ProWall

developed by Blast Dynamics, Inc.

ProWall - Operation Guide

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Introduction
The ProWall software is designed to assist with the development of blast designs that
minimize slope damage. Blast plans can be developed, evaluated and compared to
achieve optimum explosives and cost performance. The software can be used to:

create a database of explosives commonly used

easily develop relatively complex designs

plot a cross sectional and plan view of the design

perform a complete drilling, loading and blasting cost evaluation of the design

store the design in a database for future reference

compare plans in terms of design parameters, performance and cost

Installing the ProWall software

Follow the procedure below to install and use ProWall
1)

Install Microsoft Excel v5.0 or greater on your computer

2)

Create a folder (or directory) called ProWall on your hard drive

3)

Copy the workbook ProWall from the CD provided to the

ProWall folder. Remove the CD and store it in a safe place.

Using the ProWall software

1)

Start ProWall by double clicking its icon. The initial worksheet that will open will
be the Design sheet.

2)

To make ProWall easy to use there are buttons that perform specialized tasks.
The buttons on the Design sheet are shown below.

The function of each of these buttons will be covered in the description of each
sheet.

ProWall - Operation Guide

Introduction
Using the ProWall software (cont.)
3)

The ProWall worksheets will allow you to enter values only in cells that are
outlined and have BLUE text. This will prevent you from changing a formula or
label cell by mistake. If you enter a value into a protected cell and press enter the
program will not accept the entry.

4)

After you have entered your data, check the calculations by scrolling through
the worksheet using the scroll bar. If any cell displays #DIV/0 or Error then
one or more of the variable cells may not have numerical data in them. Be sure
not to enter text or blank spaces into cells that require number values. If any cell
shows ###### the value in the cell is too long to display. This can usually be
corrected by checking the variable cells for proper input or reducing the estimated
volume or mass to be shot.

5)

At the bottom of the screen there are tabs for the other worksheets.

You can activate the worksheet by pressing its tab. Each worksheet will be
discussed in detail in the following sections.

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Explosive Worksheet
Purpose:
The Explosive worksheet is a database that allows you to enter the
characteristics of over 200 explosives. Once entered, this information can
then be used by the Design worksheet. By entering explosives into the
database you will save time and reduce entry mistakes when designing
blasts.
Instructions:
Start the ProWall program and select the Explosive tab item from the bottom
of the screen. The Explosive worksheet will be opened and the screen will
look similar to the illustration shown here.

ProWall - Operation Guide

Explosive Worksheet
Instructions (cont.):
All of the ProWall worksheets share a common user interface for ease of
use. Included in the common features are action buttons and
unprotected
data entry cells. The action buttons perform tasks automatically
when
pushed.
The Explosive worksheet includes the following action buttons:

Clear All clears all of the explosive information from the database. When
the button is pressed the following dialog box is displayed:

Press the Yes button to clear all explosive information

Imperial changes the entry parameters from metric to imperial units. Note
when the Imperial button is selected its label changes to Metric. To change
the parameters from imperial back to metric press the Metric button.
Clear One allows you to delete the parameters of just one explosive from
the database. To remove the parameters select the name of the explosive
that you wish to delete and then press the Clear One button.
All of the data entry cells in ProWall are outlined and have blue text.

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Slope Calculations Worksheet

Purpose:
The Slope Calculations worksheet provides a simple way to determine catch
bench widths and calculate inter ramp slope angles. A graphical
representation of the design is produced by the worksheet.
Instructions:
Start the ProWall program and select the Slope Calculations tab item from
the bottom of the screen. The Explosive worksheet will be opened and the
screen will look similar to the illustration shown here.

The Slope Calculations worksheet includes the following action buttons:

Update From Design updates the data entry fields with information from
the design sheet and plots the current design
Goto Design opens the Design worksheet
Plot Slope refreshes the slope graphic with the current design

ProWall - Operation Guide

Print prints the information displayed on the screen

Slope Calculations Worksheet

Instructions (cont.):
A Slope Calculations data entry box is displayed the left side of the screen.

The minimum catch bench width is calculated using the Modified Ritchie formula. In the
example shown above the minimum allowable bench width is 23 ft for a 40 ft bench
height. The Bench Height multiplier typically ranges from .16 to .20 depending on the
structural conditions of the rockmass and the anticipated blast damage. Higher Bench
Height multiplier values will increase the minimum allowable bench width. The width
factor normally ranges between 14 and 15 ft depending on the required carry capacity
of the bench.
Once the Minimum Bench Width has been calculated, enter the desired bench width
and face angle in the appropriate fields. The table will then be updated to show
calculated inter ramp angle for the given data as well as the resultant inter-ramp angle
for other bench face angles. In the example shown above the calculated inter-ramp
angle is 43.8 degrees. If a bench face angle of 70 degrees can be achieved, the
resultant inter-ramp angle would be 46.8 degrees.
Press the Plot Slope button to see a graphical representation of the current design.
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Design Worksheet
Purpose:
The Design worksheet allows you to easily develop relatively complex wall
control blast designs. Once the design is entered the worksheet calculates
the presplit, energy and powder factors for each row. In addition the total
required drill production is also calculated.
Start up:
Start the ProWall program and select the Design tab item from the
bottom of the screen. The worksheet will be opened and the screen will
look similar to the one shown here.

