AKSUM UNIVERSITY SHIRE CAMPUS

DEPARTMENT OF MINING ENGINEERING

INTERNSHIP REPORT
ON
SABA DIMENSIONAL STONE PLC AT ADIELENI QUARRY SITE
SUBMITTED BY

S. N NAME ID NUMBER

1 GEBREWELD TESFAMARIAM 1001765

TAKELE

2 MAHDE ANDOM 1001665

3 TAHGUAS BRHE 09

SUBMITTED TO: 1, _Fethawi Berhe_ (Internship Guide)

2, Yemane Kide_ (Hade department of mining Eng.)

INTERNSHIP STARTEDATE: 6/02/2016 E.C INTERNSHIP END DATE:

27/05/2016
SHIRE, TIGRAY, ETHIOPIA

ii
 ACKNOWLEDGEMENT

First, we would like to thank, “Almighty God” who made it possible, to begin and finish this internship work
successfully. We express our appreciation to M.R Berekt G/silase (Aksum university shire campus school of
mines dean) and M.R Yemane Kide (mining engineering department head) for planning and organizing the
internship work. Then we go to thank to our advisor and guide M.R Fethawi Berhe for devoting his time and
efforts through contribution of his unlimited knowledge and important resources with his well approaches and
attitude to guide us during our internship report writing season. And we would like to thank our company
advisor Mr. Kibrom Welegebrel his voluntariness to give important information about the quarry site.
EXCUTIVE SUMMERY

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. The main inputs for the Saba
Dimensional stone are the raw block produced in different quarries and the Saba special produced in the
processing plant. , Saba dimensional stones private limited company has different types of
machineries and equipment’s 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 Electrial, Pneumatic, Hydraulic and Fuel (gasoline consuming)
machines.

4
TABLE OF CONTENT

5
LIST OF FIGURE

6
LIST OF TABLE

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

1. 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
syrmak, 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).

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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 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. But now there is not processing of granite and limestone. The only processes a little
extent in marble

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 GENERAL FEATURE OF THE COMPANY

1.2.1 Location and Access of Saba Dimensional Stone PLC and Adi Eleni
Granite Quarry Site

Saba Dimensional Stone PLC 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. Adi Eleni granite quarry site is one of the most recently
started (youngest) quarries of the company. It is open in 2004 E.C 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 Tigray, 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 21 km that connect Axum with Adi Eleni village passing through
Medebay Welel and Wukiro maray-Chilla towns.

1.2.2 Climate and Topographic conditions

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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 around the quarry is
covered with small and scattered vegetation’s and blocky graniodiorite boulder rocks.

Figure: 1 Adi eleni active granite quarry site

1.3 OBJECTIVE OF THE PROJECT

1.3.1 General Objective
 To build or to apply our theoretical knowledge into practical knowledge of the
dimensional stone mine activity.

 To assess the processing plant operation in order to develop practical skills

related to our profession.

1.3.2 Specific Objective

 To understand the working principle of the quarry and it’s machineries

 To understand about the waste disposal area and water treatment process in
the different activities

1.4 METHODOLOGY
1. Pre-field

 We gather information from our adviser

 Preparing the instrument which are need for during filed

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2. During field

 Taking photo
 Collecting data and basic information about the company
 Measure length, width & height of the deposit

 Primary data collection by direct observation and by formal interview or meeting

with managers at different level of the company and employers with in my section
that work during internship program.
 Secondary data collection from written material in the organization like report,
manuals and plans. And also, by referring some books, internet and handouts
related to granite mine as dimensional stone.

3. Post field

 After the conducting field work writing internship report

 Further reading for additional information

Material used

 Digital camera
 Writing equipment like pen, exercise book, paper …etc.
 Personal computer
 Measuring equipment (meter)
 prevalent data & reference

1.5 LIMITATION AND ASSESSMENT OF INTERNSHIP

During our internship there were some challenges those challenges are…

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

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  difficult to access transportation

 Lack of office to write some notes

1.5.1 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:
 By asking the workers and with concerned persons
1.5.2 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.

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CHAPTER TWO
2. Geology of Adi Eleni quarry site and its surroundings

In generally, the regional geology of northern part of Ethiopia, particularly of Tigray region
is covered by different lithologic units starting from the oldest basement Precambrian rocks
to the recent tertiary volcanic terrains. This comprises metavolcanics and met sediments
associated with the granitoids (intrusive/plutonic) rocks, Paleozoic rocks, Mesozoic rocks,
tertiary volcanic rocks and quaternary sediments. However, in the northern part of Ethiopia
(Tigray region) the metavolcanics are termed as tillite group, whereas the met sediments 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),

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 (Tigray) 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 the east by
the Daro Tekli mafic and ultramafic belts. It is occupied by thick succession (>3000m)

13
predominantly of fine grained metasedimentary rocks including phyllite, olitic schist and
recrystallized chert. Towards the western margin of the block non-carbonaceous, inter
bedded 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 Adi Elen quarry 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 has 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 THREE

3. MINE ACTIVITY OF THE STUDY AREA

3.1 Mining methods 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.

3.1.2 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.

