EXECUTIVE SUMMARY

The objective of this study is to provide an overview of the new aggregate plant at Shumaisi
site, between Makah and Jeddah. Although, aggregates are relatively inexpensive at its
source, the cost of transportation is often the major factor in determining the competitive cost
to the consumer. The absence of natural aggregate at cost-effective transportation distances
has prompted extensive use of manufactured aggregates. The extensive use of manufactured
aggregates has required proper modification of characterization, design and construction
practices. In addition, it has motivated studies to reduce energy consumption, to attain
optimal crusher design and operation, and to minimize waste. Crushing operations can
accommodate some adjustment to match the demand for each gradation.

Capital lay out cost SR 15,000,000

daily production(m3) 3000
working days(per year) 300

per m3 per day per year

Cost of
Production SR 14.35 SR 43,050.00 SR 12,915,000

Selling Price SR 20.00 SR 60,000.00 SR 18,000,000

Net Profit SR 5.65 SR 16,950.00 SR 5,085,000

1. Industry Overview

Aggregate is the chief raw material used in Portland cement concrete and asphalt, which are
universally used for construction and road paving purposes.These basic resources are
essential for building roads, houses, schools and hospitals. Aggregate has an amazing variety
of uses. More than 95 percent of asphalt pavement and more than 80 percent of a concrete
sidewalk is aggregate.

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 2. Site Selection

There are three major considerations that are a prerequisite to opening a new aggregate plant:

1) Supply and demand in the local market area.

Daily an average of 18000 tons per day (11000 tons plus 7200 tons from johrana study)
Is being supplied in local Makah market.

Local demand and daily productions at johrana aggregate plants

Sr. No Company /Owner Daily Production Remarks

(tons)
1. Musaad Almatrafy - Plant in erection stage
2. Masood Al Lakhyani 1200
3. Jamhaan Al Lakhyani 1200
4. Mohajer Al Khaleeg Co. 900
5. Rio Company - Don,t sell material
6. Mohammad Abdul Rehman Al 1800
Sewan
7. Bin Zohefa Co. 1200
8. Saudi Crushing Co. 2400
9. Al Jazeera Co. - Don,t sell material
10. Artec Co. - Don,t sell material
11. Arrfa Co. - Don,t sell material
12. Khuddrey - Don,t sell material
13. Wahda Al Antajeen - Plant is stopped
14. Al Gharmol - Don,t sell material
15. Al Martan 1200
16. Mansoor Sawadi 1200

Total daily production 11100 tons 6*1200=7200

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 2) The type of deposit to be mined and the processes required to mine it.

In makah we have only granitic deposits and for large scale production we have to install
fixed plant.

3) Obtaining the permits necessary to operate the site.

Permit for Shumaisi area is already in process and Eng. Abdul Manheim is working for it.
Meanwhile sami rock is looking to occupy another area near Shumaisi outside Makahas
soon as govt. starts licensing that area.

3. Plant Design
There are many plant-engineering options to consider, when setting up an aggregates plant
from scratch. Using quality components from the start often prevents problems later.eg
market review.
Market review
To see what the potential market is. Some of the pieces of information from the market
review are as follows:

Information Market review

1 How much of each product can be sold. 100 %
2 Total product specifications. 1/2”,1/4”,3/4”,3/8”
3 Are all sales by customer truck, or should both
delivery services be offered?
4 Selling price for all products. 20 to 26 SR/m3
5 Competition in the market area. In Shumaisi area Samirock
plant will be the 2nd one.
Mineral characteristics

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The mineral characteristics also play an important part in the decision as to whether or not
the property is suited for aggregate production. The mineral characteristics will have to be
analyzed to determine whether we can produce the materials our market review calls for.
These characteristics also help to define the type of processing equipment that can be used.
Some of the material characteristics we checked for making the proper decisions are listed
below:

