A TALK BY

MUJIB U. SIDDIQUI Assistant Mineral Economist (Int.) On

MARBLE MINING & PROCESSING

STONE TOOLS

DIMENSION STONES

Dimension

stone

can

be

defined

as

natural

rock

material

quarried for the purpose of obtaining blocks or slabs that meet

specifications as to size (width, length, and thickness) and shape (Barton, 1968, p. 4). Color, grain texture and pattern, and

surface
Durability

finish

of

the

stone
based

are
on

also

normal

requirements.
and

(essentially

mineral

composition

hardness and past performance), strength, and the ability of the stone to take a polish are other important selection criteria. method of finishing a stone, and the type of finish applied (Stone World, 2001, p. 106-139).

India has a long history of utilisation of stones. Towering temples,

acquisitive carvings, huge imposing palaces, monuments, musoleums, minarets, gates and artefacts speaks volumes about the use of stones, let it be the Khajuraho, Delwara temples, caves of Ajanta & Ellora, stupas of Sanchi, Konarktemple, Buland Darwaza of Fatehpur Sikri, Victory Tower ofChittorgarh, Forts of Rajasthan, U.P and Delhi all have been built using one stone or other. The Taj Mahal, beauty par excellence built in 17th century by Emperor Shahjahan in memory of his beloved wife Mumtaz Mahal has been built using white marble from Makrana area, Nagaur Distt. of Rajasthan. Although Delwara temple at Mount Abu, built earlier than Taj Mahal could not give impetus to marble industry as the Taj had given. It has remained the trademark of India for the last three hundred years.

MARBLE

The term marble is derived from the Latin word MURMUR which itself came from Greek root Marmorous meaning Shining Stone. Murmur in Persian means White and Sang means stone hence

Sange-murmur

Geological definition: A metamorphosed limestone produced by recrystallisation under condition of thermal and also regional metamorphism. In commercial parlance almost any rock which can take polish easily more especially unmetamorphosed lime stones are termed as marble.

Marble definition (USGS):Commercial marble includes metamorphosed lime stones and serpentine rocks, all of which are capable of taking a polish. An important member of this classification is serpentine marble, which is also known as Verde antique, and comprises green-to-black serpentine, which is a hydrous magnesium silicate mineral that is crisscrossed by veins of lighter minerals, such as calcite or dolomite.

Why is marble so beautiful?

It is largely consisting of calcite, whose boundaries are fused. This has the ability to transmit lights to a depth of 12.7 to 38 millimeters from where it is reflected by the surfaces of deeper lying crystals which gives a pleasing and cool look. Your eyes will never tire off looking at marble.

TYPES OF MARBLE
. True marbles (recrystallised metamorphic limestone, calciferous and cipolin (siliceous marbles)

Limestone dolomite and polishable calcareous breccia Travertine deposited from water solutions

Onyx
Calcareous alabaster Serpentines Ophicalcite (serpentine limestones) Verde-antique (massive serpentine with crossed vein lets of other minerals like calcite/dolomite)

Indian Classification of Marble

BIS : 1130-1969 (reaffirmed in October 1998) for marble blocks, slabs and tiles to be utilised as dimension stone has classified marbles into 25 different categories comprising 7 categories under a broad group of white marbles and 18 categories under a group of coloured marbles , 8 new varieties are also in the trade

The important new types not included in BIS classification are:

1) Yellow marble of Jaisalmer 2) Pista marble (amphibolite variety) of Andhi-Jhiri belt, Jaipur, Alwar and Dausa districts, Rajasthan 3) Brown green and golden ultramafics of Dunkar, Churu district, Rajasthan 4) Chocolate-brown and English teak wood marble of Jodhpur district, Rajasthan 5) Parrot green marble of Jhilo in Sikar district, Rajasthan 6) Chocolate-brown or wood finish marble of Mandaldeh, Chittaurgarh district, Rajasthan 7) Purple marble of Tripura Sundari in Banswara district, Rajasthan 8) Blue marble of Desuri in Pali district, Rajasthan

International Classification of marble

Group A Sound marbles with uniform and favourable working qualities containing no geological flaws or voids. Group B Marbles similar in character to the preceding group, but less favourable working qualities may have natural faults such as hairline cracks, voids and inclusions, a limited amount of wasting, sticking and filling may be required.