3.1.3 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.

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 3.1.4 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 have positive impact in this particular mining stage. However, when the
density of the joints is 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.

3.1.5 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 expect to drill vertical
holes. However, if we have a massive deposit it mandatory to drill vertical holes.

3.1.6 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
The block sketched above shows the intersection point of vertical and horizontal drilled
holes.

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 3.1.7 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.

3.1.8 Horizontal primary cutting

In massive deposit and if there are 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.

Horizontally looped wire

Vertical
Vertical Drilled
Drilled hole
hole

Block diagram showing how horizontal cutting looks like.

Horizontal Drilled holes

3.1.9 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

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 Fig Block diagram which shows vertical primary cutting

Figure5, the machine seen on the photograph shows when it’s cutting vertically.

3.1.9 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;

18
 Pushing, pulling and lifting with the help of loader using its different accessories like one
finger, fork and rake,

 Pushing using hydro bag 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.

3.1.10 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.

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 dimension 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.

19
Figure 7, the photograph taken from the quarry shows when the processes of block squaring
are ongoing.

20
3.1.11 Stock yard and grading block
It is an area or place in which all the finished blocks are collecting in to one common place
nearest to the mine site. Beside 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 (square 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%,
 Must be compacted, fine grained or have well sorted grains,
2. B standard block (Grade B block): -
 Similarly, should fit to gang saw, poly wire and Pedrina machines,
 Free from diagonal fractures,,
 May have fine and course grained textures,
 May have color variations,
 Must have greater than 70% recovery rate,

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,
 Should have a recovery rate greater than 50%,
 Should be squared or symmetrical cuboids.

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Figure 8, labeled blocks accumulated in the stockyard

3.1.12 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 tone. 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.

23
Figure 10, Double axel trucks containing loaded block to transport it.

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 CHPTER FOUR
4. Mine machineries and Equipment’s
4.1 Quarry machineries
It is known that, there are different types of machineries and equipment’s manufactured for
quarry operational purposes. However, selection of machines and equipment’s 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 equipment’s 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.

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

25
Figure 2, Fuel consuming machineries; CAT type loader (left) and Atlas Copco type
compressor (right)

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.

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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.

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 consuming machine. Some examples of
pneumatic machines are spherical machines, drillers and grinders.

27
28
Figure 4, this is a type of pneumatic machine (spherical with double jack hammer)

4. Hydraulic machines: - Are small in quantity and specially designed machine types in
our site. Some example is 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.

29
Figure 5, this is bull machine when it pulls 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 type Quantity Machine Remarks

category status

01 Fuel Loader 01 Functional CAT

consuming
02 machines Toyota car 01 “

03 Mercedes - “ On/off
truck

04 Big generator 01 “ Perkins type

05 Small 01 “ Olympian
generator type

06 Atlas 01 “
compressor

07 Electrical Marini 02 “ Marini

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 machines diamond wire quarries
sawing group
machine
25HP

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

09 Benetti 01 “
machine

10 Water pump 02 “
motor

11 Hydro bag 01 “
plant
machine

11 Pneumatic Spherical 02 “ Marini

machines machines quarries
group

12 Driller 02 “ “
machine

13 Jack hammer 03 “ “

14 Grinder 02 “ To sharpen
drilling roads

15 Hydraulic Hand held 01 “ To press

machines pressing diamond wire
machine connector

16 Bull machine 01 “ To pull sliced

cut

TOTAL 24

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

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 4.2 Quarry equipment’s
There are various types of quarry equipment’s we use them in our day to day activities.
Equipment consists of machines or major tools necessary to complete a given task.
These equipment’s could be either consumable or non-consumable materials. The main
quarry equipment’s are listed and defined as follows

1. Water Level: Used to level the driller and the bench area
2. Sprit Level: Used to level and adjust the driller when drill horizontal
3. Water Hose: Used to transmit the water from the water tanker
4. Air Hose: Used to transmit air from compressor to the driller and jack hammer
5. Electrical Cable: Used to transmit electrical power from generator to the electrical
machine-like Pellegrini, Block cutter …etc.
6. Hammer: Used for pounding
7. Sprinkle: Used for digging
8. Hand saw: Used for cutting hard wood or metal.
9. Plug and Feather: Used to create gap and push the slice block(wedging)
10. Wrench: Used to divorce the driller
11. Chain: Used to rotate and tauten the driller machine
12. Diamond wire: A wire used to cut the marble
13. Jointer: Used to connect the diamond wire
14. Cutter: Used to cut the diamond wire
15. Drill bit: Rotary cutting used to make hole
16. Track: Used for setting moving the Bennett, Pellegrini and Block cutter machine
17. Control panel: Used to control electrical and pneumatic machine

18. Rod: Used to increase the length of drill

19. Rope: Used to see the tension and to measure the bench
20. Fly wheel: Used to rotate the diamond wire
21. Spacer: Used to level the block and used in bull machine to push the primary block
22. Rake: Used for failing dawn the primary slice block
23. Pocket: Used to excavate waste material

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24. One finger fork: Used for preparing the sliced block to cut by Bennett or Block cutter
25. Two finger forks: Used for loading the square block from the working bench to stock
yard.

