Quarry Operations Research Articles

Historical Quarry Landscapes of Three Finnish Granites

The quarry landscapes of Virolahti, Uusikaupunki, and Vehmaa are results of quarry operations during the most important periods of natural stone quarrying in Finland. The quarry landscape in Virolahti was formed in connection to the quarrying of red Virolahti pyterlite for the construction of St. Petersburg in Russia from the middle of 1700s to the beginning of the 1900s, while in Uusikaupunki, the quarry landscape is connected to the start of the modern Finnish stone industry and the National Romantic architecture at the beginning of the 1900s. The quarry landscape in Vehmaa is related to the start of the modern Finnish stone industry and export of Finnish granite at the beginning of the 1900s. In Virolahti, several small quarries can be seen, while in Vehmaa, a tendency towards fewer, but larger quarries start to emerge. In each area, human settlement was formed around the quarries. The geological basis for all areas is a rock type suitable for natural stone quarrying. The geotechnical features of each rock type indicate high resistance to wear and the products from these areas are early examples of durable construction. The quarry landscapes represent well the typical quarrying technology of the time and its development from channelling by chisels through hand drilling to mechanical drilling and blasting. The quarry areas form unique industrial and cultural heritage landscapes in Finland.

Impact of Crushed Natural Aggregate on Environmental Footprint of the Construction Industry: Enhancing Sustainability in Aggregate Production

This research addresses a critical gap in understanding the environmental impact of natural rock aggregate production in Sri Lanka. The study employs life cycle assessment (LCA) and SimaPro Software to simulate natural coarse aggregates’ extraction and manufacture process. Key findings reveal significant environmental impacts, with human carcinogenic toxicity (2.45938 × 10−6 Pt), eutrophication of freshwater (1.59326 × 10−6 Pt), and fossil resource scarcity (1.4823 × 10−6 Pt) being significant concerns. The crushing process in particular shows the highest levels, contributing 2.21 × 106 to human carcinogenic toxicity and 8.92 × 107 to freshwater eutrophication. High electricity consumption, particularly from hard coal in electricity generation, is identified as a primary contributor. Although the sole source of coarse aggregate production in Sri Lanka is natural rock crushing, there is a lack of country-specific environmental impact assessment data for this process. This study provides a valuable dataset for the Sri Lankan construction industry, covering various environmental impact categories and encompassing the sub-processes inherent to natural rock aggregate production. The research highlights the necessity of implementing sustainable practices in quarry operations, proposing a transition towards more environmentally friendly energy sources. By quantifying environmental effects, this study provides valuable insights for stakeholders in the construction sector, enabling informed decision-making and targeted interventions to enhance overall sustainability while offering aggregate manufacturers opportunities to adopt more sustainable practices.

Harvesting “development minerals” for local needs in sub-Saharan Africa: The case of Malawi

This paper critically reflects on the impact of “development minerals” on rural livelihoods in sub-Saharan Africa, focusing on the case of Malawi. It does so by analysing data collected at multiple quarrying sites in Lilongwe District, with the objective of assessing how production of these commodities can help meet Malawi’s commitments to the Sustainable Development Goals (SDGs). Findings indicate that despite their extraction being associated with environmental problems, development minerals do impact positively on the livelihoods of Malawians in rural areas where very few viable alternative income-earning opportunities. To maximise the sector’s contribution to the SDGs in Malawi, however, greater emphasis must be placed on formalising and supporting quarrying operations and other activities oriented around development minerals.

Transitional and Post-Mining Land Uses: A Global Review of Regulatory Frameworks, Decision-Making Criteria, and Methods

Post-mining land management is an integral part of surface mining and quarrying operations. In this context, the questions raised concern what course of action is mandated by laws and regulations; what type of land reclamation should be implemented, taking into account the site-specific conditions prevailing in each mining area; what are the appropriate land uses; and by what criteria and methodology can these be determined? The literature review conducted as part of the present study revealed that in addition to the traditional 4R actions of land management, namely remediation, restoration, reclamation, and rehabilitation, two more actions, repurposing and co-purposing, have now been added, with the purpose to address the social and economic impacts of mine closures. Furthermore, numerous land uses were documented and categorized into 11 classes, 38 sub-classes, and 119 alternatives. Nine criteria for selecting land uses were identified, expressed through 72 attributes that served as input information for 22 multicriteria methods, which, in most cases, were applied in combination of two or more.