Material name. Rhyolite

Material source (quarry or gravel pit). quarry
Bulk density +/- 1.6----1.8
tons/m3
Specific Gravity. 2.77
Aggregate abrasive value +/- 6----10
Absorbtion 0.8%
Hardness. 6---7
Compressive strength. 150----250 N/mm2
Chemical composition used to determine abrasiveness of average
material (requires at least the following: Silica, iron oxide,
aluminum and magnesium oxide.)
Percent clay, dirt, etc. average
Moisture. 0.8%
Feed material top size. 1000mm
Feed material size distribution. 10%>900mm

Type of plant
The type of plant selected will generally depend on how long the reserves will last. Sami
rock is suggesting for stationary plant.

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Stationary plant: This type of plant is generally associated with quarried materials where
the expected life of the quarry is more than 10 years. Some of the characteristics of this type
of plant are as follows:
• Requires substantial civil work.
• Primary surge pile.
• Bins feeding crushers.
• Large stockpiles.
• Complete plant automation.
• Large clearances around equipment for servicing.
• Truck and loadout systems.
• Concrete and steel structures.
• Stationary conveyors.
Other things using jaw crusher as follows:
• Ease of replacing wear members.
• Ease of setting adjustment to both compensate for wear and also product requirements.
• Good production rate.
• Easy Serviceability.
• Easy Parts availability.
• Ease of operation.

Process flow
The process flow is one of the most important parts in defining how your new aggregate
plant is going to operate to make the required products as economically as possible.
Along with selection of the proper crusher, the proper screens and feeders need to be made.
Some of the information required to select the proper screen or feeder are listed below:
• feed size.

• Feed gradation.
• TPH.

Process flow diagram of Shamaisi aggregate plant

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 The process flow starts with the plant feed material and ends when all of the products
have been produced.
Plant layout
At this stage following factors would be considered .
• surge-pile capacities
• stockpile capacities
• minimum clearances under conveyors
• minimum clearances around crushers and screens
• and how stockpiles are going to be maintained
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 4. Computers/Automation

In the past, aggregates plants were mechanical in nature, with plant operations such as crushing,
screening and conveying functioning separately and manually. Over the past two decades,
however, automation has provided a 2 to 10 time increase in productivity in many different
aspects of an aggregate plant's operations. But one thing is certain: the process of making little
rocks out of big ones has not changed. Automation and computer technology have simply
provided the industry with the high-tech tools needed to make greater productivity possible. So
the plant will be equipped with high level of latest instruments.

5. Drilling & BLASTING

Drilling is one of the critical elements in the drilling and blasting process. The drilling phase is
the most expensive in the drilling and blasting portion of production, requiring a sizable
investment and upkeep. The impact of improper drilling can be felt throughout the remainder of
the production cycle, such as excavating and hauling, crushing, screening and so on.
For maximum success it is essential that the mine or quarry carefully design its blasts to achieve
the desired fragmentation results. These designs must be accurately implemented in the field.
The blasts must be shot in a safe manner, with the area properly barricaded and all persons
removed a safe distance away. Environmental affects such as ground vibration, airblast and fume
production must also be controlled.

Basis for drilling & blasting

a) Daily Production = 3000 M3
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b) Bench Height = 12m
c) Dia Of Hole = 76mm

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 DAILYDRILLINGCALCULATIONS

daily production = 3,000 m3

Item Value units Calculation/explanation

volume 3,000 m3
spacing 4 m
burden 3 m
Dia of hole 76 mm
production/LM 12 m3
Total drilling LM 250 m
drill rig capacity 150 m
total no of drills 2 no,s
average depth of hole 12 m
total no of holes 21 no,s
total no of holes/blast 200 no,s
quantity produced/blast 26,400 m3

