Proceedings of National Conference CRDCE13, 20-21 December 2013, SVIT, Vasad

A STUDY ON MARBLE WASTE MANAGEMENT: OPPORTUNITIES

AND CHALLENGES IN CURRENT AGE FOR MAKING VALUE
ADDED BRICKS

Mamta B Rajgor1, Nutan C. Patel2, Prof. Jayeshkumar Pitroda3

1
Lecturer, Sigma Institute of Engineering, Vadodara, Email: mamta141@gmail.com
2
Lecturer, Amiraj College of Engineering and Technology, Sanand, Gujarat,
Email:patelnutan@yahoo.in
3
Assistant Professor and Research Scholar, Civil Engineering Department, B.V.M Engineering College,
Vallabh Vidyanagar, Anand, Gujarat, India, Email: jayesh.pitroda@bvmengineering.ac.in

ABSTRACT
Waste management is a fundamental component to any manufacturing or production enterprise. It is
estimated that there are million tons of quarrying waste are produced in each year. Although a portion
of this waste may be utilized on-site such as for excavation pit refill. Waste generated at quarries and
fabrication plants is quite similar. Most commonly, scrap stone must be mitigated and managed, but
attention must be paid to other types of wastes, as well. These include marble sludge/slurry. Marble
sawing powder wastes is widespread by-product of industrial process in India. Generally these wastes
pollute and damage the environment due to sawing and polishing processes. This waste is used for
making concrete. The main aim of this ground work is to evaluate recovery and use marble waste in
making a brick.

Keywords: - Marble Waste Management, Marble Slurry, Marble Waste Fly Ash Brick

INTRODUCTION
Marble waste use as a material is a very important environmental management tool for
achieving sustainable development. On the other hand, recycling waste without properly based
scientific research and development can result in environmental problems greater than the waste itself.
Marble waste from quarry operations can be unsafe and environmentally detrimental. Now-a-days the
cost of brick is increasing so if we use the waste material in the production of the brick so we decrease
the price and also stop the excavated soil for making clay brick. In India, million tons of wastes from
marble industries are being released from marble cutting, polishing, processing and grinding.
Exposing the waste material to the environment directly can cause environmental problems.
Therefore, many countries have still been working on how to re-use the waste materials.
Marble ranks the largest produced natural stone in the world and it accounts for 50% of the
world's natural stone production. Around 90% of the world's production of marble comes from India
and approx 85% of India's production is received from Rajasthan and almost all mining and
processing activities are concentrated around Udaipur, where the proposed study is planned to
undertake. The marble mining industry has come up significantly in recent past. Rajasthan has around
4000 marble mines and about 1100 marble gang saws (processing plants). The industry involves
Mines, Processing plants, Cutters for the production of tiles for walls and floors, articles, waste
reproduction and other ancillary works.

MARBLE WASTE GENERATE

There are main two type of the marble waste generated

(1) Waste generated during Quarrying
(2) Waste generated during Processing

(1) Waste generated during Quarrying

Various type of waste generated during Quarrying of marble as follow

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(a) Overburden
(b) Side burden
(c) Inter burden
(d) Ungraded material
(e) Undersize material

The marble waste generation varies widely from 30% by weight (in mechanized mines using
wire saw cutting methods for extraction of marble blocks) to 65% by weight (at mines where wh manual
mining is resorted to and the rocks are fractured). Waste during quarrying by mechanized processes
can be estimated at 30% to 40% of the production. The Conventional quarrying techniques of blasting
leads to a waste percentage of 60% to 70% and lead to uncontrolled stripping of vegetation cover and
subsequent soil erosion. Dust generated during quarrying can also blanket surrounding areas leading
to vegetation die-off
off and adversely affecting the fertility and quality of top soil. However, since most
m
of the quarries in India are ill equipped as far as mechanization is concerned, the percentage of marble
waste, as generated during quarrying of marble blocks can be estimated at 60%. This waste includes
odd blocks of various sizes and shapes, unwanted blocks and rock fragments produced during
trimming and shaping of mined out blocks before dispatch to processing units.

Table 1
Quantum of Quarrying Waste Produced with Respect to Method of Production
Stage of Marble Using With With semi Weighted
Industry gangsaw mechanized mechanized Average
cutting mines using mines using Waste
machine blasting blasting
Mining & trimming
upto the stage of
dispatch to process 30% 55% 65% 50%
Units
Source: Status report on commercial utilization of marble slurry in Rajasthan

Figure: 1 Quantum of quarrying waste produced with respect to method of production

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(2) Waste generated during Processing

Various types of waste are generated during processing of marble are as follows:
(a) Dressing Waste
(b) Cutting waste
(c) Polishing waste

The slurry generated during processing can be estimated at about 10% of the total stone
quarried (20% to 25% of the block as received from the quarries), and during polishing as 5%
to 7%.

