This presentation is pertaining to Chittorgarh area of Rajasthan. There are are around 10 Limestone ( Cement Grade) mining leases currently working, with huge waste dumps of low grade limestone not fit for cement manufacture with current technology. This waste can be used for crushing into contraction aggregates and replace river sand with crushed rock fines.

1. Utilization of Mining Waste as Construction
Aggregates – An Overview
Mrinmoy Chakraborty
Geologist - M.Sc (Applied Geology)
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2. Table of ContentsTable of Contents
1. Introduction
2 Geological rock types used in construction aggregates2. Geological rock types used in construction aggregates
3. Details of MiningWaste generated from Chittorgarh Area
4. Statutory constraints for utilization of mining wastey g
5. Technological considerations for preparation of
manufactured sand
6. Conclusion
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3. Introduction (1/2)
 Construction Aggregates ( IS 383 : 1970)
 Coarse Aggregates > 4 75mm (10mm 20mm 40mm GSB)
( / )
 Coarse Aggregates > 4.75mm (10mm, 20mm, 40mm, GSB)
 Fine Aggregates < 4.75mm ( M sand, Stone dust, Natural Sand)
 Requirement of Alternative of Natural Sand around 50 -q
100 million tonnes, in state of Rajasthan
 Study Area : Chittorgarh District
 Mining waste from Cement grade Limestone mines in
Chittorgarh area
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4. Introduction (2/2)( / )
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5. Geological rock types used in construction aggregates
IGNEOUS ROCKS
Granite
Granophyre Granite Group
Granodiorite
Diorite
Syenite
Gabbro
Norite
Anorthosite
Gabbro Group
Peridotite
Pyroxenite
Epidiorite
Alpite Alphite Group Quartz reef
Porphyry
Dolerite Dolerite Group Lamprophyre
Rhyolite
Trachyte
Rhyolite Group Felsite
Pumicite
Andesite Basalt Group Basaltes te Basalt Group asa t
SEDIMENTARY ROCKS
Sandstone
Quartzite
Sandstone Group
Arkose
Graywacke
GritGrit
Limestone Limestone Group Dolomite
METAMORPHIC ROCKS
Granite gneiss
Composite gneiss
Granulite and Gneiss Groups Amphibolite
Granulitep g
Slate Schist Group Phyllite
Schist
Marble Marble Group Crystalline Limestone

6. Geology of RajasthanGeology of Rajasthan
AGE FORMATIONS
Recent to sub- Alluvium & Soil
recent
Pliestocene Laterite
Upper
cretaceous
Deccan trap
Vindhyan
Super Group
Kaimur
Group
Kaimur Sandstone
Kh i S k t Sh lKhorip
Group
Suket Shales,
Nimbhera
Limestone, Bari
Shales
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7. Map showing - Mining Leases in Chittorgarh Area
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8. Details of Mining waste generated from Chittorgarh Area,
Rajasthan, IndiaRajasthan, India
Sl No Lessee Name of the Mines
Reserves in Million tonnes as on
31.03.2016
Production 2015-16 ( Mill Tons)
Strippin
g
Waste
%
Total
( RSl No Lessee Name of the Mines
Reserves
Additional
Resource
( Reserves
+
Resources
)
ROM Waste
Sub
Grade
Total Ratio
1 Ultra Tech Cement Ltd Aditya Limestone Mines - - - 8 51 3 63 - 12 14 1:0 21 30%1 Ultra Tech Cement Ltd Aditya Limestone Mines 8.51 3.63 12.14 1:0.21 30%
2 JK Cement Works Ahirpura & Muraliya 23.78 32.82 56.60 0.88 0.07 - 0.95 1:1005 7%
3 JK Cement Works
Karunda Limestone
Mines
106.99 50.02 157.01 1.45 0.02 0.14 1.61 1:0.014 1%
4 JK Cement Works
MaliaKhera Limestone
105 60 23 57 129 17 1 39 0 02 0 05 1 46 1:0 008 1%4 JK Cement Works
Mines
105.60 23.57 129.17 1.39 0.02 0.05 1.46 1:0.008 1%
5 JK Cement Works
Mangrol Limestone
Mines
32.26 7.05 39.31 0.74 0.00 - 0.74 - -
6 JK Cement Works
Mangrol-Tilakhera
Limestone Mines
16.06 27.83 43.89 1.05 0.00 - 1.05 - -
7 Wonder Cement Ltd
Bhatkorti Limestone
Mines
487.65 0.00 487.65 4.10 0.06 - 4.16 1:0.033 1%
8
Nuvoco Vistas Corp
Ltd
Arniya Joshi Limestone
Mines
68.40 45.57 113.97 0.60 0.00 - 0.60 - -
9
Nuvoco Vistas Corp Sitaram Ji Ka Khera
82 05 33 12 115 17 1 53 0 28 - 1 81 - 15%
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Ltd Limestone Mines
82.05 33.12 115.17 1.53 0.28 1.81 15%
10 Birla Corporation Ltd Birla Cement Works 97.15 81.60 178.75 2.57 0.07 - 2.64 - -
GRAND TOTAL 1,019.94 301.58 1,321.52 22.83 4.15 0.19 27.17
*Source of data Indian Bureau of Mines- Mineral Environment & Mineral Conservation Week Magazine 2016
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9. Statutory constraints for utilization of mining waste
 IBM notification No. M-11012/1/2009 – CCOM (34%
CaO as minimum limit and 4% MgO) -Central India andCaO as minimum limit and 4% MgO) Central India and
States of Rajasthan & Gujarat
 Excavation of limestone with CaO between 34 – 39%
results in generation of large quantity of limestone which
is not suitable for cement manufacturing.The details of
the various impacts are listed below:the various impacts are listed below:
 Increase in mining cost
 Environmental problemsp
 Land degradation due to dumping and stacking within Mining
lease.
