LARGE DIAMETER AND DEEP HOLE PRESPLITTING

TECHNIQUES FOR SAFE WALL STABILITY

BRIDGER COAL COMPANY

PO. BOX 2068
ROCK SPRINGS, WYOMING

Rodney Burke Tom McDonald

ABSTRACT

As mining progresses in the West, the depth of material has increased, making highwall
stability a major factor in safety and production. The Jim Bridger Coal Mine has made
highwall stability a priority, concentrating on safety as well as increasing and improving
production. Overburden depths are increasing dramatically; the geological environment
consists of medium to soft material, faulting, water, and current pit alignment not favorable
to joint planes. Angle drilling the presplit at 20 degrees became necessary as vertical
presplit drilling produced wall failures.

In this paper we will discuss in detail actual presplit loading techniques tested and
developed at Jim Bridger Coal Mine. These include 10 5/8" hole diameters on 12-14 ft
spacings, foam plugs and a combination of Anfo/Emulsion blends in deck loading. Our
methods have achieved the desired presplit results in a depth range of 75 - 220 feet at 20
degrees.

Introduction

Bridger Coal Company is a subsidiary of Pacificorp and Idaho Power Company. The Jim
Bridger Coal Mine located 35 miles northeast of Rock Springs, Wyoming, USA. The mine
began coal production in 1974 and provides coal exclusively to the Jim Bridger Power
Plant. The Bridger mine is a strip mine that is presently 13 miles long and excavates
approximately 45-50 million bcy's (Bank cubic yards) of overburden and produce 6.5-7.5
million tons of sub-bituminous, low sulfur coal annually. Average coal composition is 9,400
btu, 0.6% sulfur, 19.0% moisture, 10.0% ash and 2.75% sodium.

The mining process at Bridger Coal uses four draglines; two Marion 8200's, one Page 757
and a Page 732 that excavate the majority of the overburden and inner burden. The
remaining overburden, innerburden and coal is removed with two 195B Bucyrus Erie
shovels, a Caterpillar 992 loader, a Caterpillar Dart 600C loader, a Caterpillar 994 loader
and a fleet of Caterpillar scrapers. Drilling of the presplit and production patterns is
accomplished by utilizing two Driltech D90K's with 10 5/8" bit diameter and an Ingersol
DML with a 7 7/8" bit diameter. The coal drilling is done with a Schroeder twin auger drill
system using a 5 1/8" claw bit. The annual amount of bulk explosives to shoot presplit,

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overburden, innerburden and coal are approximately 43-48 million pounds.

Geology of the mine is in the Fort Union Formation. This formation consists of sandstone,
siltstone, claystone and mudstones, with some carbonaceous content in the siltstone and
thin filaments in the bedding planes of the sandstone. The highest carbonaceous content is
in the claystone. The compressive strength of the rock ranges among 1,000 psi to 8,000
psi. Major faults are present throughout the mine having a vertical displacement of more
than 20 feet. The mined coal seams lay in an area known as the Deadman Coal Zone that
lies near the bottom of the Fort Union Formation.

Cast blasting is a critical sequence/function of the Bridger Coal drilling and blasting
program. Since highwalls are 200 feet high, development of presplitting was necessary to
ensure employee safety and highwall stability.

Previous Loading Procedures

We began our presplit program in 1984 and evolved in 1988 with the aid of Calder and
Workman Inc. The presplit vertically drilled at first had disastrous results due to wall
failures. We then looked at 20 degree angle drilling of the presplit, which has produced our
current highwalls. We loaded the presplit using a toe load of heavy anfo or anfo in dry
conditions. The explosives load amounts were based on a chart provide by Lyall Workman.
The chart was broken down into ten foot increments to a depth of 200 feet, hole size range
from 6" to 12 ¼" dia., at 14 foot spacings

Once the depth reached 125 to 175 feet, we began to see some cratering of the toe and no
visible crack at the surface. This cratering caused an overhang of rock once we cast blasted
the pit. The exposed wall was too high for a dozer to clean the overhanging material, which
meant that the dragline would have to clean the wall as it passed. The cast blast program
worked extremely well, but draglines had to replace material in order to get high enough to
reach the top of the wall. Having the dragline clean the wall created maintenance problems
due to unnecessary stress on the boom and very tight swinging conditions against the wall
developed. This motivated us to experiment and perfect new techniques to solve our
presplit problem.