The Design worksheet includes the following buttons:

Clear All clears all of the explosive information from the database
Goto Database opens the blast design database
Imperial changes the entry parameters from metric to imperial units.
Note when the Imperial button is selected its label changes to Metric. To
change the parameters from imperial back to metric press the Metric
button.
Plot Design plots and displays the current design.
Save saves the design to the data base.
Print All prints the design data, a plot of the design, the cost parameters

ProWall - Operation Guide

and a timing design sheet.

Design Worksheet
Start up (cont.):
The Design worksheet is divided into four main sections; slope design,
explosive loading, pattern design and summary data.
Each of these sections will be discussed in detail on the following pages.
To help with the learning process we will load a sample blast design into
the Design worksheet. Press the Goto Database button. The screen
should look similar to the one shown below.

Select the Sample Wall Design cell from the Operation column and press the
Plot Design button. The program will load the Sample Wall Design into the
Design worksheet and plot the design in the Design Plot worksheet. Your
screen should resemble the illustration shown below:

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Design Worksheet
Start up (cont.):
Press the Goto Design button to return to the Design worksheet. Your
screen should now look like the one shown below:

ProWall - Operation Guide

Design Worksheet
Design Parameters:
The Slope Design section of the Design worksheet is shown below:

The following graphic illustrates some of the entry data required.

crest

batter or
bench face angle

toe

desired bench face

bench
height

catch bench width

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Design Worksheet
Design Parameters (cont.):
The slope angle is calculated from the bench height, catch bench width and
batter angle parameters. The information required by the rest of the Slope
Design parameters is as follows:
Blast Length (ft) enter the length of the wall to be shot (such as the
perimeter of the pit) or simply the length of an individual blast. This
number will be used to calculate the drilling, loading and explosive
requirements of the design and the associated costs.
Staggered Pattern (y or n) enter y if the drill pattern will be staggered
and n if the pattern is not staggered. Note: staggered patterns are
typically used.

staggered pattern

square pattern

Rock Density (g/cc) enter the rock density in grams per cubic
centimetre. This number is used to calculate the tonnes of material in the
blast.
Rock Structure enter fabric or structure of the rockmass (i.e. blocky,
open joints, massive, etc.). This information is used to help define the
zone that the blast will be used in. No actual calculations will be based on
this data.
Compressive Strength (psi) enter the rocks compressive strength in
pounds per square inch. This information is used to help document the
material that the blast will be used in. No actual calculations will be based
on this data.

ProWall - Operation Guide

Design Worksheet
Design Parameters (cont.):
Water Conditions enter the anticipated water conditions that the design
will be used in. No calculations will be based on this data.
Face Height - enter the height of the final bench face. For example, if
double benching is used the face height would be 80 ft.
Blast Adjacent To Catch Bench - enter y or n depending on if the design
will be used directly above the catch bench. If double benching is used
and the design is for the top flitch enter n.
The Explosives Loading section of the Design sheet is shown below:

Note that the design sheet can accommodate up to four rows of blastholes.
Each row can have a toe and a column charge. If only one charge is
placed in the hole then that charge should be entered into the column
charge section. Explosives that are in the explosive database can
automatically be loaded into the design sheet by pressing the GET button.
Be sure to enter the desired explosive charge diameter and weight so the
sheet can calculate the charge length.

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Design Worksheet
Design Parameters (cont.):
When continuous presplit explosives are used it is common practice to double over the
charge in the bottom of the hole to help define the toe of the bench. The Toe Charge
Calculations data entry box calculates the effective weight and diameter of the doubled
column charge.

In the example shown above, a doubled 5 ft length of 1 continuous presplit explosive

would weigh 6.6 lb and have a effective diameter of 1.8 inches. Those values should be
entered as shown below along with the explosive data in the Toe Charge fields.

ProWall - Operation Guide

Design Worksheet
Design Parameters (cont.):
The row designations are shown in the next illustration.

Slope Design Parameters

slope angle
batter angle

bench
height

catch bench width

Note: the Parameters worksheet includes this same information.

All blast designs must have information entered into at least the toe and
modified production rows. This allows the worksheet to calculate the back
and the face of the blast. In other words, the worksheet can calculate designs
for two three or four row blasts.

