guidelines for cutting stones industry · khalil zein 3 l015-15/ moe guideline-cutting stones/march...

Republic of Lebanon

Ministry of Environment

GUIDELINES FOR CUTTING

STONES INDUSTRY

Prepared by

Khalil Zein

MARCH 2016

Ministry of Environment Environmental Guidelines for Cutting Stones Industry

Khalil Zein 1 L015-15/ MoE Guideline-Cutting Stones/March 2016

Table of Contents

Table of Contents ....................................................................................................................... 1

List of Figures ............................................................................................................................ 1

List of Tables ............................................................................................................................. 1

1) National Legislation and Institutional Framework: ............................................................ 3

2) Production Process ............................................................................................................. 8

3) Potential Impacts of the Production Process: ................................................................... 12

4) Detailed Description of Pollution Prevention and Pollution Abatement Methods ........... 14

5) Contingency Plan .............................................................................................................. 20

Annex 1 .................................................................................................................................... 23

References ................................................................................................................................ 24

List of Figures

Figure ‎1-1: Process for obtaining an industrial permit according to Decree No. 8018/2002

(Adapted from Policy Paper & Action Plan for Industrial Wastewater

Management in Lebanon) ....................................................................................... 7 Figure ‎2-1: Detailed Description of the Production Process ..................................................... 9

Figure ‎2-2: Typical layout plan for cutting stone plants .......................................................... 10

Figure ‎4-1: Typical settlement pond design (Dartmouth Eng. University) ............................. 16 Figure ‎4-2 Settlement silo ........................................................................................................ 17 Figure ‎4-3 Schematic diagram of a settlement silo .................................................................. 17

List of Tables

Table ‎1-1: Definition of Industrial Establishments Categories (Decree No. 8018/2002) .......... 3

Table ‎1-2: Cutting Stones Industry Classification System (according to Decree No.

5243/2001) and setback distances (according to Decree No. 8018/2002) ............... 4

Table ‎1-3: Existing Laws, Decrees and Decisions Related to the Environmental Sector ......... 6 Table ‎1-4: The Responsibilities of the concerned ministries and governmental institutions .... 6

Table ‎1-5: Permitting Applications Types ................................................................................. 7 Table ‎3-1 Typical generated wastewater quality ..................................................................... 13 Table ‎4-1: Permissible Ambient Noise Levels in Different Regions ...................................... 19 Table ‎4-2: Noise exposure limits ............................................................................................. 19 Table ‎5-1: Potential Impacts and Correspondent Mitigation Measures ................................... 22



LIST OF ABBREVIATIONS & ACRONYMS

BOD Biological Oxygen Demand

COD Chemical Oxygen Demand

EIA Environmental Impact Assessment

EMP Environmental Management Plan

IEE Initial Environmental Examination

MoE Ministry of Environment

MoI Ministry of Industry

ECC Environmental Compliance Certificate

TSS Total Suspended Solids

WW Wastewater

SS Suspended Solids

SOx Sulfur Dioxide

DGUP Directorate General for Urban Planning

CO Carbon Monoxide

O2 Oxygen

NOx Nitrogen Oxide

MoPH Ministry of Public Health

PM Particulate Matter

PPE Personal Protective Equipment



1) National Legislation and Institutional Framework:

1. Introduction

Industrial establishments may cause environmental perturbations during construction and/or

operation which will differ according to the practiced activities.

The decree law number 21/L dated 22/7/1932 defines rules and conditions related to

classified establishments that require permits. In follow up to this decree law, Decree No.

4917 dated 24/3/1994 was issued to amend the classifications of establishments with

hazardous activities or with impacts/harm on health. Decree 4917/94 categorizes classified

establishments in 3 groups depending on their location, size (production capacity) and

potential impacts.

In 2001, industrial establishments were classified according to Decree No. 5243 dated

5/4/2001 listing all available industrial facilities in categories numbered from one to five

taking into consideration its potential environmental impacts. The conditions, criteria and

rules for the permitting of the industrial establishments were set in Decree No. 8018 dated

12/6/2002.

Category I: generates very dangerous impacts on the environment, surroundings and public

health which requires moving it away from the households to prevent its impacts.

Category II: generates dangerous impacts on the environment, surroundings and public

health but does not require moving it away from the households. However, it will not be

given an investment permit unless mitigation measures are taken to prevent its impacts.

Category III: generates limited negative impacts on the environment, surroundings and

public health and must be subjected to special conditions to avoid its limited impacts.

Category IV: generates minimal negative impacts on the environment, surroundings and

public health and must be subjected to special conditions to avoid its minimal impacts.

Category V: does not generate any negative impact on the environment, surroundings and

public health. Table ‎1-1: Definition of Industrial Establishments Categories (Decree No. 8018/2002)

Cutting stones Industry Classification is presented in table 2 according to Decree No.

