PROJECT DESCRIPTION STATEMENT Final

PROJECT DESCRIPTION STATEMENT

To remove garages approved in PA 7952/06, install a stone/marble

cutting machine with overlying roof and gantry and carry out

additions and alterations

Xewkija - Gozo

TN 144863

_________________________________________________________

May 2012

TRK 144863 - Document - (26a) Revised PDS [] - DocumentID - 2037188 - Document Dated - 20/09/2012 11:49:04 - msult - Page 1 of 52 26a

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Report Reference: This report has been drawn up by Mr. George Said on behalf of AF Ellis Ltd. with respect to the alterations and installation of marble cutting machinery at an existing and operation concrete brick processing plant at the Xewkija industrial estate. This Project Description Statement was prepared in support of tracking application number TN 144863.

George Said BA(Hons) MA Geog

Jasmine Court Apartment No. 4, Triq Guze Ellul. Pieta, PTA 1034

E‐mail: [email protected]; Mob: +356 79562526; Tel: +356 21226041


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Table of Contents

1 Introduction 5 2 Background 7 3 Details of the Developer 9 Employees 9 4 The selected Site 10 Site Location 10 Access 11 Surrounding Land uses 11 5 Current Operations on Site 13 6 Proposed structural modifications to the existing plant 15 Objectives of the development 15 Components of the proposed development 15 Services to be available on site 17

7 Proposed Operations and Equipment to be installed on site 18

New industrial Operations 18 Marble cutting machines 19 Barasanti Gangsaw 19 Pedrini Bridge Saw 20 Base Jaw Crusher 21

8 Proposed operations of the marble cutting machines 23 Operations 23 By-Products 25 9 Expected Waste streams to be generated by the marble cutting machines 26 Marble cutting operational process 28 Gravels, broken slabs and chips 28 Plastic and Wood 28 Municipal Waste 28 Grey and Sewerage Effluent 29 10 Quantification of Solid Waste flows from the production process 30 Marble Chip Wastes 30 Liquid Wastes 30 Plastic and Wood 31


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11 Solid Waste Management of the Facility 32 Utilisation of waste in Concrete Bricks 32 Production of Terazzo 33 Quantities 33 12 Liquid waste management of the facility 34 Waste Water 34 Waste Water Collection 35 Treatment and Disposal of Wash Water 35 13 Emissions from the facility 38 14 Water Management 39 15 Potential impacts and Mitigation measures 40 16 Conclusions 41 Annex 1 43 Annex 2 45


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1.0 INTRODUCTION

1.1 This technical report has been compiled in accordance with the general

guidelines which have been issued by the Environment Protection Directorate

(EPD). The design and supervision of the proposed project are the responsibility

of Perit Salvu Micallef.

1.2 This document presents a Project Description Statement (PDS) for the set up of

marble cutting machinery facility at an existing concrete brick plant which is located

within the industrial zone of Xewkija as identified in the Gozo and Comino Local Plan.

This report gives a brief description of the ongoing process at the concrete brick

processing plant together with the additional processes which shall be introduced

within the site.

1.3 In addition, this technical report also presents a solid and liquid waste management

work plan for the operations of the proposed marble processing application. This

proposed plan will be endorsed by the operator of this concrete brick plant by ensuring

that the solid and liquid wastes which are generated are properly disposed of by

means of an identified flow disposal systems which have been integrated into the

production process and are explained in detail in the respective sections 9 to 12 of the

report. This is of a benefit to the operator and also to the surrounding environment.

1.4 The timing and main reasons behind this planning application are the immediate

installation of these marble cutting machines in order to compliment the existing

concrete brick production. The purchase of this machinery will enable the company to

produce a wide range of high value added products and will place it in a position to

also produce efficiently marble slabs of various thicknesses according to the client

needs. An added value would be derived from the cutting of such slabs into tiles for

commercial and domestic use by meeting the current demand such specific slab sizes.


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Thus the installation and operation of the proposed machinery will better position the

company to tap both the indigenous market for marble slabs as well as to explore

export possibilities. The details of the machinery which shall to be introduced on site is

presented in the architectural drawings which are included in Annex 2 of this report.

1.5 It is intended that the Project will be designed to high specification including

conformance with European Union (EU) policies on the operation of the marble cutting

machines and also on waste management and good practices. This project seeks to:

• Provide modern and environmentally sound method of treating and

disposing of non-hazardous waste streams;

• Provide the necessary infrastructure for the proper disposal of waste by

the date as stipulated in the Solid Waste Management Strategy;

• Ensures that the marble cutting operations are kept to optimum levels

with the necessary dust mitigating measures.

1.6 According to the Environmental Impact Assessment (EIA) Regulations (LN 114/2007),

this development proposal may fall under schedule 1. Accordingly the Project

Description Statement (PDS) which is being presented it is intended to provide all the

required information which may help MEPA to determine whether an EIA is required or

not.


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2.0 BACKGROUND

Background

2.1 The applicant, Mr Anthony Ellis, is the Director of AF Ellis Ltd is a long established tile

and manufacturing firm. Its origins date back to 1932 when a young Gozitan

entrepreneur, Anthony Farrugia Ellis started manufacturing hand-made patterned tiles.

Today, it has gained a strong market share and operates from retail outlets located

both in Malta and Gozo run by successive generations of the Ellis family.

2.2 The company is one of the major players in the production and importation, of tiles and

has over seventy five years of experience in the industry.