Group C Marbles with some variation in working qualities, geological flaws, voids, veins and lines of separation are common. It is standard practice to repair these variations by one or more of several methods - wasting, sticking, filling or cementing. Liners and other forms of reinforcement are used when necessary.
Group D Marbles similar to Group C but containing a larger proportion of natural faults such as cracks, voids, discolouration, maximum variations in working qualities and requiring more of the same methods of finishing. This group comprises many of the highly coloured marbles significant for their decorative values. The soundness classifications merely indicate what method and amount of repair and fabrication is necessary prior or during installation, as based on standard trade practices.

Resources of Marble
Geological distribution:
Dharwar System: The marble belonging to Dharwar System is mostly distributed in Aravali and Raialo Series of Rajasthan, Champaner Series of Gujarat, Sakoli Series of Madhya Pradesh and Chilpi Series of Maharashtra. Cuddapah and Delhi Systems Marble deposits of Cuddapah System are located in the Papaghani Series of Andhra Pradesh, Bijawar series of Madhya Pradesh and Kaladgi Series of Karnataka. Delhi System marbles are located in Alwar Series and Ajabgarh Series of Rajasthan. Marbles of Ajabgarh Series are exposed around Jaipur Bharatpur, Kishangarh, Ajmer, Mewar, Udaipur and Sirohi areas of Rajasthan; Danta and Palanpur area of Gujarat; and Narnaul area of Haryana. Vindhyan System It is mostly found in Morena district of Madhya Pradesh, and Guntur & Kurnool districts of Andhra Pradesh. Bhima Series are developed in Bijapur and Gulburga districts of Karnataka. Marble belonging to Vindhyan System is of creamy, grey, bluish and buff in colours and is capable of taking a good polish. Jurassic System Fossiliferous limestones of Jurassic System occurring in Jaisalmer and Bikaner districts of Rajasthan take very good polish. Cretaceous System Coraline limestone belonging to Bagh Beds of Upper Cretaceous age furnish a very handsome marble capable of taking a good polish and are located at Kherwan, Chirakhan and Bowarle in Dhar district of Madhya Pradesh.

Geographical Distribution
Andhra Pradesh: Khamam,Cuddapah,Nellore districts Gujarat : Ambuja Marble deposit, Banakantha dist, Ambaji, Jarivav, Kumbheri,
Kateshwar,Bharaj, districts Khikla etc. Chhuchupura Marble deposit in Vadodra

Haryana : Antri Beharipur, Zainpur, Chappra-Bibipur, Nangal durg, Islampur and DhanotaDhancoli in Mahendergarh districts.

Jammu & Kashmir : Doda and Kupwada districts. Maharashtra: Near villages Katta-Hiwara, Kadbikhera, Sakaritola, Pauni, Chorbaoli,Deolapar,
Mansar, Kandri, Chargaon, Junewani, etc. in Nagpur district.

Madhya Pradesh : Katni, Jabalpur, Narsinghpur, Harda, Sidhi and Jhabua districts. Rajasthan:20Districts : Ajmer,Alwar,Banswara,Bhilwara,Bundi,Chittorgarh,Churu, Dausa,Dungarpur,Jaipur,Jaisalmer,Jalore,Jodhpur,Nagaur,Pali,Rajsamand, Sikar,Udaipur

Resources of Marble 1.4.2005 (UNFC) (Grade-wise) (000 t)

(Cat 121 & 122) Cat 333) (Max.)

Grade
Total White colour Off colour Unclassified Not known

Reserve
4700 373 108 0 4219

Resources
178938 8193 677435 1080531 21779

Total
1792638 8566 677543 1080531 25998

State wise Resources of Marble, 1.4.2005 (UNFC) (000 tonnes)

State Andhra Pradesh Chhattisgarh Gujarat Haryana J&K Reserves 0 0 0 0 0 Resources 3 3000 93740 22328 404703 Total 3 83000 93740 22328 404703

Maharashtra Rajasthan
Sikkim Uttarakhand

324 2184
0 0

57723 1118058
2382 6000

58047 1122435
2382 6000

STATE WISE RESOURCES OF MARBLE AS ON 1.4.2005

Uttarakhand 0.33%

Sikkim 0.13%

Andhra Pradesh 0.00%

Chhattisgarh Gujarat 5.23% 4.63%

Haryana 1.25%

Rajasthan 62.61%

J&K 22.58%

Maharashtra 3.24%

Total resources v/s Production

State Chhattisgarh Gujarat Haryana Jammu & Kashmir Madhya Pradesh Maharashtra Orissa Rajasthan
Total resources NMI 1.4.2005 (million tonnes) Production (2005-06) (Rs. million)

