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By Italo Onederra, Gary Cavanough, Ewan Sellers

Reactivity of ammonium nitrate based explosives is associated with the presence of iron sulfides in the ground reacting with explosive products and in some instances causing spontaneous reactions which can lead to detonation. The stability of explosive products can also be linked to in-hole density, which influences detonation efficiency, breakage performance and the potential generation of Nitrogen Oxide (NOx) fumes. Reactive ground testing involves detecting a temperature rise of a mixture of a bulk explosive product sample, a ground rock sample and some specific chemical agents. This paper describes improvements in reactive ground testing involving the use of time lapse video analysis and detection of NOX gas emissions from the sample. Reactivity is stored and linked to a using cloud based software to map of the mine showing the exact location of the sample. The location marker can be selected to allow quick access to the sample test results and video. In addition to reactivity, the stability and detonation performance of bulk product can also be influenced by depth. In this paper, a system that simulates product at depth and measures density changes and monitors the structure of bulk samples is described. Results from an explosive product are analyzed and detonation performance is assessed by the measurement of velocity of detonation and detonation pressure.

Jan 1, 2018

By Andrew Theobald, Peter Dare-Bryan, Trevor Byers

The use of advanced modelling techniques and the timing flexibility of electronic initiation systems allows for unprecedented control over blast outcomes as shown in several complex blasting problems experienced by the open pit operation Xstrata Ernest Henry Mine (EHM) in north-west Queensland, Australia.

Jan 1, 2010

By Tom BoBo, Seth Gering, Jeff Loeb

Presenting a D&B feedback loop built on a well-designed blast, proven fragmentation analysis and blast monitoring solutions, underpinned by technology that not only increases profit from every blast, but also increases a mine’s purchasing power over one of the most expensive part of the process – explosives.

Feb 1, 2020

By C. Breeds, K. Jeremiah, E. Jennings

Washington State has a well developed set of blasting regulations which have been promulgated by the Department of Labor using extensive stakeholder input, not only from citizens but also from manufacturers and representatives of IME, blasters in charge, blasting engineers, blasting companies, local and federal law enforcement agencies, fire officials, and local and state government representatives. WAC 296-52 therefore provides a foundation or platform for developing city ordinances for Washington State cities should a City wish to do so. On the other hand, Oregon’s code is based on OSHA 1926, Subdivision U, Blasting and the Use of Explosives which provides scant direction regarding the modern use of explosives. Reference is also made to ODOT Section 00335 - Blasting Methods and Protection of Excavation Backslopes. This paper examines two separate programs that have been developed by two Cities, one in Washington State and one in Oregon to further regulate blasting inside City limits and discusses why the lack of a regulatory foundation made one approach more difficult than the other. One of the authors was retained by the City of Kennewick, WA to develop their ordinance and has more recently followed and reacted to a pending ordinance for the City of Redmond, Oregon. The paper will compare and contrast the different approaches and comment on the reaction from both Blasters and the public. We also present a case study that involved blasting in an urban area of Oregon to prepare a foundation for a water tank. Controlled Blasting was carried out within 70-ft of residencies and within a community that had expressed reservations regarding blasting even though the work would make a significant contribution to the betterment of the community. Pre-construction surveys of residencies located in a large area surrounding the site were performed and a well-planned blasting program was carried out. Residencies were subject to vibration levels that were monitored using six seismographs that surrounded the site and these units measured vibration levels that were significantly lower than allowed by statute. There were complaints triggered by individuals reactions to blast vibrations which validated commonly held models of human perception but no damage was caused by the Blasting.

Jan 1, 2024

By R. Narendrula, S. P. Singh

The productivity of a loading machine is affected by several factors. One of the most significant is the characteristic of the muck being loaded. A study was conducted to examine the effects of the looseness, angle of repose, size distribution and moisture content of the blasted material on the efficiency of the loading machine. The study was conducted in the following stages: (a) controlled experiments in the lab, (b) tests with loader simulator and (c) field work in an operating mine. It was found that looseness (%void) in the muck increases with the increase in the value of the mean particle size and index of uniformity of the fragmented rock. Looseness and angle of repose affect the fill factor and the digging cycle time of a loader and in turn the productivity of the equipment. Moisture content affects the angle of repose as well as the stickiness of the material to the loader’s bucket. It was observed that the angle of repose increased with the increase in the mean particle size and the moisture content of the muck. It was also found that the bucket full factor and rate of scooping decrease with the increase in the values of mean particle size and index of uniformity. This was also conformed during fieldwork that bucket fill factor decreases with the increase in the mean particle size as well as the index of uniformity.