5243/2001.Setback distances are set as per Decree No. 8018/2002.



Cutting Stones Industry ISIC code 1411

Production

process Classification Classification Criteria Setback Distances

Cutting Stones

Industry Category 2

It generates dangerous

impacts on the environment,

surroundings and public

health but does not require

moving it away from the

households. However, it will

not be given an Operation

permit unless mitigation

measures are taken to

prevent its impacts.

If project area is located

within a classified industrial

land, refer to its

correspondent legislative If

the proposed plot is located

within a non-classified area,

the following requirements

must be met:

o Distance ≤1000m from

any archaeological and

natural areas protect by

a specific and/or Urban

Decree.


main rivers (Aarka, AL

Estwan, Al Bared, Abu

Ali, Al Bouhsas, Al

Jawz, Ibrahim, Beirut,

Al Damour, Al Awali,

Al Zahrani, Al Litani)


winter drainage system.


hospitals, schools,

nurseries or shelter

plots limit.


the residential

community of five or

more houses.

o Distance 1000m from

coastal shoreline.

o Distance ≤200 m from

international highways

boundaries.

o Distance ≤100 m from

international roads

boundaries.

Table ‎1-2: Cutting Stones Industry Classification System (according to Decree No.

5243/2001) and setback distances (according to Decree No. 8018/2002)



2. Environmental Assessment

The Cutting Stone Industry is an activity of environmental significance; these activities

require an establishment permit and an operation permit. Turbid and highly alkaline

wastewater, dust emissions and noise are the key potential impacts associated with such

facilities.

The national principal legislation addressing pollution is the Environment Protection law

444/2002 that imposes the general environmental duty on industries undertaking an activity

that affects or may affect the environment to take all reasonable and practicable measures to

prevent or minimize any resulting environmental harm. In addition to MoE Decision 60/1

dated 20/9/2001, which issued a set of procedures and guidelines for the establishment and

operation of industrial institutions/facilities according to its location, production process and

procedures and its potential pollutants.

Even though Cutting Stones industries do not fall under the decree 8633/2012 (Fundamentals

for Environmental Impact Assessment), however, the MoE oblige such projects to prepare an

Initial Environmental Examination (IEE) report and submit it to the Ministry of Environment

(MoE), as such industry has various impacts on the environment. In case the plant falls under

a sensitive area as per annex 3 of the decree 8633/2012, the plant is subject to an EIA study.

3. Environmental Compliance Certificate

The Cutting Stones industry should abide by the Decree No.8471/2012 on “Environmental

Compliance for Establishments” and its related decisions. Applying for this certificate

includes preparing an Environmental Audit with an Environmental Management Plan (EMP).

Once environmental compliance is proven, after acquiring an operational permit, the facility

will be awarded with an Environmental Compliance Certificate. The plant will be required to

renew the Environmental Compliance Certificate (ECC) every three year based on a self-

audit prepared by the industry.

Table 3 and 4 indicate existing laws, decrees and decisions that are related to the

environmental sector and responsibilities of the concerned ministries and governmental

institutions.

Legislation Date of Issue Source Subject

Law 444/2002 8/8/2002 MoE Environmental Protection

Decree No. 8633 9/8/2012 MoE Environmental Impact Assessment

Fundamentals

Decree No. 8471 19/7/2012 MoE Environmental Compliance for

Establishment

Decision No. 8/1 30/1/2001 MoE

Standards and limits for air pollutants

and liquid wastes discharged by

classified facilities and wastewater

treatment plants.

Decision No. 52/1 29/7/1996 MoE Standards and limits for air, water and

soil pollutants

Decision 260/1 12/6/2015 MoE IEE Review Procedures



Decision 590/1 21/12/2015 MoE Environmental permitting clearance

Table ‎1-3: Existing Laws, Decrees and Decisions Related to the Environmental Sector

Institution Responsibilities

Ministry of Industry (MoI)

- Issues the industrial permit based on the recommendation

of the industrial permitting committee.

- Heads the industrial permitting committee.

- Conducts inspections to industrial establishments.

Ministry of Environment

(MoE)

- Sets environmental conditions for industrial and classified establishments permits.

- Review and approves environmental studies.

- Set Limit values and Standards for discharge of Liquid and solid Wastes

Ministry of Public Health

(MoPH)

- Check the compliance of the industries conditions with

necessary health related conditions.

Directorate General of Urban

Planning (DGUP)

- Checks the compliance of industry's location and construction with necessary and applicable conditions/regulations set in the Construction Law and/or in the Master Plan of the area

Concerned Municipality - Approves the issuance of the permit.

