International Journal of Civil Engineering and Technology (IJCIET)

Volume 7, Issue 6, November-December 2016, pp. 489497, Article ID: IJCIET_07_06_054

Available online at http://www.iaeme.com/IJCIET/issues.asp?JType=IJCIET&VType=7&IType=6
ISSN Print: 0976-6308 and ISSN Online: 0976-6316
IAEME Publication

IDENTIFICATION OF OCCUPATIONAL ACCIDENTS,

HEALTH PROBLEMS AND CAUSES: A CASE STUDY
OF CEMENT INDUSTRY
Shabir Hussain Khahro
Lecturer, Department of Engineering Management, Prince Sultan University,
Riyadh, Saudi Arabia

Tauha Hussain Ali

Professor, Civil Engineering Department,
Mehran University of Engineering & Technology, Jamshoro, Pakistan

Yasir Javed
Lecturer, Department of Engineering Management,
Prince Sultan University, Riyadh, Saudi Arabia

Mir Aftab Hussain Talpur

Assistant Professor, Department of City and Regional Planning,
Mehran University of Engineering and Technology, Jamshoro, Pakistan

ABSTRACT
Cement is one of the key materials used largest on planet. It helps in many areas of development
in socio economic benefits of any country. Almost three tons of concrete (containing 10-15% cement)
are consumed annually. Meanwhile, it has been reported in various studies that it has potential to
cause serious occupational accidents and health problems. Every year in the world, millions of work
related accidents occur and the world pays a high price for accidents or injuries in terms of human
suffering and economic losses. Despite some progress, the question of safety at work is still a serious
problem. Hence, this paper aids in the existing body of knowledge for occupational accident, health
problems and their causes in cement industry. Questionnaire Survey has been carried out and
Quadrant Analysis and Relative Importance Weight method has been used to analyze it. The results
show the possible vulnerable occupational accident and health problems. It also highlights the
possible root causes of them. Safety should be the priority for all industrial activity. This paper will
help the stakeholders to make and revise the health and safety policies and practices.
Key words: Cement, Construction Industry, Occupational Accidents, Health Problems
Cite this Article: Shabir Hussain Khahro, Tauha Hussain Ali, Yasir Javed and Mir Aftab Hussain
Talpur, Identification of Occupational Accidents, Health Problems and Causes: A Case Study of
Cement Industry. International Journal of Civil Engineering and Technology, 7(6), 2016, pp.489
497.
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 Identification of Occupational Accidents, Health Problems and Causes: A Case Study of Cement Industry

