AKSUM UNIVERSITY

SHIRE CAMPUS
DEPARTMENT OF MINING
ENGINEERING

INTERNSHIP REPORT
ON
SABA DIMENSIONAL STONE PLC
SUBMITTED BY
Prepared by Gebreweld,Mahder and tahguas

S.N NAME ID NUMBER

1 GEBREWELD TESFAMARIAM 1001765

TAKELE

2 MAHDE ANDOM 1001665

3 TAHGUAS BRHE 09

SUBMITTED TO _______________________

INTERNSHIP STARTEDATE INTERNSHIP END

DATE

ACKNOWLEDGEMENT

First and most our sincere gratitude to Almighty of God who gratitude us health and long life,
without which we could not have finished this Internship report. And we would like to express
our appreciation for Aksum University and our head department Mr.Yemane for creating and
organizing this practical attachment training. And we would like to thank Saba dimensional stone
PLC helped us to do there our internship report. Also we would like to thank our advisor Mr.
Fthawi, Guash for their guidance and advice for the success of this report. And we would like to
thank our company advisor Mr.Kibrom his voluntariness to give important information.

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LIST OF ABBREVATION

SDS………………………. Saba Dimensional Stone

PLC…………………..……Private Limited Company

KW………………………..Kilowatt

CM………………………...Centimeter

MM…………………….…..Millimeter

EFFORT……………………Endowment Found for Rehabilitation of Tigray

VAT…………………………..Value added tax

ESIA…………………….….Environmental and Social Impact Assessment

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CHAPTER ONE

INTRODUCTION
1.1 Background of the Hosting Company
Saba Dimensional Stones (SDS) PLC is one of the members of the hosting company of EFFORT
(Endowment Found for Rehabilitation of Tigray) which is established in 1992G.C or 1985 E.C.
Saba Dimensional Stone PLC is found 7.5 km from the center of Adwa and 233 km from
Mekelle the capital of Tigray regional state, With initial paid capital of 76milion birr.

The processing plant is equipped with primary machines like one marble Gang saw, one sermak,
one Marble block cutter, three granite block cutters, one terrazzo press machine and different
polishing and cutting machineries.but after the war only remain gang saw. It does in slow speed
In addition to processing natural blocks of marble, limestone and granite an artificial block called
Saba special made from marble chips, sand and cement is also processed. The main inputs for the
processing plant are the raw blocks produced at the quarry and special Terrazzo produced at the
processing plant.

SDS PLC is to explore extract & process marble, limestone and granite, either in standard block
size or finished (cut & polished) forms for both the domestic and international market. As for as
technology is concerned equipped with the necessary latest machinery and equipment facilitate
the smoothen operation of quarrying as well as processing activities.

For transporting purposes and processing plants are equipped with the latest the art Italian
technology are primary machines (diamond gang saw, marble block cutter, granite block cutter)
finished machinery (polishing machines, different cutting machines) different types of loading
and un loading and transporting machines(gantry crane, single beam overhead crane different
arm cranes, and trolleys).

In addition to processing natural blocks of Marble, limestone and granite an artificial block
called Saba special made from marble chips, sand and cement is also processed. At the previous

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the processing plant has annual production capacity of more than 242,000 meter square of
marble, limestone, granite, and Saba special, and 60,000 meter square of terrazzo tiles.

Saba provides products in the form of block, slab and tiles. We have standard size slabs and tiles
as well as cut to size as per customer order.

Generally, the main inputs for the processing plant are the raw block produced in different
quarries and the Saba special produced in the processing plant. And the processing factory where
located in Adwa Tigray respectively.

1.2 OBJECTIVE
1.2.1 General Objective
To convert or to apply our theoretical knowledge into practical knowledge by following
the processing activity of the dimensional stone.

To assess the processing plant operation in order to develop practical skills related to our
profession

1.2.2 Specific Objective

To understand the working principle of the crusher and production of terrazzo and Saba
special.

To understand about the waste disposal area and water treatment process in the plant.

1.3 GENERAL FEATURE OF THE COMPANY

1.3.1 Location and Access of the Company
Saba Dimensional Stone is located in Northern Ethiopia Tigray region central zone (Adwa)
which is 7.5 km asphalt road from the center of Adwa and 233 km from Mekelle the capital city
of Tigray regional state. The factory is located in between Adwa and Aksum which is nearest to
Adwa.

1.3.2. Climate and Vegetation

The climate condition of Saba dimensional stone area is normal condition to live and to do there.
Its condition not more varies from time to time. It has similar air condition in day and night.
There are the normal populated plants around Saba dimensional stone factory. It is neither low
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land nor high land, it is medium. It gains rainfall at the summer from June to September and
sometimes there is rain fall at the winter. Different types of vegetations are available around it, it
is comfortable to grow any type of plant around it.

Figure 1:Saba Dimensional Stones

1.4 Challenges I Faced

During my internship there were some challenges those challenges are

Lack of library access to read manual and some references about the operation machine also lack
of recorded data

difficult to access transportation

Lack of office to write some notes

1.5 Overcome the challenge

In order to overcome the challenges
1, difficult to access transportation

I use public transportation to transport with payment from my pocket

2, Lack of library access to read manual and some references about the operation machine also
lack of recorded data

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By asking the workers and with concerned persons

1.6 Assessment of the Internship

In this was discuss about the skills and qualifications, the responsibilities that we take, the co-
relation of the internship practice with the theoretical knowledge and finally the role of this
program on changing our future plan.

