kenanaonline.comkenanaonline.com/files/0115/115604/geomining guide.pdf · geomining guide...

October 2001

G E O M I N I N G G U I D E

Edited by DPC – CKHC

Lyon – France

Table of contents


• 1 - Introduction 1

• 2 - Exploration and Characterization 3

• 3 - Reserves Estimation 19

• 4 - Mining Plans 27

• 5 - Mining Operations 37

• 6 - Raw Material and Raw Mix Audit 57

• Appendixes

I - Chemical Analysis 67

II - Raw Materials Doctrine 69

III - Variograms 73

IV - Safety Rules 83

V - Rehabilitation Guidelines 97


Introduction

1

The main objective of the Geomining Guide is to share

our knowledge and know-how in geology and in

mining in order to increase the plant performances

regarding raw materials and raw mix preparation.

The preparation of this guide was first initiated by the CTI

and CTS.The various chapters concerning Exploration and

Characterization, Reserves Estimation, Mining Plans,

Mining Operations, Raw Materials and Raw Mix Audit

were prepared by Guy Béland (CTI), Claude Bellehumeur

(CTS), Alain Beaudet (CTS), Robert Ethier (CTS), Evgueni

Porokhovoî (CTI), Sinan Urhan (CTI).These chapters were first

presented and discussed with participants from Technical

Centers,Technical Directions and some Operating Units at the

Geomining 98 Meeting in Istanbul. Remarks made by the

participants were taken into account and the first version

of the Geomining Guide was edited in January 2000 by

M. Niyazi Gundogdu (CTI) and J.-G. Levaque (CTS). Numerous

meetings were held with Y. Derreal (CTLC), L. Descombes

(CTLC),W. Grafl (CTEC),W. Gritz (CTEC) and K. Stadlober

(CTEC) in order to obtain the agreement of all the Technical

Centers.

The Geomining Guide therefore represents a synthesis of

our international culture in cement production. It is a common

tool for technical and operational people, which also contains

good practices for raw materials. It will help us to follow up

the development of the Group and will certainly evolve in the

future. For example, another chapter on raw mix preparation

will be added.


2

Acknowledgment

The CKHC wishes to express its thanks to all the participants

who have helped with the preparation of the Geomining

Guide, in particular M. Niyazi Gundogdu and Jean-Guy Levaque.

Exp

lora

tion

&C

hara

cteriza

tion

Exploration &

Characterization


Exploration

• All exploration work must be done at the beginning of a project inorder to get a proper regional picture.

• Exploration expenses must be considered as a capital investment.

➔ Exploration is done to ensure the long term viability of a cement

operation. So, a drilling program, designed for the long term, should be

capitalized over this long term period.

➔ Exploration expenses will then be amortized and spread out over a

longer period.

Regional Scale Exploration

• The first step must be based on the following information andrepresented in a synthesis map for potential strategic targets:

➔ Geological maps and reports

➔ Topographical maps

➔ Aerial photographs and satellite images if available

➔ Land use, forest, infrastructure and hydrogeological maps

➔ Summary of mining and environment laws.

• The second step, which might not be necessary in all cases, consists ofthe following actions:

➔ Geological mapping

➔ Surface sampling along the stratigraphical sections

➔ Drilling if needed and when possible

➔ Analysis and preliminary raw mix composition

➔ Estimation of potential reserves.

Exploration and Characterization

3


Local Scale Exploration

• The following documents must be obtained before any newexploration program, which is required prior to any new quarryopening.

➔ Exploration permit

➔ Topographic map with different property ownership, permits and

infrastructures (precision of 1/2000)

➔ Geological map larger than the property limits (precision of 1/2000)

➔ When no regulations exist, the following constraints should be used to

establish a drilling plan:

❿ Buffer zone of 100 m or larger if stated by regulation

❿ Hydrological map

❿ Structural map

❿ Environmental restrictions

❿ Overburden and waste evaluation.

Local Scale Exploration

• Before any new quarry opening, the following legal requirementsmust be fulfilled to start mining operations.

➔ Mining permits

➔ Land control

➔ Environmental Impact Assessment (EIA)

➔ Operational permit

➔ Other administrative authorizations.



4

Topography

• For topographic surveys, the recommended method is an aerialsurvey:

➔ Use the standardized UTM (Universal Transverse Mercator) System.

• For every topographic survey with a scale of 1/2000, the followinginformation is required to create the DTM (Digital Terrain Model):

➔ A 3D topographic data in the Autocad dwg format

➔ A data set including all the surveyed points as an Excel file.

• GPS (Global Positioning System) is the recommended field surveymethod when applicable or justifiable.

Geophysics

• Geophysics is used: ➔ When there is a need to forecast disruptive structures (fault, karsts, filled

or open cavities)

➔ And in order to avoid high drilling cost in some cases (thick overburden).

• Results may be deceiving in some cases.

• Pros and cons of different methods:➔ Seismic: good for thick overburden, but costly and difficult to calibrate.

➔ Electromagnetics: good for structural anomalies, low cost but can be

erratic.

➔ Resistivity: more precise but costly.


5


Drilling Plan

• Each deposit is unique and standards are therefore difficult todefine.

• The following documents are required before defining a drillingplan:

➔ Geological Map

➔ Structural Model of deposit.

• When geological information is not sufficient, a preliminaryexploration phase of minimum 5 deep holes covering the area (for example 4 at the corners and one in the center) is recommended:

➔ Evaluation of strike and dip of geological formations

➔ First evaluation of stratigraphy, structure and chemistry.

Drilling Plan

• When there is sufficient information, two cases may occur:➔ Simple Geology

❿ Sub-horizontal bedding, constant thickness of beds, relatively constant

geochemistry.

➔ Complex Geology

❿ Inclined, folded, faulted bedding, highly variable geochemistry.

• For simple geology, normally there is no need for a regular grid. Thedrilling plan should be designed for the necessary structural and geochemical information about the deposit to be obtained.



6

Drilling Plan

• For complex geology, a regular grid is necessary (ex. 100 x 100m). ➔ A regular grid makes it easier to assess the variability and, by reducing the tolerance

angle, gives more credibility to the calculation of variograms.

➔ 5 supplementary drill holes at short distances (e.g. 50 m) would allow the short

horizontal scale of variability to be assessed.

➔ The interpretation of the variogram will show either that the exploration grid is

sufficient for exploitation or that a closer spaced grid is required.

➔ It is a sound practice to establish a small scale grid size within the major directions of

the main grid.

➔ For sub-vertical lithologies, the inclined drilling with a denser grid is necessary to

obtain representative data.

➔ For sub-vertical deposits, a thickness equivalent to the height of the three benches

(30 – 50 m) should be drilled.

Drilling Methods

• Diamond Drill (DDH):➔ Is the only method to be used for the characterization of a deposit.

➔ Is expensive but provides invaluable information.

➔ Allows better recovery and proper samples for humidity testing.

➔ For holes longer than 15 m, wire line equipment should be used.

➔ Size NQ (4.76 cm) is required; this makes hydrological surveys, physical testing and

hole reduction, core storage and core manipulation easier.

➔ Larger size (10 cm) is necessary to obtain good recovery rates in the

limestone-clay intercalation and in the unconsolidated lithologies.

• Reverse Circulation (RC):➔ Is required when sampling soft or unconsolidated material.

➔ Reduces contamination if holes are cleaned after each drill run.

➔ Can be used to increase the density of information when economically and

technically justifiable.


7


Drilling Methods

• Percussion ➔ Blast holes:

❿ Can not be used for modeling.

❿ Can be used to update the short term mining plan.

❿ Vertical blast holes are not representative in vertical formations.

➔ Air Track:

❿ Overburden and waste definition (additional drilling over crests

and valleys).

❿ Testing of the geological model.

❿ Sampling of clay material from karsts.

❿ Drilling in unconsolidated material.

Drilling Methods

• Sampling with destructive drilling methods must be conducted withgreat care:

➔ Adapt a sampling device or an automatic sampler

➔ Once a certain depth has been reached

❿ STOP drilling

❿ CLEAN hole with air by moving the rods up and down

❿ MAKE sure that all the cuttings from an upper level reach

the surface in order to avoid contamination

❿ RECOVER all the fines.



8

Diamond Drilling Contract Items

• Location

• Type of drilling (Diamond Drill, Rotary, Reverse Circulation, diameter,etc.)

• Approximate length (total and each drilling +%xx)

• Type of drill machine required

• Inclination measurements

• Diameter of cores versus depth of formation

• Core recovery: 100% unless justified by geology (What to do if less?)

• Type of core boxes (Who shall provide and transport them?)

• Core logging, splitting and photography of core boxes (cores, holenumber and core length)


• Access to drill location (Who is in charge?)

• Drill hole landmarks before and after drilling (concrete), as well as in house surveying

• Definition of relation between Lafarge’s representative andcontractor

• Application of Lafarge safety rules

• Water supply and land reclamation (Who is in charge?)

• Justification of the use of other drilling fluids

• Drilling supervision by Lafarge Geologist (How and who?)

• Equipment and personnel insurance

• Define jobs to be paid per hour and their costs (waiting time andspecial works)

• Services to be provided by the company (Dozer, water truck…)


9



• Cost:➔ For overburden, waste and ore (cost/m for different lengths)

➔ For inclination test in case of inclined drilling

➔ For loss of equipment.

• Special Clauses:➔ Tests: Costs can be saved by combining hydrological tests with drilling like

pumping tests, installation of piezometer, which can be provided by the

drilling company.

➔ Down-the-hole Surveying Equipment: In some cases (karstic ground or

long inclined holes), down-the-hole surveying equipment should be

provided by the drilling company (inclinometer, camera, acid test).

➔ Cementation: In some cases, it can be useful to fill a cavity with cement

in order to drill deeper.

Core Logging

• Has to be performed by a geologist on clean cores.

• It is recommended that the same geologist does the core loggingand the geological interpretation.

• The lithologic description has to be made at two levels: ➔ The first level corresponds to the major lithologies.

➔ The second level represents local change or specific features (calcite or

quartz veins, change in bedding…).

• Sampling must correspond to the first level only.

• A standardized logging journal is given in the Appendices.



10

Core Sampling

• The geologist should define the sampling intervals based on thelogging in order to isolate lithologic units.

• For normal bench thickness, a sample should be 3.0 m or 10 feetwithin a given lithology.

• The first sample should begin at the rock/overburden interface,where a drill marker is normally present.

• A marker should be present every 3.00 m or 10 feet and shouldcorrespond to the beginning or end of a run or sample.

Core Sampling

• In special cases (e.g. large clay or quartz veins to be separated fromthe limestone bed…), sampling may correspond to the second level.

• When a vein or veinlets are at a low angle with the core axis, thegeologist must take half of the vein or veinlets in the split sample inorder to obtain a representative sample.

• The use of a sampling tag system, where all the samples areindicated, is strongly recommended.


11


Core Sampling

Core Sampling

• Once the sampling intervals are defined and core splitting is done,one half of the core is kept in the original core box and the otherhalf is used for analysis.

➔ Core splitter:

❿ Can be expensive (1 000 to 4 000 USD)

❿ Faster to split

❿ Sometimes difficult to produce half core.

➔ Saw:

❿ Variable in price (about 200 USD if using a hand electrical saw)

❿ Longer time to split

❿ Requires a fixed installation with water.



12

24,0

0,0

2,0

4,0

6,0

8,0

10,0

12,0

14,0

16,0

18,0

20,0

22,0

Sh

Cal

Sample# 1: 3.0 m

Sample# 2: 3.0 m

Sample# 4: 2.0 m

Sample# 6: 1.0 m

Sample# 8: 3.0 m

Sample# 10: 2.0 m

Sample# 3: 1.0 m

Sample# 5: 1.0 m

Sample# 7: 1.0 m

Sample# 9: 3.0 m

LMST

LMST

OVB

Sample Preparation

• Crush (Jaw Crusher) the split core samples at 100% passing a Nº 4sieve (1/4’’ or 6.35 mm).

• Split the crushed sample to obtain 400 grams.

• Keep the rest for other tests or analysis (grindability, burnability…).

• Dry overnight: ➔ 110°C for normal samples

➔ 45°C for samples containing gypsum and samples to be analyzed for SO3

related to sulfides

➔ No drying for samples containing hydrocarbons.

• Grind the sample down to 100 µm with disk pulverizer.

• Split into two replicates for assay and reference.

Chemical analysis

• The following elements are to be systematically analyzed for all theraw materials: SiO2, Al2O3, Fe2O3, CaO, MgO, LOI, SO3, K2O, Na2O,TiO2, P2O5, TOC, SO3 from sulphide and Chlorine.

• All the heavy metals in the raw materials and hydrocarbons inlimestone containing oil are also to be analyzed using somerepresentative samples.


13


Chemical Analysis

• For analysis of XRF, the fused bead method must be used. Details ofan analytical procedure are given in Appendix I.

• Proper geochemical standards for different raw materials, availablein Technical Centers, must be used to calibrate the XRF.

• Selection of other standards must be approved by Technical Centers.

• An analytical control using official standards must be conductedbefore any raw material analysis program and a regular cross-checkprocedure must be defined.

Geotechnical Studies

• The main purpose is to determine the physical characteristics of theraw materials during the first drilling campaign.

• This information is necessary in order to design an optimum slope inthe overburden and ore (cohesion, hydrology).

• Many of these parameters are necessary to optimize the blasting(Young Modulus, Poisson Ratio).

• Some parameters are necessary for the process (density, abrasivity,humidity).



14


• The main geotechnical studies are usually carried out bysubcontractors.

• Stability Characteristics: ➔ Safety Factor (S.F.)= resistance forces / moving forces

❿ S.F. < 1 = instability.

• S.F. is in relation with the following:❿ Slope geometry

❿ Mechanical characteristics of the rock mass

❿ Structures and discontinuities

❿ Mechanical characteristics of the matrix

❿ Weathering factors

❿ Hydrogeological factors.


• Geomechanical parameters at the deposit scale:➔ Parameters to be studied

❿ Joints orientation and geo-mechanical characteristics

(for each group)

❿ Average strike, average dip, extension, pattern, peak

friction angle.

➔ Work to be carried out

❿ Continuous survey of joints

❿ On the benches of the present quarry

❿ In the drill holes (if they were oriented)

❿ Sclerometry and Rugosimetry

❿ Statistical study of joints

❿ Photo analysis.


15



• Geomechanical parameters at the sample scale:➔ Parameters to be studied

❿ Compressive strength

❿ Tensile strength

❿ Density

❿ Cohesion

❿ Friction angle

❿ Young modulus

❿ Poisson coefficient.

➔ Tests to be carried out

❿ Compression tests

❿ Brazilian tests

❿ Shearing tests

❿ Ultrasonic dynamic tests

❿ Los Angeles test if limestone is used for agregates.

Hydrogeological Studies

• Hydrogeological parameters at the deposit scale:➔ Parameters to be studied

❿ Water table level and configuration

❿ Water output

❿ Hydrogeological characteristics of the deposit.


❿ Piezometric studies

❿ Pumping/injection tests.

• Hydrogeological parameters at the sample scale:➔ Parameters to be studied

❿ Total/effective porosity, Matrix humidity.


❿ Porosity measurement.



16

Specific Physical Parameters for Clinker Production

• The following parameters are mandatory for each raw material andraw mix and are determined by using the Standard Lafarge Methods:

➔ Raw Materials

❿ Free silica analysis (quantity and size distribution)

❿ Abrasivity

❿ Crushability

❿ Moisture content.

➔ Raw Mix

❿ Grindability

❿ Burnability.


17


Rese

rves

Estim

atio

n

ReservesEstimation


Definitions

• Raw material reserves are defined by two parameters: tonnage andchemistry.

• Each Operating Unit must define its proven, probable and potentialreserves.

• Long term reserves, according to the Lafarge Raw Materials Doctrine,include only proven and probable reserves and should be targetedfor fifty years.

• For the definition of proven, probable and potential reserves, see theLafarge Raw Materials Doctrine in Appendix II.

Geological Modelling

• This is the computerized representation of the interfaces delineatinggeological units.

➔ Geological units: Lithotypes and RockTypes

❿ Lithotype is a basic unit defining a certain lithological and chemical

homogeneity in a given stratigraphic interval.

Never use the same lithotype more than once along the stratigraphic

column, even if the same unit is repeated.

❿ Rock Type is a unit which can equal one or several lithotypes.

Grouping together the lithotypes that make up a bench can be useful for

estimation purposes.

Reserves Estimation

19


Geological Modelling

• Interfaces represent contacts along bedding or faults.➔ They are usually defined by planes in drill holes, geological map, in situ

geological measurements or other features.

➔ The interpolation methods to define the interfaces by a regular grid of

estimated coordinates (x,y,z) are triangulation or inverse square distance.

➔ The topographical surface is an interface separating air and soil.

• The geological model based on interfaces must be verified andunderstood before performing reserves estimation.

Reserves Calculation

• Consists of the following steps:➔ Sample Compositing

➔ Block Generation

➔ Block Chemistry Estimate

➔ Block Clinkerability Assessment if necessary.

Reserves Estimation


20

Sample Compositing

• Is the generation of samples from drill hole intervals (from-to valuesalong the drill hole).

• The composite samples can group several drill hole intervals andhave specific x, y, z coordinates and average chemistry.

• 5 types of compositing are possible (for definition see QMS Help):➔ Regular

➔ Original samples

➔ Minimum by rock type

➔ Minimum by hole

➔ Regular by rock type.

Sample Compositing

• The result of sample compositing can be checked and validated bystatistics:

➔ The mean characterizes the central tendency.

➔ The variance allows calculations of the standard error of estimation.

➔ Histograms detect outliers, represent the shape of a distribution and can

be used to define rock type.

• Depending on the results of the statistical analysis, it can be decidedto redo the compositing, exclude outliers and to define a newlithotype.

• It is important to explain the occurrence of anomalous valuesrandomly scattered in the deposit or related to a specific horizon.

Reserves Estimation

21


Sample Compositing

• The shape of a distribution and the variance are influenced by thesize of a sample. ➔ Long samples are less variable than short samples.

➔ Histograms are more symmetric (normal) for long samples.

Generation of Blocks

• This is done to estimate the geological reserves.

• Detailed estimation based on the smallest possible block is wrong:blocks that are too small give very similar chemistry because of thelack of true data coming from the drill hole.

• As a rule of thumb, when using a regular grid, the minimum blocksize should be greater than 1/4 of the average drill hole interval (e.g. minimum 50 m blocks for 200 m drilling interval).