1. INTRODUCTION
Cement is one of the extensively used material on earth. The production of cement is a process of energy
and several resources that both influences on the environment and health of workforce at local and global
level. Confirming safe and healthy working conditions for employees is one the major challenge and priority
of the company's which can be assured by collective responsibility and it has been observed as a key subject
for all industries but specifically stakeholders of cement industries [1] because cement is termed to be that
crucial factor of infrastructure development and it is also one of the most important input for construction
industry, particularly in infrastructure and housing programs, which have significant role in the countrys
socioeconomic growth and development. It is also the second most consumed material on the planet [2].
Millions of occupational accidents reported every year and the world is paying high prices and human
suffering for such occupational accidents and health problems. Although there are many studies carried out
to address this problem but this issue of health and safety remains a serious problem in the industries [3-9].
The attention of the national and international media has been attracted by industrial disasters in terms of
occupational accidents. Industrial disasters, especially those resulting in multiple fatalities made global
headlines. In addition to it, many occupational incidents are not even reported and ignored. As reported in a
global assessment study by International Labour Organization (ILO), an estimated 2.3 million workers die
every year from occupational accidents and health problems and many are suffering from non-fatal injuries
(Permanent & Temporary) and illnesses. The industry is suffering from social and economic burden due to
such incidents. It effect the moral of worker, their families and communities overall. It also effects the
industry, financially due to compensation for such occupational accidents and health problems [10].
However, with the labor market constantly changing, all accidents cannot be avoided. Therefore, the
intensity of human activity, its increasing pace and continuous human intervention, risk is always present
[11]. Literacy rates and poverty are reported as main problems affecting developing countries and play a
key role in solving many problems. It was analyzed that the maximum occupational accidents reported
because the workers who begin to work in the industry is unskilled and do not receive adequate training
before work. These raw hands begin to work as unskilled labor and through working in the practical field
and in result they become experts with time. Whereas, these workers suffered from numerous industrial
accidents every year that causes fatalities and injuries. These fatalities and injuries significantly affect
national economy, as it causes loss of productive hours, workforce absenteeism, compensation costs and
more suffering for the victims and their families. Maybe enough attention was not paid on it [3].
Cement is termed to be one of the most common substances utilized on the planet. Each year, almost
three tons of concrete (containing 10-15% cement) are consumed by every man, woman and child [12]. It
has been also reported in a number of studies that it also leads to health problems due to exposure to cement
dust on respiratory symptoms such as reduced lung function, high risk of developing chronic obstructive
pulmonary disease (COPD) [13-15]. Each year a large number of minor and major occupational accidents
occur due to material handling. Material handling and crusher are two major sections of cement industry
because these two are reported to be the most vulnerable areas for occupational accidents. Therefore, it is
imperative to work on prevention methods and techniques to resist such occupational accidents. In this
context, hazard identification is a key element in any industry [16]. Cement plant is a hazards place for
workers such as exposure to cement dust that has been reported many time to have harmful effects on human
health [17]. Workers of different age groups mainly suffer from breathing and fatigue problems. The lack of
confidence found that the main causes of injuries and incidents for skilled workers and lack of awareness
and abandonment were common among unskilled workers [6].
The hazards can be categorized as Physical hazards and mechanical injuries, Chemical hazards,
Biological hazards and Psycho-Social hazards. Where, physical hazards and mechanical injuries includes;
injuries, exposure to noise & vibration, extreme heat or cold, non-ionizing ultra violet radiations usually
from exposures to the sun and electric arc welding. Chemical hazards includes; exposure to dust, fume,
moist, vapours and gases. The major risk for work force is silicosis and asbestosis. Biological hazards
includes; environmental diseases like Malaria, dengue, animals attack a histoplasmosis (Lung Infection

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 Shabir Hussain Khahro, Tauha Hussain Ali, Yasir Javed and Mir Aftab Hussain Talpur

caused by soil fungs) and other diseases due to poor sanitation and unsafe drinking water. Psycho-Social
hazards includes; heavy work load, possibility of work place violence or community violence and limited
social support which can cause addictions with alcohol, tobacco and smoking contribute to illness and
suffering [18].
The health and safety performance of the cement industry as a whole is lagging behind that of other,
more proactive, sectors of manufacturing industry [19]. Designing an approach for continuous reduction,
sustainable and homogeneous work accidents and occupational diseases is a compulsory requirement. That
is why it is urgent to deal with the problem from all sides in relation with the health and safety problems.
Thus, everything has to be done to avoid any accident that breaks or handicaps a human life. Occupational
accidents and health problems have many impacts on health of workers and also lead to considerable
economic and social impacts. One of the best strategies is prevention of such occupational accidents and
health problems which is crucial because majority of occupational accidents and health problems are
preventable. It is analyzed that good intentions in many firms have not always been implemented or
sustained. Few firms believe that health and safety practices are economic burden on firm but the reality is
the other way round. The firms have to accept that good safety is good business.
Prevention is part of a survival strategy; those who sustain their efforts to prevent occupational accidents
and health problems will find their efforts rewarded. Hence, this paper helps the managers and stakeholders
of cement industry to design efficient health and safety practices because this paper highlights the possible
occupational accidents and health problems with specific reference to cement industry. It also identified the
direct and indirect causes leading such occupational accidents and health problems. This paper is an addition
in the existing body of knowledge in the literature available for occupational accidents and health problems
for cement industry in general and Pakistan cement industry in particular.

