Hard Rock Blasting in an Underground Coal Mine

Mark D. Kirkbride
Blast Design International
San Marcos, TX

Abstract

This paper outlines the process for designing a hard rock blast in an underground coal mine. The coal
mine is located in Western Kentucky and operates four continuous miner units at 7 unit-shifts per day.
The mine operates in the Western Kentucky No. 11 Seam with local variations from 4.5 - 5.5 feet seam
thickness. The seam has sporadic siderite deposits. Usually these deposits do not significantly interfere
with the mining process. When previous siderite deposits were encountered they were small enough to
drop an entry for a couple of crosscuts. The blasting plan was called for after a siderite deposit was
encountered in the belt entry at about one third of the panel length. The other sides of the panel had
been previously mined and sealed so the decision was made to mine through the siderite deposit with the
continuous miner instead of abandoning the panel. The deposit was approximately 300 feet in length
down the belt entry. Mining through the deposit with the continuous miner was expensive in both terms
of production and of wear and tear on the continuous miner. A blasting plan for the siderite deposits
was designed to minimize damage to the continuous miner should a similar situation occur.

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Geology

The Western Kentucky No. 11 is a major source of coal for underground mines in Kentucky’s portion of
the Illinois Basin. The No. 11 Seam is a source of high BTU, high sulfur steam coal. The seam is
approximately 200 feet deep at the discussed mine. The siderite deposits are commonly formed in an
environment of low oxygen content continental waters, associated with clay and carbonaceous material.
Siderite is considered semi-hard (3.54), but informal rebound test with a rock hammer found the deposit
to be considered hard (56.5) in situ. The deposit was much too hard to be mined effectively by
mechanical methods.

Mining Method

The mining method used was a room and pillar method on 55 foot x 65 foot centers with crosscuts and
entries on the 18-20 feet width range. Two continuous miners (CM) operated on a single sweep of air in
three of the four units. In this ventilation pattern only one CM could be in production at any instance.
The fourth unit used a single CM in a typical continuous mining method with three shuttle cars. Eight
entries were driven in most panels. When the siderite deposit were encountered an entry was dropped
until the siderite deposit was passed. The entry would be picked back up after mining conditions
became more favorable (Figure 1). In cases where the deposit was situated in the belt entry (Figure 2)
the unit would be pulled out and the panel would be driven from a different side to be most
economically effective. On the occasion that brought the demand for a drilling and blasting plan was on
a panel that had sealed works on three other sides and a siderite deposit in the belt entry. Instead of
abandoning any chance of mining the remaining two thirds of a panel, the decision was made to use the
fourth unit to mine through the deposit. A partially staffed fourth unit mined the 300 feet through the
deposit. A drill and blast program was designed to eliminate the excessive teeth replacement on the CM
and allow the fourth unit to be moved to a new location to continue production, while a small crew
blasts through the deposit.

Blast Design

The main difficulties in designing a hard rock blast in an underground coal mine were the geometry and
scope of the blasting and the restrictive regulations put on blasting in an underground coal mine. These
factors in combination with a limited knowledge of blasting in underground coal due to the dominance
of mechanical mining presented a challenge to the mine engineering department.

The geometry of the entry was 16-20 feet wide x 5 feet high. The width was dictated by 16 feet
minimum needed to hang the belt in the entry and regulations limiting the maximum width of the entry
to 20 feet. The height was an average height in the mine with a desire not to remove any more material
than was necessary. Due to the infrequency that this plan would be implemented a minimal investment
was going to be made for drilling. Either an old coal drill that was left over from conventional mining
days or a jack leg drill was going to be used. This limited drill hole diameters and depth.

Blasting is one of the most dangerous methods of mining and underground coal mining is one of the
most hazardous types of mining. These two factors result in a very stringent set of Federal and State
laws concerning blasting in an underground coal mine. The regulations were written for conventional
mining using explosives to shoot the coal to a kerf or off the solid. Regulations concerning number of

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caps, pounds per hole, and hole-to-hole distance was not favorable to shooting hard rock. As with many
other situations in the mining community, a call went out to the powder companies for assistance. Two
of the leading powder companies each submitted a plan to the mine. Both were illegal to implement
without modifications. One company submitted a burn cut design which was design to have the collars
of loaded holes closer than the 18 inch minimum. The second company submitted a wedge cut that was
designed for a 24 foot entry and also suggested the use of nonpermissible caps. The legal limit for entry
width in underground coal mining is 20 feet. For blasting in underground coal, only MSHA certified
permissible caps and explosives may be used.

