BLASTING TECHNIQUES

IN HIGH PRODUCTION
UNDERGROUND METAL MINES

By: Partha Das Sharma

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Author: Partha Das Sharma, E.mail: sharmapd1@gmail.com
IMPROVED & ACCURATE BLASTING TECHNIQUES WITH MODERN
PRECISION DRILLING - KEY TO ACHIEVE TECHNO-ECONOMICS OF
HIGH PRODUCTION UNDERGROUND METAL MINES

By: Partha Das Sharma, (E.mail: sharmapd1@gmail.com)

Introduction: Method of Mining in Underground Metalliferous mines mainly depend on

type of Deposit, i.e., regular or irregular; Extent and depth of deposit, i.e., massive /
pocket etc.; Dip and Thickness of deposit; nature of Hanging wall and Foot wall etc.
Method of mining in Underground Metalliferous mines also depend on required
production level to be achieved and accordingly type of mechanization adopted in
relation to drilling of blast holes for stoping operation, for development operation as well
as for handling and transport of mineral within and out of stope etc.

Of the stoping methods commonly used today for keeping high production level in
Underground Metalliferous mines, vary from Sublevel and Shrinkage methods for
shallow / medium depth deposit to Cut & fill methods with increasing depth. Successful
efforts have also been made to extend the cheaper Open stoping methods specially Sub-
level stoping; to as great a depth as possible by introducing controlled caving of walls. By
implementing recent advances in blast hole drilling / blasting & stoping achieving
maximum Techno-Economics in mining operation has been made possible.

Sublevel stoping for high production: Sublevel stoping is one of the most important
methods of choice for achieving high production rate in Underground Metalliferous
mines. It is an overhand, vertical stoping, utilizing long hole drilling and blasting carried
out from sublevels to break the ore. As compare to other stoping method this method uses
less temporary support; no personnel including drilling and blasting crew are exposed in
the stope proper; hence method is much safer. If support is needed in sublevel it is
provided by rock bolt, wire meshes, cables etc. Although the stopes are unsupported,
pillars are usually left between stopes and occasionally within stopes. The ore flows
through the stope by gravity in the customary way and is drawn off at the haulage level.
Application of this method in wide ore bodies with strong walls enable to adopt suitable
mechanization in drilling & blasting, prevention of dilution and handling / transport of
mineral within and out of stopes for obtaining high production rate in order to achieve
effective Techno-Economics.

Sublevel stoping with Long Blast Holes: Demand for increased rate of production
coupled with improvement in drilling technique has lead to the use of long hole blasting
for ore extraction from Underground Metalliferous mines. Considerable advances have
been made by introduction of long-hole and precise drilling in stopes. Today, most of the
sublevel stopes all over the world are drilled with long blast holes. This has called for
radical changes in stope design as compare to conventional Sublevel stopes with
increased sublevel intervals, better positioning of the sublevel in the ore body, improved
method of ore handling from the stopes to the haulage level etc., for higher production.
Further, by adopting improved & precise method of blasting with introduction of new

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Author: Partha Das Sharma, E.mail: sharmapd1@gmail.com
generation Emulsion explosives and Electronic Detonators, for such Sublevel stopes the
Techno-Economic level also maintained properly.

It may however be noted that, large diameter holes (sometimes upto 100 mm or more)
reduce drilling cost per tonne of ore broken. Moreover, blasting procedure with larger
holes is safer, cheaper and less time consuming due smaller number of holes and easier
charging and checking. With larger diameter of holes and by adopting improved &
precise method of blasting with introduction of new generation Emulsion explosives the
burden can be increased so effectively that parallel drilling can be done from sub-levels /
crosscuts instead of benches.

The pattern of long hole drilling can be classed under two major categories, i.e., Parallel
hole drilling and Ring hole drilling.

Parallel holes are preferred in many western mines for better fragmentation, easier setting
up of drill rigs, greater effective drill footage and increased tonnage of broken rock per
metre hole drilled as compared to Ring drilling. In many of the African Copper mines by
adopting parallel holes as much as 30 percent cost reduction on explosives and drilling
have been reported; which to a certain extent offset the extra cost incurred for slashing
the sublevel from wall to wall. However, the greatest disadvantage with parallel hole
drilling is its slowness due to extra time required for slashing the sublevel and lesser
safety for drillers drilling on slashed out benches. Because of these disadvantages in some
of the high production underground metalliferous mines Ring drilling is much more
common than Parallel hole drilling. Fig – 1A, Fig – 1B, Fig – 2 and Fig – 3 give typical
patterns of Ring and Parallel hole drilling.