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Design Worksheet
Design Parameters (cont.):
The Pattern Design section of the Design worksheet is shown below.

ProWall - Operation Guide

Design Worksheet
Design Parameters (cont.):
In the Pattern Design section the following information is required or
calculated:
Blasthole Diameter enter the blasthole diameter drilled.
TC Borehole Pressure this calculated value represents the borehole
pressure of the top charge.
CC Borehole Pressure this calculated value represents the borehole
pressure of the column charge. When presplit techniques are used the
borehole pressure should be below the compressive strength of the
rock.
Blasthole Angle (deg) enter the angle the blasthole is drilled in
degrees, 0 degress is vertical.
Drill Offset at Toe this calculated value represents the horizontal
distance from the collar of the blasthole to the bottom of the blasthole. It is
calculated using the hole angle and bench height.
Top Overbreak enter the amount of anticipated back break at the top of
the hole.
Bottom Overbreak enter the amount of anticipated over break at the
bottom of the hole.
Batter Angle this value represents the angle of the bench face based on
the angle of the blasthole and the top and bottom overbreak dimensions.
Offset From Slope the distance the inner buffer row is away from the
toe of the bench face
Often the Crest or Modified Production Row face burden is larger at the toe
that at the crest. This is typically the result of the overbreak from the previous
blast or the excavation technique used. However, this distance is critical to
the success of the blast design. The top and bottom face burdens must be
defined as part of the design process.

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Design Worksheet
Design Parameters (cont.):
Top Face Burden enter the distance from the collar of the Crest or
Modified Production Row and the crest.
Bottom Face Burden enter the distance from the bottom of the Crest or
Modified Production Row and the toe.
The distance between the free face (assuming a straight face) and the top and
bottom of the modified production row is shown in the face confinement box.

Ideally, face burden should be between 18 and 26 charge diameters to provided

adequate relief without excessive flyrock.
Free Face Angle the angle of the free face is calculated using the top
and bottom face burdens and the blasthole angle.
Burden enter the horizontal distance between rows of blastholes
measured at the collar.
Bench Top Width this calculated value represents the horizontal
distance from the top overbreak to the crest. It is calculated using the
burden dimensions of each row and the top overbreak dimension.
Bench Botttom Width this calculated value represents the horizontal
distance from the bottom overbreak to the toe. It is calculated using the
burden dimensions of each row and the bottom overbreak dimension.
Spacing enter the horizontal distance between holes in a row.

ProWall - Operation Guide

Design Worksheet
Design Parameters (cont.):
Airdeck air decks are commonly used to reduce the charge weight and
borehole pressure in the blasthole. Enter the length of the blasthole that is
unloaded and unstemmed.

The Air Deck Calculation can be used to calculate the effective deck
length and % charge reduction for various sizes of air decks. This is
helpful when the air deck diameter is less that the hole diameter.
Subdrill or Standoff for subdrill enter the distance that the blasthole is
drilled below floor level. If the blasthole is backfilled or not drilled to grade
enter the distance that the hole is above grade as a negative number.
Stemming the stemming length is calculated.
Scaled Depth of Burial this calculated value represents the relative
confinement of the column charge. If flyrock, venting or airblast is a
concern this value should typically be greater than 1.4.
Blasthole Length the blasthole length is calculated using the bench
height, blasthole angle and the subdrill or standoff dimension.
Presplit Factor the factor is calculated for the toe or presplit row only.
Normally presplit rows are loaded lightly to reduce damage to the wall.
When presplitting techniques are used the presplit factor should be around
.5 to prevent damage. Higher presplit factors may be required in
unfavorable conditions.
Powder Factor (lb/ton) the powder factor for each row is calculated
independently.
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Design Worksheet
Design Parameters (cont.):
Energy Factor (kcal/tonne) the energy factor for each row is calculated
independently.
In the Summary Data section of the Design worksheet the following
information is provided:

Face Energy Ratio at Top this is the calculated burden to explosive

energy ratio for the burden at the top of the charge of the crest row. This
number indicates how confined the face explosives are. If the
confinement is excessive the potential for wall damage will increase. If not
enough confinement exists then the potential for excessive flyrock
increases. The energy ratios needed to provide proper confinement
typically range from .65 to .90.
Face Energy Ratio at Bot. this is the calculated burden to explosive
energy ratio for the burden at the bottom of the charge of the crest row.
The typical range is .65 to .90. In the example provided the bottom energy
ratio is 1.08 which indicates that the toe will be over confined.
Total Mass Shot this value represents the total tons produced with the
current design and blast length.
Required Drill Production this value represents the total drill
production required for the current design and blast length.
Overall Powder Factor this value represents the overall powder factor
produced with the current design and blast length.
Overall Energy Factor this value represents the overall energy factor
produced with the current design and blast length. Wall control blast
designers should be careful not to reduce the explosive energy level too
far below the normal level required for good breakage. Low energy levels
can bottle up the explosive gases which can lead to increased block
heaving. Energy levels typically should average around 180 kcal/t for
normal confinement.
Post Blast Performance enter comments about the performance of the

ProWall - Operation Guide

design here (clean wall, flyrock, backbreak, etc.).

