an early and wealthy retirement. They may resemble
Conference on Environment and Development lottery numbers but they have a more dramatic
called for the development of a globally harmonised meaning.
chemical classification and labelling system. In OSHA is required to complete an analysis of
late 2002, a United Nations committee adopted the the costs and benefits of significant regulatory
Globally Harmonized System of Classification and actions, and GHS certainly qualifies. So, what do
Labelling of Chemicals, commonly referred to as these numbers mean? They are estimates of the
GHS. From 2006 through 2010, OSHA embarked on a effects of the GHS that were developed by the
series of rulemaking notices and public comment in Office of Management and Budget (OMB). Here is an
order to align its HCS with GHS. OSHA published the explanation for each one:
Final Rule in March 2012 with an effective date of ll 43 – number of fatalities prevented annually.
25 May 2012.
ll 521 – number of injuries and illnesses prevented
With the publishing of the final rule, OSHA also
annually.
announced a series of compliance dates to allow
companies to fully implement the rule over time: ll 250 – annual monetised health and safety benefits
in millions of dollars.
ll 1 December 2013 – complete training on how to
read new SDS and labels. ll 507 – annual cost reductions and productivity gains
in millions of dollars.
ll 1 June 2015 – reclassify products; produce SDS and
labels. ll 201 – annual cost of the rule in millions of dollars.
ll 1 December 2015 – ship only with conforming GHS
labels. In effect, OMB is saying that this new rule
ll 1 June 2016 – update alternative workplace labels will save industry US$556 million per year,
and the written HazCom programme, as well as beginning after a four-year phase-in period. It is a
provide additional training on newly identified tantalising amount. However, astute readers will
physical or health hazards. want to continue to make a profit from cement
manufacturing rather than depending on a regulatory
Of course, the first deadline has passed. The next scheme upon which to make money.
major compliance deadline is 1 June 2015. Are these numbers accurate? Industry tends to
OSHA gave industry approximately 2.5 years to say that government inflates the numbers while
come into full compliance with the standard. An government argues that industry understates the
interesting aspect of the United Nation’s version of benefits. Given that OSHA’s Hazard Communication
GHS, though, is that it is revised every two years. Standard is – some would say chronically – in the
OSHA intends to handle these updates in any of top ten most cited violations, let’s hope that this rule
three ways, depending on the extent of the revisions: will achieve its objective.
1. Technical updates – for minor terminology
changes. Nuances of the revised HCS-GHS Standard
OSHA’s revised HCS-GHS standard contains complex
2. Direct final rules – for test clarification.
and nuanced features. Many of these features are
3. Notice and comment – for more substantive found in specific sections of the 16-Section SDS;
or controversial updates, such as additional or hazard statements; precautionary statements;
changes in health or safety hazard classes or pictograms; labels. Let’s look at some of these
categories. features more closely.

November 2014

20\
World Cement
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November 2014
KEYNOTE
Figure 1. SDS and product label pictograms for Portland cement.