Table 2
Quantum of Processing Waste Produced with Respect to Method of Production
Stage of marble With With With Weighted
Industry Mechanised Mechanised semi Average
Mines & mines mechanised Waste
Processing using mines using
units using blasting blasting
Gang saw
Cutting
Machines
Processing (Sawing of
Blocks into slabs and
Truing their Edges by 10% 15% 18% 15%
Cutting)
Grinding & Polishing 5% 5% 5% 5%
Source: Status report on commercial utilization of marble slurry in Rajasthan

Figure: 2 Quantum of processing waste produced with respect to method of production

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PHYSICAL PROPERTIES OF MARBLE SLURRY

Table 3(a)
Physical Properties of Marble Slurry
Property Result
Bulk Density (gm/cc) 1.3-1.5
Specific Gravity 2.83-2.87

Table 3(b)
Particle Size Distribution of Marble Slurry
Particle size (mm) % Finer by volume
363.1 100
193.0-205.8 90

Source: Research Paper on use of “Incorporation of Marble Sludge in Industrial Building Eco-blocks or
Cement Bricks Formulation” by Fakher J. Aukour

CHEMICAL ANALYSIS OF MARBLE SLURRY

Table: 4
Chemical Analysis of Marble Slurry
Test carried out Test value %
Loss on ignition 43.46
Silica 1.69
Alumina 1.04
Iron Oxide 0.21
Lime 49.07
Magnesia 4.47
Source: Research Paper on use of “Incorporation of Marble Sludge in Industrial Building Eco-blocks or
Cement Bricks Formulation” by Fakher J. Aukour.

ENVIRONMENTAL PROBLEMS DUE TO WASTE

The production of waste shown in the above table are causing following environmental problems:

(a) Conservational

The valuable national wealth is getting wasted mainly due to lack of management and lack
of technology. This waste, if recovered as useful, can change perhaps the entire scenario of the
industry. Since it is not impacting directly on the environment the non-conversion of useful mining
product is a more grave problem in longer term than other direct problems.

(b) Air pollution

This is the most direct and hazardous impact of the industry. As it is clear from the table,
slurry is produced at almost every operation and its dumping is a great problem. When it gets dried
and airborne, it causes air pollution and related problems.

(c) Water pollution

Like any industry, the marble industry needs water in its different operations for cooling and
flushing different discharge. In these operations water gets contaminated. This contamination is
considerable and it can be said that water pollution of the region is caused by discharging slurry.

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(d) Vegetation related problems

Due to opencast nature of the mining, De vegetation of the area is imminent. Also dried slurry
deposited over plants and vegetation hampers their growth.

(e) Visual impacts

Running mines, abandoned mines, dumping sites, slurry waste sites, deposition of dried
dr slurry
over almost every structure in surrounding areas are a very bad sight. Hills having been excavated and
dumps over them are very unaesthetic.

(f) Scarcity of the dump sites

The production of a large amount of waste needs additional land for its dumping
d and
handling.

(g) Accidents due to unscientific dumping

There are a number of accidents due to unscientific dumping of mine waste on road and
quarry sites.
Table 5
Marble Waste Utilization
Sr. No Utilization Area Utilization %
1 Structural fill ,Soil stabilization, and road embankment work 10-15
2 Cement 10-12
3 Aggregates 2-5
4 Bricks , Blocks, Tiles 11-13
5 Paint ,Binder ,Plaster 2-5
6 Concrete roofing sheets 5-10
7 Ceramic Products 10-12
8 Particle Board, Panels 10-12
Source: Paper on “A
A Study of utilization aspect of stone waste in Indian context”
context” By Mamta B. Rajgor,
Prof. Jayeshkumar Pitroda

Figure: 3 Marble waste utilization

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(1) As a filler material for roads and embankments
As marble dust is an inert material it can be mixed with certain types of soils for the
preparation / raising of embankments etc. which will result in the saving of valuable soil. Central
Road Research Institute (CRRI), New Delhi has carried out preliminary research on the utilization of
marble dust in road sector. Unconfined Compressive Strength (UCS) have been performed to
determine the strength of the mixes with soils and it has been observed that,
- In silty soil, there is 12 percent increase in UCS with 10% marble dust
- There is a 20% increase in UCS with 30% marble dust
- There is no improvement in clayey soil

(2) Manufacture of Portland Cement

Cement grade limestone is the main raw material along with clay and other corrective
materials for the manufacture of Portland cement. Analysis of marble waste shows that it satisfies the
chemical composition requirements of cement grade limestone to a great extent. As a part replacement
of limestone, either marble waste and or a combination of along with limestone and or lime can be
used.

(3) For manufacturing of concrete

In concrete mixes there is a 15% increase in compressive strength when sand is mixed with
35% marble dust. There is an improvement in the density of the concrete as well.

(4) For manufacture of bricks

Marble slurry is chemically dolomitic in nature and consists of very fine particles.
Considering the phusico-chemical properties, it may be used as a fine aggregate in manufacturing
bricks by using cement or lime as a binder. Central Brick Research Institute (CRRI), Roorkee has
conducted research on this aspect. The results are very encouraging and the physical properties of the
bricks produced by this process exceed those of normal bricks.