Design Plot Worksheet

Purpose:
The Design Plot worksheet plots a cross sectional and plan view of the
current blast design. It is possible to spot design flaws at this stage of the
design process.
Operation:
Once the blast design has been entered press the Plot Design button on the
Design worksheet.

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Design Plot Worksheet

Operation (cont.):
The Near Field Ground Vibration box calculates the estimated peak particle
velocity based on site specific attenuation and distance constants and the
charge weight and distance away.

ProWall - Operation Guide

The Displacement Analysis estimates the face velocity and displacement of

the face adjacent to the top and bottom of the charge.

The estimated displacement does not include the rolling of the material once
it hits the ground. This rolling can extend the edge of the muckpile to well
beyond the predicted range. The displacement prediction can be fine tuned
by quantifying the face burdens prior to blasting and measuring the
displacement range of the muckpile. By entering the actual field information
into the Design worksheet and plotting the design the displacement range
can be predicted more accurately.
If the material actually exceeded the predicted range then the Displacement
Correction value should be increased until the displacement measured and
the maximum predicted displacement match. This Displacement Correction
value can then be used to estimate the displacement of future designs.

Cost Worksheet
Purpose:
The Cost Worksheet allows the cost of the design to be calculated.
Operation:
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Once the blast design has been entered and the design plot reviewed press
the Goto Cost button to open the Cost Worksheet. The screen will look
similar to the one shown below.

Cost Worksheet
Operation (cont.):
Enter the cost information for the design in the appropriate fields. Once the
design has been entered the Cost worksheet calculates the overall cost of
the design, the total cost per metre of wall and the total cost per tonne of rock.
In addition the costs for drilling, explosives and labor are broken down into

ProWall - Operation Guide

percentages of the overall cost as shown below.

After the cost information has been entered press the Save button to save the
design and cost information in the database.

Timing Worksheet
Purpose:
The purpose of the timing worksheet is to plot the hole pattern of the design.
This plot can then be printed out to assist with the development of the
initiation sequence. No data entry is required for this worksheet.

Database Worksheet
Purpose:
The Database worksheet is used to store blast designs for future reference.
Blast designs in the database can be compared to other designs and reentered to evaluate the design.
Operation:
The Database worksheet can be opened by pressing the Goto Database
buttons in the Design or Design Plot worksheets or by selecting the
Database tab at the bottom of the screen. When the worksheet is opened it
will look like the illustration on the following page.

Database Worksheet
Operation (cont.):

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The following buttons are included with the Database workbook.

Clear All when this button is selected all of the data will be cleared out
of the database. Warning this is not undoable!!
Load for 1st Comparison this button is used to load a design into the
Design Comparison worksheet. To load a design, select the operation
field of the design you want to compare and press the Load for 1st
Comparison button.
Load for 2nd Comparison this button is used to load a second design
into the Design Comparison worksheet. To load a second design, select
the operation field of the design you want to compare and press the Load
for 2nd Comparison button.
Plot Design used to load and plot an existing design from the database.
First select the operation that you want to plot then press the Plot Design
button.
Clear One select the operation that you wish to delete then press the
Clear One button. Warning this is not undoable!!

Parameters Worksheet
Purpose:
To provide an illustration of the variables in the Design worksheet. There is

ProWall - Operation Guide

no user entry required for the Parameters worksheet.

Design Data Worksheet

Purpose:
The Design Data worksheet is a protected, internal calculation worksheet. No
user information is contained on this sheet and it should not be altered.

Initial Blast Design

Begin the blast design process by filling out the information in the Slope
Design section. Next decide if the design will have two, three or four rows. If
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the blast has only two rows enter the information into the Toe or Presplit Row
and the Crest or Modified Production Row. If the design has three rows fill in
the Inner Buffer Row data along with the two rows mentioned above.