Rings may be drilled from a central sublevel in relatively narrow stopes (about 15 to 20
m wide) to form two or more parallel sublevels in wider stopes. It is a general practice to
drill several rings of holes before blasting to make the drilling more continues process
and the blasting can be restricted to week-ends only, when enough time can be allowed
for clearance of post blast fumes and dust. The drills holes are made relatively smaller
(40 to 50 mm dia.), bored with percussion rock drills mounted on a column and drifter
with extension drill steel to a maximum length of 25 to 30 m. Hole deviation is a serious
problem, however, deflection of several metres are not uncommon. The effect in blasting
can be disastrous as ring drilling requires accuracy in hole placement to obtain proper
fragmentation. The problem of hole deviation, now a days, have been overcome greatly
because of introduction of sophisticated and accurate drilling machines; by which the
deviation is bare minimum.

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Author: Partha Das Sharma, E.mail: sharmapd1@gmail.com
 Fig – 1(A)

Fig – 1(B)

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Author: Partha Das Sharma, E.mail: sharmapd1@gmail.com
 Fig – 2

As mentioned, with long hole drilling, blasting practice has advanced considerably with
increasing use of stronger new generation emulsion explosives along with use of precise
and accurate millisecond NONEL / Electronic delay detonators for obtaining better
fragmentation during primary blasting. Judicious charging of holes in a ring using decks
with suitable delay timing ensures better fragmentation, restricted ground vibration and
reasonably better economy. In some of the mines where ring holes system is used, it is a
common practice to charge every fifth hole to within one foot (approx. 0.5m) of the
collar, every second and fourth holes to within twenty feet (approx. 6 to 7 m) and the
third to within ten feet (approx. 3 to 3.5 m) of the collar. Lesser burden on rings with
wider spacing of the toes of individual holes in ring accompanied by delaying the holes
from centre outwards helps in good fragmentation. Where ever possible proper
distribution of charge is made by using deck charges with in-hole electronic delay
system; thereby fragmentation is improved and blast induced ground vibration level can
also be reduced (Fig. – 7).

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Author: Partha Das Sharma, E.mail: sharmapd1@gmail.com
 Fig - 3

In most of the Indian condition holes are readily drilled to take advantage of cartridges 40
to 50 mm diameter. With 40 / 50 mm diameter cartridges burden of 2 to 2.5 m are
blasted; with 32 mm cartridges burden is kept of the order of 1.25 to 1.8 m. The type of
explosives used ranges from free flowing bulk loaded ANFO in dry hole condition to
high strength Emulsion explosives in wet hole condition. The charge factor / explosives
consumption in this type of blasting is generally kept of the order of 0.1 to 0.25 kg/tonne
of blasted ore.

It is a common practice to use short delay interval of 25 ms between holes in each row or
ring starting from the easiest breaking section in the middle and progressing towards the
walls. Under normal circumstances, it may be possible to charge holes extending to about
1.5 to 1.8 m (not more than the burden distance) of the collar without unduly
overcharging, but in cases where the configuration of ore body is such that the holes are
very closely spaced at the collar zone, it may be desirable to charge alternate holes only
close to the collar and others upto 3 to 4.5 m from collar in order to reduce the charge
factor (Fig – 4). The best pattern is decided by a series of actual trial blasts and it is
always advisable to slightly overcharge the holes because a failed blast could mean
considerable loss of production.

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Author: Partha Das Sharma, E.mail: sharmapd1@gmail.com
 Fig. – 4

Vertical Crater Retreat (VCR) – More advanced method of Sublevel stoping: With
the advent of large diameter (100 mm to 200mm) rotary and down the hole percussion
drills, it became practical to adopt modified version of large diameter parallel hole
drilling and blasting for sublevel stoping. With this system hole deviation is no longer a
problem (< 2%) with large, parallel holes; which can now be extended to about 90 m and
accordingly sublevel spacing is increased considerably.