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10. Technological considerations for preparation of
manufactured sandmanufactured sand
 General Preferred specification of Crushing & Screening is as follows:
1 Jaw Crusher + Cone Crusher + Screen = 10mm 20mm 40 mm Stone dust ( Two1. Jaw Crusher + Cone Crusher + Screen 10mm, 20mm. 40 mm , Stone dust ( Two
Stage Crusher)
2. Jaw Crusher + Cone Crusher + Cone Crusher + Screen = 10mm, 20mm, 40mm, M-
Sand ( Three Stage Crusher)
3. Jaw Crusher + Cone Crusher +VSI + Screen = 10mm, 20mm, 40mm, M-Sand ( ThreeJ (
Stage Crusher)
 Generally, by using suitable configuration of stone crusher produces around 60-
65% of Coarse aggregates (+4.75mm IS sieve) around 40-35% of crushed material
is screened out as Fine aggregates (-4.75mm IS sieve).There are options of even
modifying your existing crushers can result in production of manufactured sand.
 Tests for Aggregates : CrushingValue AbrasiveValue Compressive strength Tests for Aggregates : CrushingValue,AbrasiveValue, Compressive strength,
Elongation Index, Flakiness Index, Soundness , Fineness Modulus etc from any
NABL approved laboratory/ NCCBM Faridabad/Shriram Institute Delhi
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11. Technological considerations for preparation of
manufactured sand – Sieve Analysis ( M Sand)manufactured sand Sieve Analysis ( M Sand)
SIEVE ANALYSIS ( FINE AGGREGATE) Zone -1
Limit as per
SIEVE ANALYSIS ( FINE AGGREGATE) Zone -2
Li it IS
Weight
retained
%
Retained
Cum %
Retained
Limit as per
IS 383 Zone-1
IS Sieve Size
(mm)
%
Passing
Lower
Limit
Upper
Limit
Weight
retained
%
Retained
Cum %
Retained
Limit as per IS
383 Zone-2
IS Sieve Size
(mm)
%
Passing
Lower
Limit
Upper
Limit
10 0 0 0 100 100 100
4.75 58 58 5.66 94.34 90 100
2 36 300 358 34 93 65 07 60 95
( ) ass g t t
10 0 0 0 100 100 100
4.75 58 58 5.66 94.34 90 100
2.36 300 358 34.93 65.07 60 95
1.18 251 609 59.41 40.59 30 70
0.600 74 683 66.63 33.37 15 34
0 300 76 759 74 05 25 95 5 20
2.36 245 303 29.56 70.44 75 100
1.18 330 633 61.76 38.24 55 90
0.600 50 683 66.63 33.37 35 59
0.300 76 759 74.05 25.95 5 20
0.150 80 839 81.85 18.15 0 20
Pan 186
1025 100.00 0.00
0.300 76 759 74.05 25.95 8 30
0.150 80 839 81.85 18.15 0 20
Pan 186
1025 100.00 0.00
Total = 1025.00 FM 3.23
Pan 186
Total = 1025.00 FM 3.20
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12. Conclusion
 In near future, Indian Bureau of Mines may consider to increase the
threshold value from CaO 34% to 38%.
 Based on production data of FY 2015 16 15% waste is generated Based on production data of FY 2015-16, 15% waste is generated,
even if we consider an average of 10% waste from existing limestone
mining leases, we have around more than 100 million tonnes of
limestone waste is expected which can be used as an alternative ofp
natural sand.
 Mining waste resources from cement grade limestone mines can be
utilized for production construction aggregates.
C f S f Chemical analysis of M-Sand from Limestone
SiO2 Al2O3 Fe2O3 CaO MgO LOI
28.00 3.50 1.9 33.50 1.4 30.2
 We can also consider various other mining wastes generated from
Dolomite, Limestone (All Grades), Granite, Marble Chips, Silica Sand
with quartz etc and various other minerals and rock types suitable
for manufacturing of sand from crushed stone
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for manufacturing of sand from crushed stone.
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13. Acknowledgements & References
ACKNOWLEDGEMENTS
 I would like to acknowledge Shri Madhu Sudan Palliwal ADM – Dept Mines & I would like to acknowledge Shri Madhu Sudan Palliwal ,ADM – Dept Mines &
Geology, Udaipur for providing me an opportunity present the paper in the forum
 I would also like to acknowledge special thanks to Shri Raghavendrarao Jahagirdar,
Vi P id t (Pl t M ) d Sh i S th B j DGM Mi f ChittVice President (Plant Manager) and Shri Somnath Banerjee, DGM Mines of Chittor
Cement Plant (NuvocoVistas Corp Ltd) for their encouragement and support.
REFERENCES
 [1].Indian Standard,“Specification for Coarse and Fine Aggregates from Natural
Sources to Concrete,” Bureau of Indian Standards, IS 383-1970 (Reaffirmed 2002),
Ninth Reprint, Sep. 1993.
 [2].N.K. Katyal and P.K. Ghosh,“Use of Limestone waste in Construction as an[ ] y ,
alternative to Natural Sand”
 [3]. Shreekant R L,Aruna M and HarshaVardhan,“Utilisation of Mine Waste in the
Construction Industry – A Critical Review” ISSN 0974-5904,Volume 09, No. 01,
P.P.182-195, February 2016.y
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14. “Strong Forts are build using rocks and the crushed
rocks are equally stronger “
THANK YOU
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