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By R. J. Cefalo

Blast and mining spillover between phases or critical areas of the pit is a continuing problem in the mining industry and a safety concern for operating mines. The challenge for many mines is to produce the highest value in the shortest amount of time for any project. For any project, the top priority of any mine is producing ore as fast as possible. The next challenge is to keep that ore feed continuous. To achieve continuous ore feed, pits are designed with multiple phases that are connected and are mined at different elevations. This difference in elevation causes dangers with spillover between the phases during mining, drilling, and blasting. This paper covers an incident that occurred at an active mine and the work completed in creating a spillover control program over an active mining phase. The drill and blast technical group was responsible for creating blast patterns to reduce spillover between these phases. Unrealistic goals and expectations were initially set for the area of the pit. The drill and blast technical group needed to figure blast objectives and work with the geotechnical team to align with these goals. This paper will go over the executed example of setting up spillover targets and expectations for multiple sections of an operating mine. Different sections of the pit had different control measures and blast objectives due to narrow laybacks and double benching. The use and value of blast objectives and goals were beneficial in setting expectations and measuring design success. Having unrealistic blast goals can set up the operations to fail or get frustrated in trying to work on an impossible task. The problems and risks of phase interactions for many open pit operations need to be considered in the design process, along with designed controls that minimize the probability of any safety incident. Mine designs are being created in the industry and do not consider phase-to-phase mining interaction and the impact it would have on safety or production. The best future for safer mines is blast patterns that reduce spillover between phases of mining and pit designs that might account for spillover interaction.

Jan 1, 2024

By Michael Wieland

The work principle from thermodynamics is used to model the shock and heave for explosives shot in rock or under water, with the latter compared to reported results. The work principle utilizes restrictions and constraints to yield a representative fit to the irreversible (natural) shooting process. The reduction of the internal energy of the reaction-zone yields the total expansion work (TXW), the resultant sum of the rock/water shock and heave. The restoration technique of forming a closed thermodynamic loop yields the reversible mechanical work (RMW) or the rock/water heave. The residual work that remains when RMW is subtracted from TXW yields the irreversible disorder work (IDW) or the un-dissipated (without loss) shock in the surrounding rock or water. The work principle renders an unequivocal relationship for the shock-loss factor, rather than the traditional roundabout formula for correcting the underwater gauge-shock of un-modeled explosives. There’s a novel heave-ratio factor that unquestionably rates the fit of results under comparison. Rock-shots are more complex in nature than underwater shots due to rock fracture and stratum rupture, though numerical resolution is worthwhile. The proposed rock-water-jelly (RWJ) model yields rough estimates, with rock-type results not wholly different from their underwater counterparts. Though reported underwater shots reveal shock and heave trends with respect to charge formulation ingredients, there are no such rock-shot results for comparison, since the relevant test measurements in rock remain difficult, if not intractable.

Jan 1, 2007

By Roger E. Scholl

Data on off-site low-rise building damage from underground nuclear testing at the Nevada Test Site (NTS) of the United States Atomic Energy Commission (AEC) [The AEC has been called the United States Energy Research ant Development Administration (ERDA) since 1975, but because the data presented here were gathered between 1966 and 1970, the AEC rather than ERDA is referred to in this paper.] are available for seven large tests in the period from 1966 to 1970. The data, while sparse, provide an adequate sample for the investigation of motion-damage relationships. Damage in the study is statistically described in terms of the incidence of damage complaints, the incidence of buildings damaged, and damage cost. Using 5%damped response spectrum acceleration amplitude to characterize ground motion, the plotted data fit reasonably well with previous motion-damage relationships established from extensive data available from the 1969 RULISON underground nuclear explosion (UNE) experiment conducted in western Colorado.

Jan 1, 1976

By Jung-Hoon Ryu, Chang-Ha Ryu, Byung Hee Choi, Yang-Kyun Kim

Control of overbreak in tunnel blasting is one of the key factors affecting the construction expenses as well as safety. Overbreak causes an increase in the cost of construction by requiring an additional amount of shotcrete. In addition, blast damage to the final rock face may cause instability and rock fall hazards. For these reasons, controlled blasting is an indispensable routine in tunnel excavation in order to get a smooth face and to reduce damage to the final wall. We have experienced a very poor quality of excavation depending on the tunneling sites although a similar design of controlled blasting technique was applied. Field experiments over 40 rounds were carried out to investigate the cause of the poor results in tunnel blasting. In this paper, discussed are the parameters affecting the overbreak and some findings from the field experiments. Overbreak could be controlled considerably by adjusting some parameters before the efforts of developing a new blasting method.

