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By Orica Peru, Pedro Lozada

Proper management of exclusion zones in blasting operations is essential to ensure safety without compromising operational efficiency. In Peru, mining regulations establish minimum exclusion distances specifically for personnel (500-meter radius / 1,640 feet), but do not define clear technical criteria for equipment. As a result, conservative distances such as 200 meters (656 feet) are often applied, negatively impacting productivity. This study proposes a technical-scientific methodology to reduce equipment exclusion zones, based on the use of advanced technologies such as drones, high-resolution cameras, and specialized software tools. The solutions used allow video recordings of blasts to be transformed into dynamic data through artificial intelligence and computer vision, as well as execute probabilistic simulations of the flyrock phenomenon using Monte Carlo algorithms and physical models calibrated to real operating conditions. Technological integration enabled the simulation of real operational scenarios, considering variations in critical blasting parameters that directly affect flyrock generation, such as drill diameter, explosive density, linear charge, and stemming height. Additionally, the Terrock methodology was incorporated, allowing the behavior of the rock mass to be included as a variable in risk assessment, improving analysis accuracy under different rock hardness conditions. The methodology was applied in four phases: diagnosis of the current design (15 blasts), modeling, validation of the calibrated model (6 blasts), and subsequent operational implementation. As a result, it was determined that the exclusion radius can be safely reduced from 656 to 492 feet (200 to 150 meters), maintaining as the main restriction the use of stemming lengths greater than 5.0 m. This optimization has the potential to generate tangible benefits, with estimated monthly savings exceeding USD 50,000, associated with reduced evacuation times, lower fuel consumption, less equipment wear, and increased productivity in drilling and hauling activities. The comprehensive approach presented here highlights the transformative potential of digital technologies applied to blast management, contributing to safer and more efficient mining operations.

Jan 26, 2026

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 Michael Milstein

Northwest Research Station said as more and more older dams are removed to benefit fish, it’s become clearer that rivers rework themselves quickly.“Where the dam is relatively small, it’s a quick response,” he said. “The river quickly forgets.”

Jan 1, 2010

By Stephen Mansfield, Saran Sankar

The Sentinel open pit copper mine, operated by First Quantum Minerals Ltd, is located in the North West province of Zambia. The Sentinel orebody is a sediment-hosted, structurally modified deposit in which mineralisation is contained in the phyllite formation, which occurs as a series of layered, continuous sheets having a northerly 20 to 30⁰ dip. The persistent nature of the geological structure can lead to the generation of large slabs when joints are relatively close together or very large blocks when joints are more widely spaced. With standard blasting methodologies, the challenging fragmentation most commonly occurs in the stemming zone and blast interfaces, reducing excavation rates and increasing the risk of crusher bridging events and reduced throughput. A generalised approach to increase powder factor would increase in drill and blast costs and would not be sufficient to target the specific cause of the challenging fragmentation. Implementing differential blast energy based on post blast requirements for different material type, such as ore and waste, and rock mass characteristics is not new in the mining industry. High-energy blasts for ore aim to produce finer materials, enhancing downstream processes such as crushing and grinding, while reducing power consumption and increasing throughput. Conversely, waste rock often requires less energy in order to deliver optimised fragmentation for loading and hauling efficiency. Identifying and applying optimum blast energy to specific material type and geological domains will not only ensure smoother and efficient operations throughout downstream processes, but will have a direct impact on overall profitability of the entire operation. This paper will describe the methods used to model and implement differential blasting across a range of material types in order to deliver the required blast outcomes for ore and waste and the impact on downstream processes and drill and blast unit cost.

Jan 21, 2025

By Paulo Couceiro, Manuel Lopez Cano

"The Panama Canal is one of the most important engineering projects of the modern era and plays astrategic role in the global economy and international maritime trade since its inauguration in 1914. Now, a little more than one century later, the final phase of its expansion program, the largest infrastructure works undertaken since its inauguration, has concluded. This expansion program has created a new lane of traffic along the Canal with the construction of a new set of locks – one on the Pacific side and another one on the Atlantic side -, increasing the Canal’s capacity and its impact on the world’s economy even more."