The ‘16-section SDS’ refers to the fact that the Both of these hazard warning statements apply to
revised standard requires a uniform 16-section SDS Portland cement and they cannot be modified. In
with prescribed wording used in several places. fact, you can view them as sacrosanct.
There is not space here to go into detail on each Similarly, in section 2.2 one can find precaution
of the 16 sections. The key points are that the order statements. These begin with a ‘P’, followed by
of the 16 sections is prescribed to aid uniformity; a 3-digit number that begins with a 1 for general
four of the 16 sections (sections 12 – Ecological statements, 2 for prevention statements, 3 for
Information; 13 – Disposal Considerations; response statements, 4 for storage statements,
14 – Transport Information; and 15 – Regulatory or 5 for disposal statements. The next two digits
Information) are not enforced by OSHA, but these designate a specific precaution statement, such
sections must appear in SDS. as: P102 – keep out of reach of children; P201
It is in section 2 – hazards identification, that – obtain special instructions before use; P405 –
things become more interesting for the Portland store locked up; or P501 – dispose of contents/
cement SDS. In section 2.1 the hazards of Portland container in accordance with local/regional/
cement are classified. This classification is an national/international regulation (to be specified).
important and complex new part of SDS. The Precaution statements can also be combined, as in
classifications for Portland cement include: skin P305+P351+P338 – ‘IF IN EYES: rinse cautiously
corrosion; serious eye damage; skin sensitisation; with water for several minutes. Remove contact
specific target organ toxicity after single exposure; lenses, if present and easy to do. Continue rinsing.’
and, possibly, carcinogenicity. It is the carcinogen Manufacturers have more leeway in selecting,
classification that is the rub for manufacturers modifying, or combining the precaution statements.
because it is not Portland cement that is the However, they must still be consistent with the
carcinogen but crystalline silica, which, if present in hazard classifications of the product.
Portland cement, is there in very small amounts. Give careful consideration to the use of
Section 2.2 of the SDS includes hazard precaution phrases such as:
statements. In the parlance of GHS terminology, ll P272 – contaminated work clothing should not be
hazard statements begin with an ‘H’ followed allowed out of the workplace.
by a 3-digit number that begins with a 2 for
ll P405 – store locked up.
physical hazards, 3 for health hazards, or a 4 for
environmental hazards; the number ‘1’ is not used ll P403 + P233 – store in a well-ventilated place. Keep
as one of the first digits. The other two digits container tightly closed.
designate a specific and uniform hazard warning
statement. For example, H314 indicates the health Imagine the implications of such phrases on a
hazard warning statement: ‘Causes severe skin construction site where bagged cement products
burns and eye damage’ and H317 designates the are in use. It is not typical that construction workers
statement: ‘May cause an allergic skin reaction’. would change out of their work clothes before

November 2014

22\
World Cement
 PFEIFFER.
SETTING BENCHMARKS.
SINCE 1864.

From one man’s idea to the largest mill in the world

When industrialization began in Europe, Jacob Pfeiffer had a vision: the grinding of
mineral raw materials on a large scale. As a family-owned company, inspired by his
energy and enthusiasm, we carry on his idea and have been doing so for 150 years.
And still today, as a technology leader operating worldwide, we continue to set bench-
marks for the industry. Behind all this, lies state-of-the-art engineering work „made
YEARS
NG
ERIN in Germany“ and the special quality of a manufacturer with his own manufacturing
ENGINE
GERMAN 6 4 facilities guaranteeing highest durability and reliability. Jacob Pfeiffer would be proud.
SINCE 188
www.gpse.de

1864 1890 1894 1925 1956 1979 1994 2006 2007 2014
Jacob and Karl The first air The first cement The largest The first MPS mills The first vertical Launch of MPS B The first MVR The first vertical The world’s largest
Pfeiffer founded the separator in the grinding operation cement mill for raw material mill for cement series with improved mill for cement mill with vertical mill for
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factory and foundry erection
November 2014
KEYNOTE
companies may elect to include the third pictogram
in their SDS and on their labels. Also, keep in mind

...the revised that OSHA requires that the red border on the
pictograms be used on labels; black borders are not

HCS-GHS acceptable.
Speaking of labels, the revised HCS-GHS

standard includes standard includes new label requirements. The

precautionary statements developed for the SDS

new label
must be on the label and must be identical to those
listed on the SDS. Likewise, the hazard statements
must appear on the label exactly as they are
requirements. The portrayed in the SDS. The hazard statement must
be preceded by a signal word, in this case ‘Danger’
precautionary for Portland cement and related products. The
pictograms also go on the label, including the red
statements borders. OSHA allows ‘additional information’ to be
included on the label but this information must not

developed for the contradict any of the stock hazard or precautionary

phrases.