EXPLOSIVECALCULATION

Item Value units Calculation

base charge 3.7 kg
base charge length 1.1 m
coulmn charge length 8.9 m
coulmn charge wt./m 3.65 kgs
coulmn charge wt. 32 kgs
tot. wt. of exp/hole 36 kgs
production/hole 132 m3
specific charge 0.274129 kgs/m3

kemulux/m3 0.0280303
ANFO/m3 0.2460985
total kemulux 84.090909 kgs
total ANFO 738.30 kgs

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 DRILLING BLASTING COST CALCULATION

S.N ITEM UNITS NO OF UNITS S.R /UNIT COST (SR)

1 kemulux kgs 84 18 SR 1,512
2 ANFO m 738 10 SR 7,383
3 SANEL no,s 21 15 SR 315
4 EL. Det DEMS no,s 5 10 SR 50

total explosive cost SR 9,260

Blasting services/ m3 SR 0.20

services cost SR 600
total blasting cost SR 9,860
cost /m3 SR 3.29

drilling cost/m SR 10.00

production/lm 11 m3
drilling cost/m3 SR 0.91
total drilling +blasting cost SR 4.20

6. Loading/Excavating/hauling

Front-end loaders or hydraulic excavators will be used to scoop blasted material from the
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quarry face and transfer it to a haul truck to begin the processing sequence. Excavators can
further be used to pull loosely defined material directly from the quarry face.Dozers D-9
will assist the the loading process.

HEAVYEQUIPMENTS

no of units

Dailyproduction(M3) 3,000 m3

Daily daily
Required Capacity/trip working production production
# Equipment production or Bucket hours (m3/hour) (m3)

1 Dozer D9 3000 NA 10 150 1500

2 Loader Cat 966 3000 3m3 10 150 1500

3 Breaker 220 NA NA NA NA NA

4 Dumper(28t) 3000 10 10 70 700

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 cost calculations

Dailyproduction (M3) 3000

Working
hours@ Total
SR. No,sof Prod/hour 10 producti total
NO Equipment units Cost/Hr (M3) hrs/day on cost (SR) Cost/m3
1 DOZER D9 2.0 300 150 10 3,000 SR 6,000 SR 2.00
2 LOADER 966 2.0 100 150 10 3,000 SR 2,000 SR 0.67
3 Breaker 220 2.0 90 20 10 200 SR 1,800 SR 9.00
4 DUMPER (28t) 4.3 100 70 10 3,000 SR 4,286 SR 1.43

total SR 14,086
cost/m3=
SR4.70

Manpower cost

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 daily production(m3) 3000

SR.NO Catagory units Cost/Hr total hours total cost

1 Manager 1 55 10 550
2 Engineers 1 30 10 300
3 Supervisers 2 25 10 500
4 Operators 8 20 10 1,600
5 Survey staff 2 20 10 400
6 Helpers 3 10 10 300

Total 17 160 3,650

cost/m3= SR 1.22

7. Crushing

a) Primary crushing

Crushing shall be done with jaw crusher primarily and then followed by the con crusher for
secondary crushing.

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 Primary jaw crusher

The factors considered in the selection of a primary jaw crusher are:

TYPE
PE1200×1500

type Material inlet size (mm）

1200×1500

Max material size(mm)

1020
Material outlet size (mm)
150-300
capacity (t/h)
400-800
Eccentric shaft size (r/min)
180
Motor power (kw)
160
weight (t)
100.9
Overall size（l×w×h）(mm)
4200×3300×350
0

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 b) Secondary crushing
Cone crusher will be used for secondary crushing

Secondary cone crusher

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The factors considered in the selection of a secondary cone crusher are:
a) Type PYB 1750
b) Max. input (mm) 215
c) Adjusting range of output (mm) 25-50
d) capacity (t/h) 280-480
e) Electric motor power (kw) 160
f) weight (T) 50.3
g) Overall dimensions (LWH)(mm) 4870*3800*4192