Jan 1, 2017

By Cary Moffat, John Kita, Rick Walker

The Lac des Iles Mine, in an isolated area of NorthwesternOntario is a relatively new open pit platinum and palladium mine. They were encountering problems with the equipment and production scheduling when ramping down to begin production on the subsequent benches. A co-operative effort between Lac des Iles Mine operation people, ICI Explosives, and the mines drilling and blasting contractor - Consbec Inc., resulted in a decision being made to use full depth sinking cuts to provide access to the next bench.

Jan 1, 1996

By Tyler Rockley, Cara Rosen

Blasting at a granite quarry in eastern Maryland produces elevated air blast readings that can fall into the cautionary zone for the state of Maryland environmental regulations on a semi-regular basis. When designing blast patterns in this quarry, challenging geology creates rough and uneven blast faces that can be difficult to capture with 2D laser profiling fully. Utilizing several methods known to manage high air blast results like pattern adjustments, decking, and timing changes have not achieved consistent outcomes.

Feb 1, 2020

By Alexandra Yuyali

The objective of this research work is to increase the drilling ratio represented in tons per drilled meter (ton/m) to reduce mining costs. One of the key characteristics of this research is the use of the ITH (in-the-hole) drilling rig with a water-powered hammer, also known as Wassara™. The patented Wassara™ in-the-hole hammer is powered by high-pressure water instead of air. To reach the objective, a new design of the blast pattern was implemented considering the following: Burden from 1.7 m (5.6 ft) to 2.8 m (9.2 ft) Spacing from 1.7 m (5.6 ft) to 2.7 m (8.9 ft) Drill diameter from 89 mm (3.5”) to 102 mm (4”) Drilling length from 15 m (49 ft) to 30 m (98 ft) Borehole deviation < 2% The result of this new design is the optimization of the drilling ratio (ton/m); having as a baseline 5.2 ton/m with traditional equipment and obtaining 13.7 ton/m with the ITH drilling, which generates annual savings of $2.43M.

Jan 21, 2025

By George W. MacDonald

ALFRED NOBEL was born at Stockholm on October 21st. 1833, and died on December 10th, 1896. Although Sobrero’s discovery of nitroglycerin dated back to 1847, this explosive was manufactured on a commercial scale for the first time in 1862, by Nobel at a factory which he erected at Heleneborg, near Stockholm. These works were entirely wrecked by an explosion in 1864. In 1865, he erected works, which are still in existence, at Winterviken, near Stockholm. In 1864 Nobel introduced modifications in the manufacture of nitroglycerin which were the subject of a patent (see footnote No. 1), and at the same time, claimed a process for the detonation of nitroglycerin. Nobel states that, up to that time, the method used for the manufacture of nitroglycerin consisted in pouring glycerin, drop by drop, into a mixture of sulphuric acid and nitric acid contained in a refrigerating mixture. In order that the nitroglycerin should not be decomposed, the temperature was not allowed to rise above 0° C.

Jan 1, 2012

By Michael Laing

Blasting regulation and restrictions are tougher today than ever before. When blasting in population centers, strict limitations are often placed on the environmental effects caused by blasting, more specifically vibration and overpressure. Blast-induced vibration can be a tricky thing to manage at times, but there are a variety of options at our disposal to help optimize and manage vibration. This paper focuses on the application of rudimentary signature hole analysis to optimize blasting vibration in localized areas surrounding a mine.

Jan 1, 2017

By R L. Mayville

The author explains why the strategic location and important limestone reserves at Chattanooga Quarry led to a decision to extend operating life by continued benching down to lower levels. He discusses the steps taken to accomplish this objective. These include relocation of the primary crusher from the second level to the fourth level, pre-testing of explosives designs and powder factors, control of a substantial water problem, and computer monitoring of stone production costs.

