AIDICO ECO-STONE Sustainable System Implementation For Natural Stone Production and Use PDF

LIFE Project Number
LIFE08/ENV/E/126
Sustainable System Implementation for Natural Stone Production and Use
Technical Handbook
December 2012
Technical Handbook
Index
I. Introduction .................................................................................................................................................. 2
II. Environmental Evaluation of the Nowadays Production Chain. ......................................................... 7
III. Eco-efficiency of the natural stone production chain. Best available techniques. Demonstration
activities. Feasibility of the new technologies and products. ................................................................ 21
III.1. Quarrying and processing factors affecting embodied energy of natural stone products ...... 21
III.2. Energy Analysis in the Natural Stone Manufacturing Process ..................................................... 35
III.3. New Cutting Disc for Natural Stone .................................................................................................. 41
III.4. Thermal Energy Storage in Natural Stone........................................................................................ 50
III.5. LCA - Study on traditional marble chain production...................................................................... 61
IV Potential for Implementation of Environmental Management Systems & the EU Ecolabel in the
Marble Sector ................................................................................................................................................ 72
V. Conclusions .............................................................................................................................................. 80
-1-
Technical Handbook
1) Optimization of use of natural sources and raw
I. Introduction
materials.
2) Optimization of energy consumption in the
1. This Book
production chain.
This manual is a particular deliverable of the

project
Ecostone.
Considering
the
3) Use of new multifunctional natural stone based
strong
materials
component for dissemination that involves the
system of the new developed technology to
developed during the three years of the project.
increase the energy efficiency in production of
It is intended for an easy and wide dissemination
stone, with reduction of the wastes and with the
of the results with the key stakeholders, related to
substantial improvement in the use of the raw
Natural Stone sector and not only.
materials. These objectives will be achieved
Under the concept of sustainable development
through a new High-Tech Production system,
the project encompass a significant diversity of
having a Traditional but low energy cost Stone
activities, including aspects related to the life
and new High-Tech Stone products in benefits of
cycle of natural stone, with special emphasis on
the energy efficiency in Buildings and able for
the development of new materials and more

reduction
and
chapters
that
New Application for Construction.

The benefits are addressed to the stone sector
optimisation of resources.
With
an
organization
by
environmental
the dissemination and promotion of a sustainable
for the dissemination of the technical work
waste
and
In the overall objective of the project is included
other tools developed, be the preferred vehicle
equipment,
energy
efficiency in architectural use.
project this manual was designed to, with the
efficient
with
with the new systems and products, and also to

the construction sector with the new applications
corresponds to technical articles or reports, the
of multifunctional stone.
main intention is to highlight the different issues

observed in the project and submit the technical
More defined objectives are:
results achieved in each of them.
-Scientific-technological
The texts refer their authors which form part of
objective:
Implementation of the new technologies and
the project partnership and of the teams that
innovative materials: i) fast systems for natural
were responsible for the development of the
stone cutting, consolidation techniques to reduce
technical work.
stone wastes; ii) innovative materials based on

natural stone with multifunctional properties
2. Ecostone Project.
The main objective
(thermal energy storage capacity, self-cleaning

of the project
properties); iii) products based on natural stone
is the
implementation, dissemination and promotion of
wastes (slurries).
a sustainable system in order to enhance the
-Environmental
production and use of natural stone, by using the
proposed will reduce the number of wastes to the
best
environment. New stone materials with thermal
available
techniques and products to
produce an ECO-STONE (or sustainable stone).

The project is focused on three main aspects:
-2-
objective:
The
new
system
Technical Handbook
energy storage capacity will reduce the use of the
of defects, such as fractures, hairline long micro
heating/cooling systems in buildings and thus
fractures, cracks, fissures, big pores and cavities,
energy demands, contributing to the reduction of
many of which lie in the inner part of the block
CO2 emissions.
and therefore cannot be detected simply by
-Social objective: Improvement of life quality and
visual inspection. These defects are the origin
human comfort in buildings due to the reduction
and the reason for the breakage of stone blocks
of temperature fluctuations between day and
and consequently of all the stone products at any
night using natural materials.
stage of the stone production chain. These
Reduction of energy consumption in buildings
breakages can be avoided if they can be
implies the reduction of energy costs.
promptly detected and repaired before or during
-Industrial
objective:
To
increase
the block/slab processing.
the
competitiveness of the natural stone sector due
The consolidation of defected blocks and slabs
to the development of new technologies and
can be achieved by impregnation of materials in
materials. This will bring the traditional natural
the fractures, cracks and fissures of damaged
stone sector into a higher position in the market,
stone
with products with higher added value.
consolidating material will be to fill the stone
-Economical objective: Energy costs during the
defects and re-establish cohesion between the
stone production will be reduced with the new
partly separated areas of the defected stone. The
technologies (cutting, consolidation techniques)
impregnation consolidation procedure to be
and
applied
new
materials
with
energy
storage
material.
The
significantly
main
function
depends
both
of
on
the
the
properties. The project is not oriented to the
dimension of the existing defects and the size of
market. The market is not applicable in any case
the stone product under treatment block, slab,
in the actions proposed in this project, what is
strip or tile.
being promoted in the ECO-STONE project is the
Consolidating
sustainable development of the natural stone
dimension stones are organic polymers with
market.
organic solvent based on polyesters, acrylates,
materials traditionally used in
epoxies, or even polyurethanes, xylanes, and

ethyl silicates (tetraethyl silicates). However, the
2.1. Optimization of use of natural sources and

raw materials.
toxicity of these agents can cause health

problems to the working personnel during the
The use of diamonds and cutting discs during the
resin application procedure, and is strongly
natural stone production reduces the raw material
suspected
needed to obtain the same yield production as
to
seriously
pollute
the
indoor
environment due to the release of harmful
with conventional cutting techniques. Moreover,
substances in the long run after flooring or
the use of consolidation techniques to reinforce
cladding. From a technical point of view, the
natural stone during processing will also reduce
application of these polymers results in higher
breakages and thus stone wastes will be
energy consumption in certain processing stages
decreased. This means natural sources savings.
(cutting with water).
The stone blocks being part of the original natural
For a feasible and environmentally friendly
stone deposit continue to present different kinds
reinforcement system it is necessary to identify
-3-
Technical Handbook
and use environmentally friendly organic and
blocks/slabs and also verify the effectiveness of
inorganic consolidating materials and develop
the reinforcement/consolidation process.
automated
impregnation
techniques.
The
consolidated stone should generally be as
2.2. Optimization of energy consumption in the

production chain.
durable as the unweathered stone. Durability of a

consolidated stone depends on several factors,
including
the
compatibility
weathered
consolidant
of
the
stone,
durability,
consolidant
the
with
the
of
the
properties
LOWER ENERGY CONSUMPTION. The reduction
the
of energy consumption can be obtained with the

use of fast and thin cutting systems with lower
energy consumption.
consolidated stone and the environment. The
Stone blocks are cut into slabs and strips. Slabs
properties of the consolidating materials affecting
are at about 2.5 m (marble) or 3 m (granite) x 1.5
their ability to penetrate a specific stone at a
m x 2 cm in size; that is, the length and width of
given temperature are viscosity, surface tension,
the block but reduced thickness. Slabs are
and the rate at which gel or precipitate is formed
obtained by block sawing with gang sawing
and the rate of solvent evaporation. Moreover,
machines
consolidating materials should be compatible
(3-5 m).
to stone by-products.
re-establish
the
physical
Strips size is about 2.5 m (marble) or 3 m (granite)
and
x 30-60 cm x 10-30 mm. Strips have the
mechanical properties of the defected stone
approximate width and thickness of a tile but the
products and therefore significantly reduce the
length of the block. Strips are usually a semi
amount of stone products that cannot be
finished product, to be further processed in order
processed, it is necessary to develop a new
to obtain tiles or other final products. They are
generation of environmental friendly organic and

inorganic
consolidants
with
obtained by block sawing with block cutting
chemical
machines, usually equipped with many vertical
characteristics similar to that of the stone, which
diamond discs (for granite sawing up to 100 discs
will efficiently consolidate and prevent them from
are currently used) with a diameter of 1.000 mm
breaking during processing. Moreover, it is

necessary to
develop an
or more (1.700-1.800 mm are also reported).
automated block
These vertical cutting disks have about 5 mm
reinforcement process appropriate for the big
thickness and segment width about 6.8 mm. One
block sizes and a flexible slab consolidation
or more horizontal discs detach each strip from
process that can be efficiently applied in various
the block. Usually, block cutters are equipped
production lines.
with automatic strip unloaders. Strips are also
These developments are expected to increase

the
efficiency
of
the
sawing
and
sawing
cutters with a single diamond disc having big size
the stone microstructure and not to form harmful

to
wire
machines (marble), or sometimes with block
similar thermal properties, not severely disrupt
order
diamond
machines (granite), linear diamond blades sawing
with stone, which means that they must have
In
(granite),
obtained by sawing (trimming) slabs by means of
further
trimming
processing stages by 118%. The development of
machines
equipped
with
vertical
diamond discs having small sizes (300-400 mm);
an easily applicable fault detection system will

enable both the discrimination of the defected
-4-
Technical Handbook
this process gives low yield and it is no longer
between 25 and 32 m/s and removal rates of
applied.
about 150 cm2/min can be achieved in the case
Drilling and cutting operations are two time
of granite, while during marble cutting peripheral
consuming and therefore low productivity stages
speeds of more than 70 m/s and specific removal
in the stone production chain associated with
rates of 5.000 cm2/min are possible.
increased losses of valuable stone material and
Big machines equipped with up to 100 discs in
environmental impacts. Drilling operations are
parallel cut the block into strips and slabs. A
applied during quarrying, at the beginning of the
major disadvantage of this technology is the big
production chain, while cutting processes are
amount of stone waste produced due to the
mainly used for the production of tiles and slabs
thickness of the cutting tool. This proportion
at a later stage of the chain.
leads to high losses of stone material, which can
Drilling is predominantly used as an independent
be up to 40%, depending on the ratio of tool
technique, while it can be also used as an
thickness to the thickness of the stone product.
auxiliary technique, preparatory to other cutting
Economical and ecological disadvantages are the
method (e.g. making holes for diamond wire).
consequence.
Drilling
or
second problem arises from the cobalt content of
hydraulic. A series of holes are drilled along the
the existing bonding material used in the
line required to split the stone mass. Drilling, as it
diamond cutting segment. Due to the wear of the
is currently applied, is a time consuming process
metal-diamond bonds during cutting, cobalt is
as with the drilling speed of the existing
introduced in the stone waste and therefore,
equipment (10 m/hour for pneumatic 70 m/hour
stone wastes produced by the current cutting
for hydraulic) the time needed to prepare the drills
equipment are characterised as toxic. The
for the extraction of one stone block varies
development of heavy metal free metal-diamond
between 1 and 7 hours. Moreover, the current
bonds is a feasible solution for this problem.
drilling process presents serious environmental
The loss of valuable stone material can be
impacts such as high vibration (up to 25 m/s2),
decreased by reducing the thickness of the
noise (80-120 dB), depending on the equipment)
diamond discs. However, the reduction of tool
and dust generation. With the currently used
thickness leads to lower stiffness of the cutting
drilling equipment, it is not possible to safeguard
disk and increased deviations of the disc during
the straightness of the drilled holes due to the
the cutting operation, resulting in lower slab/strip
hammering movement of the tool. Deviations of
quality. Technically, this problem of the thin tools
0.1 m over 3 m are usual, resulting in stone
can be solved with the application of high
losses of about 0.5 m3 per block during the
peripheral speeds, which are able to increase the
squaring process. Therefore, the development of
dynamic stiffness and stabilize the steel centre of
new high speed drilling tools without hammering
the tool. The increase of peripheral speeds will
will increase productivity, efficiency, precision
result in increased productivity. However, high
and reduce the environmental impact.
cutting speeds result in severe mechanical and
Cutting operations are used for the production of
thermal stresses to the tool, and especially to the
slabs and strips from stone blocks. With the
diamonds, and increased diamond losses, as
available cutting equipment peripheral speeds
existing diamonds and metal-diamond bonds are
equipment
is
either
pneumatic
-5-
Besides
this
disadvantage,
Technical Handbook
not efficient under such conditions. The currently
environment and human health improvement.
available industrial diamonds are characterised
Thermal storage capacity of the new stone
by micron dimensions, not perfect structure, low
products will be achieved by the incorporation of
physicochemical properties and low thermal
Phase Changing Materials (PCMs). These are
stability. The development of mono-crystalline,
materials able to absorb, store and release heat
nano-structured diamonds with perfect crystals
when they change state, such as from a solid to a
(Ultra Fine Dispersed diamonds) and heat and
liquid. The melting point of PCMs is near the
mechanical shock resistant to withstand the high
standard room temperature (18-22C). Using
temperatures and mechanical stresses induced
PCM
during these processes is essential.
environmentally friendly
Therefore, the progress required at this stage is
functions as follows: when indoor temperature
to improve productivity and reduce the amount
rises above 22C, the PCM begins to melt and
and the environmental toxicity of the stone waste
absorbs the
produced. This can be achieved with the
becoming warmer itself. At night, the heat stored
development and application of new high-speed
is discharged for indoor heating and the cycle
drilling and cutting tools and extra thin cutting
can be continuously repeated. In such cases the
disks with Ultra Fine Dispersed Diamonds and
use of conventional air-conditioning may become
heavy metal free metal-diamond bonds.
unnecessary, saving energy and protecting the
on
indoor
walls
heat from
serves
climate
as
an
control and
the room,
without
environment. Common PCMs include inorganic

2.3. Use of new multifunctional natural stone
based materials with energy and environmental
efficiency in architectural use.
salt hydrates and paraffin. They can be used
New materials will be based on natural stones
Moreover, self-cleaning properties and photo-
and natural stone residues. Sustainable stone
catalytic properties will be introduced in the new
materials:
products with the addition of photo-catalytic
a) Natural stone materials with thermal properties
agents. The most promising agents with photo
allow the energy storage/release, contributing to
catalytic properties are TiO2 (anatase) and ZnO.
reduce the use of heating/cooling systems in
In combination with UV sun light these agents
buildings and increasing human comfort indoors.
degrade biological fouling into CO2 and water
Some studies from IDEA (Instituto para la
and transform harmful NOx into less harmful
Diversificacin y Ahorro de la Energa, Ministerio
NO2.
de Industria y Energa, Spain), indicate that a flat
This a highly innovative aspect of the project, as
consumes approximately 4000 kWh/year and
these materials (PCM, TiO2/ZnO) have never
64% of this energy is due to heating and cooling.
been applied in the production of construction
The energy demand in buildings rises every year
materials made of stone.
encapsulated in stable structures of about 20m

diameter or as they are.
due to the increased population and the higher

number of heating/cooling systems.
b) Natural stone materials with self-cleaning
properties. Main effects of these properties are
the
durability
increase
of
natural
stone,
-6-
Technical Handbook
II. Environmental Evaluation

Nowadays Production Chain.
of
The use of Natural Stone has followed the history
the
of man almost from its origins, creating a

relationship
N. Bonito , N. Cristo
1
of
coexistence
that
can
be
considered somewhat timeless.

From the beginning it was the perception of the
1. CEVALOR - Technological Centre for the Utilization and Exploitation
importance of the stone as a tool, building
of Ornamental and Industrial Stones
material, or as a mere decorative object. A close

nuno.bonito@cevalor.pt; nelson.cristo@cevalor.pt
relationship was developed that immediately led

to the recognition of the physical, mechanical and
A Sustainable Development is the one that meets the
visual characteristics of the stone as ideal for
present needs without compromising the ability of
human use, assigning this material with a value
future generations to meet their own needs.
that is not only economic and influences the

market of dimensional stone with subjective and
World Commission on Environment and Development

(Bruntland Commission), 1987.
not merely technical aspects, like fashions.

What is certain is that the ornamental rock is an
1. Abstract
endogenous resource for a given region, finite
The dimension stone industry even though is a
and irrecoverable on a human scale and that for
traditional activity, with a
rather significant
this reason deserves to be valued over the
influence on the economy of the country, has
materials that currently compete in the same
environmental
that
market but that does not follow necessarily the
the
same "rules" since they can be mass-produced in
compromise
and
social
their
constraints
relationship
with
surroundings.
the desired quantities or incorporate specific
The ornamental rock companies should be
properties according to a predetermined usage.
managed trough a sustainable perspective with
The production chain of ornamental rock consists
the integration of economic, environmental and
in three main phases, including the Extraction,
social aspects as key factor towards a better
Processing and Application/Maintenance (Figure
efficiency
1).
of
the
current
process
and
for
continuing this industry for future generations.

The ornamental Stone industry is:
Usually related with a bad image in

what concerns to the environmental
questions.
An important activity that provides

significant employment and strongly
develops the regions where it is
located.
Figure 1. Dimensional Stone Production Chain
2. Brief Description of the Sector
(ISTONE, Deliverable 1.1. Assessment of Production

Chain, 2007).
-7-
Technical Handbook
- Extraction: is the first stage in the production of

stone. It is intended at this stage to extract
blocks of regular shape and size of the mineral
mass. This is a series of operations, each one
requiring one or more types of machinery and
equipment and personnel.
Table 1. Dimensional stone products ornamental stone

sector, depending on the processing degree (adapted
from CEVALOR 2004).
The following diagram will illustrate in a synthetic

manner the flow of products in the processing
subsector (Figure 2):
- Processing: corresponds to the processing of

the rock, where the blocks are transformed into
finished products.
Figure 2. Overall flow of products in the processing of

dimensional rocks (adapted from CEVALOR, 2004).
3. Sustainability
Industry
-
Implementation
and
Maintenance:
the
"How
can
in
we
the
apply
Dimensional
the
Stone
concept
of
construction sector is the main consumer of
sustainability to the sector of ornamental
stone products, widely used on pavements and
rock?
other
interior
applications,
facades,
patios,
sidewalks, plazas, sculptures and many other
... meet the present needs without compromising
items for setup and equipment of the most
the ability of future generations to meet their own
different spaces.
needs.
The different existing rocks, after the extraction,

will lead to a diversity of products related to the
degree of transformation in the processing, which
determines the various markets in the sector of
The
need
of
exploit
natural
resource.
ornamental stone. Table 1 shows the different
products for each degree of transformation.
The capacity of the natural system to

fulfil the human demands.
-8-
Technical Handbook
The guaranty of the continuity of the
type and amount of exploitable reserves of the
process.
mineral mass.
The quarries or processing plants can obtain a
In order to be sustainable a particular human
sustainable performance with the adoption of an
venture
basic
organization and daily procedures toward a
principles that are presented without hierarchy:
greater efficiency, the increase of the value of
be
the raw materials and the extension in time of
must
necessarily follow four
economically
viable,
environmentally
sound, socially just and culturally acceptable.
the exploitation.
These four principles contain the main pillars of

sustainability.
To assess the sustainability of a specific project

we can use indicators aiming not only to analyse
the
present
situation
but
also
to
make
comparisons with similar situations.

The use of indicators appears in order to assist
the presentation of technical and scientific
information, providing a better and more direct
understanding of its meaning.
The
sustainability
indicators,
in
order
to
characterise the performance of enterprises in the

sector of dimensional stone, should answer
certain technical and scientific criteria:
Be representative;
Figure 3. Schematic representation of the structure that
Be simple and easy to interpret;
supports the concept of sustainability.
Show trends over time;

Be sensitive to changes in the aspect to
The case of the dimensional rock industry has
which they refer;
special features that distinguish it from other
Be based on existing information or
industries, first for processing a raw material that
possible to obtain a reasonable cost;
is natural, finite and not renewable on a human
Be
scale.
based
on
information
properly
documented and recognised quality;
So how it is then possible to consider
Be able to update one at regular
sustainability in the processing of a material
intervals;
that is not renewable at the scale of operation
Have a standard with which to be
and when we know in advance that when
compared (laws, rules, etc.)...
removing a geological resource of the quarry,
There should be considered four categories of
it will not recover and we cannot guarantee
sustainability indicators in general:
the continuity of the existing reserves?
Environmental Indicators.
In fact the concept of sustainability is perfectly
Economic Indicators.
applicable to this industry, however inherent to a
Social Indicators.
temporal and spatial basis, which is related to the
Institutional Indicators.
-9-
Technical Handbook
The list of indicators below is neither definitive

nor exhaustive, but illustrates one way of getting
the
industry
processing
of
to
evaluate
the
the
dimensional
mining
rock,
and
using
information that can be achieved with reliability in

the current management of the enterprises.
Table 2. Possible list of sustainability indicators
applicable to the sector of dimensional stone (ISTONE,
2007)
Figure 4. Extractive Process Layout, indicating the

inputs and outputs.
4. Dimensional Stone Production Chain Analysis

The definition of a profile related to sustainability
in the dimensional stone industry is not an easy
task mainly due to the diversity of the existing
layouts for the quarries and processing plants.
The variables are many and therefore each case
will have different frameworks regarding the
environmental performance of the enterprises.
Following the different scenarios that can exist
associated with each layout a common point to
consider is that in every operation there are
certain inputs and outputs which generally are the
same only varying essentially in quantitative
terms.
As an example we can present a typical layout for
a quarry (Figure 4) and processing plant (Figure
5).
Figure 5. Manufacturing process Layout, indicating the

inputs and outputs.
-10-
Technical Handbook
equipment (e.g. pumping and disposal of water in

Inputs
Raw Material
Energy
Water
Ancillary materials
a quarry).
Outputs
Final Product
Noise
Dust
Gases
Liquid effluents
Wastes
5. Cost Analysis
In terms of the cost breakdown is possible to find
different scenarios, depending on each company,
either for quarries (Figure 6) or for processing
(Figure 7), these scenarios will vary according to
the
company's
strategy
and
the
type
Figure 6. Cost Breakdown in three marble quarries
of
(CEVALOR-INETI, 2008).
exploitation.
The analysed costs are divided by the most
significant parameters in terms of the enterprise
management, including those related to water,
the
auxiliary
materials
necessary
for
the
development of activity, energy, the human

resources, the machines (cost of the use
equipment, excluding energy and considering the
equipment depreciation), the management of
emissions (noise and dust) and the waste.
Regarding the quarries we can see that the
largest share of the costs break down is divided
between the human resources and the machines.
Figure 7. Cost Breakdown in three processing plants
The different scenarios presented allow in one
(CEVALOR-INETI, 2008).
hand to understand the diversity of situations that

may occur, and simultaneously a slight pattern in
6. Inputs
terms of costs distribution.
Raw Material
It is interesting to note that the costs associated

with the water, energy and also waste and
When considering the raw material as an input
emissions
low
into the system we refer more clearly to the
proportions in the general costs, which is
transforming process, since the extraction as a
probably related to the accounting systems and
primary sector of activity directly exploits a
to the poor quantification of these issues. These
natural resource without processing, where the
costs are diluted in other respects, particularly in
raw material is the mineral mass itself.
the manpower and the costs with the use of
So the blocks of marble, limestone or granite, or
management,
have
very
shale and slate, are the end product of the
-11-
Technical Handbook
extraction process and the main raw material for
tone of oil equivalent, or toe, and the conversion
processing factories.
will be done according to the following table:
If we compare the mass balance of the three