2. SIGNIFICANCE OF RESEARCH
Occupational accidents and health problems have reported massive impact on the health & safety problems
of the workers. It also leads to considerable economic losses, workers absenteeism, social and moral impacts
in any workforce industry. World figures reported that occupational accidents led many workers with fatal,
permanent and temporary injuries. Major occupational accidents were the headlines of many news channels
and papers. It is also reported that many other occupational accidents are even ignored and not reported due
to various reasons. Hence, It is imperative to make and update the occupational health and safety practices
in the companies to save lifes, disabilities, health problems and money. One of the best strategies is
prevention of such occupational accidents and health problems which is crucial because majority of
occupational accidents and health problems are preventable. It is analyzed that good intentions in many firms
have not always been implemented or sustained. Few firms believe that health and safety practices are
economic burden on firm but the reality is the other way round. The firms have to accept that good safety
is good business. Therefore, this paper highlights the possible occupational accident and health problems
in cement industry with possible direct and indirect causes of accidents.

3. DATA COLLECTION & ANALYSIS

In first phase, detailed literature review of the existing literature has been carried out to identify occupational
accident, health problems, their types and causes normally occur in cement industry. Pilot study was made
to validate the identified accidents and the inputs from the respondent were considered to make the final set
of questions with specific reference to cement industry. In second phase, it was very critical to select the
cement industries to collect the data because these are mostly owned by private firms. There were problems
to get access in the plants and problems got worse once they knew about the study nature. They believe that
it will be problem for the company but they were given proper sureties that this data will be used for research
purpose only and it was even mentioned in the questionnaire. They believed this research is negative for
their companies initially but after discussions they realized the importance of it and they gave permission to
access their plants. Three cement plants were selected in the vicinity to collect the data for the occupational

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 Identification of Occupational Accidents, Health Problems and Causes: A Case Study of Cement Industry

accidents, health problems, their types and causes. Respondent experience was a key element in this research.
It was prime goal to get opinion from a person who has plenty of experience in cement industry because he
may have experienced such issues him selves and even with his colleagues during his career. The respondents
having experience ranging from 0 to 10 years were 44% in total and other ranging from 11 to 20 years were
13% in total. Meanwhile, the respondents with more than 20 years of experience were 43% in total
population of the respondents.
Each respondent was requested to give their consent regarding the impact level and frequency of
occurrence level of occupational accidents and health problems on a likert scale ranging from 1 to 4. [(1)
very low; (2) low; (3) high; and (4) very high]. Finally, the ranking of the occupational accidents and health
problems were made on the basis of Quadrant Distribution (QD) analysis. QD analysis fits for certain data
samples and conditions [20]. QD has four groups; an accident with higher impact and higher frequency of
occurrence was ranked at first group. Similarly, an accident with higher impact but this time lower frequency
of occurrence was ranked as second group. Likewise, an accident with lower impact but higher frequency of
occurrence was ranked as third group and an accident with lower impact and lower frequency of occurrence
was ranked as fourth group. Figure 2 shows the QD analysis for the occupational accidents identified in
cement industry.

Figure 2 Quadrant Distribution Analysis for Occupational Accidents

Likewise, respondents were requested to give their consent regarding the impact level and frequency of
occurrence level of health problems normally faced by workers in cement industry on same scale. The
ranking of health problems was also done of the basis of QD analysis as discussed above. Figure 3 shows
the QD analysis for the occupational health problems identified in cement industry.

Figure 3 Quadrant Distribution Analysis for Health Problems

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 Shabir Hussain Khahro, Tauha Hussain Ali, Yasir Javed and Mir Aftab Hussain Talpur

In the last phase, the respondent were requested to give his consent regarding the significance level for
the occupational accidents and health problems on a likert scale ranging from 1 to 4 [(1) not significant; (2)
slightly significant; (3) significant; and (4) very significant]. Relative Importance Weight (RIW) method has
been used to analyze the significance level of the causes of occupational accidents and health problems and
lastly the ranking of the causes was finalized.

4. RESULTS AND DISCUSSIONS

The complete rational to rank the occupational accident was discussed in detail in the last section. Table 1
shows the ranking of occupational accidents group vise for cement industry of Sindh, Pakistan.