83 94 22 405 Not covered 58 Not covered 1122

Nil 490 Nil Nil 245 Nil 0.4 11916

Sikkim
Uttarakhand

2
6

Nil
Nil

Production

Blocks Khandas Luffers Slabs Tiles Karezy Artefacts Statues Garden Furniture Lattices

All India Value of production ,2001-02 to 2005-06

(Value: Rs. Million)
2001-02 2002-03 2003-04 2004-05 2005-06
14000 12000 10000

4425 5535 5443 5780 12652

Value Rs.Million

8000 6000 4000 2000 0

2001-02

2002-03

2003-04
YEAR

2004-05

2005-06

Production
State-wise Value of production
(Value: Rs.000) State Andhra Pradesh Gujarat Jharkhand Madhya Pradesh Orissa Rajasthan 2001-02 1435 2002-03 448 2003-04 373 2004-05 659 2005-06 695

315612 15634

294576 97278

287242 177106

312587 244845

490042 106 244845

210 4092393

362 5141838

415 4978112

415 5221400

415 11916345

STATE WISE PRODUCTION OF MARBLE,2005-06 (VALUE WISE)

Gujarat 3.873% Andhra Pradesh 0.005% Jharkhand Madhya Pradesh 0.001% 1.935% Orissa 0.003%

Rajasthan 94.182%

MARBLE MINING AND PROCESSING

CONVENTIONAL MINING

Mining of marble

marble mines are semi-mechanised and few are fully mechanised preferred mining method is 'Bench-Quarrying' mining machineries like line drillers, chain saws, belt saws, diamond wire saw cutters, derrick cranes, loaders and tippers are used ultimate product in marble mining is parallelepiped regular blocks, luffers and khandas Fully mechanised mines recover about 35% regular blocks, 30% luffers and 30% khandas

SEMI MECHANISED MINING

Extraction of key block ,Gully or Toda making

Toppling of Thaddi or Phada

Use of Hydro bags for toppling Thaddi

Block cutting from Thaddi using Wire Saw

Block cutting or Khasra karna from Thaddi using Wire Saw

Block shifting by fork lift

Derrick Crane for Block Lifting

MODERN MINING TECHNIQUES

UNDEGROUND MINING OF MARBLE

Not practiced in India. Italy is fore runner owing to its Geology. Adopted where open pit mining is unfriendly to Environment.

Overburden is difficult or un-economic to move. Overburden is entirely non-productive. Rock quality is sound to sustain load. The quality and Quantity of marble is proved by

drilling.

ADVANTAGES & DISADVANTAGES OF UNDERGROUND MINING Advantages

Less destruction to environment. No generation of dust. No or less pollution. No effects on surroundings.

Cost intensive. Contamination of ground water. Not suitable for selective mining. Costly product.

Disadvantages

Processing of marble

Dressing of block by single blade cutter or wire saw cutter

Fixing on trolley for gang saw cutting

Cutting blocks by gang saw or Circular saw Processing of marble is done mainly to get sawn slabs and tiles of varying thickness Recovery of slabs from regular blocks after processing ranges from 60 to 70 per cent

INDUSTRY FLOW DIAGRAM

QUARRY/ PRODUCERS RAW BLOCKS EXPORTS AGENTS LOCAL SALES STONE PROCESSORS SLABS/TILES SLAB DISTRBUTION
WHOLE SELLERS STONE FINISHERS CONTRACTORS RETAILERS

DIRECT SALES MONUMENTS ARTEFACTS ORNAMENTAL EXPORTS LOCAL SALES MUSEUMS HOTELS PERSONAL

FLOORING CLADDING

TABLE TOPS KITCHEN TOPS

VANITIES FACADE

MOSAIC SKIRTING

Dressing Block for Gang Saw

Multi Disc Circular Saw

Cutting By Gang Saw

PLACEMENT OF BLADES AND CUTTING WASTE IN GANG SAW

Various Sizes of Slabs/Tiles

MODERN WIRE SAW MACHINE

VARIABLE THICKNESS OF SLABS BY WIRE SAW

DECORATIVE PIECES CUT BY WIRE SAW

PILLAR SECTIONS CUT BY WIRE SAW

STRENTHENING MARBLE SLAB BY NETTING AND ALUMINIUM PANEL

THE ART MAKERS

Designer Tile sequence

Inlay Work

Inlay Work

Inlay Work

Inlay Work

Decorative sofa

Statue made from Makrana Marble

Statue made from Makrana Marble

Statue made from Black Marble

CARVING USING LASER SENSOR AND CNC MACHINE

JALI CUT BY WATER JET

STAIR CASES CUT BY WIRE SAW

Jali (Lattice ) Work

Decorative Balls of Stone

TRADE

Major Trading countries from India

Major Exports U.S.A China Hong Kong Italy Spain U.A.E

Major Imports Italy Sri Lanka Turkey Egypt Oman Vietnam Iran

Exports of Marble (Total ) (Quantity & Value )

