QUARRY DESIGN HANDBOOK

2014

CONTENTS

A QUARRY DESIGN HANDBOOK

CONTENTS
INTRODUCTION TO THE HANDBOOK AND FOREWORD
INTRODUCTION AND ACKNOWLEDGEMENTS
THE NEED FOR QUARRY DESIGN ...................................................................... 2
THE PURPOSE OF THE HANDBOOK .................................................................. 3
STRUCTURE AND CONTENTS ............................................................................ 3
HANDBOOK AT A GLANCE .................................................................................. 4
FURTHER INTRODUCTORY MATERIALS ........................................................... 5

PART I

THE CONTEXT FOR QUARRY

DESIGN

CHAPTER 1

UNDERSTANDING THE PLANNING AND

LICENSING PROCESS

1.1

The role of Government, Authorities and Statutory Consultees .............. 1-3

1.2

The relevant Acts of Parliament and other Mineral/Planning

Legislation ............................................................................................... 1-4

1.3

Government Planning, Mineral and other Policy Guidance ..................... 1-4

1.4

The roles and responsibilities of competent and qualified

persons ................................................................................................... 1-4

1.5

The role of the Regional or sub-Regional local authorities...................... 1-4

1.6

The existence of any national or regional zoning relating to or

restricting mineral extraction ................................................................... 1-4

1.7

The Application process including forms, costs and

authorisations ......................................................................................... 1-5

1.8

The environmental assessment rules, regulations and process

including screening and scoping ............................................................. 1-5

1.9

Any required stakeholder consultation process ...................................... 1-5

1.10

The determination process and timescales ............................................. 1-5

1.11

Any Appeal process ................................................................................ 1-5

1.12

Any Conditions, Agreements and Obligations ......................................... 1-5

1.13

Any Licence, Permit and regulatory compliance ..................................... 1-5

1.14

Any Enforcement regime ........................................................................ 1-6

Contents

QUARRY DESIGN HANDBOOK

2014

CHAPTER 2

CONTENTS

PRIMARY INFORMATION REQUIREMENTS

2.1

THE NEED FOR PRIMARY INFORMATION .......................................... 2-2

2.2

MINIMUM LAND REQUIREMENTS ....................................................... 2-2

2.3

LEGAL .................................................................................................... 2-3

2.4

PLANNING ............................................................................................. 2-3

2.5

SITE ........................................................................................................ 2-4

2.6

ENVIRONMENTAL ................................................................................. 2-5

2.7

SAFETY .................................................................................................. 2-6

2.8

COMMERCIAL/FINANCIAL .................................................................... 2-6

CHAPTER 3

SITE SELECTION

3.1

DEMAND/NEED ..................................................................................... 3-3

3.2

NEW SITES/EXTENSIONS .................................................................... 3-3

3.3

INVESTIGATIONS & ASSESSMENTS ................................................... 3-3

3.4

CONSIDERATION OF ALTERNATIVES ................................................ 3-4

3.5

COMPANY STRATEGY ......................................................................... 3-4

3.6

QUARRY DESIGN PROCESS ............................................................... 3-4

PART II

THE QUARRY DESIGN PROCESS

CHAPTER 4

DESIGN OF THE OPERATION AND ITS

RESTORATION

4.1

INTRODUCTION .................................................................................... 4-3

4.2
4.2.1
4.2.2
4.2.3
4.2.4

ESTABLISHING THE DESIGN BRIEF (design stage i) .......................... 4-6

Objectives ............................................................................................... 4-6
Technical requirements .......................................................................... 4-7
Information requirements ........................................................................ 4-8
Deliverables ............................................................................................ 4-8

4.3

CONCEPTUAL DESIGN, OPTION SELECTION AND FEASIBILITY

STUDY (design stage ii) ........................................................................ 4-9
Objectives ............................................................................................... 4-9
Design requirements ............................................................................. 4-10
Information requirements ...................................................................... 4-11
Deliverables .......................................................................................... 4-11

4.3.1
4.3.2
4.3.3
4.3.4
4.4
4.4.1
4.4.2
4.4.3
4.4.4

DESIGN OF THE FINAL VOID AND RESTORATION SCHEME (design

stage iii) ............................................................................................... 4-13
Objectives ............................................................................................. 4-13
Design requirements ............................................................................. 4-13
Information requirements ...................................................................... 4-13
Deliverables .......................................................................................... 4-14

QUARRY DESIGN HANDBOOK

2014

CONTENTS

4.5
4.5.1
4.5.2
4.5.3
4.5.4

DESIGN OF PHASED WORKING AND RESTORATION

SCHEME (design stage iv) .................................................................. 4-17
Objectives ............................................................................................. 4-17
Design requirements ............................................................................. 4-17
Information requirements ...................................................................... 4-17
Deliverables .......................................................................................... 4-18

4.6
4.6.1
4.6.2
4.6.3
4.6.4

PRE-PRODUCTION REQUIREMENTS (design phase vi) .................. 4-21

Objectives ............................................................................................. 4-21
Design requirements ............................................................................. 4-21
Information requirements ...................................................................... 4-22
Deliverables .......................................................................................... 4-22