Table ‎1-4: The Responsibilities of the concerned ministries and governmental institutions

4. Permitting Procedure:

The following steps should be undertaken to acquire a construction or operation permit:

1. Submit file to the industrial permitting committee of the concerned Mohafaza. This

committee is formed of members from different concerned ministries (Documents

required are listed in Annex 2);

2. The file will be transferred to the concerned Municipality for their review and

approval;

3. When approved by the Municipality, the file will be transferred to the concerned

governmental authorities (MoI, MoE1, MoPH, Urban Planning);

4. After acquiring the feedback from all concerned governmental authorities, the

industrial permitting committee will recommend the final decision to the Director

General of the MoI who will transfer the file to the Minister of Industry with his

recommendation;

5. The final decision is issued by the Minister of Industry.

1 Environmental studies are required as defined previously in section 2.1 (Environmental Assessment)



Figure ‎1-1: Process for obtaining an industrial permit according to Decree No. 8018/2002

(Adapted from Policy Paper & Action Plan for Industrial Wastewater Management in

Lebanon)

Type of Application Purpose

Construction and Operation Permit

Each industry is subject to apply for

establishment and operation permit.

For categories 1,2, and 3, the industry is

subject to an Establishment Permit

followed by an Operational Permit

Construction Permit Renewal

If the construction of the industry wasn’t

achieved during the previously specified time

period

Permit Addendum

Is mandatory in the following cases:

Expansion or change in the industrial

process or classification of the industry

Addition of another industry

Table ‎1-5: Permitting Applications Types

Inter-

Ministerial

Permitting

Committee

(MoI, MoE,

MoPH & Urban

planning)

MoI

(Minister

Decision)

Submission of

Application

and requested

documentation

Department of

Industrial Permits

(MoI) or service

of regional

departments

(MoI)

Municipality or

Kaemakam

MoE

Decree No. 8018 dated 12/6/2002

Request Approval/ Rejection:

1.5 months for

establishment permit

amendment

2 weeks for

Operational Permit

Renewal

Approval/ Rejection:

30 days for the IEE report

2 months for EIA study

Review/ Comment: 1month



2) Production Process

Cutting Stones Industry is responsible for the processing and finishing of natural dimensional

stones such as marble granite and slate

The life cycle production starting from the primary cutting process until the finishing

procedure include several steps as such; receiving raw materials, cutting, polishing and

storage.


Khalil Zein 9 L015-15/ MoE Guideline- Cutting Stones /March. 2016

Figure ‎2-1: Detailed Description of the Production Process


Khalil Zein 10 L015-15/ MoE Guideline- Cutting Stones /March. 2016

Figure ‎2-2: Typical layout plan for cutting stone plants


Khalil Zein 11 L015-15/ MoE Guideline- Cutting Stone /March 2016

The production process includes five main stages, which include:

1) Reception and Storage of Raw Materials

This stage includes the acquisition of raw materials needed for the production process. The

raw stones are delivered via trucks to the facility. The raw stones are hauled from the trucks

via cranes, until their processing at a later stage.

2) Blocks Cutting (Sawing)

The blocks are sent to a cutting machine for the production of blocks of different properties

(slabs, sheets, tiles…) and various dimensions and thicknesses. Water jets are installed with

the machinery in order to trap fugitive dust. Moreover, while cutting, water is showered for

cooling the sawmill blades.

Rock Blocks

Water

Electrical power

→ Rock Cutting (sawing) →

PM emissions (emitted from dry cutting)

Wastewater

Stone cuttings and scraps

Maintenance and Spare parts Waste

Noise emissions

3) Polishing

This part of the production cycle includes the polishing treatment of the products. The

polishing operation is automated where the machine scrubs the surface until it is smooth and

shiny. Also in this production phase, water is used for cooling the blades of the polishing

equipment and for suppressing dust generated.

It is important to note that this production stage could be skipped, depending on the desired

end product.

Raw dimensional

Rock blocks

Fuel (trucks) →

Reception and

Storage of Raw

Materials

→

Fugitive particulate matter emissions (PM2.5- PM10)

from unloading of materials and movement of trucks

Exhaust emissions from trucks

Wastewater generation (stormwater runoff, dust

suppression wastewater)

Noise pollution from trucks movements

Noise pollution from the loading activities of raw

materials



Sawed Rocks

Water

Electrical power → Polishing →

Wastewater

Maintenance waste

Noise emissions

4) Storage and Distribution

At this stage, the blocks are ready to be distributed. However, in certain cases, the blocks are

stored in the facility’s premise. Delivery trucks will then access the site to haul the blocks to

their designated construction site.

Produced Stones →

Storage and

Distribution

→ Exhaust emissions from trucks

Fugitive emissions from trucks movement

3) Potential Impacts of the Production Process:

Cutting Stones Industry can result in significant environmental impacts, if not properly

managed or maintained. The environmental impacts, related to each production stage, are set

out in the following sections.