CHAPTER FIVE

33
5. PRODUCTION RATE AND RUNNING COSTS

5.1 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 per week. However, the
actual monthly production rate in our site was about 113.73m³ per month (December) 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 reduce 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 problem like deficit of supply on consumables (gasoline, diamond wire,
diamond wire connectors, rods, rubbers and others related to quarry operation).

5.1.2 Reserve Potential calculation

Within only 1500 meters length in adi eleni site, we can calculate the reserve, by
taking 20m average width & 20m average depth
V= 1500m x 20 x 20 = 612,000 m3 granite

If we consider 67.5% recovery. due to recovery rate of Adi eleni is from 65-70 so, Take
the average of recovery.

Recoverable reserve= 612,000 m3 x 67.5 % = 413,000m3 of block can be extracted

from adi eleni site. By taking the current production capability = 1800 m3

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 Mine life= 413,000m3 / 1800 m3 = 230 years

5.2 Running (operational) costs

It is known 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 of
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 machines and others are considered as operational (running) costs.

 Some of the factors that enforced 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)
 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).

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 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
machinery’s 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 to minimize the running costs in the
quarry

CHPTER SIX

6. 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.

6.1 MACHINES IN THE PROCESSING PLANT

6.1.1 Gantry Crane

The gantry crane is used to unload the block from the mine truck or 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.

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 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

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.

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 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 overhead 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, granite longitudinal, marble
longitudinal, 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 which need to be assessed as part of the ESIA process.
Environmental and social impact is the effect 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. Saba has 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.

6.13 MATERIAL 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

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 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, material handling 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.

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,

Governmental institutions, all sister company, Churches and residence complex,
Guest Houses for local and foreign guests.

CHAPTER SEVEN

7. MINE SAFETYAND MAINTENANCE

7.1 SAFETY:

Safety is the state of being safe. 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:

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 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.
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

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Safety for the head:
Wearing hat offers protection and can prevent head 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)
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

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examples of preventive maintenance tasks. Preventive 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.

CHAPTER EIGHT

8. 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. But now marble is the only input of the
processing plant.

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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.

It is clearly known that the quarry site of Adi Elen which is the source of
graniodioritic (commonly called granite) dimension stone is found at near
distance about 40km from the main factory (processing plant in Adwa), has
huge geological deposit (~6.12*10˟⁵m³??), easily accessible and has suitable
working area which make it one of the most preferred quarries of the company.
Hence, the graniodioritic rock which are found in that particular quarry site are
exposed as massive and erected boulders (reach up to 40m height) but slightly
weathered; the average production recovery of this site is about 65-70%, which
has really a very good rate of productivity. In addition to this, the commitment,
willingness and team spirit of the employees found in this particular site is also
encouraged. Therefore, from these listed above point of views; it is possible to
conclude that the quarry site of Adi Eleni is a potential and economical site of
the company.
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 are Contractors, 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.

8.2RECOMMENDATION

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  In Adi Eleni quarry site there are some operational problems to solve this operational
problem we recommended that Mining Engineer expert is available to consult and
supervise each mining activities of the quarry.
 Equipment and machines should be modified and renewed. Because they are reduce
recovery of granite production in short period of time.
 Both sites have no properly designed waste disposal area and stock yards to get ride
off these problems the company should delineate and remarket the area of waste
disposal out of the deposit are found and prepare favorable stockyards.
 In Adi Eleni site there is no safety office and safety department as well as no
sufficient safety material so, the company have to prepare a new plan for Safety
Office and first aid with full materials and safety expert person.
 To publicize the production at national and international level the company should
be create their own website
 The processing plant layout of the dimensional stone is not well designed. The
machines are not put based on their department. The flow is very complex. This
takes more time and energy and the granite, and limestone chips are difficult to
separate. We recommended them to arrange the machines based on their department.

 We strongly recommend 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.

 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.

REFERENCE
1. MuftahAdem, 2016, Marble Limestone and Special Terrazzo, Research Paper, Adwa.

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2. MuftahAdem&AmhaAlemayohu, 2014, Detail Geological Study of Adi Eleni,
Research Paper, Adwa.
3. MuftahAdem, 2008, Detail Geological Mapping and Follow Up Study of The Eastern
Extension of Adi Eleni Granite, Research Paper, Adwa.
4. Hartman, H.L. 1987. Surface Mining: Method Comparison and Summary. In
Introductory Mining Engineering. New York: Wiley-Inter science.
5. Diamante Borat, 2004, Diamond Wire Cutting, Hand Book, New York
6. Sentayehu Zewdie,2008, Dimensional Stone in Ethiopia, Addis Ababa

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Ques

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