Table 4. Conversion to Tone of Oil Equivalent (TOE).
processing plants we can observe the following

(Table 3):
Table 3. Mass Balance for three marble processing
plants (CEVALOR, INETI, 2008).
On this basis and taking into account the existing

information for three quarries and processing
plants we can present the following table:
It appears that regardless of the quantities that
Table 5. Energy consumption for three marble
vary depending on the size of the factory and its
processing plants and quarries (CEVALOR-INETI,2008).
labour market, the efficiency of the process

among the 73% and 57% is framed within the
average values assumed for this industry.
Energy
The energy appears in the extraction process and
manufacturing in several forms, electricity, diesel
and other "secondary" which will be dependent
on the first two, compressed air, which can be
produced by a diesel or electric compressor.
Energy is an input at all stages of the process,
whether extractive or manufacturing.
While in the processing the electricity is the most
consumed in the quarries where diverse mobile
Water
machinery, or even the use of compressors
Water is an essential element both in the
exists, diesel is the most used energy.
quarrying and in the processing of dimensional
In order to standardise the analysis of the energy
rock. Its function is to cool the drilling and cutting
efficiency and to frame the enterprises in a
diamond tools and clean the cuts.
consumption profile is used usually one unit that
Simultaneously
can correlate the different forms of energy and
environmental
then categorise the consumers. This unit is the
this
use
functions
also
complies
allowing
with
the
reduction of dust emissions into the atmosphere.
-12-
Technical Handbook
Table 7. Recycled Water in three marble quarries and
The water used, either in quarries or factories
processing plants (CEVALOR-INETI, 2008).
may come from three origins:

Caption:
Surface Waters.
Underground Waters.
Public Distribution.
Reuse.
Its normal to reuse about 80% of the water both
for quarries and processing plants, since the
treatment systems are increasingly effective.
In order to replace the normal losses, especially
through the sludge, it is usually necessary to have
an external supply.
Tables 6 and 7 present values of consumption
and reuse of water measured over a year in three
7. Outputs
plants and three marble quarries.
Final Products
Table 6. Water Consumption in three marble quarries
The attainment of the final product is the principal
and processing plants (CEVALOR-INETI, 2008).
object of the extraction and processing of

dimensional stones, varying that same product
from a rough block, result of the extraction of
the mineral mass to a variety of products
associated with the processing process (Table 9).
The rates of recovery are quite different for the
quarrying and for the processing, being in the
case of the ornamental rock quarries, directly
related to the conditions of the mineral mass and
in the case of the processing plants with the
quality of the raw materials purchased and the
type of product required.
The products resulting from the processing
process,
and
which
are
being
addressed
throughout this work are distinguished primarily

according to their size, ranging from the sawn or
finished plates sawn to the modular tiled.
In addition to these products usually considered
standard there are some others that are not
-13-
Technical Handbook
related to the dimensions, since these are

variable, and even those related to works by
measuring or special assignments.
Table 9 lists some of the products resulting from
the processing of the dimensional stone.
Table 8. Typical products in the processing of the
dimensional stones (OSNET vol. 1, 2003).
In situations where the emission of noise goes

beyond the legislated values it is important to
maintain
constant
monitoring
to
prevent
possible impacts. In this sense, the processing

plants carry out every year new measurements to
Noise
assess the preventive measures applied. The

specific prevention measures for workers' health,
The issue of noise as output of the production
usually includes the provision and use of
systems can be viewed from two standpoints:
appropriate personal protective equipment (PPE).

Dust
Occupational Noise - the noise to which
On open-air quarries the main air pollutant is
workers are exposed, usually considered
made of airborne dust particles, whose size
in the context of Occupational Safety and
varies between 1 m and 1000 m (Jimeno, C. et
Health at Work;
al 1989).
Environmental Noise - the noise that
These
goes beyond the facilities.
dusts
may
be
detrimental
to
the
environment and consequently for human health,

depending on some parameters such as chemical
The main sources of environmental noise can be
composition, particle size and volume in the
divided, according to the type of noise they
atmosphere. The most damaging to human
produce, in the following groups:
health are of smaller diameter (<10 m), which

are called PM10.
Operation of drilling and cutting;
Like noise emissions in the processing plants the
Use of explosives;
dust
Load and transport.
issues
arises
mostly
from
health
perspective than from surrounding environment

Table 9. Workplaces (%) with noise levels above the
point of view. In this sense, and once the process
limits established by law, for three processing plants
is carried out mostly in wet conditions, the
and three marble quarries (CEVALOR-INETI, 2008).
finishing stage is usually the one that is most

affected by dust.
-14-
Technical Handbook
On the other hand most of the wastewater, water
Gases
and suspended solids (stone dust), require a
Vehicles used on natural stone quarries, other
strict management and have relatively high costs.
combustion diesel engines, and the use of
Most companies, whether processing plants or
explosives, are activities that emit gases into the
quarries, usually use a system for wastewater
atmosphere.
treatment which allows the recovery of water for
Usually these are open-air quarries these gases
the production system on average values that
accumulation does not pose health problems for
may be around 80%, which represents a very
the workers or the public in general, since that
significant efficiency in relation this feature.
the dust spread is rather quickly.
The effluent circuit is different in quarries and
In underground quarries will have to consider the
processing units.
problem in a different way, since it can become
In quarries usually the procedure is a pumping
more relevant in terms of working conditions. For
system that takes the water from the bottom of
that, as mentioned above, should be planned and
the
designed specific ventilation systems.

From
the
perspective
gas
emissions
quarry
for
specific
deposits
that
are
strategically placed according to the capacity of
that
the pumps and the depth of the excavation. The
contribute to the greenhouse effect is possible by
treated water will be used for primary processing
converting the values associated with energy
surface of blocks or reintroduced, by gravity, the
consumption, conclude about the CO2 values
quarry (Figure 8).
emitted by a particular enterprise, in this sense

and as an example we can cite the following
data, resulting from values considered for the
year 2007 (Table 10).
Table 10. CO2-eq Emissions in 2007 for two quarries

and a marble processing plant (Eco-efficiency Project
in Quarrying Industry, 2008).
Enterprise
CO2-eq Emissions/m3 of Commercial Block
Quarry A
297 Kg
Figure 8. Schematic representation of typical system of
Quarry B
80 Kg
treatment and recirculation of water in a quarry.
Plant C
100 Kg
In the case of processing plants the effluent is

collected in gutters, and in the equipment in each
Wastewater
operation and is
subsequently referred for
In the ornamental stone the production of liquid
treatment in tanks for brewing, or for a more
effluents has particular importance since that,
complete treatment plant constituted not only by
generally, the processes take place in wet
settling ponds but also by a pumping station, a
conditions, either in quarries or in the processing
unit for flocculants, a clarifier, a press filter and a
plants.
tank of clean water (Figure 9).
-15-
Technical Handbook
The sludge, after filter-pressed, have a moisture

content ranging between 20% -30% or higher,
and are subsequently deposited in landfills.
Figure 9. Schematic representation of typical treatment

system and recycling water in manufacturing.
Figure 10. Waste heaps of natural stone.
Waste
The origin of the various types of waste provided
A waste is any substance or superfluous object
from the quarrying or processing is summarised
without economic interest from an activity and
in Figure 11.
whose holder discards, intends to do it, or is

required to.
The natural stone industry, either in quarrying or
in the processing plant, produces waste similar to
urban waste, but which stand out primarily by the
quantities produced is the waste rock debris
without commercial value.
These are not hazardous wastes and are
considered inert. Given the volume they occupy
is stored in the form of landfill or tailings, within
the licensee area of the enterprise, see Figure 10.
Figure 11. Types of waste from quarrying and
processing of natural stone (ISTONE, 2007, D5.11).
In terms of possible final destinations for the

waste is accepted and even indicated by
legislation a preferential hierarchy (Figure 12)
reflecting, in order, the prevention, recovery and
disposal:
-16-
Technical Handbook
Prevention - prevent or reduce, preferably
sector depends on the implementation of specific
at the source, as far as possible the
measures.
production or harmfulness of the waste;
The compatibility of this industrial activity goes
Recovery - recycling of waste operations,
through the adoption of good environmental
such as: reuse, recycling or energy
practices, which should allow the mitigation and
recovery.
prevent
Disposal - designed operations to give a
magnitude and providing the recovery of the
final destination to the waste, such as its
affected area, once quarrying activity ends or a
treatment, recovery or landfilling.
better harmony with the environment for the
the
major
impacts,
reducing
their
processing plants.
In situ management immediately contributes to
Preparation stages and the exploitation of a
waste production prevention, its important to
quarry usually are characterised by the major
highlight some actions that are now common on
destructive activities of the production process.
quarrying and processing of dimension stone.

The following pictures give some good practice
9. Conclusions
examples for waste management in quarries and
The concept of sustainability applied to the
processing plants:
natural stone industry will have to be seen in the

perspective of management of the premises
where the exploitation takes place, the industry in
the broadest sense will not be sustainable since it
is
not
possible
to
guarantee
continued
indefinitely, for dealing with a finite resource at a

human scale.
It appears that the costs of the environmental
component,
including
water
management,
emissions and waste, there are very limited

distribution
in
general,
which
essentially
correspond to the way they are accounted for,

possibly diluted in the emerging costs of hand
work or in energy costs, which have a significant
size.
Figure 12. Waste Management.
In the ornamental stone industry profitability of

8. Environmental Impacts
raw
Within the principles of sustainability of the
management, consisting mostly representative
natural stone industry, in both quarrying and
for more remains of stone with no ornamental
processing, its important to carry out an impact
value.
analysis of the activity on the environment,
The
because lot of the balance and continuity of the
sustainability
material
is
management
closely
from
requires
related
the
to
waste
perspective
the
of
integrated
consideration of all aspects related to resource
-17-
Technical Handbook
exploitation, with the primary objective of an
Contenido
y Metodologia. 2
ed., MOPU.
increased efficiency of industrial facilities in the
Madrid.
tight balance between consumption, production
CEVALOR - Espao e Desenvolvimento, (2004) -
and relationship with its surroundings.
Estudo de Mercado de Exportao da Pedra

Natural Portuguesa para a Alemanha e Principais
Pases do Alargamento.
10. References
Costa, J.B. Caracterizao e Constituio do

Akkoyun O., Ankara H. (2009) Cost of quality
Solo. Fundao Calouste Gulbenkian.
management: an empirical study from Turkish
Costa,
marble industry. Sci. Res. Essays, 4:1275-1285.
Aproveitamento
In Seminrio As Rochas Ornamentais e os
Pedreiras de Granito Ornamental, Tese de
Desafios da Competitividade. A Pedra, n 55/56.
Dissertao para obteno do grau de Mestre em
Costa, C., Rodrigues, M.J.; Pinelo, A., (1992) -
Geologia de Engenharia, Faculdade de Cincias e

Tecnologia da Universidade Nova de Lisboa,
Lisboa.
Caracterizao
das
Exploraes
Mrmores
de
Escombreiras
da
das
Regio
de
Estremoz-Borba-Vila Viosa. 1 estudo, LNEC,
Bradshaw, A.D. & Chadwick, M.J., (1980), The

Restoration
of
Land
The
ecology
Lisboa.
and
Dieb, A.; Bonito, N.; Paspaliaris, I (2004). OSNET
reclamation of derelict and degraded land.
Editions vol. 12, Environmental friendly practices
Studies in Ecology. Volume 5. Blackwell.

Brodkom,
F.
(2000)
As
Boas
for natural stone exploitation, NTUA, Athens.

Prticas
Direco Geral do Ambiente (2000), Proposta
Ambientais na Indstria Extractiva: Um Guia de
para
Referncia, Diviso de Minas e Pedreiras do
European
Osnet Editions, Athens, Greece.
for
Portugal e as Suas Caractersticas Gerais - Nota

Manual
Technological
Studies,
Ecology. John Wiley & sons, England.

I.,
(2003),
OSNET
Forman,R. T. T., (1995). Land Mosaics: The

Ecology of Landscape and Regions, Cambridge
quarrying and processing, NTUA, Athens.
University Press, Cambridge.
CEOTMA (Centro de Estudios de Ordenacin del
Franco, R. M.; Cupeto, C., (1995) A utilizao de
Territrio e Medio Ambiente), 1984, Guia para la

Estudios
Prospective
Forman,R. T. T.; Godron, M., (1986). Landscape
Editions vol. 1, Machines and tools for stone
de
Reference
European IPPC Bureau.

Valor
Sustentvel, INETI.
Elaboracin
2004,
Sustainability in Industry, Energy and Transport,
Breve, Rochas e Equipamentos, Lisboa.

(2007),
Commission,
Mining Activities, Joint Research Centre,Institute
Casal Moura, A, (2006), A Pedra Natural em
Paspaliaris,
de
Management of Tailings and Waste-Rock in
Calcrios Ornamentais de Portugal, INETI.
S.;
Indicadores
Document on Best Available Techniques for
Casal Moura, A; et all (2007), Mrmores e
all
de
suas aplicaes. SPEL, S. A.
Tools for Stone Quarrying and Processing, Vol 1,
et
Sistema
EXPLOSA, S. A. (1994). Manual de Explosivos e
Carosio S., Paspaliaris I. (2003) Machines and
J.
um
Desenvolvimento Sustentvel.
Instituto Geolgico e Mineiro.
Carosio,
(1995)
Valorizao de Escombreiras e outros Resduos.
Andrade, Pedro C. S. (1994) Estudo de
Catarino,
C.,
de
Medio
resduos resultantes da serragem dos mrmores
Fsico:
-18-
Technical Handbook
(nata) para cobertura de resduos slidos
project, PRIORITY 3, D5.10 - Assessment of
urbanos, U.vora.
currently
Founti et al. (2010), Environmental management
schemes.
aspects for energy saving in natural stone
I-Stone, (2006), Re-engineering of natural stone
quarries, Global Stone Congress 2010.
production chain through knowledge
Gama, D. (2001) O Futuro das Pedreiras
processes,
eco-innovation
Subterrneas, Boletim de Minas, Vol. 38 n4,
organizational
paradigms;
Instituto Geolgico e Mineiro.
project, PRIORITY 3, D5.11 - First Review of Best
Guerreiro, H., (2000) Explorao Subterrnea
Available Waste Management Techniques.
de
Mrmores
Aspectos
Geotcnicos.
applied
stone
waste
management
based
and
I-Stone
new
Integrated
Dissertao para obteno do grau de Mestre em
Georrecursos, UTL, IST.
processes,
eco-innovation
INETI, (2001), Plano Nacional de Preveno de
organizational
paradigms;
Resduos Industriais (PNAPRI) Guia Tcnico do
project, PRIORITY 3, D5.14 - Preliminary LCA
Sector da Pedra Natural, Lisboa.
study of the stone production chain and waste
Instituto Geolgico e Mineiro, (2000). Portugal
management.
Indstria Extractiva. Verso Online no site do
INETI:http://e-
Geo.ineti.pt/geociencias/edicoes_online/diversos/
processes,
eco-innovation
ind_extractiva/ndice.htm).
organizational
paradigms;
Instituto Geolgico y Minero de Espaa, (1988),
project, PRIORITY 3, D5.13 - Initial Development
Programa Nacional de Estudios Geoambientales
of Sustainability Indicators.
Aplicados
I-Stone (2007), Re-engineering of natural stone
la
Mineria,
Serie:
Geologia
and
I-Stone
based
new
Integrated
and
I-Stone
based
new
Integrated
Ambiental, Madrid.
Instituto Tecnolgico GeoMinero de Espaa;
processes,
eco-innovation
(1989), Manual de Restauracion de Terrenos y
organizational
paradigms;
Evaluacion de Impactes Ambientales en Mineria;
project, PRIORITY 3, D5.15 - Feasibility Study of
Madrid.
Alternative Stone Waste Uses.
Instituto Geolgico e Mineiro (1999) Regras de
Jimeno,
Boa Prtica no Desmonte a Cu Aberto, Lisboa.
Restauracin de Terrenos y Evaluacin de
Impactes Ambientales en Mineria,
production chain through knowledge based
Tecnolgico Geominero de Espaa.
processes,
eco-innovation
Johnson,
organizational
paradigms;
and
I-Stone
new
C.L.
Technology",
Integrated
et
(1971),
U.S.
all
I-Stone
(1999)
"Explosive
Army
and
based
new
Integrated
Manual de
Instituto
Excavation
Engineer
Nuclear
project, PRIORITY 3, Internal Report - Review of
Cratering Group, Livermore.
the European Legislation on Waste Management.
Karaca Z., Onargan T. (2007), The application of
critical path method in workflow schema in order
production chain through knowledge based
of marble processing plants, Mater. Manuf.
processes,
eco-innovation
Process, 22: 37-44.
organizational
paradigms;
and
I-Stone
new
Integrated
-19-
Technical Handbook
Lins, C; Horwitz, E.,(2007), Sustainability in the
ceramic versus marble tiles, J. Clean. Prod., 10:
Mining Sector, Fundao
283- 296.
Brasileira para o
Desenvolvimento Sustentvel.
Petts & Eduljee (1994) Environmental Impact
Magno, Carlos (2001) Indstria Extractiva Do
Assessment for Waste Treatment and Disposal
Paradigma do Controlo de Oferta para um
Facilities, John Wiley & sons, England.
Modelo de Regulamentao Orientado para os
Riemer J., Kristoffersen M. (1999). Information on
Desafios
waste
do
Desenvolvimento
Sustentvel,
management
practices.
proposed
Boletim de Minas, Vol. 38 n4. Instituto
electronic framework. European Environmental
Geolgico e Mineiro. Verso online no site do
Agency, Copenhagen, Denmark.
IGM.
RMSG
Marsh, W. M., (1991), Landscape Planning -
Indicators for the EU non-energy extractive
Environmental Applications. Second Edition;
industry in 2001, A report from the Raw
John Wiley & Sons, England.
Materials Supply Group (RMSG), a stakeholder
Martins, Cristina M. T. (1998) Abordagem dos
group,
Impactes Paisagsticos da Actividade Extractiva
Enterprise, European Commission, Final SDI
no mbito do Sistema de Auditoria Ambiental,
Report, 19 February 2004.
Comunicaes do 1 Seminrio de Auditorias
Salgueiro, T. (2001), Finisterra, XXXVI, 72, pp.37-
Ambientais
53, Paisagem e Geografia).
Internas,
Diviso
de
Minas
(2004),
chaired
Sustainable
by
Development
Directorate-General
for
Pedreiras do Instituto Geolgico e Mineiro.
Stout, K.S., (1980) Mining methods and
Martins, R.; Barroso, M.; Cupeto, C.; Monteiro, J.;
equipments. McGraw-Hill, Inc. New York.
Gonalves,
Mrmores
Traverso et al. (2010), Environmental performance
Compactos e a Cermica como possvel soluo
of building materials: Life Cycle Assessment of a
para
typical Sicilian marble, Int. J Life Cycle Assess.,
F.,
reduo
(1995)
de
Os
resduos
da
Indstria
Extractiva e Transformadora, revista Indstria e
15: 104-114.
Ambiente n 6, Lisboa.
Terezopoulos, N.; Paspaliaris, I., (2003). OSNET
Marcus, J.J. (ed.), (1997) Mining Environmental
Editions vol. 2, Dimension stone quarrying in
handbook. Effects of mining on the environment
Europe and stability of quarrying operations,
and American environmental controls on mining.
NTUA, Athens
Imperial College Press.
Terezopoulos, N.; Paspaliaris, I., OSNET Editions
Marsh, W. M., 1991, Landscape Planning -
vol. 7, Optimizing quarrying techniques and
Environmental Applications. Second Edition;
practices, NTUA, Athens (2004).
John Wiley & Sons, England.
Universidad de Oviedo, (1992) - Curso de
Midha, S., Paspaliaris, I., (2004), OSNET Editions
Impacto Ambiental y Restauration en Mineria a
vol. 9, Complementary technologies for stone
Cielo Aberto, Departamiento de Explotation y
processing, NTUA, Athens.
Prospeccion de Minas. COMETT, Oviedo.
Montani, C., Stone 2007 World Marketing
World
Handbook. Gruppo Editoriale Faenza Editrice
Development, 1987. Our Common Future, Report
s.p.a. 2007.Nicolleti et al. (2002), Comparative
of the World Commission on Environment and
Life Cycle Assessment of flooring materials:
Development.
-20-
Commission
on
Environment
and
Technical Handbook
constitute 99.2% of the total stone quarrying
III. Eco-efficiency of the natural stone

production chain. Best available techniques.
Demonstration activities. Feasibility of the
new technologies and products.
companies and employ more than 80% of the

relevant workforce (EUROSTAT, 2008). These are
necessarily located close to the natural stone
producing
III.1. Quarrying and processing factors

affecting embodied energy of natural stone
products
areas,
very
often
in
remote,
mountainous areas, may not connected to the

electricity supply grid. They are usually vertically
organized companies with limited access to
financial
A. Gazi, G. Skevis, M.A. Founti
resources
and
difficulties
with
incorporating new technologies, implementing

Laboratory of Heterogeneous Mixtures and
modern organization schemes and fully adopting
Combustion Systems, Thermal Engineering
national and supranational regulations. A lack of
Section, School of Mechanical Engineering,
skilled
National Technical University of Athens,
technologies may also be a problem.
labour
trained
in
contemporary
Marble production requires an advanced level of

technology, which results at higher costs but at
1. Introduction
the same time presents significant profit-making
Marble is a financially important and highly
opportunities. Major problems of the marble
versatile material used extensively both in the
sector relate to its conservative nature, its low
construction,
productivity coupled with low penetration of new
decoration
and
art.
Marble
production is concentrated in specific areas (e.g.
technologies
Mediterranean basin, Central and East Asia etc.)
operations, traditional manufacturing of end-
with more than 90% of total natural stone
products, significant quantities of waste material
production coming from China, Italy, India, Iran,
generated in all production stages, as well as
Spain,
and
high production costs and a lack of sustainable
Portugal. Each of the above countries which
management of resources. The latter, together
produces more than 2 million tonnes of natural
with the current fragmented nature of commercial
ornamental stones per annum (Napoli, 2010). The
activities and the small size of production
European Union (EU) accounts for approximately
companies
30% of world stone production, of which 90% is
modernization of the sector (Gazi et al., 2012).
concentrated
countries
To change the picture, it is necessary to adopt
(EUROSTAT, 2008). In the EU, stone quarrying
measures that lead to a marked increase in
activities are carried out by almost 60,000
production efficiency coupled with substantial
companies employing approximately 500,000
reductions in material waste. Energy efficiency of
people with an annual turnover of more than 20
a vertically-organized enterprise (quarry and
billion (Bruno and Paspaliaris, 2004).
processing plant) is a function of raw material
The majority of quarrying and stone processing
properties
activities worldwide are performed by Small-to-
existence of cracks etc.), type of end products
Medium Enterprises (SMEs). In the EU, SMEs
and size of production. In order to be able to
Turkey,
Brazil,
in
Egypt,
Greece
Mediterranean
in
production
poses
serious
(uniformity,
and
processing
barriers
density,
to
the
rigidness,
estimate energy saving potentials, it is necessary
-21-
Technical Handbook
to adopt a methodology capable of identifying,
3. Marble quarrying
defining, estimating and assessing energy flows
The Limenas quarry is located on the island of
in natural stone quarries and processing plants,
Thassos, at an altitude of 440-530m covering a
accounting for details and peculiarities of the
total area of about 47,800 m2. It is an open pit
examined processes (Gazi et al., 2012).

