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By Javier Castaneda, Luis Zozaya, Noel Huarachi, María Rocha

The objective of the project was to implement and calibrate drill and blast models supported by Geotechnical and Geological models as well as the mine and operation characteristics. The models would then be migrated to HxGN Blast to ensure a productive process that is simplified, digitized and optimized.

Feb 1, 2020

By B. Corrêa, M. Cavalcante

A large open pit iron ore mine in Brazil, which has a heterogeneous lithology, faces a challenge in defining drill and blast patterns to achieve the expected results. The mine needed to obtain an automated representation of the fragmentation curves and correlate them to the respective blasts, lithologies and quality parameters, seeking the continuous optimization of the fragmentation process and its benefits to the subsequent comminution processes. Trials were carried out for 5 months to demonstrate the functionality of an autonomous fragmentation monitoring system that analyzes the granulometric curve of the material throughout the muckpile and makes the results available online and in real time. The system, which contains a binocular camera, a processing unit and an antenna, was installed in a shovel, to evaluate the following KPI's: monitoring failures, monitoring capacity, physical availability and reportability of oversized boulders. The system analyzed 33,060 samples, with an average capacity of 285 photos every 24 hours, 127 during the day and 158 at night, all measured, analyzed, stored, and made available on its online platform, reporting 223 alerts of P80 above 400mm (15.7 in) and 38 particle sizes above 900mm (35.4 in). The inactive and operational hours of the monitoring system corresponded, respectively, to the idle and worked hours of the shovel, according to dispatch data. There were no camera or processor failures, and rain, dust or poor internet conditions did not impact sampling and fragmentation analysis, indicating 100% physical availability of the system. The autonomous monitoring analyzed 139 times more samples compared to the currently used manual method. In addition to increasing sampling representativeness and automating the process, it increases the safety, quality, and productivity of granulometric analysis, eliminating the exposure of people in the mine and human bias in the analyses. Additional analyses were performed by correlating digitally centralized drill and blast data, data from autonomous drills and fragmentation results. Automated obtention of granulometric curves favors quick decision-making and optimization of blasts to achieve better results in productivity and cost reduction in the plant and mine operation. The autonomous fragmentation monitoring system met the need presented by the mine, proving to be a key tool in continuous improvement projects, including Mine to Plant.

Jan 1, 2024

By Evan Smart, Andrew Palangio, David Klingspor, Blessing Taiwo

This study presents a DMAIC-based approach to optimize blasting performance and achieve crusher-compatible fragmentation at the Walker-Severn Quarry in Ontario, Canada. By applying the Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) framework, the study aims to enhance the integration between blasting and primary crushing operations. Several representative blasts will be simulated and evaluated using both aerial and terrestrial image analysis technologies to assess fragmentation characteristics. The investigation was guided by quarry-specific Key Performance Indicators (KPIs), ensuring that blast design modifications were both practical and operationally relevant. Through structured analysis and data-driven refinement of blast parameters, the study reveals how this framework was used to address the quarry production demand for increased crusher throughput, and reduced processing costs. The existing quarry blast design was assessed as a baseline and compared against the crusher's inlet requirements and the acceptable fines level specified by the quarry. This evaluation aimed to identify and implement modifications to enhance blast performance. A drone (UAV) was employed to capture post-blast images and monitor blast pile displacement. These UAV images were used to generate an orthomosaic image, which was analyzed to assess fragmentation. The orthomosaic was overlaid onto a GIS platform using a 10m-by-10m grid to evaluate fragmentation distribution across the bench and identify areas requiring optimization. Additionally, drone imagery was utilized to monitor the impact of each blast on the subsequent blast's free face and to assess energy utilization for optimizing front-row holes to achieve improved fragmentation. The outcomes of this research offer a replicable methodology for continuous improvement in quarry blasting practices, with a focus on producing fragmentation that aligns with primary crusher requirements.