Design Considerations
Introduction
Efficient wall control blast design can be defined as achieving a safe and stable slope
for the lowest cost possible. Basically the time and effort spent in developing and
implementing efficient designs is insurance against future wall failures. The question is,
How much insurance do you need? The answer to this question is not always clear,
but is related to site factors that include:

geology and water conditions

slope design
life of slope (1 year, 5 years, forever?)
value of the excavation

From a production viewpoint the goal of wall control blasting is to make the transition
from a well fragmented rock mass to an undamaged slope in as short as distance as
possible. This can be quite challenging due to the many factors that influence wall
damage. To develop efficient designs one must have a basic understanding of wall
failure mechanisms as well as the limitations of the various wall control procedures. In
addition, it is imperative that the design be precisely implemented, evaluated and
refined on a continuous basis.
Factors That Influence Wall Stability
There are four major factors that control wall stability. They are:

geology

slope design

blast design

operational control over the implementation of the design

Obviously, the geology of the site will influence both the slope and blast designs. It is
important that close attention be paid to the geological conditions of the wall at the blast
site to develop blasts that will limit damage. The key geological influences are the
rockmass structure and strength.

Design Considerations
Factors That Influence Wall Stability:

ProWall - Operation Guide

When evaluating the structural integrity of the rockmass the type, size, persistence,
orientation (strike and dip), in-fill and fracture frequency of the defects must be taken
into account.

The strength of the rockmass under shear, tensile and compressional loading will also
dictate the overall stability of the slope.
In most cases the final slope design is modified during the excavation process as the
site conditions become more understood. In addition, mine plan changes can alter the
slope design. The key slope design parameters are; overall height, bench height, batter
angle and berm width (which defines the overall slope) and top loading or surcharge.
Several blast design factors influence the stability of the wall including:

horizontal relief away from the wall

energy concentration adjacent to the wall
blast size and duration

The last major factor that controls wall stability is the field implementation of the mine
plan. Even well conceived damage control programs will not perform properly if there is
no commitment to quality. Quality, in this case, refers to proper face clean-up, accurate
drilling and precise charging of the blastholes.

Design Considerations
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Blast Induced Damage Mechanisms:

The damage caused by blasting can be grouped into the following three categories:

stress failure (compressive, tensile and shear)

gas penetration and block heaving
release of load damage
block heaving

release of
load failure
shear failure

gas driven
crack extension

compressional
and tensile failure

crest damage
from excessive
subdrill

Stress failure occurs when the stress intensity is greater than the strength of the rock.
Three generic types of blast induced breakage are compressional, tensile, and shear
stress failure. Compressional failure typically is caused immediately around the charge
when the rock is crushed by extremely high borehole pressures. During tensile failure
the rock is ripped apart by reflecting stress waves. Since rock masses are typically ten
times weaker in tension the damage envelope caused by tensile failure can be much
greater than compressional failure. Shear failure is controlled by the shear strength of
the rockmass, blast duration and blast induced vibration levels. It should be noted that
repetitive blasting can reduce the shear strength of the slope to the point of failure.
Another major cause of wall damage is gas driven crack extension and block heaving.
As the explosives adjacent to the slope detonate, high pressure gases wedge into
structural defects and cause them to expand. The damage done by this wedging action
is determined by the strength of the rock and the duration of the pressure pulse. Wedge
failure can occur as blocks of rock are isolated by intersecting cracks.

Design Considerations

ProWall - Operation Guide

Blast Induced Damage Mechanisms (cont.):
Block heaving is another pressure related damage mechanism. Basically, block
heaving occurs when the explosive pressure adjacent to the slope is poorly relieved
away from the wall. This results in cratering beyond the desired pit limit. Block heaving
is also a major factor in damage along weak fault contacts.
During the detonation of explosives adjacent to the slope the rockmass is loaded or
under compression. When this load is released the rockmass bounces back and can
cause separation along planes of weak discontinuity. This type of damage has been
observed in excess of 30 metres (100 ft) beyond the perimeter of the blast.
Overconfinement of the explosives adjacent to the slope will increase release of load
damage.
Wall Control Blast Design:
It is typically not practical or cost efficient to use one type of wall control procedure for
every area of the excavation. Instead, the sensitivity and importance of each blast site
should be evaluated to assist with the development of the most appropriate design.
This evaluation should include:

rockmass strength (compressive, tensile, shear)

rockmass structure (defect type, size, persistence, gap, roughness, infill, orientation, and frequency)
slope factor of safety
water conditions
wall importance (final or interim wall)
production constraints
operational economics
drill size, capability, productivity and availability

Once the zones have been determined specific plans can be developed to address the
conditions of each blast site. The designs should be continuously refined based on the
analysis of each blasts performance. Ideally the initial blasts should be evaluated in
non-critical areas so the design can be refined to match the existing conditions.
There are basically three keys to achieving efficient wall control blast performance. In
sensitive zones, each of these keys must be in balance with the others to efficiently
protect the wall. These three keys are illustrated on the following page.