This
article
targets
engineers,
quarry with several fronts and seven beds, each
production
6m high. The annual productivity is ca. 2,900 m3
managers and stone producers in need of
in rough blocks, of 2 m3 up to 8 m3 according to
knowledge of the energy details of specific lines
customers' orders, and ca. 4,000m3 of irregular
in order to take up specific measures. It assesses
small sized blocks with a market value ranging
the energy flows and the environmental impact
from 280 to 600/m3. The quarry has 20
related to the production stages (quarrying and

processing)
of
typical
marble
products
employees and can operate for about 10 months
by
per year (Gazi et al., 2012).
implementing an energy audit approach. The
Quarrying operations involve isolating blocks
implemented methodology is based on the
from the parent ledge by cutting them free on all
identification of energy demanding processes
sides perpendicular to each other. The basic
related to marble production in a specific plant,
quarrying
definition of appropriate operation/installation
sequence
includes:
pre-production
operations; primary cuts; secondary cuts and
parameters that control the above processes,
finishing of blocks and removal and haulage of
and evaluation of the effect of such parameters
blocks. The isolated stone block has dimensions
on the energy consumption per final product.
suitable for sale and processing or it may be

further subdivided into smaller blocks. The block
2. Marble quarrying and processing plants: An

inventory
maximum width is constrained by weight limits
that are given by safety factors in handling and
inventory,
including
machinery
transportation of the blocks, as well as the
specifications
and
operational
dimensions of the gang-saw frame, where blocks
characteristics, of the examined typical medium-
are placed and cut to produce slabs. Quarrying
sized marble quarry and processing plant in
and processing practices demonstrate that the
Greece has been presented elsewhere (Gazi et
larger the block dimensions the lower their
al., 2012). The selected plant is a typical SME in
production costs and the higher their processing
the marble production sector (Laskaridis Marble
yields (Gazi et al., 2012).
S.A., 2012) with typical quarrying and processing
The electric power requirements of the quarry are
activities, as far as equipment, quarrying and
covered by two power generators of nominal
processing methods and economic size are
power 250kVA each. These are used to power
concerned. The main activities of Laskaridis
two air-compressors, seven diamond wire saws,
Marble S.A. are extraction from privately owned
two drill machines, two pneumatic top-hammers
quarries in the Limenas and Theologos areas of
and one water drill pump. Auxiliary drilling
Thassos, Northern Greece, and processing and
equipment includes short plugs, hydraulic jacks
elaboration of white dolomite and crystalline
and air pillows. In addition, the quarry uses
detailed
technical
marble.
-22-
Technical Handbook
various vehicles such as excavators and loaders,
of slabs of varying thicknesses, not limited to the
truck/dumpers, cars and jeeps.
2mm or 3mm thickness obtained from the
Water consumption, required for cooling and
multiblade gang saw. Passing the raw block
cleaning the diamond wire saws and for the
through a monowire or a monoblade machine
drilling procedures, is of the order of 80 m3 per
(block-squaring for fitting into the gang-saw)
day. The water comes either from dams located
improves the productivity of the cutting process
on the mountain at a higher altitude than the
significantly, achieving better efficiency in block
quarry, or from a water-drill, especially during the
cutting and reducing material waste (Carosio and
summer months. The water is stored in three
Paspaliaris, 2003).
40m3 overflow-tanks, from where water is
A multiblade gang saw is used for cutting blocks
supplied to the quarry under free-fall flow.
into slabs (flat surface semi- finished product with

unfinished edges obtained by sawing or splitting
from a rough block minimum dimensions of a
4. Processing Plant
slab: 2m x 1m x 0.02m (EN 1468, 2003)). In the
The processing plant is located approximately
multiblade gang saw, up to 81 slabs are
30km from the quarrying area. The basic

processing
finishing
sequence
operations
includes
(polishing,
cutting
curing,
simultaneously cut by 80 blades. The slabs can
and
be further cut into smaller products such as
edge
strips, stairs, tiles, etc. of different dimensions, by
profiling), packaging of products and storage or
using bridge cutters.
distribution to customers. The total installed
The finishing equipment includes two polishing
power is 625kW and the processing plant electric
machines, used to adjust the product thickness
power demand is covered by grid electricity. The
to a prescribed tolerance and to give light
installed power and make/model for selected
reflecting properties to the marble surface. The
processing plant machinery are shown in Table 1.
first polishing machine is on line with curing
The processing plant operates 12 months per
treatment, resin application, UV and IR furnaces.
year, 8 hours per day and employs 15 persons
Both polishing machines offer the possibility of
either on a full or part time basis (Gazi et al.,
alternative use of bush hammering tools and
2012). An outline of the processing plant is
other ribbing heads, instead of polishing heads, in
depicted in Figure. 1.
order to give a rough surface to the products and
Processing plant employs both cutting and
make them suitable for anti-slipping applications
finishing equipment. Cutting equipment includes
(e.g. pavements), or acquire a special visual
monowire and monoblade machines, a multiblade
effect (e.g. for wall cladding). An edge profiling
gang-saw and bridge cutters. A monowire (using
machine is used to give the four upper edges of
a diamond wire) or a monoblade (using a
each product the desired inclination.
diamond blade) machine, is used to give

rectangular
shape
to
irregular
blocks.
The processing plant also includes auxiliary
The
equipment, such as two bridge cranes with a
monowire has a higher feed rate while the
lifting
monoblade has a lower level of productivity but a
capacity
of
5,000kg
and
25,000kg
respectively, a rotary crane, several trolleys and
narrower cut (better yield) and a longer lifetime.
forklifts.
Both machines are also used for the production
The
wastewater
-23-
processing
treatment
plant
facility.
The
utilizes
latter
is
Technical Handbook
necessary since the water used in all cutting and
This approach gives the possibility to compare
finishing
substantial
the total energy requirement of similar products
quantities of marble splint and dust that need to
and processes. The calculation of the energy
be
wastewater
consumption of each operation was based on
(0.005m3/sec) is fed into a conical shaped
efficiency values defined as a percentage of
settling tank, with a volume in the order of
nominal
120m3, where a chemical agent is added to
literature
increase the rate of coagulation and to facilitate
processes. Reductions in efficiency originating
faster sedimentation. The sediment formed at the
from normal wear and tear have not been taken
bottom is led through a pneumatic diaphragm
into account; as such the calculated energy
pump to a filter press which retains marble
values constitute an upper limit. Common to all
sludge containing relative small amounts of
processing scenarios are extraction in the marble
humidity (approx. 10%). The filtered water is
quarry and transportation of blocks from the
subsequently led to a 6700lt storage tank for
quarry to the processing plant. The proposed
further use. The efficiency of the water recycling
methodology can be easily extended and applied
process is about 70% (Gazi et al., 2012).
to any similar SME.
5. Energy Assessment
5.2. Calculation of Energy Inputs for Typical Final

Products
filtered
processes
before
contains
reuse.
Plant
5.1. Outline
machine
power
and
derived
from
for similar cutting and machining
Several operating sequences are possible in a
The present article proposes a methodology that
typical marble plant as described in detail in (Gazi
can be used to estimate the energy saving
et al., 2012) and shown in Table 2. In such a
potential of a typical medium sized marble plant
typical scenario (Scenario 6) a block extracted
based on the calculation of energy inputs per
from
product, taking into account the details of
the
quarry
(average
dimensions
2.15x2.10x3.10m) is shaped and squared-off in
quarrying and processing activities, as well as
the
details of machinery required for the production
diamond
monoblade
(squared
block
dimensions 2x2x3m), and cut into large slabs
of each product. Such an approach is markedly
(2x2x0.02m)
different from holistic approaches, such as Life
in
the
multiblade
gang-saw.
Subsequently, the slabs are transferred to the
Cycle Assessment (LCA) being able to account
bridge cutter and are further cut to the required
for the peculiarities of a particular plant (Gazi et
finished product dimensions (0.4x0.4x0.02m). The
al., 2012). The first step in such methodology
finishing process includes passing through the
includes product specification (e.g. slab, tile).
polishing machine where surface roughness is
Depending on the particular product, a different
reduced. At this stage, products are given the
combination of plant machinery is required, as
light reflecting properties of the marble surface
shown in Table 2. The next step is to calculate
and finally the tiles pass through the edge
the energy consumption of each individual
profiling machine to create the desired inclination
operation of the production line in order to define
for its two upper edges. An outline of this
the total energy requirement (energy input) for
scenario is shown in Figure . 2.
every specific product and processing scenario.
-24-
Technical Handbook
Calculations
for
are
to the multiblade gang-saw operation, while using
presented in Tables 3-8. Tables 3 and 4 present
a monowire or a monoblade cutter makes no
the calculated energy consumption for quarrying
appreciable
and transportation from the quarry to the
consumption. Note, however, that the monoblade
processing plant. Table
5 presents energy
energy consumption is by a factor of two higher
calculations for block squaring in the diamond
than that of the monowire machine. Polishing, on
monoblade
calculates energy
the other hand, introduces significant energy
consumption for block cutting into slabs in the
costs as shown both in Figs. 6 and 7. For
multiblade gang saw. Energy consumption for the
example, slab cutting and polishing (scenario 3) is
polishing and edge profiling finishing processes is
almost a factor of 2 more energy demanding than
shown in Tables 7 and 8, respectively. In Table 7,
simple
the total power of the polishing machine is
arguments can also be made in the case of tiles
calculated, assuming that there are 12 polishing
production
heads having a power of 4.1kW each, 3 diamond
scenarios 5-7). When curing treatment is also
heads of 18.6kW each and 3 cold air blowers of
required,
3kW each.
enormously, as clearly indicated by simple
Based on the above calculations, it is possible to
inspection
define the total energy consumption for the
associated with scenarios 7 and 10. The edge
production of a typical product (Table 9) and the
profiling machine generally has a moderate
(energy) contribution of every stage of the quarry-
contribution, of about 20-50%.
to-final product process (Fig. 3). It becomes clear
A comparison of the energy consumption of the
that cutting (in the processing plant) is by far the
processing plant machinery is shown in Fig. 8.
most
Clearly, the most energy demanding machines
and
energy
operating
Table
demanding
scenario
process
in
the
production of a polished tile.
difference
slab
cutting
(cf.
the
the
total
(scenario
compare
energy
of
to
2).
scenario
consumption
energy
energy
Similar
4
with
increases
consumptions
are the multiblade gang-saw (as far as the cutting

process is concerned) and the polishing and
5.3.
Extension
of
Energy
Assessment
Methodology and Sensitivity Analysis
curing machines (as far as finishing processing is
The methodology outlined in the previous section
calculations can be found in Table 10. For useful
is here applied to possible operating scenarios in
comparisons, all results are given in kWh/m3. In
order to assess the effect of alternative plant
the case of tile production, where the final
processes in the total energy consumption for
product has a specified thickness (2cm), results
selected final products. Figure 5 summarizes total
are also presented in kWh/m2.
energy
operating
A sensitivity analysis has also been performed in
scenarios. A breakdown of the total consumption
order to quantitatively assess the impact of
into individual processes is presented in Fig. 6 for
operating parameters for each process on the
scenarios 1-3 and in Fig. 7 for scenarios 4-10.
overall energy consumption. Values of pertinent
Clearly, scenarios 1-2 have significantly lower
parameters (e.g. the time spent by a tile in the
energy consumption than the other cases since
curing oven) have been varied within a pre-
they only involve primary cutting processes.
defined range (e.g. up to 100% of the current
The major energy cost (more than 85%) is related
production value) and the energy consumption
consumption
for
all
ten
concerned). A detailed description of these
-25-
Technical Handbook
per product has been evaluated for each case. It
than
should be noted that the specific parameter
requirement. On the other hand, significant gains
values implemented in the sensitivity analysis are
could be achieved by optimizing polishing and
not optimized solutions but are used herein order
curing
to highlight the effect of each specific parameter
almost 67% of the total energy consumption in
on energy consumption.
operating scenario 7. This can be done by, for
The energy consumption in cutting processes is
example, using only one IR oven instead of two.
simply related to
block and final product
In this case, it would be advisable to increase the
dimensions. As a result, no significant energy
time of the curing in the single IR oven, so as to
improvements
the
have the same curing efficiency. Thus, assuming
modification or replacement of the existing
a 25% increase of the time of the curing in the
machinery.
machine
single IR oven, the energy consumed for the
contributes 40% of the total energy consumption
production of the final product would be reduced
in operating scenario 6. Significant improvements
by 8%. Similarly, the possibility of reducing the
in total energy consumption could be achieved by
number of UV or IR lamps was also considered.
moderately increasing the belt advancing speed.
Using 18 instead of 24 UVA lamps makes no
For example, a 50% increase of belt advancing
significant
speed results to almost 20% less total energy
requirements, whereas the use of 15 IR lamps in
consumption, but no further gain is achieved by
each IR oven reduces by 5% the total energy
further speed increase. This is due to the fact
consumption in operating scenario 7. In this case,
that, in order to attain higher belt advancing
it would be also advisable to increase the belt
speeds, the belt motor would need to operate
advancing
beyond its maximum rated efficiency. The above
efficiencies. Sensitivity analysis shows that the
calculations are performed by assuming a certain
reduction
distance (13 cm) between products in the belt.
insignificant
Increasing tile stacking (i.e. decreasing the
consumption (only 1% for a 25% reduction in the
distance
also
number of UVA lamps). The effect of IR lamps
beneficial in terms of energy consumption. For
reduction is tenfold due to the significantly higher
example, a 10cm distance between successive
power rating of the latter (0.45 kW/UVA lamp
tiles results in 5% less total energy consumption
compared to 6 kW/IR lamp). Increasing the
per product.
processing time, using 18 instead of 24 UVA
Although the polishing machine makes large
lamps and a single IR oven with 18 IR lamps,
contributions to the total energy consumption
results in a 9% reduction of the total energy
(e.g. 20% in scenario 6), altering polishing
consumption. However, in order to fully assess
process parameters (i.e. belt advancing speed
the impact of the above, a complete thermal
and/or tile stacking) does not appreciably alter
analysis of the curing processing in the ovens
energy consumption. For example, a
needs to be performed.
can
The
between
be
edge
made
without
profiling
successive
tiles)
is
50%
increase of belt advancing speed has only 7%

positive effect on energy consumption. Also,
increasing tile stacking by 3cm results in less
-26-
1%
reduction
machine
in
operation,
difference
time
of
in
in
order
UVA
effect
lamps
on
the
total
which
the
to
the
constitute
total
attain
has
energy
energy
similar
an
almost
final
energy
Technical Handbook
product (functional unit). Similarly, Nicoletti et al.
5.4. Embodied Energy
(2002) presents primary energy consumption data
Embodied Energy is the sum of all the energy

required
to
produce
goods
or
for the production of one m2 tile (functional unit).
services,
The above data were adjusted to the functional
considered as if that energy was incorporated or
unit used in this work, which is a typical
'embodied' in the product itself. Embodied
commercial tile of dimensions 0.4x0.4x0.02m,
energy is an accounting methodology which aims
corresponding to 0.16m2. The current choice of
to find the sum total of the energy necessary for
functional unit has been based on the practical
an entire product life-cycle. Determining what
requirements of selected target groups (e.g.
constitutes this life-cycle includes assessing the
architects, energy engineers). Traverso et al.
relevance and extent of energy into raw material
(2010) follow a production sequence similar to
extraction, transport, manufacture, assembly,
that of scenario 6 that includes extraction in the
installation, dis-assembly, deconstruction and/or
quarry,
decomposition as well as human and secondary

resources.
Different
methodologies
include pre-production and marble extraction,

transportation and processing. Calculated energy
embodied energy content of a building was
values are graphically presented in Figure. 4. It is
negligible compared to the operating energy
apparent that the calculated energy consumption
spent throughout life cycle of the building. As a

focused
on
per product in the processing plant is similar for
reducing
all three cases. The increased overall energy
operating energy and improving the energy
consumption for the case of Nicoletti et al. (2002)
efficiency of the building envelope. Research has
is due to the very high transportation costs inside
shown that this is not always the case. Embodied
the quarry and from the quarry to the processing
energy can be the equivalent of many years of
plant.
operational energy. The most important factor in
Another useful comparison between Greek and
reducing the impact of embodied energy is to
Italian typical marble products can be made on
design long life, durable and adaptable buildings.
the basis of embodied energy. The term is
In this section, the energy efficiency of the

examined
quarry
and
processing
plant
and
(SIMEC LM 600, sawmill 2). Nicoletti et al. (2002)
Until recently, it was thought that the total
were
products,
machine (sawmill 1) and a tile polishing machine
of application and the type of energy embodied.
efforts
of
processing in a monoblade, a block-cutting
produce
different understandings of the scale and scope
result,
transportation
loosely used here, since in its strict definition it
is
should include the sum of all energy inputs
compared to the energy efficiency of two Italian
(fuels/power, materials, human resources etc.)
marble plants, through comparing the embodied
from extraction, and processing to bringing it to
energy of similar marble products. The calculated
the market, and disposal/re use. Traverso et al.
energy input of scenario 6 for a typical Greek
(2010) state that the embodied energy for the
marble tile is compared in Table 10 with literature
examined Italian marble is 324.4kWh/m3 for slabs
on embodied energy data for Italian marble
and 492.2kWh/m3 for polished tiles. The currently
products (Traverso et al., (2010) and Nicoletti et
estimated embodied energy for the Greek marble
al., (2002)), based on LCA. Traverso et al. (2010)
varies depending on the particular production
presents embodied energy per volume of marble
scenario. The calculated embodied energy for
-27-
Technical Handbook
slabs is 100-160 kWh/m3, whereas for polished
product (kg/tile) is calculated by equation (1). The
tiles
The
contribution of other Greenhouse Gases, besides
significantly lower embodied energy of the typical
CO2, in the environmental impact of diesel fuel is
Greek slab can be attributed to the high quality of
negligible and amounts to less than 1% of the
the raw material, which precludes the need for
total.
lies
between
300-700
kWh/m3.
slab strengthening with nets or fault repair (e.g.

crack or hole filling) using resins. Both such
3600 th E C
m CO 2 = CO 2
LHV
processes require intermediate drying of the
(kg CO2/tile)
material that significantly impacts the energy
(1)
consumption.
In Eq. (1), Ec is the energy consumption per tile in
kWh, obtained from Table 9, th is the thermal
6. Environmental Assessment
efficiency of the quarry machinery and/or diesel

The quarrying and processing of natural stones in
truck engine, assumed here to have a value of
general, and marble in particular, raise important
0.4, LHV is the lower heating value of a typical
issues that relate not only to process efficiency
diesel fuel in kJ/kg and is the diesel fuel density
but also environmental impact. There are three
in kg/m3. Eq. (1) has been formulated on the
aspects relevant to the marble industry: energy
basis of dimensional analysis and takes into
consumption, material waste management and
account the crucial process parameters (e.g. th,
environmental pollution (gaseous and particulate
LHV) affecting CO2-eq emission. The values
emissions, dust, noise, disturbance of natural
considered
habitats).
and
combustion, CO2, is assumed to have a value of
Section 3. However, any improvements in energy
2.58kg/m3
consumption will naturally have a direct beneficial
with
all
process
of
CO2-eq
stages
of
(quarry
Eads,
2004).
For
grid electricity for thermal power plants in
emissions
the
and
processing plant, the CO2-eq emission factor of
such will improve the sustainability of the plant.

quantification
(Fulton
estimating carbon dioxide emissions from the
impact to greenhouse gases emissions and as
production
LHV=45000kJ/kg
CO2 emission factor corresponding to diesel fuel
processing practices has been discussed in
associated
are
=850kg/m3 (Borman and Ragland, 1998). The
The energy efficiency of the current quarrying and
The
here
Greece, having a value of 1.094kg CO2/kWh, is
marble
used (EEA, 2007). Results are summarized in
extraction,
Table 11. Calculated equivalent CO2 emissions
transportation, processing) is presented in this
for Greek marble tiles correspond to a total of
section.
440kg CO2-eq/m3. This can be compared to a
The energy consumption of operating scenario 6,
value of approximately 315kg CO2-eq/m3 for a
as outlined in Table 9, was considered as a basis
typical Sicilian marble (Traverso et al., 2010). The
for CO2-eq emissions calculations. In the case of
higher carbon dioxide emissions associated with
quarry extraction and transportation phases, the
the
primary energy source is diesel fuel, used to
Greek
marble
production
are
clearly
attributed to the Greek grid electricity energy mix.
power the quarry machinery and the trucks,
It is clear that, at least for this particular operating
respectively, and the CO2-eq emission per final
scenario, the processing plant consumes almost
-28-
Technical Handbook
85% of the total required energy for tile
marble waste is the major environmental issue
production but at the same time is responsible for
related to
98% of the total CO2-eq emissions. This is due
embodied energy mainly reflects the processing
to the fact that electricity in Greece is mainly
plant activities. Similarly, the embodied carbon is
produced in coal (lignite)-fired plants which emit
only affected by the processing of the marble
significantly
products. Consequently, it is obvious that rather
engines.
more
Further
CO2
than
improvements
diesel-fuelled
in
different
CO2-eq
marble
quarrying,
and that
the
eco-efficiency approach should be
emissions can be accomplished by adopting
followed for the quarry and processing plant, in
better
possibly
order to have a better environmental performance
sharing resources, as will be described later in
and promote sustainability of this typical marble
this section.
industry.
transportation
logistics
and
Reduction and management of solid waste

material is possibly the most crucial sustainability
7. Conclusions
issue in the marble industry, given the very low
The chapter presents a detailed methodology for
quarrying efficiency of the sector. Solid waste
assessing
material is mainly the non-usable pieces of
and
consumption was calculated for each individual
Although marble solid by-products are inorganic
operation of the quarrying, transportation and
and non-hazardous, their local, continuous and
processing lines and has been used to define the
long-term deposition and accumulation may
total energy inputs (embodied energy) for every
change the ecological profile. For the examined
specific product. Several operating scenarios
quarry, it has been estimated (Founti et al., 2010)
were considered and the total energy requirement
that only ca. 30% of marble extracted is of high
of products and processes were compared. It has
quality and can be further processed in the
been shown that, in the processing plant, cutting
processing plant. The rest is deposited at the
processes
quarry as waste material. Additionally, in the
are
significantly
more
energy
consuming than finishing processes, with curing
processing plant, there is a 25% loss of marble
being
as solid waste due to fractures of slabs, rejected
particularly
energy
demanding.
The
environmental impact of current quarrying and
final products and smaller marble pieces from
processing practices has also been assessed.
cutting processes.
The methodology that involves the systematic
the
overall
environmental
record of energy flows can act as a prototype
performance of the plant can be described by

indices:
performance
marble quarry and processing plant. The energy
cutting procedures in the processing plant.
three
energy
environmental impact of a typical medium-sized
quarried stones and smaller marble pieces of
Summarizing,
the
embodied
energy
guideline for the energy overview of similar
(energy
middle-sized marble industries.
consumption per product), embodied carbon