2.3 Tile-making and subsequently, marble manufacturing were originally carried out in the

company's premises located in the centre of Victoria which were acquired by the

company's founder. The current premises are situated in an area which has become

increasingly built-up, resulting in the need to re-locate to an industrial zone. Such need

arises not only from the constraints of the present location but also form internal

pressure to expand the operations in order to be more competitive and efficient in the

firms operations.

2.4 In 1991, the company had sought to minimise the problems resulting from the

constraints of the existing premises in Victoria by moving the majority of its operations

to a new factory set out on area of 5,000 square metres, located at Xewkija Industrial

Estate. Since 1991, it intended to set up a state-of-the-art manufacturing process with

high levels of technology. The company had in the early 90’s commenced its

installation for the cutting and polishing of marble and granite as well as the cutting

marble blocks. Investment in the plant included a computer-programmed cutter, a 12

head polisher and an edge-milling machine. The company has already invested


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heavily in technology and has taken great care to choose the best machinery in each

relative sector in which it operates as it firmly believes that investment in technology

leads to higher productivity and better quality products.

2.5 However, after a division of the family firm in 2001, this machinery is now being

managed by different shareholders. Such division also resulted that the site was

segmented into two, where the portion of the undeveloped part was transformed into a

brick plant.

2.6 The company is now intending to expand the current operations at this industrial plant

in Xewkija and a planning application has been submitted to undergo some minor

alterations within the site and also the installation of the marble cutting machines.


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3.0 DETIALS OF THE DEVELOPER

3.1 The developer of this site is Mr. Tonio Ellis who has been in the business of tile

manufacturing for the past 30 years. The continuous growth and intensification of the

tile manufacturing is creating demand for high end products and thus a more

elaborated set up of cutting machines is required in order to meet the required

demands and also respects the surrounding environment.

3.2 Marble cutting and also tile manufacturing offers a number of challenges, the major

one being the control of dust dispersion from the cutting process and also the

management of the generated marble sludge. Professional industrial operations must

not only focus solely on the output of their products but also must balance the benefits

of this specific industry with environmental sustainability. This is the main objective of

the proposed development in terms of the installation of the marble cutting machines at

the existing brick processing plant and its operations together with the specific site

modifications where such development is being earmarked.

Employees 3.3 In view of the current concrete brick operations unit Mr. Ellis at present is employing 8

full time persons. These are as follows:-

1 Director

1 Technical Manager

1 Foreman

2 Drivers

1 Clerk

2 Skilled labourers


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3.4 Mr. Ellis is the owner and director of this industrial plant unit. In view of the proposed

development he will be adding another 2 skilled labourers to the existing workforce.


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4.0 THE SELECTED SITE

Site Location 4. 1 As stated earlier, the site is located within the industrial zone in the locality of Xewkija

as targeted by the local plan. The site is subject to policy GZ-CMRC-6 which outlines

particular conditions for such industrial site. The details of such policy are as follows:-

GZ-CMRC-6: Areas are indicated at Xewkija on MAP 14.13-A to accommodate Use Classes 11 and 12 (Use Classes Order, 1994) micro-enterprises. A Business Incubation Centre on one of the sites would be favourably considered. The design of the sites shall take into consideration the following:

a) the buildings shall have a maximum height of not more than 10 m. above the finished surrounding surfaces; b) at least 30% of the site shall be left as open space to accommodate vehicular circulation and landscaping; c) preferably at least 25% of the built-up area should be allocated for warehousing; d) services should be directed through underground conduits; and e) a perimeter of at least 3 m. shall be left around the site for soft landscaping. Trees employed in this stretch shall have a mature height of 3 m. or more and shall conform to the approved Guidance on Planting. This requirement may be partially waived on sites which are already committed by development.

4. 2 The area is already serviced with the basic service utilities. In fact the site is connected

to the power and water supply as well as sewerage, and telephone networks. The

facility does not house a generator on site since it has a direct three phase supply from

the nearby industrial area.

4. 3 The site covers 5,000 square meters and consists of a new complex of buildings,

which are being utilised for the production of cement tiles and ancillary products. In all,

this complex has three building units plus parking spaces for 14 vehicles. The existing

brick plant facility can be viewed in the aerial photo which has been included below.


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Photo 1 Aerial photograph of the existing brick plant at Xewkija

Access

4.4 The site can be accessed via Triq Il-Biccerija which runs along the eastern perimeter of

the site. The site has two separate entrance / exit points of which one is dedicated for

the vehicular movements and the other for the pedestrians. Vehicles will access the

site via a ramp which has a gradient of 1:10 as shown in the architectural drawings.

Surrounding Land Uses

4. 5 The aerial photo presented below shows the site location and the immediate

surrounding areas comprising mostly industrial buildings, greenhouses and agricultural

land parcels.


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Photo 2 Aerial photo of the site and surrounding land uses

Legend

Agricultural Industrial Residential Site

The existing Industrial complex forms part of a

complex of industrial developments in the Xewkija

area. These industries were relocated to this area

which is specifically designated for industrial

development since their activities which were

operating with the residential areas were

considered incompatible with the surrounding urban environment.


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5.0 CURRENT OPERATIONS ON SITE

5.1 At present the site houses a concrete brick manufacturing plant which was approved

as per permit PA 7362/07. The site covers 5,000 square metres, of which 3,467 square

metres are built-up and 1,533 square meters are used for circulation and parking.

5.2 The existing concrete products manufacturing plant stores cement, sand and

aggregates in order to produce cement bricks. These are then transferred to trucks for

transportation to construction sites. The site also caters for the necessary stockpiling of

aggregates and the storage of cement, a production area, a stacking area, staff

facilities, an office and access between different areas and facilities.