1) Impacts on Air Quality:

The major air emissions are Particulate Matter (PM2.5 and PM10), mainly sourcing from the

following operation activities:

- Delivery of raw materials: unloading of rock blocks from delivery trucks onto storage

piles, movement of delivery trucks, etc.

- Dimensional blocks sawing/cutting on dry basis

Exhaust gases are released along the operation of the plant as a result of the operation of

back-up generator(s), machinery requiring the burning of hydrocarbon based fuels and

vehicles to conduct transfer and delivery activities.

2) Impacts on Water and Soil Quality:

Wastewater generated during the production process mainly consists of:

- Contaminated storm water (storm water runoff)

- Cooling wastewater

- Dust suppression wastewater

In general, it is estimated that about 20 % of the total weight of the stone block is converted

into slurry. Studies indicate that 96 % of slurry generating from the stone cutting process is



water while the solid particles represent only 4 % (Al Zboon, Al-Zou’by, 2014). Thus, the

recycling of wastewater can significantly decrease fresh water consumption.

The main environmental concerns related to the generated wastewater from plants are the

high turbidity of the water. The typical quality of the wastewater generated from the cutting

stones industry is presented in the table below.

Parameters Value

pH 7.2

Temperature (oC) 20

Turbidity (NTU) 390

Electrical Conductivity (μs/Cm) 12500

Total Solids (mg/L) 9600

Total Suspended Solids (mg/L) 2100

Total Dissolved Solids (mg/L) 7500

Source: Fahiminia, Ardani, et.al. 2013

Table ‎3-1 Typical generated wastewater quality

If mishandled, the generated wastewater would negatively affect the physical, biological and

chemical characteristics of both the local water and soil quality, resulting in inevitable

implications on both the environment and the public health.

3) Impacts on Solid Waste Generation Rates:

The operation of a cutting plant results in stone cuttings and scraps of different sizes, types

and shapes. Moreover, dried up sediments resulting from sedimentation pond(s)/ settlement

silo at site are considered a major solid wastes source at the cutting stones industry.

The amount of solid waste generated depends on the operation capacity and the processed

materials. The improper disposal of generated wastes can lead to several environmental

problems including adverse effects on soil quality, flora, biodiversity, public health, and

surface and ground water quality.



4) Acoustic Environment

Noise emissions are considered as an environmental impact due to its disturbance to the local

community and the operators of the cutting plant. The major noise sources include:

- Trucks, cranes and other heavy machineries

- Sawing/ cutting of stones

- Alarms/ warning devices

If noise pollution is not well managed, it is most likely to affect the health of the personnel

on-site and the plant’s surroundings. In fact, such pollution negatively affects human health

and its wellbeing as it induces and promotes health problems such as hearing loss, stress, high

blood pressure, sleep loss, distraction and lost productivity and a general reduction in the

quality of life and opportunities for tranquility.

5) Occupational Health and Safety

The main occupational hazards in the plants include:

- Dust emissions emitted during the delivery, storage and handling of raw materials,

which result in eye and upper respiratory system irritations

- Noise hazards emitted from mechanical equipment, trucks and heavy machinery

- Poor ergonomics upon mechanical activities (i.e. Lifting, loading, unloading of raw

material, etc.)

- Risk of exposure to injury from sawing actions.

- Tripping hazards(i.e. during repairs and maintenance works)

- Traffic related accidents

4) Detailed Description of Pollution Prevention and Pollution

Abatement Methods

Applying best environmental management practices in Cutting Stones Industries is essential

to maximize the efficiency of raw materials and resources, reduce water consumption,

minimize wastewater generation, reduce air pollution, decrease solid waste generation rates

and protect the amenity of the site. The environmental management practices required to

protect the major environmental components is presented in the following sections.

1) Air Quality

The appropriate facility design and management practices can prevent the release of air

pollutants. The measures, which should be taken to prevent the degradation of air quality,

include:

The entire plant premises should be paved with hard, impervious materials, including

the drive ways from and into the plant.

The entire plant floor should remain dust-free

Natural or artificial wind barriers are to be placed to help control the emission of dust

into the surroundings of the facility (i.e. trees, fences and landforms in accordance

with prevailing wind direction).



Ensure that the trucks hauling stones from quarries or other raw materials are covered

during transport.

Cutting and polishing as part of the production process must be contained in a close

hangar with concrete base

Cutting and polishing process should include continuous water spraying to reduce

dust emissions.

All trucks leaving the facility’s premises should be clean and free of dust.

2) Water and Soil Quality

The main purpose of the environmental management of water quality is to ensure that the

generated wastewater does not directly reach sewerage network(s), surface waters, ground

water or land, prior appropriate treatment. The two major approaches to manage wastewater

in cutting stones plants are through: wastewater (cutting or cooling water) minimization,

waste water treatment, water recycling/reuse.