The major innovation in Vertical Crater Retreat (VCR) method is of blasting. In this
method, horizontal slice blasting of ore body with near spherical charges into the
undercut is under taken. Spherical placement of explosives is the most efficient in terms
of fragmentation and explosives consumption. Holes are charged from collar after
plugging the opposite end. The size of charge is generally restricted to a Length-to-
Diameter ratio of 6:1; which suffices in the practice to simulate a spherical charge. All
holes in the stope are blasted together. After the broken ore from the stope is drawn, the
next slice of ore (generally about 4 to 5 m thickness in one slice) is charged and blasted

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Author: Partha Das Sharma, E.mail: sharmapd1@gmail.com
as before. As mentioned, drilling is carried out from sublevel and is usually complete
before slice blasting commences; the high level of efficiency and productivity is obtained
with VCR method of sublevel stoping.

Fig. – 5

Rock mechanics, blasting and material handling considerations are the important points
in deciding dimension of stopes, location of boundary pillars etc. In addition, because of
the unique reliance on long hole drilling and blasting special attention in sublevel stoping
must be paid to rock-breakage / blast design, hole diameter, length, burden, explosives
selection, powder factor etc., to obtain desired Techno-economics of the mining system.

Basting in Vertical Crater Retreat (VCR) sub-level stope: Blasting is done in stope
worked by Vertical retreat method by drilling holes in slashed sublevel. The holes are
drilled parallel, mostly either vertical or inclined along dip of the ore body. A few holes
at both the ends of the rows near the walls are drilled inclined into the walls to prevent
any ore to be left out in the vicinity of walls (Fig. – 6). Blasting is done in slices, after the
holes are charged from collar by plugging at the opposite end. Extensive surveys are
carried out before charging in order to know the exact extent of holes, their depth,
inclination, end points etc., to ascertain correctly the placement of plugging at the bottom
of holes. Delay sequence is used by using NONEL. Delays are so adjusted that, centre
holes of middle rows are blasted first. Side holes are blasted subsequently.

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Author: Partha Das Sharma, E.mail: sharmapd1@gmail.com
 Fig. – 6

Drilling and blasting for Depillaring of various pillars – As the competent nature of
rocks called for adoption of Sublevel open stoping, thus open stoping essentially results
in leaving a network of mine pillars for maintenance of overall stability of the mine. In
sublevel open stoping, as pressure abetments are quite high in the various pillars, these
pillars encounter high level of lateral stresses and with prolonged working these pillars
undergo continuous deterioration. One of the methods of relieving ground stresses is to
mass blast these pillars regularly. Drilling activities in such high stress zone encounter
following constraints.
a) Failure of Drill drive and spalling from it.
b) Failure or collapsing of drill holes.
c) Development of extension fractures.

Thus, in such a high stress zone, explosives charging into the hole and blasting thereof
are important aspect, which very carefully and efficiently should be organized.

With proper support spalling at the drilling site is checked. By use of non-cartridge
explosives blasting operation in partially collapsed holes can be undertaken. Because of
generation of extension cracks problem back-break become obvious, which require
proper blast design to tackle. The adoption of following measures can effectively reduce
chances of back-break.
a) Use of deck charging
b) As far as possible by reduction of charge density

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Author: Partha Das Sharma, E.mail: sharmapd1@gmail.com
 c) As far as possible by using de-coupled explosives.

Deck charging is done to minimize the maximum charge per delay. In longer hole to
restrict charge column separation of charges are done by giving deck (Fig – 7). Apart
from reduction of chances of back-break, ground vibrations also are checked.

Fig. – 7

Discussion on modern precision Drilling and Electronic Delay Detonator system for
enhancement of efficiency in Mines: Computerized drilling and electronic detonators
add precision at the mines to lower downstream costs. Gaining a competitive edge in a
mature and basic industry like underground and opencast mines / quarries, it has taken a
major leap forward in enhancement of Techno-Economics advantages in working of
mines.

Drilling and Blasting is the most important activities in working of any mines. In
particular, electronics are bringing a level of unprecedented precision to the process of

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Author: Partha Das Sharma, E.mail: sharmapd1@gmail.com
rock breaking in the mines. Computerized drills, Measure-While-Drilling (MWD)
systems, and electronic detonators are gaining wider acceptance in quarries, opencast and
underground mines.

