Social – Health and Safety
Committed to a responsible journey towards zero harm
At Hindustan Zinc, our commitment to responsibility prioritises health and safety as core values. This commitment extends beyond our employees to embrace our business partners and the communities surrounding our operations.
Integral to our organisation’s DNA, this ethos reflects our unflinching dedication to minimising and ultimately eliminating any adverse impacts of our operations on people, both within and outside the organisation.
Material topics
M1Capitals affected
UN SDGs
Strategy Response
S5
Health and safety vision
We aim to create a culture where safety is a core value, driving continuous improvement in all aspects of our operations.
Our vision is to ensure zero harm to all stakeholders by proactively identifying and eliminating unsafe conditions.
04
Work-related fatalities*
54%
Reduction in total recordable injury frequency rate (from base year)
*Including 1 at our subsidiary, Vedanta Zinc Football & Sports Foundation
Key focus areas
- Achieve zero fatality
- Achieve 50% reduction in total recordable injury frequency rate (TRIFR) from base year 2020
- Achieve zero cases of occupational illness and improve occupational health and hygiene
HEALTH AND SAFETY GOVERNANCE AT HINDUSTAN ZINC
At Hindustan Zinc, safety is not just a commitment but a fundamental aspect of our operations. Our structured safety governance framework ensures that best practices are implemented and continuously improved to achieve a zero-harm workplace. The Corporate Safety Council integrates safety across all business functions. Our safety governance structure is supported by seven dedicated sub-committees and eight zonal apex committees to ensure effective oversight and implementation across all operational areas. We also actively engage business partners in decision-making to align with our stringent safety protocols. Additionally, we have incorporated occupational health & safety (OHS) standards into our contract and procurement requirements.
We have implemented an Integrated Management System aligned with ISO 45001 and the Vedanta Sustainability Framework (VSF) across all sites. The occupational management system was developed in consultation with workers and their representatives. Our Health & Safety Policy applies to all employees and business partners’ employees, suppliers, and all other business relationships.
AAROHAN: SAFETY EXCELLENCE JOURNEY
Since 2013, Hindustan Zinc has been advancing safety excellence through the ‘Aarohan’ initiative, in partnership with DuPont Sustainable Solutions. This journey focuses on strengthening leadership engagement, enhancing safety systems, and developing competencies to achieve ‘Zero Harm’. The strategic initiatives under Aarohan drive continuous safety improvement across all operational levels.
Aarohan: Key focus areas
- Visible Felt Leadership
- Process Safety Management
- Critical Control Assurance
- Standardisation
- Skill Development
- Risk Perception
- Employee Engagement
- Effective MIP implementation
Our safety performance
| FY2021 | FY2022 | FY2023 | FY2024 | FY2025 | |
|---|---|---|---|---|---|
| Fatalities | 0 | 4 | 7 | 0 | 4* |
|
Lost time injury frequency rate (LTIFR) (per million hours worked) |
0.97 | 0.81 | 0.70 | 0.88 | 0.55 |
|
Total recordable injury frequency rate (TRIFR) (per million hours worked) |
2.57 | 2.22 | 1.93 | 1.84 | 1.20 |
*Including 1 at our subsidiary, Vedanta Zinc Football & Sports Foundation
REINFORCING SAFETY STANDARDS
Vihaan – Critical Risk Management Programme
Background
At Hindustan Zinc, workforce safety is our top priority, and we are committed to achieving zero fatalities through continuous improvements. To advance this commitment further, we have implemented Critical Risk Management (CRM) as a strategic initiative to mitigate high-risk factors that could lead to severe incidents. This initiative aligns with Vedanta’s vision of zero harm and enhances our safety culture.
Solution
CRM focuses on principal global risks to ensure the effectiveness of safety resource allocation. A centralised system enables real-time monitoring of critical control checks, facilitating proactive interventions to prevent incidents. In FY2025, we launched CRM for key risks, including slope failure (surface), rail operations, excavation safety, gas exposure, water inrush, and infrastructure risk management.
41,381
Inspections in FY2025
115.45% YoY
8,24,256
Critical Checks in FY2025
226.2% YoY
Infrastructure Inframatrix Implementation
The Infrastructure Inframatrix is a structured framework for assessing, monitoring, and controlling infrastructure-related risks to enhance safety and reliability. It systematically evaluates vulnerabilities and integrates lessons from past incidents to refine safety protocols. Currently, 13 critical risks are managed under this framework, ensuring infrastructure safety remains a key focus.
89%
Infrastructure Compliance in FY2025
24% YoY
Safety Pause Across Hindustan Zinc
The Safety Pause initiative reinforces safety awareness by temporarily halting work for discussions and articulation of best practices. In FY2025, five such Safety Pauses were conducted across all locations to amplify risk awareness and prevent serious incidents.