The entire plant should be paved with hard, impervious materials such as asphalt or

concrete.

Cutting areas should be bunded with small bunds or canals to ensure that the

wastewater , including storm water, is captured and collected and retained on-site to

the Waste Water treatment Settlment pond or silo (below are the specs. of the

treatment pond and silo) (Sediments and sludge from settlement pond(s)/silo must be

removed when the storage capacity of the pond/silo is half full. In case any material is

causing flow restrictions, this material must be removed immediately.

Sediments must be stored in a manner that does not promote the generation of fugitive

dusts.

Collected sediments must be properly handled and managed, promoting future reuses

whenever possible (i.e. construction sites) or their disposal in designated licensed

landfills.

Recycled wastewater (effluent water from settlement tanks/silos) should be used at

the earliest opportunity to ensure that the settlement system is ready to receive newly

generated wastewater. Potential uses of recycled wastewater mainly include: cutting

process, dust suppression over stockpiles and washing of vehicles and machinery.

Water meters should be installed to monitor water consumption in the facility.

The generated domestic wastewater should be separated from industrial wastewater

and should be directed to the local sewerage network. In case a sewerage network is

absent, a well-controlled septic tank should be used to store the domestic wastewater,

prior its evacuation by the responsible personnel.

Used oils from the generators and machines shall be stored in mounted well-

maintained containers and handled to specialized contractors for recycling.

Characteristics of Settlement Pond/Pit:

Wastewater settlement ponds should be made of impervious watertight material (i.e.

concrete).

Installed settlement ponds should be sized according to the following:

- Facility operation expectancy (days per week, hours per day)

- machinery per hour requirement of cooling water



Installed settlement ponds should have slopped flooring to facilitate settlement and

removal of sludge and sediments.

The use of a series of two or more settlement ponds increases removal efficiency

Collection pits should have visual alarms to notify operators in cases of pump failures

and when water reaches high levels in the pit.

The settlement pond/pit should be protected from rainwater

Figure ‎4-1: Typical settlement pond design (Dartmouth Eng. University)

Characteristics of Settlement silo:

Wastewater can be also treated using a settlement silo, which enables the rapid separation of

water and suspended solids. The wastewater will be actively pumped into the silo system.

The wastewater silo tower includes a unique interior structural design, which enables the

rapid separation of water and suspended solids. As a result, a fraction of sludge is settled in

the cone-shaped compartment at the bottom of the tower where it should be later dried.

The cleared water is then pumped through an outlet at the top of the tower and collected into

a designated collection tank to be reused in on-site activities.

The settlement silo should be made of impervious watertight material (such as steel,

concrete…)

Installed silo should be sized according to the following:

- Facility operation expectancy (days per week, hours per day)

- machinery per hour requirement of cooling water

All installed pools and storage tanks are to be made of impervious material, preferably

with a hard concrete base.



The sludge discharge valve at the bottom of the wastewater tower is to be closed or

opened automatically according to the upper and lower limits of the sludge tank, to

avoid over-flooding.

Figure ‎4-2 Settlement silo

Figure ‎4-3 Schematic diagram of a settlement silo



A belt filter press can be installed to handle the generated sludge. It squeezes sludge between

moving belts to remove liquids from sludge solids. This can thicken primary sludge, creating

dewatered thickened sludge which can be used in various operations (construction sites…).

The extracted water should be redirected into the system.

Figure ‎4-4 Belt press filter sample design

3) Solid Waste

Solid wastes are inevitably generated during or after the operation of cutting stones.

However, a number of management practices and operation modalities can be implemented

to minimize generation and ensure the proper handling and disposal. These practices include:

Reduction of solid waste generation rates by optimizing the type of raw materials

received or extracted. Stone blocks with good shape and less tails can modify the

cutting process, leading to lower amounts of wastes.

Promotion of the reuse and recycling of generated waste. The waste can be used in

different operations such as brick production, filler for hot mix asphalt plants and

others. The usage opportunities for generated waste are presented in Annex 1.

Sediments resulting from settlement pond /silos should be dried in specific basins,

where it is protected from external weather conditions such as wind or rain.

All domestic solid wastes should be sorted at source and handled by designated solid

waste management facilities.

4) Acoustic Environment

Noise pollution can be mitigated to prevent environmental and social implications, as such:

Ensure that the facility’s noise emissions doesn’t exceed the Environmental Limit

Values provided in MoE Decision 52/1 dated 12/9/1996.

Locate noisy equipments away from sources of conflict or behind noise

absorbers/receptors.

Noise emitting equipment should be fit with silencers or enclosed (i.e. compressors,

pumps…etc.)

The machines should be lined with sound absorbing materials such as rubber or wood

All roads should be paved with concrete or asphalt.