5.3 The pathways and roadways circulating around the factory area are wide enough for

wheel barrows, trolleys and trucks in order to make the necessary movements for the

operation processes. These circulation spaces are also adequately paved so that they

are also accessible in wet weather conditions. In addition, it is also easier to channel

and handle runoff water appropriately and also minimise hazardous conditions around

the site.

5.4 The site is mostly occupied by the brick processing equipment which is housed within

the main structure. The facility also has three hoppers of the ground type as these can

be easily loaded with the aggregates directly from the delivery trucks at ground level.

The hopper has been fitted with a bucket which transports the aggregates into the

concrete mixer for the brick production process.

5.5 A silo which has been equipped with dust abatement equipment is also present on site

for the storage of cement. This raw material is transported to the site in bulk by trucks

which then transfer the cement load into the single compartment silo by means of a

pressurised pump using a vertical 4-inch pipe with a close 90 degree bend to a diffuser

in order to avoid dust dispersion.


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5.6 At present, this batching plant with the current installed batching technology an

average of 2,000 cement bricks are being produced every day. Such production

volume requires an average of 17 cubic meters of cement, aggregates, sand and water

daily which will be proportionally mixed by the mixer in order to produce the cement

bricks and tiles.

5.7 The mixer capacity undertakes a total volume 0.364 cubic meters of mixture at one

time. Such volumes of raw materials are enough to produce 20 bricks per minute by

the block machine which is currently installed on the site.


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6.0 PROPOSED STRUCTURAL MODIFICATIONS TO THE EXISTING PLANT

6.1 In order to install and operate the required marble machinery, the applicant is

proposing to remove the garages which have been proposed to be constructed at the

western perimeter of the wall as indicated in the approved permit PA 7362/07. The

plans of such a proposal are included in Annex 2.

6.2 The applicant will also be installing a stone crusher, possibly near the entrance of the

site in order to produce aggregate materials for the concrete brick production. Such

equipment will be totally enclosed as outlined in the annexed drawing plans.

6.3 The marble cutting machinery will be housed within the existing building located at the

southern perimeter of the site while the biggest marble cutting machine will be set up

at the south western corner of the site as indicated in the architectural plans.

Objectives of the Development

6.4 The objectives of these alterations to the existing industrial development are to:

• Provide a wide range of high value added marble products.

• Increase efficiency and decrease running costs, making the marble processing

operations more competitive, especially in view of market liberalisation

following EU accession;

• Continue to provide a high quality to achieve a high output of marble tiles with

international standards and consumer expectations;

• Improve the environmental management of the operations by recycling the

marble aggregates for the production of cement bricks which is currently

going on at the plant premises.


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Components of the proposed Development 6.5 The proposed development consists in the installation of various machines for the

production of marble. Brief details of the proposed machinery is as follows:

• A Barsanti TLD60 gangsaw for the sawing of marble and hardstone blocks in

various sizes.

• A Pedrini M940 bridge-saw which will cut the slabs produced by the gangsaw in

tiles of various sizes. This specialised saw also permits the manufacture of high

value added marble objects such as kitchen tops, balustrades and columns

through a numeric control process.

• A Monlevi Fresamatic New FP 350 bridge-saw which will also be used for the

cutting of slabs into tiles and thus, would allow the other bridge saw to be used

primarily for the manufacture of higher value added products

• The installation of a gantry crane which would enable the efficient movement of

the marble blocks and the finished marble products.

• A small manual polisher in order to be able to polish the marterial as part of the

finishing process.

• The applicant will also set up a jaw crusher in order to process the wastes which

will be coming for the cutting process in order to be used for the brick block

making process.

• Car parking/cultivation unit-servicing area:

• This industrial unit requires adequate service areas to accommodate

medium sized trucks, vans, and similar vehicles. In fact the existing parking

area will be relocated as shown in the annexed architectural plans. The

layout of the plant is structured to accommodate these vehicular

movements.

• Run-off management:

• The site is already equipped with rainwater collection system where the

water is being directed to an underground reservoir which was constructed


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beneath the entrance to the site. This will cater for the landscaping and

cleaning requirements of the plant

• A dirty water reservoir was also built underground. This will be equipped with

a settling tank and will collect the water from the surface runoff of the site

area.

• Additional reservoirs for the recycling of marble sludge:

• In view of the installation of the marble machinery, another three water

reservoirs with a total capacity of 200 cubic meters are going to be

constructed so as to recycle the marble sludge water which will be

automatically drained from the impermeable floor where the marble

machines will be installed on site. This is so since the marble machines

require an amount of water which is used during the cutting processes. Thus

more water volumes are required together with the existing water reservoir,

and thus a water recycling process will be introduced at this industrial plant.

These reservoirs are being proposed to be constructed at the south western

area of the site as indicated on plans.

• Settling tanks systems provide a relatively easy and effective method for

collecting, treating, and reusing water at the marble processing facility. This

is so since the top of the tank will be equipped with a filtration system in

order to retain the sand and aggregates so that they can be removed from

the tank and reused as raw materials for the brick production process. In

addition the water originating from the dewatering process will be collected

for treatment and subsequent recirculation.

6.6 It is being proposed that, two of these machines will be installed in the existing

workshop building situated at the rear of the site while the other marble cutting

machine will be installed at the corner of the site. This machine which will be the

largest in size which will be installed on site. The applicant is also proposing that this

machine will be under cover, thus the structure has to be constructed at the corner of

the site as indicated on the architectural plans.


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Services to be available on Site 6.7 The industrial plant will utilise the following infrastructure services:

• Water collected from the site will be channelled to an underground reservoir

(to be excavated under the site), for use for washing and also the use for the

cutting discs of the marble machines;

• Mains water used in the toilets and showers will be discharged to the

connected main sewerage network.

