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By Ery Wardhana, Fathur Rozaq, Jeff Averett, Nella Lubis, Carl Lager, Herry Saputra, Rudolf Sitorus, Relinda Sanistrya, Hormat Sinaga, Andhiko Maharjono

Efficient drill and blast operations are crucial for achieving optimal fragmentation, productivity, safety, and operational efficiency for the mining industry. However, conventional methods face significant challenges, including manual borehole marking and retrieval by survey teams, limited real-time data monitoring, excessive borehole collar deviation affecting blast quality, suboptimal drill productivity impacting person-hours and fuel usage, subjective judgment by drill operators on voids during drilling, and limitations in explosive charging design that do not match rock hardness. Rock hardness determination using lithological data from exploration models is often inaccurate due to the interpolation effect of wide drilling distances and depths, necessitating manual field verification using drill cuttings and historical blasting results. Furthermore, using single-density bulk emulsion throughout blast holes leads to suboptimal results due to varying rock properties. This study introduces an integrated approach that combines smart drilling technology with advanced emulsion technology to enhance drilling and blasting efficiency. The method utilizes smart drilling technology with GPS for precise borehole placement, Measure While Drilling (MWD) loggers, and real-time performance monitoring. Additionally, it integrates a smart Mobile Processing Unit (MPU) featuring a digital system and an automated gassing system (AGS). This setup allows for multiple emulsion densities within a single blast hole, customized to match the hardness index parameters determined from MWD data, addressing the challenges in drilling and blasting operations. The study evaluates the effectiveness of this innovative approach through comprehensive field trials and data analysis. While maintaining the digging rate according to production targets, key metrics such as drilling productivity, drilling accuracy, fuel consumption, powder factor, drilling and blasting cost, and fragmentation size were compared between conventional and new methods. Results showed a 56% increase in drilling accuracy, a 23% increase in penetration rate, a 19.6% increase in drilling productivity, and a 29% reduction in fuel consumption. This new method decreased the powder factor by 5.2%, impacting the drill & blast cost reduction by 2.3%. Moreover, fragmentation size improved by 12.8%, demonstrating the effectiveness of rock hardness-adjustable emulsion density in achieving better blast energy placement. In conclusion, integrating smart drilling and advanced emulsion technology significantly enhances drilling and blasting efficiency. This approach offers substantial cost savings and operational improvements, providing a strong rationale for adopting this innovative method in drilling and blasting activities.

Jan 21, 2025

By Thomas E. Ricketts

Occidental Oil Shale, Inc. constructed two commercial-sized modified in situ (MIS) retorts, Retorts 7 and 8, at its Logan Wash Oil Shale Mine in February and April 1981, respectively. One of the primary objectives of this two-retort program was to examine large-scale blasting reproducibility for commercial-sized retorts. The blast design used 545 blastholes and 550,000 pounds of explosive in ANFO equivalent per retort. Each retort was blasted using millisecond delay blasting caps tied into a single round. The blasts resulted in rubble beds very close to one another and to predicted results obtained using newly developed limited void blasting technology. The heights of the remaining void rooms over the beds after blasting were within 0.3 feet of one another. This excellent reproducibility is brought into true perspective when compared to the scale of the rubble beds which were 230 feet high with volumes of over six million cubic feet each.

Jan 1, 1984

By ISEE

Micrometer Crack Response to Vibration and Weather, by Prof. Charles H. Dowding of Northwestern University, adds to Prof. Dowding’s already important contributions to the industry with his “Construction Vibrations” books. This new book reports and interprets important data on crack response that are essential for differentiating the unseen effect of weather on structural cracking from the usually much smaller effect of vibration. In addition, the book contains detailed descriptions of data collection methodology.

Jan 1, 2010

By Ron Woolf, Corry Goumans

With increasing traffic volumes experienced thro u g hout North America, a common goal for Highway officials is to keep traffic flowing as much as possible and to keep disruptions to the flow to a minimum. Our experience throughout the US and Canada has shown that all Departments of Transportation are under extreme pressure from the private sector to keep highways open for various reasons, convenience and revenue being the most common. For example, on Highway 99, from Vancouver, BC to the Whistler resort area, local merchants, homeowners and ski hill operators exert extreme pressure on the Ministry of Transportation to keep the highway open, and in Pennsylvania, the Turnpike Commission requires traffic to flow on a continual basis. Loss of revenue in these two cases is the main impetus to keep the traffic moving.

Jan 1, 2003

Hello, everyone. Way back in 1965, Devine and others at the US Bureau of Mines showed that a presplit fracture plane did not affect vibration levels transmitted across the plane (RI 6695).