Efficient muffling devices should be installed on engines or noisy equipment

Replace audible alarms with visual alarms, whenever possible.

Limit, whenever possible, late night working shifts.

Maintenance operations should be conducted in enclosed areas or sheds.



The national maximum allowable noise level as per MoE Decision No. 52/1/1996 are

presented in the table below.

Region Type

Limit for noise level (dBA)

Day time

(7 am - 6 pm)

Evening time

(6 pm - 10

pm)

Night Time

(10 pm - 7am)

Industrial areas 60-70 55-65 50-60

Table ‎4-1: Permissible Ambient Noise Levels in Different Regions

The maximum national standard of 90 dB for occupational noise exposure limits should not

exceed an average duration of 8 hours working days. If the limits are higher than the

acceptable limits, then the exposure duration should be reduced as mentioned in the Table

below.

Sound Pressure Level dB(A) Exposure Duration (hrs.)

95 4

100 2

105 1

110 0.5

115 0.25

Table ‎4-2: Noise exposure limits

5) Occupational Health and Safety

A series of occupational behaviors are required at all times during plant operation to ensure

that all foreseeable risks and hazards are prevented, minimized and mitigated. Such actions

and behaviors include:

Wear required Personal Protective Equipment (PPE) when handling raw material or

cutting and polishing process (i.e. gloves, long sleeved and full-length pants coveralls,

waterproof boots and eye protection).

Eat and drink only in dust-free areas to avoid ingestion of dust (i.e. Stone cutting dust

in particular). In case of eye contamination with dust, rinse eyes with water and consult a physician. In case of eye injury with sparking stone cuts, immediately contact physician for

further treatment.

Meticulously follow advised lockout/tagout procedures when servicing equipment or

machinery.

Avoid working prohibited cutting spots, conveyor belts and polishing machinery.

Minimize the mechanical lifting of material and bulky material, relying mainly on

forklifts or frontload lifters.



Keep floors clear to avoid slipping and tripping hazards.

Provide appropriate lightening in closed or dark work places to avoid slipping or

tripping hazards.

Avoid working in awkward postures and in confined areas.

Make sure back-up alarms on all vehicles are functioning.

Avoid overloading equipment or machinery.

Beware of hot surfaces on equipment and truck components.

Use hearing protection during noisy operations.

5) Contingency Plan

Fire Emergency Response Plan:

Provide all areas with sufficient fire detectors (heat and smoke) and adequate

firefighting equipment (sprinklers, hoses, distinguishers, etc.).

Develop an emergency response plan which includes the floor map and the evacuation

directions, exits, stairs and location of extinguishers (this should be written in

languages understood by all workers).

Ensure that contact details of the local firefighting services are available to the

relevant staff and operators.

Every escape route should be distinctively and conspicuously marked by emergency

exit signs of adequate size and languages.

Provide environmental friendly fire-fighting equipment such as dry powder

extinguishers within the premises of the project.

All fire safety equipment and fixtures shall be regularly serviced and maintained. The

owner or shall annually certify that each of the fire safety measures specified in this

statement has been assessed by a properly qualified person.

Conduct annual firefighting and leak checks training drills for the operating staff.

Prohibit smoking as well as flammable materials build-up within the facility’s

premises.

Response Actions:

Activate the nearest fire alarm (i.e. pull-stations) in case alarms have not yet been

automatically activated

Confine the facility by closing all windows and doors and access points within reach

Evacuate the premises immediately using stairways or designated fire escapes only

Call the local fire department and provide them with prompt and accurate details (i.e.

accident, location, extent, etc.)

Ministry of Environment Environmental Guidelines for Cutting Stone Industry


Type of Impact Source Mitigation Measures Monitoring Plan Frequency of sampling

and testing

Impact on Air Quality

Particulate matter emissions from:

Movement of trucks and heavy

machinery

Unloading of raw materials

Storage stockpiles

Transferring of raw materials into the

production process

Exhaust emissions from trucks, front

end loaders or any other fuel-

based machinery

The plant premises should be paved with hard, impervious materials .

The entire plant floor should remain dust-free.

Natural or artificial wind barriers are to be placed landforms in accordance with

prevailing wind direction (i.e. trees, and fences).

Trucks hauling stones from quarries or other raw materials should be covered

during transport.

The loading bay of raw materials should be roofed and enclosed in at least 3 sides

Stockpiles storage areas should be fitted with dust suppression water sprayers to

dampen the stockpiles.

Cutting and polishing as part of the production process must be contained in a close

hangar with concrete base

Cutting and polishing process should include continuous water spraying to reduce

dust emissions.

All trucks leaving the facility’s premises should be clean and free of dust.