• Along the vertical direction, minimum block size must not be smallerthan the average length of sample.

• Generally, the block thickness equals the rock type or benchthickness.

Reserves Estimation


22

35

30

25

20

15

10

5

0

0 2 4 6 8 10 12

15

10

5

0

0 2 4 6 8 10 12

MgO composited at 1,5 m

Freq

uen

cy

Freq

uen

cy

MgO composited at 3 m

Mean = 2.5

Var = 3.1

Mean = 2.5

Var = 5.8

Block Chemistry Estimate

• The trends and anisotropies in a complex deposit are identified byusing the variogram, which allows the following parameters to bedefined:

➔ Search ellipsoid

➔ Kriging weight

➔ Estimation variance.

• For details of variogram see Appendix III.


• Definition of Search Ellipsoid ➔ As a rule of thumb, the radius of the search ellipsoid is defined as

approximately the range of the variogram depending on the density of

the information.

➔ More importantly, it should reflect the anisotropy axes determined with

the variogram.

➔ If the density of samples is very high and the search elipsoid is well

defined, 15 to 20 samples are sufficient to perform the estimation of

a block (max = 30).

➔ If there is very short continuity (high nugget effect >70% of spatial

variation, short range):

❿ It is hazardous to define large ellipsoid especially if the variance is high

(s2/m > 1).

❿ The ellipsoid should be only slightly larger than the average drilling

distance.

Reserves Estimation

23



• There are two main methods of estimation: ➔ Kriging and Inverse Distance (for details see QMS Help).

• If the data is clustered (groups or drill holes):➔ Kriging should be used since this method automatically spreads the

influence among the samples in the cluster, avoiding its over-

representation.

➔ Inverse distance method can be used if a declustering procedure is used

(search by quadrants).


• If the variability along the vertical is much more important (shortrange and high sill) than along the horizontal, it would be better toperform kriging to properly weight the influence of these directions.

• If the data is not clustered, inverse distance methods will performalmost as well as ordinary kriging. However, estimation variance willnot be optimal.

• If a bench corresponds exactly to a given rock type, it is soundpractice to:

➔ Generate blocks with a thickness = rock type

➔ Composite samples to a length = rock type

➔ Estimate blocks with these long samples.

Reserves Estimation


24

Block Clinkerability Assessment

• Is the classification of the blocks according to their chemistry and thecomposition of available additives and targeted clinker.

• Allows reserves to be estimated in the case of complex andheterogeneous deposits.

Reserves Estimation

25


Min

ing

Pla

ns

MiningPlans


Long-term Mining Plan

• A long-term mining plan consists of the systematic development of aquarry, based on the whole of the proven and/or probable reserves.

• Geochemical, mineralogical and physical characteristics of reserves,topography and geology of deposit, property limits, mining rightsand methods, transportation and crushing system, reclamation planand cost, clinker quality and cost targets, production levels are themain parameters used to develop a long-term plan.

• Long-term mining plan is associated to long-term rehabilitation plan(for the rehabilitation guidelines, see Appendix V).


• The long-term mining plan includes the following: ➔ All existing features of the site such as:

❿ Topography, gates, fences, roads, drainage facilities.

➔ Buildings and other structures, vegetation areas, stockpile and storage

areas.

➔ Property or Mining leases and all Right-of-Way limits.

➔ Boundary of the mining zones and development sequence.

➔ Title information, such as:

❿ Key map, drawing title and number, scale reference, date of last revision.

➔ True north and magnetic arrow, and key.

Mining Plans

27



• When the total reserves are large enough, each quarry should have asystematic phasing or development sequence, which represents thestep-by-step development over the limit of the proven and/orprobable reserves (or the maximum life of the deposit if possible).

• Phasing should be based on the reserve distribution, the miningmethod used, the bench height, the waste to ore ratio, and thesurface topography.

• Phasing or development sequence has to be reviewed every 5 years.


• Each phase should include the following: ➔ Boundary of the mining zones.

➔ Property or Mining leases and all Right-of-Way limits and distances.

➔ All proposed new ramps including grades, width, cut and fill design.

➔ Bench limits, setback distance and wall slope.

➔ The specific location and size of proposed stockpiles of topsoil, subsoil

and overburden.

➔ Any proposed water diversions or storage, wash ponds and drainage

facilities on the site and points of discharge to surface water.

➔ The location, dimensions and design of existing and proposed earth

berms.

➔ The sequence and the direction of operation of the quarry, e.g. details of

stripping and stockpiles, lifts, and progressive rehabilitation.

➔ All existing features and title information.

➔ All potential environmental risks.

Mining Plans


28


• Standards and rule-of-thumb for quarry design:➔ Ramp or road design width

❿ For two way traffic the ramp or road should be no less than 4 times the

width of the widest haulage truck(s) at the quarry.

❿ This allows for two-way haulage truck traffic and room for an outside

berm and inside ditch for adequate drainage.

➔ Outside protective Berm ❿ The height of the berm should be at least the same as the radius of the

trucks’ tires.

❿ The berm should be made with “soft”material like overburden, or

crushed material.

❿ The use of heavy boulders is not recommended.


• Standards and rule-of-thumb for quarry design:➔ Acceptable road grade design ranges between 8 and 10%.

➔ A runaway ramp should be designed under specific conditions for any

road grade above 10% or for other dangerous situations at lower grade.

➔ Curves design should be constructed with the maximum radius

permissible under the conditions (at least 20 m), and they should be as

horizontal as possible.

❿ Superelevation of sharp curves increases tire life, and improves truck

handling and stability.

❿ Crowning improves drainage and the recommended roadway crown

should have a higher center and straight lateral slopes of 1:25 (width).

Mining Plans

29



• Standards and rule-of-thumb for quarry design:➔ In quarry design, the width of the safety bench is generally in the order

of 2/3 of the bench height.

➔ All pertinent information, such as a summary of reserves or waste and

overburden to be removed for each bench, ongoing reclamation and

techniques, should be shown in table note in each mine map.

➔ All control points (bench mark) should be located on each map produced

with the x, y, z coordinates.

➔ Surveying is needed throughout the whole process of quarrying

operation and site investigation or rehabilitation.


• Standards and rule-of-thumb for quarry design:➔ In quarry design, the final slope of any loose material is generally

recommended to be in the order of 3:1.

❿ This grade helps to achieve soil stability and to control landslides,

erosion and sedimentation.

❿ Irregular slopes make it easier to integrate the final landscape.

➔ The main rule in quarry design is to always comply with all country or

local laws applicable to the design, construction, operation, and

maintenance of dams, dikes, diversions, drainage channels, and

impoundment.

Mining Plans


30

Short-term Mining Plan

• A short-term mining plan consists of a small scale, detailed miningdevelopment of a quarry, according to the long-term mining plan.

• It covers a maximum period of 5 years.

• It is the basis for the yearly budget.

• It should be reviewed and updated when required.➔ For the clinker production greater than 2 millions tons per year, the

revision is yearly.

Short-term Mining Plan

• A short-term planning should include the following: ➔ Any proposed new ramps including grades, width, cut and fill design.

➔ Bench limits, setback distance and wall slope requirements.

➔ The specific location and size of proposed stockpiles of topsoil, subsoil

and overburden.

➔ Any proposed water diversions or storage, wash ponds and drainage

facilities on the site and points of discharge to surface waters.

➔ The location, dimension and design of existing and proposed earth

berms.

➔ The sequence and direction of operation of the quarry, e.g. details of

stripping and stockpiles lifts, and progressive rehabilitation.

➔ A table with the quantity of materials to extract, chemical or physical

targets, waste to ore ratio and cost development.

➔ All existing features and title information as stipulated in the long-term

plan.

➔ Any potential environmental risks.

Mining Plans

31


Software

• QMS:➔ In addition to long term reserves calculation, QMS is also used for long

term mine planning as well as short term planning.

➔ QMS is used in TCs with CORALIS software for long-term and short-term

mine planning.

➔ QMS is also used by TDs where there are enough staff sufficiently

experienced in geology and mining.

• MINECAD:➔ MineCad, insuring the optimization of raw materials and raw mixes,

allows the implementation of short-term planning.

➔ It is used in the Plants where there are competent quarry staff.

Mining Methods

• Simultaneous Slicing or Benching Method: ❿ Includes Backfilling, Opencast, Dragline and Cross Pit Conveyor

Methods.

• Successive Horizontal Benching Method (full width): ❿ Includes Bench Stopping and Hillside Quarry Methods.

• Nested Pit Method: ❿ Includes Successive and Cyclic Methods.

• Mixed Method: ❿ Includes Simultaneous and Successive Methods.

Mining Plans


32

Mining Methods

• Glory Hole and Rock Slides:➔ Can only be used for vertically homogeneous deposits.

➔ Are used in cases where the topography is steep.

➔ Allow transportation costs to be reduced.

➔ Glory hole is a combination of opencast with underground mining

system.

➔ Rock slides may create environmental problems due to dust.

• Underground Mining System: ➔ Different methods, conventional or mechanical, can be used depending

on geomechanical characteristics of the rocks and mining cost.

❿ Room and Pillar (recommended), Block caving, Sublevel Stoping,

Sublevel Caving, Vertical Crater Retreat, Shrinkage Stoping and

Cut & Fill.

Mining Methods

Simultaneous Slicing or Benching Method

Mining Plans

33


Overburden is stock-piled in the exploited part of deposit(dragline, round pit conveyor, cross pit conveyor…).

Overburden

Mineral

Mining Methods

Successive Horizontal Benching Method (full width)

Mining Methods

Nested Pit Method

Mining Plans


34

Cu

mu

lati

ve t

on

nag

e o

f O

verb

urd

en

Successive Horizontal Benching Method at flank

Cumulative tonnage of mineral

WasteWaste

Waste

Mining sequences:1&2; 3&4…Cumulative tonnage of mineral Cumulative

tonnage of mineral

Cum

ulat

ive

tonn

age

of w

asteC

umul

ativ

eto

nnag

e of

was

te

Waste Extraction

Working Slope

Mineral and intercalated waste extractionMineral

2 1

12

3

3

5

4

Han

ging

Wal

l

Foot

Wal

l

Mining Methods

Nested Pit Method

Mining Methods

Mixed Method

Mining Plans

35


Cyclic method

AB

CWorking Slope

Final Slope

Hanging Wall

Working SlopeFoot Wall

Min

ing

O

pera

tion

s

MiningOperations


Definition

• Mining operations include all mining activities from extraction to millinlet, (e.g. drilling & blasting, loading & hauling, crushing & sizing,stockpiling…), which take into account the plant requirements interms of quantity, quality, safety and cost.

• All activities need to be well managed in order to obtain an efficientsystem.

Mining Operations

37


PLANTREQUIREMENTS

PILING & RECLAIMING, PROPORTIONING

MINE DESIGN

DRILLING & BLASTING

LOADING & HANDLING

CRUSHING & SIZING

Each mining activity interrelates with

and impacts the others

Main Mining Activities

• Bench Design

• Drilling & Blasting

• Loading & Hauling

• Crushing & Sizing

• Equipment Management

• Safety

• Rehabilitation

Bench Design

• Factors affecting bench orientation:

➔ Dip and strike

➔ Fractures

➔ Geochemical variability orientation.

• Factors affecting bench height:

➔ Vertical variability ❿ In high variability cases, avoid high benches (> 10 m) in order to

control the geochemical variations better.❿ If the reclaiming of the pile is parallel to the front, the control of

variability may be better.However, in the case of a mobile crusherin the quarry, make sure that the crusher-front hauling is optimized.

➔ Level of Production

➔ Rod length of the drill rig❿ If possible, make bench heights multiples of drill rod length to

minimize the maneuver time.

Mining Operations


38

Bench Orientation

Quarry heading directions following the strike

Drilling & Blasting

• Main Drilling Objectives:

➔ Blast hole alignment

➔ Drill cost per meter drilled

➔ Representative sampling of cuttings Automatic sampling device is recommended.

• Main Blasting Objectives:

➔ Good fragmentation

➔ Good muck pile profile

➔ Good diggability

➔ Good overall quality and productivity versus drilling & blastingcosts

➔ No nuisance (e.g. ground and air vibrations, dust…)

➔ Good and well shaped quarry floor and faces.

Mining Operations

39


Reclaiming directionsStay in same bench as long as possible

In case of horizontal bedding In case of inclined bedding

Blast holes shall be on the line of the arrow

Drilling & Blasting

• Type of drilling:

➔ Top hammer (TH) in competent rock (for hole diameter from

76 to 150 mm and depth less than 15 m).

➔ Down-the-hole hammer (DTH) in soft, fragmented, karstic rock

(for hole diameter 150 - 200 mm and depth less than 30 m).

More air, so bigger air compressor is needed for DTH.

➔ Rotary drill (hole diameter > 200 mm and holes depth > 30 m).

• Bit and stem selection:

➔ This is related to the drillability of the rock and the air flow

required to remove the cuttings.

➔ Penetration rate is inversely proportional to hole section area

with the same power applied to the bit/stem arrangement.

Drilling & Blasting

• Factor affecting drilling efficiency:

➔ No diameter smaller than 4” or 102 mm because of ANFO(except justified cases).

➔ Drill holes shall be parallel with constant burden.

➔ Bottom of holes must be at the same level.

➔ Drill rig perpendicular to face.

➔ Drill rig leveled.

➔ Drill rig well set on hole position.

➔ Drill operator communicates rock properties (fracture, karst,water…) to blasting crew.

➔ Measure drill hole locations with tape (do not pace) and mark(e.g. with spray paint) before drilling.

Mining Operations


40

Drilling & Blasting

• Explosives:

➔ Dynamites, nitrate-fuels (ANFO), slurries, watergels, emulsions,heavy ANFO.

➔ Energy is expressed in calories per gram based on ANFO(Ammonium Nitrate with Fuel Oil is the reference at 100).

➔ Density is expressed in grams per cubic cm, and determines theweight of the loaded explosives.

➔ Use water resistant explosives in holes with non-evacuablewater.

• Detonators:

➔ The booster is a charge into which a detonator is inserted to initiate a primary charge.

➔ The primer is a booster armed with an initiating charge.

Mining Operations

41


22 - Drill cuttings pile23 - Stemming24 - Column explosive25 - Crest26 - Borehole collar27 - Bottom priming

Legend :1 - Bench height2 - Hole-to-crest3 - B = Burden4 - Borehole Coverage Area = S x B5 - S = Spacing6 - Hole Dia.7 - Back break

8 - New crest (After mucking) 9 - Rear row of boreholes10 - Side break11 - Intermediate row(s) of boreholes12 - Crest row of boreholes13 - Front burden14 - Bank angle

15 - Toe16 - Hole-to-toe17 - Subrilling18 - Exp. column height19 - Hole depth20 - Floor or final grade21 - Stem height

Mine Blast Pattern

2

7

3

4

5

9

8

13

15

14

12

6

11

1

16

17

20

21

22

23

24

25

1819

B S

26

10

27

Drilling & Blasting

Drilling & Blasting

• Factor affecting blasting efficiency:

➔ Rock properties❿�Young modulus❿�Poisson ratio❿�Compressive and tensile strength❿�Porosity.

➔ Explosive properties❿�Type (ANFO, emulsion, dynamite)❿�Velocity of detonation❿�Distribution in the column❿�Quantity❿�Delaying.

➔ Blast design❿�Hole diameter length and inclination❿�Pattern❿�Stemming length and material❿�Subdrilling.

Drilling & Blasting

• Geological factors influencing blasting efficiency:

➔ Structure ❿�In case beds are dipping, blasting rows must be parallel to the

strike.❿�In case of irregular faces or walls, the orientation of the first

row must be perpendicularly adjusted to the strike of beds orjoints.

❿�In all cases, the holes of the last row of the next blast should bemarked before blasting.

➔ Rock hardness❿�Hard rock requires the generation of many cracks, thus high

bore hole pressure, high velocity and energy.❿�Soft rock requires more gases and needs more than shock

energy for adequate fragmentation and displacement.

Mining Operations


42

Drilling & Blasting

• Blast Design (1):

➔ There is no magical formula to optimize blast design.

➔ The only way to optimize blast is by trials.❿�Choose hole diameter appropriate to bench height.❿�Start with:

– Square pattern (Space and burden in meters = 0.9 x holediameter in inches)

– Crushed stemming material (cleaned 20 mm stone)– Bottom initiation with Nonel (non electric detonetor)

depending on the local law– and delays:

• 17-25 ms between holes,• 42-50 ms between rows.

Drilling & Blasting

• Blast Design (2):❿�Evacuate water (if there is any) from the hole before loading

explosive.❿�Evaluate the last result:

– Vibration– Fragmentation– Muck pile profit– Back break– Video film each blast to evaluate when possible.

❿�Modify only one parameter at each trial until optimisation.❿�Environmental constraints can increase the number of holes

to be drilled per ton of rock blasted, thus limiting the tonnageincluded in any drill pattern.

Mining Operations

43


Drilling & Blasting

Muck Pile Profile Types

Drilling & Blasting

• Key Indicators for drilling and blasting efficiency:

➔ Energy factor (gr equivalent ANFO per ton)

➔ Fragmentation curve (distribution curve, swell factor)

➔ Productivity of drilling (m per ton of rock)

➔ Productivity of blasting (ton per blast)

➔ Optimized drill hole diameter (power at bit)

➔ Penetration rate

➔ Number of blasting incidents over time

➔ Number of new environmental complaints

➔ Total drilling cost (unit of cost per ton)

➔ Total blast cost, including secondary blasting or mechanicalbreaking of oversized boulders (unit of cost per ton)

➔ Vibration level in relation to permissible level.

Mining Operations


44

Hard to dig, poor fragmentation related toinsufficient interval between rows (<35 ms).

Hard to dig, moderate fragmentation, suitable for shovelexcavation related to short delay interval (35-50 ms) athigh benches. Good for quality control while reclaiming byloader in quarries with horizontal or inclined continuousbedding and suitable for loading at low benches (7-8 m).

Easier to dig, good fragmentation, suitable for loaderexcavation related to longer delay interval (>50 ms). Too much displacement may need bulldozer to prepare the muck pile for loading.

Little overbreak

Some overbreak

Tight,compact

Tight

Loose, spread out

Material thrown back onto benchExcessive backbreak

Loading & Hauling

• Main applications of loading equipment (1):

➔ Wheel Loaders❿�For frequent blasts❿�Multi face loading❿�Sorting and transporting boulders❿�Reclaiming ripped material❿�Polyvalent equipment in the quarry (assistance and aid)❿�Stock forming equipment❿�Needs good floor and lower face profile.