From the training we have got both practical and theoretical skills as well as Communication
skills.

Practical skill: How to use machinery and equipment, How to unload, How to cut, How
to polish, and How to splitting and to crush.

Communication skill: Individual speaking skill and Group discussion skill.

Theoretical skill: Different types of safety equipment, and machinery.

1.7 General overview of the Adi Eleni site

1.7.1 Location and accessibility

The site of Adi Eleni is one of the most recently started (youngest) quarries of the
company. It is open in 2004 Geez calendar and it is also the nearest quarry to the
main processing plant found in Adwa. The site of Adi Eleni is found in the central
zone of Tigrai, specifically in Chilla wereda and specific place of Adi Eleni
locality. It is located about 40km away from the main processing plant (placed in
Adwa) towards North West direction. It could be accessible through the main road
(Asphalt) of Adwa-Axum, and branched gravel roads that connect Axum with Adi
Eleni village passing through Medebay Welel and Wukiro maray-Chilla towns.
1.7.2 Climate and Topographic conditions

The climate condition of Adi elen site is semi arid to arid, and it is lowland with
undulating and small hilly forming topographic conditions. The majority area

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around the quarry is covered with small and scattered vegetations and blocky
graniodiorite boulder rocks.

Figure 1 the active and open quarry (site#2) when observed at distance; the camera man
(myself) was standing in East and taken the picture towards West direction.
1.7.3 Objective of the work
To produce and deliver high quality dimensional stones (blocks) at
minimum running costs.
To maximize production rate and to create less wastages (which are
discarded) in the quarry operation, this is related to resource optimization.
To be more competitive in the dimensional stone industry sector at regional
level, and even throughout the country.
To create more job opportunities and to contribute a lot in growth and
development of the region as well as in the country.
Of these, mainly the specific objectives of the quarry sites (where I had been
there in Dichinama and Adi Eleni) is only and only “ to produce and
deliver high quality, standardized dimensional blocks at minimum
running costs and to maximize production rate by creating less
wastage. ”
1.1.3 Human resource of the quarry

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It is clear that human resource is one of the most important and interesting
to consider it, because there could no more work without human capital
involvement in any work. Quarry operation is a type labor intensive work
and partially technology aided operational work. Hence, there are about 17
human resources found in this particular site of Adi Eleni, and let me briefly
describe them in tabular form below in table 1.

No Field of employees No of employee Remarks

involved

1 Site coordinator 01 Permanent

2 Loader operator 01 “

3 Senior quarry machine 01 “

operator

4 Junior quarry machine 05 “

operator

5 Fresh quarry machine 02 Temporary

operator

6 Trainee geologists 02 Contracts

7 Food cooker 01 “

8 Scouts (guards) 03 “

9 Toyota double pickup 01 Permanent

driver (service car)

Total number of emlpoyees 17

Table 1, shows the total of employees deployed in the quarry site of Adi Eleni.

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5.2.1 Methodology

For this problem design projects used known as mechanical operated transporting system.
In it I used for transporting of bulk material or other to out or in.

2.1 Data collection

2.1.1Primary data collection
Direct observation
Formal interview or meeting with managers at different level of the company and
employers with in my section that work during internship program.
2.1.2 Secondary data collection
Written material in the organization like report, manuals, plans and soon.
Referring to some books and handouts related to the study.
Using internet

Chapter two

2. Quarry machineries and Equipments

2.1 Quarry machineries
It is known that, there are different types of machineries and equipments
manufactured for quarry operational purposes. However, selection of machines and
equipments depend on the type of the quarry and potential capital investment of the
company owning the quarry. Therefore, Saba dimensional stones private limited
company has different types of machineries and equipments deployed in the
different quarry sites owned under the company. On the basis of the energy they
used, these quarry machineries are broadly classified in to four categories. These
are Electrical, Pneumatic, Hydraulic and Fuel (gasoline consuming) machines.
Therefore, let me describe them briefly each individually.

2.1.1 Fuel (Gasoline consuming) machines: - are machine types which run
mainly using the consumption of gasoline. Machines like generators and
compressors which are indirectly sources of electrical and pneumatic energy
respectively are primarily generated using the consumption of fuels; that is why
they are called fuel machineries. Here, not only the listed above but also loaders

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and excavators, Toyota car, Mercedes tracks are also gasoline consuming
machines.

Figure 2, Fuel consuming machineries; CAT type loader (left) and AtlasCopco type compressor
(right)

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2.1.2 Electrical machines: - these types of machines are machines which run
using the power supply of electricity which is sourced from the service of
hydropower electricity or giant generators e.g., Bennett and Marini diamond wire
sawing machines; and electrical water pump motors.

Figure 3, this is an electrical type of machine (Marini diamond wire machine, 75HP) in
primary vertical cutting (lift picture) and block squaring (Marini diamond wire machine,
25HP) in the right side.

2.1.3 Pneumatic machines: - Machines which can run using the compressed air
(7bar) are called pneumatic machines. These machines get their source of energy
particularly from big compressor machines which were grouped gasoline

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consuming machine. Some examples of pneumatic machines are spherical

machines, drillers and grinders.