CHAPTER 5

INFORMATION REQUIREMENTS AND

INVESTIGATIONS

5.1

INFORMATION TO SUPPORT ESTABLISHMENT OF THE

BRIEF ..................................................................................................... 5-4

5.2

SITE PLAN ............................................................................................. 5-5

Why?....................................................................................................... 5-5
What & How? .......................................................................................... 5-5
Who? ...................................................................................................... 5-6
Input into the design process .................................................................. 5-6
Design of the operation and its restoration, and environmental
assessment ......................................................................................................... 5-6
Safety .................................................................................................................. 5-7
Costs and benefits............................................................................................... 5-7

5.3

GEOLOGY .............................................................................................. 5-7

Why?....................................................................................................... 5-7
What & How? .......................................................................................... 5-8
Desk Study .......................................................................................................... 5-8
Design and notification of site Investigation ........................................................ 5-8
Investigation ........................................................................................................ 5-9
Reporting to support quarry design ..................................................................... 5-9

Who? ...................................................................................................... 5-9

Input into the design process ................................................................ 5-10
Design of the operation and its restoration, and environmental
assessment ....................................................................................................... 5-10
Safety ................................................................................................................ 5-11
Costs and benefits............................................................................................. 5-11

5.4

SURFACE WATER ............................................................................... 5-11

Why?..................................................................................................... 5-11
What & How? ........................................................................................ 5-12
Background desk study ..................................................................................... 5-12
Site investigations ............................................................................................. 5-13
Analysis and consultations ................................................................................ 5-13

Who? .................................................................................................... 5-13

Input into the design process ................................................................ 5-13
Design of the operation and its restoration and environmental
assessment ....................................................................................................... 5-13
Safety ................................................................................................................ 5-13
Costs and benefits............................................................................................. 5-13

Contents

QUARRY DESIGN HANDBOOK

2014

5.5

CONTENTS

GROUNDWATER ................................................................................. 5-14

Why?..................................................................................................... 5-14
What & How? ........................................................................................ 5-14
Desk study. ........................................................................................................ 5-14
Baseline investigations ..................................................................................... 5-15
Conceptual modelling ........................................................................................ 5-15
Further site investigations ................................................................................. 5-16

Who? .................................................................................................... 5-16

Input into the design process ................................................................ 5-16
Design of the operation and its restoration, and environmental
assessment ....................................................................................................... 5-16
Safety ................................................................................................................ 5-16
Costs and benefits............................................................................................. 5-26

5.6

LANDSCAPE AND VISUAL .................................................................. 5-17

Why?..................................................................................................... 5-17
What & How? ........................................................................................ 5-17
Background desk study ..................................................................................... 5-17
Site visits and investigations ............................................................................. 5-18

Who? .................................................................................................... 5-18

Input into the design process ................................................................ 5-18
Design of the operation and its restoration, and environmental
assessment ....................................................................................................... 5-18
Costs and benefits............................................................................................. 5-19

5.7

NOISE, DUST AND VIBRATION .......................................................... 5-19

Why?..................................................................................................... 5-19
What & How? ........................................................................................ 5-19
Background desk study ..................................................................................... 5-19
Site visits and investigations ............................................................................. 5-20

Who? .................................................................................................... 5-20

Input into the design process ................................................................ 5-20
Design of the operation and its restoration, and environmental
assessment ....................................................................................................... 5-20
Safety ................................................................................................................ 5-20
Costs and benefits............................................................................................. 5-21

5.8

TRAFFIC ............................................................................................... 5-21

Why?..................................................................................................... 5-21
What & How? ........................................................................................ 5-21
Background desk study ..................................................................................... 5-21
Site/surrounding investigation ........................................................................... 5-22

Who? .................................................................................................... 5-22

Input into the design process ................................................................ 5-22
Design of the operation and its restoration, and environmental
assessment ....................................................................................................... 5-22
Safety ................................................................................................................ 5-22
Costs and benefits............................................................................................. 5-22

5.9

ECOLOGY ............................................................................................ 5-23

Why?..................................................................................................... 5-23
What & How? ........................................................................................ 5-23
Background desk study ..................................................................................... 5-23
Site visits and investigations ............................................................................. 5-23

Who? .................................................................................................... 5-23

Input into the design process ................................................................ 5-24

QUARRY DESIGN HANDBOOK

2014

CONTENTS

Design of the operation and its restoration, and environmental

assessment ....................................................................................................... 5-24
Costs and benefits............................................................................................. 5-24

5.10

GEOCONSERVATION ......................................................................... 5-24

Why?..................................................................................................... 5-24
What & How? ........................................................................................ 5-25
Who? .................................................................................................... 5-25
Input into the design process ................................................................ 5-25
Environmental assessment ............................................................................... 5-26
Safety ................................................................................................................ 5-26
Costs and benefits............................................................................................. 5-26

5.11

ARCHAEOLOGY/CULTURAL HERITAGE ........................................... 5-26

Why?..................................................................................................... 5-26
What & How? ........................................................................................ 5-26
Background desk study ..................................................................................... 5-27
Site visits and investigations ............................................................................. 5-27