Loading & Hauling


➔ Hydraulic excavators (Back-hoe)❿�For important blasts (one face loading)❿�For extraction after weakening blast or direct extraction when

possible❿�Narrow and difficult working areas (2-4 m bench width is

enough for working)❿�Usable in loose underfooting areas❿�For selective mining (better quality control while loading)❿�For removing overburden (less effected by the surface

conditions).

Mining Operations

45


Loading & Hauling


➔ Hydraulic shovels❿�For important blasts (one face loading)❿�Possibility of direct extraction❿�Narrow and difficult working areas❿�Usable in loose underfooting areas❿�For hard materials❿�Cleaning working front (foot, faces)❿�Possibility of “drop ball”*❿�Good adaptation to all type of hauling equipment.

* “Drop ball”: a method of breaking big boulders of a blast by dropping

a steel ball onto the boulder.

Loading & Hauling

• Comparison of loading equipment:

Equipment Wheel Loader Hydraulic Excavator Hydraulic Shovel

Capacity 4-10 m3 2.5-6 m3 4-7 m3

Life time (hours) 10-15 000 10-20 000 15-20 000

Penetration force low (tires) 250-400 KN 350-550 KN

Cycle time (min.) 0.50 - 0.65 0.30 - 0.55 0.30 - 0.55

Bucket fill factor 0.90 - 1.15 0.90 -1.30 0.85 - 1.00

Operation cost (loading) moderate low high

Purchasing cost moderate low high

Mining Operations


46

Loading & Hauling

• Selection criteria for distance and slope for hauling equipment (1):

Equipment Distance Slope

Track dozer < 100 m < 20-25°

Wheel loader < 100 m < 10°

Scraper < 1000 m < 10-20°

Articulated truck ~ 1000 m < 20°

Rigid frame truck < 10 000 m < 8-10°

Wagon or rail car ~ 10 000 m < 6°

Loading & Hauling

• Selection criteria for hauling equipment (2):

➔ Truck dozer❿�Used when slope is important

Compared to horizontal, 20% production loss or gain for ± 10° slope

variation.

❿�Blade selection with regard to material properties must be done carefully

❿�Life time: 50 000 hours.

➔ Scrapers❿�For very bad road conditions (rolling resistance >10%)❿�For earthworks and non-consolidated rocks❿�High dead load❿�Not good for distances longer than 1 km❿�Life time: 15 000 hours.

Mining Operations

47


Loading & Hauling


➔ Wheel loaders❿�Difficult working conditions for the operator as well as for the

equipment.Compared to 2% rolling resistance, ~ 30% production loss at

8% rolling resistance.

❿�High tire cost.

➔ Belt conveyor❿�Especially for crushed stone❿�Low operation cost❿�High investment.

Best choice when road construction is difficult.

➔ Wagon or rail car❿�Needs loading equipment❿�Low operation cost❿�High investment cost.

Loading & Hauling


➔ Rigid Frame Truck❿�High payload (25-350 t)❿�For all type of rocks (robust and polyvalent tray)❿�Needs good underfooting and roads (rolling resistance < 6%)❿�Good working condition for operator (suspensions)❿�Life time: 40 000 hours.

➔ Articulated trucks❿�Limited payload (<40t)❿�For earth works (tray not well adapted for hard rocks)❿�For bad roads (rolling resistance > 6%) and difficult loading

and unloading zones❿�Good for small sites where road construction can not

be justified.❿�High maintenance cost❿�Life time: 10 000 hours.

Mining Operations


48

Loading & Hauling

• Matching factors for loading and hauling equipment:

➔ Bench height restriction and required flexibility

➔ Diggability and muck pile configuration

➔ Lift-dump height clearance

➔ Bucket fill factor

➔ Loading cycle time❿�Loader 3-5 passes, Excavator 3-7 passes.

➔ Floor condition and rolling resistance, road grade

➔ Travel distance

➔ Required crusher throughput

➔ Labor cost (hourly cost, shift structure…)

➔ Other costs (capital, fuel & oil, tires, parts & maintenance).

Loading & Hauling

Truck and loader spotting

Mining Operations

49


60°

120°

Front

Dumper

Wheel Loader

Loading & Hauling

• Key indicators for loading and hauling efficiency:

➔ Truck or bucket fill factor (%)

➔ Diggability (sec per cycle and t/h)

➔ Productivity (t/h)

➔ Fuel consumption (liter per hour)

➔ Tire consumption ($/km)

➔ Number of gear changes in cycle

➔ Fleet capacity versus requirement

➔ Total cost for loading and hauling (cost unit per ton).

Loading & Hauling

• Ancillary equipment:

➔ Track bulldozers are the most common, particularly foroverburden removal.

➔ Scrapers can be used for overburden or clay removal.

➔ Motor grader should be used to maintain roads.

➔ Water truck reduces dust and improves road maintenance.

Mining Operations


50

Loading & Hauling

• Roads and Underfooting:

➔ The quality of roads and underfooting is one of the parametersfor assessing the performances of mining operations.

➔ Roads and underfooting affect production and maintenancecosts.

❿�For 1 km road, about 10% production loss at 5% RR* compared to 3% RR.

❿�More tire and fuel consumption, etc.

* Rolling Resistance: force opposed by the road to the progression of thewheels of the hauling equipment.

Underfooting Rolling Resistance

Good, hard road 1.5 - 2.0

Dirty road, little maintenance 3.0 - 5.0

Dirty road, soft under footing 6.0 - 8.0

Loose sand or gravel 10.0

Dirty road, soft under travel, no maintenance, muddy 11.0 - 20.0

Loading & Hauling

• Hauling Road Maintenance:

➔ Water truck should wet roads lightly and frequently becausewet tires are more prone to cut.

➔ Roads should be maintained by graders not only to clear debrisbut also to ensure drainage and level. The loader can also dothis in small quarries.

➔ Rolling Resistance, being an important factor in cycle time,should be minimized.

➔ Haul roads include loading and dumping areas.

➔ The width of haul roads has to be adapted to truck traffic. Inthe case of two way haul roads, 4 X width of truck.

➔ All road slopes must be regular and adapted to the truck’scharacteristics.

Mining Operations

51


Crushing and Sizing

• Factors affecting crushing & sizing efficiency:

➔ Feed area must always be kept clean.

➔ Wear patterns need to be reviewed frequently along with setpoints.

➔ Feeders and their crushers should be interlocked.

➔ Feed should be adjusted to sized materials for vibrating step-type grizzlies.

➔ The required raw mill power (kWh) is affected by particle sizedistribution.

➔ Screens should be sized to 133% the required capacity.

➔ Screens should be specified for wet or dry applications.

➔ Feed must be evenly spread across the screen.

➔ Bed depth should not exceed 4x the deck opening.

Crushing and Sizing

• Crushing equipment:Rock Output Crushing properties Characteristics equipmentSticky Compaction may choke device at exit Toothed Double RollMoist for Hammer, Impact and Jaw crushers Toothed Single Roll

Hard rock For close size distribution Jaw (double toggle)(watch for slabbing) Jaw or GyratoryAbrasive rock ImpactFor cubical shape output and high Vertical Shaft Impactcapacity (watch for abrasionFor high capacity, less wear but less reduction ratio

Soft rock Compact in shape, high capacity ➔ Jaw (single toggle)High output, max fines ➔ ImpactClose distribution ➔ HammerCompact in shape ➔ RollFor friable rocks ➔ Vertical Shaft Impact

Mining Operations


52

Crushing and Sizing

• Crushing equipment:

Operation Max Feed Reduction Typical Power (HP) CostSize (mm) ratio equipment For 400-600 tph (x 1000 US$)

Primary 500-1500 3-4 Gyratory 150-250 250-350crushing 2-3 Jaw 175-300 250-350

4-7 Impact (double rotor) 300-400 200-4005-10 Hammer 700-1100 400-5005-10 Toothed Roller 150-400 350-8003-10 Vertical Shaft

Impactor

Secondary 50-500 5-10 Gyratory 100-200crushing Cone 200-300 250-400

Impact (double rotor) 300-500HammerRoller

Crushing and Sizing

• Key indicators for crushing & sizing efficiency:

➔ Throughput (t/h)

➔ Size distribution curve

➔ Power consumption (kWh per crushed ton)

➔ Re-circulation rate (t/h)

➔ Dust suppression efficiency

➔ Total crushing cost.

Mining Operations

53


Equipment Management

• Has a great impact on mining costs and therefore can not beneglected.

• The purpose of equipment management is:

➔ To choose the most suitable equipment for the required work

➔ To lengthen equipment life

➔ To minimize downtime

➔ To control service intervals

➔ To improve re-sale value.


• New equipment choice parameters:

➔ Justification of replacement (EVA…)

➔ Compatibility with mining methods and raw materialscharacteristics

➔ Type of machine❿�Best operating cost❿�Preventive maintenance requirements and cost❿�Cost-effective repair strategy and after-sale service❿�Equipment and components life expectancy❿�Re-sale value

➔ Benchmarking

➔ Training and implication of operators.

Mining Operations


54


• Preventive maintenance recommends tasks and intervals to help toplan downtime and prevents unexpected failures.

➔ Systematic oil sampling provides analysis of oil contaminantsand trends to identify problem areas.

➔ Inspections and performance evaluation, often done by theequipment operator on a checklist, help to identify potentialproblems and to make some small repairs.

➔ Customized operator training can be a key factor in reducing oreliminating operator error.

➔ A well kept schedule should be followed to ensure timelyrepairs.

➔ A close cooperation between maintenance and operationpeople is required for preventive maintenance.

➔ Record keeping provides a history to optimize preventivemaintenance scheduling, predicts maintenance costs forequipment, and helps select new equipment.

Safety

• Proper safety performance is based on team work and goodcommunication.

• Each quarry must have safety regulations. The following are justgiven as an example. See Appendix IV for detailed safety rules which are applicable in all quarries.

➔ Housekeeping in the quarry➔ Posted safety policy and rules➔ Clean operator cabins➔ Posted emergency procedures and phone numbers➔ Regular meetings of Safety Operators➔ Proper road signs and speed limits placed at key areas➔ “Danger” or “No Trespassing” signs to prevent unauthorized

entry➔ Back-up signals on all mobile equipment➔ Working safety guards where required➔ Personal safety equipment like hard hats, steel-toe boots,

safety glasses.

Mining Operations

55


Raw

Mate

rial

Raw

Mix

Au

dit

Raw MaterialRaw Mix Audit


Introduction

• Audit’s objective

• Plant Characteristics:

➔ Process type

➔ Main equipment

➔ Clinker types and capacity.

• Competitors on the same market

Location

• Geographic location of plant and quarries (illustrated on a map).

• Description of the local transportation system (into the plant,between plant and deposits, around the deposits…).

• Description of the plant and quarries neighborhood (villages, otherinhabited areas, springs, places of worship, cemeteries, historicalmonuments, natural parks, other industrial sites…).

• Geomorphologic description (landscape, relief, surface waters…).

• Regional climatic conditions.

Raw Materials & Raw Mix Audit

57


Regional Geology

• Stratigraphy and lithology with a focus on present and potential rawmaterial sources (illustrated on a geological map and stratigraphicalcolumn).

• Regional tectonic, seismicity and volcanism.

• Regional hydrogeological conditions.

Legal Aspect

• Status of cement raw materials in the mining legislation.

• Land control (for the plant and deposits):

➔ Private properties

➔ Leased lands

➔ Other (depth restriction…).

• Required legal permits (delivered by…, expiration date):

➔ Exploration license

➔ Mining license(s)

➔ Operating license

➔ Other permits (explosives use, public roads use, watermanagement…).

• Type and amount of taxes for the land and underground use.

• Other data relating to the local regulation.



58

The following points, up to “Raw Mix”should be applied separately to each of the raw materials.

Geological Characteristics

• Existing data:

➔ Geological and topographical maps (1:2000 or 1:5000)

➔ Aerial photo frequency, precision of topographical restitution

➔ Geological reports, drill holes, analyses…

• Detailed geological description of the deposit (raw materials,overburden, karst…).

• Local hydrogeology (surface and underground water).

• Local geotechnical problems (slope instabilities, land-slides…).


59


Reserves

• Reserves tonnage and chemistry (according to official local data):

➔ Proven and probable reserves including their calculationmethods and equivalent in clinker.

• Geological or potential reserves:

➔ Horizontal and vertical extension of the deposit under-mining

➔ Other potential deposits.

• Possibility of acquiring more land to increase reserves and to supportthe environment strategy.

Quality

• Geochemical characteristics of the extracted raw material fromdrilling and sampling programs as well from quarry assaying.

➔ Variability ❿�For each of the major oxides, the average and standard

deviation from both the drilling program and the quarryassays should be given

❿�Analyses of the major oxides and LOI including SO3, alkalis,Cl, P205, pyrite and free quartz

❿�Some samples from deposit can be collected to checkgeochemistry.

➔ Physical characteristics❿�Density❿�Moisture (seasonal variations)❿�Compression and tensile strength.



60

Mining

• Description of the long and short-term mining plan as well as themining method.

• Geometric parameters of the quarry:

➔ Reasons for the orientation of mining fronts

➔ Bench height and general appearance

➔ Floors and haulways conditions

➔ Safety benches and berms protection.

• Extraction mode: Conventional (Drill & Blast) or Mechanical (Ripping…).

• Mobile equipment:

➔ General appearance, type & number, capacity (m/h anddiameter for drill, m3 and hp for others), availability, mainconcerns should be given for each of the following:

❿�Drill, excavator, loader, truck, bulldozer, grader and other mainservice equipment.

• If quarry is sub-contracted, specify general conditions of contract.

Mining

• Drilling:➔ General position of the drill: perpendicular to the bench,

leveled, positioning on hole location➔ Advance of drilling with respect to blasting.

• Blasting:➔ Geometric parameters (number of rows, hole per row, hole

layout, hole diameter, burden, spacing, sub-drilling, inclination,stemming…)

➔ Grid type (square, rectangular or staggered) ➔ Explosive types and characteristics➔ Column load description and stemming material➔ Initiation and detonator types➔ Firing sequence➔ Consumption of explosives per ton of blasted material➔ Quantity of oversize blocks and cost ratio (cost of oversize/total

blasting cost)➔ Average blasted tonnage➔ Suitability of the blasted rock to the crusher type➔ Safety measures.


61


Mining

• Loading:

➔ Loading efficiency ( bucket fill factor, cycle time, waiting time,ease of loading equipment to dig into blasted rock)

➔ Cleanness of the operation

➔ Blending done by the loading if required

➔ Safety of the operation.

• Hauling:

➔ Hauling efficiency ( dumper fill factor, cycle time, waiting time,rock spills at loading and on roads)

➔ Bunching

➔ Matching of the trucks with the loading and crushingequipment

➔ The conditions of the haulways (Drainage, crown, curves,wetting…)

➔ Safety of the operation.

Mining

• Crushing:

➔ Type of crusher

➔ Year of construction and general state

➔ Feed size distribution

➔ Type of feeding mechanism and its capacity

➔ Designed and effective production rates

➔ Main crushing related problems

➔ Type of circuits (open or closed)

➔ Re-circulation rate

➔ Suitability of conveying systems

➔ Reliability

➔ Types of screens and their efficiency (when applicable)

➔ Heave and throw of screens

➔ Safety measures around the crusher.



62

Mining

• Cost ($/t):

➔ Blasted material

➔ Delivered material at crusher

➔ Sub-contracted work (when applicable)

➔ Crushed material

➔ Total cost of material delivered to raw mill.

• Staff:

➔ Quarry staff and organization

➔ Capability of staff to control contractors.

Environment

• Nuisances:

➔ Ground and air vibration

➔ Dust

➔ Surface and ground water outlet control

➔ Visual impact

➔ Buffer zone.

• Environmental Impact Assessment (EIA) report if available.

• On-going and final reclamation plans.

• Emergency plan.

• Access restriction measures to the quarry.

• Main problem related to environmental protection.


63


Raw-mix

• Description of raw mix line including comments:

➔ Raw material stocks

➔ Prehomo or blending tanks

➔ Bins and feeders

➔ Homogenization.

• Origin, composition, regularity and cost of raw mix additives.

• Current raw-mix composition and analyses (monthly mean values andstandard deviation for 1-2 last years):

➔ Chemical composition

➔ Fineness

➔ Moisture

➔ Raw-mix and clinker uniformity.

• Potential improvement of raw-mix composition and logic.

• Some samples can be collected for each type of raw material, rawmeal and clinker.

Quality Control

• Description of control logic:

➔ Sampling points and type (automatic, manual)

➔ Sampling methods (automatic, manual)

➔ Sampling frequency

➔ Analysis frequency

➔ Analyzed parameters

➔ Corrective actions (manual or automatic, software…).

• Description of laboratory equipment for chemical analysis(equipment type, analytical methods).

• Description of data processing software.



64

Conclusions

• Legal aspect

• Geological characteristics

• Reserves and quality

• Mining plan

• Mining equipment

• Mining cost

• Environment

• Raw-mix

• Quality control


65


Chemical Analysis

Appendix I


Chemical Analysis

• LOI determination for high-calcium or dolomitic limestone:

➔ Dry at 110°C overnight

➔ A pre-loss at 750° C for 1 hour is performed on the sample so asto prevent loosing material from effervescent de-carbonation

➔ Then ignition for 1 hour at 1000°C.

• LOI determination for other raw materials:

➔ Dry overnight❿�110°C for normal samples❿�45°C for samples containing gypsum and samples to be analyzed

for SO3 related to sulfides

➔ Ignition for 2 hours at 1000°C.

Chemical Analysis

• Preparation of fused beads (method used at CTS):➔ Pulverize the ignited sample to 100% passing the 300 µm in

order to crush the lumps (mortar and pestle).➔ The ignited sample 1.0000 +/- 0.0003 is combined with 6.5000

+/- 0.0003 g of lithium tetraborate (anyhdrous) in a small jar.➔ A glass Leco spoon (0.3g) with lithium nitrate as a fluidity and

oxidizing agent is added.➔ The above mixture is transferred (carefully and completely) to

a clean crucible and blended with a clean Teflon stirring rod for 1 minute.

➔ Two drops of Lithium Bromide solution as an anti-wetting agentis added to the crucible.

➔ The Claisse Fluxers Bis are used to fuse the mixture by heatingProgram 1 to 1050°C for 20 minutes and to pour out fusedliquid into a polished mold.

• A glass bead is ready to be analyzed by the XRF after the coolingperiod.

