Cement Manufacturing
Cement Plant Operations
Cement Manufacturing Typical Incidents Part (3)
Part three: safety and environmental incidents, including the confined space and hot material events that kill.
- Duration
- 5 days
- Contact hours
- 30
- Level
- Intermediate
- Fee from
- On enquiry
Overview
Where part two deals with process upsets, part three deals with incidents that hurt people and breach consents. Hot material burns, silo and bin entry, falls from height on a tall plant, mobile equipment interactions, dust explosions and emission excursions are each examined as event sequences with their controls identified. The treatment is deliberately serious. These are the events cement plants kill people with, and the controls are well known, which makes each recurrence a management failure rather than bad luck.
Who should attend
Safety and environmental managers, production and maintenance supervisors, engineers responsible for controls, and incident investigators.
What you will be able to do
- Identify the fatal risks specific to cement manufacturing.
- Analyse a safety incident without stopping at operator error.
- Specify critical controls for confined space and hot material work.
- Handle an environmental excursion correctly, including reporting.
- Verify that a control is working rather than present.
How it is taught
Short input, then work, across 5 days of roughly 6 teaching hours each. Exercises run on situations delegates bring rather than on a case study written for a different organisation. Cohorts are capped so that everybody is asked something.
Available as classroom, live online, in house.
Programme outline
Day 1
Hot material
- Hot meal and clinker burns
- Blowback and sudden release events
- Access, barriers and protective equipment
Day 2
Confined space
- Silos, bins and preheater entry
- Engulfment and atmosphere hazards
- Entry permits, rescue and standby
Day 3
Mechanical and height
- Falls on a tall plant
- Mobile equipment and pedestrian interaction
- Isolation failures and stored energy
Day 4
Dust and emissions
- Dust explosion conditions
- Emission excursions and their causes
- Notification and regulatory reporting
Day 5
Learning
- Investigation past operator error
- Control verification
- Why the same incident recurs
What you leave with
- A fatal risk register for one plant.
- Critical control verification routines.
- An incident response and reporting procedure.
Dates and fees
| Dates | Location | Format | Fee |
|---|---|---|---|
| 23 to 27 November 2026 | Windhoek, Namibia | Classroom | R15,000 |
| 30 November 2026 to 4 December 2026 | Cape Town, South Africa | Classroom | R15,000 |
| 7 to 11 December 2026 | Nairobi, Kenya | Classroom | US$1,500 |
| 14 to 18 December 2026 | Port Louis, Mauritius | Classroom | US$1,500 |
Fees are per delegate and cover tuition, all programme materials and the certificate. Travel, accommodation and visas are arranged by the delegate. Registration closes two weeks before a programme starts.
Certificate
A GATI certificate recording what was attended, issued after the programme has run and attendance has been taken. Attending at least 80 per cent of the days earns a certificate of completion; attending less earns a certificate of attendance stating exactly what was attended. Every certificate carries a code that anybody can check against GATI's own record.
It records participation. and GATI does not claim one it does not hold.