Jan 1, 2010

By S. S. Bud Jenkins

I went to an underground limestone mine recently to demonstrate the use of borehole liners. The liners were for horizontal holes in a normal “V” cut tunnel round. I hadn’t been in this mine for about 40 years. What a change. Way back they used cap and fuse and lit each fuse individually with a blowtorch. The face was about 40 feet wide and 14 to 16 feet high. They used ladders to get to the upper holes. The rounds were mostly slab rounds. I never saw this happen but had heard several times that the first holes were going off before the last holes were lit. I guess if this was true the use of slab rounds was a plus for safety. As far as I know they never had an accident but it was a scary procedure. There were a lot of scary procedures in the past and thankfully things have changed.

Jan 1, 2010

By Joshua Hoffman, Philip Mulligan, Braden Lusk, Tristan Worsey

Blasters rely upon detonators to achieve the designed timing sequence to move material where it needs to go, minimize vibration, or optimize fragmentation. At times detonator inventory on seldom used delays may be slow moving. This can lead to detonators being used long after they were manufactured. This paper addresses the potential shelf life concern as it relates to timing accuracy of shock tube detonators. A recent study was conducted to study the timing accuracy of non electric shock tube detonator systems. A follow up study was then conducted to determine the degradation of the non electric shock tube systems accuracy with time. The follow up study is presented in this paper. Samples of detonators from the initial study were set aside for approximately one year and then tested. The results from the aged detonators were compared to those of the detonators that were tested in the original study. As an extreme case a third set of shock tube detonators was tested using detonators that were between eight and nine years old. The results from these tests are presented as well. Each system was tested at a short medium and long delay time. Statistical analysis was conducted to determine the effect of time on the detonators accuracy. This paper quantifies the importance of regular inventory cycling to help preserve manufactured timing when using non electric shock tube detonator systems.

Jan 1, 2013

By Ian Bell, Saman Nouranian, Shahram Tafazoli, Bahram Sameti, Mahdi Ramezani

"Image-based rock fragmentation sensing in mining and quarry applications includes an important rock boundary delineation step, which is commonly referred to as rock segmentation. This paper presents a novel approach to solve this problem, using artificial intelligence. In the proposed technique, priorknowledge of previously analyzed images is encoded into mathematical/statistical models. A set of human labeled images are used as training inputs. These images are used to train neural networksthrough an optimization process. The networks can then be used in real time for rock delineation. "

Jan 1, 2017

By M. Ganster

Austria’s biggest supplier of oil and gas, transports gas through the West Austria Gasline for domestic consumption. In addition, the OMV also works as gas carrier and ensures the transit into neighbouring countries.

Jan 1, 2010

By Kia Riihioja, Mike Higgins

A major difference between electronic and pyrotechnic detonators is that, in almost all but the simplest of blast layouts, computer software is required to plan a blast using electronic detonators. While it may be possible to program delay times without software, using only the manufacturer’s control hardware, the full potential of electronic detonators can only be realized through software. Until recently, the only software available has been provided by the suppliers of the electronic detonators. These usually have just enough features to create a hole layout and to assign times to the detonators in the holes. The software is also able to communicate only with the manufacturer’s detonators. This means that the client may be compelled to change several parts of the blasting process when a different delay system is adopted, from design through to implementation and reporting, even though these may be sub-optimal at the client’s mine. While many authors have demonstrated improvements in blasting outcomes using electronic detonators, very few have discussed how the delay times were calculated. Where the calculations are discussed, it is also obvious that the delay times must be monitored and re-evaluated as conditions in the mine change. For example, the principles of superposition and scaled distance, burden relief and energy cooperation between holes should be checked constantly for different locations within the mine, changes in rock properties, or even for differences between design and actual hole positions. The most common methods in blast design software to calculate delay times are inter-hole interval, relief contour and direct editing. Although they are simple in concept, they can result in fundamental errors if they are not applied correctly. The software for electronic blast designs should be capable of not just a timing calculation, but also of showing, to some degree, the impact and interaction of the calculated times.