Chemical Analysis

67


Lafarge Raw Materials

Doctrine

Appendix II


Lafarge Raw Materials Doctrine

69


Reserves

Raw MaterialsCement plants belong to heavy industry, and as such,are built to last. Therefore, they must own or havecontrol over substantial reserves of raw materials.

Each operating unit must have a policy concerning the acquisitionand preservation of its reserves of raw materials (limestone, marl,clay, sand…).

• The raw material reserves of a cement plant represent a major competitive asset in terms of their location, quantity and quality.

• In order to assure long plant life and prepare for the future, each Operating Unit must ensure it has adequate reserves for:

– plants currently in operation,– plants projected for the relatively near future,– long-term projects to assure growth, restructuring or strategic

positioning,– the anticipation or prevention of potential projects undertaken by

competitors.

• The exploration for deposits must be based on rigorous geological in-vestigations and conducted as discreetly as possible.

• Each Operating Unit will define with its Technical Center, its “proven,probable and potential” reserves in terms of years of clinker produc-tion at current plant rated capacity (CKHC # 0005).The target is fiftyyears of proven and probable reserves for the existing plants (exceptjustifiable cases such as use of secondary raw materials) and for newprojects.

• The proven reserves must guaranty a supply of at least ten years.



70

Management And Preservation of Mining Operations

• For each deposit, Operating Units must establish a long term plan for ob-taining or extending of mining rights, land control and administrative per-mits.This plan will contain for all areas impacted by the long term miningplan including buffer zones; the following information:

– property limits,– expiry dates of mining permits,– tonnage and chemistry of reserves,– characteristics of the deposits and their environmental constraints,– action plans and necessary budget.

• For each deposit Operating Units must establish a long-term plan for min-ing, based on geological investigations and the following issues:

– long-term optimization,– economic objectives of mining,– environmental protection.

This plan,periodically updated,will be carried out using the best tools available,in particular deposit modeling techniques.The Operating Unit is responsible forimplementing these plans.

Each Operating Unit will also implement and maintain a policy of protectionand preservation for deposits which are being mined.This policy will require:

– protecting the environment and maintaining close relations with all con-cerned (government, local officials, neighborhoods, etc.),

– creation and preservation of buffer zones around operating areas,– rehabilitation in harmony with the neighboring landscape,– continuous research for improvement in environmental protection

(i.e. vibration, noise, dust, visual aspect…),– prohibition of the storage or burial of materials or waste in the quarry

which may pollute the ground water or create other risks,– mining operations respecting internal and external safety rules,– a professional supervision of mining operations by plant staff.

Reserves of raw materials must be certified byTechnical Centers and classified as follows:


71


Definitions

Proven ReservesReserves in fully controlled land for which we have the mining rightsand the necessary administrative permits for mining operations.

– They have been evaluated on the basis of representative coredrilling and reliable geochemical analyses.

– The revision of the short term mining plan is based on these re-serves.

Probable ReservesReserves in fully controlled land for which we have the mining rights,but the necessary administrative permits for mining operations may beincomplete, or reserves in incompletely controlled land for which wehave the mining rights and the necessary administrative permits formining operations.

– They have been evaluated on the basis of representative coredrilling, or equivalent, and reliable geochemical analyses.

– The long term mining plan includes these reserves.

Potential ReservesReserves in a land which is uncontrolled, but recognized as potentiallyminiable after obtaining the necessary permits.

– The necessary geological investigations are not fully carried outto ensure their quantity, quality and miniability.

– Their technical and economical feasibility is uncertain.

– These reserves have the same value for a competitor as for La-farge.

ReferencesRelated practices can be found in Geomining Guide.

Variograms

Appendix III


Absolute Variogram

• γ (h) = 1/2N Σ (xi - xi+h)2

N: number of pairs xi, xi+h

xi, xi+h: values of the variable of interest at locations i and i + h, separated by

the distance h

• This is the most common type of variogram, which must be used todefine Kiriging parameters.

Relative and Logarithmic Variograms

• Can be useful for detecting spatial structures when:

➔ There are anomalous high values

➔ Positively skewed distribution

➔ Relative Variogram

➔ γ (h) = 1/2N Σ [ (xi - xi+h)2 / m2](division by a local mean squared)

➔ Relative variograms are resistant to outliers (isolated highvalues) when applied to positively skewed distributions(asymmetrical distribution with a tail of high values).

• Logarithmic Variogram:

➔ Use the logarithm of values

➔ Do not use logarithms to perform estimations as it iscomplicated to back transform an estimated logarithm to theoriginal variable.

Variograms

73


Power of Differences

• Exponent 2 is the standard value for the absolute variogram (squareddifferences between values separated by a vector h).

• Exponent 1 can be used to underline particular features of the spatialstructure.

➔ Efficient to detail long scale structures (range and anisotropy),but should not be used to model nugget effect. However, kriging should be done with standard variogramcalculations (power of 2).

Search Angle

• Horizontal Angle:

➔ Azimuth measured in degrees clockwise from north (0° = north).

• Vertical Angle:

➔ Dip measured in negative degrees down from horizontal (0° = horizontal).

➔ These angles must be chosen according to the sampling anddrilling patterns (could require many angles, not necessarily at90º). Also consider the strike, the dip and the intermediatedirection.

Variograms


74

Tolerance Angle

• Aperture angle of a cone centered on the azimuth and dip.

• Any pairs of points falling within the cone is used for variogramcalculation.

• For variograms along the holes, the tolerance angle can be smallbecause data is collected on a regular grid.

• For variograms along the holes (in the plane of the strata), thetolerance angles are determined by trial and error. The number ofpairs and spatial continuity are the main criteria for determining theproper angle.

• A directional tolerance of 180° corresponds to an omnidirectionalvariogram (the direction of h is neglected, and only the magnitude of h is considered).

• The omni-directional variogram should be used when the drillingpattern does not allow for a sufficient number of pairs.

Slicing along X, Y or Z

• Always apply slicing along Z to limit the search for pairs of samples to more specific stratigraphic horizons (for horizontal deposit).

• This means pairs from the same stratigraphic horizons can becompared.

• If the deposit is inclined, apply slicing along the direction of thestrata, and try to reduce the tolerance as much as possible alongother directions.

Variograms

75


Estimation: weights according to distances

Section View: horizontal layer

Variograms


76

d1<d2<d3but sample #3 should have a moreimportant weight than sample #2

Point to be estimated

Section View: inclined layer

Maximum Number of Steps

• Number of steps x Step length = total distance for which thevariogram is calculated

Step Length (basic unit distance)

• Average distance between holes

• Distance between samples (length of composite)

Variograms

77


Step Length

• Anisotropic sampling pattern => the step length must depend on thedirection.

➔ Sample spacing along the hole is much smaller than samplespacing between holes.

• Clustered drilling pattern => several step lengths.

Distance of Reliability

• The distance of reliability can depend on the direction (if the studyarea is rectangular).

• Set to one-half the length of the area to insure that the vector h andincrements xi - xi+h characterize the whole study area, and not onlythe edge points.

Step Length

Variograms


78

Variogram Modeling

• Variogram model specifications are required for:

➔ ESTIME, to compute confidence intervals for inverse distancemethod

➔ KRIGE to perform ordinary kriging to estimate unknown valuesand to calculate kriging variance.

• Nugget effect: Intercept at the origin (h=0), which represents thenoise in the data (short spatial scale):

➔ Usually defined from the variogram along the hole, or fromclose pairs of holes

➔ The nugget effect is the same for each direction.

Variogram Modeling

• The spherical model is the most commonly used variogram model:

➔ It can describe almost all practical cases of the cement industry.

➔ It reaches a sill at a distance referred to as “the range”.

➔ The distance for which the data are no longer correlated.

• The Linear and Exponential models could also be used.

• The Exponential model is similar to the Spherical model, but risesmore steeply near the origin

• The Gaussian model, used to model extremely continuousphenomena, is not very useful for mining applications.

Variograms

79


Variogram Models

Variogram Components

Variograms


80

1.50

1.25

1.00

0.75

0.50

0.25

0.00

0 50 100 150 200 300250

Distance (h)

Distance (h)

(h)

(h)

1.50

1.25

1.00

0.75

0.50

0.25

0.00

0 50 100 150 200 300250

Range

C1, sill

C0, nugget effect

Sph

Exp

Gaus

Calculation and Modeling Strategy

• Calculate directional variograms for various directions and theomnidirectional variogram.

➔ Geology and drilling pattern give important indications.

• Verify the criteria N(h) =>20-30 and h<dmax/2.

• If necessary, increase the angular tolerance or the step length to increase N(h).

• Model the nugget effect and the sill with the omnidirectionalvariogram.

• Model the directional variograms (ranges and anisotropies) using the previous parameters (if possible).

Inverse Distance Method

• Traditionally, 2 is arbitrarily chosen as an exponent for inversedistance methods.

• If the nugget effect is high (> 70% of spatial variation), an exponentof 0 or 1 should be chosen.

• Continuous models with lower nugget effect should have anexponent of 1 or 2 and give more weight to close samples.

Variograms

81


Safety Rules

Appendix IV



Modified from Safety Manual of Western Mobile Inc.,Denver Colorado, USA (1996).

Accident Reporting

• Any employee sustaining a work-related injury or illness, shall reportto his or her supervisor immediately.

• All work-related injuries or illnesses will be treated by a designatedprovider of medical services. See your immediate supervisor for thenearest location and the proper form. In the case of an extremeemergency, the nearest facility shall be used. All follow-up care willbe done by a designated provider of such services.

Personal Protection

• Employees in construction areas, plants, and work sites shall wear:

➔ Head protection (hard hat)➔ Approved shatter-resistant safety glasses or safety goggles➔ Approved hard-toed foot wear.

• Additional protection such as safety goggles or a full face shield andprotective clothing, appropriate for the work being done, shall beworn when:

➔ Grinding or chipping

➔ Using a metal-working machine

➔ Performing any operation where an unusual hazard to the eyeexists.

Safety Rules

83


Personal Protection

• When the danger of falling more than two (2) meters exists, anapproved safety belt (or harness) with a lifeline suitably attached andfastened to a secure point shall be worn.

• Approved hearing protectors shall be worn where the Managementrequires it.

• Approved respiratory protection shall be worn where theManagement requires it.

• Clothing will be appropriate to working conditions. Hair, includingfacial hair, must be contained around rotating equipment and/ormoving machine parts.

Cleanup

• Work places, passageways, storerooms, service rooms, shop andlubrication areas, shall be kept clean and orderly.

• Ladderways, stairways, walkways, ramps, and platforms shall be keptfree of material which could cause stumbling or slipping hazards, orinjure persons below.

• Protruding nails, rebar, wire and other similar materials, which createa hazard to personnel, shall be removed or completely bent over.

Safety Rules


84

Electricity

• You must always call an electrician when electrical work is needed,with the exception of changing light bulbs, or when working onautomotive circuits. All repair work on any type of electricalequipment shall be performed by qualified and/or experiencedelectricians.

• The metallic frame, case, or enclosure of all stationary electricalequipment such as motors, motor generators, transformers, startingand control apparatus, oil switches, metallic conduits, cable sheaths,hoists, telephones, heaters, and any other equipment that maybecome accidentally charged with electric current shall be grounded.

• No person shall open a manual switch to disconnect power from arunning motor, except in case of emergency and only when theregular starter control is not functioning.

Electricity

• Lamp sockets shall be of a weather-proof type material where theyare exposed to weather or wet conditions that may interfere withillumination or create a shock hazard.

• Electric equipment and circuits shall be provided with switches orother controls. Such switches or controls shall be of approved designand construction and shall be properly installed.

• Transformer stations shall be enclosed to prevent anyone fromunintentionally or inadvertently contacting energized parts; suchenclosures shall be kept locked to prevent unauthorized entry.

• All power stations shall be marked in such a way as to show whatthey control. This identification is to be done on all switches withoutexception, unless there is immediate, obvious identification.

Safety Rules

85


Electricity

• Mobile equipment shall not run over power cables unless the cableare properly bridged or protected.

• Blasting circuits shall be:

➔ Insulated

➔ Ungrounded

➔ Isolated from all other conductive elements.

• Circuits shall be protected against excessive overload by fuses orcircuit breakers of the correct type and capacity.

• Power wires and cables shall be insulated adequately where they passinto and out of electrical compartments.

Electricity

• Cables shall enter metal frames of motors, splice boxes, and electricalcompartments only through proper fittings.

• Dry wooden platforms, insulating mats, or other electrically nonconductive material shall be kept in place at all switchboards andpower control switches where shock hazards exist.

• Permanent splices and repairs made in power cables, including theground conductor where provided, shall be:

➔ Mechanically strong with electrical conductivity as near aspossible as that of the original

➔ Insulated to a degree at least equal to that of the original andsealed to exclude moisture

➔ Provided with damage protection as near as possible to that ofthe original, including good bonding to the outer jacket.

Safety Rules


86

Electricity

• Electrically powered equipment shall be de-energized beforemechanical work is done on such equipment; power switches shall be:

➔ Locked out or other measures taken which shall prevent theequipment from being energized without the knowledge of theindividuals working on it.

➔ Activated only after such locks or preventative devices areremoved by the persons who installed them or by otherauthorized personnel.

• Always refer to the Plant Lockout procedure when in doubt.

Explosives

• Any person who removes or attempts to remove explosives ordetonators from company property shall be subject to immediatedischarge and criminal prosecution.

• No person shall blast, store, transport, guard, use or handleexplosives or detonators unless he or she is completely familiar withthe blasting procedure and authorized to do so.

• Explosives or detonators in transit shall not be left unattended.

• Vehicles containing explosives or detonators shall not be taken to arepair shop for any reason, and explosive conveyance shall be cleanedand inspected by a supervisor before it is brought into a repair shop.

• Explosives and detonators shall not be contained in the samecompartment.

Safety Rules

87


Fire Prevention and Control

• No person shall smoke or use an open flame within an unsafedistance of an area where smoking or the use of an open flame maycause a fire or explosion.

• Signs warning against smoking and open flames shall be posted sothat they can be readily seen in areas or places where fire orexplosion hazards exist.

• Means shall be provided to confine, remove, control, or drain awayspilled or flowing flammable or combustible liquids.

• Drip pans shall be provided to catch leakage or spillage when oil orflammable or combustible liquids are dispensed in a place or mannerwhich may create a hazard; floor areas where drip pans are used shall be kept clean.

• In areas where fire is a hazard, materials such as oily waste and ragswhich are subject to spontaneous combustion, shall be placed incovered metal containers until disposed of properly.

Fire Prevention and Control

• Fuel lines of gravity-feed fuel systems shall be equipped with valvesto cut off fuel at the source and shall be located and maintained tominimize fire hazards.

• Firefighting equipment shall be strategically located, readilyaccessible, plainly marked and properly maintained.

• Discharged, damaged, or unserviceable equipment shall be reportedto a supervisor as soon as possible. Valves on oxygen and acetylenecylinders shall be kept closed when the contents are not being used.

• When welding or cutting, suitable precautions shall be taken to insure that smoldering metal or sparks do not result in a fire;firefighting equipment shall be immediately available at the site.

• No welding, cutting or open flame is allowed within ten (10) feet ofexposed batteries.

Safety Rules


88

Machinery, Equipment and Tools

• Machinery or equipment that is to be used during the shift shall beinspected before work begins by a competent person; defectsaffecting safety shall be corrected before the machinery is used.

• Machinery or equipment shall not be lubricated while in motionwhere a hazard exists unless equipped with extended cups or fittings.

• Where a hazard exists, work shall not be done above machinery orequipment without building stagings, wearing safety belts, or othersuitable protective precautions being taken.

• Defective tools shall not be used.

• Tools and equipment shall not be used beyond the design capacityintended by the manufacturer where such use may create a hazard topersonnel.

• Conveyor start up must be preceded by an audible alarm 30 secondsbefore start.

Material Handling and Storage

• A manway shall be provided where materials are stacked or stored.

• Material shall be stacked or stored in such manner to preventstumbling or fall-of-material hazards.

• Secure footing and an adequate escape route shall be maintainedwhen moving, erecting, or removing material.

• Compressed and liquid gas cylinders shall be securely fastened in an upright position.

• Valves on compressed gas cylinders shall be protected by covers when being transported or stored, and shall be protected fromdisplacement when in use.

Safety Rules

89


Material Handling and Storage

• Working under or passing under suspended loads is forbidden.

• Hitches and slings used to hoist materials shall be constructed andsuitably issued for the particular material being handled.

• Taglines shall be attached to loads that may require steadying orguidance while suspended.

• No one shall work from or travel on the bridge of an overhead craneor hoist where catwalks, toeboards, and railings are not provided.

• Operators of cranes and hoists shall construe unclear signals to mean“Stop”.

• Do not walk on a sand or rock material pile, unless over stabilizedslope.

Mechanical Guards

• Exposed moving machine parts, which may be contacted by andcause injury to persons, shall be guarded, including:

➔ Gears, sprockets and chains➔ Drive, head, tail and take up pulleys➔ Flywheels, couplings, and shafts➔ Sawblades and fan inlets➔ Other similar moving parts.

• Guards at drive, head, and tail pulleys of conveyors shall extend adistance sufficient to prevent a person from accidentally reachingbehind the guard and becoming caught between the belt and thepulley.

• Except when testing or repairing machinery, guards shall be securelyin place while machinery is being operated.

• Hooks on cranes, chainfalls and similar equipment used for hoistingshall be equipped with operating safety catches.

Safety Rules


90

Mobile Equipment

• Defects, which affect safe operation of the equipment, shall becorrected before a unit is placed in operation.

• Operators' compartments of mobile equipment shall be kept free ofdebris and extraneous materials.

• Except for training purposes, no person shall ride on mobileequipment unless a seat is provided.

• Where provided, seat belts shall be used.

• Operators shall insure that all persons are in the clear before startingor moving equipment.

• Operating speeds of mobile equipment shall be consistent withconditions of roadways, grades, clearance, visibility, traffic and typeof equipment in use; tailgating is prohibited.

Mobile Equipment

• Equipment, materials or supplies to be transported on mobileequipment shall be loaded and secured so as to prevent sliding,shifting or spillage during transport.

• Jumping from any vehicle is absolutely forbidden.

• You must make sure your position is secured while on or around any vehicle.

• Any equipment left unattended at night shall have reflectors, lights and barricades if near a roadway or highway in normal use.

• Any equipment parked at a worksite shall be choked if theequipment is to be left out of service for the working shift. Park brakes should always be set on parked equipment.