Physico-Mechanical and Petrographic Appraisal of Carbonate Rocks as Construction Aggregate: A Case Study from Lesser Himalaya, Pakistan

Owing to the exceptional role of crushed rock aggregates in construction, their prospective reserves fulfilling qualitative and economic parameters should be identified to meet their ever-increasing demand. This research aims to unlock new sources of high-quality construction materials, thereby optimizing concrete performance and meeting the requirement for sustainable building materials. The study investigated the physicomechanical and petrographic properties of Jurassic, Cretaceous, and Eocene limestones of the Kawagarh Formation (KF), Samana Suk Formation (SSF), and Margalla Hill Limestone (MHL) along the Abbottabad–Nathiagali roadside section, as per the American Society for Testing and Materials (ASTM) and British Standards Institute (BSI). The results of geotechnical investigations are flakiness and elongation index (19.6–34.85% and 17.53–31.2%), specific gravity (2.64 to 2.67), water absorption (0.34–0.63%), unconfined compressive strength (41.72–80.65 MPa), loss angeles abrasion value (15.63–19.08%), impact value (15.38–19.36%), and the soundness (0.9–1.97%). These results showed values within the acceptable range according to ASTM and BSI standards. Petrographically, the KF is classified as mud and wackestone, the SSF was mainly classified as wacke-packstone and grainstone, while the MHL was classified as bioclastic wacke and packstone. The dominancy of micrite matrix favors the strength of aggregate, whereas porosity, microfractures, stylolites, and allochems adversely affect the mechanical properties of rock aggregates. Based on reserve estimation, the studied sections possess significant exploitable reserves and are feasible for quarry operations. The studied rocks can be utilized to produce high-strength concrete, optimizing its performance and quality.

Proposal of a Transport Planning Model for the Removal of Quarry Stone Using a Simulation

This article describes a transport planning model which applies a simulation to support decision-making in quarry operations. The analysis of the transport system was used as input for creating the model and the subsequent research. There are five loading points in the quarry from which, according to the plan, the quarry stone is transported to the crusher, where it proceeds for further processing. The required daily capacity of the downstream technological line is 3800 t/day. Based on the analysis, it was found that it was impossible to fulfill this requirement from the two loading points which were the furthest from the unloading point. For this reason, two simulation models of the transport system were created. The first simulation model is a transport system (loading, removal and dumping of quarry stone) from one loading point. Simulation experiments were performed on this model for all loading points. The findings from the analysis confirmed the results of the simulation experiments. Subsequently, a model of the combined quarry stone removal from two loading points was proposed. The model was designed for two variants of dividing the work shift into two work sections. In the model, which had a tabular form, the combinations of loading points and values of the minimum number of unloaded cars for stone removal were suitable to ensure its necessary daily capacity. The last part of this research was expanding the original model with an additional loading point. Several experiments were performed on this model. The aim of these experiments was to verify the combinations of loading points presented in the proposed model and the combinations of unsatisfactory loading points. Based on the research results, the transport planning model and simulation models are suitable additional tools for the decision-making process in removing quarry stone.