Jan 1, 2004

By John C. Brulia

PowerAN is a tradename of Atlas Powder Company for a new line of explosive products comprising blends of emulsion and ANFO in a variety of bulk and packaged grades. The bulk PowerAN grades are either augered or pumped depending upon emulsion content. Augered PowerAN blends contain up to 60% emulsion. Pumped PowerAN grades have an emulsion content of 75% or higher. The blending of PowerAN is usually accomplished at the borehole to satisfy specific borehole conditions. Packaged PowerAN grades are produced in several types of mix plants in diameters of 4" and greater. PowerAN 300 (30% emulsion) and PowerAN 500 (50% emulsion) are the two most popular grades and their chief application is as an economical, high energy replacement for ANFO HD in wet holes. PowerAN combines the cost effectiveness of ANFO with the high performance of emulsions, permitting the blasting engineer to strike an optimum balance between drill pattern expansion and increased productivity according to need.

Jan 1, 1985

By John S. Manka

Of the various methods used to reduce the density of emulsion explosives prior to detonation; ammonium nitrate prill addition, glass micro-balloon addition and chemical gassing, chemical gassing is the method most often selected by emulsion explosive end users. Chemically gassing emulsions costs less than adding micro-balloons and chemically gassed emulsions have better water resistance than emulsions that add ammonium nitrate prills to reduce the bulk density. Unfortunately, the chemical gassing of emulsion explosives can be intricate and is often more art than a science. To gain a better understanding of chemical gassing, we investigated the factors that may affect the chemical gassing of emulsion explosives. Variables investigated as having an effect on gassing were the pH of the oxidizer phase, the amount and type of nitrogen in the emulsifier, the composition of the oxidizer phase, the use of pH buffers in the oxidizer phase, and how the gassing reagents are added to the emulsion.

Jan 1, 2004

By Ralph E. Burnham, J. Kelly Ratliff

"The words “dynamite,” “TNT,” “explosives,” and “blasting” typically cause the general public, andjurors, apprehension and fear. Although blasting operations conducted by well-trained, skilled, andexperienced blasters rarely cause damage or injury, the public’s perception of blasting is that it isdangerous, disruptive, and results in damage to nearby properties. As a result, blasting operations have always resulted in complaints, claims, and lawsuits. However, in recent years, the public perception combined with an increase in public opposition, social media, more stringent regulations, predatory plaintiffs’ attorneys, and the application of strict liability to blasting claims has resulted in an increased threat of litigation to blasting companies and individual blasters. Consequently, many blasting companies find themselves receiving more complaints, involved in more litigation, and facing an alarming number of frivolous claims, which can result in increased insurance costs and other financial tolls. Accordingly, today’s blasting companies must be prepared for litigation and take steps to eliminate accidents and claims before the first shot is detonated on a job. The best way to accomplish this is standard operating procedures that incorporate best management practices, industry standards, and regulations in daily operations. This paper outlines some of the considerations that a blasting company should incorporate into its standard operating procedures before, during, and after the shot."

Jan 1, 2016

By Sergio Segovia Parra, Victor Hernan Sheen Uriol

This contribution of the concept of mass blasting both closing and production allows breaking paradigms, to limit the number of tons to thunder. The areas of geotechnical different mining large mining companies worldwide and especially from the National Copper Corporation (CODELCO, Chile) has been declining volumes closing blasting and production, with the misconception to protect the end walls of the pit, before any geotechnical risks caused by various types of faults; especially the circular faults. A blasting of small tonnage can do more damage to a wall when it is not properly sequenced, leading to the coupling of the wave train and therefore the exponential damage in/s (peak particle velocity, PPV) on the wall of the Tagus. Blasting closing mass production and contribute technically and operationally in the dynamics of the following operations: loading, hauling, crushing, processing and preparation of the final product; eliminating delays to return to thunder small volumes where one must stop all mine equipment, incurring high costs and especially losing valuable time in the continuity of the following unit activities.

Jan 1, 2015

By Lee Wehner, Daryl Kin, John Bolger

The Maumee Quarry, located in the city of Maumee, Ohio, has large in-situ cavities, ranging in size from 3 ft (.91 m) in diameter to over 15 ft (4.5 m). The drill/blast team challenge is to drill, load and shoot the geologically disturbed rock in a safe, cost efficient manner, while in close proximity to a commercial area. A continuous improvement process, managed by a Blast Optimization Team (BOT), was implemented to quantify the innovative explosive loading techniques that have been implemented. Borehole camera monitoring, modified loading practices, the need for accurate drill hole logging and open communications between the drill and blast crew proves critical to the success of the operation. Safe Standard Operating Procedures (SSOPs) have been developed and are strictly enforced for the drill/blast cycle. All blasts are monitored with seismographs and recorded on video to provide detailed information as part of the Blast Management Plan. Despite the geological challenges, the measurement of rock fragmentation index versus loader dig rates has provided near optimal crusher throughput.