Jan 1, 2005

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

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

Jan 26, 2026

By David Leidel, James Stuart

The 50 ohm resistorized electric detonator is commonly used in the oilfield for initiation of wireline conveyed perforating guns and other downhole explosive tools. This type of electric detonator provides some degree of safety above that of the conventional one ohm electric detonator, since a higher current level is required to initiate the device. In order to obtain the necessary data to develop safe distance tables from RF sources for the 50 ohm electric detonator, laboratory tests were conducted to determine the detonator’s “no-fire” current, AC impedance, and its susceptibility to ESD. The results were surprising as two types of failure modes were observed. The “no-fire’ current levels determined from Langlie “One-Shot” Test Methods were determined for the devices tested providing values for the 0.999 probability “no-fire” power level at a 95% confidence level. This data will serve as the basis for sets of safe distance tables from RF sources that will appear in the forthcoming edition of the Institute of Makers of Explosives Safety Library Publication 20, “Safety Guide for the Prevention of Radio Frequency Radiation Hazards in the Use of Commercial Electric Detonators, (Blasting Caps)”.

Jan 1, 2010

By L. Chaves

In rock blasting, due to numerous factors, both controllable and uncontrollable, the execution rarely meets the planning. The powder factor is an important KPI for blasting since it represents the amount of explosive used to fragment the rock, therefore it depends on the rock mass characteristics and may be influenced by factors such as weathering and drilling quality. The blasts at the Serra Sul mine, S11D project, are usually big blasts and the high productivity is a challenge for maintaining the quality of the whole drill and blast process. It is important to know the contributions of each of the most common influencing factors of the powder factor to direct the efforts to the improvement of the process. A buildup model is presented to evaluate the contributions of five influencing factors to evaluate the planed x executed powder factor. The factors considered in the model are the average hole depth, the amount of hole/blasted volume, the stemming and decking length, the linear charge weight, and the density of the explosive used. The build-up may be applied for both individual blasts and for overall view of the blasts in a period. A case study is presented with the application of the model for the monthly powder factor analysis at Serra Sul mine has contributed to direct efforts to enhance drilling quality and preservation of the drilled holes.

Jan 1, 2024

By Luis Huaroc, Augusto Sotomayor, Erick Rodriguez, Paulo Fernández, José Ricaldi, Luis Alejandro

The application of the Kuz-Ram model for the prediction of fragmentation is used worldwide, in Coimolache Mine it was used to determine blast domains and optimize the process by obtaining drilling patterns that meet a required X80 and reducing the uncertainty of drilling.

Feb 1, 2020

By Scott G. Giltner, Alex Schwenk

This paper is an update on a paper presented at the 2022 ISEE conference. The original paper presented how the mine operator desired to open up ore reserves near several mine structures including two crushers, the conveyor belt drive and the concentrator thickeners. In order to open up additional ore for extraction (over 3 million long tons or 3 million tonnes) it was necessary to blast out two benches near the mine structures. Since the two benches have been successfully shot, the mine has now conducted nine production blasts in this area at distances as close as 116 m (380 ft) to the two primary crushers. These production blasts are full size production blasts consisting of up to 300 or more blast holes. For these blasts the two primary crushers were still the critical structures as they were the production life blood of the mine. If the crushers were shut down due to any damage from the blasting, the revenue of the mine would be adversely affected. As with the initial bench blasts, two issues provided an extra challenge to the blast design. The first was that the blast holes were still considered large diameter at 12¼ inches (311 mm) and 16 inches (406 mm). The second issue was that the bench heights were short, with the average varying from 34-40 ft (10.3-12.2 m). This combination of large diameter blast holes with a short bench provided an unfavorable geometry for the goals established by the mine management. The mine management established the following goals. 1) None of the mine structures would be damaged by fly-rock. 2) Minimize the blast vibrations at the crushers. 3) The last goal was to produce a muck pile that could be dug easily by hydraulic shovels. Electronic detonators were applied to achieve the necessary control of the blast and optimal fragmentation throughout the mine. UAV surveys of the blast area were also conducted to provide a 3-D representation of the free faces and bench surface. The 3-D point cloud produced from this was used to measure the shape of the free faces. Once the shape of the free faces was quantified, it was possible to establish proper placement of the crest holes and develop a custom explosive load for each blast hole. The results of the nine blasts have provided what the customer requested. The peak vibration level at the crushers for the nine production blasts was 1.6 in/s (40.6 mm/s) at a frequency of 18.9 Hz. There have been no fly-rock or blast vibration issues at any of the nearby mine structures. As a result, the mine has been able to maintain its production with no downtime. The muck piles have been well fragmented with reports from the shovel that they have all dug well.