Jan 26, 2026

By Virgil J. Stachura, Calvin L. Cumerlato

The U. S. Bureau of Mines is conducting research on blasting methods that reduce highwall overbreak and the associated rockfall hazards. This paper presents the results of tests using a low-density water gel to improve the quality of air-decked presplit blasts at a surface coal mine in New Mexico. The explosive's specific gravity averaged 0.50 and was bulk loaded using a modified truck which injected the gassing agent. Reductions in overbreak and resulting rockfall were achieved in comparison to a highwall presplit with ANFO. The test sections used 15° angled blast holes and resulted in 1,119 m (3,672 ft) of air deck presplit highwall using a low-density water gel which was then compared to 894 m (2,934 ft) of highwall shot with an ANFO air decked presplit design. The total quantity of explosives per hole ranged from 68 to 113 kg (150 to 250 lbs) and the 27 cm (10-5/8in) holes were 19- to 33-m (62- to 108-ft) deep on 5.5 m (18-ft) centers. Periodic visual examination and photographic surveys of the highwall test areas were used to document the amount of rockfall. In addition, laser profiles of selected sections were conducted to further delineate the damage and highwall contour differences.

Jan 1, 1995

By Seokbin Lim

According to published literature, the equation of motion of linear shaped charges (LSCs) has been investigated as early as the 1960s in a few research organizations. However, due to the comparatively low penetration performance, the amount of research has not been extensive, and the use of this device is quite limited in very specialized applications. Traditionally, the equation of motion of an LSCs’ liner shares the same basis as conical shaped charges (CSCs) because they are under the same functional category and generally have similar geometric configuration. However, the nature of LSCs is not quite similar with that of CSCs due to multiple reasons, and they required a new set of equations to properly address their performance. In this paper, we reviewed different sets of approaches in describing the liner collapse behavior of LSCs mostly based on the author’s contributions.

Jan 1, 2014

By Armin Iravani, Changping Yi, Matthias Wimmer, Daniel Johansson, Santiago Gómez, Håkan Schunnesson

Sublevel caving (SLC) is a mass mining method based upon the utilization of gravity flow of blasted ore and caved waste rock. Drilling and blasting are the initial and the major impact on primary fragmentation and later material flow characteristics. The heterogeneity of rock mass has a great impact on materials’ mechanical properties and plays a significant role in rock fragmentation by blasting. In this work, a numerical model for sublevel caving based on 3D Voronoi tessellations was developed to section rock mass into arbitrarily shaped regions for modelling the heterogeneous rock mass. A coupled finite element and discrete element method was employed to investigate both the fragmentation due to blasting and the gravity flow of ore in a heterogeneous orebody. In the coupled model, the caved waste rock was modelled with loose discrete particles while the orebody to be blasted was simulated with bonded particles. The detonation of explosives was described with a particle blast method and a finite element model was used to model the remaining orebody. The results indicated that the fragmentation at the upper part of the ring is coarse while it is fine at the lower part of the ring. The heterogeneity of rock mass induced some boulders after blasting.

Feb 6, 2023

By K. Hausmann, P. A. Sashin, G. J. Prejean

Misfires caused by unreliable shock tube constructions can have significant cost implications and place field workers at serious risk during remediation. Ionomer materials, used as a subtube in shock tube constructions, provide superior hot tack strength, oil resistance, impact resistance at cold temperatures and excellent thermoformability properties. These are important features for resisting blast-throughs and ensuring blasting reliability in demanding environments, such as open pit mining in harsh environments. Superior hot tack strength, strain hardening, and excellent thermoformability properties of the ionomer materials ensure uniform powder distribution along the shock tube during construction and avoid undesired powder accumulation due to deformation or vibration during use. Oil or chemical resistance is another feature of Ionomers. This allows improved property retention in contact with oils and hence longer sleep times of the shock tube. Another feature of these highly engineered ionomers is superior impact strength at low temperatures. This plays an important role considering the resistance to fly rock impact in open pit mining operations in particular in cold climates.

Jan 1, 2011

By R. Ranjan

Stanstead granite has been investigated with respect to its dynamic compressive strength and its strain-rate dependency. A standard Split-Hopkinson Pressure Bar (SHPB) apparatus has been employed to generate strain rates of up to ~500/s through high-velocity impact. The diameters of the test samples were 19 mm, and tested under impact velocities up to ~20m/s. It is found that even within this limited range of strain rates, the dynamic compressive strength for the granite showed nearly a 100% increase in value compared to those obtained under static loading conditions (e.g. compressive strength of 394 MPa at a strain-rate of 600/s, compared to 215 MPa obtained under static loading). The details of the test are described in terms of incident, reflected and transmitted stress pulses, along with means to achieve stress equilibrium in the test samples under dynamic loading conditions. The advantage and drawback of the use of ‘pulse shaping’ techniques to achieve dynamic stress equilibrium are also detailed.