Air quality control equipment should be regularly maintained

Ensure that all stockpiling area of raw materials are damp

All ground and handling surfaces are sprayed with water to ensure fugitive

dust suppression

Upon each delivery

Confirm that all trucks and vehicles exiting the facility are dust-free and all

raw materials delivery trucks are covered with impermeable covers Upon each delivery

Check water cooling system are working properly during cutting and

polishing process Weekly

All installed alarms and warning devices in machinery and silos are

operating correctly Weekly

Ensure that back-up generators are operating with optimal burning efficiency

through undergoing exhaust gas emissions testing (PM, CO, SOx, NOx,

O2%)

PM 10, PM25

Biannually

Impact on Water and

Soil Quality

Cutting water generated from

manufacturing process of:

- Stone cutting

- Polishing

Dust suppression wastewater

The entire plant should be paved with hard, impervious materials such as asphalt or

concrete.

All generated wastewater should be collected and retained on-site, including storm

water.

The generated domestic wastewater should be discharged in a safe manner.

Domestic wastewater should be directed to the local sewerage network. In case

a sewerage network is absent, a well-controlled septic tank should be used to

store the domestic wastewater, prior its evacuation by the responsible

personnel.

Used oils from the generators shall be safely stored and handled to specialized

contractors for recycling.

Cutting areas should be bunded with small bunds or canals to ensure that the

wastewater is captured.

The water captured from bunds should be diverted into a designated settlement

pond or a series of ponds.

Sediments and sludge from settlement pond(s) must be removed when the storage

capacity of the pond is half full. In case any material is causing flow

restrictions, this material must be removed immediately.

Sediments must be stored in a manner that does not promote the generation of

fugitive dusts.

Collected sediments must be properly handled and managed, promoting future

reuses whenever possible (i.e. construction sites) or their disposal in designated

licensed landfills.

Recycled wastewater should be used at the earliest opportunity to ensure that the

system is ready to receive newly generated wastewater. Potential uses of

recycled wastewater mainly include: cutting process, dust suppression over

stockpiles and washing of vehicles and machinery.

Ensure that all water piping systems, drainage systems and bunds/canals are

intact (i.e. no leakages, blockages). Daily

Water quality testing should be done on the effluent water of the settlement

pond. Testing is to be done by an accredited laboratory or testing center.

The parameters that should be tested include: pH, COD,SS

Biannually

Monitor generator rooms or individual generator units are free of spills or

leakages of oils, lubricants or any contaminant Daily

To ensure the quantities of generated wastewater are limited, the following

should be monitored

- The average quantities of water used for cutting and polishing

should be estimated

- The settlement pit’s pump efficiency

- The settlement pit’s alarms and warning devices

- The capacity of the settlement pit during periods of high rainfall

Weekly

Monitor settlement pond(s)/silos to ensure that a minimum of 50% of the

capacity is available, and that there are no blockages and ensuring that

the pond linings are intact (i.e. no leakages)

Weekly /After heavy rains

Ensure that fresh, semi-hardened and hardened waste are directed towards

the designated enclosed pit, upon occurrence.

Ensure that wastes and collected sediments from treatment units are

adequately stored prior to handling or disposal.

Record and monitor the quantities of waste rock cuts

Daily

Impact on Acoustic

Environment

Trucks, front end loaders, loading

devices and other heavy

machinery

Hydraulic pumps

Raw materials delivery activities to

cutting (using cranes)

Conveyors

Alarms/ warning devices

Compressors

Air valves

Ensure that the facility’s noise emissions doesn’t exceed the Environmental Limit

Values provided in MoE Decision 52/1 dated 12/9/1996.

Locate noisy equipment away from sources of conflict or behind noise

absorbers/receptors.

Provide adequate buffer zone of a minimum of 100 meters between the facility and

any identified sensitive receptor(s).

All pressure-operated equipment should be fit with silencers or enclosed (i.e.

compressors, pumps, etc.).

The machines should be lined with sound absorbing materials such as rubber or

wood

All roads should be paved with concrete or asphalt.

Efficient muffling devices should be installed on engines or noisy equipment

Replace audible alarms with visual alarms, whenever possible.

Limit, whenever possible, late night working shifts.

Maintenance operations should be conducted in enclosed areas or sheds.

Calibration of the adopted noise meters Quarterly

Monitoring of noise levels should be conducted for the overall noise

generations of the facility (Noise monitoring must be undertaken for at

least one hour and in the presence of normal background noise).

Biannually

Inspect generators, mixers and pumps

Monthly

Ministry of Environment Environmental Guidelines for Cutting Stone Industry


Type of Impact Source Mitigation Measures Monitoring Plan Frequency of sampling

and testing

Impact on

Occupational Health

and Safety

Physical hazards (tripping,

electrocution)

Chemical hazards (exposure to dust

emissions…etc.)