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Design Considerations
Wall Control Blast Design (cont.):

O p t im u m
B la s t
P e rfo rm a n c e
E n e rg y L e ve l
The distribution of the explosive energy will be based on the charge diameter and
blasthole pattern used. Excessive charge diameters can increase slope damage due to
uneven energy distribution. In many cases it is necessary to airdeck such holes to
improve the distribution of energy and reduce damage.
In wall control blasting the degree of confinement of the explosive energy adjacent to
the slope will play a major role in the amount of damage produced. The blast designer
should always provide the explosive energy with a path of least resistance away from
the wall.
The goal of wall control blasting is to make the transition from a well fragmented rock
mass to an undamaged slope in as short as distance as possible. This can be a difficult
process that can give blast designers the false notion that to limit blast damage the
explosive energy must be minimized, which can adversely effect excavator productivity.
In reality, the designer should be developing (for the most part) designs that direct the
explosive energy away from the wall while providing satisfactory fragmentation.
Four methods are generally used for wall control blasting. The methods are:

modified production blasts

trim blasts
pre or mid splitting
line drilling

ProWall - Operation Guide

Design Considerations
Wall Control Blast Design (cont.):
Modified production blasting is most successful in competent rockmasses or on slopes
designed with a high factor of safety. The primary disadvantage of modified production
blasting is that the wall is not protected from crack dilation, gas penetration and block
heaving. In modified production blasting the energy level is decreased adjacent to the
wall to reduce overbreak.
This is often achieved by simply reducing the charge weight (30 to 60%) in the row
nearest the slope as shown here (included in the database as Modified Production Blast
Favorable Conditions).

However, most rock types require additional design modifications to minimize damage.
These modifications can include air decking, reducing the burden and spacing
dimensions (by 25%), minimizing subdrill and increasing the delay interval between the
last two rows of blastholes. These potential design changes are shown below (Modified
Production Blast, Unfavorable Conditions).

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Design Considerations
Wall Control Blast Design (cont.):
When modified production designs are used the excavator digs beyond the last row of
blastholes. As a result one of the key elements in the success of modified production
blasting is standoff of the last row of holes. The blasthole standoff is the distance from
the last row of holes to the final slope. This offset controls both the wall stability and
ease of excavation of the toe. The optimum standoff distance will depend on the
strength and structure of the rockmass and should be determined by carefully analyzing
blast performance.
The following guidelines are for initial modified production designs:

locate the modified production row 1 metre out from toe of the slope
reduce production charge weight by 50% in the last row
use air decks and minimize the stemming length in the last row
minimize subdrill when drilling adjacent to the next catch bench
reduce the burden and spacing of the last row by 25%
increase the timing between the last two rows of holes

These guidelines were developed for a wide range of rock type and structural
considerations. The performance of this initial modified production design should be
evaluated in terms of overbreak, diggability and cost. In some cases it may not be
necessary to apply all of the recommended design modifications to achieve good
results.
While modified production blasting generally provides the best excavator productivity of
the wall control methods, it is unlikely that it will be suitable for all of the rock types and
structures within the excavation. In most modified production blasts the explosive
energy in the last rows of blastholes is overconfined and will damage weak or sensitive
walls.
The second method for wall control is trim blasting. Trim blasts are generally used for
rockmasses that are too sensitive for modified production blasting. Three types of blast
holes are used; trim, buffer and modified production holes. In order for trim blasting to
perform as designed a free face must be established to fragment and displace the rock
horizontally away from the wall. If the free face does not exist the explosive energys
path of least resistance will be uncontrolled and wall damage can be excessive. A
typical trim blast for favorable conditions is shown on the next page. This design is
included in the database as Trim Blast, Favorable Conditions.

ProWall - Operation Guide

Design Considerations
Wall Control Blast Design (cont.):
It is advisable to use air decking in at least the trim row to improve energy distribution
and reduce backbreak. Air decks may also be required in the other rows to compensate
for the reduced burden and spacing dimensions.
The graphic below shows the type of modifications that may be required for trim blasts
in unfavorable conditions.
trim
row

inner
buffer
row

outer
buffer
row

stemming
plug
air deck
reduced charge
in trim and
outer buffer rows

face angle
around
70 deg
no subdrill
unless the rock
is very hard

typical
production burden

The critical design elements for trim blasting are:

standoff of trim row from toe of slope (dictated by rock strength)
catch bench width (dictates buffer row locations)
subdrill depth (particularly important adjacent to the bench crest)
trim row spacing is typically less than the burden dimension
face burden (horizontal relief)
bench width to height ratio (should be less than 2)
timing configuration
overall energy level (depends on rock strength)
energy distribution (trim row may require airdecking)

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The following table illustrates initial trim row design parameters:

Blasthole Diameter
mm
(inch)
76
(3)
89
(3.5)
102
(4)
127
(5)
152
(6)
171
(6.75)
200
(7.87)
229
(9)
251
(9.87)
267
(10.62)
311
(12.25)