A laboratory study on the durability of limestone wastes in harsh environments for their suitability as aggregate in concrete

One of the critical environmental issues in the Chegeni area (Lorestan Province, western Iran) is the production of a large volume of limestone wastes during the quarrying operations. Releasing limestone wastes in the areas neighboring the quarries has caused visual damage to the environment, and adverse effects on the quality of the soil, running water, and groundwater used for agricultural and drinking water purposes. One solution to this issue can be recycling limestone wastes to produce building materials. In the present study, a comprehensive laboratory program is planned for the durability evaluation of the limestone wastes under harsh environments for their suitability as aggregate in concrete. For this purpose, five aging tests, including freeze-thawing (F-T), salt crystallization (SC), acid attack (AA), wetting-drying (WD), and heating-cooling (HC), were conducted on the limestone sample up to 60 cycles. After every 10 cycles, the physico-mechanical characteristics of the sample, including porosity (n), Brazilian tensile strength (BTS), point load index (PLI), and P-wave velocity (Vp) were determined. Moreover, the pores structure modification of the sample subjected to aging tests was examined through scanning electron microscopy (SEM). Data analyses revealed that the sample is highly vulnerable to the AA and SC processes but is durable against FT, WD, and HC actions. These results were in good agreement with the SEM data such that the sample exposed to AA and SC underwent more changes in their pore structure compared to FT, WD, and HC. Among the physico-mechanical characteristics, the Vp and PLI had the highest and the lowest accuracy, respectively, in the durability evaluation of the sample exposed to aging tests. Based on the data analysis, limestone wastes can be used as aggregate in concrete in environments with the possibility of FT, WD, and HC. However, this type of concrete is not suitable for conditions with occurrences of the AA and SC. Finally, in addition to reducing the environmentally harmful impacts of the study area, using limestone wastes as aggregate in the construction of concrete can also be a practical solution for sustainable development from an economic viewpoint. The results of the present study can be used for assessing limestone wastes produced in other areas of Iran and the world.

Changes in the physical and mechanical properties and structure of rocks depending on the depth of mining operations in iron ore quarries

The trend of the activity of open-quarry mining enterprises of iron ore raw materials is an increase in depth quarries. It is investigated in the work, changes in physical and mechanical properties and rock structure depending on the depth of mining operations in quarries. Natural geophysical and laboratory methods of research were applied. It was established that the angle of internal friction, Poisson’s ratio and rock density practically do not depend on depth of mining operations. But with an increase in the depth of iron ore quarries, there is an increase in the compressive and tensile strength of rocks. Indicator of specific adhesion has significant dynamics of fluctuations depending on the mineral composition of rocks and can either increase or decrease in deep horizons, which must be taken into account in each specific calculation. For example, by determining marginal angles of slopes of sides and ledges. According to the data of geophysical studies, it is established a characteristic increase in the intensity of creep shear processes and surface deformations rocks when the quarry depth increases. The results of research are recommended to be taken into account when organizing the mining and technological process in deep iron ore quarries.

Quarry soil and quarry stream water baseline level parameters around Chestedi Quarry, F.A.U.C. Golden Ltd Quarry, Fakunle Quarry and River Oyanmi in Igarra, Akoko Edo

The primary objective of this research was to investigate the initial levels of chemical parameters surrounding quarry operations in Igarra, Akoko-Edo, Edo State. Specifically, three prominent quarries (Chestedi, F.A.U.C. Golden Ltd, and Fakunle) were examined, along with the water of River Onyami flowing through these quarries from the Ojirami dam. Each quarry site yielded four soil samples collected at a various depth (between 0 – 15 cm) and different geographical coordinates, while four water samples were obtained from River Onyami. These samples underwent analysis for their physicochemical properties and the chemical speciation of Fe, Zn, Cu, Pb, Cr, and Mn. As Tessier et al. (1978) described, a sequential extraction method was employed to partition the heavy metals into five different fractions. Total concentrations of heavy metals in both soil and water samples were determined. The distribution of heavy metals in the soil exhibited the following order of accumulation: Fe > Zn > Mn > Cu > Pb > Cr, whereas in water samples, the order was Fe > Zn > Cu > Mn > Pb > Cr. Iron and zinc emerged as the predominant heavy metals in the soil, with iron within permissible limits but zinc, copper, manganese, lead, and chromium exceeding their respective limits. In the stream water, iron and lead surpassed their permissible limits, while Zn, Cu, Cr, and Mn remained below theirs. Comparative analysis against WHO, NIS DPR, and CCME maximum contamination/permissible limits was conducted for heavy metal concentrations and physicochemical properties in both soil and water samples. Mobility Factors (MF), Environmental Risk Factors (ERF), Contamination Factors (CF), Pollution Load Index (PLI), and Geoaccumulation Index (GI) were computed. Results from this study indicate that the soil is conducive to supporting growth and is nutrient-rich for various applications, while the water is suitable for irrigation and other domestic purposes.