Jan 1, 2007

By W. Fourney

In the late 70’s and early 80’s in conjunction with other oil and gas well stimulation studies, personnel from the Dynamic Effects Lab performed model testing to demonstrate the effectiveness of utilizing an open section of borehole just before a plug. We called the process stem induced fracturing. The open section beneath the stem was used to increase the pressure magnitude and spread out the duration of the pressure pulse. This technique was later utilized to by Frank Chiapetta (1) in the fracture and fragmentation of rock in quarry blasting situations. He called his technique air deck blasting. In fact, Frank found that the Russians had previously discovered the same technique. There is currently interest in utilizing air deck blasting with an open section of hole beneath the explosive at the bottom of the bore hole to better remove the toe in a fragmentation shot. This paper reviews the development of stem induced fracturing and then describes a series of model tests conducted to measure borehole pressure at points along a borehole when an explosive charge is detonated at the midpoint of the borehole. Tests were conducted in both stiff boreholes (aluminum) and less rigid boreholes (PMMA-Plexiglas). Pressure time profiles were measured at the charge site, midway between the charge and the bottom of the hole, at the stemming at the top of the borehole, and at the bottom of the borehole. Crack initiation sites and crack propagation were also determined in the PMMA models. Some high speed pictures were taken of the event in the PMMA.

Jan 1, 2006

By Rafael Tadeu Pinto e Moura, Giorgio De Tomi, Jacopo Seccatore

This paper describes a research and development project in an open-cast mine with the goal to achieve an average P80 of 300 mm (11,8”) in the run-of-mine (ROM) product without altering the existing budget. The project included several variables in the blast design that were not previously taken into account, such as the orientation of natural joint sets in the rock mass, specific energy of the explosive and firing sequence. The new blast design method considered the directions of natural joint sets and determined the drilling pattern and the firing sequence accordingly to favor the movement of the blasted rock along its preferential direction, to reduce its confinement. At the end of the project, it was achieved an average P80 of 304 mm (12”) in the ROM, 50% lower than the one at the beginning of the project. The final blast of the project showed a reduction of 3% of the drill and blast cost, employing the same powder factor and the same drill pattern size used at the beginning of the project. The results achieved show how rock fragmentation is related to variables that are not contemplated in the most common fragmentation models: the firing sequence and the direction of movement in the blast.

Jan 1, 2015

By Gregory B. Poole

Data collected with 16K sampling at a variety of blasting sites (construction, quarry, trench, mine) and monitoring locations was analyzed to effectively show the 16 different 1K readings all based on the microsecond that the unit went into monitoring.

Feb 1, 2020

By Don Houston

Vertical crater retreat mining (VCR) requires initiation methods that minimize debris in the borehole. The use of detonating cord and shock tube detonators eliminates debris that could interfere with subsequent loading operations and avoids the cost of using drilling equipment to clear the debris. The explosive must not be sensitive to the strength of detonating cord used, otherwise timing will be affected. “Slicing and Dicing” of product before “Air mailing” down boreholes may facilitate loading, especially in wet holes, and can result in product surrounding the detonating cord. Cord sensitivity testing confirmed that having the detonating cord surrounded by product significantly increases the likelihood of an energetic reaction. Careful formulation and testing, based on a thorough knowledge of the application and the role of ingredients in affecting performance, ensures reliable initiation and avoids cord sensitivity. The use of certain metallic nitrate salts, even in relatively small amounts, was found to significantly increase the cord sensitivity of watergel formulations. Evidence of increasing cord sensitivity includes increasing amounts of damage to product and packaging, to ejection of product from the test pipe, then cracking of the pipe, followed by deflagration then detonation of the product. Predictably, the likelihood of an energetic reaction increases with product temperature, cord strength, and borehole diameter, while it is inversely related to product density.