There was also some confusion inside of Mine Safety and Health Administration (MSHA) as to the 18
inch minimum distance between loaded holes regulation. On the wedge cut design the backs of the
holes were going to be closer than the 18 inch minimum. After getting a MSHA official to comment
that the 18 inch minimum was for the collar of the holes, a second MSHA official declared that if holes
were intentionally drilled at an angle, as with a wedge cut, the regulation applied to the collar and back
of the hole. Both officials made calls to a higher office to determine that the regulation was intended to
regulate where the collar of holes could be placed.

Permissible dynamite and caps also presented limitations. Permissible caps were limited to 9 delay
periods with 50-75 millisecond delays. The author searched for a permissible sequential timer, but as
none was found, the blast designs were limited to 9 delays. Most permissible dynamites were designed
for shooting coal and had a lower velocity of detonation (VOD) than is desire for shooting hard rock.
One permissible dynamite was found that was designed with a higher VOD to be used in hard rock. The
blast designs intentionally had higher powder factors (PF)(PF being measured in pounds/ cubic yard)
than would probably be needed. This was due to not having submit a new blasting plan for Federal and
State approval if conditions needed a higher than expected PF. The plan was written with options to
decrease the PF by either reducing pounds of explosives per hole or increase hole-to-hole distance.

Burn Cut Design

The burn cut design had the advantage of having drill holes perpendicular to the face. A template would
be made to assist in drilling the closely spaced holes in the burn round. The holes are to be drilled 6 feet
deep (Figure 3 and Figure 4). Disadvantages of the burn cut design when compared to the wedge cut
design are the need for a higher powder factor, a tighter drilling pattern, and a greater number of holes
that needed to be drilled, but not loaded.

The blast design consisted of 40 loaded holes with three pounds each and 7 relief holes. The initial hole,
first delay position would be alternated from top of the design to the bottom to give some movement of
the burn in the pattern. All holes are drilled parallel to direction of the entry. A maximum powder
factor of 6.0 lb/cubic yard should be more than sufficient to pull this shot. Contingencies were made in
the blasting plan to reduce the powder factor from 6.0 lb/ cubic yard by either increasing hole-to-hole
distance or decreasing the pounds of explosives in each hole. A suggestion was made by a cap
manufacturer to shoot the burn round first, delays 1-4, before drilling and shooting the remaining holes,
delays 5-9. This method might be implemented if there is some concern for the burn round not pulling
to full depth.

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Wedge Cut Design

The wedge cut design has the advantage of a lower powder factor than the burn cut due to the angle
drilling. The angle drilling itself is a disadvantage of this design when compared to the burn cut. It is a
much more complex drilling pattern than the bum cut. Ribs that are not uniform is another disadvantage
of the wedge cut. Another disadvantage of the wedge cut design is that there is a danger of the “Baby-
Breaker”, or center “V”, crossing at the center of the shot.

The wedge cut design is shorter by 0.5 feet in height and narrower by 2 feet in width(Figure 5, Figure 6,
& Figure 7). To compensate for this change and to keep the production shot similar in number of cubic
yards per shot for comparison reasons the depth of the shot was increased to 7 feet. The design consists
of 36 loaded holes drilled at angles and 3 relief hole drilled perpendicular to the face to half depth. With
3 pounds of explosives per hole, the Powder Factor for this design is 5.4 lb/cubic yard. This is
intentionally higher than is expected to be needed and can be adjust downward by further separation of
holes or decreasing pounds of explosives per hole.

Blasting Plan

A blasting plan is included in Appendix A. The plan includes an application for the use of a non-
permissible shot-firing unit including the exception to the 20 shot limit for rock excavation. A MSHA
District Manager must issue a permit to the mine to exceed the 20 shot limit. Included in the Blasting
plan are other safeguards that need to be taken during blasting in an underground coal mine.