Safety Rules

91


Mobile Equipment

• Seatbelts need not be provided on equipment that does not have aRoll Over Protection Structure (ROPS).

• Any person locating himself beneath a truck box without the safetydevice engaged shall be subject to immediate disciplinary action, upto and including discharge.

• It is mandatory that you have a spotter, or clear vision to the rear,before backing your vehicle.

• Do not position our truck parallel to a basement or other excavation.

• Do not get sideways on any slope or hill. Keep mixers on even groundto the extent possible.

Travelways, Escapeways and Ladder/Stairs

• A safe travelway shall be provided and maintained to all workingplaces.

• Crossovers, elevated walkways, elevated ramps, and stairways shall beof substantial construction, provided with handrails, maintained ingood condition; where necessary, toeboards shall be provided.

• Ladders shall be of substantial construction and maintained in goodcondition.

• Fixed ladders shall not incline backwards.

• Portable rigid ladders shall be provided with suitable bases ; whenused, ladders shall be securely placed.

• Persons climbing or descending ladders shall face the ladders andhave both hands free for climbing.

• A ladder or stairway must be provided where there is a break inelevation of 45 cm or more.

Safety Rules


92


• Extension ladders must have rungs evenly spaced less than 30 cmapart.

• Ladder landings must have platforms every 6 m and cages if over 6 m.

• Ladder rungs must be spaced evenly and have no obstruction behindthem (17.5 cm clearance behind ladder rungs). Rungs should becorrugated, dimpled, or coated with skid-resistant materials andthere must be 25 cm behind rungs, not to exceed 35 cm. Ladderhandrails or the ladder itself must extend 1 meter above the landing.

• Ladders must be able to support 10 kg per rung and 220 kg persection (section is between landings). Rungs should be at least 40 cmwide.

• Cages are not required if a safety cable system is in place.

• Stairways and ladderways must be kept clear. No storage ofmaterials, etc.


• Stairway landings must be at least 45 cm wide and 5 cm deep, if theyare permanent.

• Stairways should be installed at 30 degrees. Up to 50 degrees isacceptable (30 degrees from horizontal position).

• Stairs should be 22 cm dep. Variations in riser height should notfluctuate more than 1 cm.

• If doors or gates are located at the top of stairways or ladderways,there must be a landing with 50 cm or more clearance beyond theswing of the door. There must also be a window in the door, ifpossible.

• Stairways must have handrails. If more than four steps, a midrail mustalso be provided. The top handrail must always be 90 cm higher thanthe steps.

• Employees shall not jump from any elevation.

Safety Rules

93


Welding and Cutting

• Welding, arc welding, cutting, or soldering shall be done only by acompetent person; trainees may weld, arc weld, cut or solder onlyunder the supervision of a competent person.

• Persons cutting or welding shall wear proper clothing andequipment.

• No person shall work alone when welding or cutting in a hazardousor confined area and adequate ventilation shall be provided.

• Electrode holders not in use shall be placed so that accidental contactwith a grounding medium will not occur.

• Welding cables shall be inspected for defects or beaks in theinsulation and shall be repaired or replaced if defects or breaks arefound.

Welding and Cutting

• Compressed and liquid gas cylinders shall be secured in a safeposition.

• Hoses shall not be hung from or exert undue strain upon regulators.

• Hoses shall be kept clean and free from oil and grease.

• Acetylene bottles that have been laying down shall be stored uprightfor thirty (30) minutes or longer prior to use.

• Oxygen cylinders shall not be stored in rooms or areas reserved for oilor grease storage.

• The frames of all welding and cutting machines shall be grounded(third wire or separate wire).

Safety Rules


94

Excavation – Trenching

• Employees exposed to vehicular traffic at excavations or trenchingsites shall wear warning vests.

• Trenching shall be conducted at one to one repose. The removedearth must be stored at least 90 cm from the trench edge.

• Trenching of more than 102 m deep will require the ManagementSupervisor in attendance for the duration of the task. Storage of theremoved earth will have to be at least 1.8 m from the edge of thetrench.

Miscellaneous

• Horseplay shall not be tolerated.

• Any person who removes, displaces, damages, destroys or carries offany safety device, safeguard, notice, or warning furnished for theprotection of personnel shall be subject to disciplinary action up toand including discharge.

• No one shall advance beneath persons working overhead until thoseworking above have given permission in a clear, positive, and obviousmanner.

• Persons shall not get on or off moving equipment or ride hanging onto the side of any type of equipment.

• Absolutely no one will be permitted to ride in buckets of movingfront-end loaders.

Safety Rules

95


Miscellaneous

• Employees shall use proper lifting techniques: lift with your legs,keep your back straight, keep the load close to your body, do not liftand twist with a load, get help if a load is too heavy.

• Any employee who is operating any company equipment at any timewhile taking, using or consuming prescribed drugs must notify his/hersupervisor prior to using or operating company equipment.

• Employees are not allowed to walk up conveyors.

• To work from a conveyor you must be tied off with a harness.

Safety Rules


96

RehabilitationGuidelines

Appendix V


Taken fromStrategic Quarry Rehabilitation Project (SQRP) of the Group

ObjectiveTo assess major issues before applying for a permit: geology, waterregime, biodiversity, landscape, heritage, archaeology, humanenvironment, zoning by-laws.To assess the project's ability to be integrated into the environment andthe local community's ability to accept it.

ApplicationAll future quarries and extensions.

PrinciplesAn environmental survey must be carried out before opening any newquarry or major extension.The survey will include: • An ecological assessment (flora and fauna)• A detailed geological assessment including hydrogeology and

hydrology• Transport infrastructure (roads, waterways, rail) and proximity to

market• Human environment: sufficient distance from urbanized areas;

compatibility with urban planning documents and constraints• Environment: avoid or safeguard designated areas as well as those of

high ecological, archaeological or other interest • Restoration of worked areas to be planned to blend into the wider

landscape or recreate landscapes lost to intensive management• Alternative solutions.

List of proven techniques available• Bio-geographical context:

– topographical maps, – geological report,– mining report,– climate,– hydrography, hydrology (flood plains) and water wells,– quality of species (flora and fauna),– endangered and endemic species (flora and fauna),– potential rehabilitation program.

• Human and cultural context:– neighboring human population inventory, including active groups,– inventory of representative ecological interest groups,

Site Selection

97


GU

ID

EL

IN

EN

º1

– archaeological investigation,– physical constraints (cemeteries, pipes, etc.), – ceremonial and sacred grounds of indigenous peoples.

Costs• Cost depends on country, size, history, etc. Can vary from US$10K to >

US$100K.

List of reference documentsARQUIER Georges 1990, Granulats, presse de l'ENPC.Organisation et Environnement 1993, Guide prospectif d’aménagementde carrières calcaires en Lorraine. UNICEM URPG Lorraine – available atMillery (69 – France).

List of show cases for this guideline

Site Division Region/dep. Country Comment

LA COURONNE Cement Charente France New operation plan taking into

account ecological assessment

LA FARE-LES-OLIVIERS Aggregates Bouches-du- France Choice of mining area and

Rhône operation plan according to

landscape

MUIDS/DAUBEUF Aggregates Eure France Sand and gravel terrace, to

(BERNIERES-SUR-SEINE) replace wet pits soon exhausted

same processing factory

HOPPEGARTEN Roofing Brandenburg Germany New operation in the Nature

Park “Märkische Schweiz”

SAINT-CONSTANT Cement Québec Canada Site extension

Experts to contact

Name Division/region/sector Country Phone nº

Ron FOSTER Aggregates United Kingdom 44 1 530 241 088

Serge DALLAS Aggregates France 33 1 40 95 69 30

Yves DERREAL Cement France 33 1 49 11 40 40

Philippe CHEVALIER Gypsum France 33 4 90 21 21 81

Site Selection


98

ObjectiveThe rehabilitation objectives and future use must be socially andenvironmentally beneficial, as well as technically and economicallyfeasible.

ApplicationAll quarries in any geographical context.

PrinciplesThe rehabilitation project must be designed according to the followingcriteria:

– ecological considerations (see Guideline nº 1), – geological and hydrogeological contexts, – surrounding landscape (see Guideline nº 14),– habitat creation and biodiversity enhancement when possible,– economic feasibility,– social and cultural preferences and opportunities.

List of proven techniques available• Ecological and geological studies (see Guideline nº 1)• Landscape studies (see Guideline nº 3 and 14)• Consultation of any party – mineral planning authority, local authority,

neighbors, the land owner, statutory agencies or NGOs – involved inthe choice of the appropriate after-use.

CostsGeological studies (see Guideline n° 1)Landscape studies: 7 000 to 20 000 €Ecological survey: 3 000 to 8 000 €

List of reference documentsOrganisation et Environnement 1993, Guide prospectif d’aménagementde carrières calcaires en Lorraine. UNICEM URPG Lorraine – available atMillery (69 – France).

Choice of Rehabilitation Objectivesand Future Use

99


GU

ID

EL

IN

EN

º2

Experts to contact

Name Division/region/sector Country Phone nº

Ron FOSTER Aggregates United Kingdom 44 1 530 241 088


Georg THOMAS Roofing Germany 49 6171 61 26 42

Arnaud COLSON Aggregates France 33 1 40 95 69 00

Choice of Rehabilitation Objectivesand Future Use


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101


ObjectiveTo facilitate choices and validate the concept. To enable the visualamenity of the site to be considered at successive stages as the mineralworking and rehabilitation progress in order to communicate with theauthorities and the general public.

ApplicationAny quarry where the landscape is expected to be a major issue andwhere the use of such techniques is relevant.

Principles• Involve landscape architects in the project.• Transfer geological, topographical and hydraulic data to a simulation

software program.• Quantify the deposits to be mined:

Topsoil/Subsoil/Overburden/Mineral.• Use aerial and/or line-of-sight photography coupled with landscape

design software.

List of proven techniques availableTopography on Autocad, Ortho-Photo, Coralis or comparable softwareprograms• 3 D imaging:

– AMAP: software that can simulate plant growth, with variousspecies,

• Hydrogeological modeling• Hydraulic modeling• Scale models• Photomontage• GIS

Costs• Software (AMAP): 15 000 €.• For visual simulation:

– overall modeling 3 000 to 10 000 €,– cost per visualisation point: 2 000 €

• For visual animation (approx. 3 minutes):– visual only: 15 000 €,– audiovisual: 20 000 €.

Those software programs are complex and should be contracted out.

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List of reference documentsAtelier Architecture Environnement1999-2000, Carrière de la Malle – Variante de réaménagement paysager,LAFARGE GRANULATS PROVENCE available at Marseille (13 – France).TUP/GVA (P. Thebault): CD ROM about the rehabilitation of Port LaNouvelle, St Pierre La Cour, Le Teil, available at Lafarge ciment St Cloud Tavernola.



MUIDS / DAUBEUF(BERNIERES-SUR-SEINE) Aggregates Eure France 3 D simulation, scale

models

PORT LA NOUVELLE Cement Aude France 3D simulation

YAMNUSKA Cement Alberta Canada AMAP

TAVERNOLA Cement Lombardia Italy Landscape simulation of the mining stages

LA MALLE Cement Bouches-du-Rhône France Simulation drawings for+ Aggregates project of rehabilitation

modification

MAZAN Gypsum Vaucluse France 3D simulation

Experts to contact

Name Division/region/sector Country Phone n°

Claire PAJON Aggregates France 33 1 40 95 69 00

Jean Pierre GRASSI Gypsum France 33 4 90 69 71 14

Jean-Guy LEVAQUE Cement North America 1 514 738 1202

Louis DESCOMBES Cement France 33 4 75 49 60 23

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ObjectiveThe rehabilitation plan describes the series of phased operations thatmake the future use of the site possible. The rehabilitation plan is usedas an internal and external communications tool. It is a fundamentaldocument for the quarry manager.

ApplicationAll quarries are required (under the Lafarge Rehabilitation Policy) tohave a rehabilitation plan, which must be updated periodically.

PrinciplesThe rehabilitation plan is essential to the implementation of the policy. It must be part of or coordinated with the mining plan. • Support from local stakeholders is necessary.• The rehabilitation plan should be defined taking the extraction

program and the after-use into account (see Guideline nº 2).• Gradual reclamation will spread the costs of rehabilitation over the

lifetime of the site. It must be illustrated with detailed phase plans.• For cement operations, the rehabilitation plan must be defined in

collaboration with the relevant Technical Centers or departments.• Coordination with the mining plan, as well as supervision and

monitoring of earthmoving, should minimize the displacement of plantand equipment (see Guideline nº 9) and prevent environmentaldamage.

List of proven techniques available• The rehabilitation plan should include:

1. Final topographical data2. Fencing, gates and boundaries3. Water regime, aquifer levels4. Plantings: hedges, bushes, woodlands5. Habitats to be created6. Rights of way7. Public access and car parking facility (if intended)8. Buildings (birdwatching hides, club house, offices, visitor center…).

• Areas for storage of soil and overburden should be carefullydesignated on the rehabilitation plan (see Guideline nº 11). These areasshould take the ultimate use of the stored material into account andpreferably be located close to their final destination (see Guideline nº 9). Where overburden is thick and storage will be long-term (hardrock quarries), land outside the extraction area should be identified for storage.

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• Simulation tools and models.• Map of the site showing measures prescribed by the planning

permission.• Use of past examples and published research documents.• Supervision and monitoring, included in the rehabilitation budget

and systematically carried out (frequency to be set according to sitecharacteristics: for example, every second year for cement quarries,every year for sand and gravel pits).

Costs Vary considerably, and use of consultants can be expensive. In-houseexpertise could be used for advice. In North America: US$ 20000 to 80000.

List of reference documentsDINGETHAL F. J., JÜRGING P., KAULE G., WEINZIERL W.1998, Kiesgrube und Landschaft, 3. AuflagePaul Parey – available at Oberursel (Germany), Issy (France)



SENAS Aggregates Bouches-du-Rhône France

GUERNES/SANDRANCOURT Aggregates Yvelines France landscape-designed maps

LLYNCLYS Aggregates Shropshire UK

STONE CASTLE FARM Aggregates Kent UK

PONT de PEILLE (Contes) Cement Alpes Maritimes France

KARSDORF Cement Sachsen-Anhalt Germany

MATOZINHOS Cement Minas Gerais Brazil

DAVENPORT Cement Iowa US Park

HOPPEGARTEN Roofing Brandenburg Germany

BAMBURI Cement Kenya

Experts to contact


Bernard BOURGUE Aggregates France 33 4 95 09 45 00

Ron FOSTER Aggregates UK 44 1 530 241 088

Claire PAJON Aggregates France 33 1 40 95 69 00


René HALLER Cement Kenya 254 11 48 61 55


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ObjectiveTo identify key stakeholders. To seek the approval of the local community, statutory and non-statutory agencies, by presenting them with proposals and beingprepared to consider their concerns and requirements.To obtain acceptable conditions within a reasonable timeframe inorder to draw up the operation plan.

ApplicationAll quarries requiring a new or modified approved plan.

Principles• Determine the main concerns of the community and the authorities.• Justify the choice of the site and [operation plan (including

rehabilitation): economics, geography, environment (see Guideline nº 1 and 2).

• Ensure that all consultees understand the facts of a proposeddevelopment.

• After hearing the concerns of authorities, associations and neighbors,modify the application and proceed with a new consultation topresent the modifications following this new application. Therefore,this is an iterative process and may require a series of consultations.

List of proven techniques available• Exhibitions, visits, opinion surveys, public inquiry, open days

(Guideline nº 24), public meetings.• Becoming part of the local community, for example by establishing a

follow-up committee (Guideline nº 23).• Simulation tools (see Guideline nº 3).• Presentation of data about the company, especially existing

reclaimed sites (photographs and explanations).• Tours of reclaimed sites to show the techniques implemented and

their result.• One on one or small group discussions are preferable to large public

meetings.• Mailings to neighbors.

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Costs• Documents.• Time devoted to presentation (can save time later).• Opportunity cost (mitigation).

List of reference documentsMinistère de l’Environnement 1992, Charte de la Concertation, Ministèrede l’Environnement, France. Available at Issy or Millery (France).

Union Nationale des Producteurs de Granulats1992, Charte Professionnelle de l’Industrie des Granulats UNPG, France –Available at Issy (France).

List of show cases for this guidelineSite Division Region/dep. Country Comment

LA FARE-LES-OLIVIERS Aggregates Bouches-du- France Concertation for quarry Rhône instead of controlled

rubbish dump

CAVAILLON Aggregates Vaucluse France Concertation committee before quarry extension

SANDY Aggregates Bedfordshire UK

LA COURONNE Cement Charente France Concertation with associations to deal with ecological constraint

MONTMORENCY Gypsum Val-d’Oise France Early and close contact with neighbours, authorities and associations


Experts to contact



Jean-Claude MARCOU Aggregates France 33 1 60 73 54 40


Andi HODGSON Aggregates UK 44 1 530 24 11 16


Patrick PARIS Cement France 33 1 49 11 43 37

Denis SCHMID Gypsum France 33 4 90 21 21 28

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ObjectiveOnce the operation plan has been developed, and before its approval,the objective is to reach a consensus with the local community.

ApplicationAll quarries needing a new or modified approved plan.

PrinciplesTo reach consensus:

– presentation of the main characteristics of the project,– ensure that consultees are made aware of the facts using reliable

data,– understand possible political implications, – support community access to independent expertise.

List of proven techniques available• Meetings, including: town and/or regional councilors, planning

authority, local community representatives.• Allocate staff resources and time to meet, possibly by appointment,

in order to directly answer the questions of each party concerned.

CostsTime and documents devoted to presentation.

List of reference documentsMinistère de l’Environnement 1992, Charte de la Concertation,Ministère de l’Environnement, FranceAvailable at Issy or Millery (France).

Union Nationale des Producteurs de Granulats (UNPG)1992, Charte Professionnelle de l’Industrie des GranulatsUNPG, France – Available at Issy (France).

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GUERNES/ Aggregates Yvelines France For extension on SANDRANCOURT Flicourt


LA GRANDE-PAROISSE Cement Seine-et-Marne France

MONTMORENCY Gypsum Val-d’Oise France Early and close contact with neighbours authoritiesand associations


Experts to contact


Pierre PROY Aggregates France 33 3 44 38 30 00

Dominique EVRARD Aggregates France 33 4 72 24 46 25

Jean-Claude MARCOU Aggregates France 33 1 60 73 54 40

Patrick PARIS Cement France 33 1 49 11 43 37

Denis SCHMID Gypsum France 33 4 90 21 21 28

Andi HODGSON Aggregates UK 44 1 530 24 11 16

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ObjectiveDefine and allocate the resources and measures needed to implementthe rehabilitation plan in line with its budget and schedule.