Jan 1, 2002

By Paulo Couciero

Since explosives are the source of all energy used for rock blast fragmentation and heave, multidimensional effects in the detonation driving zone become essential to better describe the detonation process. In order to use the explosive as an energy source-information for more realist blasting performance simulations, a simple and effective modelling strategy is desirable. Facing this challenge, an engineering approach to two-dimensional unconfined non-ideal detonation is proposed. Based on the elliptical construction of the shock locus, the model combines the axial cylindrical stick Q1D solution with some additional limiting conditions to determine the sonic edge of the charge. For a given set of rate law parameters and velocity of detonation, a complete axial solution is firstly computed through the Q1D model. From this solution, a vital relationship between the axial shock curvature with the shock shape parameters can be stablished. Once this relationship is found, the problem simply reduces in finding the shock shape parameters subject to the sonic edge condition. As a result of this calculation, the corresponding charge diameter can be found. Consequently, the proposed model can map the diametereffect curve by relating the unconfined velocity of detonation with its corresponding diameter. Finally, because of its low computation cost, the proposed engineering approach can be also used for characterizing the rate law parameters by fitting to data from unconfined detonation experiments

Jan 1, 2019

By Thomas Leonard, Philip R. Berger, Bryan E. Papillon

Bardon Trimount Inc., a large producer of aggregate, crushed stone, and concrete, was experiencing significant public opposition to its five quarries in the Boston area. It was believed by the authors that this opposition could be significantly lessened if the total number of blasts per week were reduced. Although the blasting company at these quarries, Austin Powder Company, contended that this could easily and safely be accomplished by increasing the size of the blasts, regulations precluded this alternative by limiting the total amount of explosives that could be used per blast.

Jan 1, 1996

By Jim Hall, Denis Rickman, Jon Windham, John Ehrgott, Stephen Akers, Byron Armstrong

With the growing concerns about terrorism world-wide, numerous agencies conduct experiments to investigate the effects of terrorist vehicle bombs. In many cases, the vehicle bomb of interest utilizes some form of ammonium nitrate/fuel oil (ANFO) as the explosive source. Due to the high cost of fullscale testing, it is advantageous to conduct at least some vehicle bomb experiments at reduced scale. Extensive testing has shown that ANFO is a non-ideal explosive, and its explosive output does not scale reliably at explosive masses below approximately 400 lb (182 kg). Most scale-model testing requires explosive masses 1 to 5 orders of magnitude smaller. Thus, scale-model testing is typically conducted with “ideal” explosives, such as composition C-4, which perform in a scalable manner at virtually any charge mass. The utilization of an ideal explosive to model ANFO requires the existence of an accurate means of equating the performance of the two explosives. The airblast equivalence of C-4 and ANFO has been well established. However, the cratering equivalence of these explosives is not thoroughly quantified. This is especially true for the case of an above-ground detonation, which is precisely the scenario of interest in vehicle bomb studies. A study has been conducted to better define the cratering equivalence of C-4 and ANFO for above-ground detonations. This paper presents a discussion of results from this research.

Jan 1, 2008

By John L. Floyd

The use of explosive energy to displace overburden or waste material can provide substantial savings to operations which normally rely on mechanical means for material removal. To optimize the available explosive energy, it is important to quantify the rock's response to the type of explosive and explosive accessories used. During a blast, rock breakage and movement occur so rapidly that the naked eye cannot detect the details of the fragmentation process. A relatively high speed motion picture camera (500 frames per second) can provide the extended time base needed to analyze in detail the site-specific rock response to the explosive detonation. The data of importance to blast casting that can be quantified from these films includes initial face movement, trajectory of rock, and differential face velocities of the material shot. In addition, the ground swell velocities, stemming confinement, and stemming ejection velocity can be determined. The performance of explosive products and delay element accuracy can also be ascertained. The use of high speed motion picture photography and analysis can reduce the number of field trials necessary to maximize explosive performance and increase the benefit provided by blast casting, and in turn, lower production costs. This paper will discuss the methods used for data accumulation and analysis. In addition, three field studies conducted at three separate mining operations will be presented.

