Tackling EHS Challenges in the Metal & Mining Industry with Smart Digital Solutions
In one of the world’s most hazardous and tightly regulated environments, metal and mining companies face daily safety and compliance challenges—from managing high-risk operations and heavy equipment to controlling exposure to toxic substances and extreme temperatures. Inconsistent reporting, delayed response to hazards, and fragmented training often limit the effectiveness of traditional EHS systems.
Our EHS management platform is purpose-built to address these complexities head-on. With real-time visibility, automated compliance tracking, and mobile-first tools for on-ground teams, we help streamline your safety workflows and drive accountability from pit to plant. Whether managing incidents, monitoring equipment, or ensuring contractor safety, our platform enables teams to stay compliant, reduce downtime, and foster a proactive safety culture.
Modules Designed for High-Risk Mining & Metal Operations:
Smarter PTW for Smelters, Refineries, and Mining Operations
In high-risk environments like smelters, refineries, and mines, manual Permit to Work (PTW) processes leave too much room for error. These gaps can escalate into serious incidents, from inadequate isolation during maintenance to unauthorized entries in confined spaces and uncoordinated SIMOPS.
Our Digital PTW Solution brings structure, visibility, and control to the entire permit lifecycle, minimizing risk and ensuring safe execution of every task.
Key Features:
Empower teams with the tools they need to execute jobs safely, efficiently, and with full compliance—every time.
Optimize Scaffold Safety in Shutdowns & Maintenance
Scaffolding Management for Complex Industrial Yards
Manual scaffolding processes in coke ovens, acid plants, and casting areas often lead to inefficient coordination, delayed inspections, and safety gaps.
Our Scaffolding Management Software streamlines:
With efficient scaffolding operations, you can reduce downtime, improve safety compliance, and gain complete control over your maintenance and shutdowns.
Simplify Complex Procedures with 3D Animated SOPs
Traditional text-based SOPs often fail to explain high-risk, technical procedures, especially in complex environments like smelting units, casting plants, and refineries. Our 3D animated SOPs transform these static documents into clear, visual learning tools that enhance comprehension, retention, and safe execution.
These animations visually guide operators, engineers, and contractors through step-by-step procedures, covering equipment handling, critical safety checks, and process flows with unmatched clarity. They are especially impactful for multilingual, shift-based teams working in dynamic and hazardous environments.
We have developed SOPs for various clients in the Metal and mining industry, such as Battery Process Units, Coke Oven by-product and main Unit SOPs, Mantle and Bowl Liner Replacement, Cast House Operations, Claus Units for Sulphur Recovery, Scaling Operations, and Silver Refinery Process.
These animations reduce training time, improve retention, and standardize execution—especially useful for multilingual teams and shift-based operations.
3D Animated Incident Recreation – Learn from the Past, Protect the Future
Organizations overlook and misinterpret traditional incident reports—missing the opportunity to influence behavior. Our 3D animated incident recreations bring real-life safety events to life, turning them into powerful visual lessons that resonate across all levels of your workforce.
Safety teams use these animations in toolbox talks, safety briefings, contractor inductions, and leadership walk-throughs—ensuring that critical safety messages are heard, remembered, and applied.
We have recreated Incidents into 3D animated movies for various clients in the Metal and mining industry. Incidents include a Forklift Collision, a Slag Raking Machine Mishap, an SP II Fatality Case, a Flashover in MRSS, Roadway Accidents in a Scrap Yard, Boiler Bundle Replacement, a Coke Yard Fire, a Purification Hydro LTI Incident, Shell Debris and Loco Car Accidents, a Worker Injury in an Acid Plant, a JCB Loader Incident, an OWC Machine Malfunction, and a Hot Water Burn Incident.
Each animation helps teams visualize what went wrong, understand contributing factors, and adopt safer practices. These aren’t just recreations—they’re culture-shaping tools that prevent history from repeating itself.
“ For the service part, we appreciate your work, also you have created a virtual world for learning, training and communicating safety in form of animation movie”
BALCO
Gagandeep Ojha, Safety-in-Charge
3D Visualizations for Technical Process Proficiency
Equip your workforce to understand end-to-end operations with 3D technical process simulations—especially valuable for engineers, operators, and new recruits.