Ergonomic hazards

Wear required Personal Protective Equipment (PPE) when handling raw material or

cutting and polishing process (i.e. gloves, long sleeved and full-length pants

coveralls, waterproof boots and eye protection).

Eat and drink only in dust-free areas to avoid ingestion of dust (i.e. Stone cutting

dust in particular).

In case of eye contamination with dust, rinse eyes with water and consult a

physician.

In case of eye injury with sparking stone cuts, immediately contact physician for

further treatment.

Meticulously follow advised lockout/tagout procedures when servicing equipment

or machinery.

Avoid working prohibited cutting spots, conveyor belts and polishing machinery.

Minimize the mechanical lifting of material and bulky material, relying mainly on

forklifts or frontload lifters.

Keep floors clear to avoid slipping and tripping hazards.

Provide appropriate lightening in closed or dark work places to avoid slipping or

tripping hazards.

Avoid working in awkward postures and in confined areas.

Make sure back-up alarms on all vehicles are functioning.

Avoid overloading equipment or machinery.

Beware of hot surfaces on equipment and truck components.

Use hearing protection during noisy operations.

Monitor the use of PPEs by the labor in the facility Continuously

Monitor the presence of safety signs, first aid kits, firefighting devices, etc. Monthly

Ensure that the fire extinguishers are properly installed and in an easily

accessible location Monthly

Table ‎5-1: Potential Impacts and Correspondent Mitigation Measures



Annex 1

Recycling Potentials of Stone Cutting Solid Wastes

According to the literature review, the solid waste generated in Stone Cutting Industries can

be used as raw materials in other processes. Some of the recycling potentials of these wastes

are presented below.

The physiochemical characteristics of granite sludge were proven to be suitable for

brick and roof tile formulations (Ferreira et al., 2004; Menezes et al., 2002); Al-

Zboon, 2010). Results showed that granite and marble waste content, up to 50 wt%,

can be incorporated into clay materials, already in use for brick production, without

degrading their mechanical properties (Dhanapandian and Gnanvel, 2009).

Experimental researches proved the utilization of waste in tiles and porcelain

production, where the waste incorporation had negligible effect on density, shrinkage,

and plasticity during all stages of the tile-production process (Torres, Fernandes, et.al.

2009).

Al-Zboon and Tahat utilized stone cutting waste for terrazzo tiles production and

proved the transverse strength, water absorption, and tile measurements, for all of the

taken samples, comply with the required standards.

The use of wastes from cutting process in concrete mixes was thoroughly studied by

different researchers. It was used to replace fine aggregates in concrete mixtures.

Almeida et al. used natural stone slurry to replace fine aggregates in concrete mixtures

and found that the mechanical properties of the produced samples are compliant with

concrete requirements.

The marble dust generated can be used as filler in asphalt mixtures (Karasahin and

Terzi, 2007). Karasahin and Terzi report that marble dust resulting from block

processing gives almost the same results with limestone fillers but, since the asphalt

mixtures including marble have higher plastic deformation, they should be used in

low traffic roads.

Carrao and Castelli found that the use of generated sludge, in a proportion not higher

than 40 to 50 % of the weight of the soil, resulted in greater water retention. Adding

20 to 40 % sludge to porous, acidic soils would enrich them with potassium,

magnesium, phosphorus, and other micro-elements, which are useful for vegetable

production (Al-Zboon and Al-Zou’by, 2014).



References:

Al-Zboon and Al-Zou’by (2014). Recycling of Stone Cutting Slurry in Concrete Mixes.

Al-Zboon K, Tahat M, Abu-Hamatteh Z, Al-Harahsheh M (2010) Recycling of stone cutting

sludge in formulations of bricks and terrazzo tiles. Waste Manag Res 28(6):568–574

Dhanapandian S, Gnanvel B (2009) An investigation on the effect of incorporation of granite

and marble wastes in the production of bricks. ARPN J Eng Appl Sci 4(9):46–50

Fahiminia, Ardani, et.al. (2013). Wastewater Treatment of Stone Cutting Industries by

Coagulation Process.

Ferreira JMF, Torres PMC, Silva MS, Labrincha JA (2004) Recycling of granite sludge in

brick-type and floor tile-type ceramic formulation. J Eur Ceram Soc 24(10–11):3177–

3185

Karasahin M, Terzi S (2007) Evaluation of marble waste dust in the mixture of asphaltic

concrete. Constr Build Mater 21(3):616– 620

Menezes RR, Ferreira HS, Neves GA, Ferreira HC (2002) The use of granite wastes as

ceramic raw materials. Ceramica 48(2002):92–101

Torres P, Fernandes H, Olhero S, Ferreira J (2009) Incorporation of wastes from granite rock

cutting and polishing industries to produce roof tiles. J Eur Ceram Soc 29(1):23–30