(CO2 equivalent emissions), embodied raw
8. References
material (a measure of material efficiency). The

environmental performance of the examined
Akkoyun, O., Ankara, H., 2009. Cost of quality
quarry and processing plant, related to the above
management: an empirical study from Turkish
indices is summarized in Fig.9. It is obvious that
marble industry. Sci. Res. Essays. 4, 1275-1285.
-29-
Technical Handbook
Alzboon, K.K., Mahasneh, K.N., 2009. Effect of
Founti, M., 2004. Stone for construction and
using stone cutting waste on compression
architecture from extraction to the final product,
strength and slump characteristics of concrete,
Vol. 10, Osnet Editions, Athens, Greece.
Int. J. Civil Env. Eng. 1, 168-173.
Founti, M.A, Giannopoulos, D., Laskaridis, K.,
Atici, U., Ersoy, A., 2009. Correlation of specific
2010. Environmental management aspects for
energy of cutting saws and drilling bits with rock
energy saving in natural stone quarries. Paper
brittleness and destruction energy, J. Mater
S3-03, Global Stone Congress 2010, Alicante,
Process Tech 209, 2602-2612.
Spain.
Bockhorst, J., 2010. Trennschleifbearbeitung von
Fulton, L, Eads, G., 2004. IEA/SMP Model
Granit mit hohen Schnittgeschwindigkeiten. Dr.-
Documentation and Reference Case Projection
Ing. Dissertation, Universitt Hannover.
http://www.wbcsd.org/web/publications/mobility/
Borman, G. L., Ragland, K. W., 1998. Combustion
smp-model-document.pdf (Last assessed 10-02-
Engineering, McGraw-Hill International Editions,
2012).
Boston.
Gabbrielli, R., Medeot, C., Miconi, D., 2006.
Bruno, R., Paspaliaris, I., 2004. Ornamental and
Energy saving in the tissue industry: technical
dimensional stone market analysis, Vol. 13, Osnet
and economic aspects of a case study. J. Clean.
Editions, Athens, Greece.
Prod. 14, 185-193.
Carosio, S., Paspaliaris, I., 2003. Machines and
Gazi, A., Skevis, G., Founti, M.A., 2012: Energy
tools for stone quarrying and processing, Vol. 1,
efficiency and environmental assessment of a
Osnet Editions, Athens, Greece.
typical marble quarry and processing plant, J.
Dovi, V.G., Friedler, F., Huisingh, D., Klemes, J.J.,
Clean. Prod. 32, 10-21.
2009. Cleaner energy for sustainable future. J.
Gencel, O., Ozel, C., Koksal, F., Erdogmus, E.,
Clean. Prod. 17, 889-895.
Martnez-Barrera,
ECD, 2009. European Commission Decision
Properties of concrete paving blocks made with
2009/607/EC establishing the ecological criteria
waste marble. J. Clean. Prod. 21, 62-70.
for the award of the Community eco-label to hard
Glatzel, T., 2004. Trennschleifen von Granit mit
coverings. Off J Eur Commun L208 (2009), pp.
dnnen
21-38.
Universitt Hannover.
ECOLABEL,
2011.
European
Commission
Environment - Ecolabelled products,
G.,
Werkzeugen,
Brostow,
Dr.-Ing.
W,
2012.
Dissertation,
Hashish, M., 2009. Trends and cost analysis of
(Last
AWJ Operation at 600 MPa pressure. J. Pressure
assessed: 10-02-2012).
Vessel Technol. 131, 021410.
EEA, 2007. Greenhouse gas emission trends and
Karaca, Z., Onargan, T., 2007. The application of
projections in Europe 2007 Country profile,
critical path method in workflow schema in order
www.eea.europa.eu (Last assessed: 10-02-2012).
of marble processing plants. Mater. Manuf.
1468, 2003. Hellenic Standards, Natural Stone-
Process. 22, 37-44.
Rough Slabs- Requirements, EN 1468:2003 (E).
Kolotouros, K., 2011. Trends in marble exports-
EUROSTAT, 2008. Schmiemann M., Industry,
imports in January-November 2010 (in Greek),
trade and services, Statistics in focus, 31/2008.
MARMAROnet
2011.
http://www.marmaronet.com (Last assessed: 1002-2012).
-30-
Technical Handbook
Konstantopoulou, P., Founti, M., Laskaridis, K.,
Ozcelik,
Assessment of energy saving potentials in marble
Comparison of the water jet and some traditional
quarries, in: Prikyl, R. (Ed.) Dimension Stone 2004
stone surface treatment methods in different
- New perspectives for a traditional building
lithotypes. Constr. Build. Mater. 25, 678-687.
material. Taylor & Francis, London, pp. 309-314.
Perdikatsis,
Konstantopoulou, P., Founti, M., Laskaridis, K.,
Karantasi, S., 1998. Experience in cutting Greek
2005.
Environmental
applications
in
the
Y.,
Ciccu,
.,
R.,
Costa,
Laskaridis,
K.,
G.,
F unti,
2011.
M.,
and
energy
saving
marbles with C 2 laser. Proceedings of the 9th
marble
quarry
sector,
Workshop "Eur care Eur marble EU 496", pp. 31-
Proceedings of the 5th International Symposium
37, Munich, Germany.
on Multiphase Flow, Heat Mass Transfer and
Seiffert, F., Bockhorst, J., Denkena, B., 2010.
Energy Conversion, Paper 019, Xian, China.
Process and tool design for high speed cutting of
Labuschagne, C., Brent, A.C., van Erck, R.P.G,
granite. Global Stone Congress 2010, Alicante,
2005. Assessing the sustainability performances
Spain.
of industries. J. Clean. Prod. 13, 373-385.
Shu, Z., Zhou, J., Wang, Y., 2010. A novel
Laskaridis Marble S.A., 2011.
approach of preparing press-powders for cleaner
(Last assessed:
10-02-2012).
production of ceramic tiles. J. Clean. Prod. 18,
Marras, G., Careddu, N., Internicola, C., Siotto,
1045-1051.
G., 2010. Recovery and reuse of marble powder
Terezopoulos, N., Paspaliaris, I., 2003. Dimension
by-product.
stone quarrying in Europe and stability of
Global
Stone
Congress
2010,
Alicante, Spain.
quarrying operations, Vol 2., Osnet Editions,
Misra, A.K., Mathur, R., Rao, Y.V., Singh, A.P.,
Athens, Greece.
Goel, P., 2010. A new technology of marble slurry
Traverso, M., Rizzo, G., Finkbeiner, M. 2010.
waste utilisation in roads. J. Sci. Ind. Res. 69, 67-
Environmental performance of building materials:
72.
Life cycle assessment of a typical Sicilian marble.
Moors E.H.M., 2006. Technolodgy strategies for
Int. J Life Cycle Assess. 15, 104-114.
sustainable metals production systems: a case
Turchetta, S., Carrino, L., 2005. An energy based
study of primary aluminium production in The
model for laser cutting natural stone. Int. J Mach.
Netherlands and Norway. J. Clean. Prod. 14,
Tool Manu. 45, 761-767.
1121-1138.
Zannis, G., Makris, P., Founti, M., Laskaridis, K.,
Napoli, S., 2010. Stone Sector 2010: Industria
2004. Exploitation of marble wastes through
Italiana
pulverization in a prototype ring-mill, in: Prikyl, R.
Congiuntura
Internazionale,
Internazionale Marmi e Macchine Carrara S.p.A.
(Ed.) Dimension Stone 2004 - New perspectives
Nicolleti, G., Notarnicola, B., Tassielli, G., 2002.
for a traditional building material. Taylor &
Comparative life cycle assessment of flooring
Francis, London, pp. 321325.
materials: ceramic versus marble tiles. J. Clean.

Prod. 10, 283-296.
-31-
Technical Handbook
Figure Captions
Figure 1. Outline of the processing plant.

Figure 4. Breakdown of energy consumption for marble
production Validation.
Figure 2. Operating scenario 6 (polished tile,

0.4x0.4x0.02 m).
Figure 5. Total energy consumption for operating

scenarios 1-10.
Figure 3. Energy consumption per process for

operating scenario 6.
Figure 6. Breakdown of energy consumption for
operating scenarios 1-3.
-32-
Technical Handbook
Table 2. Required equipment combinations for typical

operating scenarios.
Figure 7. Breakdown of energy consumption for

operating scenarios 4-10.
Table 3. Energy consumption for raw block extraction

(cutting with diamond wire saw).
Figure 8. Comparison of energy consumptions of the

processing plant machinery (a) cutting machines, (b)
finishing machines.
Table 4. Energy consumption for transportation of

blocks from quarry to processing plant.
Figure 9. Environmental impact of marble production

line
Table Captions
Table 5. Energy consumption for block squaring in the

diamond monoblade.
Table 1. Installed power and make/model of selected

processing plant machinery.
-33-
Technical Handbook
Table 6. Energy consumption for block cutting into

slabs in the multiblade gang saw.
Table 9. Total energy consumption of a 0.4x0.4x0.02m
tile (Scenario 6).
Table 7. Energy consumption in the polishing machine

for 0.4x0.4x0.02m tiles.
Table 10. A summary of energy consumptions of
selected processing plant machinery.
Table 8. Energy consumption in the edge profiling

machine for 0.4x0.4x0.02m tiles.
Table 11. Total CO2 emissions for the production of a

0.4x0.4x0.02m tile (Scenario 6).
-34-
Technical Handbook
Those
III.2. Energy Analysis in the Natural

Stone Manufacturing Process
characteristics
provide
an
incessant
presence of natural stone in the international

panorama as a result of the use of natural stones
in architecture. In spite of all these advantageous
Vicente J. Gonzlez-Penella1,a, Francisco Beltrn Berenguer

, Jaime Martnez1,c, Celia Guillem Lpez1,d, ngel M. LpezBuenda1,e and Javier Martnez-Mingote Navarro3,f
1
AIDICO, C/ Cam de Castella n4, 03660 Novelda (Alicante),
Spain
2
AMI, C/ Benjamn Franklin n17, 46980 Paterna (Valencia),
Spain
3
LEVANTINA, Autova Madrid-Alicante s/n, 03660 Novelda
(Alicante), Spain
a
vicente.gonzalez@aidico.es bfrancisco.bletran@aidico.es,
c
jaime.martinez@aidico.es,
d
celia.guillem@aidico.es, eangel.lopez@aidico.es,
f
javier.mingote@levantina.es
2,b
properties, there are many problems that affect

this sector such as the global economic crisis
and the low environmental awareness.
The global economic crisis is affecting every
productive sector; however, energy consumption,
even at a lessened degree, keeps on increasing
and supply constitutes a serious problem since
the sector requires large investments in order to
Keywords: natural stone, energy consumption,
maximize
energy efficiency, production process.
consumption. Those sectors related to the
Abstract.
which
Current
comprises
socio-economic
energy
and
decrease
energy
construction sector are specially affected and,
situation,
problem
efficiency
like
and
the
case
of natural stone
processing
environmental awareness, urgently requires an
industries in Spain, many very visible impacts are
innovative
the following [1,2]:
intervention
that
enhances
the
competitiveness and strength of the companies
Drop in production, and the consequent slowing
in general, and those belonging to the natural
down of economic development, by more than
stone manufacturing and elaborating sector in
35% from the maximum value reached in 2006 (in
particular. Productive processes are the largest
fact, the current production levels are back to
source of information within a factory and it is
those of 15 years ago).
therefore necessary to measure them since an
The current situation has meant a reduction of the
energy analysis is a prerequisite for balanced
amount of companies and most of the remaining
decision-making. The most important areas in
companies do not stay competitive. Especially,
which energy is consumed have been identified
this pronounced decrease in the number of
via an energy analysis, which has enabled to
companies of the sector has been about 12%
focus the existing and future research lines so
during the last four years.
that the industrial sector can improve those
Since 2006, there is incentive to invest in finished
productive stages with potential energy and
product production-commercialization in favour
environmental impacts and, hence, companies
of raw product, which raised the maximum value
can prevail in this current economic situation.
in 2008.
In order to gain a competitive edge, those
1. Introduction
companies have to increase the energy efficiency
Natural stone is a raw material which represents a
which is deeply related to production costs,
main source of economic resource not only
protection of the environment and life cycle of the
because of its high aesthetic content, but also
final
due to its high quality and excellent finishes,
characterized by the huge amount of waste
durability, versatility and thermal performance.
produced and disposed in the environment. A
-35-
product.
Additionally,
this
sector
is
Technical Handbook
research action should be arisen in respond to
obtain a big picture whereby represent the
the demand from the natural stone sector which
current situation in this region.
is not only influenced by the international
Furthermore, the energy study was performed
economic
analysing each stage of the production process
crisis
but
also
by
the
current
environmental legislation.
as well as the entire production process. In this
To conclude, it is known that the natural stone
way, besides having a clear general idea about
sector in Spain is among those most affected by
the energy impact of the production of slabs and
the global economic crisis, and in particular those
tiles, this methodology helped to detect the
companies focused in manufacture processes.
critical points from an energy point of view. This
An energy diagnose has been proposed in this
also helped to identify the needed improvements
kind of companies (especially those related to
or innovative interventions in order to reduce
manufacture) in order to obtain a big picture of
consumption (and so costs) and elaborate more
the real situation. This energy diagnose will help
competitive commercial products.
companies to carry out new improvement actions

based on R&D activities which will contribute to
Notation.
enhance the current situation. In that sense, the
standard notation [3] in order to represent each
research centres AIDICO and AMI and the big
productive process for both considered products.
corporation
working
This function modelling methodology offers a
synergies
reliable way for modelling functions involved by
Levantina
collaboratively
and
have
also
been
creating
Researchers
divides
IDEF0
enterprises
innovation actions at the service of companies
processes by activities, actions, processes and
will provide a mean towards progress in general
operations. Additionally, this notation involves the
and, in particular, towards a way to handling and
utilization of functional relationships and data
overcoming the current adversity.
whereby
integration
the
the
between research and business world. These
the
which
utilized
of
the
production
mentioned
functions is carried out. This notation also allows

2. Methodology
subdividing one process as sum of other sub-
Scope of the Energy Study. This energy study
processes making easier the analysis of the entire
was focused on productive processes within the
production process.
factory
(regarding,
for
example,
with
the
processes executed in quarries) since these
Slabs Production. Slab is a semi-finished product
activities are the most problematic and represent
which has a high added value and that is
the greatest challenges today. Due to the strong
commonly included in the products portfolio of
causal factor of companies and commercial
the companies placed in the region under
products related to the natural stone sector, two
consideration. The productive process basically
of south-eastern Spains most representative
consists of cutting operations of blocks via
productive processes were under consideration.
multiblade frame saws, reinforcing pieces using
Since those productive processes were related to
resin
slab production (semi-finished product) and tiles
treatments (as it is shown in Figure 1 which
(finished product), this approach allowed to
represents the slab production process).
-36-
and
fibbers,
and
applying
surface
Technical Handbook
Initially, how to measure each energy source was

established. On the one hand, power analysers
were utilized with the intention of monitoring the
consumption associated with activities which
made use of an electrical source. On the other
hand, with respect to the thermal energy source,
researchers utilized a consumers meter available
in the factory as well because almost the entire
Figure 1
gas consumption goes to the ovens located in

the reinforcing activity.
Tiles Production. Slab is the most common
In order to relate the energy consumption
finished product. The productive process is
(electrical and thermal) with the production, plant
composed of a first main phase of cutting
working information was utilized, i.e., the material
operations of blocks via disc block cutters which
flow (normally expressed in m2) which have been
create stripes and a reinforcement of pieces
manufactured in each activity during the period of
using resin and fibbers. Subsequently, these
time that this activity has been studied and
pieces are split, surface treated and cut to size.
analysed.
Finally, the resultant products are finished by

means
of
processes
finishing
are
shown
treatments.
in
Figure
All
those
which
Therefore, information of each activity during

productive periods of time was captured. Indeed,
these
represents the tile production process.
periods
of
time
were
sufficiently
representative in order to quantify the energy

impact in the global process of the companies of
the natural stone sector. It is important to know
that the energy study carried out does not seek
an optimization of a specific activity of a
particular company, but obtain the big picture
that could represent the sector of natural stone
which is under consideration.
Energy Indicators. The analysis of the information
obtained during the measuring of the processes
required a homogenization in order to compare
the activities and determine their impact and
Figure 2
possible improvements.
Therefore,
Energy Balance. All the processes involved in
the
registered
parameters
were
transformed via the following ideas:
slab as well as tile processing utilized energy
Different energy sources: In order to be able to
resources of quite a different kind (which were
associate
thermal and electrical) and affected productive
electrical
consumption,
units with different formats (blocks, slabs, stripes
those
and
thermal
kilowatts
values
energy
were
converted into CO2 emissions. These energy
or tiles) were taken into account.
-37-
Technical Handbook
conversions were performed based on different
electrical energy consumption represents 31.66%
conversion factors available in references as [4].
of the total electrical consumption and a 21.52%
Different product format: In order to associate
of the total energy.
each activity with the production process, the

mass flow rate was indicated depending on the
products which are manufactured regardless of
their format, expressed in m3.
Therefore, the energy impact for each activity
expressed in kgCO2 emissions for 1 m3 of
processed material was obtained. In the same
Figure 3
way, the sum of activities involved in each

process (slab as well as tile) allowed to obtain the
The energy consumption distribution associated
global impact.
with the tile production process is shown in Fig. 4
Results
which
Based on productive activities and on the energy
represents
energy
consumption
distribution in the tile production process. The
indicators acquired for each activity, it was
energy source which represents the higher
necessary to distinguish three basic activities:
amount of energy utilized in the tile processing is
cutting, reinforcing and abrasion.
the electrical energy because this represents
The energy consumption distribution associated
91.95% of the total consumption.
with the slab production process is shown in
Divided by activities, the distribution of energy
Figure 3. First of all, the energy source more
consumption is explained as it follows:
utilized in the slab processing is the electrical
Cutting
energy because it approximately represents
process:
There
are
several cutting
operations which generate different kind of
67.97% of the total consumption. The distribution
formats (blocks, stripes and tiles), but they all
represented for activities can be explained as it
have in common the type of cutting tool which is
follows:
a cutting disc. The energy source utilized is
Cutting process: There is a single cutting
electrical energy and it is behind the greater
operation which is executed with frame saws.
consumption
The energy source utilized is electrical energy and
within
the
process,
which
represents 49.13% of the total amount of energy
it is behind the greater consumption within the
consumption and 53.43% of total electrical
process, which represents 38.05% of the total
energy consumption.
amount of energy consumption and 55.98% of
Reinforcing process: The main energy source
total electrical energy consumption.
utilized is gas and the energy consumption
Reinforcing process: The main energy source
related represents 85.11% of the total gas
utilized is gas and the energy consumption
consumption and 6.85% of the total amount of
related represents 94.74% of the total gas
energy.
consumption and 30.34% regarding with the total
Abrasion process: The main energy source
amount of energy.
utilized is the electrical source. The electrical
Abrasion process: The main energy source
energy consumption represents 42.88% of the
utilized is the electrical source. Therefore, the
-38-
Technical Handbook
total electrical consumption and a 39.43% of the
optimize the tool design and the operating
total energy.
conditions (spin and forward speed) in order to

reduce the energy consumption [5].
Multiblade frame saws tool design. Via a static
MCS will be possible to define the working
conditions of the machine and to optimize the
tool design in order to reduce the energy
consumption.
Curing
Figure 4
system
design
using
microwave
technology. Currently, formulation and behaviour

3. Conclusions
of different resins are been studied, which are
The research performed fulfilled the proposed
cured using this technology, in order to reduce
objectives because the investigation allowed
the energy consumption.
analysing
sector.
Rotary MCS design. This new measuring system
Furthermore, this research helped to identify
will help to quantify the working conditions of
critical control points and propose innovative
abrasive operations, overcoming the obstacles
actions in order to improve those activities which
which suppose the utilization of the static MCS.
represented the most important impact regarding
Continuous diagnose tools design. This kind of
with the industrial process:
tools will allow researchers to control the
The significance of electricity compared to gas
production activities in real time.
the
current
state
of the
(as energy source more utilized in both slabs and

tiles production processes) was clearly identified.
4. Acknowledgements
Cutting processes were those that had the
Financial support of the E.C., ECO-STONE
greatest effect on the energy bill, both in slabs
project (LIFE08 ENV/E/000126).
and tiles production processes.
References
Reinforcement processes in general, and in
[1]
particular those performed in ovens in order to
de
cure resins, were the processes more important
Economy and Competitiveness, Madrid, 2012.
from a thermal energy point of view, having
[2]
greater impact in the slabs production process
Natural. Informe Sectorial de la Piedra natural
than the tiles production process.
2005-2010, AIDICO.
The abrasive processes were the second more
[3]
critical from an electrical point of view.
Publication
Therefore, and after finishing this energy study,
Function Modelling (IDEF0). Gaithersburg, MD:
several research lines were proposed with the
National Institute of Standards and Technology.
intention of introducing potential innovation in
[4]
those activities with a higher energy impact:
Industry, Energy and Tourism.
Cutting disc tool design: Via a static Maltese
[5]
Cross System (MCS) was possible to determine
Romero Snchez, JM. Cuevas, C. Guillem and
the working conditions of the machine and
AM. Lpez-Buendia: New Cutting Disc for Natural
-39-
Instituto Nacional de Estadstica. ndice

Produccin
Industrial
(IPI),
Ministry
of
Observatorio del Mercado de la Piedra
Federal Information Processing Standard