Conclusion

The author left the company for which this blasting plan was designed. To the best knowledge of the
author the plan has yet to be submitted for State or Federal approval, therefore implementation of the
plan has yet to take place. However, due to the rarity of this kind of situation in present day
underground coal mine this paper will be a valuable reference to other mines finding similar situations.

References

Austin Powder Company, 1995, “Product Information Bulletins”, Beachwood, Ohio.

“Code of Federal Regulations, Title 30, Parts l-199”, 1992, pp 602-609.

Commonwealth of Kentucky Department of Mines and Minerals, 1995, “Laws Governing the Mining of
Coal and Clay”, pp 21-27,47-48.

Commonwealth of Kentucky Department of Mines and Minerals, “Study Guide for General Blasters
Examination.“.

Crickmer, D. F., Zegeer, D. A. (Eds), 1981, ‘Elements of Practical Coal Mining’, Port City Press, Inc.,
Baltimore, Maryland.

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1999G Volume 1 - Hard Rock Blasting in an Underground Coal Mine - P 326 4 of 10
Hartman, H. L. (Ed), 1992,‘SME Mining Engineering Handbook’, 2nd Edition, Volume 1, Society for
Mining, Metallurgy, and Exploration, Inc., Littleton, Colorado, pp 722-760.

Hopler, R. B. (Ed), 1998, ‘Blaster’s Handbook’, 17’h Edition, International Society of Explosives
Engineers, Cleveland, Ohio, pp 35 I-408.

Hustrulid, W. A. (Ed), 1982, ‘Underground Mining Methods Handbook’, The American Institute of
Mining, Metallurgical, and Petroleum Engineers, Inc., New York, New York, pp 234-235.

ICI Explosives, 1994, “Blaster’s Handy Tables and Guidelines”.

Kirkbride, M. D., Worsey, P. N., Rupert, G. B., 1995, ‘Vibration Monitoring and Control of Blasting
Associated with the Relocation of Highway H, Green County, Missouri’, Rock Mechanics and
Explosives Research Center, Rolla, Missouri, pp A2-A6.

Worsey, P. N., “Mining 307 Course, Blaster’s Training and Certification Course”, University of
Missouri-Rolla, Rolla, Missouri.

Figure 1. Bypass Siderite Deposit

I /Deposit 1

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Figure 2. Siderite Deposit in Belt Entry

pBBr_rBBBq
! tr n B
am
Figure 3. Burn Cut Design Drilling Pattern
::::i

DRILL PATTERN

A------l
t ‘. I -
21’
0 0
18’ = :-I
24’ 0 0 0 5’
0 0
18’
t

24’ 24’ 24’-

I’wvdw I~uclnr C:alcidalions
oLooded Hole
40 holes X 3 lb/hole = 120 Ib
*Relief Hole (not loaded) 18’ wide X 5’ high X 6’ deep = 540 tuft
5 4 0 cu. ft. = 20 cu. yd.
40 Loaded Holes P.F. = 120 lb/20 cu. yd. = 6.0 Ib/cu. yd.

7 Relief Holes Holes ore drilled perpendicular to face.

3 @ 3 ’ radius
4 @ 6’ r a d i u s

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Figure 4. Burn Cut Timing Pattern

BLAST TIMING

oLooded Hok Powder Factor Calcuhtions

4 0 ho(es X 3 lb/hole = 120 lb
*Relief Hole (not loaded) IS’ wide X 5’ high X 6’ deep = 540 cu.ft.
5 4 0 cu ft. = 20 cu. y d .
40 Loaded Holes P.F. = 120 lb/20 cu. yd. = 6.0 lb/cu. yd.

7 Relief Holes Holes o r e drilted perpendrulor to face.

3 I? 3 ’ rndks
4 @ 6’ radius

Figure 5. Wedge Cut Drilling Pattern

DRILL PATTERN
:;;Lb.;;
, 0 0 0. 0 0 0 .1
4.5’
18’ .
0 0 0 0 0 0
.
18’
i : ::I
-330’ ( 30’ 30’ ( 30’1

D Looded Hole POWDER FACTOR CALCULATION

36 holes X 3 Ib/hole = 108 Ibs
. Relief Hole (not loaded) 16-B wide X 4.5’ high X 7’ deep = 536 cu. ft.
536 cu. ft. = 19.83 cu. yd
36 Loaded Holes Pf = 1OE lb / 19.83 cu. yd = 5.4 Ib/cu. yd

3 Relief HoIes Holes drilled in wedge pattern.

Center of Face ( s e e a t t a c h e d drowlng)
Perpendickar to Face

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Figure 6. Wedge Cut Drilling Pattern, Top view.