Figure 4, this is a type of pneumatic machine (spherical with double jack hammer)

2.1.4 Hydraulic machines: - Are small in quantity and specially designed machine
types in our site. Some example are like crimping hydraulic press machine which
is very important for connecting diamond wires and hydraulic bull machine which
are used to push big slice cut or boulders to fall down in to suitable working area.

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Figure 5, this is bull machine when it pull huge sliced cut (left); and the red colored (Bull
machine) hanged by the loader’s rake when transported to the pick to pull.

The lists of machine types and their quantities which are specifically found
in the quarry site of Adi Elen are described in the table below.

No Machine Machine Quantity Machine Remarks

category type status

01 Fuel Loader 01 Functional CAT

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02 consuming Toyota car 01 “

machines
03 Mercedes - “ On/off
truck

04 Big 01 “ Perkins
generator type

05 Small 01 “ Olympian
generator type

06 Atlas 01 “
compressor

07 Electrical Marini 02 “ Marini

machines diamond quarries
wire sawing group
machine
25HP

08 Marini 02 “ Marini
diamond quarries
wire sawing group
machine
75HP

09 Benetti 01 “
machine

10 Water 02 “
pump motor

11 Hydrobag 01 “
plant
machine

11 Pneumatic Spherical 02 “ Marini

machines machines quarries

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group

12 Driller 02 “ “
machine

13 Jack 03 “ “
hammer

14 Grinder 02 “ To sharpen
drilling
roads

15 Hydraulic Hand held 01 “ To press

machines pressing diamond
machine wire
connector

16 Bull 01 “ To pull
machine sliced cut

TOTAL 24
Table 2, total machineries deployed in the site of Adi Eleni.

2.2 Quarry equipments

There are various types of quarry equipments we use them in our day to day
activities. These equipments could be either consumable or non consumable
materials. Some of the most commonly used are diamond wires, drilling extension
rods and rods, Hammers (both small and big), different size wrench, electrical
cables, air hoses, water hoses, fuels and lubricants, water tankers, different size
electrical breakers, plug and feathers, hacksaws, screwdrivers, oil container jars,
gasoline tanker, meter tap, markers, FRACT powder (powder demolishing
chemical), shovel, and so on.

3.1 Geology of the site of Adi Elen and its surroundings

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In generally, the regional geology of northern part of Ethiopia, particularly of

Tigrai region is covered by different lithologic units starting from the oldest
basement Precambrian rocks to the recent teritiary volcanic terrains. This
comprises metavolcanics and metasediments associated with the granitoids
(intrusive/plutonic) rocks, Paleozoic rocks, Mesozoic rocks, tertiary volcanic rocks
and quaternary sediments. However, in the northern part of Ethiopia (Tigrai
region) the metavolcanics are termed as tsaliet group, whereas the metasediments
are commonly known as tembain group. The Paleozoic sedimentary rocks are
Enticho sandstone and Edagarbi tillites; and the Mesozoic sedimentary rocks are
Adigrat sandstone, Antalo supersequences (Antalo limestone and Agulae shale),
and Ambardom sandstone. Accordingly, the lithostratigraphy of northern part of
Ethiopia includes:-

 Quaternary sediments,
 Tertiary volcanic rocks,
 Ambardom formation (sandstone),
 Antalo supersequences (Antalo limestone and Agulae shale),
 Adigrat formation (sandstone),
 Paleozoic sediments (Enticho sandstone and Edagarbi tillites),
 Basements of tembain group and tsaliet group; associated with intrusive
(Forestiga graniodiorites and Mereb granites) rocks,

In addition to this, the basement rock types of tsaliet group and tembian group
associated with intrusive rock units found in the central northern part of the region
(Tigrai) is identified into six tectonostratigraphic blocks (Tadesse et, al 1997).
Thus includes; from west to east:

 Sheraro block,
 Adi Hageray block,
 Adi Nebrid block,
 Chilla block,
 Adwa block,
 And, Maiketal block.

Of these, the Chilla block is the area that covered the quarry site of Adi Eleni and
its surroundings. This block is bounded to the west by the central steep zone and to

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the east by the Daro Tekli mafic and ultramafic belts. It is occupied by thick
succession (>3000m) predominantly of fine grained meta sedimentary rocks
including phyllite, 18olitic schist and recrystallized chert. Towards the western
margin of the block non-carbonaceous, interbedded impure marble, phyllite and
light grey recrystallized chert occurred. It is also intruded by composite tonalite–
granodiorite–granite intrusive. (Tadesse et, al 1997)

Having this in mind, the specific (local) geology of the site of Adi Elen site and the
surroundings is dominantly composed of graniodioritic rock. This rock type is
characterized by light to dark gray colored, medium to course grained texture of an
intermediate rock. Due to both the chemical and physical weathering effects, the
widely spaced master joints forms undulating and small hilly type of topographic
features. Most of the localities in the vicinity area of the quarry are covered by
boulders of such graniodioritic rock especially towards south west direction of the
quarry. Some of the simply identified minerals of this rock at hand specimen scale
are pyroxene, both type of micas (muscovite and biotite), plagioclase and quartz. In
addition to the described above, this intermediate rock have also some patches of
xenoliths and rarely visible quartz veins. However, the detail mineral composition
of any type of rock could be only identified through the detail study of
petrographic studies and geochemical analysis techniques. Having said this, the
report I am writing it now is simply from my visual observations and some
geological reviews done so far in the country, and particularly in the region only.
The randomly oriented mineral textures of the plutonic rock which are easily
visible to necked eye and the less deformed structures of the rock infer us this
graniodiorite rock is a post tectonic rock unit. However, in the particular quarry
site there are three dominantly observed sets of master joints; which are trending to
NE-SW, NW-SE and nearly E-W directions. These joints are widely spaced (2-
20m) and which are found in vertical, inclined and sub horizontal patterns. It has
been known that such master and conjugated joints affect the production of
dimension stone both in negative and positive ways (the detail will be discussed
later in the section of ‘‘effects of geological structures in mining and production’’).