• Mains electricity used for all of the industrial unit electricity requirements. The

supply already exists on the site and does not require the back up power of a

generator.


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7.0 PROPOSED OPERATIONS AND EQUIPMENT TO BE INSTALLED ON SITE New Industrial operations on site

7.1 During the processing of marble and granite, that will take place within the industrial

plant, marble materials will be cut either into tiles or slabs of various thicknesses

(usually 2 or 4cm), using diamond blades. Water is showered on blades while stone

blocks are cut into sheets of varying thickness to cool the blades and absorbs the dust

produced during the cutting operation. The amount of wastewater generated from this

operation will be collected in a septic tank / pits where in the suspended particles settle

and then the water will be recycled to be used again in the cutting operations. The

slurry is then collected from the pits to be used in the brick manufacturing processes,

also carried out on site.

7.2 The cutting of marble and granite units generates solid waste which is referred to as

cutting wastes as this results from cutting slabs into the required dimensions. After the

stone has been cut to specific dimensions, the slabs are finished either by polishing or

texturing, as requested by the client. The polishing operation is fully automated with

the use of powdered abrasives that keep on scrubbing the surface of the marble until it

becomes smooth and shiny. Constant water showers are also essential to prevent

overheating of the blades during the cutting process.

7.3 Such processes require the installation of a number of machinery on site which vary in

size and dimensions. They will be located at the rear of the site as identified in the

annexed plans. The machinery will be used for the different processes required for

marble cutting industry. Details of the proposed machinery which are being proposed

to be installed at the plant are described below.


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Marble Cutting Machines Barasanti Gangsaw

7.4 A Barsanti TLD60 gangsaw for the sawing of marble and hardstone blocks in various

sizes. The machine is equipped with 60 adjustable blades, thus, allowing for the

concurrent cutting of a maximum of 60 slabs at the same time.

7.5 The monoblade gang saw is designed for the squaring of marble blocks, to cut slabs

and thick pieces of marble materials. The saw is built form electrowelded steel which

guarantees the maximum resistance capacity to all dynamic actions. The sliding

guides are designed to guarantee the maximum cutting precision. The cinematic

components are assembled on roller bearings of suitable diameter and are well

lubricated. The blade holding trolleys system is formed by casehardened guides, which

are also tempered and rectified on which the wheels slide allowing for a greater

reduction maintenance requirements. The alternate blade movement is balanced by

two fly-wheels. The blade tensioning is made through a special oleodynamic circuit

which guarantees the precision and the suitable tension. The downward movement is

obtained through an electric motor at variable speed with frequency converter. This

allows keeping a regular descent blade speed. The different possibilities of the down

speed regulation along the plant use on all types of stone and marble.


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Photo 3 The proposed gangsaw which is going to be installed on site

Pedrini Bridge Saw 7.6 A Pedrini M940 bridge-saw which will not only cut the slabs produced by the gangsaw

to smaller tiles of various sizes but would also permit the manufacture of high value

added marble objects such as kitchen tops, balustrades and columns through a

numeric control process. Basically, this bridge-saw will allow what can be drawn on the

autocad system to be manufactured in marble.

7.7 This avant-garde machine has been engineered for the construction of building

elements and the manufacturing of furniture and tombstone art elements. The numeric

control is handled by an industrial PC. The automatic cycles are easily programmed by

touch screen from a colour monitor. The tool-holder head can perform step cutting

even in 0°/90° tilted positions. Perfect movements control allow for processing by

spatula. Owing to the adjustment system on all guides, the M 940 CN maintains the

original precision timing.


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Photo 4 An example of a marble bridge saw machine

Base Jaw Crusher

7.8 This machine will permit the crushing of damaged cement bricks which cannot be

marketed, thus, allowing for the re-use of the cement coated aggregate. It will also be

used for the crushing of the marble residue from the gang-sawing operation into

aggregates. The aggregate to be produced will be utilized in the production of cement

bricks, thus, allowing for considerable synergies. It will also permit considerable

savings on transportation and dumping charges of damaged concrete bricks and

marble residue. The production of high quality aggregate will also save on cement

input costs which are a considerable expense in the production of bricks. An example

of the base jaw crusher is presented in photo 5 below.


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Photo 5 An Example of a base jaw crusher


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8.0 PROPOSED OPERATIONS OF THE MARBLE CUTTING MACHINES

Operations

8.1 The manufacturing of marble involves cutting and finishing marble obtained from

quarries, where specific dimensional marble is prepared for various uses in specialized

mills equipped with saws, polishing machines, and others. Marble sawing equipment

includes large circular saws, where various types of diamond and other equipment are

used for smoothing, polishing, and edging the raw marble. The marble production

process includes several steps. In the first phase, blocks and slabs are stored, band

deposited in the park of prime materials by means of two bridge cranes for great

tonnage.Saws (gang saw or slab cutting machines) are used for cutting blocks into

more governable units (slabs) for the following processes of production.

8.2 During the processing of marble cutting which shall occur on site the raw stone block is

cut as demanded either into tiles or slabs of various thicknesses (usually 2 or 4cm),

using diamond blades. Water will be showered on blades while stone blocks are being

cut into sheets of varying thickness to cool the blades and absorbs the dust produced

during the cutting operation. These operations generate an amount of wastewater

which will be stored in the sedimentation reservoirs until the suspended particles settle

and the water will be reused again.