Jan 1, 2010

By Carlos Campos Junior, Leonardo Soares Chaves, Raul Carretero Hoz, Renato Jacome Costa, Davi Bastos Martins de Oliveira

The Vale’s Serra Sul mine, also known as S11D project, is one of the world’s largest open pit iron ore mines, located in Brazil’s Amazon region. The mine produces around 90 Mt of high-quality iron ore annually. Its unique orebody enabled the S11D project to adopt a truckless mining system with In-Pit Crushing and Conveying (IPCCs) for ore exploitation and waste stripping. The IPCCs system requires crushing the waste, mainly composed by the jaspilite lithology, and is also conveyed to waste deposits several kilometers away from the mine. Due to Amazon’s environmental restrictions, the project was designed with preliminary geological knowledge, leading to the installation of primary crushers not designed for the hardest jaspilite, with uniaxial compressive strength (UCS) up to 500 MPa. This resulted in low waste crushing performance, affecting stripping ratio and threatening future production. A project was developed to improve the fragmentation of the jaspilite, allowing higher waste IPCC production, and reducing the risk to the production due to low performance of waste crushing and conveying. The first challenge was the independence of the geological and the geomechanical models, while only the geological model was considered in blast designs, the geomechanical model describes six waste groups of jaspilite classified according to their strength. A new geological model was then created to incorporate the geomechanical classification, allowing different blasting design according to the rock strength of the jaspilite. The blasting pattern on most compact jaspilite was reduced 27%, from 22m² to 16m² in 9 7/8” diameter holes, with a proposed theoretical reduction of 23% of the P80, from 326mm to 250mm. The second challenge was the implementation of the new design, as this pattern size and the high powder factor (2.9 kg/m3) were paradigms for such a large iron ore mine. The measured results have shown 25% reduction of the P80, the crushing rate was increased by 17% (230t/h), saving around $2.4 million annually in crushing and conveying system maintenance.

Jan 21, 2025

By M. Szumny, P. Mertuszka, K. Fuławka

Multi-face destress blasting is the basic method of reducing rock bursts hazard in Polish copper mines. Blasting operations of this type are carried out regularly, twice a day in order to minimize the geomechanical threat while maintaining high extraction efficiency. Unfortunately, the assessment of the effectiveness of this type of work until recently was based solely on determining whether a given destress blasting triggered a seismic tremor or not. Information on the characteristics of seismic waves generated by blasting has so far been omitted in analyzes of this type. The lack of reliable knowledge about the generated seismic effect makes the introduction of constructive corrective actions impossible, which in turn significantly reduces the triggering potential of conducted destress blasting. This study presents the results of comprehensive work aimed at increasing the effectiveness of active rock burst prevention in Lubin underground copper mine. For this purpose, an innovative system for continuous monitoring of seismic waves induced by multi-face blasting was developed, and a new method for seismic assessment of the effectiveness of the destress activities was developed. Based on the monitoring data and the comprehensive analysis of waveforms, the effectiveness of individual blasting operations was determined, and on this basis, modifications to the drilling and blasting patterns aimed at increasing the generated seismic effect were proposed. The use of innovative methods of monitoring and data analysis made it possible to increase the effectiveness of the conducted activities, in terms of the magnitude of seismic vibrations, up to 250%. It should be emphasized that the introduced modifications were aimed at increasing the effectiveness of blasting operations while maintaining the current level of costs. As a result, the proposed solution turned out to be highly effective, significantly affecting the safety of the work carried out in Polish copper mines. Thus the proposed approach is planned to be implemented in other Polish copper mines belonging to KGHM in the near future

Jan 1, 2024

By J Silva Castro, Braden Lusk

Information management is important in all disciplines. In mining; collection and analysis of information before, during and even after mining is a keystone to performance. During mining, information is useful to optimize the resources and make appropriate decisions. Current technologies allow for collecting information in real time. Records of blasting activity at the mine are common practice in surface coal mining operations. The most common blast information recorded contains the location of the blast, scaled distance, geometry of the blast, weight of explosive used and quantity of blasted rock. Sometimes due to the proximity of protected structures, seismograph evidence of the particle velocity and airblast levels is required. However, in the majority of cases, the seismograph information is not linked to the blast information. Blast related information is recorded separately from the seismograph information and seismograms are little more than an attachment to the blast record. This fact makes simultaneous visualization and analysis of the technical details of the blast with the vibration and airblast information difficult.