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 Crusher cost

# Item Calculation Value Units Rate: $/hr Notes

1 Expected life 20 yrs
2 Expected utilization 3000 hrs per yr
3 Age when sold 60000 hours
4 Purchase price $4,000,000
5 Estimated residual value $600,000 15%
6 Depreciation (4-5)/1 $170,000 per year
7 Rate to cover 6/2 $56.67
depreciation
8 Basis for annual insurrance AAV $2,385,000
9 annual insurrance rate 2 %per year
10 annual insurrance cost 8x9 $47,700 per year
11 rate to cover insurrance 10/2 $15.90
12 annuall cost for zakat $100,000 per year 2.5%
13 Rate to cover other 12/2 $33.33
owning
14 TOTAL OWNING COST 7+11+13 $105.90

15 Fuel cost $0.27 per gal

16 Fuel factor 1.7 This factor covers the
cost of fuel and daily
oil and lubrication
17 Fuel consumption 80 gal per hour Look to your records
18 Rate to cover fuel 15x16x17 $36.18
19 Wear parts $300,000 per set
20 Factor on cost 1.02 hours Covers the cost of
routine welding etc
21 Expected life 1800 Look to your records
22 Rate to cover wear parts 19x20/21 $170.00
23 Track chain $0 1 set
25 Expected life 0 Look to your records
26 Rate to cover tracks 23x24/25 $0.00
27 Cost of a PM service $2,000 The average cost of labor
and supplies for PM
28 PM service interval 250 Fixed
29 Rate to cover PM 27/28 $8.00
30 Lifetime expected $1,200,000 20%
repair costs
31 Rate to cover repairs 30/3 $20.00

32 TOTAL OPERATING COST

18+22+26+29+31 $234.18

33 TOTAL OWNING AND 14+32 $340.08

OPERATING COST

$340.08 1275.285 SR

cost/m3 = SR 1.65
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 Summery of all costs

SR. ITEMS
NO Amountunits

1 Heavy duty Equipments 4.70 S.R

2 drilling blasting 4.20 S.R
3 Crusher cost 1.65 S.R
4 Manpower 1.22 S.R
5 Miscellaneous cost 0.32 S.R
6 Overheads @10% 2.26 S.R
7 profit @ 20% 4.96 S.R

Total 19.31 S.R

8. Secondary Breaking

Hydraulic breakers will be used for secondary breaking, where breakers will be tasked to
reduce a pile of oversized boulders or even tackle primary breaking responsibilities.

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 9. Plant layout
We have planned a proper plant layout keeping in view following concept.
a) With a minimum of difficult turning angles, which are always subject to plugging and
blockages.
b) All crushers and screens will be visible from operator-control area.

10.Screen plants:
The screen will be hydraulically raised inclined screens as it is more benicial than horizantel
screen.
Also Twin screen plants will be used due to their ability to pre-screen material before the
secondary crushing stage and allow more complete screening at the finished stage.
Many of the new material specifications can be met only with the use of two screens.

11. Product conveyors:

Radial-stacking conveyors, in lengths of 125 ft. and longer will be used instead of free
standing conveyors which will allow the operator to put up large quantities of material at
relatively little cost.
Because of their length, most stacking conveyors will have to be folded for travel. Hydraulic
folding and lifting will allow the operator to self-erect with no chance of damage.

Conclusions

This study provided an overview of the potential export market for Samirock aggregates and
as a result offers several conclusions for consideration.

Many areas near Makkah Jeddah have abundant aggregate resources, however the
constraining factors influencing development is location, quality, quantity and regulatory
processes.
Although the presence of a high-quality quarry aggregate deposit in Shumaisi is a necessary
condition for development, it is by no means a sufficient condition.

There are many obstacles to overcome relating to marketing, distribution and access into the
highly competitive Saudi market.

The long-term trend is that aggregate prices are steadily increasing, reflecting land
ownership restrictions, high costs and difficulties in obtaining regulatory approvals. These
are factors that increase transportation distances, which in turn drives up the costs of
delivered aggregate.

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