8.3 Marble will be also cut into different shapes and sizes as necessary and then the slabs

are finished either by polishing or texturing, as requested. The polishing operation is

fully automated with the use of powdered abrasives that keep on scrubbing the surface

of the marble until it becomes smooth and shiny. Water showers are also essential in

this manufacturing process in order to prevent overheating of the blades. Diagram 1

presented below shows the processes flows which will take place on site.


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Diagram 1 Marble Cutting Processes Flows

Delivery of Marble Blocks to the Plant

Marble Sheet Cutting

Cutting of Slabs and Tiles

Production of Marble Value

Added Products

Marble Chips Marble Slurry

Crushed Into Aggregates

Diverted to the dedicated

sedimentation reservoirs on site

Generation of Waste Products

New Composite Brick Blocks

Terrazo Marble

Generation of Recycled Products


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By Products 8.4 It is estimated that the manufacturing of marble generates around 10 per cent of

material as wastes. In actual fact these are not considered as wastes since this prime

material will be used in another processing phase .i.e. that of brick making. Thus, the

difference between raw material consumption and production is not necessary

assigned as waste products but rather should be referrer to as by products since

factories can sell flagstones as ornamental or construction units for garden

landscaping, and house floor flagstones. The sources of the generated residues in

marble manufacture can be categorized into (i) gravels and broken slabs, (ii) slurry and

sludge.


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9.0 EXPECTED WASTE STREAMS TO BE GENERATED BY THE MARBLE CUTTING MACHINES.

9.1 One of the fundamental assets of a waste management plan is waste minimization. In

the building materials industry, waste minimization principles can be applied to water,

cement, aggregates and all other inputs. Minimizing waste not only reduces the

environmental impact of the project but goes hand in hand with a profit maximization

strategy. The reuse of the waste material generated during the production process

reduces the production costs thus providing an added incentive to the producer to be

aware of the environmental impact of the project. The greater amounts of waste

generated the larger are the costs of production.

9.2 Waste streams will be generated namely from two major activities being

(1) the construction activities since another two additional structures have to

be built up in order to house one of the marble machines and also the

jaw crusher.

(2) the day to day operations of the marble cutting machines.

9.3 The waste streams can also be identified as aggregates and liquid wastes. These will

be generated and separated at different periods, depending on the operational stages

of the marble cutting process.

The Construction Phase 9.4 The initial works of the site will include excavation of sections of the site where the

additional reservoirs will be constructed. These will be excavated down to 4 metres

from the existing surface level. The excavation volume is estimated at 210 m3 It should

take approximately 3 weeks to complete using an excavator and a tipper truck.


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9.5 The inert waste which is generated from the site will be transported by trucks to the

appropriate designated landfill which is in operation during that period.

9.6 Following the first phase of the excavations for the reservoirs on site, the construction

activities will follow. This will consist of the building of the structures at the front and

rear of the site in order to house one of the marble cutting machine and also for the

crusher.

9.7 A number of construction related wastes will be generated from the facility during the

construction period. The likely generated wastes have been labelled below in

accordance with the European Waste Catalogue list of wastes.

Table 1 List of Construction Wastes which are likely to be generated from the Site

17 01 concrete, bricks, tiles and ceramics

17 01 01 Concrete 17 01 02 Bricks

17 01 03 tiles and ceramics

17 02 wood, glass and plastic 17 02 01 Wood 17 02 02 Glass

17 02 03 iron and steel

17 04 metals (including their alloys)

17 04 05 iron and steel

17 04 07 mixed metals

17 05 04 soil and stones other than those mentioned in 17 05 03

17 09 other construction and demolition waste

17 09 04 mixed construction and demolition wastes other than those mentioned in 17 09 01, 17 09 02 and 17 09 03

9.8 It is not foreseen that there will be the generation of hazardous wastes from the

construction and also the marble cutting processes.


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Marble cutting operational processes 9.9 The waste generated on site from these operation processes will include: (i) gravels,

broken slabs and chips (ii) slurry and sludge, (iii) plastic and wood (iv) municipal waste

from the office, and (v) sewage & grey water (from the toilets and showers).

Gravels, broken slabs and chips 9.10 Marble chips and aggregates will be generated from the cutting of marble slabs during

the day-to-day processes. It is being estimated that around 0.25 tonnes of marble

chippings will be generated on site daily. Thus there will be a weekly generation of

1.25 tonnes of wastes. Such quantities are not considered as wastes but are raw

materials to produce other building products, namely bricks.

Plastic & Wood 9.11 Packaging is one of the important processes in the production of marble products.

Finished tiles and slabs have to be adequately packaged so as to maintain the

durability and assuring the safe delivery of the product to the respective client.

9.12 Marble Slabs are inserted safely within wooden pallets with polished surfaces

separated by thick plastic so as to be scratch proof. Tiles are packed with plastic

sheets between their polished surfaces and thermocoal sheet cover in all six sides of

the wooden box, fixed and tightened by iron strips. Thus some waste arising from

packaging materials will also be generated from the plant. Such wastes are going to be

stored into a designated bin in order to be transported by a licensed operator to a

recycling facility.

Municipal waste 9.13 The Scheme will generate only a small amount of municipal waste, namely waste from

the office (estimated at around 1 bag per week) and from the canteen (estimated at

between 1 and 2 bags weekly). All municipal waste will be collected and temporarily

stored in an on-site skip, which will be taken to a licensed landfill or other appropriate


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facility once full. Where possible, separation of waste into different recyclable streams

will be attempted.

Grey and Sewage Effluent 9.14 Grey water and sewage effluent will be generated from the toilets and the showers. All

such effluents will be discharged directly to the main sewer which is connected directly

to the site.


