100% elimination of fall exposure

Semi-automated tarp system for the cement industry

Context and Identified Problem:

During an audit in the shipping area, it was detected that cement sack tarping was done manually, forcing staff to climb onto trailers without lifelines or anchor points, posing a constant fall risk from heights over 2.5 meters. This condition represented a serious vulnerability and a breach of the NOM-009-STPS regulation for working at heights.

Implemented Solution:

Our team conducted a technical analysis of the structure, loading logistics, and operational mechanics. We designed and installed reinforced concrete foundations to support metal structures with 500 kg electric hoists, controlled by a PLC system and operated from a floor-level console. Electrical wiring and conduit installation were executed in compliance with NOM-001-SEDE-2021, ensuring safety in environments with high levels of dust and vibration.

Results Achieved:

- Tarping time reduced from 60 to 18 minutes per unit.
- Complete elimination of human exposure to working at height during this maneuver.
- Full compliance with safety and electrical standards.
- Replicable system for other shipping lines.

Coordination and Execution:

The implementation was carried out in collaboration with the plant’s maintenance, industrial safety, shipping, and civil works departments, ensuring that each phase complied with internal protocols and technical standards. This project demonstrates how a critical risk can be turned into an operational advantage through preventive, applied engineering.