Table 1 Occupational Accidents in Cement Industry

Ranking
S.
Type of Accident Impact Frequency of
No
Accident
1 A worker burns due to chocking of cyclones & 3.03 1.93 1
feed pipes
2 Snake bite 2.70 1.53 2
3 Fall from elevation 2.66 1.60 3
4 A worker burns by hot gases/material 2.60 1.66 4
5 Struck By 2.33 1.90 5
6 Coal/Furnace oil burning 2.30 1.73 6
7 Blasting of Preheater 3.00 1.26 7
8 Blasting of Electrostatic Precipitator 2.83 1.40 8
9 Caught between 2.43 1.46 9
10 A worker burns by hot furnace oil 2.20 1.43 10
11 A worker burns while checking the rotary kiln 2.20 1.26 11
12 Electrocution from faulty tool 1.96 1.60 12
13 Slip and fall 1.70 1.80 13
14 Fall at ground level 1.66 1.53 14
15 Electrocution from building power 2.10 1.40 15
16 Trip and fall 2.00 1.36 16
17 Struck against 1.63 1.36 17
18 Caught in 1.63 1.26 18
19 Caught on 1.50 1.13 19
20 Others 1.40 1.43 20
The results show that worker burns due to chocking of cyclones & feed pipes, snake bite, fall from
elevation, worker burns by hot gases/material, struck by and coal/furnace oil burning are the major types of
occupational accidents in cement industry because all of these accidents are located in group one where
accident frequency of occurrence and impact both are higher. Blasting of preheater, blasting of electrostatic
precipitator, caught between, worker burns by hot furnace oil and worker burns while checking the rotary
kiln are group two accidents. Where frequency of occurrence is low but the impact of the accident is higher.
Electrocution from faulty tool, slip and fall and fall at ground level are group three accidents. Where
frequency of occurrence is higher but the impact of the accident is low. Electrocution from building power,
trip and fall, struck against, caught in and caught on are group four accidents. Where, frequency of
occurrence and impact of the accident is low. Likewise, the complete rational to rank the occupational health
problems was discussed in detail in the last section. Table 2 shows the ranking of occupational health
problems group vise for cement industry of Sindh, Pakistan.

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 Identification of Occupational Accidents, Health Problems and Causes: A Case Study of Cement Industry

Table 2 Occupational Health Problems in Cement Industry

S. No Type of Accident Impact Frequency Ranking of Accident
1 Lungs Irritation 2.70 2.36 1
2 Throat Irritation 2.43 2.30 2
3 Heat Stroke 2.43 2.16 3
4 Nose Irritation 2.20 2.06 4
5 Skin Disease 2.10 1.90 5
6 Hearing Disorder 1.90 1.76 6
7 Blood Poisoning 1.86 1.10 7
8 Eye Strain 1.76 1.90 8
The results show that lungs irritation, throat irritation, heat stroke and nose irritation are the major types
of occupational health problems in cement industry because all of these health problems located in group
one where health problems frequency of occurrence and impact are higher. Skin disease, hearing disorder,
blood poisoning and eye strain are group four health problems. Where, frequency of occurrence and impact
of the health problem is low. The complete rational to rank the causes of occupational accidents and health
problems was discussed in detail in the section of data analysis. Table 3 shows the final rank of causes
leading occupational accidents and health problems in the cement industry of Sindh, Pakistan.