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Chapter four
4.1 Mining processes and procedures
Mining is the process of extracting the usable minerals from the surface or
underground of earth. The techniques of mining processes and steps of
mineral extraction are varied with respect to the type of the mineral deposit.
Thus, the mining process of industrial mineral like dimension stone is
always simpler than that of mining base metal minerals. It requires simple
techniques and processes to extract the mineral from the base ground. The
most common type of such mining process in dimension stone is called
Quarrying.
4.1 Quarrying
Quarrying is a type of open pit mining and it is the process of extracting the
usable mineral from the surface of the earth (see fig1). However, the
different types of mining processes and procedures that frequently used in
the site of Adi Elen quarry are described below.
5.2.1 Development work
Here in this early stage, activities like acquiring the ownership license, land
surface clearance and opening front of the quarry has been begun. Opening
front quarry requires detail knowledge about the geological and geotechnical
properties of the parent rock with respect to its mineral deposit and it must
be systematical opening. It is recommended that the front of the quarry
should be always across the strike and away from the dip direction of the
mineral deposit. However, for this case the quarry of Adi Elen site has been
already stayed me open and it is a type boulder mining.
4.1.2 Drilling

Drilling includes both the horizontal and vertical drillings. To conduct

drilling and to meet the drilled holes in one point of intersection it is
required to have three open faces (X, Y and Z axis) in the quarry. However,
since the mining in the quarry of Adi Elen site is mostly boulder
(Graniodiorite) type of mining there is no need to drill vertical holes. This is
because we used the widely spaced vertical master joints instead of the
vertical drilling holes. In this regard, the vertical master joints have
significant importance both in case of cost minimization and eases of work.
Simply, these widely spaced and unfilled (open) master and conjugate joints
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have positive impact in this particular mining stage. However, when the
density of the joints are increased and they are tightly closed, it will have a
negative impact in case of decreasing the quality of dimension stone blocks
and inversely increasing wastage of discarded pieces of blocks and boulders.
Hence, the horizontal drillings in our particular site of Adi Eleni have been
conducted rarely yet.
4.1.2.1 Vertical Drillings
As I have been described it above since we have a boulder type of mining in
the quarry site of graniodiorite and there are a number of open vertical
master joints; we didn’t expected to drill vertical holes. However, if we have
a massive deposits it mandatory to drill vertical holes.
4.1.2.2 Horizontal Drillings
To conduct horizontal drilling it is required to have two open faces (X and Y
axis) to drill two holes from both sides in the quarry. The main purpose of
the horizontal drilling is to meet with the vertical drilled hole in one
intersection point in the bottom side. Therefore, it is critical to intersect the
vertically drilled hole with the horizontally drilled holes from two side of the
wall (X-axis and Y-axis)

Vertical
Vertical Drilled
Drilled hole
hole

Horizontal
Horizontal Drilled
Drilled holes
holes

The block sketched above shows the intersection point of vertical and horizontal
drilled holes.

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4.1.3 Primary cuttings

Following to the drilling has been completed; the primary cutting processes is
started. Similarly to the drillings done the primary cuttings have also two types of
cuttings. Thus, these are horizontal and vertical cuttings.

4.1.3.1 Horizontal primary cutting

In massive deposit and if there is no clear and open horizontal master joints, the
first thing to do is to cut horizontal cutting. But, before horizontal cutting has been
started it is required to pass the diamond wire through the horizontal drilled holes
with the help of pushing by pneumatic pressure. Next to this crimping or jointing
(connecting) of the diamond wire follows. Then, after the rail of the diamond wire
sawing machine has setup horizontal cutting is started immediately. This is to
isolate the primary cut from the remaining of main deposit below.

Vertical
Vertical Drilled
Drilled hole
hole Horizontally looped wire

Horizontal Drilled holes

Block diagram showing how horizontal cutting looks like.

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4.1.3.2 Vertical primary cutting

The same principle and procedures with the horizontal cuttings are applied to
vertical primary cutting also. This is simply to isolate the primary from both of
vertical sides of the main mineral (rock) deposit.

Vertically looped wire

Vertical
Vertical Drilled
Drilled hole
hole

Horizontal
Horizontal Drilled
Drilled holes
holes

Fig Block diagram which shows vertical primary cutting

Figure 6, the machine seen on the photograph shows when it’s cutting vertically.

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4.1.4 Slice cutting

Slice cutting is commonly a type of vertical cutting and it is a process of

partitioning the earlier primary cut in to different slices on the basis of different
criteria. Therefore, to do such slice cutting it is necessary to consider the following
parameters;

 Dimension of blocks expected to be produced (volume of the block),

 Lifting machine’s capacity (particularly loader in our case),
 Suitability conditions which is related with bench height (boulder’s height in
our case),
 And, working area extensions whether it is wide or narrow working areas.

