Blasting Optimisation

Client: Lafarge
Project: Worldwide Blasting Optimisation Initiative
Laser System: Quarryman® and Boretrak®

Lafarge is implementing a worldwide initiative to

optimise drilling and blasting operations across its
600 sites globally. The initiative aims to reduce costs,
increase safety, and lessen the impact on the
environment. The potential savings have been
estimated at 10-25 million Euros annually.

Blast Design Metrics Fragmentation has a large impact on quarry performance at every
stage of the drilling, loading, and blasting process. The initiative
therefore plans to increase awareness and understanding of
fragmentation and implement best practices to reduce direct and
indirect costs. Best practices include the identification of experts,
suppliers and equipment to improve the blasting process plus setting
up procedures and ensuring competency of operators through
training.

Principles of Successful Blasting

Blast Design Parameters

The measurement, understanding, and use of accurate design

metrics are very important for successful blasting. This should also
include consultation with mining plans and a good understanding of
the quarry geology.
3D Face profiling using MDL Quarryman® Pro
Blast Design Pre-requisites

Face preparation – Benches must be cleared, scaled of loose rock,

and inspected for condition before profiling and blasting.

Surveying –Accurate bench profiling and surveying is the first stage in

the manufacturing process and is critical to the efficiency of the
remaining downstream activities. Key to this is the use of correct
equipment and trained operators. Measurement of bench heights,
level of crest and toe, slope angle, and maximum & minimum burden
can be done using 2D and 3D laser profiling. By mapping a rock face
in detail it is possible to determine actual burdens in front of each
planned borehole to avoid excessive burden (vibration, oversize) and
insufficient burden (flyrock, airblast). If neglected or if surveying is
done incorrectly it can have a detrimental effect on the rest of the
Quarry face profiling manufacturing process including poor quality drilling and mining
operations with increased safety risks and cost.
 Blasting Optimisation
Blast Design

Pattern Design – Blast hole layout should be designed with respect to

the collected survey data and hence the accuracy and interpretation of
this data is paramount. Safety parameters, vibration limits, explosives
to be used, and design floor elevations must also be considered when
designing the pattern. The resulting blast design plan should clearly
specify the collar elevations, burden, spacing, drill hole diameter, type
and quantity of explosives and type and delay of detonators. The
layout of the blast hole pattern should then be set-out through the use
of surveying instruments.

Drilling

Execution - Checking that the drilling is done correctly as per the blast
design is very important including verifying the hole depth, diameter
and inclination using accurate blast hole geometry measurement
equipment. Incorrect drilling including wrong positioning, incorrect
angle, hole deviation, and incorrect depth can pose serious risks.

Explosives
Incorrect drilling execution
Loading Plan – Effective implementation and validation of the loading
plan including the position of delays, charge, charge distribution, type
& quantity of explosives, and stemming requirements.

Conclusion

The improvements gained from an optimised drilling and blasting

operation can be measured by reduced costs per tonne for blasting
and drilling, improved loading speeds, reduced oversize breakage and
handling, reduced energy consumption and less fines.

The average measured saving from the pilot study across 12 sites is
about 4 Euro cents per tonne. Across Lafarge’s total aggregate and
cement mined tonnes (250Mt) this equates to a 10 million Euro
savings annually. Lafarge is confident that further savings can be
made through a rigorous optimization process and is currently rolling
Borehole geometry survey using MDL Boretrak®
out the system across the group.

X.Thérin VP Land, Minerals & Mining