ApplicationAll quarries before the beginning of any rehabilitation phase.

Principles• Gradual restoration should be implemented as identified in the

rehabilitation program (see Guideline nº 4).• The person responsible for the rehabilitation should understand and/or

apply:– the existing mining plan,– all the rehabilitation processes required by the approved plan

(earthmoving, vegetation…),– management of contractors,– the potential benefits (or damage) that can result from

rehabilitation operations if they are successful or not, especially interms of coordinating equipment and supplies with climaticconstraints,

– the internal and external skills required for providing advice andguidance,

– make sure adequate funds are accrued and allocated in a timelyfashion, in accordance with Group policy and procedures.

List of proven techniques available• Choice of contractors: already known by the company or proven

specialists.• Restoration audits, periodic project meetings with contractors.• For seeding, planting…, see the relevant Guideline.• Collecting data on the rehabilitation program, for future work and cost

assessments (see Guideline nº 8).

CostsA good program that is properly implemented avoids additional costs.US$ 5000 to10 000 /ha without transport or rough grading of rawmaterial.

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List of reference documentsMineral Planning Guidance (UK)



GUERNES/SANDRANCOURT Aggregates Yvelines France

BELLEGARDE Aggregates Gard France

BESTHORPE Aggregates Nottinghamshire UK

VILLIERS-ADAM Gypsum Val-d’Oise France Already subcontracted


EXSHAW Cement Alberta Canada CKD site

Experts to contact


Hervé CHIAVERINI Aggregates France 33 2 32 54 70 75

Claire MORICE Aggregates France 33 1 34 97 02 70



Pierre MATEU Gypsum France 33 1 60 26 64 04


David PARK Aggregates UK 44 1 7406 54 461

Stephan NICOLAY Roofing Germany 49 6171 61 24 36

Frédéric THOUE Cement (CTI) Worldwide 33 4 74 82 18 04

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ObjectiveGuarantee the sustainability of the plan and apply corrective measures.Monitor and report the progress and cost of the rehabilitation to ensurethat they are compliant with the rehabilitation plan.Record the history (annual diary) of the rehabilitation work.

ApplicationAll quarries in the process of rehabilitation.

Principles• Inspection and monitoring: by the person responsible for the

rehabilitation, who should immediately report any problems ofimplementation or excessive cost to a higher authority, before thesituation gets out of hand.

• Ensure that the rehabilitation work is carried out in accordance withcompany and regulatory safety and environmental requirements.

• Reporting is done by the person in charge of the rehabilitation: thelocal management chooses the recipient according to the type ofoperations.

• Identify improved practices and update Guideline.

List of proven techniques available• Monitoring done by quarry manager if competent and possibly cross-

checked by internal advisor or consultant.• Control during rehabilitation: ensure compliance with the

rehabilitation plan (which must be compliant with the approved plan).• Keep a rehabilitation diary to record the main operations and the

conditions in which they have been carried out (dates, operations,climate conditions, contractors, species planted or habitat created,pictures, advisors…).

• Regular surveys (maps) of the quarry identifying rehabilitation worksalready completed or planned.

• Inspection after rehabilitation: photographs year by year, taken fromthe same points, to check plant growth and general establishment, forexample (satellite and aerial imagery are excellent, if available).

• Ecological assessment.

Costs• Time devoted to the operations.• Consultants.

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List of reference documentsObservatoire du paysage,Mission paysage, Ministère de l’Aménagement du Territoire et del’Environnement (France) / LAFARGE – ISO 14004 standard.



LA FLECHE Aggregates Sarthe France ISO 14001 records of rehabilitation

SENAS Aggregates Bouches-du-Rhône France Reporting of therehabilitation by a consultant

VAL D’AZERGUES Cement Rhône France

MAZAN Gypsum Vaucluse France Operational miningplan includes reclamationwork

RAHMSTORF Roofing Niedersachsen Germany Reporting of the rehabilitation by a consultant

GODMANCHESTER Aggregates Cambridgeshire UK

Experts to contact




Bruno BIANCO Cement France 33 4 72 54 11 65

Jean-Pierre GRASSI Gypsum France 33 4 90 69 71 14

Frédéric THOUE Cement CTI 33 4 74 82 18 04

Stephan NICOLAY Roofing Germany 49 61 71 61 24 36

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ObjectiveTo minimize the costs of earthmoving through the use of appropriatetechniques and machinery.The technical objectives for successful handling are mentioned inGuideline nos. 10, 11 and 12.

ApplicationAll quarries in which materials are stripped and handled.

PrinciplesAdhering to planned works which have been agreed with regulatorybodies.• Use equipment appropriate for each type of earthmoving operation.• If possible, choose the right climate conditions to handle materials.• Coordinated rehabilitation can minimize intermediate storage and

double handling of materials.• Provide some access roads or paths: this must be planned early to

avoid additional costs.

List of proven techniques available• A comprehensive rehabilitation plan including the volume of

materials to be handled during each phase of rehabilitation: theearthmoving optimization strategy is easier to visualize on a serie ofdrawings.

• Moisture conditions during the earthmoving operations: thisparameter is even more important than the choice betweencoordinated rehabilitation and intermediate storage, especially fortopsoil and subsoil (see Guideline nº 10). A wet material can be easierto extract, but damages soil structure by smearing and consolidation.

CostsBlasting: 0.40 to 0.60 €/t (can be necessary for waste from crystalline

rock quarries).Loading + transport + grading: 1.5 €/m3.Extraction: 0.50 €/t if necessary, with a shovel.Loading: 0.30 to 0.40 €/t.Bulldozer: 800 €/day.

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List of reference documentsB. ODENT, M. LANSIART 1999, Remise en état des carrières : principesgénéraux, recommandations techniques et exemples par typesd’exploitation, Ministère de l’Aménagement du Territoire et del’Environnement (France), 64 pages.



WEST DEEPING Aggregates UK High grade soil reestablishment

FRENEUSE Aggregates Yvelines France

BROOKFIELD Cement Nova Scotia Canada

LIMAY Cement Yvelines France

TAVERNOLA Cement Lombardia Italy Waste material monitoring

VILLEVAUDE Gypsum Seine-et-Marne France Continuous backfilling with overburden

Experts to contact




Roger HYNES Aggregates UK 44 1 707 356 000

Frédéric THOUE Cement CTI 33 4 74 82 18 04

Ghislain JOUBAND Gypsum France 33 1 60 26 64 04

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ObjectivePreserve the quality and productivity of soil.

ApplicationQuarries in which soil is handled, stockpiled or returned to the site.

Principles• Segregate materials whenever possible: at least topsoil, and possibly

subsoil if such soil level can be distinguished.• Soil handling requires appropriate climatic conditions.• Avoid excessive handling, to preserve soil integrity and minimize costs.

List of proven techniques available• Comply with planning conditions, which may specify moisture criteria

and machinery to be used.• If topsoil and subsoil can be distinguished from each other, the two

materials must be removed separately, and replaced in sequence torestore the soil profile. In some cases, when the topsoil layer is too thin,both layers can be removed as one.

• Topsoil and subsoil thickness vary from site to site. Consult soil surveysor ask restoration managers or suitably qualified people.

• Climate conditions: the soil should not be handled when it is too wet ortoo dry, to avoid compaction and loss of structure. The ideal moisturecontent or soil plasticity limits are based on local knowledge, as soilcharacteristics vary from region to region.

• For nature conservation objectives, it can be better to strip topsoil afternative vegetation has set seed, in order to maximize the stores NdT:seeds in the soil.

• If possible, soil must be placed directly on areas to be reclaimed.• If soil must be stored, the location of stockpiles must be planned to

avoid excessive handling. Stockpiles must be close to areas to bereclaimed, and away from drainage channels. They must not exceed 2 to 3 m height (according to the type of soil and climate). Whenstored for long periods of time (more than 1 year), topsoil piles must be seeded and stabilized to protect the soil from erosion, discourageweeds and maintain active microorganisms.

• Once the soil has been placed on the site or stockpiled, heavymachinery must not be allowed to travel over it.

CostsSee Guideline nº 9.

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List of reference documentsMICHALSKI, M.F.P. et al.1987, Rehabilitation of pits and quarries for fish and wildlife, Ministryof Natural Resources of Ontario, Land Management Branch, 59 pages.

PERRY, David A. et al.1988, The plant-soil bootstrap: microorganisms and reclamation ofdegraded ecosystems, Restoring the Earth Conference, “Environmentalrestoration” edited by John J. Berger.

STROHMAYER, Patti1999, Soil stockpiling for reclamation and restoration activities aftermining and construction, University of Minnesota, Department ofHorticultural Science, H5015 Restoration ecology, Restoration and Reclamation Review 1999 @ www.hort.agri.umn.edu/ h5015/rrr.htm.

List of show cases for this guidelineIt’s a very common practice, used on all LAFARGE quarries covered by asoil (only quarries located in deserts may not be concerned).


BUCKDEN Aggregates Cambridgeshire UK

PRASVILLE Aggregates Eure-et-Loir France Agricultural rehabilitation

FRANGEY Cement Yonne France

MAZAN Gypsum Vaucluse France Management of soil deficit

Experts to contact


Ron D. FOSTER Aggregates UK 44 1 530 241 088




Khalid SAMAKA Cement France 33 3 86 54 61 77



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ObjectiveTo optimize handling by placing overburden or waste rock in its finallocation.To maintain availability and quality of materials for rehabilitation.

ApplicationAny quarry / All quarries.

Principles• If possible, handle overburden/waste rock only once.• The implementation of the rehabilitation plan should take visual

impact into account, and preserve the accessibility of reserves.• Overburden storage must conform to a stable engineering design.• Avoid any erosion or landslide hazard.• Avoid compaction, in the case of agricultural or forestry restoration.

List of proven techniques available• Choice of the final location:

1. direct return to the surfaces to be reclaimed;2. site chosen according to the following criteria: geology (preserve

access to the deposit), distance from the deposit (as short aspossible), landscape integration (see Guideline nº 13 and nº 14)possibly outside the working area (this may require planningpermission).

• Stability of the proposed stockpile:1. stability study,2. final slope: less than the natural angle of repose of the material

(as specified by local regulations and/or geologists'recommendations),

3. compaction of the materials may be necessary after each layingphase,

4. if the storage is long-term, the pile should be seeded (seeGuideline nº 20) to control erosion (see Guideline nº 15).

• If necessary:1. drainage to prevent ponding within and around the storage area

(see Guideline nº 17),2. where final landforms are created, decompaction (ripping) may

be necessary to facilitate root development (see Guideline nº 19).

CostsSee Guideline nº 9.

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List of reference documentsCFEGOctober 1994, Projet de comblement d’un talweg : étude géotechnique(Rivolet Quarry, Rhône, France) – available at Millery (France).BRGMMarch 1990, Carrière de La Patte (Rhône, France) : établissement duprojet de stabilisation et de stockage de stériles – available at Millery(France).CETE LyonNovember 1992, Carrière de La Patte (Rhône, France) : mise en dépôtde matériaux – available at Millery (France).MICHALSKI, M.F.P. et al.1987, Rehabilitation of pits and quarries for fish and wildlife, Ministryof Natural Resources of Ontario, Land Management Branch, 59 pages. STROHMAYER, Patti1999, Soil stockpiling for reclamation and restoration activities aftermining and construction, University of Minnesota, Department ofHorticultural Science, H5015 Restoration ecology, Restoration andReclamation Review 1999 @ www.hort.agri.umn.edu/h5015/rrr.htm.



QUATRO BARRAS Aggregates Curitiba Brazil

RIVOLET Aggregates Rhône France Stability study for a future pile

MOUNTSORREL Aggregates UK


ST-CONSTANT Cement Québec Canada 3D golf course

ST-PIERRE-LA-COUR Cement Mayenne France

VILLEVAUDE Gypsum Seine-et-Marne France Management of soil deficit

Experts to contact


Jean-Luc BOURGUET Aggregates France 33 1 40 95 69 30

Jean-Christophe Cement France 33 2 43 66 44 47FAUCHADOUR

Ghislain JOUBAND Gypsum France 33 1 60 26 64 04

Jaïr FERNANDES Cement Brazil 55 21 217 31 00


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ObjectiveCreate stable landforms that can be integrated into the existingenvironment and landscape.

ApplicationAll quarries.

PrinciplesThe proposed landforms should take the following aspects intoaccount:

– local/regional geomorphology,– proposed restoration design (included in planning permission),– stability of the materials deposited,– soil erosion hazards,– biodiversity,– integration within the surrounding landscape (see Guideline

nº 14), whether final landforms are natural-looking or not: someartificial cliffs are now even classified as valuable features thatmust be protected.

List of proven techniques available• Materials used to create landforms are usually waste rock and

overburden, which are graded prior to the placing of the soil.• On level areas and gentle slopes, grading must be minimized to avoid

soil compaction.• In abandoned areas of quarry sites, selective blasting can be used to

create slopes that link the top of the quarry to the quarry floor, andmimic a natural cliff and scree feature.

• For agriculture, maximum slope is 10°.• On sloped sites:

1. for conservation purposes: ripping should be parallel to thecontours to reduce runoff and encourage infiltration;

2. for agriculture: ripping should be carried out following naturaldrainage patterns.

• In wet sites, especially pits, creating islands and shallow zonesenables the development of plants such as reeds, constitutinghabitats for many animals and plants.

• For areas that are to be built upon: compaction if necessary (see Guideline nº 22).

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CostsBulldozer, grader or shovel: 600 to 800 €/day.

List of reference documentsMICHALSKI, M.F.P. et al.1987, Rehabilitation of pits and quarries for fish and wildlife, Ministry ofNatural Resources of Ontario, Land Management Branch, 59 pages.



COURNONSEC Aggregates Hérault France Selective blasting

BALLOY Aggregates Seine-et-Marne France

BRADBOURNE Aggregates Kent UK Sevenoaks Wildfowl Reserve

SANDY Aggregates Bedfordshire UK Wholly recreated slopes using waste rock, overburden and soil

BROOKFIELD Cement Nova-Scotia Canada

LE HAVRE Cement France

RAHMSTORF Roofing Germany

LE PIN Gypsum Ile-de-France France

Experts to contact



Ron D. FOSTER Aggregates UK 44 1 530 241 088


Rogelio DUPONT Cement France 33 2 32 79 20 40




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ObjectiveIntegrate permanent visual and acoustic barriers into the rehabilitationplan.

ApplicationThis practice can be applied to sites where permanent visual andacoustic barriers have to be set.

Principles• Mask critical viewpoints of the future or existing quarry.• Integrate barriers into the surrounding environment (see Guideline

nº 14).• If possible, create these barriers before opening the site, especially if

the barriers are intended to be built or topped with vegetation.

List of proven techniques available• Visual and acoustic barriers can be either berms (bunds) built on

purpose, or natural relief kept untouched at the boundaries of thesite.

• Berms can be built directly with overburden materials. The resultinglandforms must then be topped with growth medium, seeded, andpossibly planted (see Guideline nº 20 and 21).

• The plant species for visual barriers should be chosen from the localvegetation. Fast-growing species (to rapidly establish a barrier) andlong-lived species (to perpetuate/ensure the durability of theintervention) can be combined.

• Contouring of berms should be considered for visual effect and easeof maintenance.

CostsSee Guideline nº 9 (earthmoving), Guideline nº 20 (seeding), Guidelinenº 21 (planting).

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List of show cases for this guidelineSite Division Region/dep. Country Comment

BAIXAS Aggregates Pyrénées- France Visual bermOrientales

MOUNTSORREL Aggregates Leicestershire UK

ST-CONSTANT Cement Québec Canada

LE HAVRE Cement Seine-Maritime France Natural relief

CARRESSE Gypsum Pyrénées- France Visual bermsAtlantiques

WHITLINGHAM Aggregates Norfolk UK


Experts to contact




Jean-Louis BARON Gypsum France 33 5 59 38 49 40




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ObjectiveTo integrate the site into the surrounding landscape, during and aftermineral extraction.

ApplicationAll quarries and sand and gravel pits.

Principles• Define the landscape context: criteria based on physical, historical,

social and biological characteristics of the site and region.• Determine the site characteristics.• Establish a list of skilled landscape experts according to the region.• Be wary of trends (e.g., regular alignments of conifers are nowadays

inadvisable in many cases): solutions must be adapted to specific siteconditions reflected in the inventories.

List of proven techniques available• The first step is to carry out a visual impact assessment of the site,

taking into account topography, hydrology, climate, vegetation types,wildlife; historical and social components of the landscape; as well assurrounding land uses and development patterns.

• Use of simulation tools (Guideline nº 3).• Specific interventions are then developed to prevent damage to the

visual resource, or to mitigate the existing impact on the landscape.These interventions must also consider ongoing operations andpotential future land uses.

• These operations are best established by local landscape architectswhen the project size justifies their work.

CostsLandscape studies with visual simulation: about 7 000 to 20 000 € (see Guideline nº 2 and 3).

List of reference documentsLots of references:DINGETHAL F. J., JÜRGING P., KAULE G., WEINZIERL W.1998, Kiesgrube und Landschaft, 3. Auflage Paul Parey – available atOberursel (Germany), Issy (France).

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COMON Marie-Laure1998, Paysage et aménagement de carrières, UNPGComité National de la Charte (France) – available at Issy.



AIX-EN-PROVENCE Aggregates Bouches-du-Rhône France limestone quarry

BARBEY Aggregates Seine-et-Marne France sand and gravel pit

FALKLAND Cement British Columbia Canada

PORT-LA-NOUVELLE Cement Aude France

BAMBURI Cement Mombasa Kenya

VILLIERS-ADAM Gypsum Val-d’Oise France Plantation of trees in landscape area


Experts to contact



Pierre DE PREMARE Aggregates France 33 1 40 95 69 33

Jean-Marc GONZALEZ Cement France 33 4 68 40 41 05




René HALLER Cement Kenya 254 11 486 155

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ObjectivePrevent erosion on re-created landforms in order to avoid landslides, lossof soil and discharge of solids outside the site.

ApplicationAll quarries and sand and gravel pits where soils need to be stabilized.

Principles• Erosion control measures should be implemented as soon as possible.• Erosion control should be properly engineered.• Remediation is much more expensive than prevention.• Gentle slopes, where possible, are cheaper and more efficient than

more sophisticated products.• Take the main hydrological network into account and maintain it if

possible.• Take erosion control techniques into account prior to earthmoving

operations.• Adapt the techniques to climate conditions: the erosion hazard is

higher in a Mediterranean climate than in an oceanic one.