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10.0 QUANTIFICATION OF SOLID WASTE FLOWS FROM THE PRODUCTION PROCESS

10.1 Wastes produced from marble cutting process can be categorized as either by-product

or waste, in all cases; the wastes disposal should follow specific regulations according

to type and quantity. It is foreseen that a number of solid wastes will be generated from

this industrial plant. The marble and granite chips will be the biggest waste by product

for such a production process.

Marble Chip Wastes 10.2 It is being estimated that around 1.25 tonnes of marble chips will be generated each

week. Thus this industrial plant will be generating 65 tonnes of marble and granite

chips on an annual basis.

10.3 This generation of marble chips is considered as a raw material for the production of

other by products which are going to be integrated in the existing processes which are

currently going within the plant.

Liquid Wastes 10.4 Large amounts of water shall be used for cooling, cutting, calibrating and polishing

machines. It is estimated that around 16 cubic meters of water per day will be used for

these processes. Such volumes of water will spill on to the concrete flooring to be

drained into the settling system which will be specifically constructed for this purpose.

This type of wastewater produced during the cutting process shall be collected and

diverted through special drains to this septic system, where solid fragments will be

removed by a mechanical system. Water can than be recycled in order to be used

again during the cutting process. The septic tank will be cleaned each week in order to


33

collect the generated marble slurry. Eventually such ‘wastes’ will also be used in the

brick making process.

Plastic and Wood 10.5 Plastic and wood are minor waste type produced from marble manufactures by which

they are used as complementary materials as holders or packing materials. Both of

two waste types will not exceed 200 kilogram’s per working year where they are sold to

companies who are involved in the recycling business.

10.6 These industrial and municipal related wastes which will be generated from the facility,

have been labelled below according to the European Waste Catalogue list of wastes

as listed in Table 2 below.

01 04 0801 03 08

03 03 09

10 13 14

11.1 Waste water treatment sludges

15 01 15 01 01 paper and cardboard packaging15 01 02 plastic packaging15 01 0315 01 04 metallic packaging15 01 05 composite packaging15 01 06 mixed packaging

20

20 01 separately collected fractions (except 15 01)20 01 01 paper and cardboard20 01 02 glass20 01 08 biodegradable kitchen and canteen waste20 01 25 edible oil and fat

Municipal wastes (Household waste and similar commercial, industrial and institutional wastes) including speparately collected fractions

wooden packaging

dusty and powdery wastes other than those mentioned in 01 03 07

waste concrete and concrete sludge

Table 2 List of Wastes which are likely to be generated from the Marble Cutting Process Industry

lime mud waste

packaging (including separately collected municipal packaging waste)

waste gravel and crushed rocks other than those mentioned in 01 04 07


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11.0 SOLID WASTE MANAGEMENT OF THE FACILITY

11.1 The management of this concrete brick plant will take all necessary steps to ensure

that the wastes generated are recycled through their use for other production

processes in the building materials industry. These type of wastes, namely the marble

chips and slurry can be used for the production of various products which can be used

in the construction industry.

11.2 An added benefit will be the reduction of dumping costs as well as the reduction of

CO2 emissions through reduced transportation of the marble by-products to the

dumping site and less transportation of hard stone aggregates from the quarry sites to

this industrial plant.

11.3 It being proposed that such ‘wastes’ will be reutilised in the production of concrete

brick and also manufacturing of a particular nature of tile products.

Utilization of Waste in Concrete Bricks 11.4 Concrete bricks can be the best application for marble and granite waste replacing the

conventional sand and aggregates. Normally, aggregates in concrete bricks are Lower

Coralline Limestone as the coarse aggregate, and sand as the fine component. These

can be replaced by marble and granite waste aggregates of different sizes with slurry

powder added. The mix utilizes marble and granite mixed pieces of various sizes:

coarse sand (A), fineness modulus (FM) of 4.596, fine sand (B), FM of 2.755, coarse

aggregate (C) of maximum nominal aggregate size of 12.5 mm and slurry powder. The

slurry powder which shall be collected from the sedimentary pits, has a very low grain

size (less than 70 micron) and high surface area can add cohesion to the bricks and

micro-filling ability.


35

11.5 Marble and granite slurry cement bricks yield similar mechanical criteria, in terms of

compressive strength, and physical, in terms of density and absorption, properties.

11.6 Recycling of such wastes as building materials appears to be a viable solution not only

to reduce pollution problems but also to the problem of economical design of buildings.

The increase in the popularity of using environmental friendly, low cost and durable

construction materials in the building industry have brought about the need to

investigate how this can be achieved to benefit the environment as well as to maintain

the material requirements affirmed in the standards.

11.7 Such actions are following the concept of Eco Gozo launched by Government in the

past years.

Production of Terrazzo 11.8 The management of this industrial plant is also considering that from the marble chip

wastes an artificial tile product known as Terrazzo can also be produced. Terrazzo is a

building material that has the cross-section of polished rock chips decorating its

appearance. It is a composite material made up of chips surrounded by a binder. It is

poured into precast shapes and can be used for floors or walls. It consists of marble,

quartz, granite or other suitable chips, sprinkled or unsprinkled, and poured with a

binder that is cement-like, chemical or a combination of both. Terrazzo is cured,

ground and polished to a smooth surface. Sometimes, it is finished to produce a

uniformly textured surface that is not flat.

Quantities 11.9 It is being estimated that 2m3 of marble slurry and 1.25 tonnes of marble chip wastes

will be generated from the marble cutting process at this industrial plant. However

none of these materials will end up in the waste stream since they shall be used for a

particular brick block making process. Thus these solid wastes will not be going out of

the facility since they are being considered as raw materials for other by products.