Jan 1, 1984

By Reinhold Daykin, Piers Wendlandt, Nathan Rouse

Drilling and blasting are key components of every hard-rock (i.e., metal/nonmetal/coal) mining operation. Well-executed and maintained drilling and blasting can have a major positive impact on the overall success of such operations. This case study presents the implementation of a new drill and blast engineer position and systematic improvement of the drill and blast operations at a surface metal mine.

Feb 1, 2020

By Ph. D. Favreau, Favreau Patrice B. Eng, R. F.

Geology is important in mining by helping to identify the rocks which contain sufficient valuable ore to justify their excavation. Geologists give a geological name to each rock type, so geology is a player in blasting; when a blaster has successfully blasted rock of a given geological name at a former site, and he later has to blast rock at another site whose rock has the same geological name, then his first trial often is the same method as he used at the former site, since the geological name of the rock is the same

Jan 1, 2019

By Andreas Gaich

A new 3D fragmentation analysis method for muck piles is presented. It works with aerial imagery from UAVs (drones) and handles entire muck piles with minimum user intervention.

Feb 1, 2020

By Felix Degold, Mark Ganster

Achieving a customer optimized fragmentation by using robust data from new technologies e.g. GPS positions of boreholes, fragmentation analysis to calibrate the geology and fragmentation prediction models. The inclusion of the collected data into the blast’s design makes it possible to accomplish a desired particle size distribution.

Feb 1, 2020

By Andrew Palangio, Blessing Taiwo

Understanding rock mass structural features is essential for optimizing blast design, highwall control, and evaluating post-blast performance in both surface and underground mining operations. This paper presents a comprehensive methodology utilizing image-based structural mapping to accurately characterize geological discontinuities including joints, faults, and lineations captured from both terrestrial and aerial imagery at varying scales. Key structural parameters such as joint orientation, spacing, and apparent in-situ block size are extracted to understand rock mass classification and enhance blast design inputs with greater geotechnical precision. The study introduces a significant enhancement to the existing discontinuity assessment algorithm by integrating a deep learning-assisted detection process. This improvement enables more accurate, quantitative and consistent identification of pre-existing cracks and surface features across complex bench free faces. The enhanced system facilitates better evaluation of how structural features influence blast fragmentation, energy distribution, and slope stability. A case study from a limestone quarry illustrates the use of a derived comminution factor based on the relationship between joint-controlled pre-blast block sizes and post-blast fragmentation to evaluate blast performance and optimize future design strategies. The results highlight the value of structural analysis in reducing overbreak, minimizing underbreak, and improving fragmentation predictability. This paper emphasizes the importance of integrating structural assessments into the blasting workflow to enable a more data-driven, geotechnically informed, and performance-optimized approach to modern blast design and evaluation.

Jan 26, 2026

By Jorge Blázquez, Pablo Ravanal, Paulo Couceiro, Juan Navarro

Blasting performance is influenced by rock mass properties and blast design parameters. From them, the rock is the only variable that cannot be modified, but it can be measured, so that, blast design variables can be adapted to optimize the results. A new methodology to assess rock mass quality from drill-monitoring data from both autonomous and manual rotary drilling modes is described to guide blasting in open pit operations. For that, a thorough normalization process has been developed to minimize external influences induced in the data by the rig system for autonomous mode and by the operator intervention for manual mode. Principal component analysis has been used to combine MWD information. Two rock description indexes are derived directly from Measurement While Drilling (MWD) data collected. The first index is a Structural factor that classifies the rock mass condition in three classes (massive, fractured and heavily fractured). The second index is a Strength factor that classifies the rock according to the strength properties. Both indexes have been combined to obtain an overall drilling rock factor along the hole. This has been named by the authors as the X-Rock model.

