Camalco — Vision AI safety across bauxite excavation operations.

Heavy excavation and workers — close proximity, every shift.

Bauxite excavation operations at Camalco involve heavy excavators, haul trucks, dumpers, and on-foot workers operating in close proximity throughout every shift. The proximity is unavoidable — bench monitoring, equipment guidance, and operational support all require workers to be near operating heavy equipment. The risk is constant.

Manual safety supervision could not provide continuous coverage at the scale required. Spot inspections caught only a fraction of unsafe events. No-go zones existed on paper but were not enforced in practice. Near-misses occurred regularly without being documented — meaning the patterns that should have triggered systemic change were invisible.

• Heavy equipment and on-foot workers in close proximity every shift
• Manual safety supervision unable to provide continuous coverage
• No-go zones unenforced in practice — boundaries existed on paper only
• Near-misses occurred regularly but were not documented
• Pattern recognition across incidents not possible without structured data

Vision AI as the watch that never blinks.

Cognecto deployed Photon's Vision AI across Camalco's existing CCTV infrastructure — covering bench operations, equipment movement corridors, blast areas, and dump points. Geofenced no-go zones were drawn directly onto the camera feeds. Crane swing radii, excavator working zones, and explosive storage perimeters became actively enforced boundaries with real-time alerts on any breach.

Continuous enforcement where manual coverage was impossible.

Camalco's safety profile changed structurally — not because workers became more careful, but because the system watching them never stopped. Near-misses fell 50% in the first deployment phase. The pattern data being generated is now driving systemic improvements that were impossible without it.