Investigation of Surface Marble Quarry Enterprises in Marmara Island with Different Risk Methodologies in Terms of Occupational Health and Safety

Since our country is located on the Alpine-Himalayan orogenic belt, both surface and underground mining sectors have developed. Occupational health and safety have gained importance as the developing mining sector, the increase in raw material production and the increase in the workforce. In this study, considering the geological structure of the marble quarry operating areas and the activities carried out in the quarry on Marmara Island, the second largest island of Turkey in Balıkesir province, 59 hazards and risks from 26 activity areas were determined.These hazards and risks were compared using 5x5 L-type Matrix, Fine-Kinney and Potential Failure Modes and Effects Analysis (FMEA) quantitative risk methods.In the 5x5 L type Matrix method, 25 are high risk, 1 is medium risk, in the Fine-Kinney method, 16 are very high risk, 8 are high risk, 2 are in the important risk group, and in the FMEA method, 13 "precautions need to be taken" according to RÖS values, 11 “precautions can be taken” and 2 “no precautions needed” risks were identified. Among these methods, it has been determined that the Fine-Kinney method is a suitable method to be used in the operation of surface marble quarries, as it provides safer results by analyzing the hazards and risks specific to the environmental conditions, work areas and employees in a more detailed, comprehensive and more sensitive manner.

Correlation of Rock and Blast Properties with Elevated Quarry Floor and their Effects on Mining Costs

This study investigates the relationships between rock properties, blasting parameters, and their impact on quarry floor elevation and mining costs at Mount Olives quarry. Rock properties (uniaxial compressive strength, tensile strength, density) and blasting parameters (blast hole diameter, explosive type, stemming length) were analyzed. Statistical models correlated rock, blast, and quarry floor properties. Results showed significant correlations between rock properties and blasting parameters, affecting quarry floor elevation and mining costs. Compressive strength and tensile strength influenced blast energy, while rock density impacted quarry floor stability. Mining costs were predicted using statistical models incorporating rock and blast properties. This research demonstrates the importance of understanding rock and blast interactions in optimizing quarry operations and reducing mining costs. The findings provide valuable insights for quarry managers, blasting engineers, and geotechnical professionals.

Impact of Limestone Surface Impurities on Quicklime Product Quality

Quicklime is produced through the thermal processing of limestone in industrial kilns. During quarry operations, fine particulate quarry dust adheres to limestone lump surfaces, increasing the bulk concentration of impurities in limestone products. During thermal processing in a kiln, impurities such as Si, Mg, Al, Fe, and Mn react with Ca, reducing quicklime product quality. Which reactant phases are formed, and the extent to which these result in a reduction in quality, has not been extensively investigated. The present study investigated as-received and manually washed limestone product samples from two operational quarries using elemental compositions and a developed predictive multi-component chemical equilibrium model to obtain global phase diagrams for 1000–1500 °C, corresponding to the high-temperature zone of a lime kiln, identifying phases expected to be formed in quicklime during thermal processing. The results suggest that impurities found on the surface of the lime kiln limestone feed reduce the main quality parameter of the quicklime products, i.e., calcium oxide, CaO (s), content by 0.8–1.5 wt.% for the investigated materials. The results also show that, in addition to the effect of impurities, the quantity of CaO (s) varies greatly with temperature. More impurities result in more variation and a greater need for accurate temperature control of the kiln, where keeping the temperature below approximately 1300 °C, that of Hatrurite formation, is necessary for a product with higher CaO (s).