183.
Integration
Definition
for
La Energa en Espaa 2010. Ministry of

J. Martnez, VJ. Gonzlez-Penella, MD.
Technical Handbook
Stone Designed by Simulation, Proceedings / 1st
Produktionstechnisches Zentrum. Ed.: Berend
International Conference on Stone and Concrete
Denkena.
Machining. Hannover, Germany, November 23 24,
2011
Leibniz-Universitt
Hannover,
-40-
Technical Handbook
developments, with the aim to raise the
III.3. New Cutting Disc for Natural

Stone
efficiency of the stone machining, were

released in the last years. At the same time,
Jaime Martnez1,a, Francisco Beltrn Berenguer2,b, Vicente

J. Gonzlez-Penella1,c, Celia Guillem Lpez1,d, ngel M.
Lpez-Buenda1,e
many efforts have been taken regarding the

environmental
protection
like
cobalt-free
AIDICO, C/ Cam de Castella n4, 03660 Novelda

(Alicante), Spain
bonding systems and thin cutting tools to
save
AMI, C/ Benjamn Franklin n17, 46980 Paterna

(Valencia), Spain
raw
material
and
reduce
waste
generated by the process [1,2].
jaime.martinez@aidico.es, bfrancisco.beltran@aidico.es,
c
vicente.gonzalez@aidico.es, dcelia.guillem@aidico.es,
e
angel.lopez@aidico.es
In
spite
of
all
of
these
technological
enhancements, the main problems associated

with the current stone production chain
Keywords: processing, natural stone, cutting,
include a very low efficiency and productivity,
energy consumption, simulation.
the huge amount of waste produced and

disposed
in
the
environment
and
the
Abstract. Embedded energy in natural stone
significant fluctuations in the quality and
industry includes the extraction, transport and
performance
processing stages. Main energy consumption
construction of the final stone products [3].
in stone processing is due to the abrasive
Improving
effect of cutting and polishing processes. A
productivity of cutting operations in the
systematic measurement on factory has been
production chain is the main objective of this
designed and carried out with a cutting disc
study. In fact, a new thinner disc would
process
simultaneous
increase energy efficiency in cutting so that
parameterization of: (1) cutting rate, (2) cutting
the amount of energy consumption required
power and (3) power consumption in order to
to manufacture stone products would be
obtain the specification needed for simulation.
lower than using a conventional disc. Clearly,
The geometry of a new thinner disc has been
energy required to make spin a thinner disc,
designed by means of the working conditions
and so lighter, would be smaller than the
extracted
energy needed to move a conventional and
based
on
from
the
the
experimental
measurements.
during
significantly
application
efficiency
in
and
weighty disc. Moreover, another essential

objective of this research involves reduction of
1. Introduction
Within
the
the big amount of waste produced during

last
century,
stone
cutting
cutting
processes
and
its
environment
technologies changed substantially. In fact,
disposal. Obviously, a thinner disc will imply
the
less quantity of waste material as a result of
introduction
provides
faster
of
and
synthetic
diamonds
profitable
cutting
cutting operations.
processes as well as making use of numerical
In the first part, a system for measuring forces
control systems allows precise cutting of
and efficiency on a natural stone cutting
stone with almost no restrictions regarding the
machine will be presented. This system,
design
named Maltese Cross System, is able to
of
the
final
product.
lot
of
-41-
Technical Handbook
obtain working conditions generated during
forward and cutting motors and to monitor all
cutting operations. Two tests of the cutting
the involved variables via single software.
process will be described where obtained
Development of the Maltese Cross System. A
optimum cutting parameters and cutting
static baseplate with strain gauges arranged
parameters
according
recommended
by
the
to
the
Maltese
Cross
manufacturer will be presented (cutting rate,
configuration that permits acquire deflections
cutting power and power consumption of the
generated by the cutting disc was designed
process, forward and spin speeds, cutting
(Figure 1a-b) [4,5,6,7]. A previous design was
forces, electrical consumptions,).
carried out
In the second part of this paper, the design
obtaining
process of a thinner cutting disc by using
dimensions, materials, standard parts,, (Fig.
Computer Aided Design (CAD) and Computer
1a). This 3D model was validated by using
Aided Engineering (CAE) will be explained.
CAE Technologies (Fig. 1b shows the Von
This design, based on the working conditions
Mises Stresses) in order to confirm if the
extracted from both tests, will overcome
elements within the main assembly were able
efficiency problems and will minimise the
to resist the cutting requests. Additionally, the
waste material produced during cutting.
system was simulated with the purpose of
by using
3D
CAD
model
technologies
provided
with
verifying the behaviour of the device during a

2. Maltese Cross: System for 3D Forces
cutting operation and with the intention of
Captation
calibrating the strain gauges virtually. Finally,
This device is capable of measuring and
the system was manufactured, assembled
monitoring
and calibrated (Figure. 1c) [8].
forces
produced
during
disc
cutting processes as well as all the variables

and parameters directly related to the cutting
process (e. g. forward speed, spin speed,
cutting time, intensity required, feed voltage
and cutting force) and indirectly related to the
(a)
cutting process (e. g. electrical consumption,

cost, CO2 emissions, cutting power, power
consumption
and
global
efficiency).
The
system can work out in a static baseplate

cutting machine for slabs and tiles.
Hardware
architecture,
based
(b)
on
Programmable Logic Controller (PLC), was

designed so that those parameters could be
monitored. The selected PLC (Siemens S7200) allows reading the analogic signal
coming
from
the
strain
gauges,
(c)
to
communicate with the control system of the
Figure 1.
-42-
Technical Handbook
3. Data Acquisition of the Cutting Process.
parameters optimization (cutting depth of 20
Two
mm, forward speed of 5 cm/s, spin speed of
tests
with
different
parameters
configurations were carried out in order to
2500 rpm and cutting time of 17.2 s).
obtain the needed input parameters for the
The optimal parameters were obtained as a
simulation (Fig. 2a-b). Both cutting operations
result of changing forward and spin velocities
were performed in a cutting machine AURO
of the disc. The optimization process sought
3000-4 by using slabs of Crema Marfil marble
to maximize the global efficiency :
(thickness of 20 mm and length of 700 mm).

Moreover, a diamond disc with thickness of 4
= 100
mm and diameter of 450 mm was used to

perform the cutting tests.
PD
PM .(1)
PD represents the cutting power of the disc

(multiplication of the cutting disc force, disc
radius and spin speed) and PM represents the
total electrical power consumption of the
machine (both variables obtained from the
machine using the Malta Cross System).
The cutting machine reaches the optimum
situation at the maximum forward-spin speeds
that does not reduce the life time of the disc.
(a)
The
optimum
recommended
configuration
relative
to
configuration
by
the
manufacturer increases the global efficiency

from 52.5% to 66.2% and reduces electrical
consumption and cutting time by two.
Table 1. Experiment results of the two studies
performed
(b)
Figure 2.
The first test was based on the configuration

of
parameters
recommended
by
the
of 20 mm,
Many different working conditions of the
forward speed of 2.5 cm/s, spin speed of
cutting disk were obtained as a result of the
1950 rpm and cutting time of 28.6 s) and the
performed experiments (Table 1). From these
second one was the result of a process of
working conditions, the values related to the
manufacturer (cutting
depth
-43-
Technical Handbook
cutting disk force and spin speed were taken
process and the deviation of the tool were
into account during the simulation stage.
analysed by means of variation of the spin

speed. The maximum value of spin speed was
4. Simulation of a Thin Cutter Disc
2500
This design will overcome efficiency problems
between the recommended cut and the
and will minimize the waste material produced
optimum cut).
during cutting and will therefore decrease the
Additionally, eigen frequencies have been
consumption of the valuable raw stone
evaluated in order to verify problems related
material.
to vibrations and resonance. These results
Design and Simulation of the Conventional
built the basis for the improvement of the
Disc. First of all, a conventional disc was
cutting process with a thinner cutting disc.
selected in order to study the mechanical
By
parameters (Figure. 3a). The selected disc had
considerations, it can be supposed that
a diameter of 356 mm, a plate thickness of 6
material properties of the disc are: Youngs
mm and a tooth thickness of 10 mm.
Modulus of 205 GPa, Poisson Coefficient of
rpm
(maximum
theoretical
spin
speed
calculations
value
and
0.28 and Yield Limit of 250 MPa.

To simplify the model and accelerate the
simulation process only a triangle-shaped
portion was taken into account (Fig. 3b). The
applied restraints were a fixed geometry and a
circular
symmetry.
On
one
hand,
the
cylindrical face of the disc related to the

rotating shaft had all translational and all
rotational degrees of freedom are restrained.
On the other hand, the symmetry used in the
cut faces of the triangle-shaped portion
allowed to simulate as the disc was complete.
The created mesh was based on curvature
and the total number of nodes and elements
was 62498 and 40255, respectively. The
maximum and minimum mesh elements were
2.7 mm and 0.54 mm, respectively. As a result
Figure 3.
of this mesh configuration the percentage of
As a first step, the cutting performance of the
elements with an aspect ratio

(b) lower than 3 is
99.1%; the aspect ratio of an element is
conventional tool has been investigated in a

cutting process under the working conditions
defined as the ratio between the longest edge
provided by the Maltese Cross System. The
and the shortest normal dropped from a
selected force was 98.7 N (maximum force
vertex to the opposite face normalized with
value between the recommended cut and the
respect to a perfect tetrahedral. By means of
optimum cut, Table 1). The occurring stress
-44-
Technical Handbook
CAE-simulations [9,10,11], different results
deflection at approximately 2500 rpm is 3.95
were obtained by applying a variable spin
m, a low value (Figure. 4b). The value of the
velocity and a cutting force of 98.7 N as load
eigen frequency increases by increasing the
conditions, (Figure 4a-c).
rotatory
speed
(Figure.
4c)
obtaining
minimum value of 39980 rpm (far away from

the maximum spin speed value settable in the
cutting machine).
Design and Simulation of the Thinner Disc. By
means
of
CAE-simulations
[9,10,11],
situation applying the previous simulation

configuration parameters was performed but
modifying
disc
dimensions.
Moreover,
majoration factor of 2 was taken into account
(a)
which means a spin speed of 5000 rpm and a

force of 197.4 N and a minoration factor of
1.25 were taken into account which means a
yield limit of 200 MPa. For the decision
process a safety factor of 4 was taken into
account, which means a Von Mises Stress
maximum
of
50
MPa.
The
maximum
deflection value taken into account was 0.1

mm due to technical specifications of the
(b)
Crema Marfil Marble.
Figure 5.
As new parameter slope, S, was defined as:
(c)
S=
Figure 4.
T t
Rr .
(2)
In any case, values of Von Mises Stresses are

under the yield limit of the material 250 MPa.
T is the maximum thickness of the plate of the
In order to increase the stiffness of a thin tool,
disc (6 mm), t is the minimum thickness of the
discs have to run under higher cutting speed
plate of the disc (5.5 - 1 mm), R is the radio of
(Figure. 4a). Deflection increases by increasing
the disc (356 mm) and r is the radio of the
the spin speed but the absolute value of
clamping flange (100 mm). Another variable
-45-
Technical Handbook
studied was the thickness of the tooth, L.
Von Mises Stresses decrease by decreasing
During the simulation values of S and L were
teeth thickness (Figure. 6a) but the minimum
changed. The values are represented in
value allowed is 6 mm because the union
Figure. 5.
between disc and tooth has to be bigger than

1.5 mm. Deflection increases by increasing
teeth thickness (Fig. 6b). The eigen frequency
decreases by increasing tooth thickness (Fig.
6c).
As a result of the simulation process, the
thinner disc projected had T=6 mm, t=3 mm
and
(a)
account
L=6 mm. This disc, by taking into

the
mayoration
and
minoration
factors, stands a Von Mises Stress of 47.3

MPa (Fig. 7a), has a deflection of 5.7 m (Fig.
7b) and the eigen frequency is 43709 rpm (Fig.
7c).
(b)
(a)
(c)
(b)
Figure 6.
Von Mises Stresses increase by increasing

slope and the maximum value allowed of 49.8
MPa happens at t=3 mm with a tooth of 9 mm
(Figure. 6a). Deflection increases by increasing
slope but the maximum value of deflection is
8.3 m (Figure. 6b), a low value. The eigen
(c)
frequency decreases by increasing slope but

the minimum value is 32169 rpm (Fig. 6c), a
Figure 7.
high value.
-46-
Technical Handbook
Comparison between the Conventional and
Tests
the New Thinner Disc. The conventional disc
configurations were carried out. The tests
simulated with a cutting force of 98.7 N and a
were
spin speed of 2500 rpm involved a maximum
parameters
Von Mises Stress of 27.5 MPa (lower than 50
manufacturer
MPa) and a maximum deflection of 3.9 m
forward speed of 2.5 cm/s, spin speed of
(lower than 0.1 mm). The new disc simulated
1950 rpm and an approximated cutting time
with a cutting force of 197.4 N and a spin
of 30 s). Those cutting operations were
speed of 5000 rpm involved a maximum Von
performed in the same cutting machine AURO
Mises Stress of 47.3 MPa (lower than 50 MPa)
3000-4 by using slabs of Crema Marfil marble
and a maximum deflection of 5.7 m (lower
(thickness of 20 mm and length of 600 mm).
than 0.1 mm).
As a result of the experimentation, two
Even though the thinner disc was subjected to
important findings related to forces and
worse working conditions and presented
consumptions were discovered. On the one
higher
Mises
hand, the force that the thinner disc required
Stresses and deflection, those parameters
to perform the cutting operation was inferior;
were below the established limits. Moreover,
indeed, the thinner disc needed a 6.20% less
the thinner disc will execute the cutting
force than the conventional disc. On the other
operation wasting less material than the
hand,
conventional disc and consuming less energy
experienced by the machine was lower when
so that the needed power to move a mass is
the thinner disc was utilized than with the
smaller by decreasing the weight. This is why
conventional
the utilization of a new thinner disk in natural
operations performed with the thinner disc
stone industries will have an impact in the
consumed 4.86% less energy than those
environmental issues and in the embedded
executed with the conventional disc.
values
of
maximum
Von
with
the
based
on
same
the
configuration
recommended
(cutting
the
total
disc;
parameters
by
of
the
depth of 20 mm,
power
actually,
consumption
the
cutting
energy related to cutting processes.

Experimentation of the New Thinner Disc
5. Conclusions
Two discs with the same dimensions and
The first prototype of Maltese Cross System
characteristics were acquired. Those discs
has
had a maximum thickness of the plate of 6
simulation by CAD/CAM. Two specific studies
mm, a radio of 356 mm and a thickness of the
using a cutting machine AURO 3000-4 and
tooth
was
slabs of Crema Marfil marble were performed
manufactured as pointed out in the presented
in order to obtain experimental data. The
design.
was
configuration of parameters recommended by
were
the manufacturer and the configuration of
carried out in order to assess the forces
parameters obtained optimizing were taken
generated during the cutting operation and
into account.
the power consumption of the machine.
The optimum cut with a forward speed of 5
of
10
Once
manufactured,
mm.
the
One
of
designed
several
them
disc
experiments
been
produced
after
design
and
cm/s, a spin speed of 2500 rpm and a cutting
-47-
Technical Handbook
time of 17.2 s involved a efficiency of 66.2%
previously obtained. As a result of those tests,
while the recommended cut specified by the
two important findings were exposed:
manufacturer with a forward speed of 2.5
The thinner disc needed a 6.20% less force
cm/s, a spin speed of 1950 rpm and a cutting
than the conventional disc.
time of 28.6 s involved a efficiency of 52.5%.
The cutting operations performed with the
By means of these experiments, the data
thinner disc consumed 4.86% less energy
needed to simulate the performance of the
than those executed with the conventional
cutting
disc.
disc
was
acquired.
Firstly,
conventional disc was simulated based on the
To conclude, it can be assumed that a
worst working conditions analysed in both
diminution in the amount of the required force
tests. The maximum Von Mises Stress and
for the cutting operation will also involve a
deflection were 47.3 MPa and 3.9 m,
saving in the costs related to maintenance
respectively. Secondly, a new thinner disc
and an increment in the life cycle of the
was designed and simulated. As a result, a
cutting disc. Additionally, the thinner disc
thinner disc with T=6 mm, t=3 mm and L=6
provides a drop in the energy consumption
mm was proposed. The simulation resulted in
which helps to decrease the bill of the factory
a maximum Von Mises Stress and deflection
reducing in this way the production costs.
of 47.3 MPa and 5.7 m.
Effectively, these features will help to improve
The new designed disc was able to work in
the natural stone production chain making it
worse conditions than the conventional disc
more sustainable.
without
exceeding
the
established
performance limits. Moreover, as the new disc
6. References
is thinner than the conventional disc, the
[1]
cutting operation can be carried out wasting
Application of Diamond Technology, Osnet,
less material and consuming less amount of
Vol. 4
energy. In this way, a more efficient cutting
[2]
operation can be obtained.
Machines and Tools for Stone Quarrying and
Once
the
design
was
finalized,
Carosio, S., Paspaliaris, I., 2004,
Carosio, S., Paspaliaris, I., 2002,
Processing, Osnet Editions, Vol 1
two
conventional discs were acquired and one of
[3]
them was manufactured as the design pointed
Rocas
out. Once the thinner disc was manufactured,
Explotacin,
several tests were performed the conventional
Entorno Grfico S.L.
and the new thinner disc will be tested using
[4]
the Maltese Cross System in order to obtain
Strain Gage Selection: Criteria, Procedures,
and analyse parameters related to energy
Recommendations, Technical Note TN 505-4
working conditions and energy consumption
[5]
using the cutting machine AURO 3000-4 and
Improvement of a 6 Axis Force-torque Sensor
also the optimum parameters configuration
via
-48-
Lpez Jimeno, C., 1996, Manual de

Ornamentales.
Elaboracin
Prospeccin,
y
Colocacin,
Vishay Micro-Measurements,
Kang,
Novel
C.
G.,
2005,
Electronics and
2007,
Performance
Cross-shaped
Technical Handbook
Double-hole Structure, International Journal of
[9]
Control, Automation and Systems
Autodesk Inventor 2010, Ed. Wiley Publishing
[6]
Kim, G. S., Kang, D. I., 1999, Design
Inc.
and fabrication of a six-component force
[10]
moment sensor, Department of Precision
with Autodesk Inventor Simulation 2010, Ed.
Engineering, Hanyang Universty
Butterworth-Heinemann
[7]
[11]
Richard M., Voyles, Jr., 1994, A
Waguespack, C., 2009,
Mastering
Younis, W., 2009, Up and Running
Ciarlet,
P.
G.,
1978,
The
Finite
Comparison of Force Sensors, Cornegie
Element Method for Elliptic Problems, North-
Mellon University, Robotics laboratory
Holland, Amsterdam
[8]
Gorinevsky,
D.
M.,
1997,
Force
Control of Robotic Systems, CRC Press
-49-
Technical Handbook
III.4. Thermal
Natural Stone
Energy
Storage
well as the temperature peaks maximum-
in
minimum between day-night are reduced.

Keywords: Phase Change Materials, thermal
MD. Romero-Snchez, N. Baeza, M. Fuensanta, A.M.

Lpez-Buenda
AIDICO. Asociacin De Investigacin de Las Industrias de
la Construccin. Cam de Castella, 4. 03660 Novelda.
Alicante. Spain.
md.romero@aidico.es
energy storage, natural stone

2. Introduction
The worldwide economical and technological
1. Abstract
development requires higher energy demands
The objective is to improve thermal properties
and
of natural stone by means of latent heat
global warming and environmental problems.
building and thus, reduction of the use of
In particular, the building sector is responsible
heating/air conditioning systems and increase
for more than 40% of the total EU energy
of comfort of the people in the room will be
consumption. Thus, efforts to improve energy
obtained, contributing to energy savings:
efficiency in the building sector are required.
Natural stone as a building material which can
PCMs are proposed as a solution to reduce
effectively contribute to energy savings.
energy demands from buildings. PCMs are
In this study, PCMs have been applied by

on
incorporated to construction materials such
the
as concrete, gypsum or plasterboard panels,
porosity of the natural stone and moreover,
as an energy solution to reduce energy
selection of PCMs has been done depending
demands in buildings [1-5]. In this project, the
on their melting temperature (PCMs with
use of natural stone treated with PCMs is
different melting points have been used).
proposed as a system for thermal energy
Thermal energy storage properties of PCM
storage. The viability of this system is
treated natural stone have been evaluated and

demonstrated.
techniques
have
Different
been
considered of great importance due to the
experimental
used
for
high number of applications: walls, floors,
the
indoors, outdoors, etc.
characterization of the PCMs and the natural
PCMs store latent heat as the ambient
stone after treatment with the PCMs.
temperature rises up to their melting point
The results have shown that these new
(solid
products based on natural stone have the

ability
to
store
energy.
and
which are responsible for climate changes,
will reduce temperature variations inside the
depending
(heating
are limited and related to harmful gases,
(PCMS). In this way, natural stone materials
procedures
expectations
cooling systems). However, energy sources
storage by using Phase Change Materials
different
comfort
to
liquid
state
change).
As
the
temperature cools down, the PCM returns to
Temperature
the solid phase and the latent heat is released.
fluctuations in the place of use are reduced as

This absorption and release of heat takes
The use of PCMs for the treatment of natural
place at a constant temperature, which is
stone to improve its thermal properties is
ideal to smooth temperature fluctuations.
proposed for several reasons: 1) Energy

savings
-50-
in
heating/cooling
systems;
2)
Technical Handbook
Enhancement of thermal comfort inside the
This makes these products vastly superior
building (reduction of temperature fluctuations
over conventional heat storage.
between day and night and different rooms
In general, PCM's are long-lasting and stable
inside the building); 3) Storage of the heat
throughout phase change cycles. This is
from outdoors; 4) Avoid excessive heat from
because there is no chemical reaction during
outdoors; 5) Protection of the natural stone in
the thermal energy storage process, not within
extreme climatic variations.
the material itself, nor with the heat transport
It has also been demonstrated that the
medium, nor with the construction materials
introduction of PCMs with different melting
used in the application construction. Melting
temperatures provides materials with energy
and
storage
climatic
processes, which is the reason why the heat
conditions (summer or winter times). In this
storage capacity remains at a high level
way, by selecting the appropriate PCM
throughout the unit's working life.
melting temperature, new stone products can
The way of incorporating PCMs to the stone
be designed for different climate conditions of
material depends on the type of stone, mainly
different regions and for special exposure
on its porosity. AIDICO has used a different
conditions.
way of incorporating PCMs depending on the
The objective is to use PCMs incorporated to
porosity of the stone:
natural stone as an environmentally friendly
macroporous or high porosity materials
capacity
for
different
solidification
are
purely
physical
low, medium and
system in buildings as a way to improve

thermal properties and to achieve
heat
3. Materials and experimental techniques
storage when temperatures are high and
Materials
release
temperatures
Table 1 includes the selected natural stone
decrease, thus reducing the use of heating/air
materials according to their porosity and the
conditioning systems, increasing comfort of
type of PCM used for each application.
this
energy
when
the people in the room, contributing to energy

savings. Natural stone is a building material,
Table 1. Natural stone materials selected for the
which can effectively contribute to energy
PCM application depending on their porosity.
savings.
Most commonly used PCMs are paraffin wax,
due to their high latent heat. The specific heat
capacity of latent heat paraffin is about 2,1
kJ/(kgK). Their melting enthalpy lies between
120 and 160 kJ/kg. The combination of these
two values results in an excellent energy
storage density. Consequently, latent heat
paraffin/waxes offer four to five times higher
heat capacity by volume or mass, than water
at low operating temperature differences [6-8].
-51-
Technical Handbook
4. Experimental Techniques
mortar, which is 0.72wt% respect to the stone
Different experimental techniques have been
piece.
used for the characterization of the PCMs and
Thermal analysis of the mortar containing the
the natural stone containing the PCMs:
PCM was carried out from -20 to 100C at
-Scanning Electron Microscopy (SEM). PCMs
5C/min
in the pores of Bateig azul have been
Calorimetry (DSC). Figure 1 shows the peaks
observed, distribution and shape. Hitachi S-
corresponding to the melting point of water
3000 N.
and the PCM. From this peak the energy
-Porosimetry. Porosity of Bateig azul before
released during the melting process of the
and after PCM treatment has been evaluated
PCM is 45.55 J/g PCM.
by
using
Differential
Scanning
(Hg porosimeter, Micromeritcs Autopore IV).