Loading Density
kg/m
(lb./ft)
.5
(.35)
.7
(.45)
.9
(.60)
1.3
(.90)
1.9
(1.3)
2.5
(1.7)
3.4
(2.3)
4.9
(3.3)
5.9
(4.0)
6.8
(4.6)
8.1
(5.5)

Burden
1.5
1.7
2.0
2.4
2.9
3.4
3.8
4.4
4.7
5.0
5.5

m
(ft)
(5)
(5.5)
(6.5)
(8.0)
(9.5)
(11.0)
(12.5)
(14.5)
(15.5)
(16.5)
(18.0)

Spacing
m
(ft)
1.2
(4.0)
1.4
(4.5)
1.7
(5.5)
2.0
(6.5)
2.4
(8.0)
2.7
(9.0)
3.2
(10.5)
3.7
(12.0)
4.0
(13.0)
4.3
(14.0)
4.6
(15.0)

The table on the previous page was used to develop the following trim blast design. If a
200 mm (7.87 inch) blasthole is used on a 15 m (49 ft) bench the trim row would contain
51 kg (113 lb.) of explosives and would have a burden of 3.8 m (12.5 ft) and a spacing
of 3.2 m (10.5 ft). Due to the relief provided by the free face trim blasting should
perform better than modified production blasting in unfavorable conditions. However,
since the trim row is detonated last gas penetration and crack extension may still cause
excessive damage. The next design option is presplit blasting.
Presplitting blasting consists of a row of lightly charged, closely spaced holes adjacent
to the final slope that is fired prior to the detonation of the other holes. This creates a
breakage plane to vent explosive gases and reduce crack propagation. A typical
presplit blast in favorable rock is shown here.

angle drillled
presplit

inner buffer
row

outer buffer
row

modified
production row

15 - 30 deg

standoff
distance

no subdrill on bench
unless rock is very hard

70 deg
face angle

ProWall - Operation Guide

In most rock types the presplit blasthole should be angled to achieve a more stable wall.
The angle selected should be based on the slope design, rock structure, drill type and
charging requirements of the blastholes.
The key factors that control the success of presplitting are:

drill accuracy
geological structure, hardness
presplit spacing
presplit charging
standoff distance of inner buffer row
face burden (horizontal relief)
bench width to height ratio (should be less than 2)
timing configuration
overall energy level

As conditions become more challenging the presplit design will have to be modified to
produce satisfactory results. In hard rock masses a short stab hole is often required
between the inner buffer and the presplit to achieve adequate fragmentation.
Subdrilling may be required to establish the proper bench grade when the rock is hard.
If the rockmass is highly structured and relatively weak, air decks may need to be used
in the buffer rows. The following illustration outlines some of the modifications required
for presplit blast design in unfavorable conditions.
"stab" hole
if required

inner buffer
row

20 deg angle
drillled presplit

outer buffer
row

modified
production row

air decked
if required

standoff
distance

70 deg
face angle
no subdrill on bench
unless rock is very hard

normal
production
burden

Figure 10. Presplit design in unfavorable conditions

One of the key elements of presplit blast design is the charging of the presplit row.
Normally the charge is decoupled to reduce the borehole pressure to well below the
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compressive strength of the rock. This can be achieved by air decking or using a
charge diameter that is smaller than the blasthole diameter.

increasing performance in unfavorable conditions

air
deck
air
deck

charge
plug

charge
charge

charge

air
deck
charge
single
bulk deck

charge
multiple
bulk decks

charge
multiple
decoupled
decks

continuos
low density
explosive

continuos
decoupled
explosive

Air decking is the least expensive method and is appropriate when the rockmass is
relatively massive. It typically consists of placing a small bulk charge in the bottom of
the hole and leaving the remaining hole open to achieve decoupling. As the rock
becomes more structured better explosive energy distribution is required. To improve
the energy distribution multiple small explosive decks, continuous small diameter
packaged explosive, or in some cases detonating cord can be used. While continuous
explosive is the most expensive option for presplitting it also provides the best
performance in unfavorable conditions. Unless airblast is a concern, the presplit holes
should be left open to reduce borehole pressures and protect the crest region of the
hole.