Assessment of the Erosion and Outflow Intensity in the Rif Region under Different Land Use and Land Cover Scenarios

The port of Tangier Med is essential due to its strategic location, as it is an important trading center linking Europe, North America, and Africa. However, the increased rates of downstream sediment transportation put pressure on the sustainable future of the port. Thus, assessing the existing erosion rates and future improvement scenarios is imperative for planning sustainable management at the catchment level. We utilize the Erosion Potential Model (EPM) combined with the Intensity of Erosion and Outflow (IntErO) algorithm to assess the erosion and outflow intensity and to distinguish the sediment-producing areas in the R’mel watershed. The port’s proximity at the bottom of the slope opposite the R’mel Dam is relevant in this context. Initial results show an average erosion rate of 13 t/ha/year. Quarry operations were identified as the primary sediment source, as indicated by the factors contributing to erosion. The qualitative PAP/RAC (Priority Actions Program/Regional Activity Center) model was used to assess the development trends in the watershed, confirming a clear tendency toward irreversible degradation in the quarry areas. Considering that the mined carbonate lithology represents 23.77% of the total area of the catchment, the situation in the region could deteriorate if quarry operations continue. The simulation of quarry rehabilitation scenarios through land use and land cover change (LULC) with IntErO shows that reforestation of quarries can significantly reduce erosion rates (4.78 t/ha/year) compared to their conversion to agricultural land. This study underlines the effectiveness of IntErO, based on the EPM model, in quickly and effectively mapping and quantifying water erosion.

The Use of Remote Sensing in the Study of Open-pit Mining and the Ecology of Disturbed Lands in Deposits of Cement Raw Materials in the Regions of Russia

Based on the results of remote monitoring, the state of mining operations in quarries for the extraction of mineral raw materials consumed by cement plants in Russia was investigated. The fleet of mining and transport vehicles in operation in cement quarries was studied. The production capacity of each quarry in terms of rock mass and the total production potential of quarries in Russia, estimated at 210 million tons per year, have been determined. The environmental indicators of disturbed lands during the development of mineral deposits for use in the cement industry as a whole are presented.

Results of Remote Monitoring of the Technological Potential and Ecology of Open-pit Mining at Mineral Deposits for the Production of Crushed Stone

Based on the results of remote monitoring, the state of mining operations in quarries for the extraction of mineral raw materials consumed by crushed stone plants in Russia was investigated. The indicators of integrated mechanization of crushed stone quarries based on the presence of operating mining and transport vehicles have been identified. The production capacity of each quarry in terms of rock mass and the total production potential of the crushed stone plants in Russia, estimated at 285 million tons per year, have been determined. The environmental indicators of disturbed lands during the development of mineral deposits for use in the crushed stone plants are presented.

Information Management for Remote Monitoring of the Ecology of Disturbed Lands During the Development of Deposits of Chrysotile-asbestos and Fluxing Limestone

Based on the results of remote monitoring, the current state of mining operations in quarries for the extraction of chrysotile-asbestos and metallurgical fluxes used in various sectors of the Russian national economy was studied. The production capacity of each quarry in terms of rock mass at the studied deposits and the total production potential of the quarries for the extraction of minerals, estimated at at least 95 million tons per year, have been determined. The environmental indicators of disturbed lands during the development of deposits of chrysotile-asbestos and metallurgical fluxes are presented.

Cost modelling for dimension stone quarry operations

Dimension stone mining is Increasing because of growing demand from the building and construction industries. Diamond wire saw cutting is a popular dimension stone mining technique around the world. Estimation of the production cost for this method is critical for these operations. In this research a production cost model was developed for the mining of granite using a diamond wire saw. Cost and production data were collected from a granitic dolerite operation in Pakistan for a 4.5-year period, and analysed to identify the cost components. Fuel (34%), labour (15%), consumables (40%), and maintenance (5%) were found to be the four major cost components in this operation. A regression-based dimension stone production cost model incorporating statistically significant variables was developed. The data presented a strong correlation of production cost with fuel, labour, and consumables costs. Finally, a production cost model based on the consumption cost of diamond wire is presented. The model was verified using actual production cost data, which indicated 95% (R2 = 0.95) variance in the data between the predicted and actual production cost values. The model may help field engineers in computing their dimension stone operational cost during the cutting phase.