Table 3 Causes of Occupational Accidents & Health Problems in Cement Industry

S. No. Causes Mean Rank
1 Worker negligence for safety practices 3.70 1
2 Lack of trainings 3.70 1
3 Workers working even in case of exhaustion/sickness 3.60 2
4 Inadequate supervision 3.45 3
5 Lack of responsibilities 3.30 4
6 Lack of safety meetings 3.30 4
7 Higher targets 3.15 5
8 Failure of equipment 3.10 6
9 Rough weather 3.00 7
10 Workers avoidance reporting unsafe act/condition 2.80 8
11 Worker resistance to adopt safety practices 2.80 8
12 Coordination gape 2.80 8
13 Equipment without safety device 2.55 9
14 Lack of safety equipments/instruments 2.35 10
15 Defective equipment 2.10 11
16 Workers irresponsible behavior 2.10 11
17 Inadequate light provision 2.05 12
18 Workers use of prohibited elements 2.00 13
19 Improper use of equipment 1.75 14
20 Poor quality equipment 1.55 15
21 Insecure methods and task 1.25 16
22 Unsafe working condition/environment 1.10 17
23 Workers unawareness to use machines 1.10 17
24 Confined working area 1.05 18
25 Problematic attitude of worker 1.05 18
26 Complex and/or unfamiliar nature of work 0.90 19
27 Productivity bonus 0.80 20

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 Shabir Hussain Khahro, Tauha Hussain Ali, Yasir Javed and Mir Aftab Hussain Talpur

The results show that worker negligence for safety practices, lack of trainings, workers working even in
case of exhaustion/sickness, inadequate supervision, lack of responsibilities, lack of safety meetings, higher
targets, failure of equipment and rough weather are the major causes of occupational accidents and health
problems with average mean weight ranges from >3.0 to 4.0 and termed to be highly significant causes
leading to occupational accidents and health problems in cement industry. Workers avoidance reporting
unsafe act/condition, worker resistance to adopt safety practices , coordination gape, equipment without
safety device, lack of safety equipments/instruments, defective equipment, workers irresponsible behavior,
inadequate light provision and workers use of prohibited elements are the primary causes of occupational
accidents and health problems in cement industry with average mean weight ranges from >2.0 to 3.0 and
termed to be significant causes leading to occupational accidents and health problems in cement industry.
Improper use of equipment, poor quality equipment, insecure methods and task, unsafe working
condition/environment, workers unawareness to use machines, confined working area and problematic
attitude of worker are the secondary causes of occupational accidents and health problems in cement industry
with average mean weight ranges from >1.0 to 2.0 and termed to be slightly significant causes leading to
occupational accidents and health problems in cement industry. Whereas, complex and/or unfamiliar nature
of work and productivity bonus are minor causes of occupational accidents and health problems in cement
industry with average mean weight ranges from >0.1 to 1.0 and termed to be non-significant causes for
occupational accidents and health problems in cement industry.

5. CONCLUSION
Cement is termed to be widely used material on earth. It has been reported that cement production process
harms environment, health and safety problems to its workforce. The employee well-being especially their
health and safety issues are important priorities for employers including cement companies. The
implementation of occupational health and safety management systems in cement industries are not
advanced when compared to other manufacturing industries.
The best way to save from occupational accident and health problem is to avoid it by supporting health
and safety practices at work and if it occurs than the best way to minimize damages and expenses of accidents
and health problems by introducing reactive practices. It is also necessary to evaluate the lessons from such
accidents and health problems and update the health and safety practices and policies accordingly. It will
ensure a sustainable solution for such problems and also ensures quickly return of workers with positive
moral. These identified occupational accidents and health problems with help the cement industry
practitioners to make their health and safety plans and practices and it also helps the companies having
existing plans to update them to address all the potential risks associated with this occupation.
One of the best strategies is prevention of such occupational accidents and health problems which is
crucial because majority of occupational accidents and health problems are preventable. It is analyzed that
good intentions in many firms have not always been implemented or sustained. Few firms believe that health
and safety practices are economic burden on firm but the reality is the other way round. The firms have to
accept that good safety is good business.
This study is a step ahead to safety culture at work places to energize policies to attain decrease such
problems and improve working conditions in factories. Hence, this paper helps the key stakeholders of
cement industry to design efficient health and safety policies and practices because this paper highlights the
possible occupational accidents and health problems with specific reference to cement industry only. It also
identified the direct and indirect causes leading such occupational accidents and health problems. This paper
is an addition in the existing body of knowledge in the literature available for occupational accidents and
health problems for cement industry in general and Pakistan cement industry in particular.

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 Identification of Occupational Accidents, Health Problems and Causes: A Case Study of Cement Industry

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