(5) Manufacture of Ceramic Tiles

A possibility of utilizing marble slurry as a raw material for production of Ceramic Wall
tiles needs to be evaluated on a pilot plant level. A leading ceramic producer in the country has
undertaken laboratory scale studies on this matter, which were reported to be highly successful.

(6) Manufacture of Thermoset Resin Composites

The Macromolecular Research Centre at Jabalpur has conducted a short term programme
with a view to explore the possibility of converting marble slurry into Resin Composites. The
preliminary results have demonstrated the technical feasibility of such an option. However, a pilot
plant level study needs to be conducted.

(7) Manufacture of lime

Limestone is the main raw material for the production of Lime. Limestone can be replaced
by marble waste.

(8) Manufacture of Activated Calcium Carbonate

Limestone or combination of marble waste and marble dust (from slurry) can be used on the
production of activated or precipitated calcium carbonate.

(9) Hollow Blocks and Wall Tiles

Marble slurry waste and other clay products can be used in the production of Hollow
prefabricated blocks for buildings if used in the right proportion.

(10) Manufacture of Ground Calcium Carbonate

Detailed feasibility analysis and pilot studies are needed to be conducted about the above.

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ADVANTAGE OF MARBLE WASTE
(1) Marble slurry is used for replacement of other material and saves the material.
(2) Marble slurry used in concrete so Increase the strength in concrete.
(3) Marble slurry we get in nominal or free of cost.
(4) Marble scrape is used to make attractive flooring in minimum cost.
(5) Use of the marble waste decrease the cost of construction because replace the material by
marble waste
(6) In Fly ash brick if lime is replace by marble waste so increase the strength of brick.
(7) Binding property of marble slurry is very good.

DISADVANTAGE OF MARBLE WASTE

(1) Marble slurry increases the soil alkalinity.
(2) Marble slurry affects the plants.
(3) Marble powder affects the human body.
(4) Marble slurry or powder affect the soil fertility and reduce them.
(5) The waste is dumped on land the dust is airborne by the wind and makes air pollution in
environment.
(6) Marble slurry increases the accident of the slip.

CASE STUDY
“Utilization of Marble and Granite Waste in Concrete Bricks” by Rania Hamza, Salah El-Haggar,
Safwan Khedr International Conference on Environment and Bio Science IPCBEE vol.21 (2011)

MATERIAL AND METHOD

Concrete bricks can be the best application to utilize marble waste in large quantities to
replace the conventional sand and aggregates. Normally, aggregates in concrete bricks are dolomite as
the coarse aggregate, and sand as the fine component. These can be replaced by marble waste
aggregates of different sizes with slurry powder addition. The mix utilizes marble mixed pieces of
various sizes: coarse sand (A), fineness modulus (FM) of 4.596, fine sand (B), FM of 2.755, coarse
aggregate (C) of maximum nominal aggregate size of 12.5 mm and coefficient of uniformity (Cu) of
1.9, and slurry powder. The slurry powder, marble is of grain size less than 70 microns and surface
area more than 4200 cm2/g (comparable to that of cement, 2600-4300 cm2/g), which gives cohesion
and micro-filling ability. The mix design incorporates 10wt% cement, 30wt% fine aggregates with
ratio 3:7 A:B (FM 3.307), 50 wt% coarse aggregates, and marble slurry(M) powder of 10, 20, 30 and
40 wt%, with proportional re-distribution of coarse and fine aggregates to accommodate the added
slurry powder, beyond 10%. In addition, 0% slurry brick (zero), and control brick, with conventional
dolomite coarse aggregates and sand, were tested, as shown in Table 6.

Table 6
Concrete Brick Mix Design
Mix ID Cement Slurry Fine aggregates Coarse aggregates
(kg/m3) wt % kg/m3 Wt % Kg/m3 Wt % Kg/m3
Control 300 800 1000
Zero 235 0 0 33.75 704 56.25 1173
M10 232 10 232 30.00 696 50.00 1160
M20 220 20 441 26.25 579 43.75 965
M30 210 30 630 22.50 472 37.50 787
M40 204 40 818 18.75 383 31.25 639

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RESULTS
The results show that the marble slurry in terms of compressive strength.

Figure 4:: Compressive strength for marble slurry samples

CONCLUSIONS
Marble waste used in brick production so increase the strength. In the different percentage of
the addition 10, 20, 30, 40 % in which 10% 10% marble slurry use give the maximum strength as
compared to other.
Use of Marble Waste in Brick results in saving of soil.
Marble Waste Savings on difference in cost of natural soil, besides protection of environment.
By using Marble Waste in bricks leads to solve the dumpling problem.

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Mamta B. Rajgor , Prof. Jayeshkumar Pitroda “A study of utilization aspect of stone waste in Indian
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