List of proven techniques available• Grading of slopes and general topography management is the main

factor of erosion control (Guideline nº 12).• Bioengineering:

– Some plants have an appropriate root system to stabilize soils. Theycan be set up by the following means: seeding (see Guideline nº 20),planting (see Guideline nº 21), live staking or live fascine.

– Slopes with slumps, headcuts and gullies can also be repaired bybranch packing (wood stakes + layers of vegetative cuttingsinterlaid with compacted soil).

• Manufactured erosion control products:– Mulches: degradable material consisting of straw, hay and other

plant debris, possibly sprayed with a bonding agent, or evenapplied hydraulically (hydromulches).

– Meshes, used to stabilize slopes or to prevent soil erosion:degradable open weave geotextile (coconut fiber, jute) rather thanpolypropylene.

– Erosion control blankets.• River-erosion hazard near sand and gravel pits: see Guideline nº 16.• Rip-rap (massive stone wall), gabion or armored stone.• Wind-breaks for wind erosion.

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Costs– seeding: see Guideline nº 20.– planting: see Guideline nº 21.– mulches: 0.1 €/m2.– geotextile: 1 €/m2

List of reference documentsSOTIR, Robbin B.1988, Introduction to soil bioengineering restoration, Restoring the EarthConference, “Environmental restoration” edited by John J. Berger.HARDING, Michael V.1988, Erosion control effectiveness: comparative studies of alternativemulching techniques, Restoring the Earth Conference, “Environmentalrestoration” edited by John J. Berger.BOBROWSKI, John 1997, Soil bioengineering with woody vegetation for slope stabilization,University of Minnesota, Department of Horticultural Science, H5015Restoration ecology, Restoration and Rehabilitation Review 1997 @www.hort.agri.umn.edu/h5015/rrr.htmKNAPP, Leslie H.1997, Use of manufactured materials in shoreline restoration projects,University of Minnesota, Department of Horticultural Science, H5015Restoration ecology, Restoration and Rehabilitation Review 1997 @ www.hort.agri.umn.edu/ h5015/rrr.htm



LA CALMETTE Aggregates Gard France

CANTAGALO Cement Rio Brazil

CARRESSE Gypsum Pyrénées- France Use of fascineAtlantiques

VAL D’AZERGUES Cement Rhône-Alpes France Rip-rap

Experts to contact



Bruno BIANCO Cement France 33 4 72 54 11 65

Jean-Louis BARON Gypsum France 33 5 59 38 49 40

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ObjectiveTo avoid scour of the banks of pits, sea shores and riverbanks due towave action, currents and water level changes, as well as regressiveerosion during and after exploitation.

ApplicationAll sites located on shores.

Principles• Use shore protection techniques to reduce wave action, encourage

sediment deposition, and stabilize the shore.• Adapt protection techniques to river dynamics.• Avoid any obstacle to riverfloods.• Critical factors for shoreline and bank stability are:

– lake level and geometry,– groundwater flow direction and velocity,– surface roughness,– prevailing winds,– climatic conditions and seasonal weather variation.

Reduce wave action and stabilize the shore or riverbank, especially atvulnerable points.

List of proven techniques available

Configuration of shorelines and slopes.

Beach fillCost-effective technique used for existing beaches.

Rock blocksRock blocks can be used in the event of river-erosion hazards.

Breakwaters (for quarries located on a sea or lake shore)“Breakwaters are structures placed offshore to dissipate the energy ofincoming waves.”

GroinsGroins are finger-like structures that extend perpendicular from theshore.

Discharge, weir

RevetmentsRevetments are placed on banks or bluffs to absorb wave energy.

VegetationIn a natural environment, vegetation is the primary source ofstabilization for dunes, banks, and bluffs.

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Costs• rock blocks: € 25 – 40/t (supply +placing).

List of reference documentsAlabama Coastal Hazard Assessment @ http://payson.tulane.edu/inhl642/Alabama/htm/sps.htm available at Montreal.

Jean-René MALAVOI - EPTEAU - LATITUDE -1998, Guide Technique nº 2 : Détermination de l’espace de liberté descours d’eau – Agence de l’Eau Rhône Méditérannée-Corse (France).

HYDRATEC 1993-1994: hydrological studies for CREVECHAMPS site,available at Millery (France).



CREVECHAMPS Aggregates Meurthe-et-Moselle France Diverse rock block structures against flood damages

WHITLINGHAM Aggregates Norfolk UK

DAVENPORT Cement Iowa Canada Mississippi shore

Experts to contact



Jean-Guy LEVAQUE Cement Canada 1 514 738 1202

Shore Protection

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Objective Control major discharge of water collected in the quarry.

Application All quarries.

Principles Prepare a water management plan. • Storm water control: establish drainage strategies to avoid

concentration of streams and therefore erosion (see Guideline nº 15)and excessive suspended solids.

• Ensure that long-term devices (drainage layers, pipes, paths…) cannotbe threatened by natural phenomena: where possible, choose devicesthat require minimal maintenance.

List of proven techniques available• Discharge of surplus water through defined channels.• Establishment of settling ponds, deemed necessary in the early years

after rehabilitation until vegetation has developed sufficiently, toavoid the entrainment of suspended solids during rainstorms.

• Conversion of pits and quarries into flood retention basins: choice ofthe final dimensions and levels of basins and connections betweenthem (pipes or open channels); agreement with a long-term partner(see Guideline nº 29), usually a local authority or association.

• Structures against flood damage: see Guideline nº 16.• Drainage: pipes, drains, ditches.

CostsSite specific.

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List of showcases for this guideline


BELLEGARDE Aggregates Gard France Flood retention basins

MARFIELD Aggregates North Yorkshire UK Regulation of water level in ponds

INHAUMA Aggregates Rio Brazil


MONTES-CLAROS Cement Brazil Collection of water for the plant needs

PORT-LA-NOUVELLE Cement Aude France

MAZAN Gypsum Vaucluse France Flood control basin


Experts to contact






Storm Water Management

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ObjectiveTo preserve the quality of aquifers and bodies of water whenever lakesand wetlands are created.

ApplicationAll quarries having a link with aquifers and natural bodies of water.

Principles• Avoid any operation that could generate pollution.• Strict management of any landfill operations taking place in wet

environments (lakes, marshes, etc.). See Guideline n° 22.• Monitor water quality.• Lake size and depth have an influence on nutrient levels.• Quarry management can have a major influence on water quality.

List of proven techniques available• Regular water analyses in lakes and wetlands, or the use of

piezometers.• Check landfill materials (Guideline nº 22) before putting into water.• Avoid planting deciduous trees around pond shores.

Costs• Piezometer: € 2 000• Water sampling and analysis: € > 400• Hydrogeological surveys: € > 50 000

List of reference documentsSYMALIM (Syndicat Mixte pour l’Aménagement et la Gestion du Parc deLoisirs et du Lac de Miribel Jonage) 1997, Atlas de l’Ile de Miribel-Jonage SYMALIM – Parc Nature des Iles de Miribel-Jonage. Document availableat Millery (France).

Jean-Luc BOURGUET1997, Chronique de la piézométrie et de la qualité des eaux de la nappedu Garon, Internal document, available at Millery (France).

Philippe BARDOT1999, Rapport d’expertise hydrogéologique : compatibilité desexploitations des ressources en granulats et en eau de la vallée du Garon,35 pages + annexes, available at Millery (France).

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Bernard DONVILLE2000, La Carrière de Saint-Caprais (Haute-Garonne) : 20 ans de suivihydrogéologique – LAFARGE GRANULATS – available at Issy or Toulouse(France).



MONTLOUIS Aggregates Ille-et-Vilaine France Neutralization of acid drainage by limestone

GRENADE Aggregates Haute-Garonne France pits being reclaimed inorder to be compatiblewith production ofdrinking water.

DECINES Aggregates Rhône France

Experts to contact


Jean-Luc BOURGUET Paris France 33 1 40 95 69 30

Didier COLLONGE Brittany France 33 2 99 14 87 14

Water Quality Protection

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ObjectiveTo safeguard and/or improve soil characteristics and where possible to establish self-sustaining vegetation.

ApplicationAll quarries with soil used for rehabilitation.

Principles• Preserve, restore and/or enhance soil properties in accordance with the

initial characteristics.• Original topsoil should be preserved.• Encourage natural regeneration processes in line with biodiversity

objectives.• Monitor crop production to adjust fertilization.• Preparation should not be at the expense of the environment.

List of proven techniques available• Topsoil stripping: see Guideline nº 10.• Amendments may be necessary when topsoil must be brought from

another site.• Biological amendments (e.g., compost, organic supplies, nitrogen-fixing

grasses, sewage sludge) are suitable for long-term results; however,chemical fertilizers are often necessary to induce the process of naturalregeneration.

• If topsoil is not available: mycorrhizae can be used (see Guideline n° 21).

• Decompaction can be necessary to facilitate root development.

Costs– Chemical fertilizers: added to hydroseeding: additional cost

about € 0.1/m2.agricultural technique: € 0.02 /m2.

– Amendments: lime, about € 400 /ha.

List of reference documentsChambre d’Agriculture1999, Etude agropédologique : diagnostic de remise en culture del’ancienne carrière “Bergerie de Broussan” à Bellegarde (Gard), 15 pages,available at Rognonas (Bouches-du-Rhône, France).

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CEMAGREF TPG1999/2000, Techniques de réaménagement agricole et forestier.MICHALSKI, M.F.P. et al.1987, Rehabilitation of pits and quarries for fish and wildlife,Ministry of Natural Resources of Ontario, Land Management Branch, 59 pages.

PERRY, David A. et al.1988, The plant-soil bootstrap: microorganisms and rehabilitation ofdegraded ecosystems, Restoring the Earth Conference, “Environmentalrestoration” edited by John J. Berger.

REUTER, Ron1997, Sewage sludge as an organic amendment for reclaiming surfacemine wastes, University of Minnesota, Department of HorticulturalScience, H5015 Restoration ecology, Restoration and RehabilitationReview 1997 @www.hort.agri.umn.edu/h5015/rrr.htm

STURGES, Susan1997, The use of mycorrhizae in mined land rehabilitation, University ofMinnesota, Department of Horticultural Science, H5015 Restorationecology, Restoration and Rehabilitation Review 1997 @www.hort.agri.umn.edu/ h5015/rrr.htm



BELLEGARDE Aggregates Gard France Agropedology study

BERNIERES Aggregates Eure France

SOMERSHAM Aggregates Cambridgeshire UK drainage

EXSHAW Cement Alberta Canada CKD site

KARSDORF Cement Sachsen Anhalt Germany Vineyard

Experts to contact






Soil Preparation

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ObjectiveTo establish vegetation by seeding in reclaimed areas.


Principles1. Natural recolonization:

– organic topsoil contains residual seed bank,– recolonization can be achieved by the natural spread of seeds.

2. Seeding:– indigenous seeds harvested in the vicinity,– commercial seeds bought for this specific purpose (check origin).

List of proven techniques availableThe techniques depend on the nature and physical characteristics of thetopsoil, the accessibility of the area and its slope.• Agricultural techniques (with a tractor, cultivation and seeding

machine) can be used on regular land and prepared topsoil.• Hydroseeding requires little preparation (seeds, mulch and water

sprayed together over the area to be seeded).• Hand seeding on small area.• Tree and shrub seeds can be scattered and sown along with grass seeds

(for tree and shrub planting, see Guideline nº 21).

CostsAgricultural seeding of purchased seeds (including seeds): 0.02 €/m2.Hydroseeding: 0.3 to 0.4 €/m2.Additional costs: harvest of local seeds: 0.02 to 0.2 €/m2,

difficult access or very poor topsoil up to 0.2 €/m2.

List of reference documentsG. ARNAL November 1979, L’Engazonnement des emprises routières, ministère del’Environnement du Cadre de Vie et des Transports, France.

CEMAGREF 2000 (in progress), Synthèse bibliographique des techniquesd’aménagement agricole et forestier.

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AIX-EN-PROVENCE Aggregates Bouches-du- France Ssuccessful seeding in Rhône dry climate conditions

TOSNY / BERNIERES Aggregates Eure France

GUERNES/SANDRANCOURT Aggregates Yvelines France

LLYNCLYS Aggregates Shropshire UK Natural regeneration

WEST DEEPING Aggregates Lincolnshire UK Agriculture

QUATRO BARRAS Aggregate Curitiba Brazil


VAL D’AZERGUES Cement Rhône France

VILLEVAUDE Gypsum Val d’Oise France Seeding of intermediate quarry slopes

RAHMSTORF Roofing Germany

Experts to contact


Pierre de PREMARE Aggregates France 33 1 44 34 11 11








Seeding

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ObjectiveTo enable tree and shrub species to develop on reclaimed areas.

Planting can be used for landscaping, bio-diversity, commercial forestry,orchards and to develop an amenity, etc.

ApplicationAll quarries, whenever possible.For natural recolonization see Guideline nº 20.

PrinciplesSelect the indigenous or exotic species, the age of the plant stock andthe planting pattern according to:

– the final use and landscape design (distinguish between forestryand amenity),

– the physical characteristics of the substrate,– the climate.

Take the planting season into account.Prepare the soil and subsoil (ripping, weeding, gyro-crushing, plowing,plant pits) In the case of an ecological objective, opt for a medium-term reconstitution of a consistent biotope (diversity, edge effects)rather than a massive and immediate reforestation by uniform conifers,for example.

List of proven techniques available• Get some help from a real pro!• Techniques vary according to species, plant age and substrate.• Planting of large or ornamental species: staked and/or protected

against pests or wild animals.• Forestry plantation: small plants (0.1 to 0.3 m), 1 000 to 4 000 plants/ ha.• A maintenance program in accordance with the rehabilitation

objective (Guideline nº 31) is compulsory; if watering is used it shouldbe continued.

• Decompaction may be necessary (see Guideline nº 19).• Plants can be bare or root balled and may need watering at the

planting stage.• On sterile soils, mycorrhizae can prove successful.

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Costs (forestry)Plant € 0.7 to 1/unitProtection € 0.2 to 0.3/unitOperation € 0.6 to 0.7/unit

List of reference documentsCSS (LAFARGE GRANULATS)1997, Our environment development techniques, Internal documents.



SENAS Aggregates Bouches-du- France Orchards (olive trees)Rhône

GUERNES Aggregates Yvelines France Reconstitution of SANDRANCOURT various local biotopes

MILLERY Aggregates Rhône France Mycorhiza plantations

MOUNTSORREL Aggregates Leicestershire UK

KARSDORF Cement Sachsen Germany Vines planted in a redeveloped area; visual barriers with plantations

MATOZINHOS Cement Minas Gerais Brazil Plantation nursery


HOPPEGARTEN Roofing Germany

VILLEVAUDE Gypsum Val d’Oise France

QUATRO BARRAS Aggregates Curitiba Brazil

Experts to contacts




Loïc ROYERE Aggregates France 33 4 72 24 46 25






Tree and Shrub Planting

ObjectivesTo create landforms by filling in excavations with imported inert landfillmaterials while preserving the quality of soil and subsoil.

ApplicationAny site lacking enough internal fill material to implement therehabilitation plan.

Principles• Assess the sources of input and optimize the costs of transport.• This activity must be compliant with regulations.• Rigourous control of environmental quality.• Assess the geological (hydrogeological & geotechnical) capability

to receive such materials.

List of proven techniques available• Landfill management: volumes, quality, terracing, tipping techniques

(direct tipping or tip & push).• Monitoring: maps, monitoring of water on site or using piezometers,

soil analyses; mechanical testing (bearing and settling capacity).• Final cover quality must be taken into account.• Perform appropriate soil compaction for areas that are to be built

upon.

CostsEarthmoving: see Guideline nº 9.

List of reference documentsEuropean directive 1999 - Nº 1999/31/EC of 26.04.1999concerning the dumping of waste.

CFEG October 1994, Projet de comblement d’un talweg : étudegéotechnique (Rivolet Quarry, Rhône, France) – available at Millery(France).

BRGM March 1990, Carrière de La Patte (Rhône, France) :établissement du projet de stabilisation et de stockage de stériles –available at Millery (France).

CETE Lyon November 1992, Carrière de La Patte (Rhône, France) : mise endépôt de matériaux – available at Millery (France).

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CHEVRIERES Aggregates Oise France Diversified backfill and run-in backfill procedures

ST FARGEAU- Aggregates Seine-et-Marne France 60 ha of backfill, PONTHIERRY 180 villa plots

HILL FARM Aggregates Leicestershire UK

PAULDING Cement Ohio USA CKD site

VILLIERS-ADAM Gypsum Val-d’Oise France Underground mine filling with earthworks and demolition waste

FORCHHEIM Roofing Bavaria Germany 20 ha of backfill

Experts to contact


Pierre de PREMARE Aggregates France 33 1 44 34 11 11




Landfilling


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Objective To communicate and publicize achievements and progress with respectto the rehabilitation plan.To prevent or resolve crises within the neighborhood.

ApplicationAny quarry; this concerns both rehabilitation and operation.

PrinciplesCommittee should include representatives of local stakeholders, primarilyneighbors and local authorities.Organize meetings on site to inform people regularly about ouractivities.Listen to criticisms in order to improve the implementation details of therehabilitation project.

List of proven techniques available• For establishing a follow-up committee:

– the list of members should be representative of the variousinterests,

– role of committee secretary is fulfilled by the company,– the frequency of meetings should be tailored to the mandate of the

committee.

For each meeting• Site preparation (meeting room, quarry site).• Agenda.• Minutes of previous meeting.• Proof of improvements based on agreed indicators: photos, water

analyses, acoustic measurements, etc.

CostsSite specific.

List of reference documentsMinistère de l’Environnement 1998, Charte de la Concertation – Ministère de l’Environnement, France.Available at Issy or Millery (France).

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Braas Dachsysteme GmbHRecords of the project Kiessandtagebau Münchenberg-Wildermann, roof tile work – Hoppegarten, files stored at the unit. Product technology and Raw Materials (DP).

Kurt FleckensteinAktuelle Probleme des Rohstoffabbaues. Verlagsgesellschaft Grüter,Hannover, 121 pages.

Christoph Werner1998, Akzeptansmanagement, Journal “Steinbruch und Sandgrube 06/98”, pages 24-26.

