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By Steve Dillingham

Today, a typical blaster is likely to wear many hats, including, but not limited to, supervisor, risk manager, safety coordinator, explosives engineer, communicator, as well as professional decision maker. Simply put, a blaster in the new millennium is an all encompassing blast site manager. As you know, accidents on the blast site can range from blast crew injuries to blasting incidents resulting from vibration, flyrock, misfires, etc. Not surprising, the incidents can quite often be traced back to direct preventable human action on the blast site. They can, however, frequently be avoided, if responsibly identified early and managed properly by an efficient blast site manager. Your company cannot afford to simply employ blasters; good blast site managers are necessary to produce the safest results possible.

Jan 1, 2001

By Mick Fritz, Ryan Gilmore

The Center for Disease Control [CDC] is in the midst of a twenty year project, part of which includes demolishing existing buildings and erecting taller, more modern structures within the same foundation foot print. Controlled Blasting Inc, a large and experienced construction drilling and blasting company in Metro Atlanta, was contracted to provide the drilling and blasting for the new building foundations. Working on a construction site, in this type of environment, creates many challenges for the drilling and blasting crews.

Jan 1, 2008

By John A. Franklin, Tom C. Palangio, Norbert H. Maerz

WipFrag systems I and II have become the world standard in photoanalysis systems to measure fragmentation. Mines, quarries and excavating contractors can now easily measure blast results and track the progress of optimization efforts. This technology was developed and evolved to allow automatic measurements of the size distribution of patiicles on moving conveyors, in truck boxes and on crusher feeds. Production machinery can now be controlled by photoanalysis results and multiple cameras allow various locations to be monitored by a single system. Blast designs can be monitored on a shot by shot basis. Changes in delay times, explosives, patterns and hole sizes can be quickly evaluated. Along with this measurement capability has come a heightened awareness of the importance of “optimum size” and uniformity of particles for lowest cost production and material handling efficiency. In the past, savings in the “drill / blast” cycle of the operation were sometimes overshadowed by downstream production costs related to fragmentation. Now total production costs can be compared with fragmentation sizes which will immediately show the trend towards optimum size for economical production. No cost reduction program can be complete without this critical information.

Jan 1, 1997

By Ron Lutz

In today’s world, production is the name of the game. We are all in business to make money. In the Quarrying and Mining industry the same holds true. The primary goal is to develop the best drilling and blasting program available to maintain uniform fragmentation to maximize production. Also we want to maintain drilling and blasting costs and minimize escalators. This paper is intended to discuss ways for all parties (quarry’s, blast service and drill companies) to attain this through understanding what can be done to help blasthole drilling and production. Blast designs and seminar’s emphasize the accuracy of drilling to produce better fragmentation. Blast design must also include basic concepts in the drilling process. The type of drill to be used for example whether it is a crawler or truck mount, top hammer or down the hole is important. Quarry operators have a role to play as well. They hold the key to the production of drilling. What the customer does or does not do has a direct effect financially to the drilling. The phrase of pay me now or pay me latter comes to mind. This paper will explore the detail of planning that is required by the quarry and/or blast service companies before a single hole is drilled. The drill must be able to meet the production need of the operation. The type of drill available and what can and cannot be done. The drill cost must be competitive. This paper will touch on comparison drill costs from 1967 to 1999.

Jan 1, 2000

By Michael Karmis, Syed Muhammad Tariq, Zeshan Hyder

This paper analyzes the blast design for lime stone quarries of two major cement plants in Pakistan. The production blast of these quarries was resulting in excessive boulders production. At some instances, the rate of boulders production was approximately 10%-15% of the main production blast i.e. if a round of main blast gave around 4000 tons of material; almost 400 to 500 tons of that material was in the shape of massive boulders. This gave rise to increased operating costs requiring boulders collection, drilling and secondary blast.