36

Solid Waste Movement within site 11.10 The material which will be crushed by the crusher will be transferred to the hopper

area via a small dumper truck. The distances between the crusher and the hopper are

so short that it is not expected that there will be any spillages of the material on to the

circulation area of the plant.


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12.0 LIQUID WASTE MANAGEMENT OF THE FACILITY

Waste Water

12.1 The management will be adopting a waste minimisation approach. The key to avoid

adverse impacts on water quality is to minimise wastewater generation and above all

to recycle the wastewater which is generated. In fact a waste water dedicated drainage

system is already present on site and an additional facility for the marble cutting

process will be provided for contaminated and clean storm water runoff.

12.2 Two reservoirs have already been constructed on the site as shown in the architectural

plans and are covered by permit PA 7952/06. All contaminated waste water is currently

collected in a 400 cubic meter reservoir. This water is also recycled since it is being

used as a raw material for the concrete mixture which is used for brick making. The

runoff water which comes from the roofs of the office building and the shed as well as

from the staff car park is being stored in the other reservoir as indicated on the plans

and is also used for the concrete manufacturing process.

12.4 Contaminated storm water and process wastewater are also being captured in a

specific reservoir which will have a sloping sieve filtration system; to separate water

and sediments. The sloping surface enables easy removal of sludge and sediments.

12.5 Wastewater stored in this specific reservoir will be reused at the earliest possible

opportunity. This will restore the system’s storage capacity, ready to deal with

wastewater generated by the next rainfall event or floor washing processes. The re-

usage of waste water will be gone for the following operations simultaneously.

• Drum and chute washing, and for slumping

• Plant and grounds wash-down and dust suppression

• Re –use for the manufacturing of the concrete products


38

12.6 The facility also has all the necessary infrastructure, i.e. double bottomed leak proof

cesspits to cater for these waste water flows. This is identified in the annexed

architectural plans.

Waste Water Collection

12.7 Grey water (sewerage) will be generated from the industrial plant ancillary facilities i.e.

bathrooms and showers. These facilities shall have a separate drainage connection to

the main sewer since the facility has a direct connection to the public sewerage

network.

Treatment and Disposal of Wash Water 12.8 Wash water which will be coming from the watering of the circular marble cutting

blades shall be collected via the floor drains which are directly connected to a

sedimentation reservoir which is to be constructed at the rear of the site as indicated

on plans.

12.9 This reservoir tank filtering system is the first step in the process of the marble sludge

conditioning, in a subsurface disposal system. This system will serve three functions:

1. Removal of solids. As the marble sludge enters the septic tank, its rate of flow

is reduced so that the larger solids sink to the bottom and sludge and smaller

solids rise to the surface. These solids are retained in the tank, and the clarified

effluent with suspended and dissolved solids is discharged.

2. Sludge and scum storage. Sludge is the accumulation of solids at the bottom

of the tank, while scum is a partially submerged mat of floating solids that may

form at or near the surface. Space must exist in the tank to store these residues

during the intervals between pumping. Otherwise, the sludge and scum will

eventually be scoured from the tank and will clog the leach field and the other

receiving reservoir tanks


39

3. Water will then be pumped out of the third reservoir in order to be re used for

the jet watering process during the marble cutting operations. It is important that

the water must be adequately filtered from the marble sludge residues since it

will damage the blades during the watering process.

12.10 It is being estimated that around 4 cubic meters of water are required on a daily basis

for the watering of the marble cutting blades, meaning 20 cubic meters per week.

Thus the new reservoir filtering system which is being proposed is adequate enough

for a month’s supply of water for these specific operations of marble cutting.


40

13.0 EMISSIONS FROM THE FACILITY

13.1 Fugitive dusts are the main environmental concern of marble cutting process. Dust

generation is normally associated with the cutting of the raw material, by which the

emission source originates from the marble processing operations. Dust emission to

the atmosphere from the marble cutting process can be drastically reduced by

implementing a wet medium cutting process. Such a technique controls dust

dispersion from this industrial plant to the extent that any emissions will be contained

within the site itself. Moreover, the marble machines will all be located under cover so

there will be no dust dispersion from these areas within the site itself.

13.2 A management strategy should be implemented to avoid the negative impacts of dust

contamination and to avoid the translocation of dust outside the plant. This can be

achieved by the installation of water sprinkling devices, and also the collection of

produced slurry from the cutting process directly to special tanks entered into the slurry

treatment and re-use process again.

13.3 Water spray systems remain the most efficient and cost effective means of dust control

for the control of dust emissions, the reason being that the dust remains at source

without being disturbed.

13.4 The applicant is also proposing to remove the aggregate open storage bins which were

approved in the previous permit PA 7952/06. In view of the current operations the

applicant has no need to store such a large quantity of materials on site. Raw materials

are transported to the site on the production day, and thus the space on site will be

used more efficiently. Such action will also reduce the possibility of dust dispersion

from the site.

13.5 The management of this plant shall apply all recommended measures in order to

minimize as far as possible the dust generated from this site. It is to be noted that the


41

site is situated approximately 5 meters below the current road levels due to the

topographical features in the area. Such a geographical position offers a degree of

protection for dust to be contained and controlled within the site.


42

14.0 WATER MANAGEMENT

14.1 The facility also caters for a planned water management system to handle clean rain

water. The water management system, which is being adopted, is adequate enough to

divert, collect and reuse or dispose of all the rain water received. Storm water

management has been designed to minimize the amount of contaminated water that

must be handled on site. It is critical to minimize the amount of rain or storm water

runoff that comes in contact with dust particles and other building materials, but since

the raw materials are being stored inside roof covered stores there will be no water

contamination. Still on site, there is a separate containment and diversion systems to

direct any runoff which might be contaminated with dust particles, into a recycling or

treatment system adopting the sedimentation tank storage methodology.