Who? .................................................................................................... 5-27

Input into the design process ................................................................ 5-27
Design of the operation and its restoration, and environmental
assessment ....................................................................................................... 5-27
Costs and benefits............................................................................................. 5-28

CHAPTER 6

DESIGN RISK ASSESSMENT

6.1
6.1.1
6.1.2
6.1.3

INTRODUCTION .................................................................................... 6-2

Elements of design risk assessment ....................................................... 6-2
Key terms ................................................................................................ 6-3
Environmental, operational and commercial risks ................................... 6-5

6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5

RISK ASSESSMENT .............................................................................. 6-6

Description of action ............................................................................... 6-7
Hazard identification ............................................................................... 6-7
Identification of consequences ................................................................ 6-9
Estimation of the magnitude of consequences ....................................... 6-9
Magnitude of consequences ................................................................. 6-10
Magnitude of environmental consequences ..................................................... 6-10
Magnitude of operational consequences .......................................................... 6-10
Magnitude of commercial consequences .......................................................... 6-12

6.2.6
6.2.7
6.2.8
6.2.9
6.2.10

Estimation of the probability of consequences ...................................... 6-13

Risk estimation...................................................................................... 6-13
Risk evaluation...................................................................................... 6-14
Risk perception ..................................................................................... 6-15
Reviewing the process .......................................................................... 6-16

6.3

DEVELOPMENT AND MAINTENANCE OF A RISK REGISTER ......... 6-17

Contents

QUARRY DESIGN HANDBOOK

2014

PART III

DELIVERING SUCCESSFUL
QUARRY DESIGN

CHAPTER 7

CONSULTATION AND COMMUNICATION

7.1
7.1.1

CONTENTS

CONSULTATION .................................................................................... 7-2

Stakeholder groups ................................................................................. 7-2
Local, Regional and National Government ......................................................... 7-2
Statutory Consultees ........................................................................................... 7-3
Non statutory consultees ..................................................................................... 7-4
Public consultees ................................................................................................ 7-5

7.1.2

Existing methods of public Consultation in the quarrying

industry ................................................................................................... 7-5
One to one meetings ........................................................................................... 7-6
Liaison groups: .................................................................................................... 7-6
Public exhibitions: ................................................................................................ 7-6
Quarry open days: ............................................................................................... 7-7
Public meetings: .................................................................................................. 7-7

7.1.3
7.1.4
7.1.5
7.1.4

Mineral Planning application decisions and public consultation .............. 7-8

Stakeholder workshops ........................................................................... 7-8
Issues and Concerns of Stakeholders .................................................... 7-8
Successful consultation and engagement in the Quarry Design
process ................................................................................................... 7-9

7.2
7.2.1

COMMUNICATION ............................................................................... 7-10

Graphic Communication ....................................................................... 7-10
Graphical visualisation techniques .................................................................... 7-11
Spatial and Geographic Information Systems (SIS & GIS) ............................... 7-12

7.2.2
7.2.3

Written Communication ......................................................................... 7-12

Verbal communication .......................................................................... 7-13

CHAPTER 8

MANAGING THE QUARRY DESIGN PROCESS

8.1

INTRODUCTION .................................................................................... 8-2

8.2
8.2.1
8.2.2
8.2.3
8.2.4
8.2.5
8.2.6
8.2.7
8.2.8

PROJECT MANAGEMENT .................................................................... 8-2

Scope management ................................................................................ 8-3
Time management .................................................................................. 8-3
Cost resource management .................................................................... 8-3
Quality management ............................................................................... 8-4
Human resources management .............................................................. 8-4
Communications management ............................................................... 8-5
Risk Management ................................................................................... 8-5
Procurement management ..................................................................... 8-6

8.3
8.3.1
8.3.2
8.3.3
8.3.4
8.3.5
8.3.6
8.3.7

SYSTEMS MANAGEMENT .................................................................... 8-6

Administration ......................................................................................... 8-6
Data Storage and retrieval ...................................................................... 8-7
Information Technology (IT) .................................................................... 8-7
Health & Safety ....................................................................................... 8-7
Operational management system ........................................................... 8-8
Quality management system .................................................................. 8-8
Environmental management systems ..................................................... 8-8

QUARRY DESIGN HANDBOOK

2014

CONTENTS

PART IV

APPENDICES SUPPORTING
CHAPTERS 1 AND 4

APPENDIX 1-1

THE PLANNING AND LICENSING PROCESS ENGLAND

APPENDIX 4-1

RESOURCE EVALUATION FOR AGGREGATES

APPENDIX 4-2

PRINCIPLES OF DESIGN FOR SAND AND GRAVEL

QUARRIES

APPENDIX 4-3

PRINCIPLES OF DESIGN FOR HARD ROCK QUARRIES

APPENDIX 4-4

QUARRY SLOPE DESIGN

APPENDIX 4-5

HAULAGE METHODS AND HAUL ROAD DESIGN

APPENDIX 4-6

ECONOMIC MODELLING FOR FEASIBILITY STUDIES AND

BUSINESS PLANNING

PART V

BIBLIOGRAPHY

Contents