2025 Safety Innovation Award Winners
Innovative Bearing Heater Eliminates Fire Risk
Ash Grove Cement
Durkee Plant – Durkee, OR
In the past, maintenance staff heated bearings in a barrel of oil over an open flame—creating serious fire and injury risks. To eliminate this hazard, employees introduced a portable, induction-style bearing heater. The device uses controlled, flameless heat to safely expand bearings, replacing the need for hot oil and open flames. Its enclosed design ensures consistent, safe heating in both shop and field use. This employee-driven solution has prevented incidents and highlights a proactive, practical approach to reducing risk and improving workplace safety.
Dust Control Solution Prioritizes Employee Health
Buzzi Unicem USA
Joliet Terminal – Joliet, IL
To protect employees’ lung health during barge unloading, the team designed a mobile Bobcat cleaning hut that captures airborne dust. Operators park the Bobcat inside, then use a blow wand from outside through plastic-skirted walls. A built-in vacuum port connects to the unloading system to collect dust. Mounted on caster wheels with crane lift points, the unit is easy to move and disassemble. This innovation reduces dust exposure, improves air quality, and significantly lowers respiratory health risks for workers.
Fail-Safe Lockout Valves Protect Workers and Equipment
GCC Rio Grande
Tierjas Cement Plant – Tierjas, NM
The original lockout system for air cannons used unreliable ball valves that frequently failed, bent, or plugged, causing delays and safety concerns. Lockout devices often went missing and disrupted work. To resolve this, employees installed durable pneumatic lockout valves with large ¾-inch exhaust ports that quickly and reliably vent air. Their bright yellow bodies and blue handles improve visibility and identification. This upgrade eliminated manual handling issues, improved safety, and streamlined the lockout process across all air cannon systems.
Monorail System Eliminates Hazardous Lifting in Conveyor Maintenance
Buzzi Unicem USA
Hercules Cement Company LLC – Stockertown, PA
Maintaining the Rexnord drag conveyor required workers to lift heavy chain links, tools, and idlers which often exceeded safe limits and risking injury. To eliminate manual lifting, the team installed a 40-foot monorail with a trolley and hoist above the conveyor. Over four days, they assembled and aligned the system to lift chain sections, idlers, and tools safely. This innovation protects workers, streamlines maintenance, and is now considered the best practice for drag conveyor servicing at Hercules Cement Company.
Kiln Burner Safety Improvement Reduces High-Risk Maintenance
Ash Grove Cement Company
Chanute Plant – Chanute, KA
A refractory sleeve in the FTC kiln main burner caused a “rhino horn” buildup of hot clinker, disrupting the flame and kiln performance. Removing this buildup with an industrial gun exposed workers to extreme heat and hazardous energy, a high-risk task. To improve safety, the team installed an air cannon and pipe cooling fan on the sleeve. This system prevents clinker buildup and enables safer, more efficient removal. The upgrade significantly reduces high-risk maintenance, protects workers, and improves process reliability.