T O P V I E W OF D R I L L P A T T E R N

Figure 7. Wedge Cut Design Timing Pattern.

BLAST TIMING
J i. =, a ? A 5 L J

? a 2 d . d 3 a 6

a 2 d l

.
d 2 3
e
o Loaded Hole POWDER FACTOR CALCULATION
36 holes X 3 lb/hole = 108 Ibs
s Relief Hole (not loaded) 16-18’ wide X 4.5’ hioh X 7’ deep = 536 cu. ft.
536 cu. Ct. = 19.83 cu. yd
36 Loaded Holes PF = 108 Ib / 19.83 cu. yd = 5.4 [b/w. yd
3 Relief Holes Holes drilled in wedge pottern.
Center of Face (see attached drawing)
Perpendicular to Face

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Appendix A - Blasting Plan

Application of use of Non-Permissible Shot-Firing Unit, including the exception of the 20 Shot
Limit for rock excavation.

The permit entitles the operator to use a non-permissible shot-firing unit while blasting siderite deposits
in the mine (maximum of 100 holes), provided that the operator complies with the safeguards as set
forth in the application for permit. Utilization of the attached plan will reduce exposure to miners to
unstable roof if advancement was taken in segments of 2 or 3 shots.

A copy of this permit and all safeguards proposed by the operator pertaining to use of non-
permissible shot-firing units shall be posted on the mine bulletin board and near the blasting site.

The shot-firing unit shall have adequate capacity to fire all charges in a round. The unit will have
a capacity to discharge 1000 caps (parallel series) or 100 caps (straight series).

The shot-firing units shall be properly maintained and tested annually to insure compliance with
the rated capacity.

The person using the shot-firing unit shall be a qualified person designated by management who
shall be thoroughly familiar with the plans and safeguards designed to protect the miners.

The entire blasting operation shall be under the direct supervision of a certified person.

Adequate rock dust shall be applied to the mine floor in the blast area for a distance of 100 feet in
all approaches to the blast area.

The Following Criteria will be Followed

All brows will be supported according to the approved Roof Control Plan.

Detonators shall be properly identified and stored separately from the explosives. The detonators
will be inserted into the blasting cartridge in such a manner that they will not become dislodged or
damage the wires during handling or charging of holes.

Stemming will be used in compliance with State and Federal regulations. Clay dummies will be
used.

The area will be dangered off on all approaches prior to blasting.

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At least 2.50 feet of not less than 16 gage shot firing cable will be used.

The shooting circuit will be tested with a blaster’s galvanometer prior to detonation.

The area will be checked for stray currents prior to blasting.

The area will be checked for methane prior to blasting.

The area will be checked after blasting for misfires, dangerous roof conditions, methane and other
dangerous gases.

After blasting, the rock will be loaded and the cavity bolted as per the approved roof control plan.

Permissible explosives will be used in blasting the advance. A maximum of three (3) pounds per hole
will be used. The amount of explosives per hole may only adjusted downward from the three (3) pound
maximum, depending on the elasticity of the rock.

All persons in the blast area will be alerted when loading operation are begun. All accessible entries to
the blast area will be posted to warn persons entering the area.

No persons shall be located inby the blast area during detonation. Blasting of the charged holes shall be
completed as soon as possible after loading of the holes is completed.

“Bootlegs” or holes that have contained explosive charges will not be used for starting other holes.

Two (2) drill hole patterns are attached. Either pattern may be use based on blasting conditions. No
holes containing explosives are closer than 18 inches, assuming solid rock. The drilling patterns may
only be altered to increase hole spacing, to compensate for a loaded hole in coal or other geologic
conditions. A loaded hole in coal may be no closer than 24 inches to any other loaded hole. Holes may
be omitted if drill spacing is increased.

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