Thermal
Scanning
behaviour
temperature,
Calorimetry
of
entalphy,
PCMs,
etc.
have
(DSC).
melting
-0,1
been
-0,2
Mortar + PCM
Heat flow (W/g)
-Differential
evaluated with DSC (Stare SW 8.10, Mettler

Toledo).
-0,3
Melting temperature = 28 C
-0,4
-Thermal conductivity and heat capacity. CT
-0,5
METRE from SA TELEPH.
-0,6
-20
20
40
60
80
Temperature (C)
5. Results and Discussion
Figure 1. DSC measurements of the mortar

containing PCMs.
Procedure of PCM incorporation to natural

stone
Low porosity materials
An experiment has been designed to measure
PCMs included in different polymeric mortar
the temperature inside a box. Cubic boxes
formulations can be applied as reinforcing
(30x30x30 cm) have been built using an
agents for the back surface of the low porosity
isolating material. One side of the box was a
stone
really
stone slab (30x30x2 cm). Different box were
interesting application for flats or houses with
built with different PCM-treatments of the
the heating systems on the floor. Crema Marfil
stone. The side with the PCMs was placed on
(CM) marble was selected as low porosity
the interior side. The boxes were placed on
material to be treated with the PCMs.
the outdoor environment for several days and
Several formulations of mortars have been
variations on temperature were measured
prepared using different percentages of epoxy
using a thermocouple placed inside each box.
resin, CM aggregates (particle size <1 mm)
The objective was to analyse temperature
and PCMs. Micronal DS5001 (powder, melting
differences indoors for the box with the stone
temperature = 26C, provided by BASF) was
side and with the stone slab with PCMs.
used for the experiments. 25 wt% of PCM
The boxes were allowed to stabilise outdoor
was added respect to the total weight of the
for 24 h before starting the measurements.
materials.
This
can
be
-52-
100
Technical Handbook
Temperatures were measured every 10 min.
provided by BASF). For the treatment, BA has
Thermocouples were previously calibrated.
been
In Figure 2, the temperature inside 3 boxes
impregnated with the PCMs.
has been represented: temperature inside a
DSC
box with one side Crema marfil (CM) marble
properties of BA with PCM (20 to 60C at
with a mortar containing the PCMs, a box with
5C/min). Considering the 0.5 wt% PCMs
CM with the mortar without PCMs and a box
introduced into BA, the entalphy for the
with a slab of CM marble.
melting process is 39.60 J/g PCM.
The effect of the PCMs is more marked at
Data obtained from Hg porosimetry show that
high temperatures: maximum t for CM with
the porosity of BA decreases from 14.6 to
the mortar with PCMs is 1.6C lower than that
13.9
for CM without mortar and 0.7C difference
confirming the presence of PCMs into the bulk
for CM with mortar without PCM.
of BA. Moreover, the pore size has been
At lower temperatures, more comfortable
decreased because of the presence of PCMs.
inside a house for example, there is a delayed
Figure 3 shows the accumulated intrusion of
time of 20 min to get for example 20C for the
Hg (ml/g) in BA and BA with PCM versus
CM with mortar with PCM.
pressure. For all the range, the intrusion is
immersed
was
used
% when
in
to
this
solution
characterize
treated with
the
to
be
thermal
PCMs,
lower for BA with PCM, indicating again the

45
presence of PCMs in the sample.
40
CM+mortarPCM
0.7C
1.6C
CM+mortar
Crema Marfil
30
0,07
25
0,06
20
Accumulated intrusion (mL/g)
Temperature (C)
35
20 min
15
10
5
0
200
400
600
800
1000
1200
Time (min)
0,05
0,04
0,03
BATEIG AZUL
BATEIG AZUL+PCM
0,02
0,01
Figure 2. Temperature vs time inside a box with a
side of CM marble with a mortar containing the
10000
20000
30000
40000
50000
Pressure (psi)
PCMs, a box with a side of CM marble with a
Figure 3. Hg porosimetry. Accumulated intrusion vs
mortar without PCMs and a box with a side of CM.
pressure for Bateig azul and Bateig azul+PCM.
Medium size porosity materials
Cross sections of BA and BA with PCMs have
Bateig azul (BA) has been selected to study
been observed with SEM. Figure 4 includes
thermal storage properties of natural stone
micrographs of BA showing the distribution
materials after PCM treatment. This material
and porous structure.
has medium porosity size.
Micrographs of BA with PCMs are included in
A water-based emulsion of PCMs has been
Figure 5. It can be observed that the PCMs
used for the treatment of BA with 26 C

melting temperature (Micronal DS 5000X,
-53-
60000
Technical Handbook
are in the bulk of the stone, as previously
of BA, thus an increase in thermal conductivity
obtained with Hg porosimetry.
can
be
produced
for
this
reason.
Nevertheless, the volumetric thermal capacity

has
been
increased
(5.3%)
with
the
introduction of PCMs into the bulk of BA. This

indicates that the sample with PCMs requires
a higher amount of energy to modify its
temperature, because the PCM absorbs part
Figure 4. SEM micrographs of Bateig azul.
of the energy. With these results, it has been

checked that thermal properties of natural
stone can be modified with the introduction of
PCMs. The degree of modification can be
optimized by changing the type and amount
of PCM.
Figure 5. SEM micrographs of Bateig azul with
To evaluate these modifications on thermal
PCMs.
properties of BA when PCMs are introduced,

an experiment has been designed to analyse
Thermal conductivity and volumetric thermal
the response of BA without and with PCMs
capacity of Bateig azul and Bateig azul with
towards
PCMs have been measured in order to
experiment consists on the analysis of the
evaluate the effect of PCMs in the thermal
propagation
storage properties of the natural stone (Table
different places of BA.
2).
Figure 6 shows the experimental set-up. It
heating/cooling
of
thermal
processes.
waves
The
between
consists of a cylinder (12 cm length, 5 cm

Table 2. Thermal properties of Bateig azul and
diameter). 3 holes have been opened with
Bateig azul with PCMs.
3cm spacing (3, 6 and 9 cm from cylinder

edge),
where
thermocouples
have
been
placed. Another hole has been opened at one

of the vertical faces of the cylinder to place a
heating source.
Data show 6.7% increase in the thermal
conductivity of BA with PCMs compared to
Thermocouple 1
Thermocouple 2
BA without PCMs. However, the influence of

porosity on the thermal conductivity has to be
considered, because a higher amount of
pores means lower thermal conductivity, due
to the lower thermal conductivity of air. The
Thermocouple 3
introduction of PCMs decreases the porosity
Figure 6. Experiment designed to evaluate the
-54-
Technical Handbook
heating/cooling behaviour in Bateig azul with and

without PCMs.
The BA cylinder is heated by producing heat

pulses during 15 min via the heating element
140 cm
2m
inserted in one of the vertical faces of the

sample. After the pulses, the samples have
80 cm
been left to cool (sinusoidal variation of heat

supply, Figure 7). Temperatures are measured
in the positions of the 3 thermocouples for
Figure 8. Pilot station made of concrete and Bateig
similar cylinders: without and PCM treated. As
azul as natural stone for the faade.
expected, the temperature decreases from

thermocouple 1 to 3, as the distance from the
The objective is to analyse the effect of the
heating source is increased. It is interesting to
PCM treated stones in different parts of the
note that maximum temperatures of BA with
pilot station: south or east walls, ceiling, in the
PCMs (measured at the locations of the 3
air gap, etc. In all cases, sensors have been
thermocouples) are reduced with respect to
placed in the control and the PCM stations
the BA without PCMs, indicating that thermal
in the same positions and temperatures have
energy is stored by the PCMs. Furthermore, a
been monitored every 10 min for several day-
delay in the time required to get maximum
night cycles. Figure 9 shows the recorded
temperatures is obtained.
50
45
Outdoors:
-East side
-Contact with
Bateig stone in air
gap
40
63
T (C)
53
Temperature (C)
35
12 min
58
6.7C
1.3
30
Thermocouple 1
48
Thermoc1-PCM
16 min
43
4.5C
38
33
Thermoc-2
T (C)-With PCM
15
23
10
760
18
100
150
T (C)-Control
Thermoc3-PCM
28
50
0.6
20
Thermoc-3
1.9C
1h
25
Thermoc2-PCM
20 min
200
250
300
350
400
Outdoor T (C)
765
temperature
Time (min)
770
775
Time (h)
780
785
790
variation
for 1 cycle.
Figure 7. Heating/cooling behaviour by heat pulses

in Bateig azul with and without PCMs.
Figure 9. Temperatures in the pilot stations of
As
further
step
to
demonstrate
Bateig azul with and without PCMs as faade
the
materials.
effectiveness of PCM treated natural stones, a
Several differences between temperatures in
number of pilot stations made out of concrete
the pilot stations of BA without and with
and Bateig azul (with and without PCMs) as
PCMs as faade can be observed. The
natural stone for the faade have been built
maximum recorded temperature in the PCM
and placed outdoors (Figure 8).
treated station is 1.3C lower than for the
-55-
Technical Handbook
station without PCMs, demonstrating at pilot
viscosity.
scale the energy storage potentials of PCMs.
properties will be provided to the stone
The cooling process is smoother for the pilot
material. The amount of PCM added to the
station
mastic can be varied, depending on the heat
with
PCMs
(the
temperatures
Secondly,
thermal
requirements
storage
occurring in the reference station are reached
storage
(place,
melting
with an hours delay in the station with the
temperature of PCM, range of temperatures
PCM treated stones), indicating that the
during day and night, etc.).
stored energy is being released. Minimum
In order to evaluate the thermal properties of
temperature in the PCM treated station is
the mastic containing the PCM, a DSC
0.6C higher compared to the station without
experiment was carried out from -20 to 100C
PCMs.
at 5C/min (Figure 10).
These temperature measurements at the pilot

2
stations confirm the effectiveness of PCM
-2
Heat flow (mW)
At temperatures higher than the melting point

of the PCM (26C in this experiment), the
PMCs
store
energy.
When
-4
-6
ambient
-8
temperature decreases (cooling process), the
-10
higher
temperatures
Melting temperature = 27 C
-12
PCMs release energy at a controlled rate

maintaining
Mastic + PCM
treated stones as a system for energy storage.
-20
20
40
60
80
100
Temperature (C)
in
comparison to the station without PCMs. In a
Figure 10. DSC measurement of the mastic
real building, this would imply a reduction in
containing the PCMs.
the temperature fluctuations between daynight, reducing energy demands of the
Moreover, the energy associated to the
heating/cooling
melting process of the PCMs is 69.6 J/g PCM.
systems
and
increasing
This value can be increased or decreased
human comfort indoors.
depending on the application requirements.

Vuggy materials macroporous materials
Figure 11 includes some micrographs of LR
Lumaquela rosa (LR) has been selected as a
filled with the mastic containing the PCMs
high porosity stone material to be filled and
(SEM). The micrographs correspond to the
coated with a mastic containing PCMs in its
profile (cross section) of LR. It can be
formulation.
observed the particles of PCMs and a
The mastic has been prepared using epoxy
complete filling of macropores of LR. PCMs
resins and PCMs (Micronal DS5001). The
seem to be destroyed in the micrographs.
mastic has been prepared using 40wt% PCM
This can be explained because of the vacuum
respect to the total weight of the mastic.
applied
PCMs will have two different functions when
microscope.
incorporated into the mastic formulation.

Firstly, PCMs will act as a filler increasing
-56-
for
the
introduction
into
the
Technical Handbook
slab filled with the mastic containing the

PCMs. Temperature has been measured
inside the boxes every 10 min.
Figure
12
shows
variations
in
indoor
temperature for the boxes with a side of LR,

LR with a resin without PCM and LR filled with
a mastic containing PCMs.
T environment
Lumaquela stone
Lumaquela+masticPCM
45
Temperature (C)
40
35
30
25
Figure 11. SEM micrographs of Lumaquela rosa

filled with the mastic containing the PCMs.
20
3 h delay
15
0
Thermal
conductivity
and
specific
10
15
20
25
30
35
heat
40
45
50
55
60
65
70
75
80
85
Time (h)
capacity of LR and LR filled with a mastic
Figure 12a. Temperatures inside a box with a
containing the PCMs have been measured.
Lumaquela stone side and a Lumaquela stone filled
Values are included in Table 3.
with a mastic+PCM.
From Figure 12a it is important to focus on
Table 3. Thermal conductivity and specific heat

capacity of Lumaquela rosa and Lumaquela rosa
several points:
filled with a mastic containing the PCMs.
1.
The maximum temperature for the box
with a LR side is always higher than that for

the
box
with
the
LR
filled
with
the
mastic+PCM. The difference is approximately

0.8 - 1C.
Thermal
conductivity
of
LR
has
2.
been
The minimum temperature at night for
increased when it has been filled with the
the box with the SR is lower compared to that
mastic containing the PCMs. Specific heat
of the box with the LR filled with the
capacity
The
mastic+PCM. The difference is approximately
percentage of increment for the thermal
1.0 1.2 C. This could be explained in the
conductivity is 6.29%, and that for the specific
following way. The heat accumulated during
heat capacity 6.82%.
the day in the LR with the mastic+PCM has
Boxes of isolating thermal material and one
been
side of LR have been prepared. One box
temperature has not decreased as the box
contains one side of LR, another box with LR
with the LR without PCMs.
has
also
been
increased.
filled with the resin and the third one with a LR
-57-
liberated
during
the
night.
Thus,
90
Technical Handbook
3.
used, in order to increase the range of
The time needed for the boxes to get
temperatures in which PCMs are effective.
a low temperature is also different. When

temperature is going down at night, the box
with the LR filled with the mastic+PCM side
Influence of the melting temperature of PCMs
needs 3 hours more to get a low temperature.
in the effectiveness as thermal energy storage
4.
materials
From this, it could be concluded that
PCM reduces the maximum and minimum

temperatures during day and nights cycles.
To
extend
the
Moreover, the time to get lower temperatures
possibilities
is delayed.
temperature range, BA as natural stone has
of
thermal
the
energy
PCMs
to
storage
a
higher
been treated with PCMs of different melting

temperatures: 8C, 26C and both 8 and 26C
34
32
Temperature (C)
in the same piece. These pieces have been
T environment
Lumaquela stone
Lumaquela+masticPCM
30
placed in the cubic boxes in order to evaluate
28
their effectiveness as thermal energy storage
26
24
systems and temperatures inside the boxes
22
have been registered and compared.
20
Figure 13 shows the temperature inside the
18
20
21
22
23
24
25
26
27
28
29
30
control box compared to the PCM-treated
Time (h)
boxes. A day-night cycle has been selected

Figure 12b. Temperatures inside a box with a
ranging from low temperatures at night to high
lumaquela stone side and a lumaquela stone filled
temperatures
with a mastic+PCM. Amplified scale.
During
the
the
summer
period,
when
high
with the PCM with a melting temperature of
mastic+PCMs, indicating that the increase in
26C is more effective for thermal energy
temperature is slower when containing the
storage compared to BA with the PCM-8C,
PCMs. Thus, PCMs affect not only in the
because there is not phase change at this
cooling process but also during heating.
temperature range.
It has been observed that the effect of PCM is

more marked at high temperatures. Thus,
depending on the final application of the
construction material with the PCM a different
melting
with
temperatures are observed, the BA treated
is higher than that for LR filled with the
different
day,
melting temperatures of PCMs.
can observe that the slope of the curve for LR
with
the
objective to analyse the effect of the different
If we amplify the scale during the heating, we
PCM
during
temperature
should be selected. As we have seen in our

experiment, for low temperature atmosphere a
PCM with a lower melting point should be
-58-
Technical Handbook
29
40
28
Outdoor T
Outdoor T
Bateig azul
27
Bateig azul
PCM-8C
26
PCM-26C
Temperature (C)
Temperature (C)
35
PCM-26C
30
25
PCM-8+26C
25
0.5 C
1.6 C
24
23
22
21
20
20
19
2379,5
15
750
2380
2380,5
2381
2381,5
2382
Time (h)
752
754
756
758
760
762
764
766
768
Figure 14. Temperature inside adiabatic boxes with
Time (h)
Bateig azul with and without PCMs. Effect of
Figure 13. Temperature inside adiabatic boxes with
melting temperature of PCMs during winter.
Bateig azul with and without PCMs. Effect of

melting temperature of PCMs during summer.
14
13
To study the effects of PCMs melting
Outdoor T
Bateig azul
PCM-26C
PCM-8+26C
12
Temperature (C)
temperature in winter, BA has been treated

with both 8 and 26C PCMs in the same
piece. Because the temperature range is 025C, the box with BA treated with PCM-
11
10
9
8
7
8+26C is more effective for thermal energy
storage (Figure 14) compared to the PCM-
5
1770
1775
1780
1785
Time (h)
26C, because at temperatures lower than
Figure 15. Temperature fluctuations for the box
26C there is not phase change and it can not
with Bateig azul and Bateig azul treated with PCM-
store energy.
26C and PCM-8+26C at low temperatures.
When going to low temperatures, the PCM8C releases the thermal energy previously
6. Conclusions
stored, and thus not so low temperatures are
The thermal storage properties of natural
obtained for the BA treated with PCM-8C
stone treated with PCMs have been confirmed
(Figure 15). On the other hand, and as a
with
consequence of the reduction in the peak
Therefore,
it
of
several
experimental
treatment, two main effects are observed:
natural stone will be subjected to lower

fluctuations.
use
techniques. As a consequence of the PCM
temperatures between day and night, the

temperature
the
Reduction on the peak temperatures between
is
day-night and delay in the time point to reach
expected that durability of natural stone
the minimum or maximum temperatures in a
treated with PCMs will be increased.
closed space. However, the effectiveness of

PCMs as thermal energy storage systems
depends on the selection of the melting
temperature of PCM, the place where located
(i.e northern or southern climates). A reduction
-59-
1790
Technical Handbook
in energy consumption can be anticipated and
2007. "Use of microencapsulated PCM in
an increase in human comfort, due to a
concrete walls for energy savings," Energy
reduction of temperature variations during day
and Buildings, vol. 39, pp. 113-119.
and night.
5.
Romero-Snchez,
Lpez,
C.,
M.D.,
Guillem-
Lpez-Buenda,
A.M.,
7. Acknowledgements
Stamatiadou, M., Mandilaras, I., Katsourinis,
Financial support of the E.C., 6th Framework
D.,
Prog., Integrated Project I-STONE, Contract
natural stones with Phase Change Materials:
No. NMP2-Ct-2005-515762 and the ECO-
Experiments and computational approaches,"
STONE project (LIFE08 ENV/E/000126).
Applied Thermal Engineering, vol. 48, pp. 136-
and Founti, M., 2012. "Treatment of
143, 2012.
8. References
6.
1.
Hawes, D.W., Banu, D., Feldman, D.,
review on energy conservation in buildings
1990. Latent heat storage in concrete, Solar
applications with thermal storage by latent
energy Mater, 21, 61-80.
heat using phase changing materials. Energy
2.
Conversion and Management, 45, pp. 263-
Salyer, I.O., Sircar A.K., Kumar A.,
Khudhair, A.M., Farid, M.M., 2004. A
1995. Advanced phase change materials
275.
technology: evaluation in lightweight solite
7.
hollow-core building blocks. In: Proceedings
Mehling, H., 2003. Review on thermal energy
of the 30th Intersociety Energy Conversion
storage with phase change: materials, heat
Engineering Conference, Orlando, FL, USA,
transfer analysis and applications, Applied
pp.217-224.
Thermal Engineering, 23, pp. 251-283.
3.
Zhang, D., Li, Z., Zhou, J., Wu, K.,
8.
2004.
Development
energy
Review on Thermal Energy Storage with
storage concrete. Cement and Concrete
Phase Change Materials (PCMs) in building
Research, 34, pp. 927-934.
applications. Applied Energy, vol. 92, pp.593-
4.
605.
of
thermal
Cabeza, L., Castellon, C., Nogues, C.,
Medrano, M., Leppers, R., and Zubillaga, O.,
-60-
Zalba, B., Marn, J.M., Cabeza, L.F.,
Zhou, D., Zhao, C.Y., Tian, Y., 2012.
Technical Handbook
also to locate their causes. The out coming
III.5. LCA - Study on traditional marble

chain production
results should pave the road in finding solutions

to reduce the environmental problems caused
Irini Kostopouloua
a
by marble use as a building material. Moreover
Laboratory of Metallurgy, School of Mining and
Metallurgical Engineering, National Technical University of
study results can lead to the detection and
Athens, Zografos Campus, Athens, Greece
identification of problems, which can allow the

development and execution of new actuation
Keywords: marble stone, life cycle analysis,
lines for environmental impact minimization in
energy
natural stone quarries.
consumption,
water
consumption
Among
quarries outputs, processing plants outputs,
the
tools
available
to
evaluate
environmental performance, Life Cycle Analysis

Abstract. Buildings have many different negative
(LCA) has gained recognition as the most
impacts on environment during each stage of
powerful
their life cycle and especially during production
environmental
process of building materials. Marble, being one
technologies or services with a view to their
of the most widely used materials in the
whole life cycle. This cradle to grave approach
construction sector, has several environmental
studies the potential impacts from all stages of
impacts
manufacture,
generated
from
quarrying,
tool
for
the
impacts
product
use
comparison
of
and
of
products,
end-of-life
transportation and processing processes. In this
stages. According to Eco-indicator 99, which is
study the LCA method was used in order to
one of the most widely used impact assessment
understand
aspects
methods in LCA, a Life Cycle Analysis is carried
throughout its life cycle, and to analyse
out in three distinct phases as illustrated in
possibilities for processes improvement. The
figure 1. Phases are often interdependent,
study was focused on the examination of
meaning that the results of one phase are used
several
and
as necessary data for other phases. The main
processing scenarios, producing marble blocks,
phases of an LCA are: Goal and Scope
slabs and tiles, identifying their energy and
Definition; Life Cycle Inventory Analysis and Life
water needs and wastes production. The
Cycle Impact Assessment (Figure 1).
marble
environmental
combinations
of
quarrying
processes/scenarios with the greatest impact

were allocated in order to better manage marble
products life cycle.
1. Life Cycle Analysis methodology
Laboratory of Metallurgy of National Technical
University of Athens has performed study in
order to detect the environmental impacts of
marble, one of the most used construction
materials at the moment in the building sector,
during quarrying and processing processes and
-61-
Technical Handbook
help identify the stages/processes with the

greatest
environmental
impact
and
consequently will constitute a very useful tool

for several industries and organisations related
to marble quarrying and processing.
Final objective of the study is, based on clear
and ample information associated to the life
cycle of marble products, to help determining
the necessary actions in order to reduce the
environmental
impacts
of
marble
stone
production.
For the scope definition factors such as the
Figure 1. Life Cycle Assessment phases
studied
system/subsystems,
the
system
2. Goal and Scope Definition stage
boundaries, the functional unit, the selected
An LCA starts with an explicit statement of the
impact categories and the allocation of the
goal and scope of the study, which sets out the
environmental loads to impact categories have
context of the study and explains how and to
to be determined.
whom the results are to be addressed. This is a
System boundaries include the stages of marble
key step and the ISO standards require the goal
blocks extraction, their transportation to marble
and scope of an LCA to be clearly defined and
processing plants and production of final
consistent with the intended application. The
products such as slabs and tiles. Moreover the
goal and scope definition therefore includes
process of fossil fuels extraction and their
technical details that guide subsequent work:
conversion to electricity has been studied in the
the functional unit, which defines what precisely
frames of air emissions.
is being studied and quantifies the service
In the studied case, the system is the set of
delivered by the product system, providing a
processes that constitute the extraction, and
reference to which the inputs and outputs can
processing of marble blocks, as well as their
be related;
transportation from quarry to processing plants.