SDS must be on the One last SDS/label issue, easily overlooked, is

the requirement to include a statement about the

label and must be percentage of ingredients in the Portland cement

mixture that are of unknown acute toxicity. The

identical to those purpose for this arcane information is not well

understood, is likely to be seen as confusing and

listed on the SDS.

therefore not useful to consumers or users of
Portland cement products. Still, it is a requirement
and the person or firm that prepares SDS and labels
should address it appropriately on both.

leaving the site, that locked storage is always Conclusion

available, or that a bag of Portland cement could OSHA’s hazard communication standard is
easily be kept tightly closed once opened. The familiar to most in industry; it has been around
phrases just mentioned, however, could apply to since the early 1980s. However, the revised
Portland cement because the product receives the HCS-GHS standard is more complex and requires
carcinogen classification due to the presence of a knowledgeable person to correctly classify
equal to, or greater than, 0.1% crystalline silica. products, develop SDS and produce compliant
The carcinogen issue turns this discussion labels. Carefully review the content of new SDS
to the pictograms that are now required on SDS and labels to ensure that each product has been
and on product labels. Two, and potentially three, correctly characterised and meets regulatory
pictograms apply to Portland cement (Figure 1). requirements. Deadlines loom for meeting the new
The first two – skin corrosion/eye damage and requirements and wise companies are well on their
skin sensitiser – apply across the board to Portland way to meeting those dates.
cement. The third pictogram, indicating health
hazard – carcinogen, is required if Portland cement Note
contains equal to or greater than 0.1% crystalline Steve Minshall, CIH, CSP, is Ash Grove Cement
silica. Some manufacturers may know with Company’s Director of Corporate Health and Safety.
certainty that their product always contains less He joined the company in 1994 and has directed
than 0.1% crystalline silica and those companies its health and safety programme since 2008.
may elect to not include the third pictogram in their Minshall is actively engaged in the Portland Cement
SDS and on their labels. Others may know that Association’s Occupational Health and Safety
variations in raw materials may produce variable Committee. He works to ensure every employee
crystalline silica levels and for that reason those returns home safely each day.

November 2014

24\
World Cement
Material handling
and sizing solutions
MMD has been involved in sizing and handling of the disparate raw
materials used in cement production for over 30 years.

The MMD Sizer’s breaking action makes it ideal for sticky and hard
material, both separately or combined. The “churning” action of
its twin shafts making it ideal for blending different material and
centralizing it on the take-away conveyor. Its compact profile, low
weight and the generation of minimal external loads enabling
it to be easily retro fitted in to existing plants and eminently
suitable for mobile units.

MMD also produces heavy duty, variable speed apron plate and
chain feeders which, when used in conjunction with the MMD
Mineral Sizer, and controlled by cross-belt analysers, can provide
a consistent blend of material, allowing for independent mobile
installations and a reduction in the number of stockpiles required.

MMD’s world wide support structure enables them to provide the

complete sizing solution to the global cement industry.

THE MMD GROUP OF COMPANIES

W W W. M M D S I Z E R S . C O M
 Suez Cement Group of Companies, Egypt,
explains how the group is working to advance
environmental standards at its facilities across
Egypt.

S
uez Cement Group of Companies, a subsidiary of the Italcementi Group – the world’s fifth biggest cement producer,
is one of the largest and oldest cement producers in Egypt. Its industrial network comprises five production facilities,
which are located in Suez, Kattameya, Tourah, Helwan and El Minya.
All SCGC plants are ISO 9001 and ISO 14001 certified. They are also subject to comprehensive audits by the Egyptian
Environmental Affairs Agency to ensure full compliance with local standards.
SCGC employs more than 3500 direct staff, all of whom participate in ongoing safety training and advancement programmes
at each plant. The company follows international safety, environmental and energy policies, a philosophy that embodies the
foundation of a sustainable workplace for staff as well as the communities where SCGC operates.

26\
/27
 The Kattameya plant.