Jan 1, 2012

By Luiz Guilherme Isfer Maciel, Marilena Cardu, Fernando Golin, Jacopo Seccatore

"This study applies the concept of the difficulty of tunnelling by drilling an blasting (D&B) to selectedcases from the Brazilian tunnelling industry. The difficulty of tunnelling has been defined in previouswork as the difference of specific drilling (SD) from industrial average trend: easier when SD is lowerthan average, more difficult when SD is higher than average. Results show how tunnels in Brazil tend tobe unrealistically more difficult to excavate when compared to similar excavations in similar geologies elsewhere in the world. It is thoroughly discussed the reason for such anomaly (up to +90% SD compared to industrial average). One reason could be the lack of options amongst explosive products on the brazilian market. Only ANFO and explosive emulsions are available in Brazil. Lacking high VOD(Velocity of Detonation) products might result in reducing the maximum allowable burden amongstproduction holes, therefore increasing SD. Another reason could be found in the tunnel designers’tendency of choosing D&B as excavation method for weak rock masses that would benefit from mechanical excavation. The reason to this tendency can be partly found in the lack of availability of mechanical excavation machines in the brazilian market. Blasting in weak rock masses requires more careful smooth blasting, hence a closer spacing amongst contour holes to avoid costly overbreak: this increases SD. A third reason could be found in the lack of skill amongst the local workforce. When dealing with unskilled workers the blast designers naturally tend to avoid highly optimized blasts thatrequire very skilled workforce to be realized on field. The designer in this case tends to leave the blastdesign simpler but more robust, at the cost of higher specific drilling and specific charge. The conclusions suggest that this unrealistic difficulty when compared to world average could be a simptom of the so-called “Brazilian cost” within the tunnelling industry."

Jan 1, 2017

By Alan Hooper, James E. Mischler

Construction began in 1984 for a 5 megawatt hydroelectric power retrofit at the O'Shaughnessy Dam for the City of Columbus, Ohio. The construction necessitated excavation of limestone bedrock up to 27 feet below the normal water level of the river downstream of the dam. Proximity to the river and difficult terrain resulted in an interesting and challenging construction project.

Jan 1, 1986

By Pharis E. Williams

The ability to predict the performance of an explosive relies upon having a Reaction Rate Law and knowing its functional dependence upon various parameters of the explosive. In particular, emulsion explosives have a matrix cell size and may be sensitized with glass or plastic microballoons. The cell size dependence should. be very nearly the spherical grain burning dependence upon web that appears in the reaction rate laws for ball gun powder. The dependence of the reaction rate law upon the parameters of the sensitizing microballoons has been explored using hydrocode analysis of the pressure field produced by the collapse of a microballoon. This pressure field provides an increase in pressure in the vicinity of the microballoon which, in turn, increases the rate of reaction within this field and provides the energy release that must be achieved in order to have a steady state detonation for use as a blasting agent. Hydrocode analysis allows the determination of an approximate functional form for the reaction rate law which shows the dependence upon the size, type, and quantity of microballoons. This presentation includes the theoretical background and the determined functional form of the reaction rate law.

Jan 1, 1995

By J. Fresnillo, M. Lopez Cano, S. Burgada, P. Couceiro, A. Jafa

This paper explores the sustainable use of the explosive’s energy for rock blasting and its role on the performance of downstream unit operations in mining applications. Since energy efficiency is becoming important for long term mining strategies, cost-effective optimization strategies are required to increase productivity and revenue while minimizing environmental impact. These optimization strategies involve continuous ability to model and measure all related phenomena and operational performance, integrated under a continuous improvement program where all involved counterparts act in close coordination. Although mining is complex, it can be regarded as a set of interconnected processes, where energy is consumed in a sequence, following all unit operations from the pit to the concentration. In this sense, the performance of downstream operations is potentially influenced by the initial energy input, since the explosive is the source of all energy used for rock fragmentation and heave. In this line, sustainable energy blasting is recognized as one of the main strategies for mine energy optimization projects. Finally, a special case study from an important gold mine in South America is presented, where benefits of a sustainable blasting energy strategies has been proved to deliver important downstream benefits.

Jan 1, 2019

By W. J. Birch, R. Farnfield, S. Hosein, C. Johnson

Modern smart phones include accelerometers based on MEMS (Micro Electro Mechanical System) technology giving the possibility to measure both acceleration and orientation. The widespread use of such phones has driven technological development to such a degree that it is now possible to obtain a triaxial accelerometer unit, that also include signal conditioning and analogue to digital conversion, in a package smaller than 1 cm2 (1/2 sq.in) for a relatively low cost.