Current Loading Procedures

The first step is to determine if the hole is dry or if there is water in the hole, marking the
water surface and total depth of the hole on a lathe. Parameters were tested and developed
at Bridger Coal regarding how to load each hole based on how much water, if any, is in the
hole. We are currently using a powder factor of 0.11 lb/sqft on 12 ft. spacing, 10 5/8" hole
diameter.

The steps and criteria for loading presplit holes are listed below.

(1) Dry Hole 75 ft or Less:

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A. If the hole drilled is in good competent rock then only a toe charge of anfo is required
using 15 gr. cord and ¾ lb. primer.(Refer to Fig. 1)

B. When the hole has been drilled in an area where there is a large amount of alluvium or
unconsolidated material, use a foam plug and split the charge in half as close to the
transition plane of solid or unconsolidated material as possible. This will cause a crack to
form bottom to top of the borehole.

Using 15 gr. cord, downhole delays and ¾ lb primers in both decks. (Refer to Fig. 4)

(2) Wet Hole 75 ft or Less:

A. When water is present in the hole and is less than 5 ft deep, place a foam plug on top of
the water, if dewatering is not possible or a liner cannot be used. Then, calculate the total
pounds of a water resistance emulsion blend.

Using 15 gr. cord, downhole delay and a 1 lb primer. (Refer to Fig. 2)

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B. If the water is greater than 5 ft, dewater the hole if possible and load with a water
resistant product. When dewatering is not possible, use a liner (7" diameter, 8-12 ft in
length) and load a minimum of 75 lbs at the bottom of the hole. This toe load is only to
eliminate the water with minimal presplitting expected of the charge. Then, place a foam
plug on top of the water with a water resistant emulsion blend to achieve desired results for
the remaining length of hole.

Use a 2 lb primer with the toe load and a 1 lb primer in the other deck with 15 gr. cord and
downhole delays. (Refer to Fig. 3)

(3) Dry Hole 75 ft to 150 ft:

A. When a hole is dry, calculate the total pounds of anfo needed. The total load is split in
half and two smaller loads are used with a foam plug at a point half the depth of the total
depth of the hole.

Use 15 gr. cord, downhole delays and a ¾ lb. primer in the toe load with a ¾ lb primer in
the upper deck. (Refer to Fig. 4)

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(4) Wet Hole 75 ft to 150 ft:

A. When water is present in the hole and is less than 5 ft deep, place a foam plug on top of
the water, if dewatering is not possible or a liner cannot be used. This toe load is intended
to eliminate the water with minimal presplitting expected of the charge. Then place a foam
plug on top of the water with a water resistant emulsion blend to achieve desired results for
the remaining length of hole.

A third deck may need to be placed in the hole when the hole depth is nearly 150 feet.
Consider the total length of the hole when calculating the total pounds. Then split the total
pounds in half and load the deck above the water with a water resistant emulsion. Placing a
foam plug half the distance of the hole depth measured above the water, using anfo for this
deck load.

Use a 2 lb. primer with the toe load, a 1 lb. primer in the second deck and a ¾ lb primer in
the third deck with 15 gr. cord and downhole delays in all decks. (Refer to Fig. 5)

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B. If the water is greater than 5 feet deep, dewater the hole if possible and load with a
water resistant product. When dewatering is not possible, use a liner (7" diameter, 8-12 ft
long) and load a minimum of 75 lbs at the bottom of the hole. This toe load is intended to
eliminate the water with minimal presplitting expected of the charge. Then, place a foam
plug on top of the water with a water resistant emulsion blend to achieve desired results for
the remaining length of hole.

A third deck may be needed in holes when the hole depth is nearly 150 feet. Consider the
total length of the hole when calculating the total pounds. Then, split the total pounds in
half, loading the deck above the water with a water resistant emulsion and placing a foam
plug half the distance of the hole depth measured above the water using anfo for this deck
load.