This system includes different subsystems
the system boundaries;
represented by the individual activities of
any assumptions and limitations;
extraction (initial cutting, etc.) or processing
the impact categories chosen.
(block cutting, polishing, etc.). The system and

the corresponding subsystems selected for this
The goal of the current study is to perform a Life
study are presented in figure 2, by means of a
Cycle Analysis that covers most important
processes diagram that includes inputs such as
stages of marble quarrying and processing
raw materials and energy consumption, and the
mainly focusing on the estimation of energy and
outputs such as finished products of the
water consumption and of the produced wastes
manufacture process and all the emissions and
quantities. This environmental assessment will
-62-
Technical Handbook
wastes associated to the life cycle of the
Quarrying wastes are divided in two categories.
product.
Dust wastes produced during cutting processes

and wastes from breakages and excavations.
Processing stage wastes, include dust from
cutting processes and broken or rejected due to
bad quality slabs and tiles. In present study
dust wastes will be calculated. Average waste
production in quarries is estimated to 90%,
while in processing plants to 30%.
Air emissions for electric energy production
from coal burning are also calculated.
CO emissions
Figure 2. System subsystems
produced
by
transportation
vehicles has not been calculated as, this

emission is not included to Eco-Indicator 99
All the assumptions made in the frame of the
study results.
Life Cycle Analysis study, are presented below:
Table 1 presents the outputs associated with
The products dimensions in the quarrying and
the quarrying, transportation and processing
processing process are presented in table
stages, as will be calculated in the inventory
below.
analysis step, allocated to the above impact

categories.
Table 1. Outputs and Impact Categories associated
with block extraction - processing and transportation
The working hours of each machine unit, has

been defined to 8 hours.
The distance between the quarry and the
processing
plant,
has
been
estimated
to
30 km. The working time of transportation

vehicles has been defined to 8 hours daily.
The type of final product, in the case of
quarrying is a marble block. In the case of
3. Life Cycle Inventory Analysis stage
processing the possible final product, slab or

tile,
determines
the
applied
Inventory Analysis stage, involves the creation
processing
of an inventory flows from and to nature for a
scenario.
product system. Inventory flows includes inputs
In the quarry, the blocks are considered to be
of water, energy and raw materials, and
cut directly in almost commercial dimensions.
releases to air, land and water. To develop the
Marble density has been defined to 2.8 tn/m3.
inventory, a flow model of the technical system
-63-
Technical Handbook
is constructed, using inputs and outputs data,
plants. Data sheets contain questions to collect
which is typically illustrated with a flow chart
information on the amount of raw materials,
that includes the activities to be assessed in the
energy, and water consumed during production,
relevant supply chain and gives a clear picture
as
of the technical system boundaries.
atmosphere, water and soil.
Data collection is the basis of the Inventory
Thereinafter possible scenarios for the quarrying
Analysis. It is a difficult procedure (because its
and processing stage have been developed and
cost might be prohibitive or the needed data
all the related inputs and outputs of the system
might not be available) and demands a detailed
have been recorded and calculated in addition
knowledge of each primitive procedure in order
to the finalisation of the system assumptions.
well
as
on
the
wastes
released
to
to be able to describe, both quantitatively and

qualitatively, all the related inputs and outputs.
3.1. Scenarios identification
The data must be related to the functional unit
Studied Quarrying scenarios
defined in the goal and scope definition.
Each block can be extracted by using certain
Potential
processes
techniques and each technique is based on the
designers, estimations from similar operations,
use of different cutting tools. In the case of
published data and commercially available
commercial blocks extraction, the most widely
databases
used
sources
and
of
data
market
are
place
patterns
of
cutting
machines
are
Chain
cutter,
products use. Usually data for products Life
Diamond wire and Drilling machine. Practically,
Cycle Analysis studies are typically collected
these cutting machines are applied in different
through survey questionnaires.
combinations and in this way various scenarios
The next step after data collection is the
are created. In the case of marble commercial
calculation of the inventory results with the use
blocks two scenarios have been modulated,
of the collected data. The calculations are made
QMA and QMB a short description of which is
according
presented in the following paragraphs.
to
the
methodology
and
the
assumptions defined in the Goal and Scope

Definition
stage.
The
inputs
for
all
Quarrying marble scenario A (QMA)
the
operations are used to calculate the mass
Drilling,
balance linking all the subsystems in the system
Chain cutter and
and estimate the outputs of each subsystem
Diamond wire
and of the overall system as well.

In current study to perform the life cycle
inventory
analysis,
datas
main
Quarrying marble scenario B (QMB)
origin,
Drilling and
concerning marble quarrying and processing
Diamond wire
processes, were collected from industries,

estimations
from
similar
operations,
and
Studied Processing scenarios
published data. A data sheet was prepared and
Two alternative scenarios (Figure 3) have been
information was collected through face-to-face
designed having as final product marble slabs
interviews with official personnel of production
and tiles. These scenarios are designed by
-64-
Technical Handbook
Table 2. Technical characteristics of wheel loader,
combining various techniques, according to the

specifications
of
the
final
products,
excavator, dumper and truck
the
characteristic properties and the restrictions set

by the raw material (block):
Processing marble scenario A (PMA) starts from
block squaring and results in big polished slabs.
Processing marble scenario B (PMB) is used for
the mass production of standardised size tiles,
3.2. Inputs - outputs of the studied systems
starting from block squaring, block cutting into
In this stage of the study, all necessary inputs
strips and resulting into tiles.
and outputs of the systems/subsystems are

defined. Inputs concern:
energy per operational unit. It must be

noted that in the current LCA study,
energy indicators refer not only to the
necessary electric energy for machines
function but also to the extraction and
production of fuels and their conversion
to electricity.
raw material per operational unit.
water consumption per operational unit.
Outputs concern:
type and quantity of product.
quantity and composition of wastes

which are grouped to air emissions,
Figure 3. Processing scenarios
liquid emissions and solid wastes.

Transportation from quarry to processing plant
There are mainly two issues that affect the
The examined air emissions CO2, H/C, NOx,
selection of a suitable transportation vehicle: the
SO2 are emitted from vehicles transporting
type of product to be transported and the
block
travelling distance. Excavators and dumpers are
electricity generation that is necessary for
used, depending on the quarry morphology, to
machines operation.
support quarrying process, while wheel loaders
Dust wastes that is created from the friction of
are used to load blocks on road trucks which
cutting tools with the surface cutting. On
transfer blocks to processing plants. The
quarries the main air pollutant is made of
average distance covering between quarry and
airborne dust particles, whose size varies
processing plant is 30 km. The technical
between 1 m and 1000 m. In present study
characteristics of wheel loaders, excavators,
dust
dumpers and road trucks, are summarised in
including any particulate matter with a diameter
table 2.
less than or equal to 10 microns. These dusts
-65-
from
quarries
particles
size
to
plants
considered
and
is
from
PM10,
Technical Handbook
may be detrimental to the environment and
Emissions quantities have been calculated
consequently for human health, depending on
taking into account average emission rates
parameters such as chemical composition,
published by U.S. Environmental Protection
particle size and volume in the atmosphere.
Agency (EPA). Table 4 presents CO2, NOx and
Solid wastes are marble pieces, resulting from
SO2 emissions produced from electric energy
breakages,
unsuitable
production, necessary for the operation of the
and processing
quarrying equipment, and CO2, NOx, SO2 and
excavations
products during
quarrying
and
phase.
CxHy
Sludge resulting from the mixture of dust and
transporting
used water constitutes liquid wastes.
plants. The study shows that transportation
produced noise during machinery operation.
vehicles contribute more to air emissions than
Having
quarrying equipment operation.
as
final purpose
the record and
emissions
produced
marble
from
blocks
to
vehicles
processing
calculation of each scenario inputs and outputs,

collection of machines technical characteristics
Table 4. Energy production emissions for QM1 and
is absolutely necessary. Inputs and outputs
QM2 and transportation stage.
calculation has been made by developing

appropriate mathematical models, which relate
system assumptions and by simulating the
behaviour of machine units included in each
scenario taking into consideration with their
technical characteristics.
From the calculations made, those processing
Table 3 summarizes energy, water consumption
scenarios using multi blade cutter for block
and pulp volume per machine unit. It can be
cutting into slabs, have higher energy demands
seen that in both quarrying scenarios, Diamond
and produce bigger dust wastes quantities than
wire cutter consumes the biggest energy and
scenarios using the giant disc cutter, but on the
water quantities comparing to other cutting
other hand, scenarios using multi blade cutter
units.
consume less water comparing to scenarios

using giant disc cutter. Examining energy and
Table 3. Energy, water consumption and pulp volume
water values for each machine unit separately, it
per quarrying machine unit.
can be seen that Multi Blade cutter needs the

biggest energy quantities, followed by Giant
Disc cutter which consumes though bigger
water quantities.
For
processing
scenarios
producing
tiles,
examining energy and water values for each

machine unit separately, it can be seen that
Disc Block cutter needs the biggest energy
CO2, NOx and SO2 gases are emitted through
quantities,
coal combustion for electric energy generation.
-66-
followed
by
resin
application
Technical Handbook
machine and also the biggest water quantities
categories taken into account are presented in
by far from the rest processing equipment.
table 5.
Moreover single blade cutter for block squaring

consumes bigger energy and water quantities
Table 5. Damage Categories, Impact categories and
and produces bigger dust wastes quantities
related quarrying and processing outputs
than the scenario using monowire cutter for the

same process. In addition both scenarios
produce approximately the same noise levels.
4. Impact Assessment stage
Specifically noise produced by the machines is
This stage of LCA aims at evaluating the
an output whose impact to the environment
significance of potential environmental impacts
cannot
based on the Life Cycle Inventory flow results
be
calculated
due
to
insufficient
information by Eco Indicator 99.
and generally includes the following actions:

Selection of the Impact Categories to be
4.2. Characterisation Stage
considered in the studied system. This selection
The
is made based on Inventory Analysis results.
classification
in
is
which
possible,
aggregation of the impacts within the given
considering that some of them can produce
impact categories takes place. An estimation of
more than one impact.
their individual contribution to a particular
Calculation of the individual contributions of
environmental impact is made allowing the most
each parameter of the Inventory to a determined
significant
impact, later calculating the total contributions
reflects
order
of
burdens
to
be
identified.
All
substances are multiplied by a factor which
to the same one.

an
after
analysis/quantification, and where
Impact Categories to which they contribute,
of
step
Characterisation,
Allocation of the results of the Inventory to the
Establishment
next
importance
their
relative
contribution
to
the
environmental impact and thus the impacts are
between the considered impacts.
transformed to indicator results which are
These actions are carried out through four steps
summed per impact category. The group of
that will be briefly described below:
results for the various impact categories is

called environmental profile and it is used for
4.1. Classification stage
the evaluation of the alternative technologies
The selection of appropriate impact categories
and the optimisation of the system (table 6).
on the basis of the existing inventory data, the

general
knowledge
relationships
inventory
and
data
the
into
about
assignment
the
The
cause-effect
different
of
impact
indicator
of
each
output
is
calculated, by multiplying the results from
the
inventory analysis stage and the relevant
impact
damage factors according to the equation:
categories, constitute the first step of the
Inventory Data Characterization Factor =
Impact Assessment stage and it is called
Impact Indicators
Classification. In the current study the impact
-67-
Technical Handbook
Table 7. Normalised environmental profile for total life
4.3. Normalisation Stage
cycle
It is a Life Cycle Impact Assessment tool used

to express impact indicator data in a way that
can be compared among impact categories. It
includes a series of techniques to evaluate the
importance
of
the
environmental
profile
obtained in the characterization step and is

defined as calculation of the magnitude of
indicator
results
relative
to
reference
information. It must be noted that normalized

data can only be compared within an impact
a
As presented in Figure 4 for the whole marble
normalized environmental profile is calculated,
life cycle, scenarios QMA PMBa, QMA
by dividing the results coming out of the
PMBb and QMB PMBa, QMB PMBb are
previous stage by the normalization factor
responsible for the most notable impacts in
calculated for the relevant damage category.
Human Health damage category. As far as
Table 6 gathers the normalized environmental
Ecosystem
profiles for all possible combination of quarrying
concerned, QMA PMAa, QMA PMAc, QMB
and processing scenarios.
PMAa, QMB PMAc are the scenarios that
category.
For
each
alternative
studied,
Quality
and
Resources
are
make the greatest contribution.

Table 6. Characterization factors Impact Indicators
for total life cycle
Figure 4. Normalized environmental profile of marble

life cycle (Human Health
-68-
Technical Handbook
example the one causes significant damages to

human health while the other to the ecosystem.
The calculations made in weighting stage
provides a weighted environmental profile for
each impact/damage category and the sum of
the weighted profiles of each category provides
a global environmental index for the system.
The environmental profile is calculated by
multiplying the weighted damage factor and the
normalized
environmental
profile.
Table
gathers the normalized environmental profiles
for all possible combination of quarrying and
life cycle (Ecosystem Quality)
processing scenarios
Table 8. Weighted environmental profile for total life
cycle
In
life cycle (Resources).
figure
is
presented
the
weighted
environmental profile for all possible quarrying

and processing scenarios combinations. From
4.4. Weighting stage
all combinations, the QMA-PMBa, QMA-PMBb,
In this stage the normalized impact scores, are
QMB-PMBa and QMB-PMBb are predominant.
weighted against each other in a quantitative

and/or qualitative way in order to be able to
make the impact information more decisionfriendly. The purpose of this step is to place
weights on the various impacts that reflect their
relative importance, thus obtaining an overall
picture of the environmental impact of each
scenario. The weighting step is necessary when
trying to compare two or more alternative
systems. In fact, between two different systems,
it is impossible to compare which of the two is
Figure 7. Marble life cycle, Eco-indicator points
more aggravating to the environment if for
-69-
Technical Handbook
5. Conclusions
transportation to the production plants plays an
Today, we live more and more pressed with the
important role in determining their level of
negative impacts of growing environmental
energy efficiency. So in order to better manage
problems. Natural resources are fast consumed
marble products life cycle, some proposed
without having a chance to replenish them and
improvements enhancing the environmental
the harmful produced wastes have negative
assessment of marble products production are
implications on human health and environment.
presented below:
Buildings contribute to these problems at
Regarding
different levels and various stages.
energy
efficiency,
all
companies in the sector should set
The environmental impacts of building materials
goals for improvement. This requires
during their production stage must be taken into
detailed knowledge of the consumption
account and in order to do that people must
in each production phase in both
have in mind how can building materials be
quarries and processing plants, in order
resource efficient, energy efficient and water-
to redefine inefficient processes and
efficient and thus not having a negative impact
establish improved processes.
on human health. These qualities should be

Raw materials used in production of
achieved right from the start during important
building materials should not be gotten
stages of their production process and must be
from
maintained throughout their life cycle.
depletable
resources
as
this
diminishes their supplies in nature
Ecological building materials are materials that
preventing
do not have negative implications on human
their
use
by
future
generations. Having a low rating of
health during the whole duration of their life
renewable resource usage adversely
cycle. Therefore, materials that damage human
affects resource efficiency. Sourcing of
health during some or all stages are evaluated
building materials from local resources
as negative from an ecological perspective.
adds on an important ecological quality
Materials which are energy efficient are those
in terms of resource efficiency. The use
which make efficient use of energy during the
of local raw materials reduces the need
sourcing and production of raw materials, those
for
which preserve energy when they are used for
energy
for
transportation
and
therefore has many environmental and
the building construction and those which can
economic benefits.
be reused or recycled by using less energy after

being demolished.
The
use
of
recycled
materials
is
Energy used in the production of building
important in terms of resource efficiency
materials adds on gas emissions and has a
and adds a significant ecological quality
negative effect on the environment. A correct
to the material
selection of materials and products must be
Water is an important natural resource
done to save energy, as well as to reduce CO2
that is depletable. Therefore, during the
emissions. It must also be noted that the
production of the material, water needs
amount of energy used for raw materials
to be used efficiently and not polluted.
-70-
Technical Handbook
Recovery of wastewater, collection of
3. Machines and tools for stone quarrying and
rainwater and use of processes that
processing, OSNET Technical Editions, Vol.
consume
1, 2001
ecological
less water are

approaches
important
that
ensure
4. Caterpillar Performance Handbook, edition 29
water efficiency.
5.
Protection
and-you/affect/air-emissions.html,
http://www.pe-international.com/topics/lifecycle-assessment-lca-methodology/,
Agency,
last
6. M. Goedkoop, R. Spriensma, Eco-indicator

99 A damage oriented method for Life
http://www.tangram.co.uk/TILCA_Introduction.html,
last
last
accessed November 19th, 2012.
accessed November 19th, 2012.

2.
Environmental
http://www.epa.gov/cleanenergy/energy-
6. References
1.
U.S.
Cycle Impact Assessment, Methodology
accessed
Report, 3rd edition, 2001
November 19th, 2012.
-71-
Technical Handbook
resources for developing, implementing and
IV Potential for Implementation of

Environmental Management Systems &
the EU Ecolabel in the Marble Sector
maintaining
policies
for
environmental
protection. The EU Ecolabel is a voluntary

scheme that encourages businesses to market
products and services that are kinder to the
A. Gazia , G. Skevisb and M. Fountic
environment. Currently the EU Ecolabel covers
National Technical University of Athens, School of

Mechanical Engineering, Laboratory of Heterogeneous
Mixtures and Combustion Systems
Heroon Polytechniou 9, 15780 Zografou, GREECE
a wide range of products and services, with

further groups being continuously added. The
agazi@central.ntua.gr, bgskevis@central.ntua.gr,
c
mfou@central.ntua.gr
work assesses the potential for implementation

of such schemes in typical medium sized
Keywords:
Environmental
Assessment,
Technology and Markets, EU Ecolabel, Greek
marble.
marble industries. It is demonstrated that

adoption of an EMS system is quite demanding
for a stone sector SME. A detailed analysis of
1. Abstract.
the requirements for obtaining the EU Ecolabel
Marble is an important economic asset in
for hard floor coverings certificate is presented
several
its
and the potential for a typical SME marble
attractiveness as a building and decorative
industry for meeting the above criteria is
material
The
quantified. Possible measures that may improve
majority of marble quarrying and processing
overall environmental impact is proposed and
the adequacy of the EU Ecolabel qualification
Medium Enterprises (SMEs). These are usually
procedure
of limited size with traditional organizational
assessed.
European
and
countries,
its
significant
due
to
reserves.
for
the
particular
industry
is
schemes that yield difficulties in incorporating

new
technologies,
implementing
modern
2. Introduction
organizational schemes and fully adopting
Natural stone is an important economic asset in
national and supranational regulations. The
several
marble industry is also associated with low
attractiveness as a building and decorative
production efficiency and high waste material
material
generation due to the nature of the raw material.
International natural stone production is of the
A possible first step in increasing production
order of 100 million tons per annum. In the EU,
efficiency
in particular, stone quarrying activities are
and
performance
procedures
improving
would
to
practices,
adopt
carried
out
by
significant
almost
60,000
to
its
reserves.
companies
employing approximately 500,000 people with

an annual turnover of more than 20 billion [1].
the
the
The majority of quarrying and stone processing
management of an organization's environmental
program
systematic,
Medium Enterprises (SMEs) that, in the EU,
planned and documented manner. It includes
constitute 99.2% of the total stone quarrying
the
companies and employ more than 80% of the
in
EMS
refers
comprehensive,
organizational
structure,
as
its
due
Environmental Management System (EMS) and