Year 2001-02 2002-03 2003-04 2004-05 2005-06

Quantity 000t 170 253 261 242 259

Value Rs. Million 1841 1894 2383 2230 2494

Per Unit Value 10.82 7.49 9.13 9.21 9.62

Exports of Marble by type (Dressed & Others) (Quantity : in 000 t) ; (Value: in Rs. Million)

Dressed Others Year Quan Value PerUnit Quan Value PerUnit tity Value tity Value 2001-02 157 1716 13 125 9.62 10.92 2002-03 239 1748 14 146 10.43 7.31 2003-04 175 1875 59 392 6.64 10.71 2004-05 202 1728 40 502 12.55 8.55 2005-06 198 1611 61 883 14.48 8.14

Value of Exports of Marble vis--vis Granite (Total) Value: Rs. Million

Year 2001-02 2002-03 2003-04 2004-05 2005-06

Marble 1841 1894 2383 2230 2494

Granite 18739 23746 25063 27258 34906

Imports of Marble (Total) (Quantity : in 000 t) ; (Value: in Rs. Million)

Year 2001-02 2002-03 2003-04 2004-05 2005-06

Quantity 52 87 97 134 182

Value 922 1476 1713 2564 3410

Per Unit Value 17.73 16.96 17.65 19.13 18.73

Total Demand (Value-wise) (Rs. million)

Year

Produ ction

Export

2001-02 4425 2002-03 5535 2003-04 5443 2004-05 5780 2005-06 12652

1841 1894 2383 2230 2494

Balance Imports Total A B consumption A+B 2584 922 3506 3641 1476 5117 3060 1713 4773 3550 2564 6114 10158 3410 13568

DEMAND OF MARBLE (Value in Rs. Million) 16000

y = 2112.1x + 279.3
14000 12000 10000 8000 6000 4000 2000 0 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07
Series 1 DEMAND OF MARBLE

20112012

POLICY

Marble, and other stones are minor minerals, as per the definition contained under Section 3 (e) of Mines and Minerals (Development and Regulation) Act, 1957.

Group on Marble Development Subgroup- 'Building up a Database on Marble' Subgroup- 'Examining Mechanisation in Marble Quarries' both the Subgroups had submitted the reports. Marble Development and Conservation Rules (MDCR), 2002 framed for conservation and systematic development and scientific mining of marble throughout the country As per the export-import policy announced for the years 2004-09; the imports of Marble (excluding alabaster) under heading 2515 and Marble & other items under code no. 25174100 and 25174900 are restricted.

SWOT MATRIX

STRENGTH
Huge deposits

High quality stones

A developed quarrying base A leading exporter of stones which is ranked 3rd in the world

Cheap availability of labour

Easy availability of indigenously developed machinery Large domestic market

A well established distribution network within India

A large processing capacity A tradition of stone architecture & usage

WEAKNESS

Low quality awareness in customers Poor quality consciousness in manufacturers Absence of a training mechanism for the stone industry and a resultant shortage of skilled and trained workforce Lack of scientific exploitation techniques in quarries Poor polishing and finishing techniques Poor segregation, sorting and gradation Improper packaging practices Inability to stick to a strict delivery schedule Improper installation techniques. Lack of promotion of new deposit areas Dumping of stones abroad at low prices Lack of Value addition for the export market Absence of long-term and a rational policies Absence of sales tax initiatives to the stone craft industry Lack of understanding about the need for testing of stones Lack of testing facilities in Northern India Unorganised Lack of education and training facilities Lack of global outlook Presence of unscrupulous exporters

OPPORTUNITIES

A large domestic market Increase in construction activity in India

Increasing awareness amongst Architects Unexplored potential for exports growth An expanding world market An increased trend towards exports of finished goods Globalisation and liberalization Strategic location with sea links to all the major continents Export Demand for stone handicrafts Export potential of sandstone and slates

THREATS

Opening up of import regulations Competition from ceramic products Import restriction in Europe without proper test certifications Widespread environmental degradation Closure due to unscientific exploitation

Rescession due to over production Competition from China, South Africa, South Korea, Brazil, Turkey, South Korea etc. Group promotion strategies of competitor countries Dropping prices of Indian stones in the International market Lack of monopolistic and consortium approach