Jan 1, 2004

By Jorge Cárdenas, José Luis Hurtado

The critical distance determination test through direct recording for the mine in Phase 03 was carried out in January 2024, and in it the vibration and pressure models were obtained for the Sedimentary breccia unit. The method of obtaining the records is based on the capture of individual pressure waves generated by distant loads, sequenced in periods of 600 ms for easy identification. The test set up corresponds to a variation of that used to obtain the vibration model, and uses 08 wells for loads and 04 for instrumentation. The results apply a safety factor of 1.2 and 1.5, being 16,000 PSI and 13,250 PSI respectively. The values are valid for any distance greater than 5.5 m, this being the minimum established between wells for loads according to the configuration defined in the field, also considering that in 5.0 m of instrumentation the section of the drill hole with the sensor called S1 collapsed. The results of the analysis of the test, generated with Heavy Anfo 82 explosive, with a final density of 1.15 g/cc, are presented. The results of the modeling and generation of the graphs and tables presented show behavior in line with the concept of scaled distance. It is important to consider that in water conditions there is a high impact by the condition, which causes the records to be higher than those expected in dry conditions and present less variability. It is for the above reason that the row corresponding to distance with safety factor 1.5 is declared valid. The results are only valid for the rock analyzed, whose medium is homogeneous and constant in terms of lithological composition and that present similar resistance characteristics, fracture frequency and water table levels. As future steps, the objective is to quantify the increase in pressure generated between wells by analyzing time and sequence factors. This analysis aims to explain the occurrence of dynamic pressure events in areas where critical safety distances are observed.

Jan 21, 2025

By John Atkinson, Steve Repola

This paper will describe two blasting plans that have been developed for American Aggregates' Marble Cliff Quarry located near Columbus, Ohio. Two different limestone formations are mined on different levels of the quarry. Each formation requires a different blasting plan which address vibration considerations, crusher productivity, drilling and blasting costs and adjacent neighborhood concerns. Controlled blasting is critical to continued mining operations in this Midwest urban setting.

Jan 1, 1993

By Randy Wheeler

In recent years the issue of seismograph calibration and accuracy has been a major focal point of the ISEE Blast Vibration and Seismograph Section. In fact, questions concerning the consistency and reliability of seismograph measurements essentially led to the development of this ISEE section. One of the early actions of the section involved the development of “Field Practice Guidelines” for the use of seismographs. These guidelines specifically state that “Placement and coupling of the vibration sensor are the two most important factors to ensure accurate ground vibration recordings.” This paper will address the results obtained from using different coupling methods to record vibration and airblast levels generated from production blasting in a limestone quarry. The data obtained clearly indicate that seismometer burial provides the best coupling for recording ground vibrations. Microphone height has also been an issue regarding the accuracy of recorded airblast levels. The data we obtained indicates that microphone height is not a significant factor.

Jan 1, 2004

By Gungor Tuncer, Ali Kahriman, Abdulkadir Karadogan

In the bench blasting, the realisation of an economic, and safe blasting is only possible with a reliable blasting design on condition that considering all sequential activities such as drillingblasting, excavation-loading, haulage, crushing (especially primer crushing). Here what we mean with a good, and reliable design is that ensures an almost displaced, adequately swelled muckpile with desired fragmentation degree for the loaders effectivity, and succesive usage. Meanwhile it must also has no environmental problems such as ground vibration, air blast, and rock flyings, or at least these matters have to be minimised. Two main parameters which have generally being questioned to achieve a safe and economic design on any rock conditions, are specific charge, and burden. In the condition of determining these elements, the other blasting parameters could be calculated according to them, and the blasting design could be completed. Within the scope of this study, it was aimed to determine the optimal blasting conditions of gypsum which is major rock unit of overburden at Sivas Celestine open pit mine. First of all, the engineering (mass, and material) and digging difficulty classifications of gypsum were done according to the current classification systems by using the results of field and laboratory studies. Then the blasting system which was being used on all rock units, was considered, and the necessary data were obtained. After previewing the site properties, predesigns were done, and applied by adopting Langefors design model. The necessary adjustments were done before, during, and after the shots, and the applications were observed. In order to determine, and record the data from each shots properly, a practical form was developed, and all data were transfered to these forms which give information about the blasting results such as muckpile displacement, and height, average particle size, back break, and rock fly existence, number of boulders etc. The blasting parameters such as burden, hole diameter, hole inclination, the amount and position of primers, bench height, delay sequence, and blasting geometry were considered for the iteration of each shots. During the applications, ANFO, gelatine dynamite, and electric delay detonators were used as explosives.

