Application and productivity analysis of new channel opening method in natural stone quarries with diamond wire cutting machine

Abstract

Channel opening methods (V and U) are used in natural stone quarries with the aim of designing and planning benches. A channel opening method (V-shape) is widely used in natural stone quarries where a quarry face is plain and continuous, in order to form a new bench. The most important shortcomings of this method are high production losses, long preparation process to form a bench, and failure to control the progress in the quarry. Providing that the topography and geological structure of the quarry are appropriate, the U-shape channel opening method can be applied using armed chained cutting machines. However, the channel opening equipment is operated in an integrated way with diamond-wire cutting machine, which can perform a back-cut directly in natural stone quarries; this equipment has high initial investment cost and limited application. A series of characterization tests were conducted on two different commonly used natural stone types which were categorized according their formation. This study investigates a recently developed hole design that enables a diamond-wire cutting machine to produce a U-shape cut, and compares the efficiency of this method with the V-shape method. With the U-channel opening method, production losses decrease and quarry benches can be formed in 60 % less time. The recently developed channel opening method is being applied in natural stone quarries. At these sites, productivity has increased threefold with respect to V-channel opening method. It was observed of the U-channel opening method, resulted in production of blocks at a lower cost per unit time. It was calculated that block efficiency in natural stone quarries increased to 12–15 % values with use of the U-channel opening method.