Here, after the slice cutting has been completed the next step which is expected to
carry out is the process of falling down the sliced cut. This is done by applying or
using different techniques. Some of the techniques we have practiced are;

 Pushing, pulling and lifting with the help of loader using its different
accessories like one finger, fork and rake,
 Pushing using hydrobag inserted in the sliced cut face using filling of
pressurized water to it,
 And, also pushing by using hydraulic bull machine.

Then after this process is finished we are going to the next step of block squaring
process.

4.1.5 Block squaring process

This block squaring cut is a process of changing the sliced cut in to rectangular and
cuboids shape of blocks. Simply this is removing of the edge of irregular shapes by
using diamond wire sawing machines or spherical machines if applicable. Here
also, there are some points that must be taken in to account while block squaring is
processed. These are;

 Lifting and loading machine capacity (loader),

 Transporting machine capacity (Mercedes truck),
 And, dimension of blocks that fits with the machines that are found in
processing plant.

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Accordingly, the minimum and maximum dimension of blocks we have produced

earlier are Length 2.50-3.50m, Width 1.30-1.80m, and Height 1.05-1.20m.
However, some special ordered blocks with small dimensions were also produced
sometimes. Producing of blocks in this limited dimensions were enforced us to
create huge discarded wastes. Such problems were happened when we produce
blocks by keeping the limited dimensions listed above instead of producing at any
sizes of blocks.

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Figure 7, the photograph taken from the quarry shows when the processes of block squaring are
ongoing.

4.1.6 Stock yard and grading block

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This is collecting all the finished blocks in to one common place found at near
distance. Following to this, labeling and grading of all the finished block was given
by the responsible person. Labeling is more related with putting the dimension of
the block, block number and grade of block using colorful marker on the block
itself in one smooth surface; but grading is more related with describing the quality
of blocks in terms of its shape of the block (squareness of the block), presence of
defects like fractures, veins and patches, and color variations (Homogeneity versus
Heterogeneity).

Therefore, the grade of blocks is given the basis of the following standards.

1. A standard block (Grade A block):-

 Should fit to gang saw and/or poly wire machines,
 Free from diagonal fractures,
 Has uniform color,
 Less weathering effect,
 Symmetrical and shaped,
 Has expected recovery ≥ 80%,
 Width 150-180cm (for marble and limestone)
 May give >150cm length final product,
 Must be compacted, fine grained or have well sorted grains,
 Has a foliation lines of 90⁰/ or 180⁰ (perpendicular or parallel),
mainly for marble and limestone.
2. B standard block (Grade B block):-
 Similarly should fit to gang saw, poly wire and pedrini machines,
 Free from diagonal fractures,
 Its foliation lines must be at 90⁰,
 May have fine and course grained textures,
 May have color variations,
 Without reddish material impurities (basically for marble),
 Must have greater than 70% recovery rate,
 Must produce up to 150cm length.
3. Standard C blocks (Grade C blocks):-
 Mainly it could be for block cutter machines,
 Could have diagonal fractures, but may produce small ordered
slabs and/or pieces,
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 Should have a recovery rate greater than 50%,

 Should be squared or symmetrical cuboids.

Figure 8, labeled blocks accumulated in the stockyard

4.1.7 Transportation processes

This process is mainly related with the loading and hauling of the finished blocks
by the single and/or double axel trucks depending on their carrying capacity of the
trucks (Mercedes), that is single axle trucks carries up to ≤ 4.50m³ (12.15tonne)
and double axel truck carries up to 6.5m³ which is equal to 17.55 tonne. Therefore,
this process is the final process done in the quarry site.

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Figure 9, Double axel truck (Sino Truck) waiting ready to transport blocks.

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Figure 10, Double axel trucks containing loaded block to transport it.

Chapter five

5.1 Production rate and running costs

5.1.1 Production rate

Production rate means the amount of the block production that could be produced
continuously in daily, weekly, monthly and annually. The unit measure of the
production rate in our quarry site is expressed in terms of cube meter (m³) which
is resulted from the multiplied length (m), width (m) and height (m) of the finished
block. When expressed mathematically it is as

Length (m) x Width (m) x Height (m) gives 1m³ = 1m*1m*1m

Where, meter (m) is unit of measurement of length, width and height.

Having said this, the monthly plan of our site (Graniodiorite quarry) was to
produce a volume of 150m³ products; which in turn means 5m³ per day and 37.5m³

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per week. However, the actual monthly production rate in our site was about
113.73m³ per month (Feburary) which is accomplished by 75.82% effectively.
Although, the monthly production rate of our site Adi elen (source of graniodiorite
rock type) was good; some of the reasons that may reduced our productivity are:-

1. Difficulty to access the larger erected boulders (Geological constraints),

2. Electrical problems observed on all of the diamond wire sawing machines
(Small 25Hp and large 75Hp machines),
3. Both electrical and mechanical problems seen on loader, compressor and
generator,
4. And, another problems like deficit of supply on consumables (gasoline,
diamond wire, diamond wire connectors, rods, rubbers and others related to
quarry operation).

5.2 Running (operational) costs

It is know that any type of mining operation is costly and risky work, however
if it is managed properly the cost and risk could be minimized. Consequently, to
do this it is very important and critical to know about the cost and cost rising
materials (consumables). The costs that are expended in the quarry site to
produce dimensional stone blocks could be considered as operational costs.
Although, there are a number cost types, but broadly they are classified in to
two types. These, the most common are fixed costs and variable (running) costs.

