Risk prevention in aggregate quarries, cement plants and concrete plants

I. Introduction – Industrial environments at the heart of risk

Quarries, cement plants and concrete plants form the basis of the entire construction industry. These sites, essential for the production of construction materials, nevertheless concentrate many occupational risks : dust, noise, handling, machinery, chemicals, heat, etc. According to data from CARSAT and INRS , the frequency rate of workplace accidents regularly exceeds the industrial average, particularly in quarries where handling and the movement of machinery are involved in nearly one in three accidents.

Beyond trauma, the long-term health of workers is threatened by chronic exposure to silica and cement dust , which is responsible for sometimes serious respiratory and skin diseases. This article, inspired by the recommendations of INRS , OPPBTP and CARSAT , aims to provide a clear and concrete vision of the risks and good prevention practices to adopt.

II. Aggregate quarries: extraction and multiple risks

Activities and environment

Quarries produce aggregates through extraction, crushing, screening, and transportation. Operations take place outdoors, often with significant co-activity between machinery and pedestrians.

Main risks

Mechanical risks: falls from height, collisions, crushing by machinery.

Physical risks: noise up to 110 dB(A), hand-arm and whole-body vibrations.

Chemical risks: inhalation of crystalline silica dust (classified as a proven carcinogen, IARC Group 1).

Traffic risks: co-activity of vehicles/pedestrians, tipping of vehicles.

According to CARSAT, accidents related to handling equipment represent more than 25% of serious accidents in a career. The INRS estimates that an employee exposed to crystalline silica without suitable protection risks, in the long term, irreversible lung diseases (silicosis, chronic bronchitis) .

Preventive measures

• EPC:

  • Watering of tracks and conveyors to limit dust.

  • Capture of emissions at drop-off points.

  • Signage and marking of traffic lanes.

  • Non-slip railings and floors.

• PPE:

  • EN 397 helmet ( Protective helmets for industry)

  • FFP3 EN 149 mask for silica.

  • Goggles or visor EN 166 ( Personal eye protection - Specifications)

  • S3 EN ISO 20345 shoes.

  • EN 352 earplugs ( Personal protectors against noise)

III. Cement plants: high-temperature chemistry

Industrial process

Cement is made from limestone and clay, heated to over 1,400°C to produce clinker, which is then ground with gypsum and additives. These sites combine thermal, chemical and mechanical hazards.

Specific risks

• Chemical: Exposure to clinker dust, crystalline silica, alkalis and calcium oxides.

• Thermal: radiant heat from ovens and burns.

• Physical: high noise (up to 105 dB(A)), heavy handling, vibrations.

• Fire and explosion: related to alternative fuels and combustible dusts.

The INRS (ED 6264) points out that inhaled crystalline silica causes, in addition to silicosis, an increased risk of lung cancer . The regulatory OEL is 0.1 mg/m³ (8 h) .

Preventive measures

• EPC:

  • Containment of facilities and localized ventilation.

  • Suction at source and gas filtration.

  • Automatic fire detection.

• PPE:

  • FFP3 masks or P3 half-masks with cartridges.

  • EN 374 chemical gloves.

  • Goggles or visors EN 166 ( Personal eye protection - Specifications)

  • Flame-resistant clothing EN ISO 11612 ( performance requirements for protective clothing against heat and flames)

  • EN 352 ear defenders ( Personal protectors against noise)

• Best practices:

  • Regular checks of the VLEP.

  • Wet cleaning, never dry.

  • Strict logging before any maintenance.

IV. Concrete plants: a confined and dynamic environment

Process and risks

Concrete batching plants measure, mix, and deliver ready-mix concrete. Operations involve handling, cleaning, maintenance, and exposure to chemical admixtures.

Main risks

• Chemicals: cement, additives (plasticizers, retarders), formwork oils, acid cleaning agents.

• Cutaneous irritants: cement with pH > 12, often containing chromium VI .

• Physical: noise, falls, handling.

• Fine dust: inhalation during mixing and cleaning of silos.

