Geo-locating your Workers’ Platform Level
can save their Life

In a blast furnace, with high exposure to CO, you need to know at which platform level your workers are, to be there as fast as possible in an emergency.

Steel manufacturing is one of the largest and most complex industries in the world, and with this comes a few challenges. To create steel, Iron Ore is melted in a blast furnace in a reducing atmosphere. Iron ore is a mineral composed of Iron (Fe) and Oxygen (O2). By melting Iron Ore in a reducing atmosphere at 1,250 °C, the Oxygen is removed, and the Iron Ore is produced. Melting substances at such high temperatures results in toxic gases and chemicals potentially escaping into the atmosphere, for example carbon monoxide (CO), ammonia (NH₃), methane (CH4), benzene (C6H6) and nitrogen (N).

Blast furnaces, coke ovens, and sinter and iron production are hazardous processes which require a great deal of caution and monitoring. Steel manufacturing occurs in confined spaces, and when combined with scorching temperatures, heat and fatigue stress, and potential gas leaks, worker safety is crucial when it comes to the steel manufacturing industry.

Common Challenges

Some of the main challenges faced while working in the steel manufacturing industry include:

Toxic Gases and Chemical Exposure

  • Very high exposure to toxic gases, particularly carbon monoxide, which comes in clouds at unpredictable intervals
  • Inhalation or contact leading to chemical burns, lung damage, blindness, or even a fatality

Slips, Trips, and Falls

  • Ranking 1st in the cause of injuries among steel workers worldwide
  • Falling from heights
  • Slipping and tripping over equipment, uneven ground, or obstructed walkways

Harsh and Rugged Environmental Conditions

  • Hot environment, which may be leading to heat stress/fatigue

Heavy Machinery

  • Machinery misuse due to heat stress/fatigue


  • Steel mills and construction sites aren’t quiet environments. Hearing loss is common among steel workers, especially when proper ear protection isn’t used religiously. Continuous harsh noise also takes a psychological toll, leading to fatigue and anxiety

Our Solutions

To prevent and minimise the dangers of working in the Steel Manufacturing Industry, Universal Site Monitoring (USM) have designed and developed Australian-made advanced connected worker safety monitoring solutions: an integrated system of wearable personal safety monitoring devices, mobile apps, communications hubs, reporting, and management software, plus ancillary products, providing essential safety data accessible from anywhere, at any time.

Our Personal Safety Monitors & Mobile Apps collect live data and feed it into the fully integrated Universal Data Interface smart alert and navigation system. This live data enables proactive decision making, prevention of rising emergencies, and can save lives in case of an emergency.

These are some of the connected worker solution highlights that address the common challenges of the steel manufacturing industry:

Real-time Data Streaming and Communication

  • Live data allows proactive decision making from facility controllers
  • Live and automatic emergency call & text messages (cellular)
  • Push-to-talk & text messages (mesh)
Connected Worker Safety Solution
Vertical Geo-Location

Location & Motion Sensing

  • Find a worker’s location indoor, outdoor and underground
  • Monitor a no motion event and speed over ground of the worker
  • Show the vertical geo-location of the worker, i.e. the platform level within the blast furnace where the worker is located, to be there as fast as possible in case of an emergency. This is possible thanks to the uni-, bi-, trilateration localisation capabilities of the Universal Site Monitoring’s proprietary Mesh Access Point system.

Slips, Trips & Falls
Monitoring & Alarm Capability

  • Reporting G-Force events thanks through an in-built accelerometer in the Personal Safety Monitor PSM Hero 825
Slips, Trips and Falls
6 Multi Trends

Biometric Monitoring

  • Detecting early signs of heat stress/fatigue: heart rate monitoring & alarm capability
  • Detecting early signs of infection: body temperature monitoring & alarm capability
  • Ambient air temperature & atmospheric data monitoring & alarm capability

Ambient Noise Monitoring

  • Ambient noise can be monitored and reported by the Personal Safety Monitor PSM 825
Ambient Noise Monitoring
Geo-Fenced Area


  • Ability to restrict areas where dangerous machinery is operating, where hazardous chemicals are stored, or high temperature zones

Gas Detection Capability

  • Carbon Monoxide (CO)
  • Oxygen (O2)
  • Hydrogen Sulphide (H2S)
  • Explosive Gases (LEL)
  • This image shows an example of increasing CO exposure 
CO Carbon Monoxide Steel Manufacturing Safety
See Our Solutions