Jan 1, 1988

By Gungor Tuncer, Ali Kahriman, A. Kadir Karadogan, Savas Gorgun

The environmental problems arisen from ground vibration and air blast have been faced and discussed frequently in various industries such as mining, construction, quarry, pipe line etc. where blasting is unavoidable operation. Structural damage due to ground vibrations creates great socio-economic problems for mine and quarry management as well as for the people residing in its vicinity, therefore in bench blast design, not only the technical and economical aspects, such as block size, uniformity and cost, but also the elimination of environmental problems resulting from ground vibration and air blast should be taken into consideration. With the general trend towards larger blasts in mining and infrastructure excavation, ground vibration and air blast problems and complaints have significantly increased. With increasing environmental constraints on the levels of disturbance induced by blasting operations upon nearby residents, there is an increasing need to be able to design cautious blasting with greater precision, therefore determination of maximum amount of explosive per delay for a certain distance especially in large blasts is of great importance for the elimination of these environmental problems. In another word, prediction of ground vibration components is extremely important for the minimisation of the environmental complaints. Estimating of particle velocity and other components of ground vibration with reliable approaches will give important facilities to the blasters. Although many studies had been carried out to isolate environmental problems induced by blasting in the past, a general reliable formulae has not been established yet. Due to restrictions on the complexity of ground motion, blasting and test site factors, experimental studies are still necessary for each site to minimise environmental issues. This paper presents the results of ground vibration measurements carried out during the excavation activity for contruction of an organised industrial region located nearby Istanbul in Turkey. The major rock type is granite that is encountered at this site. Within the scope of this study, in order to predict peak particle velocity level and produce a site-specific propagation curve for this site, ground vibration components were measured for blast events during bench blast optimization studies over a long period. In blasting operations; ANFO (blasting agent), gelatine dynamite (priming) and delay detonators (firing) were used as explosives. While the parameters of scaled distance (charge quantity per delay and the distance between the shot and the station) were recorded carefully, the ground vibration components were measured by means of two different vibration monitors for every event. Then, the data pairs of scaled distance and particle velocity were analyzed. The equation of scaled distance extensively used in the literature was taken into consideration for the prediction of peak particle velocity. At the end of statical analysis and evaluations an empirical relationship with good correlation was established between peak particle velocity and scale distance for this site.

Jan 1, 2000

By N. Paley

An engineering project was undertaken at the Cominco Alaska Red Dog Mine to determine the extent that Semi-Autogenous Grinding (SAG) mill throughput could be increased by blasting differently. The Julius Kruttschnitt Mineral Research Center (JKMRC) blast fragmentation, jaw crusher, and SAG mill breakage models were used to relate changes in the blast design to the SAG mill performance. For optimum performance a SAG mill requires a particular size distribution; a number of large rocks to facilitate breakage by impact, as few as possible middle size rocks that become critical size, and the maximum fines which will pass quickly through an open-circuit mill. Physical constraints of drill and charging equipment size limit the extent that pattern geometry can be changed and the powder factor increased to maximize fines. However, JKMRC research had shown that it appeared possible to increase primary breakage by blasting to such an extent that SAG mill throughput could reach a plateau or even begin to decrease. Modeling was carried out on a range of blast pattern geometries and emulsion explosive blends to determine if a plateau existed and at what powder factor it would be reached. It was found that the relationship between powder factor and grinding throughput was nonlinear. Modeling was also used to compare the SAG mill throughput which could be expected from different emulsion explosive blends to determine which blends should be used in dry and wet holes to provide similar fragmentation. For heavy-ANFO mixtures, the highest modeled throughput was at a ratio of 30/70, with ratios on either side indicating lower throughput. For emulsion blends, the highest modeled throughput was at a ratio of 80/20; however, ratios from 80/20 to lOO/O were similar. Crusher product size distributions were obtained from belt cuts early in the analysis to confirm model predictions. At later stages, actual SAG mill throughput was compared to predicted. The economic benetit from the different blast designs was calculated by accounting for the reduction in recovery due to the higher throughput and the additional drilling and blasting costs. Increasing the powder factor by 150% from the 0.29kg/t {0.58lb/st] being used to 0.72kg/t { 1.44lb/st}, the maximum feasible with mine equipment, could provide a sign&ant net benefit of $3OWyr due to the increased concentrate production. However, because the relationship between throughput and recovery is affected by other factors which were not modeled, a more conservative approach was taken. The powder factor was instead increased by 50°h, providing 45% of the gain. This was possible because the relationship between powder factor and grinding throughput was nonlinear.

Jan 1, 2001

By Alain Blanchier, Pascal Bernasconi

Blasting operations took place on Channel coast NW of France to extend Flamanville Nuclear Power Plant (EPR new generation). The closest operating reactor building was monitored by a 24 remote vibrations transducers network to fulfil, on one hand, the severe environment constraints and satisfy high degree of productivity required by the project, on the other hand. Although these requirements usually are incompatible, this challenge compelled to introduce a seismic modelling technique to optimize blast designs using electronic initiating system. The “Hybrid Seismic Modelling” (MSH) uses blastholes signatures (seismic vibrations records) which are greatly dependent on geology and alteration of rock mass, explosives, charge geometry, blast configuration, and the final excavation shape. In order to respect severe vibrations limits, excavation layout was divided into areas with specific blasting modules - type and number of charges, single charge, initiating sequence. Thanks to this technique, it has been possible to reach lowest blasts vibrations levels and a better productivity compared to classical blasting operation at the same location in the past. After the modelling method presentation - principle and use precautions, technical improvements are reported.

Jan 1, 2008