Feb 6, 2023

By Aris Tambunan, Nella Lubis, Nurafrianti Saala, Komang Widhiayanto, Herry Saputra, Rudolf Sitorus

Maximizing mining recovery rates and minimizing ore loss are pivotal objectives for economic efficiency and operational effectiveness. This study explores methods to address these imperatives by enhancing ore production and recovery through improved blasting techniques and spillage control in the Martabe Gold Mine Project in North Sumatra Province, Indonesia. Between 2018 and 2021, the average mining recovery rate stood at 93%, resulting in a potential annual ore loss of 7% and a potential quarterly financial impact of close to $2 million. Maintaining and enhancing mining recovery became crucial, with a planned 30% increase in total material movement for 2022. The mining recovery target for 2022 was set at 96% based on best achievement historical data from 2021 to increase ore tonnage by 203 KTon per annum. To achieve the primary objective of increasing ore production by improving mining recovery, the study focused on predicting and controlling the movement of blasted ore to reduce spillage and enhancing the grade control model to reflect actual conditions post-blasting. Several alternative solutions were explored, primarily emphasizing drilling and blasting activities. Essential methods included capturing the actual blasting movement to adjust the ore block based on blasting design data and post-blasting muckpile topography. This approach minimizes ore loss by providing output as ore block adjustment based on post-blast movement data. In addition, the tie-up design was adjusted to control ore spillage outside the pit ridge. The implementation of these methods yielded significant improvements. Adjusting the ore block based on actual blasting movement contributed $1,545,764 in benefits. Controlling ore spillage outside the pit ridge achieved a 10% reduction in spillage, contributing $79,184 in benefits. These enhancements successfully met the 2022 mining recovery target of 96%, marking a 3% increase from 2021. Consequently, ore loss was reduced by 178 KTon throughout 2022, resulting in a financial impact of $7.3 million. The study underscores the significance of precise blasting techniques and effective spillage control in enhancing mining recovery rates.

Jan 21, 2025

By James C. Irvine

Meramec Mining Company's Pea Ridge underground mine is presently involved in a large scale pillar recovery program and has made use of both rotary and down-the-hole drills for large diameter blastholes. Groups of pillars have been blasted with water gels in massive blasts which have broken in excess of one million tons of ore per blast. An outgrowth of the pillar recovery program is the combination of rotary and down-the-hole drills to develop vertical "raises" between mine levels. This paper outlines the Pea Ridge procedure for pillar blasting including the use of non-electric caps. Techniques and loading rates are discussed, and safeguards against blasting damage which were developed as a result of the program are presented.

Jan 1, 1976

By Walter Voglauer, Elisabeth Zechmeister

Description of Project: The four photos show a chimney blasting operation in Vienna’s district of Floridsdorf on May 4 2011. The blasting was done with two types of charges. An internal charge provided a force of blast which resulted in 135 single electrical blasting caps initiated detonations on the basic ensured the straight collapse of the chimney. The preparation work was done by reserve force military engineers. The series of photos were shot by Elisabeth Zechmeister. She works in the Austrian DOD but not as a professional photographer; much more she did all activities in her spare time.

Jan 1, 2013

By Sedat Esen

"This paper presents a critical review of the fragmentation data obtained from some large open pit copper and gold mines. Database ncludes 35 mines with Uniaxial Compressive Strength values ranging from 19 MPa to 227 MPa (2756 psi to 32923 psi). Variation in the fragmentation data and the causes are discussed in detail. Quality assurance/quality control (QA/QC) in drilling and blasting was shown to have significant impact on fragmentation. In addition, controllable blast design parameters including drill pattern, powder factor, blast timing, stemming length, etc as well as the large blast sizes havesignificant potential to improve fragmentation. Feed size requirements of crushing and grinding circuits were discussed in detail. The paper discusses the effects of different size fractions (top size, 80 %passing size and % passing 10 mm (0.5 in)) on the downstream processes and the role of the fragmentation model in the mine to mill process. Blast domains based on rock strength and structure canbe established by using a fragmentation model which is calibrated using measured fragmentation data. This allows the blast engineer to compensate for changing rock characteristics and stabilize the ROMfragmentation size and result in increased crusher and mill throughput. Two case studies were presented to demonstrate the benefits achieved in downstream processes. Main benefits were reduced downtime at crusher circuits, improved mill throughput as well as reduced total operating cost. A simple relationbetween uniaxial compressive strength and powder factor was proposed using the database for the optimized mines as a guideline to allow site engineers to compare their sites against the other sites."