Jan 1, 2004

By Tapas Kumar Mukherjee, Sujit Kumar, Sanjay Kumar Singh

This paper dwells on the epic blast conducted at Tata Steel’s captive coal mine in India and the insights drawn from it. Optimal blast design parameters had to be ascertained for operating benches (6.56 yards (6 meters) to 16.40 yards (15 meters)) where shovels and mining pay-loaders are deployed. Better fragmentation and suitable muck profile with controlled vibration levels were the pre-requisites. The landmark blast was carried out at Quarry-AB, West Bokaro on 17th March 2017. The colossal blast was done with 275 US ton (250 tonnes) of explosives poured down 1074 drill holes of 6.5 inch (165 mm) diameter. This blast is unique from the perspective of vibration control as it was conducted near local villages situated beyond 546 yards (500 meters) but within 601 yards (550 meters)) from the blast site. The entire array of preparatory activities had been successfully and impeccably executed within the same day. The optimization was achieved through meticulous coordination between TSL team, M/s Solar and M/s IEL. When a rock is blasted, numerous interactions occur among granular particles which are impacted by rock mass properties, explosives properties, blasting geometry and the detonation timings. Optimized use of resources requires a better understanding of these interactions. Extensive field studies have shown that blast fragmentation and suitable muck profile influences the performance of downstream processes in a mine. Consequently, profitability of whole mining operation can be greatly improved through optimized fragmentation. For arriving at the best blast geometry, several blasts were conducted with differing ‘burden and spacing’ design and charging pattern at various loading benches of the mine. Eventually, the largest ever blast was successfully carried out. This accomplishment is the culmination of the insights derived, confidence built, and expertise evolved through a progression of larger blasts conducted earlier (202 US tons (184 tonnes) and 143 US tons (130 tonnes) respectively) by the same team. All blast parameters were within the recommended level and no adverse impact on nearby structures was evidenced. In-the hole VOD of different explosives was determined and placement of boosters was standardized. The signature blasts were conducted to optimize the delay interval between the holes in a row and between the rows. Blasting parameters were fine-tuned in alignment with the desired fragmentation level and muck pile profile conducive to smooth and expeditious loading and hauling by mining HEMM. Rock fragmentation analyses were carried out using photo-analysis system. The insights gained from this blast would serve as the cynosure for planning and carrying out more such blasts with highly optimized parameters in the future with the intent of improving mining efficiency and productivity

Jan 1, 2019

By Mick Lownds, Ruilin Yang

The potential advantages of electronic detonators with accurate timing have been increasingly recognized by the blasting community. However, in comparative blasts the results with pyrotechnic timing are sometimes comparable to those from electronic timing. Statistical variation in blast results is a plausible cause of these observations.

Jan 1, 2011

By Barbara Rutter, Shonn Kevin McNeil

"This study discusses how a prototype was built to measure the sonic velocity in powdered explosives.The sonic velocity of an explosive is a benchmark to determine if the explosive deflagrates or detonates;however, little work has been done to determine this value for powdered explosives. This paperdiscusses the results of the initial prototyping tests where two known mediums, air and water, were used for validation. The prototype did record the sonic velocity within the known velocity ranges of air and water; however, a few depths did not fall into this range. This prototype could be used for testinggranular materials."

Jan 1, 2017

By Thomas Pallua, William C. Gates

"Two major railroad companies have identified several segments along the railroad corridor betweenTehachapi and Bakersfield, Kern County in California that require construction of a second track to improve operations in this area. The total project proposes an upgrade of five segments along the Tehachapi-Bakersfield route. The authors focused on two segments: Walong to Marcel and Cliff Siding Extension. The second track project comprised design of a through-cut adjacent to an existing tunnel and up to 120-feet-high (36m) side-hill cuts (both in granitic rock). The authors characterized the geologic ground conditions and ground behavior, including rock mass quality and strength using a combination of rock core drilling and rock slope mapping. The rock mass is generally characterized as granitic tonalite with strong core stones surrounded by a matrix of decomposed granite (DG)."

Jan 1, 2017

By Ali Kahriman, Olivio Angelini, Ibrahim Sefer, Burak Ekmen, Koray Arpak, Ertugrul Kaya, Yucel Karakus, Abdullah Sak, Aziz Ozdemir

In recent years, in order to bring solution to traffic intensity arising from transportation problems and facilitate public transportation in the modern world in paralel to urbanization and to the increase in population, it’s well known that, the construction of Access tunnels is inevitable. The driving of the tunnels is a subject of special interest in the technique of rock blasting. The essential factors in terms of tunnel driving and safety in tunnel blasting that is applied in metropolitan areas, an in depth knowledge of ground vibrations and the ways of reducing them to safer levels.

Jan 1, 2010

By Cesar Guerra, Alejandro Rojas, Dr. Jhon Silva, Luis Velasquez

The ANN method is applied to predict the P_80 size in one open pit gold mine in Peru. The ANN was implemented in Matlab programming language, and the results from the ANN are compared with data obtained using photo-fragmentation analysis software.

Feb 1, 2020