Fixed costs are costs that may not vary within short period of time. Capital costs
are example of fixed costs, whereas operational costs are variable costs which vary
with time. Therefore, the costs which are resulted from daily activities of the
quarry operation are also called operational costs. Generally, the expenses of the
consumable materials of gasoline, oil, diamond wire, diamond wire connector
(joints), percussion drilling rods, rubber of fly wheel of diamond wire sawing

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machines and others are considered as operational (running) costs.

Impurity

Impurities are a mineral or rocks those associated with the marble deposit. Impurity in dichinama
marble is quartzite, calcite, schist, slate, phyllite

Advantage of impurity

 Increase the attractiveness of the marble

 To conduct geological environment

Disadvantage of impurity

 Affect the color

 Affect strength of the marble for example if the marble consist more amount of quartz the
marble will be hard but if consist calcite the marble deposit will be weak strength
 Make difficult our mining operation
 Increase our production cost
 Decrease the recovery rate of the marble

Having said this let me describe some of the factors that enforced us to increase
the operational costs. The most commonly seen cost optimizing activities are:-

 Unwanted transportations around the working area especially loader’s

movement.
 Improper utilization of diamond wire, joints, rods, rubbers and other
consumable materials.
 Resizing once processed and/or produced finished blocks (simply related
with re-working processes)
 Producing blocks with dominant defects (quality less blocks)

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 Random quarry front opening, this implies quarry front selection and
opening must require systematic selection based on the detail geological
and geotechnical studies.

However, to reduce the operational costs we should have to practice some of the
following activities:-

1. Reducing unwanted movements of loader and another transporting

Toyota car (double pickup).
2. Minimizing to cut in resizing processes or using smooth faces as cut
surface. Similarly trying to become accurate in drilling cases also may
save both the time and costs.
3. Adjusting the track of diamond wire machines and the block to cut two
faces simultaneously by reversing the fly wheel, this is because the fly
wheel of the diamond wire machines especially the Marini model
machines can work at any angle (0-360).
4. Serving the vertical and horizontal master joints as vertical and horizontal
holes to pass the diamond wire for vertical and horizontal cuttings.
5. Proper utilization of all the consumable materials.
6. Producing blocks with international standards and that perfectly fits with
the machineries standard found in the main processing plant (in our case
the factory found in Adwa).

Therefore, identifying and controlling the main factors that increases the
operational costs may help us to minimize the running costs in the quarry.

CHPTER SIX
PROCESSING PLANT OF DIMENSIONAL STONE
The processing plant is located in Adwa, Tigray and equipped with primary machines like one
marble Gang saw, one Marble block cutter, two Granite block cutters, one Terrazzo press
machine and different polishing and cutting machineries. In addition to processing natural blocks
of marble, limestone and granite an artificial block called Saba special made from marble chips,
sand and cement is also processed.

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6.1 MACHINES IN THE PROCESSING PLANT

6.1.1 Gantry Crane

The gantry crane is used to unload the block from the truckor car.

The squared block which comes from the granite quarry site is unloading by the Gantry
Crane Machine and placed in appropriate place. Unload the truck with the help of the
Gantry crane is the first process in this factory.

A mechanical lifting device that used for lifting heavy load.

The Gantry crane has 6 directional motions and its capacity of tonnage is 25 tons.

The carrying capacity of block carrying Trolley is 40 tons.

The gantry crane uses to load the block to the trolley in order to cut by the cutting machine.

Loading selected block in to the motorized trolley using gantry crane after getting order
from line leader.

Transferring loaded motorized trolley into the block cutters rail using transferring table.

Figure 6: Gantry Crane

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6.1.2 Transferring Table

Transfer table is used to transfer or move the slabs from the poly wire or gang saw to the next
process by the outside of the plant, which has its own remote control system uses to move or
stop.

The carrying capacity of this table is 30 tons.

Figure 7: Transferring Table

6.1.3 Over Head Crane
The operator should handle slabs or tiles during transportation from place to place with
limited height for safety so that the risk of damage on personnel, machine and material is
reduced.

Incase fractured slabs or tiles is transported, the operator should be cautious not to hurt
any personnel, machine and material.

The shift operator is responsible for any damage caused by any other personnel operating
these machines.

The over head crane has 6 directional motions and its capacity of tonnage is 5 tons.

The operator should give due attention not to cut the loading rope or string at the top
compartment.

Overhead cranes are used to transfer slab from place to place in the company.

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Figure 8: Over Head Crane

6.1.4 Arm Crane
Arm crane is a crane which uses to load slabs to the polish machine, longitudinal machine,
bridge cutter etc in the processing plant. There are eight arm cranes inside the processing plant.
These are at granite slab polish, marble slab polish, granitelongitudinal,
marblelongitudinal,bridge cutter etc. it rotates 180 degrees. In SDS arm crane loads 2 slabs if 3
cm thickness and 3 slabs if 2 cm thickness at the same time.

Arm crane is used to loading and picking different material.

Figure 9: Arm Crane

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6.12ENVIRONMENTAL AND SOCIAL IMPACTS

The scoping phase of any given ESIA process is aimed to identify those impacts that are most
likely to be significant and whichneed to be assessed as part of the ESIA process.Environmental
and social impact is theeffect of one company to the environment.

The following main receptor/resource types were identified.

