Construction of a new production line in Beni Suef, Egypt

The construction of a second production line started in TITAN’s cement plant located close to the city of Beni Suef, Egypt started in January 2008.

During construction the main challenge was the implementation of high safety standards by all parties involved while the cement plant continued to operate.

The turnkey contractor was the French company Fives FCB in cooperation with a number of local subcontractors. More than 1,000 people were working on a daily basis for the bigger part of the construction time.

The project was completed on time and the new line started production in the fourth quarter of 2009. It is remarkable that a total of 6.5 million working hours were accomplished without Lost-Time Injury.

To achieve this goal, as main factors contributed are considered the following:

• An effective TITAN safety organization ensuring continuous monitoring and maintaining direct control of high risk activity permits, safety meetings, safety rewards and consequences.
• Clear and rigorous safety standards, regulations and requirements included in the contract signed between TITAN and contractors.
• Continuous monitoring and assessment by a multi-disciplinary management team comprised of TITAN Group and local experts. 
• Delegation of a third party safety consultant to support the project in the field by: Training, Auditing the Safety Management System, developing a Permit to Work System and conducting monthly field tours. 
• On-going communication of performance achieved and sharing of lessons learnt from any incident or near miss.