ProWall - Operation Guide

The suggested initial presplit design parameters are as follows:

"stab" hole
if required

inner buffer
row

outer buffer
row

10 - 30 deg
drillled presplit
depending on
slope design

75%
normal
production
burden

presplit charge
weight based on
the hole spacing
x hole length
divided by 2

air decked
if required

1m
standoff
distance
for average
rock

normal
production
burden

70 deg
face angle

no subdrill on
bench unless
rock is very hard

presplit
shot with
previous
blast

presplit
spacing

production
row

outer buffer
row spacing
based = the
production
hole spacing
inner buffer
row spacing
based on 1/2
the production

angled double
free face at
initiation point

staggered
pattern for
improved

Presplitting can be the most expensive and labor intensive of the wall control methods.
However, the long-term benefits can outweigh the costs if a maximum slope angle is
required. If the wall is so weak that even well designed presplit techniques cause
damage the next wall control consideration should be line drilling.
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Line drilling consists of a row of closely spaced holes drilled along the perimeter of the
excavation. These holes are left open and not loaded with explosives. The stress
waves of the blast create a plane of breakage between the holes. Typically, line drilling
is used in very soft material. In hard rock, the hole spacing required is so small that
presplitting becomes more cost efficient. Line drilling can be used in conjunction with
modified production or trim blast designs. The line drilled row is normally placed
between 50 and 100% of the normal production burden from the trim or production row.
Design Implementation
Wall control programs should be established and implemented in a consistent and long
term basis. Since it is difficult to analyze the cost/benefit relationship of controlled
blasting techniques they are often viewed as an expensive luxury. As a result, many
operations fail to implement procedures until the walls start to fail, which results in
higher overall costs.
Optimum blast performance can only be achieved with a group effort, as shown below.
Site
Evaluation

Design
Refinement
Performance
Evaluation
Blast
Excavation

Blast
Recordkeeping

Optimum
Wall
Control
Blasting

Blasthole
Loading

Blast
Design
Bench
Preparation
Pattern
Layout

Blasthole
Drilling

Explosive
Quality Control

Figure 13. Group approach to achieving optimum blast performance

If one individual does not perform their job properly it will effect every individual that

ProWall - Operation Guide

follows in the process. In addition, if the design is not implemented accurately it will be
difficult to refine the plan based on its performance.
The keys in implementing this group approach to blast optimization are:

provide means for open communication between operations

establish performance goals for each operation
establish and document quality control procedures for the design and
implementation

train each group in the appropriate quality control procedures and their
role in achieving optimum blast performance
test for comprehension and conduct field audits to promote
consistency in design implementation
provide feedback forms for each operation to be used for blast
refinement
establish weekly planning meetings for representatives of each group
approve blast plans as a group
monitor each blast (video tape, seismograph)
maintain accurate blast records on a shot by shot basis

process

Damage Assessment and Performance Analysis

Wall control blasting is a process of continuous improvement. The following factors
should be evaluated to thoroughly evaluate the performance of the design:

overbreak
ground vibration levels
drill production requirements
ease of excavation
cost

Overbreak can be defined as blast induced damage to the bench, crest and slope of the
wall. Often this damage can be observed by reviewing the video recording of the blast.
Ideally no surface swelling will exist beyond the pit limit and the blast will horizontally
displace material away from the wall at a rate that is two to three times greater that
vertical movement. The damage to the slope should also be determined by
documenting any crack extension and heaving beyond the designed excavation limit.
Excessive ground vibration levels can damage the structural integrity of the wall. It is
recommended that a vibration monitoring program be developed to evaluate the
intensity, frequency and duration of blast induced vibrations. This program should
include a number of seismographs to determine the relationship between distance and
the nature of the vibrations produced. If the slope is saturated with water it may be
appropriate to include pore pressure gauges to quantify the influence that blast
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vibrations have on in-situ pressures.

Drilling and excavator productivity must be considered during blast performance

analysis. Often the use of wall control techniques will adversely effect production levels.
This is due to the additional time required to prepare the face prior to blasting, drill the
blastholes, excavate the oversize produced by low blast energy levels and to carefully
dig to the pit limit. Production requirements will influence the selection of the wall
control method used.
It is suggested that a database be used to track the performance factors of each blast.
Included in the records should be the costs for bench preparation, drilling, loading and
excavating each blast. Once the cost relationships have been defined for each design
option an accurate cost benefit analysis can be performed. This analysis will help to
select the most appropriate design for future blasts.
Conclusion
The short and long term profitability of any surface excavation relies on slope stability.
This stability can be achieved by establishing a wall control program that includes the
following:

conduct a detailed geological/geotechnical analysis of the excavation

divide the excavation into zones that have various levels of sensitivity
define the value of each zone or wall adjacent to each blast site
develop a series of designs to match the conditions of the excavation
draft and document specific procedures for implementing the design
train all related personnel in the application of the procedures and test
for comprehension
audit field procedures
keep accurate blast reports
perform comprehensive blast performance evaluations
establish a database of blast performance data
refine the design based on the performance evaluation
consider the wall control process to be one of continuous improvement

There is no magic involved in developing efficient wall control designs, just careful
design development, implementation and refinement.

ProWall - Operation Guide

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