FINALIST - Safer handling of inbound and outbound materials
CEMEX had encountered four incidents with hot boxes over the last two years. Three involved hot boxes exploding and one where a customer was trapped inside his own hot box chamber when the lid closed onto his shoulder and head, trapping him in a heated hot box for nearly two hours.
CEMEX undertook a face to face survey of hot box drivers which highlighted a lack of training for hot box operation and an understanding of the dangers that can be created by the operators of the hot box. Discussions with the manufacturers revealed that many new hot boxes are supplied under lease agreements which include servicing for the lease period. When the lease ends, the hot boxes go to auction being purchased by less professional operators who don’t have the hot boxes serviced or offer driver training.
A common problem is that when the hot box gas system starts to have issues with lighting, the drivers fiddle with the gas regulators and thermostats. If the gas regulators are incorrectly set, the air to gas ratio makes the hot box difficult to light. If the operators keep trying to light the hot box it can fill the body cavity with gas, when it does light, there is the risk of an explosion.
Other issues are.
- Drivers getting on top of the hot box when the doors have not opened
- Drivers getting on top of the hot box to clear spilled material due to poor loading
- Drivers using diesel to keep the body and screws clean, this can vaporise when the lid is opened causing an explosion
- Thermostats on the heating systems being turned up above 135 degrees, in some cases up to 200 degrees.
Please view the video of how CEMEX tried to mitigate these risks.