Since 2005, Suez Cement Group of Companies (SCGC) In that vein, the company has implemented numerous
has invested a significant percentage of its industrial long-term projects at its plants that are designed to reduce
investments in the implementation of comprehensive emissions, pollution and waste. In fact, in 2013, SCGC
environmental and safety policy.  received several awards from the Ministry of State for
SCGC understands that the cement industry must Environmental Affairs for its comprehensive environmental
take a leadership role in consolidating sustainability at management and performance programmes.
the root of its business. The company has therefore made The Kattameya plant was honoured with the
environmental protection one of its key corporate pillars, ‘2013 Greenest Company in Egypt’ first prize certificate in
driven by its comprehensive energy policy. This policy forms recognition of its ongoing initiatives designed to reduce the
part of the driving force behind efforts to move toward a environmental impact of cement production.
low-carbon economy and develop feasible environmental
solutions in partnership with the government and other Environmental projects
players in the building materials sector.
As part of SCGC’s ongoing efforts to reduce adverse Reducing emissions
environmental impacts, regular consultations and Last November, SCGC launched a new, state-of-the-art
information sessions are held with local stakeholders. A filtration system at its Helwan plant. The filter system
company-wide Compliance Action Plan was launched in reduces dust emissions levels to a maximum of
2012, with key goals set to be reached this year. 10 mg/m3, which is well below Egyptian and European
standards.
In addition, a project to convert electrostatic precipitators
The Suez plant.
to baghouses at the Kattameya, Suez and Minya plants was
approved in 2013 with a budget of LE116.7 million.

Alternative fuel utilisation

In light of the fuel crisis currently affecting Egypt, SCGC is
working to replace traditional fossil fuels with alternative
fuels, and thereby decrease its total CO2 emissions.
Meanwhile, waste heat recovery is being explored as a
promising option in terms of electricity production or district
heating.
On 25th and 26th July 2013, SCGC began construction
of innovative waste fuel projects at the Helwan and
Kattameya plants. Both have been registered with the Clean
Development Mechanism Executive Board of the United
Nations Framework Convention on Climate Change.

November 2014

28\
World Cement
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 The purpose of these two projects is to increase the participate and fund similar projects to ensure that the
percentage of energy it produces from refuse-derived fuels. renewable energy sector meets its full potential.
Also known as alternative fuel, this RDF is comprised of
agricultural waste that includes rice straw, and cotton Sustainable products
stalks. The hope is that RDF will soon comprise 14% of the Furthermore, the company’s products are made with
company’s overall energy mix. sustainable environmental practices in mind. SCGC controls
the quality of each cement type and strength class through
Looking to renewable energy its Quality Management System. The goal is to consolidate
As for renewable energy, Italgen, a subsidiary of the the company’s strategy to improve the quality of its products,
Italcementi Group, has signed agreements with the processes and services, thereby creating added value along
Egyptian Electricity Transmission Company to develop the life cycle of products.
the first privately owned and operated wind farm in Egypt.
Phase I is slated to produce 120 MW of electricity and cost Water management
€140 million, with the aim of eventually producing 400 MW of Water has been increasingly recognised as a key factor
power in the next phases. in sustainable development by major industrial sectors,
The deal will see Italgen build wind turbines in the including building materials producers. Cement production
Gulf El Zeit, which is currently under development, just north requires water to produce ‘slurry’ in wet process kilns, cool
of Hurghada. The electricity will be transmitted to plants run gases, improve the efficiency of process filters, control
by SCGC as part of the company’s plans to incorporate a fugitive dust and cool mechanical equipment.
higher percentage of renewable power in all of its facilities. SCGC is striving to improve water management practices
The government’s goal is for 20% of the country’s and efficient water use as well as apply reporting processes
electricity, approximately 7000 MW, to come from renewable in this area in line with the 2010 WBCSD Global Water
sources, such as solar, water and wind, by 2020. To reach Measurement Tool. Some 70% of total water withdrawals
this ambitious target, it is essential that the private sector were monitored by counters. The remaining 30% are set to be
counted by the end of 2014.

The team at the waste processing plant. Quarry rehabilitation

Last but not least, the Egyptian group is currently
implementing four quarry rehabilitation projects, three of
which were undertaken voluntarily. In 2007, SCGC began the
first rehabilitation plan by refilling its clay quarry near the
Tourah plant, which is the oldest quarry in the country. The
other two refilling projects are located in the Suez plant’s clay
quarry, while the fourth involves planting palm trees around
the Kattameya clay quarry to create a barrier between the
site and the highway.
“Our hope is that others see us as a leader in
environmental protection and are inspired to follow our
lead. Our aim is to ensure Egypt’s natural resources can be
enjoyed by future generations to come,” explained Mr Carré,
CEO of Suez Cement.

The waste processing plant in Kattameya.

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