Physical environment: including the atmosphere, soils, surface and groundwater.

Biological environment: including habitats, flora and fauna; both aquatic and terrestrial.

Infrastructure: including roads/tracks, water supplies and the built environment

(households, settlements and villages).

Land based livelihoods: including land ownership and crop cultivation.

Socio-economics: including tourism waged based employment, provision of goods, road

users, education and demographics.

Health: including sanitation, healthcare, health and well-being, safety and security.

Heritage: including physical archaeological and cultural sites and cultural events.

Most impact of Saba dimensional stone is on sound and dust emission to the environment.

Noise

Noise is the loud sound which disturbs to the environment.Saba dimensional stone factory has
high noise which disturbs to the workers and to the environment.

Dust

Dusts are very fine soils that makes dirty to the environment.Sabahas high dust emission when
the car moves and wind flow to the disposal area.So that it affects to the workers and peoples
who live around.

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6.13 MATERIL HANDLING

Materials handling means providing the right amount of the right material, in the right condition,
at the right place, at the right time, in the right position, in the right sequence, and for the right
cost, by using the right method(s).A material-handling system can be defined as movement,
handling, storage and controlling of materials throughout the manufacturing process. The main
purpose of using a material handling system is to ensure that the material in the right amount is
carefully delivered to the desired destination at the right time at minimum cost.An efficiently
designed material handling system ensures the reduction in operation cost, manufacturing cycle
time, MH cost, delay and damage.Material handling is a means by which manufacturing quality
is inventory and damage through improved handling. Finally, materialhandling is the means by
which any production strategy is executed.

Most of the material handling using in Saba Dimensional Stone is belt conveyor which is used in
the crusher plant, in terrazzo, and in slab polishing etc.

Belt Conveyor

A belt conveyor system is a common piece of mechanical handling equipment that moves
material from one location to another. During the project design stage for the transport of row
materials or finished products, the choice of the method must be favor the most cost effective
solution for the volume material moved; the plant and its maintenance; its flexibility for
adaptation and its ability to carry a variety of loads and even be over load at times.

The belts or ropes are used to transmit power from one shaft to another by means of pulleys
which rotate at the same speed or at different speeds. The amount of power transmitted depends
upon the following factors:

Roll Conveyor
Uses to transfer materials from one process to another. The material moves when the rollers
rotate. In Saba Dimensional Stone uses roll conveyor at titling, granite polish, tiles polish and
splitting lines.

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6.14 APPLICATIONS OF PRODUCT AND END USERS

Use of Products

The products are used for;

Flooring

External and internal wall cladding

Window and door sill

Skirting

Monuments

Counter table tops

Kitchen Cabinet

Table tops

Pool and Billiard table top Product samples

Main customers are

Contractors

Government agency

Private sectors

Government institutions

All sister company

Churches and residence complex

Guest Houses for local and foreign guests

Health centers

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CHAPTER SEVEN

SAFETYAND MAINTENANCE

7.1 SAFETY
Safety is the state of beingsafe. In the SDS processing plant they use different safety materials to
prevent any hazard or injure unless damage will be easily happened.

There are different safety materials and first aid medical safeties in the processing plant
of Saba dimensional stone to avoid any type of risk before happen.
Safety regulations

General safety rules the operator have to check before connecting the machine to power supply
are.

Checks that the moving parts of the machine are freely running.

Make sure there are not damaged machine parts and that all the components are
assembled correctly and working correctly. Qualified personnel must carry out any
adjustments or replacements.

Make sure that all the machines fixed guards are in place and secured with the relevant
screws.
During the working phase the field worker shall follow carefully the following instructions.

The field worker or operator shall

Follow carefully the instructions established by the company, especially by both

production and maintenance departments.

Use the safety devices properly and carefully, such as footwear and clothing .it is
forbidden to work in production area without wearing those safety devices provided by
the company. Every line leader and production supervisor should enforce to do so.

Inform immediately the line leader or shift production supervisor in charge of the
malfunctions of devices and means, as well as any other dangerous conditions, acting
directly, in order to remove or reduce these malfunctions or dangers.

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Keep the work place tidy. Untidiness in the work place increases the danger of fire.

Dress in suitable manner. The operator's clothing must be the most suitable, i.e. not too
loose and without parts that could flap and get caught. The sleeves must be elasticized.
Belts, rings and chain jewelers must not be worn. Wear safety footwear. Long hair shall
be tied with a ribbon or properly contained in a cap.

The field worker shall never:

Remove or modify, without being authorized, the safety devices, the signaling devices,
measurement and those individual or collection safety means.

Do not climb over the machine. It is strictly forbidden to put pathway or other structures
suitable to climb over the machine. It is moreover forbidden to climb on the belt or on
other machine fixed parts.

Never climb on the machine during its running .climb on the machine only when the
auxiliary circuit ignition keys have been removed from the machine control panel.

Never lean ladders or tools on the machine if the current is applied.

Never introduce foreign bodies. Do not introduce foreign bodies underneath the guard of
the electric motors and in to the machine part.

Safety materials

Safety for the head:

Wearing hat offers protection and can preventhead injuries. Saba Dimensional Stone uses
a hat instead of helmet to prevent from sun and dust.

Protect your eyes:

The eyes are the most complex and fragile part of our body. Thanks to a good pair of
safety glasses, these injuries could be prevented.They use safety for eye to protect from
dirty spraying water in the cutting process, dust, and ray in the maintenance department.