Ecolabel.
such
best
and
countries
the
EU
and
be
environmental
European
to
planning
and
-72-
Technical Handbook
relevant workforce [2]. These are necessarily
The second part of the work presents a detailed
located close to the natural stone producing
analysis of the requirements for obtaining the
areas, very often in remote, mountainous areas
EU Ecolabel for hard floor coverings. Possible
that are not connected to the electricity supply
measures
grid. These are usually of limited size with
environmental impacts are proposed and the
traditional organizational schemes that yield
adequacy of the EU Ecolabel qualification
difficulties in incorporating new technologies,
procedure
implementing modern organizational schemes
assessed.
that
for
may
the
improve
particular
overall
industry
is
and fully adopting national and supranational

regulations. A lack of skilled labour trained in
3. Environmental Management System
contemporary technologies may also be a
The
problem [3]. The natural stone production
Management System (EMS) is a step towards
process is characterized by very low efficiency
the achievement of low environmental impact
and productivity, a huge amount of waste
and enhancement of public acceptance of the
produced and locally disposed and significant
company. Operations or actions that interfere
fluctuations in the quality of the final stone
with the environment are identified, quantitative
products. The impact and significance of these
information on energy flows, energy balances,
problems become apparent by considering that
energy
in order to produce 190m2 (approximately 7 tn)
comparative assessment
of stone tiles, which corresponds to the average
measures as well as classification of operations
floor surface of a modern house, it is necessary
and actions that interfere with the environment
to quarry 100 tones of natural stone. The overall
is realized. An EMS may become a powerful
production efficiency, therefore, is only 7% and
tool in the hands of those natural stone
the
enterprises
waste
potentially
disposed
to
the
implementation
of
consumption,
that
an
are
wish
Environmental
provided
and
of energy saving
to
evaluate
the
environment is about 93 tn [4].
environmental impacts of their activities, set the
The above clearly show that the marble industry
basis for rational re-arrangement of internal
should make an effort to implement measures
structure, adopt workers training and improve
that would improve energy efficiency and
their economic competitiveness, although the
sustainability, in order to maintain and enhance
cost for its application can be considerable.
its global market position. A step towards this
The two formal EMSs in the market place are
direction can be the adoption of environmental
EMAS (Eco-management and audit scheme)
schemes that are already into force both at
and ISO 14001 [5]. They both provide guidelines
national and international levels. The present
towards the implementation of a number of
work assesses the potential for implementation
management system stages to formalize the
of such schemes in typical medium sized
organizations
marble
practices that control environmental aspects.
industries.
First
the
Environmental
policies,
procedures
and
Management Systems are briefly presented and
EMAS
benefits
such
documented verification process of objectively
environmental auditing systems are discussed.
obtaining and evaluating evidence to determine
and
barriers
of
adopting
-73-
has
an
added
systematic
and
Technical Handbook
whether the organizations EMS conforms to
changes.
audit criteria and for communication of the
outcomes from the implementation of an EMS
results of this process to the management. It
that relate to the external interactions of an SME
should be noted that only a very small
[5]. These are naturally mainly environmental
percentage of SMEs of the sector apply for an
(improved
EMS.
increased energy and material efficiencies,
The difference between EMSs and Ecolabels is
increased recycling and reduced pollution).
that environmental management schemes are
Further, the implementation of EMS and the
focused
environmental
resulting development of more environmentally
performance of the company, while ecolabelling
friendly products are expected to create a
schemes like the EU Ecolabel focus on the
positive public image for the company leading
specific products or services of the firm. There
to a competitive marketing advantage.
are many synergies between these voluntary
Nevertheless, there are several disbenefits
schemes, major benefits include reductions in
associated with the adoption of an EMS [e.g. 5].
annual fees and recognition of environmental
These are mainly related to the high capital
commitment: Applicants to the EU Ecolabel
expenditure, including certification fees and
scheme who have already received certification
time and cost required to develop the EMAS
under EMAS or ISO 14001 can be granted
environmental statement. Further, EMSs tend to
reductions of up to 20% on the annual fee and
emphasize paperwork instead of environmental
Competent Bodies are advised to take into
performance and as such market rewards are
account the implementation of recognized
not clearly visible.
on
the
general
External
benefits
are
environmental
positive
performance,
environmental management schemes, such as

EMAS
or
ISO
14001
while
assessing
4. The European Ecolabel
applications and monitoring compliance with
The European Union, in its attempt to set high
the EU Ecolabel's ecological criteria [6].
and
Benefits and disbenefits. Several internal and
standards for products, has recently established
external
the
the EU Ecolabel brand as a tool for stimulating
implementation of formal EMSs such as EMAS
ecological behaviour among producers and
and ISO 14001. Internal benefits are positive
consumers [6]. The European Ecolabel is a
outcomes from the implementation of an EMS
voluntary
which relate to the internal operation of an SME
businesses to market products and services
[e.g. 5]. These include organizational benefits,
that are kinder to the environment. Products
such as improved quality of management and
and services awarded the EU Ecolabel carry
improved working conditions and safety and
the
financial benefits such as cost savings from
including public and private purchasers - to
material, energy and waste reductions and
identify
efficiencies and possible tax incentives. Overall,
schemes exist at a national level such as Blue
the EMS may stimulate significant process,
Angel [7], Nordic Swan [8] and others. The
transport,
objectives of the EU Ecolabel scheme, as set
benefits
raw
are
expected
materials
and
from
packaging
-74-
uniform
efficiency
scheme,
Flower
them
logo,
and
aimed
at
allowing
easily.
Similar
sustainability
encouraging
consumers
ecolabelling
Technical Handbook
out in the original regulation are to promote
weighting factor. In order to satisfy this
products which have the potential to reduce
particular criterion, quarrying processes must
negative environmental impacts, as compared
obtain a specific weighted score (of at least 19
with the other products in the same product
points), provided that the score for each
group, thus contributing to the efficient use of
indicator is higher or lower than a specified
resources and a high level of environmental
threshold. The indicators considered are the
protection [9]. Today, the EU Ecolabel covers a
following. Water recycling ratio (I.1) defined as
wide range of products and services, with
the waste water recycled over the total water
further groups being continuously added. In
leaving the process; quarry impact ratio (I.2),
general, to be awarded the EU Ecolabel, a
defined as the percentage of the total area
product must fulfil certain conditions. It should:
affected by the quarrying operations; natural
(a) represent a significant volume of sales and
resource waste (I.3), defined as the percentage
trade in the internal market, (b) involve, at one or
of usable material; air quality (I.4), defined as the
more stages of the product's life, a significant
yearly limit value of PM10 suspended particles
environmental impact on a global or regional
measured along the border of the quarry area;
scale and/or of a general nature, (c) present a
water quality (I.5), defined as the total number of
significant potential for effecting environmental
suspended solids and finally noise (I.6), also
improvements through consumers choice as
measured along the border of the quarry area.
well as an incentive to manufacturers or service
Scoring rules and threshold values for each
providers to seek a competitive advantage by
indicator are summarized in Table 1. Each
offering products which qualify for the EU
indicator is also multiplied by a corrective
Ecolabel. Finally, (d) A significant part of its
weighting factor, W1-W3, also shown in Table 1.
sales
The relative weights refer to the potentialities
volume
should
be
sold
for
final
consumption or use [9].
and the severity of its limitations for crop growth
Requirements for obtaining the EU Ecolabel in
(soil protection), the population density of
the hard floor covering industry are described in
settlements which lie within a 5 km radius
European Commission Decision 2009/607/EC
(distance) from the quarry site (population
[10] and include several quantifiable ecological
density) and the quarry interference with surface
criteria. For the case of natural products, such
water bodies with average flow less than 5 m3/s
as marble, these criteria fall into five main
(interference with water bodies).
categories: raw material extraction, raw material
Raw material selection. This criterion dictates
selection,
waste
that several toxic or otherwise potential harmful
management and packaging and use. Each
substances are not involved at any stage of the
criterion is discussed in detail below.
quarrying, finishing and transportation stages.
Raw material extraction. The raw material
Finishing operations. This criterion sets upper
extraction management is scored according to
limits to particular pollutants that may be
a matrix of six main indicators. The total score is
present in the finishing process and imposes a
based on the sum of individual scores given for
strict limit on waste water recycling in the
each indicator, multiplied by a
processing unit, Table 2.
finishing
operations,
corrective
-75-
Technical Handbook
Waste management. Waste management and
equipment, quarrying and processing methods
reuse of by-products has to be declared for all
and economic size are concerned. The main
stages of the production process, according to
activities
current EU directives.
extraction from privately owned quarries in the
Packaging and use. Requirements include that
Limenas and Theologos areas of Thassos
packaging is made primarily out of recycling
Island, Northern Greece, and processing and
materials, that the final product is fit for use
elaboration of white dolomite and crystalline
based on well defined international, national or
marble.
in-house test procedures and that the required
Raw material extraction. The first criterion
consumer information is clearly presented in the
scoring
I.1. Water
recycling
ratio [%]
I.2. Quarry
impact ratio
[%]
I.3. Natural
resource
waste [%]
I.4. Air
quality
[g/Nm3]
I.5. Water
quality [mg/l]
I.6. Noise
(dB(A))
3
(Good)
1
(Sufficient)
> 80
80 - 70
69 - 65
W3
< 15
15 - 30
31 - 50
W1, W2
> 50
50 - 35
34 - 25
< 20
20 100
101 - 150
W2
< 15
15 - 30
31 - 40
W1, W2,
W3
< 30
30 - 55
56 - 60
W2
are
achieved
by
the
Theologos
and
Eq. (1)
W2
S=I1W3+I2W1W2+I3+I4W2+I5W1W2W3+I6
(1)
Table 3 The EU Ecolabel score for raw material

extraction for the Laskaridis Marble S.A. Theologos
quarry
Table 2 Matrix for scoring finishing operations

management for natural stones [10]
Parameter
Particulate emission to air [g/Nm3]
Styrene emission to air[mg/Nm3]
Water recycling ratio [%]
Suspended solid emission to water [mg/l]
Cd emission to water [mg/l]
Cr(VI) emission to water [mg/l]
Fe emission to water [mg/l]
Pb emission to water [mg/l]
S.A.
respectively. The total score is calculated using
Relative
weights
5
(Excellent)
Marble
Limenas quarries is shown in Tables 3 and 4
Table 1 Matrix for scoring raw material extraction

management for natural stones [10]
Score
Laskaridis
considered is raw material extraction. The
packaging.
Indicator
of
Limit (to pass)

150
210
90
40
0.015
0.15
1.5
0.15
Indicator
Score
W1
W2
W3
1.1 Water
recycling ratio
1.2 Quarry impact
ratio
1.3 Natural
resource waste
1.4 Air quality
Weighted
Score
5
0.8
0.9
0.72
0.9
4.5
1.5 Water quality
0.8
0.9
3.6
1.6 Noise
0.9
2.7
Total Score:
Application to a Typical SME Marble Plant

In this work the potential for a typical SME
marble industry for meeting the above criteria is
quantified. The selected plant is a typical SME
in the marble production sector [11] with typical
quarrying and processing activities, as far as
-76-
17.52
Technical Handbook
Table 4 The EU Ecolabel score for raw material

extraction for the Laskaridis Marble S.A. Limenas
quarry
Indicator
Score
W1
W2
W3
(habitants/km2) of 9 and 40 and W2 values of

0.9 and 0.7 respectively. For the examined
marble quarries, it has been estimated [13] that
Weighted
Score
ca. 30% of marble extracted is of prime quality

and can be further processed in the processing
1.1 Water
recycling ratio
1.2 Quarry impact

ratio
1.3 Natural
resource waste
1.4 Air quality
0.7
3.5
locations at both the examined quarries have
1.5 Water quality
0.8
0.7
2.8
shown
1.6 Noise
0.7
2.1
combination of noise level and duration of
plant, thus the natural resource waste is

0.8
0.7
characterized as sufficient. Air and water
0.56
quality are both assigned the maximum score. A

final consideration relates to noise emissions.
Detailed measurements performed at specific
Total Score:
that
the
noise
dose,
that
is
exposure evaluated relative to a noise exposure
14.96
criterion and exchange rate, was generally

between 30% and 60% of the recommended
The rationale behind the allocation of scores is
as
follows.
The
water
recycling
ratio
limit for earplug use [3], so a good score is
is
assigned.
effectively 100% since all the water used for the
Other criteria. The second criterion is satisfied
quarrying processes is rainwater stored during
since no toxic substances are involved at any
the raining season (October to April) in large
stage
storage troughs. Although the water is not
finishing
and
and particulate matter emissions. On the other
cycle. Relative weight W3 is assigned a value of
hand, the criterion of water recycling is met
1, since the quarry does not interfere with any
since there is a wastewater treatment facility
surface water bodies. A low sufficient score
with high efficiency The water recycling system
has been assigned to the quarry impact ratio
is
since a large part of the surrounding area is
also
beneficial
to
the
overall
waste
management since the water used contains
affected by the quarry operations. Relative
substantial quantities of marble splint and dust
weight W1 is assigned a value of 0.8, since the
are filtered. The sediment formed at the bottom
surrounding land is generally unsuitable for
of the wastewater treatment facility is led
cultivation and is not a wild life habitat. Relative
through a pneumatic diaphragm pump to a filter
weight W2 (population density) is calculated
press which retains marble sludge and deposits
according to the latest Greek census [12]. The
it safely [3]. Packaging and use guidelines are
two quarries are located within a 5km radius to
also followed.
the villages of Theologos (710 inhabitants) and
Discussion. The above calculations clearly show
Limenas (3,130 inhabitants) respectively. These

population
quarrying,
plant, there is no data relating to heavy metal
aquifer and incorporated into the natural water
to
the
transportation stages. Regarding the processing
mechanically recycled, it is absorbed in the
correspond
of
that the particular marble industry, despite its
densities
modern equipment and organization, does not
-77-
Technical Handbook
manage to fulfil all the criteria required for the
Significant weight is also given to the locality of
award of the EU Ecolabel. Regarding raw
the quarry and its proximity to inhabited areas.
extraction scoring it would be useful to consider
Although the population density near the
the global equation, Eq.(1). The directive gives
particular quarries is rather low, naturally there
undue weight to a criterion that is very difficult
is
to be fulfilled given the current state of the art
corresponding weighting factor (W2) which
and the best practices of the marble industry
affects four out of six indicators.
(i.e. natural resource waste - indicator I.3).
However, it should be noted that the EU
Keeping all other indicators unchanged, a
Ecolabel criteria for hard floor coverings are
quarrying efficiency of 35% would have to be
quite
achieved, to meet the criterion. This exceeds
environmental certification and have raised
the
efficiencies
discussions within parts of the stone industry,
worldwide, which for a high quality marble are
especially regarding the block recovery criteria,
ca 30%. There are two ways of improving this
which possibly would exclude a significant part
ratio: increasing the amount of usable material
of the European stone industry. In fact, the EU
mainly through recycling and/or decreasing the
Ecolabel for hard floor coverings is only certified
quantity of extracted material through detection
to ceramic products [6]. Critics emphasize that
and surveying techniques. There is a significant
the criteria are not well adapted to the real
potential for recycling marble by-products, as
situation in natural stone quarrying In any case
discussed in [3]. For instance, mid-sized wastes
these criteria are very unfavourable for small
can be used as paving stones, marble by-
enterprises [14].
best
recorded
quarrying
no
room
for
demanding
improvement
for
an
SME
in
the
seeking
products crushed as aggregates can be used in

the construction industry, pulverized marble and
5. Conclusions
process dust have various industrial uses, ultra-
The present work explores the potential for
fine white calcium carbonate resulting from
implementing environmental performance and
pulverization of quarry wastes or recovered
management schemes in a typical medium-
from process waste, can be used as filler or
sized marble quarry and processing plant. The
reinforcing and ultra-fine calcareous particles
benefits and disbenefits of implementing an
can be recovered and marketed for agricultural
EMS are discussed. The performance of the
soil amendment and in the building industry.
particular
Further, the amount of usable marble resulting
criteria required for the awarding of the
from
voluntary EU Ecolabel scheme is quantified and
cutting
processes
can
be
achieved
marble
industry
against
specific
tool
assessed in detail. It is shown that the
technologies. Finally, the use of innovative
enterprise narrowly misses the criteria and
technologies
Ground-Penetrating
possible measures are proposed in order to
Radars (GPR) allow for a semi-quantitative
overcome the hurdle. It is further highlighted
evaluation
and
that the criteria set for obtaining the hard floor
homogeneity, potentially leading to primary
coverings EU Ecolabel do not reflect the natural
waste reduction.
stone industry state of the art in quarrying and
through
use
of
such
of
innovative
as
massive
rock
cutting
quality
-78-
Technical Handbook
processing. The current work identifies the

steps and technical measures that
[5] R. Hillary: Environmental management

systems and the smaller enterprise, J Clean
Prod 12: 561-569, (2004).
could
potentially upgrade the sector to meet the
[6] Information
http://ec.europa.eu/environment/ecolabel/
particular EU Ecolabel standards. Nevertheless,

even without formally obtaining EMAS or
on
[7] Information
engel.de/en/
on
http://www.blauer-
company operation at all levels.
[8] Information
ecolabel.org/
on
http://www.nordic-
6. Acknowledgements
[9] European Regulation (EC) No 1980/2000

on a revised Community eco-label award
scheme. Off J Eur Commun L 237, pp. 1-12,
(2000).
Ecolabel certificates, conforming to the relevant

guidelines may prove highly beneficial for
The authors are grateful to the E.U. for financial

support
through
(LIFE08/ENV/E/126)
the
ECO-STONE
and
to
project
LASKARIDIS
[10] European
Commission
Decision
2009/607/EC establishing the ecological criteria
for the award of the Community eco-label to
hard coverings. Off J Eur Commun L208, pp.
21-38, (2009).
MARBLE S.A, Greece for the quarry and

processing plant technical and operational data.
7. References
[11] Information
http://www.laskaridismarble.gr
[1] R. Bruno, I. Paspaliaris: Ornamental and

dimensional stone market analysis, Vol. 13,
Osnet Editions, Athens, Greece (2004).
[12]
Information
on
http://www.statistics.gr/portal/page/portal/ESY
E/PAGE-database
[2] M. Schmiemann: Industry, trade and

services, Statistics in focus, EUROSTAT
31/2008.
[13] M.A. Founti, D. Giannopoulos, K.

Laskaridis: Environmental management aspects
for energy saving in natural stone quarries,
Paper S3-03, Global Stone Congress 2010,
Alicante, Spain.
[3] A. Gazi, G. Skevis, M.A. Founti: Energy

efficiency and environmental assessment of a
typical marble quarry and processing plant,
Journal of Cleaner Production 32, 10-21 (2012)
[4] Information
http://www.ecostoneproject.com/
on
[14] N. Terezopoulos, I. Paspaliaris: Dimension

stone quarrying in Europe and stability of
quarrying operations, Vol 2, Osnet Editions,
Athens, Greece (2003).
on
-79-
Technical Handbook
environmental performance of the enterprises in
V. Conclusions
the
natural
stone
implement
providing
opportunity
consists in a deliverable of the Ecostone, was
towards a greater energy efficiency, an optimum
intended not only to frame and consider the
use of the raw material, the reduction of waste
actual situation of the Natural Stone industry
and
regarding its eco-efficiency and environmental
improving the level of water consumption, and
sustainability, but also to make a technical
the reduction of the general environmental
approach to a wide diversity of topics that were
impacts.
addressed by the partners during the three
The
years of the project.
handbook,
development
obtained
results,
should
not
of
the
With the preparation of this manual, which
the
to
sector
management
new
products,
compiled
in
this
constitute
final
to
statement of the approached issues but in other
technical articles or reports, the main intention
way should constitute a checkpoint that will
is to highlight the different issues observed in
permit the advance of the studies in these
the project and submit the technical results
matters and improve the general awareness of
achieved in each of them.
the main stakeholders related to the stone
The text refers their authors which form part of
industry.
the project partnership and of the teams that
In order to be more competitive the enterprises
were responsible for the development of the
must
technical work.
management.
This is a project with a strong component for
sustainability of the products are more and
dissemination that considers the framework of
more important and a fundamental factor of
the natural stone industry in the perspective of a
competitiveness.
sustainable development approaching several
The Natural Stone must be seen as a prime
aspects that work together to understand issues
raw material that will not get be paid according
like
waste
to the produced quantities but according to the
management, the water management, and the
added value of the products considering that
environmental impacts.
we are working with a primary raw material, rare
So the diversity of the themes developed in the
with unique characteristics, finite and highly
project goes from the characterization of the
versatile in its application.
actual situation of the enterprises, the study in
On
situ of the energy efficiency of equipment and
modernization of this industry, it is fundamental
processes, the study of new eco-efficient
to organize better and more efficiently, in order
materials, the development of new tools, like
to optimize not only the economical costs but
thinner cutting disks, a life cycle analysis and
also the environmental and social ones.
the framing of the Eco label system in the
We want the natural stone to be considered and
Natural Stone Industry.
treated as an Eco-Stone, that origins highly
Ecostone aims to contribute with tools that will
valued and sustainable products, friends of the
allow
environment.
Organized
the
by
chapters
energy
significant
corresponding
efficiency,
the
improvement
of
the
-80-
adopt
the
new
The
other
paradigms
issues
side
and
for
related
to
towards
their
the
the

AIDICO ECO-STONE Sustainable System Implementation For Natural Stone Production and Use PDF

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

AIDICO ECO-STONE Sustainable System Implementation For Natural Stone Production and Use PDF

Uploaded by

Copyright:

Available Formats

LIFE Project Number

Sustainable System Implementation for Natural Stone Production and Use

1) Optimization of use of natural sources and raw

This manual is a particular deliverable of the

3) Use of new multifunctional natural stone based

component for dissemination that involves the

system of the new developed technology to

developed during the three years of the project.

increase the energy efficiency in production of

It is intended for an easy and wide dissemination

stone, with reduction of the wastes and with the

of the results with the key stakeholders, related to

substantial improvement in the use of the raw

Natural Stone sector and not only.

materials. These objectives will be achieved

Under the concept of sustainable development

through a new High-Tech Production system,

the project encompass a significant diversity of

having a Traditional but low energy cost Stone

activities, including aspects related to the life

and new High-Tech Stone products in benefits of

cycle of natural stone, with special emphasis on

the energy efficiency in Buildings and able for

the development of new materials and more

New Application for Construction.

the dissemination and promotion of a sustainable

for the dissemination of the technical work

In the overall objective of the project is included

other tools developed, be the preferred vehicle

efficiency in architectural use.

project this manual was designed to, with the

with the new systems and products, and also to

corresponds to technical articles or reports, the

main intention is to highlight the different issues

More defined objectives are:

results achieved in each of them.

The texts refer their authors which form part of

Implementation of the new technologies and

the project partnership and of the teams that

innovative materials: i) fast systems for natural

were responsible for the development of the

stone cutting, consolidation techniques to reduce

stone wastes; ii) innovative materials based on

(thermal energy storage capacity, self-cleaning

properties); iii) products based on natural stone

implementation, dissemination and promotion of

a sustainable system in order to enhance the

production and use of natural stone, by using the

proposed will reduce the number of wastes to the

environment. New stone materials with thermal

techniques and products to

produce an ECO-STONE (or sustainable stone).

energy storage capacity will reduce the use of the

of defects, such as fractures, hairline long micro

heating/cooling systems in buildings and thus

fractures, cracks, fissures, big pores and cavities,

energy demands, contributing to the reduction of

many of which lie in the inner part of the block

and therefore cannot be detected simply by

-Social objective: Improvement of life quality and

visual inspection. These defects are the origin

human comfort in buildings due to the reduction