According to the INRS , nearly 30% of concrete workers experience skin irritations related to cement. Prolonged contact with wet skin or laitance can lead to chemical burns and chronic eczema .

Preventive measures

• EPC:

  • Ventilation of silos and mixers.

  • Dust collection on hoppers.

  • Wet cleaning and vacuuming.

  • Closed storage of adjuvants.

• PPE:

  • EN 374 waterproof gloves and cuffs.

  • Waterproof suit EN 14605 ( performance requirements for protective clothing against liquid chemicals)

  • S5 EN ISO 20345 boots.

  • Goggles/visor EN 166 ( Personal eye protection - Specifications)

  • FFP3 mask for dry dust.

• Best practices:

  • Never wash your hands with solvent, use a mild soap instead.

  • Clean up spills immediately.

  • Change gloves if punctured.

  • Maintain ventilation and filters.

V. Good cross-cutting prevention practices

1. Safety culture

Establishing a shared safety culture is essential. Safety talks, feedback, and practical training help reinforce good habits: wearing PPE, reporting anomalies, and following procedures. Our consultants can help you establish a robust safety culture, regardless of the size of your company.

2. Training and awareness

The OPPBTP recommends short, frequent sessions focused on professional gestures: handling, movement, fall prevention and chemical risks.

3. Co-activity and subcontracting

External company interventions require a prevention plan and rigorous HSE coordination (Labor Code, art. R4512-6). Each participant must be familiar with the site's risks and local regulations (traffic, confined areas, lockout). See our article on the subject. We can train your teams to carry out joint preliminary inspections and to draft prevention plans and safety protocols.

4. Monitoring of exposures

• Update of the DUERP (Single Risk Assessment Document). We can train your teams to create or update this document or provide you with one of our consultants to create or revise this document.

• Traceability via exposure sheets and MSDS .

• Regular checks of dust and noise levels.

5. Support from prevention organizations

INRS , OPPBTP and CARSAT offer:

• Practical sheets (INRS ED 6005, OPPBTP 2023).

• Training in chemical risks and noise prevention (we can train your teams on these risks)

• Financial aid for dust capture (CARSAT subsidies).

VI. Preventive medicine: a key player

Regulatory framework

Employees exposed to silica, noise > 85 dB(A) or corrosive products are subject to enhanced individual monitoring (SIR) (Labor Code R4624-22 to 28).

Role of the occupational physician

• Complete the initial medical examination before assignment.

• Provides periodic monitoring (every 2 to 4 years).

• Prescribes additional examinations (spirometry, X-ray, hearing tests, skin monitoring).

• May recommend job adjustment or temporary reorientation.

Interprofessional collaboration

The occupational physician works with the employer, the CSE and the safety officer to adapt preventive measures and monitor occupational pathologies (silicosis, dermatoses, hearing loss, etc.).

VII. Conclusion – Collective and sustainable vigilance

Quarries, cement plants, and concrete batching plants present varied environments but converging risks : dust, noise, handling, and chemicals. Prevention is based on an integrated approach :

• Technical (EPC and modern equipment),

• Individual (adapted PPE and systematic wearing),

• Organizational (training, coordination, medical monitoring).

Beyond legal obligations, safety culture must become a collective reflex, supported by management, relayed by teams, and supported by preventive medicine.

VIII. Summary table: main risks and preventive measures

Type of site	Major risks	Recommended PPE / EPC (standards)	Key best practices
Career	Silica, machinery, noise, falls	FFP3 mask EN 149, helmet EN 397, earplugs EN 352, watering, signage	Wet cleaning, separate tracks, machine maintenance
Cement works	Heat, silica, chemicals, noise	P3 mask, EN 374 gloves, EN ISO 11612 clothing, ventilation, containment	Consignment, VLEP control, wet cleaning
Concrete plant	Cement, laitance, additives, handling	Waterproof gloves EN 374, boots S5, overalls EN 14605, visor EN 166	Regular washing, closed storage, replacement of gloves