Feb 6, 2023

By Dipankar Gorain, A K. Vishwakarma, Vivek K. Himanshu, Murari P. Roy, Shubham Singh, R S. Yadav

The industrial establishments of a power plant consist of many important structures viz. cooling tower, wagon tippler, track hopper, plants and offices. The leveled foundation is the utmost need for erecting these structures. The leveling of the foundation is done by rock excavation, when the establishments have to be setup in hilly/rocky areas. Drilling and blasting is the cheapest and most dominant method of rock excavation. However, this method has associated hazards in terms of blast induced ground vibration, air overpressure, flyrocks etc. The foundation work and erection of the industrial buildings are done in parallel to achieve the faster construction of the establishment. The challenges to reduce the induced hazards in such cases are more. This paper presents a case study on the controlled blasting method devised for the rock excavation for construction of 2 × 660 MW Obra-C thermal power plant. The foundation work for this power plant was made by excavation of Dolomitic rock. The excavation work was performed in the proximity of the existing residence of the local people and Obra market. With the advancement of project, the excavation was also performed in the proximity to the ongoing construction work of various industrial buildings. Accordingly, the controlled blasting pattern was devised suitable to the specific sites. The pattern consisted of variations in blasthole diameter, burden-spacing, maximum explosive charge per delay, total explosive in a blasting round, initiation system and direction of initiation. The suitable muffling arrangements were also used, when the blast was conducted in the close proximity to the structures. The initial blasting pattern was established by analysis of blast vibration wave propagation characteristics. Thereafter, the final pattern was adopted for the safe excavation at the site. The safe excavation for the foundation work of this power plant has been completed successfully based on the devised controlled blasting pattern.

Feb 6, 2023

By Johan Hillman, D. Scott Scovira, Thomas Gustavsson, Alexander Bihlar

Hydrogen Peroxide Emulsion (HPE) explosives are an alternative to conventional commercial explosives. HPE does not contain nitrates or ammonia thus eliminating post-detonation NOx fumes and aqueous nitrate discharge. Production of HPE is less carbon intensive than industry standard ammonium nitrate-based emulsions (ANE) and employment aligns with end users seeking to meet Scope 3 ESG emission targets. Swedish tunneling contractor Implenia Sverige was awarded the Högdalen Depot Expansion Project by the City of Stockholm. Implenia Sverige partnered with Hypex Bio to be the first to pilot the application of a nitrate-free explosive system in a large-scale civil construction tunnel. The purpose of the joint project was to evaluate the operational suitability of replacing conventional nitrate-based bulk explosives with HPE in a large-scale tunnelling project. When the project commenced in September 2023 both standard nitrate-based emulsions and HPE emulsion were used in parallel (Tunnel Right and Tunnel Left) to enable operational, performance, and environmental comparison. Identical drill patterns and initiation techniques were applied to both tunnel headings. Performance data collected included round advance, usage, and perimeter quality. Implenia managed all drilling and charging operations and Hypex Bio provided technical support, including technicians and chemists. HPE is viscous and pumpable using conventional emulsion pumping delivery systems. Variable density functionality enabled loading different charge weights into cut, lifter, production, and perimeter holes. The primary rock type was hard sedimentary gneiss with approximately 150 MPa [21,755 psi] Uniaxial Compressive Strength (UCS). Fracture systems with infilling occurred in both tunnel directions. Rock quality factor was “Good to Very Good” on the RMRb (Rock Mass Rating) scale. Epiroc Boomer rigs were used to drill rounds averaging 4.9 m [16 ft] deep with high accuracy and precise reference positioning.

Jan 26, 2026

By Adam Stremcha, John MacGregor

Initial planning called for 3 separate drop shafts and 3 separate vent shafts to be pulled back from the excavated tunnel with a large diameter raise bore machine. With time constraints and the raise bore machine already in high demand on other shafts, a more “traditional” drill and blast approach was taken on a few of the larger drop shafts. This decision proved to be not only cost effective, but also reduced schedule impact as the shafts were excavated simultaneously with the other raise bores.

Jan 1, 2010