Suraksha Kavach Implementation: Broadening Safety Spectrum
Suraksha Kavach, a proactive safety stewardship programme, is designed to ensure adherence to strict safety controls across all routine and non-routine activities. Initially launched for 25 mining activities, its scope broadened during the year to include 13 smelting activities. In contrast to CRM, which targets critical risks, Suraksha Kavach ensures comprehensive safety compliance across all tasks, integrating real-time hazard identification and continuous monitoring
31,008
KAVACH checks done in FY2025
53% YoY
Community of Practice – Maintaining Structural Stability
Our Structure Integrity Management Committee is instrumental in assessing, monitoring, and mitigating structural risks to maintain a safe work environment. A criticality ranking system prioritises high-risk structures such as steel frameworks, chimneys, silos, pressure vessels, and mine shafts. Continuous improvements, compliance checks, and partnerships with business associates ensure structural integrity and long-term safety.
2,453.36 MT
Asset integrity/structural stability works carried out in FY2025
STRENGTHENING SAFETY CULTURE
Competency Enhancement and Skill Development
At Hindustan Zinc, competency enhancement and skill development are integral to fostering a workplace safety ethos.
Safety Skills Training
We continuously augment our workforce capabilities through technical and behavioural skills training, equipping them to proactively identify hazards, mitigate risks, and respond effectively to emergencies.
External Competency Programmes
Prioritising industry-recognised certifications such as NEBOSH Safety & Process Safety Management (PSM), Occupational Hygiene Training Association (OHTA) Industrial Hygiene, IOSH Safety Certification, and Lead Auditor courses aligns our workforce with global best practices and evolving safety standards.
Rescue Capability Enhancement
Hindustan Zinc is committed to world-class rescue operations with advanced technology and highly trained professionals. Our teams handle emergencies in underground mining, confined spaces, and high-risk areas using cutting-edge equipment and rigorous training. The Company has won multiple awards at the International Safety Awards 2025 by the British Safety Council.
23
women employees qualified for a 7-day Work at Height and confined space rescue operation in FY2025
Life Saving Mission by our Rescuers
Our rescue team’s expertise transcends beyond our operations. Hindustan Zinc’s expert rescuers successfully saved 15 trapped individuals in a critical mission for another industry player, demonstrating professionalism, advanced rescue skills, and commitment to saving lives across operational boundaries.
OCCUPATIONAL HEALTH MANAGEMENT
Comprehensive Workplace Health Governance System
At Hindustan Zinc, we prioritise occupational health to achieve zero occupational illnesses and ensure optimal employee well-being.
- We ensure proactive health management through lifestyle training and advanced health technologies, reducing absenteeism and improving productivity
- We monitor hazardous exposures and conduct regular health check-ups at dedicated occupational health centres, ensuring care for all employees
Zero
Occupational Illness in FY2025
30,139
Medical Examinations in FY2025
- A centralised health system streamlines medical evaluations
- 24/7 advanced life support ambulances provide emergency assistance
HOLISTIC EMPLOYEE WELL-BEING THROUGH OHS ASSESSMENTS
At Hindustan Zinc, in our quest to achieve the goal of zero occupational illness cases, we engage competent third-party organisations to conduct thorough and independent industrial hygiene assessments across all our operational sites. These assessments meticulously evaluate environmental conditions and identify any risks stemming from exposure to hazardous substances, noise, air quality, and ergonomics.
Third-party experts use advanced monitoring equipment and methodologies to conduct comprehensive evaluations, providing an objective and unbiased analysis of workplace hazards. This analysis is pivotal in pinpointing areas where exposure levels may exceed regulatory thresholds or pose potential health risks. The insights gathered through these assessments guide the implementation of appropriate corrective measures.
This proactive approach helps us continually optimise our safety protocols, reduce the risk of occupational health issues, and ensure the well-being of our employees. Through these ongoing efforts, we strive to maintain a workplace where safety is intrinsically woven into our operations, reinforcing our commitment to zero harm.
1,300+
sample assessments done in FY2025
SCALING SAFETY WITH DIGITALISATION
Digitalisation in safety is revolutionising workplace risk management by integrating advanced technologies to enhance surveillance, mitigate unsafe acts, and optimise emergency responses.
Key Digital Interventions
AI-based surveillance
Implementing AI-driven detection systems at sites significantly improves surveillance capabilities, enabling real-time identification of unsafe acts. The system instantly alerts respective teams for timely interventions for proactive hazard mitigation.
Image processing technologies
We have deployed image processing technologies providing real-time video feeds in high-risk areas to detect unsafe acts in restricted or critical zones in underground mines. This is crucial in proactively identifying hazardous behaviours and preventing accidents.
AI-based man-machine interaction system
An AI-powered man-machine interaction system at the cell house in Dariba Smelting Complex, with advanced sensors and cameras, continuously tracks the crane’s movement/speed. Real-time analysis of this data detects potential collision risks, automatically adjusting the crane’s speed or halting its operation to avoid accidents.
Digitalised key management system
Implementation of a digitalised key management system restricts vehicle access solely to the authorised drivers, reducing the risks associated with unauthorised usage and enhancing overall fleet safety.
Motion sensor lights to avoid collisions
To further eliminate machine-to-machine interactions, motion sensor traffic lights are installed at portals and junctions to regulate movement dynamically, minimising collision risks.
Pumphouse automation
Automation of the pumphouse strengthens emergency response mechanisms through swift and efficient activation of critical systems during crises.