B. Wohlrab et. al1995, Oberflächennahe Rohstoffe. Gustav Fischer Verlag Jena, Stuttgart,304 pages (ISBN 3-334-60963-4).

Ulrich Tränkle, Thomas Beirwenger1999, Naturschutz in Steinbrüchen, Industrieverband Steine+ErdenBaden-Württemberg, Ostfildern, 84 pages (ISBN 3-934184-00-6).



SENAS Aggregates Bouches-du-Rhône France

SANDRANCOURT Aggregates Yvelines France



LA COURONNE Cement Charente France

MAZAN Gypsum Vaucluse France

HOPPEGARTEN Roofing Brandenburg Germany Operation in the nature park “Märkische Schweiz”

Experts to contact





Pierre ARDANT Cement France 33 5 45 23 39 15


Ron FOSTER Aggregates UK 44 1530 242 151

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Objective To improve general relations with site neighbors by presenting ourrehabilitation achievements to a broad public.

ApplicationAny quarry undergoing rehabilitation

PrinciplesOrganization• Invitation, advertising• Safety • Site preparation• Internal information• Formation and training of team.

Content• Rehabilitation plan• Rehabilitation techniques• Monitoring tools • Guided tours.

The site must be clean and welcoming. Local journalists should beinvited.

List of proven techniques availableVisitors may include employees and their families, neighbors, schools,local authorities, customers.Have suitable sites available with, for instance:• Exhibition in a tent • Slide show (beware of excessive ambient light)• Self-guided tours • Narrated visit: partly in tour bus or minibus, for extensive sites and

depending on the number of visitors• Promotional gifts (discuss with communications or commercial

department) • Organization of participatory and observation activities: ornithological

journeys, fishing, and similar.

Open Days, Visits

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Costs€ 5 to 25 k/day• Mobilization of Group employees (preparation + day).• Rental of tents, tour buses, display equipment for exhibition, etc.

graphic communication: production of signs and boards, descriptivesheets, brochures.

• Promotional gifts.

List of reference documentsMinistère de l’Environnement 1998, Charte de la Concertation, Ministère de l’Environnement, France.Available at Issy or Millery (France).



BERNIERES Aggregates Eure France

BOULBON Aggregates Bouches-du-Rhône France Quarry used once a year as theatre for the “Festival d’Avignon”

GODMANCHESTER Aggregates UK

CONTES Cement Alpes-Maritimes France

Experts to contact





Open days, visits


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ObjectiveTo enlist the participation of third parties for the development ofquarrying plan and rehabilitation objectives in order to utilize theirexpertise, take their expectations into account and hear their points ofview.

ApplicationAny site in the Group, even in the absence of local pressure, providedinterested parties can be involved.For instance, when the site represents a scientific – especially natural orarcheological – novelty or is of possible importance for tourism, leisure orland use.

Principles• Search locally for the most interested/appropriate partners.• Prepare a suitable presentation of the project and communicate to

stakeholders.• Identify mutual interests of parties.• Define concrete objectives for partnership and consider written

contract.• Clarify mutual obligations.• Partnership document, if any, must include objectives, commitments,

means, duration, termination clause.

List of proven techniques available• Associate scientific organizations with our research into natural

environments, water or landscapes.• Facilitate the study of a phenomenon generated or revealed by our

activity by the appropriate scientific bodies.• In return, solicit the most complete information possible about the

methodology of the studies and the results obtained.• Draft agreements with a nature conservation group for studies on

natural ecosystems, specific animal or plant species.• Sale of the land to a scientific partner such as: National or Regional.

Partnerships with Conservation Groups, Organizations and Statutory Agencies

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Nature Trust, Natural Regional Park where applicable, conservationorganizations, (see Guideline nº 29).

• Lease granted to this type of partner, see also Guideline nº 29.• Tri-partite agreement between the owners of rented sites the partner

and LAFARGE.• Authorization for research works, such as archaeological or geological

salvage excavations (e.g.: amber deposits atCHEVRIERES/HOUDANCOURT).

• Archaeology: agreement with the appropriate public structure.

CostsExtremely variable/main cost is related to time spent in preparingpartnership• Amber: permitting access to deposit by pumping for the Natural

History Museum + participation in financing the research (€30 k).• LPO/FIR Brittany (LAZ site): Arranging nesting facilities.

List of reference documents• Agreements Agence des Espaces Verts Région Ile-de-FranceFédération Rhône-Alpes de protection de la Nature (FRAPNA)Institut National de Recherche Agronomique (INRA)Ecole Nationale Supérieure du Paysage (Versailles).

• CORA Rhône1999, L’EFFRAIE nº 13 : La Gravière du Garon à Millery, documentavailable at Millery (France).

• Internal documentsUne découverte scientifique exceptionnelle : ambre de l’Oise – documentavailable at Issy, Verberie, Sandrancourt, Millery (France).

• Various press articles



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HOUDANCOURT Aggregates Oise France Study of fossil invertebrates in the Sparnacian amber ( - 54 My)

LAZ Aggregates Finistère France Monitoring of bird ofprey nesting by LPO/FIR Brittany

SANDRANCOURT Aggregates Ile-de-France France Agence des Espaces Verts - Ile-de-France


BESTHORPE Aggregates Nottinghamshire UK

MARBLEHEAD LCM: Ohio USA Ohio State Nature aggregates Preserve with

continued monitoring and inventory of rare plants

LE TEIL Cement Ardèche France FRAPNA


RAHMSTORF Roofing Lower Saxony Germany Specific preparing of slopes for sand martins

Experts to contact



Patrick ROLLAND Aggregates France 33 2 99 47 39 61

Irv MAURER LCM: aggregates USA 1 410 847 32 00




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ObjectiveTo prepare for final rehabilitation by removing all disused productionfacilities and waste material, before the partial or complete closure ofthe quarry.

ApplicationAll quarries of the Group ready to be totally or partly rehabilitated.

Principles• List all necessary cleaning operations.• Plan for cleaning of site.

Many site cleaning procedures used during operations can also apply toterminal cleaning:• Disposal of any items that have become useless or undesirable for

esthetic or environmental reasons. • Prior selective sorting on site and storage as required.• An environmental audit to determine whether there are any issues that

require special attention or cleanup, particularly prior to sale of the site• Maintenance of sufficient staff and budget until the site is permanently

rehabilitated as planned.

List of proven techniques available• Sort the recoverable structures (hoppers, conveyor belts…), to be

stored separately.• Waste skips: scrap, oily waste, etc.• Prevent intrusion, especially via access ways that could lead to the

dumping of undesirable products (refuse, drums…): fencing to bechecked at these points (see Guideline nº 27).

• Inert waste: to be removed to a specialized sorting center; keep thedelivery vouchers.

• Obtain third-party acknowledgment of cleaning.• Prepare a document gathering data on site cleaning and plant

decommissioning, especially cost data (see Guideline nº 8).

Costs Provide for the following expenses:

– disposal of used oils: free for a sufficient volume;– dismantling of the installations: see documents below;– environmental remediation where necessary.

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List of reference documentsInternal documents:LAFARGE GRANULATS, Direction Environnement et Ressources MinéralesNov. 1999 – Coûts des travaux de remise en état, provisionnables au31.12.1999 – document available throughout the LAFARGE GRANULATSEnvironment network (France).

LAFARGE GRANULATSDismantling and refurbishing of the port of Lyon-Vaise – notes availableat Millery (Rhône, France).



AIX-EN-PROVENCE Aggregates Bouches-du-Rhône France

BRADBOURNE Aggregates Kent UK Sevenoaks Wildfowl Reserve

HAUBOURDIN Cement Nord France

LOTINGHEN Cement Nord France


PORTEL-DES- Gypsum Aude France Team workingCORBIERES continuously until

the end of the program

Experts to contact


Loïc ROYERE Aggregates France 33 4 72 24 46 25




Terminal Cleaning


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ObjectiveTo limit the risks of accident after site closure.


Principles• Control all hazardous points (ponds, benches and faces).

• Whenever hazards cannot be completely eliminated, access

must be forbidden and the area must be enclosed.

List of proven techniques available• Fencing: using either barbed wire, impenetrable hedge barriers or wire

netting (except in flood areas).

• Stakes: either of wood or metal with anchoring (for hard outcrops).

• Berms: with constraints as to height and direction in flood areas.

• Entrances: either barriers or gates (more costly but more efficient).

• Signage: mark out property limits.

• Surveillance: regular checking (monthly or even weekly) of fencing

especially at points accessible to outside vehicles.

A thorn hedge can be planted along the fence, best at the beginning ofmining operations, so as to develop a more lasting and impenetrablephysical obstacle.

CostsFencing: € 5/m with wood stakes every 3 m, 6 rows of barbed wire,

€ 15/m with metal stakes every 3 m, 6 rows of barbed wire.

Barrier: ≈ € 200: supply + installation with anchorage.

Gate: € 600 – 800: supply + installation with anchorage.

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List of show cases for this guidelineMany cases on our different operations.


AIX-EN-PROVENCE Aggregates Bouches-du-Rhône France Fencing and gate

CHEVRIERES Aggregates Oise France Wooden fencing for landscape integration


Experts to contactLegal consequences must not be overlooked, therefore, the legaldepartment experts should be called upon as needed.




Louis DECOMBES Cement France 33 4 75 49 60 23



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Objective To obtain formal approval of authorities, associations and neighborsabout the rehabilitation implemented.

Use the Group’s rehabilitation references to earn broader approval bythese stakeholders regarding our activity, including new projects.

ApplicationAll quarries that have just been totally or partly rehabilitated

Principles• Present actual rehabilitation achievements rather than planned

projects (which can sometimes be modified).• Explain the benefits to the local community of the rehabilitation

program implemented.• Anticipate the questions and concerns of stakeholders.• Ensure that the Group has honored its commitments, and highlight

this fact.

List of proven techniques available• Site meetings with authorities, associations, neighbors, journalists.• Document that explains the rehabilitation plan, the techniques

implemented, the final use.• Information panels at the entrance or on viewpoints, if the risk of

vandalism (damage, graffiti…) is low enough.• Application for environmental awards and communication on site after

winning them.

Costs• Time devoted to meetings.• Information panel: 200 to 1 000 €.

List of reference documentsGRANULATS SUD1999, Présentation du réaménagement de la carrière,GROUPE LAFARGE de la Plaine des Dès à Aix-en-Provence – available atMarseille (France).

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LAFARGE – CSS1993, Moisson-Freneuse (78) : valorisation forestière et écologique desterrains réaménagés, 2 pages – available at Issy or Sandrancourt (France).

LAFARGE – CSS1996, Guernes/Saint-Martin-la-Garenne (78) : un site paysager de valeurécologique, 2 pages – available at Issy or Sandrancourt (France).

Service Foncier Est1995, Le réaménagement du site du Saulcy (now part of LAFARGE)(Crévéchamps quarry) – Redland Granulats, 6 pages.

List of showcases for this guidelineMany cases on our different operations.


AIX-EN-PROVENCE Aggregates Bouches-du-Rhône France

CREVECHAMPS Aggregates Meurthe-et-Moselle France 28.09.1995: presentation and visitfor administrations, local authorities, customers, profession

LA CROIX-ST-LEUFROY Aggregates Eure France Graduate UEPG-award

MOISSON-FRENEUSE Aggregates Yvelines France Graduate UNICEM

URPG Ile-de-France award

CHAVAGNE- étang de Aggregates Ille-et-Vilaine FranceBabelouse (a pond)

SHALERSVILLE LCM: USA Graduate “Wildlife Aggregates Habitat” award,

1994


KARSDORF Cement Germany

Experts to contactName Division/region/sector Country Phone n°



Francis STEPANOFF Aggregates France 33 2 99 14 87 14


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ObjectiveTo find solutions to ensure an acceptable long-term development of thesite through an adequate management scheme.To avoid challenges to the future site use and the resulting impact on ourimage.

ApplicationAll quarries, especially those whose future use is related to natureconservation, or other purposes of general interest.

Principles• Technical conditions of rehabilitation must make it difficult to change

the final use of the site.• Find an appropriate third party who will ensure long-term

management of the site according to agreed final use.• If the quarry site is sold, agree on use and site management with future owner.• Final use of site must be enacted in official documents on urban

planning and land-usage.

List of proven techniques available• Involve ourselves with local community through local conservation groups.• Communicate the value of the site to a wide audience.• As all quarries and landholdings will require management, partners

have to be involved as a part of the management process.• Maintain an influence to ensure the rehabilitation and site

management aims are achieved through the partnership arrangement.

Lease, licence or sale under conditions, to the followingpossible partners• Partnerships with policy groups:

– U.K.: Green Alliance (advising Government), English Nature (statutory agency),

– France: Conservatoires Régionaux des Espaces Naturels.• Partnerships with non-statutory agencies.

– U.K.: Royal Society for Nature Conservation & the Wildlife Trustmovement Royal Society for the Protection of Birds (RSPB),

– France: Ligue pour la Protection des Oiseaux (LPO) France NatureEnvironment (FNE),

– Kenya.• Partnerships with specific and local associations on species or habitat.• Partnerships with Local Authorities.

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• Partnerships with farmers for an environnementally designed farming(woodlands, hedges, specific agricultural practices…).

CostsVaried and site specific.

List of reference documentsRené Haller, From Wasteland to Paradise


Site Division Region/dep. Country Associated partnershipComment

LAGRUERE Aggregates Lot-et-Garonne France Local association created on purpose for future management after rehabilitation

GUERNES/ Aggregates Yvelines FranceSANDRANCOURT

SANDY Aggregates Bedfordshire UK The Wildlife Trust for BedfordshireBedfordshire County Council RSPBEnglish Nature

BRADBOURNE Aggregates Kent UK The Jeffrey Harrison Memorial Trust

BESTHORPE Aggregates Nottinghamshire UK Nottinghamshire Wildlife Trust

PORTEL-DES- Gypsum Underground quarry CORBIERES transformed into

successful tourisme place of interest

Experts to contact



David DUBOIS Aggregates France 33 5 53 93 46 71

Claire MORICE Aggregates France 33 1 34 97 02 70






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ObjectiveTo identify and implement the after-use project best suited to thesurrounding context.To maximise the potential of the after-use of the site in the best costeffective manner, if this after-use is different from the initialrehabilitation objective (otherwise, see Guideline nº 2).

ApplicationAll quarries ready to be partly or totally rehabilitated.

Principles• Based on a global approach that considers the site in its context, strive

to seize opportunities for projects able to add value in both economicand environmental terms.

• Remember: the type of rehabilitation project must take the geologicaland hydraulic consequences of quarry operations into account.

• The management costs related to the chosen rehabilitation system, aswell as any additional revenue streams, must be integrated into projecteconomics.

List of proven techniques available• Ecological studies.• Landscape studies.• Economical studies: final land uses will generate a revenue such as

agriculture, forestry, angling and boating. Grant aids may also beavailable from a variety of sources.

• Consultation with interested parties: local authority, neighbours, theland owner, statutory agencies and NGOs…

CostsSee Guideline nº 2.Feasibility studies if necessary (i.e.: water quality for fishing).

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CHEVRIERES Aggregates Oise France Future fishing center

BROADWATER Aggregates UK Sailing

WATERFORD Aggregates UK (mentioned on 26th June)

GODMANCHESTER Aggregates UK Zoned fishing

KINGSWOOD NNR Aggregates UK Forestry(Undug land)

Choose between: Aggregates UK AgriculturePANSHANGERCOLE GREENSOMERSHAM

Choose between: Aggregates UK Housing and FOXHOLES industrial DOUBLEGATES development

SHALERSVILLE Aggregates USA Local water supplyHousing development

MARTES Cement France

GAGNY Gypsum Seine-St-Denis France Housing and urban park

MONHEIM Roofing Germany Football pitch(KIESGRABEN)

Experts to contact


Pierre PROY Aggregates France 33 3 44 38 30 00

Pierre DE PRÉMARE Aggregates France 33 1 40 95 69 33


Irv MAURER LCM (Aggregates) USA 1 410 847 3200


Francis HORTEMEL Corporate France 33 1 44 34 11 11


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ObjectiveTo ensure the long-term viability of the rehabilitation program bothduring and after quarry operations, in order to protect the Group’simage and investment.

ApplicationThis practice must be applied to all reclamation and landscaping work, aslong as LAFARGE group keeps control on the rehabilitated site.

PrinciplesMaintenance and monitoring are an integral part of any rehabilitationprogram. Sufficient budgetary and human resources must therefore beallocated to these aspects. They must be defined in a program andcoordinated by a project manager. Maintenance and monitoring must be practiced to insure thatappropriate corrective measures are executed for all deficiencies thatmay impair future uses. In case of sale, suitable information andrequirements must be transmitted to the buyer.

List of proven techniques available1 – Above all, maintenance and monitoring refers to upkeep of

fences, site access control, cleanliness, and landscapemaintenance.

2 – In natural areas, maintenance will consist of watering, amendingthe soil, replacing dead trees and shrubs, controlling pests,removing weeds, moving between tree lines, cutting grasslandareas… Il can usefully be managed together with local NGOs orpartners. Monitoring will address issues of physical nature (soilstability, resistance to erosion, drainage efficiency, water quality)and biological nature (species richness, plant density, canopycover, seed production, fauna return, weed control, productivity,and nutrient cycling) on a regular basis to insure the viability andsuccess of rehabilitation.

Nature Conservationa. Produce and follow a management plan.b. Keep an open mind and seek to enhance the site by further habitat

creation as appropriate.c. Prepare a database of species and regularly review to identify

changes.d. Issue periodic reports on the evolution of the site.e. Seek the help of volunteers and associations to draw up the

inventory.

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Forestry & Woodlanda. Produce and follow a woodland management plan.b. Entrust the management of woodlands to professionals.

Agriculturea. Produce a 5 year forward plan of agricultural enhancement.b. This plan is to ensure the soil structure improves and drainage is

effective.c. Crop selection and management must be defined to improve soil

structure.The quality of the rehabilitation program must be certified throughan agronomical assessment.

List of reference documentsMichalski, M.F.P. et al.1987, Rehabilitation of pits and quarries for fish and wildlife, Ministry ofNatural Resources of Ontario, Land Management Branch, 59 pages.Cemagref de GrenobleEtude du Museum UNPG – Carton vert.



BERNIERES Aggregates Eure France Forestry

GUERNES Aggregates Yvelines France Grassland

HOPPEGARTEN Roofing Brandenburg Germany Forestry

FORCHHEIM Roofing Bavaria Germany Agriculture

STEINBACH Roofing Bavaria Germany Forestry

Experts to contact






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