Jan 1, 2017

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 John M. Bolger, Keith E. McMaster

Excessive salt fines are undesirable in underground salt mining as they are considered a costly waste byproduct. This paper describes an extensive explosive application program conducted at The Canadian Salt Company Ltd, located in Pugwash, Nova Scotia, Canada. The prime objective of the program was to reduce the quantity of fines generated from this company’s underground production blasts. The program was known as the “The Fines Reduction Program”.

Jan 1, 1996

By L. Wilson, M. Kotzel, T. Pienaar

An empirical equation is presented for the maximum airblast from unconfined charges. This has been tested at a number of sites and with charges ranging from 0.1kg to 311kg. The equation is developed to predict community response to potential explosive test range sites and the testing has added to our knowledge of the effectiveness of mitigating measures. The first site had 10m to 15m high walls that were intended to ameliorate the airblast. These walls functioned to a limited extent and reduced the airblast levels by 2dB to 5dB. The airblast was affected somewhat by topography. Noise levels at the nearest residences exceeded 130dB for charges larger than 1kg, whereas the vibration levels were very small. Formal complaints were received where the airblast level exceeded 128dB as per conventional expectations. Pedestrians and pets in the suburbs were startled by the blasts, emphasizing that the community response is much more sensitive to noise and airblast than vibration levels. The maximum airblast levels were too high for this site to be used on a regular basis. At another site, the airblast levels were significantly increased downwind by up to 10dB due to a moderate wind. A third site, at a quarry, produced unconfined airblast levels beneath the derived limits, but are much higher than the normal quarry blasting. By involving community forums there were no complaints, possibly due to desensitization by the normal blasting activities. The study has highlighted new areas for research in understanding the effect of noise, air blast and vibration on the low cost and informal housing typical in South Africa

Jan 1, 2011

By Steve Colburn

The CRITERION Survey Systems utilize both theodolite mounted and hand held reflectorless distance meters. These are eye safe, easy-to-use, and specifically designed to endure the harsh environments characteristic to the mining, quarry and explosives industries. Survey data collected by the systems is digitally stored in a ruggedized data collector and then processed with a specialized, Windows-based, interactive software program which can be run on’ any standard PC.

Jan 1, 1998

By Erik Nygaard, Klaus Voges

ANFO is the most used industrial blasting agent in the world, and is often used as a reference for comparison of other explosives. It is known to work very well under dry conditions in large borehole diameters, whilst in small borehole diameters increasing amounts of toxic fumes (CO, NO and NOz) can be formed. In underground blasting, problems can also occur with reduced visibility caused by unreacted ammonium nitrate and overall composition of the detonation fumes. ANFO is made by mixing Ammonium Nitrate Porous Prills (AN-PP) and fuel oil. We have measured velocity of detonation (VOD), toxic fumes and visibility after blasting of ANFO in 54x2 mm steel tubes, and the differences are remarkable: By using an AN-PP grade developed for underground blasting and small diameters, the following can be obtained:

Jan 1, 2001

By Francisca Tapia, Jorge Blázquez, Paulo Couceiro, Patricio Vergara, Luis Manriquez, Luis Martínez, Juan Navarro

Efficient energy transmission is critical for effective rock fragmentation in open-pit blasting. However, in zones with highly fractured or soft rock, mismatches in acoustic impedance between the explosive and the rock can lead to significant energy loss. These mismatches reduce fragmentation efficiency and, when energy input is increased to compensate, can trigger unintended side effects such as NOx fume generation. This paper presents a novel methodology that integrates the Fragment Size Energy Fan model with acoustic impedance theory to dynamically optimize explosive energy delivery. A redefined impedance formulation captures volumetric energy transfer and enables the calculation of a Rock Impedance Factor (RIF), calibrated through non-linear regression. To operationalize the model, rock impedance is estimated using the X-4Traits Model—a meta-learning algorithm that interprets Measurement While Drilling (MWD) data from both autonomous and manually operated drills to produce high-resolution, spatially distributed impedance maps. The methodology was calibrated and applied at Minera Escondida Limitada (MEL), using data from over 218,447 blastholes and 526 blasts. Two case studies illustrate its application: Expansion 1 demonstrates improved fragmentation consistency and a 10.7% reduction in powder factor by aligning explosive energy with local impedance variations; Expansion 2 highlights the model’s utility in managing NOx emissions in fractured zones by optimizing energy distribution and confinement without compromising fragmentation. This impedance-based framework provides a robust tool for improving fragmentation outcomes, optimizing energy use, and enhancing control in geologically variable blasting environments.

Jan 26, 2026