We have developed 3D technical movies for various clients in the Metal and mining industry such as Acid Plant Operations, Roaster, Leaching & Purification, Cell House Workflows, RMH, Refining, Melting & Casting, CPP-CHP & Switchyard Operations, Hot Metal Handling & SO₂ Risk Zones, Lead CO Safety & Ventilation Requirements, LDO Yard Handling Protocols
Drive precision, reduce operational errors, and ensure safety through a crystal-clear understanding of complex process flows.
Safety Induction, Visitor Awareness & Plant Walkthroughs
First impressions matter. Use animated visitor walkthroughs and contractor inductions to deliver consistent, site-specific safety messaging.
Includes:
These are delivered via kiosks, mobile devices, reception, or control room displays—ensuring readiness before step one.
Mobile-First Safety with QR Code Observations
Your workforce is mobile—your safety system should be, too.
Organizations empower on-ground teams to scan QR codes and report real-time safety observations with few clicks using mobile devices.
Key Mobile Capabilities:
Enable safety on the move—anytime, anywhere.
Data-Driven Safety Is No Longer Optional for Mining and Metal Safety Excellence
With contractors, equipment, and safety data distributed across multiple systems, safety teams struggle to gain full visibility. Leadership, in turn, lacks a consolidated view of organizational safety performance, making proactive decisions harder and reactive responses the default, which may be inadequate or fall short due to hidden insights and missed data outliers.
Harness the Power of Business Intelligence to Enhance Safety and Operational Efficiency
Business Intelligence transforms disconnected safety, permit, and scaffold data into a centralized, real-time intelligence hub for metal and mining operations. It empowers plant/site-level safety officers and corporate team alike with actionable insights drawn from across incidents, hazard reporting, inspections, trainings, operations and more.
With a unified view of critical metrics — ranging from behavior-based safety observations and visibility into live and planned isolations to training compliance and identification of contractors consistently causing work delays, teams can proactively respond to risks and performance bottlenecks. This level of visibility helps ensure safe work execution, optimize resource allocation, and safety compliance across every plant or site and operational tier.
Key Benefits
Plant-to-Enterprise Safety Visibility
Give plant/site safety teams a real-time operational lens into incidents, near-misses, unsafe acts and conditions, site and equipment inspections, audits, and training compliance, helping them detect issues early, prioritize actions, and close safety gaps faster.
At the same time, provide executives with consolidated dashboards that benchmark performance across mines, smelters, and processing units, enabling data-driven decisions, resource planning, and a stronger focus on enterprise-level risk reduction and compliance assurance.
Contractor Safety Performance Evaluation
Assess contractor safety compliance based on incident history, training status, permit violations, and behavior-based safety data to enhance oversight and accountability.
Scaffold Operations Intelligence
Gain real-time visibility and get daily updates on scaffold planning, erection status, and dismantling delays. Benchmark project-wise completion timelines, and track contractor productivity.
Operational Control over High-Risk Work
Track the live status of high-risk permits, including hot work, confined space entry, lifting operations, work at height, and isolations across all sites and plants. Identify delays in work commencement or closure, gain visibility into Simultaneous Operations (SIMOPS), and uncover recurring bottlenecks such as poor housekeeping or repeated safety violations by specific performing authorities.
Equipment and Site Inspection Insights
Monitor equipment inspections status, site audit compliance, recurring non-compliances and open findings to address risks before they escalate into serious incidents.
Training Compliance Visibility
Track safety and technical training completion rates to identify gaps and ensure your workforce is prepared for task-specific hazards.
“ TECH EHS has been a great partner in accelerating and elevating our EHS journey. With “a click of a finger,” the platform could retrieve and present any useful information or data.”
Natsteel Holdings, Singapore
Driving a Culture of Safety and Efficiency through Data
Business Intelligence enables mining and metal organizations to move from fragmented safety reporting to a connected, insight-driven approach. Whether improving permit to work process, reducing scaffold delays, or strengthening contractor compliance, your teams are equipped with the right data at the right level, helping safeguard your workforce and drive operational excellence across all sites.