Jan 21, 2025

By Jose Pineda, Abraham Lindo

The Panama Metro System’s Network expansion involves excavating a launching shaft for a tunnel boring machine (TBM) to traverse beneath the Panama Canal. The blasting needed for this shaft construction poses significant challenges due to the presence of concrete walls encircling the excavation. These walls must remain intact throughout construction and the tunnel's future operation. This case study is focused on devising and implementing safe blasting techniques crucial for the shaft's construction, ensuring the preservation of surrounding concrete walls and project equipment. As the interest was potential damage to the concrete walls, an appropriate vibration threshold for this project was also required as an alternative to the traditional U.S. Bureau of Mining RI-8507 limit (USBM RI8507). Blast modeling software was employed to conduct a series of blasting simulations. Parameters like hole diameter, spacing, depth, explosive type, and initiation methods were varied to evaluate their potential effects on wall stability and damage risk. The simulations revealed that smaller diameter holes and reduced spacing between blast holes would effectively mitigate the risk of wall instability. Additionally, utilizing electronic delay detonators and carefully planning the blast hole detonation sequence proved critical in minimizing potential damage. Executing these blasts in the field presented unique challenges, including strict charge per delay thresholds and logistical constraints. Consequently, continuous adjustments to blasting parameters were made and comparative result analysis. Beyond providing a safe blasting strategy for the TBM launching shaft, this study offers invaluable insights into adapting blasting designs to align with environmental and structural safety standards. These findings hold great potential to shape guidelines for analogous sensitive construction projects. They underscore the importance of leveraging prior research as a reference point, engaging with project designers and local authorities, and continually conducting testing and adjustments to ensure project success.

Jan 21, 2025

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 Karl Christopherson, Vanessa de Viterbo

Trim blasting is an integral part of the mining processes at the Morenci Mine, a Freeport-McMoRan Copper & Gold Inc. property. Trim blasting near high-walls or Finals blasting requires a tighter distribution of energy but a reduction in total energy factor near the wall. Recent Finals blasting in Morenci Mine was allowing the shovel to dig to the final design limit, but causing high-wall instability due to excessive energy or production of energy (blast design and timing). Slope instability events reduced production in two of the three operating pits in Morenci over 2009. In order to avoid high-wall instability from Finals blasting, a new method was required. The new method utilizes air-decks, unconventional row timing, and blast design based on the geology predicted. Many different geologic structures and rock types exist in Morenci, and different strategies were needed for the many predicted geologies. Drill penetration rate and core mapping were the primary tools for determining the blast design. Patterns were designed within a consistent geology; with weaker rock types receiving a lighter load than the stronger rock types. Penetration rate returned by the drill would be the determining factor on the actual rock hardness. Maintaining the pattern geometry on Finals designs should not be an issue as long as the lb/hole is adjusted to reduce powder factor close to the high-wall. One requirement of Finals blasting should be that the powder factor matches the geology as closely as possible. A softer, fractured zone should use approximately one-half to two-thirds the explosive charge of a competent, sound geological zone. This has been incorporated into the final Trim blast design. It is impossible to protect every high-wall from close-in blasting, especially those with crossing prominent joint sets inclined toward wedge failure, but this new design has provided protection on walls where the mine was encountering problems.

Jan 1, 2011

By Tristan Worsey

This work was performed during the summer of 2008 during the junior year of a BS in Mining Engineering. It was observed that the mine was having a problem with back break during the blasting of development drifts. The unwanted back break was causing the mine extra costs in ventilation, ore dilution, ground support, back fill, explosives and man-hours. The blasting practices were observed for four weeks and the problems and their solutions were defined. In this paper the reasons and causes of the problem are explained with the proposed solutions to eliminate back break.