Hearing protection (Ear Muffs or Ear Plug)

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It is difficult to work in an environment with high sound level. In that case it is very
important to consider hearing protection. Earplugs are very comfortable, but earmuffs are
convenient on the work floor as you can quickly put these on or take them off.if we
cannot use this safety material ,our ear drum can be damaged.

Safety for hand with the right gloves

Hands and fingers are often injured, so it is vital to protect them properly. Depending on
the sector you work in, you can choose from gloves for different applications.

Protection against vibrations, protection against cuts by sharp materials, protection

against cold or heat, protection against bacteriological risks, protection against splashes
from diluted chemicals.

Safety for the feet

Even our feet need solid protection. Safety shoes and boots are the ideal solution to
protect the feet against sharp and heavy weight materials such as chips of the granite,
marble and limestone fall down.,
Wear the correct work Clothing (Gabon)

Preventing accidents is crucial in a crowded work shop. That is why a good visibility at
work is a must high visibility jacket and pants made of a strong fabric can help prevent
accidents.
Safety for the nose

Uses to protect our noses from dust or moisture inside the processing plant.

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Figure 38: Safety Materials

7.2MAINTENANCE
Saba dimensional stone uses two types of maintenance which are preventive maintenance which
is mostly used and corrective maintenance.

Preventive maintenance

Preventive maintenance (or preventive maintenance) is maintenance that is regularly performed

on a piece of equipment to lessen the likelihood of it failing. It is performed while the equipment
is still working so that it does not break down unexpectedly. Preventive maintenance (or
preventative maintenance) is basically a type of maintenance that is done at a regular interval
while the equipment is still functioning with the objective of preventing failure or reducing the
likelihood of failure. These screens help identify, schedule and allocate resources to critical
recurring maintenance tasks. The purpose of Preventive Maintenance is to get the best return for
money spent by prolonging equipment life and avoiding costly corrective and emergency repairs.
Preventive maintenance can be defined as “an equipment maintenance strategy based on
replacing, or restoring, an asset at a fixed interval regardless of its condition. Scheduled
restoration tasks and replacement tasks are examples of preventive maintenance tasks.Preventive

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maintenance can be time based i.e. every week, every month or every three months. But
preventive maintenance can also be based on usage.

Corrective maintenance

When we are conducting corrective maintenance the failure has now occurred and we are
basically reinstating equipment functionality. To be clear, corrective maintenance can be the
result of a deliberate run-to-failure strategy. This maintenance uses after failure occurs but a
preventive use before failure happens.

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CHAPTER EIGHT

CONCLUSION AND RECOMENDATION

8.1 CONCLUSION
Saba dimensional stones (SDS) plc is one of the members of the hosting company of EFFORT
(Endowment found for rehabilitation of Tigray) which is established in 1992G.C or 1985 E.C.

In the processing plant raw blocks are taken as an input to the production such as granite, marble
and limestone from different quarry sites.

The overall internship program was one step forward in the field of work that we were study.
The internship helped us to learn various practical skills. In our Internship we observe different
machines with respect to their working principle and operations accordingly.

We observe the working principle of processing plant machines such as gantry crane, block
cutters in slab form, block cutters in tiles form, polishing machines, longitudinal machines, cross
cutting machines, bridge cutters, trimming machines, splitting machines, dryer, bullnosing,
manual polish, and over head cranes in our internship program. We understand about how the
product is processed and delivered to the customer, the working principle of crusher and mixing
ratio to prepare terrazzo.

In SDS high amount of water is needed for the whole process and the waste water is recycled to
reduce water consumption by using decantation process.

The products are used for; Flooring, External and internal wall cladding, Window and door sill,
Counter table tops, Kitchen Cabinet, Table tops, Pool and Billiard table top Product samples.

The Main customers areContractors, Government agency, Private sectors, Government

institutions, All sister company, Churches and residence complex, Guest Houses for local and
foreign guests, Health centers. Generally, we have gained more skill about the overall processing
plant of Saba Dimensional Stone.

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8.2 RECOMENDATION
The process layout of the dimensional stone is not well designed. The machines are not
put based on their department. The flowis very complex. This takes more time and energy
and the granite, marble, and limestone chips are difficult to separate. We recommended
them to arrange the machines based on their department.

We strongly recommend you that to use a proper maintenance schedule and maintain
every broken material on time and are involvement and commitment for every action that
you` taken in daily activity to increase the production capacity of the company and
satisfied. So please use it wisely and properly because this machine is very important and
mandatory in this work area. Lastly we are ready to do again and modify it if you want to.
It is necessary in heavy duty and sites we think as some people said me that they really
need it. I strongly recommend you again that use properly and correctly the preventive
maintenance schedule.

The material handling system from inside of the factory to the storage area is labor based;
it takes more time, cost and energy. To minimize this time, cost and energy we
recommended them to use forklift machine.

The products from the crusher have not their own area to store, they are mixed. We
recommended them to build storage area separately.

The waste disposal area is no well designed, it is open dump. It has a dust disturbs to the
environment. We recommended them to construct engineered design disposal area.

We strongly recommended them to use well designed storage area or product layout to
become more suitable arrangement and to understand easily for customers.

In Saba dimensional stone there is no granite slab polish; the slab is cut in to tiles in
granite longitudinal before polishing.

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Question?

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