Development of mining operations in deep quarries using automobile and combined transport

Aim of this paper is to explore the development of mining operations in deep quarries utilizing automobile and combined transport systems to overcome these challenges. The use of automobiles in mining has been a growing trend, offering flexibility, maneuverability, and increased productivity. In deep quarries, traditional automobile transport faces limitations in terms of reach and efficiency, combined transport systems incorporating a combination of automobiles, conveyor belts, and other transport mechanisms have been proposed. This paper discusses the advantages of automobile transport in deep quarries, including its ability to navigate narrow passages and transport smaller loads efficiently. It examines the integration of combined transport systems, which leverage the strengths of automobiles alongside other modes of transportation to optimize mining operations. Key considerations in the development of these systems include infrastructure design, vehicle specifications, safety protocols, and environmental impact. By implementing innovative solutions tailored to the specific challenges of deep quarry mining, such as automated vehicle control and monitoring systems, it is possible to enhance efficiency, reduce operational costs, and improve safety standards. Also, this paper highlights case studies and examples of successful implementations of automobile and combined transport systems in deep quarries around the world. These real-world examples demonstrate the feasibility and benefits of adopting such approaches in challenging mining environments. In the paper criteria requirements and recommendations for the implementation of this process are presented in the technological processes of compaction using separators, which are carried out during the construction of highways, and the interdependence of indicators is presented through tables, graphs and calculation expressions.

An integrated approach to safety in the design and operation of open-pit mining facilities

The article presents a pioneering integrated approach to assessing compliance with environmental, fire, industrial safety, and labor protection requirements in open-pit mining operations. The study was conducted at two existing open-pit mining facilities located in the Trans-Baikal Territory of the Russian Federation, analyzing the causes of injuries, statistical data, and comparing the mining technologies used. The key findings emphasize that the efficiency of deposit development and the safety of mining operations are heavily dependent on the quality of the technical design. The article also discusses software systems used for the design of mining facilities, which enable monitoring of the safety and labor protection aspects during quarry operation. The results of the comparative analysis are expected to be of interest to both quarry design specialists and the engineering and technical personnel of existing open-pit mining facilities. This integrated approach represents a significant advancement in the field, providing a comprehensive framework for enhancing safety and operational efficiency in the mining industry.

Technological solution of the quarry parameters to develop mining operations and systems

Quarry development involves numerous challenges, particularly in defining the necessary parameters for effective and safe extraction. These challenges are primarily managed by specialized design organizations during the pre-project phase, which includes detailed geological surveys, environmental impact assessments, and evaluations of resources. The objective is to ensure that the quarry’s design is economically feasible while complying with safety and environmental regulations. During this phase, essential decisions are made regarding the location, size, and operational techniques to be employed, all in accordance with established technological design standards in the mining sector. In addition to the contributions of design organizations, mining companies also have a significant role in the continuous assessment and management of quarries, particularly those with limited reserves. These companies must strategically balance the need for resource extraction with the long-term sustainability of the mineral resource base. This necessitates ongoing monitoring of reserve levels, extraction rates, and safety conditions to maximize the efficient use of available resources. Furthermore, mining operations are subject to stringent safety regulations unique to open-pit mining, which require meticulous planning to mitigate risks to workers and the environment. This encompasses the design of appropriate slopes, roads, and drainage systems to avert accidents and environmental harm. By fostering collaboration between design organizations and mining companies, it is feasible to enhance resource extraction processes while adhering to safety standards and reducing environmental impact. This holistic approach guarantees that quarry operations remain sustainable, productive, and safe for both workers and the surrounding ecosystem.