Jan 1, 2012

By Tassilo Baur

In the motion picture/television industry and to some extent in the entertainment industries in general, there is often a need to use energetic materials to create special effects as part of a production which travels, generally by truck. This can in certain instances create unique compliance challenges given that a production may change its filming location daily or even more often

Jan 1, 2009

By Bonifacio Digay

Stawell Gold Mines (SGM) is an underground mining operation located in Victoria, Australia.The mining method employed is long hole retreat stoping, utilising up and downholes and artificial concrete pillars. Stawell is currently mining the Golden Gift and Magdala orebodies.

Jan 1, 2012

By Ray Jambakhsh, John Okell, Frank Cook

"In early 1988, an experimental study was carried out at the Inco's McCreedy West Mine inLevack, Ontario. The objective was to develop blasting techniques which would allow themine to maintain production targets and reduce blast induced vibrations and overpressure.Due to its close proximity to the town of Levack (approximately 900 feet), particularconcern was expressed as to the vibration and overpressure resulting from the undergroundblasting operations."

Jan 1, 1993

By Rob Farnfield, Mark Pegden

Old Cliffe Hill quarry produces between 4 and 5 million tonnes of crushed granite per year and is located in the county of Leicestershire in the East Midlands region of England. Blasting is carried out with bulk emulsion explosives in combination with either shock-tube or electronic detonators.

Jan 1, 2010

By Robert Jacob Cefalo

In 2019, the Bingham Canyon Mine, owned by Rio Tinto Kennecott Utah Copper Company, mined through the active underground that dewaters the pit. The active underground required the limitation of vibrations to avoid catastrophic damage or damage that would require work to the shotcrete and additional roof support. The surface design of the current sector was mined next to and through portions of the active underground.

Feb 1, 2020

The quiet banks of the Maumee River in Toledo, Ohio, received a wake-up call July 16 as two smokestacks in the Marina District were leveled with dynamite. B&B Wrecking, Inc. of Cleveland contracted the project with the city to bring down the twin stacks, both measuring over 250 feet tall. The structures were part of the Toledo Edison Steam Plant and were erected nearly a hundred years ago. A week’s worth of preparation went into final planning, drilling and loading holes with over 80 pounds of explosives. The felling went precisely as planned as onlookers cheered as the stacks were reduced to rubble.

Jan 1, 2015

By Dal Sun Kim, Michael K. McCarter

"Comminution (crushing and grinding) of rock materials is energy-intensive and expensive. Mucheffort has been directed to improve the efficiency of conventional milling practice, but relatively littleattention has been given to the potential benefits of blast-induced damage on comminution processes. To help assess this effect, research has been conducted at the IRECO Laboratory and the Generic Center for Comminution at the University of Utah. The objective of this research is to investigate the effect of shockinduced “crack-like” damage on rock properties and subsequent breakage efficiency for three petrologically different rock materials under laboratory conditions. In order to evaluate the effect of shockinduced damage, a quantitative measure of rock damage is needed. For this purpose, a scalar variable (0) is proposed."

Jan 1, 1993

By Ruilin Yan, Kameron Ray

This paper reports a simple approach to model the waveform change due to travel distances based on the field measurement. A linear interpolation is used to estimate the waveform at a distance from two vibration waveforms recorded at two different distances. The resulted waveforms are compared with actual recorded waveforms at the point in both time and frequency domains. It shows that the proposed method to estimate the waveform change yield reliable results. The advantages of the proposed method are that it does not require assumptions that a transfer function does and that it is based on purely the measured waveforms that are encoded with in-situ rock properties. The method could be more reliable for far field seismic waveforms and could be an approximation for near field waveform estimation.

Jan 1, 2014

By Benjamin Cebrian

The new technology presented in this paper is a patented system that is installed on board excavators (backhoe or front shovel types). Several control points are set along ore/waste contacts and their position is uploaded on the corresponding shovel. The operator proceeds on mucking until he is alerted when reaching any of the several control points previously located in the blast patterns and that have moved with the muckpile. A case study is presented at a high grade copper mine, were unique 3D shapes are showing as a result of using an on-board excavator dilution control system. Both ore-loss or dilution cost of opportunities are analyzed.

Feb 1, 2020