Cost centers such as drilling, blasting, excavation, hauling and crushing are seen as
interrelated variables in the total cost equation. As the first step in this interrelated
process, improved results from drilling and blasting; even if it costs more; can
significantly improve costs and productivity of downstream cost centers such as
excavating, hauling, and crushing. In order for the advances in blasting technology to
effectively reduce the mining industry’s cost equation, smart equipment and other
innovative measurement technologies will need to be developed or advanced so that
information can flow back into the process for continuous improvement.

Conclusion – Therefore, with proper blast design and implementation of recent advances
in blast hole drilling in open stoping methods of Sub-level inclusive of Vertical Retreat
method gives a great deal of Techno-Economic advantages in order to achieve high
production level. As far as possible, new techniques with improved systems are to be
adopted in order to enhance over all efficiency of the mine workings.

References

1. Atlas Powder Company, Dallas, Texas, USA - “Explosive and Rock Blasting” 1987.

2. Blasters’ Handbook – E.I.du Pont de Nemours & Co. (Inc.), Wilmington, Delaware 19898.

3. Mishra, G.B. – “Recent trends in Mechanization and stope designing for higher production in
underground metalliferous mines and their applicability to Indian condition”, JMMF, Proc., of
symposium on Mechanisation of Mines in India at CMRS, Dhanbad (December 1961).

4. Sharma, P.D.; - ‘Improved Blasting with precision drilling patterns in Underground

Metalliferous mines’; Procc. of ‘Golden Jubilee Seminar’ - present status of Mining and
future Prospects, - Seminar organized by MEAI (April 2007) at Hyderabad, India.

5. Rajmeny.,P.K; Jain Suman; Rathore., S.S. – “Dealing with problems of blasting of

highly stressed benches during open stoping at Mochia Mine”- IMEJ proc., of National
seminar on Drilling & Blasting for next millennium; Bhubaneswar, January 2000
(Mintech Publications, Bhubaneswar).

6. Howard L. Hartman – Introductory Mining Engineering, John Wiley & Sons.

7. Product Literatures of various Drilling Machine manufacturers; such as M/s Atlas

Copco, M/s Thunderbird Mining system, Aquila Mining Systems of M/s Caterpillar
company etc.

8. Product literatures of various Electronic Detonator manufacturers; such as Digidet of

Ensign-Bickford Co., Ikon of Orica, Daveytronic’s Digital Blasting System, Delta Caps
Initiators’ Deltadet II system etc.

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Author: Partha Das Sharma, E.mail: sharmapd1@gmail.com
9. Sharma, P.D.; - ‘Controlled Blasting Techniques – Means to mitigate adverse impact
of blasting’; Procc. of 2nd Asian Mining Congress, organized by MGMI at Kolkata
(India) dt. 17th – 19th January 2008 (pp: 286 – 295).

10. Langefors, U & Kihlstom, B.K. – ‘The Modern Technique of Rock Blasting’, John Willy & sons, 1963.
***

Author’s Bio-data: Author is Graduate (B.Tech – Hons.) in Mining Engineering from

IIT, Kharagpur (1979) and was associated with number of mining and explosives
organizations, namely MOIL, BALCO, Century Cement, Anil Chemicals, VBC
Industries, Mahashtra Explosives etc., before associating with the present organization,
M/s Solar Explosives Ltd., Nagpur, few years ago.

Author has presented number of technical papers in many of the seminars and journals on
varied topics like Overburden side casting by blasting, Blast induced Ground Vibration
and its control, Tunnel blasting, Drilling & blasting in metalliferous underground mines,
Controlled blasting techniques, Development of Non-primary explosive detonators
(NPED), Electronic detonators etc.

Currently, author has following useful blogs on Web:

• http://saferenvironment.wordpress.com
• http://www.environmentengineering.blogspot.com
• www.coalandfuel.blogspot.com

Author can be contacted at E-mail: sharmapd1@rediffmail.com,

sharmapd1@gmail.com

Disclaimer: Views expressed in the article are solely of the author’s own and do not
necessarily belong to any of the Company.

***

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Author: Partha Das Sharma, E.mail: sharmapd1@gmail.com