14.2 The roofs of the building structures on site have downspouts to channel the water into

the designated underground water reservoir which is already present on site. The

location of the receiving reservoir has been set up at the corner of the site near the

entrance gate as indicated on plans.

14.3 Due to the water requirements of the brick plant, the developer has catered for the

construction of an adequate water reservoir which shall meet the required demand. It

has been estimated that around 23 cubic meters of water are required on a weekly

basis for the production of bricks and also for the watering process of the marble

cutting plates. This means that the site must have a water storage capacity for at least

three months. At present the site has a total water storage capacity of 500 cubic

meters and another 200 cubic meter reservoir shall be added in view of the installation

of the marble cutting machines. Thus the site shall have a total water storage of 700

cubic meters, which means that it has an adequate supply of water for six months of

operations.


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15.0 POTENTIAL IMPACTS AND MITIGATION MEASURES

15.1 The potential impacts of the proposed development are illustrated in Table 3 below. No

impacts from the additional construction work which has to take place are envisaged.

Potential Impacts Description of Impact Impact Classification Mitigation Measures.

Visual impact

The site is part of an identified industrial area and is surrounded by other industrial units. Half of the perimeter of the site is surrounded by high walls due to topographical properties of the area. The installed marble equipment will be located within these perimeter walls and will be covered by adequate structures.

Minor Positive

Since the site is part of a industrial estate it is surrounded by other industrial units. However since it is visible from the road running along the southern perimeter wall an effective landscaping scheme can be introduced around the site perimeter in order to mitigate the visual impacts from the south area section of the site.

Impacts on ecology

The area is already committed for industrial operations. The area does not feature any ecological restrictions as outlined in the Gozo and Comino Local Plan.

None None deemed necessary.

Impacts on geologyNo impacts on geology are anticipated as only small ammount of excavation work needs to be done for the construction of the additional reservoirs.


Impacts on archaeology The area is devoid of any features of archaeological importance. None None deemed necessary.

Noise and vibration impacts

During the operational processes. However this will not present any particular impact over and above what is currently being generated in the area, and from the current operations which are currently ongoing in the area.

Minor negative

All staff is to utilise appropriate ear protection equipment where necessary during the operations which are taking place within the plant.

Impacts on air quality / dust generation

The nature of the proposed operations will generate a limited amount of dust during the excavation process. However dust dispersion will be controlled since the marble cutting machines will be adopting a water jet cutting process which does nor perimt dust emissions from such operations.

Minor negative

It is being proposed that dust dispersion will be adequatley controlled by the continuous spraying of water as necessary.

Artificial lighting arrangements

The proposed facility does not need to have exposed artificial lighting since all the operaions will be carried within the building.


Energy

The existing industrial facility has a direct connection to the main electrical supply in the area. However in the nearby future the management will be trying to take the opportunity to harvest solar energy to be use for the electrictiy reqirements of the facility

Positive None deemed necessary.

Recycling / Re use of Wastes

The facility will be designed to carry out the required recycling of different waste streams. Positive

By products will be producted from the wastes streams which will be generated on site. Thus no waste materials will be going out of the facility.

Table 3 Potential Impacts and required mitigation measures for the construction and operational impacts of the development

Job Creation The new industrial extension create another 2 job opportunities with the already existing ones. Positive None deemed necessary.


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16.0 CONCLUSIONS

16.1 The proposed installation of the marble cutting machines at the existing concrete brick

and tile manufacturing plant will be constructed in an industrial area as designated by

the Gozo and Comino Local Plan.

16.2 Such installation and operation of these machines are compatible with the present

operations of the concrete brick operating process. State of the art marble cutting

equipment will be installed so that it ensures that the best possible operational

practices currently operating in the market. The plant will have smooth operations and

will generate very minimal waste amounts, as specified in this report. Wastes

generated from such operational processes are going to be recycled and used for the

production of other by products.

16.3 Thus the set up of this equipment within the plant will be creating an opportunity not

only to create value added products but also the development of other by-products

which will be composed from the wastes generated from the other operational process

which are ongoing within the same plant.

16.4 The facility shall have a holistic waste management plan which is innovative since

there shall be the usage of waste by-products from the marble cutting process in order

to produce eco bricks and tiles without using the normal hard stone aggregate which is

a limited limestone resource in our islands.

16.5 However this proposed development comes with an environmental challenge to

address the dust emissions which will be originating from the plant. Mitigation

measures have been well addressed with minimal dust generation possible as

specified in this report and the site will not be a detriment to the surrounding

environment in the area.


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16.6 The construction phase of this project is anticipated to generate very little waste as

only the excavation of the additional reservoirs for the storage and water filtering of the

marble sludge which will be generated from the marble cutting equipment.

16.7 The operations and the precautions taken for this plant will ensure that no type of

hazardous or leaching waste will be generated from the site. A recycling process will

be adopted and the solid municipal wastes which will be generated will be disposed

accordingly adopting the recycling concept.

16.8 This industrial facility as shown in the architectural plans will also render it possible to

provide better and more appropriate conditions for the recycling of construction

material wastes whilst at the same time ensuring the elimination of the possible causes

of dust pollution from the plant.

16.9 Great care has been taken by the management of this plant to make sure that the

facility will compliment the standards established by the EU directives in this particular

sector.


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Annex 1


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Annex 2


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Documents

PROJECT DESCRIPTION STATEMENT Final