Jan 1, 2010

By Thierry Bernhard, Johan Finsteen, Charles Dowding, Mathias Jern

To bring some clarity to how different standards relate to each other a project was initiated within the European Federation of Explosives Engineers (EFEE). The first part of the project was a literature study and a survey including an evaluation of the answers provided by members of EFEE. The results were presented at the International Society of Explosives Engineers (ISEE) conference in Denver 2020 as well as the EFEE conference in Helsinki in 2019.

Feb 1, 2020

By Peter Moser, Mark Ganster, Radoslava Ivanova, Florian Bauer

Blasting accurately in underground drifts and creating a smooth contour requires proper drilling, knowledge about the apparent geology, a well designed blast pattern and ideally a smooth blasting product. These products are usually cartridged explosives with less energy and are charged in the contour holes in order to reduce the energy concentration and therefore the cracking into the surrounding rock. With the development of a new contour blasting system, a device can now be delivered to the industry that that avoids the additional storage of cartridged products when bulk explosives are used. The system consists of a foldable hose that is charged with bulk emulsion, in the same way as the rest of the blast, from the base to the collar of the hole. It centers automatically in the borehole and provides a decoupled charge. The paper describes the system in detail, gives background information on smooth blasting and presents the first successful field tests using the system in the drifts of an underground mine. It shows the advantages of blast results that produce more stable contours that reduce the amount, time and cost for support but also increase safety underground.

Jan 1, 2012

By Fred Baldassare, Marcia Harris, Kenneth K. Eltschlager

Surface mine blasting was recently investigated as a potential source of high concentrations of stray gases found in nearby residences of western Pennsylvania. In one incident carbon monoxide was detected in a home and in the other, high concentrations of carbon dioxide were found in a home. Both carbon monoxide and carbon dioxide are by-products of blasting. However, other potential sources of these gases may also exist in a residential setting. In each case, gas chromatography (GC) and carbon isotopic analyses were used to define atmospheric concentrations inside the homes, and to determine the source of a stray gas. Molecular and isotopic analyses provide geochemical evidence as to the origin and source of the stray gas. This paper discusses elements of a stray gas investigation and the analyses necessary to identify the source of a stray gas.

Jan 1, 2004

By Thierry Bernard

Since the signature hole method principle has been described in the 80's, there has always been a lot of controversy about it. The theory is easy to understand but when it comes to apply it for predicting vibration level, optimizing timing to reduce PPV or shifting frequencies, it’s not always working as expected. Simulations show waveforms that don't make any sense or predictions that are far away from actual results.

Jan 1, 2012

By J. P. Proulx, Richard O’Meara, Ruilin Yang

A blast optimization project was carried out at an Open Pit Metal Mine using the Multiple Blasthole Fragmentation (MBF) Model and the Multiple Seed Waveform (MSW) blast vibration model. The aim of the project was to optimize rock fragmentation of the ore blasts to significantly increase metal recoveries while keeping the blast vibration levels at the highwall under control. The project also examined the blasts in the waste rock using the Fragmentation model to expand the blast pattern and select economical explosives for drill and blast cost savings while minimizing any adverse effect on the dig rates. Two sets of near field signature blasthole tests were conducted in both hard ore and relatively soft waste rock. The information from the near-field signature blasthole vibration was used as input to both the MBF and MSW models, as site specific geological information interacting with blasting. The implementation of the full blast design is also input to the MBF and MSW models. A production blast for each rock type was monitored for blast vibration and rock fragmentation. The full blast information and the blast results are used to calibrate and validate the models. The Fragmentation and Vibration model were established for the two rock types at the mine. At each site the Fragmentation modeling was conducted in parallel to the Vibration modeling to ensure blast vibrations were under control while the rock fragmentation was improved. The Fragmentation MBF and MSW are each an integral part of the blast optimization tool. Various scenarios using different explosives, hole delays and blast patterns were modeled for rock fragmentation and blast vibration. The recommendations from the modeling project were to be field trialed at the mine. The implementation of the recommendations was expected to help the mine significantly in terms of the mining economics, and high wall stability and safety.

By Braden Lusk

Vibrations as a result of blasting practices in mining engineering are a complex phenomenon controlled by many variables. Mine blast vibration modeling and prediction is becoming more important as a consequence of the general negative perception of mining activity by the public. Many communities (all over the world) close to mining activity often complain about airblast and vibrations produced from blasting activity. It is important for the mining industry to have tools and understandable methodologies to model and predict blast vibration. These tools can then be used to control vibration at neighboring structures.

Jan 1, 2013