Use a 2 lb. primer with the toe load, a 1 lb. primer in the second deck and a ¾ lb primer in
the third deck with 15 gr. cord and downhole delays. (Refer to Fig. 6)

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(5) Dry Hole 150 ft to 220 ft:

A. When a hole is dry, we can calculate the total pounds of anfo needed. Split the total load
in three decks utilizing anfo loads, placing a foam plug at a point two-thirds of the depth of
the total depth of the hole. Then place the second plug at one-third of the depth remaining
for the third charge.

Use ¾ lb. primers, 15 gr. cord and downhole delays in all decks. (Refer to Fig. 7)

(6) Wet Hole 150 ft to 220 ft:

A. When water is present in the hole and is less than 5 feet deep and dewatering or a liner
can not be used, place a foam plug on top of the water with a water resistant emulsion
blend. The possibility of the water flowing in from above the water level must be evaluated.
The total explosive pounds needed for this load is calculated using the entire length of the
borehole and splitting the total pounds in half. A third deck may be necessary in the hole.

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By taking the total length of the hole above the water dividing the length in half for the
plug location. Loading the other one-third of the total explosive pounds with anfo at the
third deck.

Use a 2 lb. primer with the toe load, a l lb. primer in the second deck and a ¾ lb primer in
the third deck with 15 gr. cord and downhole delays in all decks. (Refer to Fig. 8)

B. If the water is greater than 5 feet, dewater the hole if possible and load with a water
resistant product. When dewatering is not possible use a liner (7" diameter., 8-12 ft long)
and load a minimum of 75 lbs at the bottom of the hole. This toe load is intended to
eliminate the water with minimal presplitting expected of the charge. Place a foam plug on
top of the water with a water resistant emulsion blend, being aware that water may flow in
from above the water level. The total explosive pounds needed for this load is calculated
using the entire length of the borehole and splitting the total pounds in half.

A third deck may be necessary in the hole. By taking the total length of the hole above the
water dividing the length in half for the plug location. Loading the other one-third of the
total explosive pounds with anfo at the third deck.

Use a 2 lb. primer with the toe load, a 1 lb. primer in the second deck and a ¾ lb primer in
the third deck with 15 gr. cord and downhole delays in all decks. (Refer to Fig. 9)

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Conclusions

Our presplit program began over ten years ago and is a continuing process. We have tested
numerous ways to presplit, which include vertical drilling, angle drilling, different hole
diameters (7 7/8", 10 5/8", 12 ¼"), increased hole spacings (8-16 ft), toe loading with an
open hole, air decking with a toe load, hanging or suspending anfo bags, loading with liners
and now decking using foam plugs.

We have had our best results using the foam plugs in decking with a combination of anfo
and emulsion blends. Development of the air deck technique which allows the energy of the
explosive charge to be contained for a longer period of time and lower the total amount of
explosive charge used, has proven to be beneficial in our presplit techniques. We are using
a modified version of this technique that does not use stemming to contain any of the
explosive energy, but are leaving an open borehole and utilizing the foam bags as our
containment and the added ability to separate the charges throughout the borehole with
excellent results. This current practice will allow us to experiment and possibly increase our
hole spacings once again.

There is no one certain way to load and shoot presplit over the entire length of any mine.
By continuing our development and evaluation program we are determined to establish the
appropriate presplit procedure; ensuring a safe, stable and production-oriented presplit
wall, at the lowest possible cost.

Acknowledgments

The authors would like to thank all the Drilling and Blasting crews at Bridger Coal
Company for their continued effort in making our highwalls some of the safest and most
stable in the country and for being patient in the development of the presplit loading

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techniques. We would like to also thank Lyall Workman who provided the technology to
advance our presplit program.

References

Workman, J. Lyall and Calder, Peter N.; "Considerations in Pre-Split Blasting for Mines
and Quarries", Calder and Workman, Inc., Washburn, ND 58577, 16 March 95

Workman, J. Lyall and Calder, Peter N.; "A Method for Calculating the Weight of Charge
to Use in Large Hole Presplitting for Cast Blasting Operations", Calder and Workman,
Inc., Washburn, ND 58577, 16 March 95

Teller, Albert E.; "Blasting Techniques III, Controlled Blasting", July 1993

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