Chapter 19: Borehole Loading
Borehole loading is an ordered process regardless of the method used. Loading must be done as accurately as possible according to the blast plan. The drilling log and preblast inspection may provide information about the boreholes and blast site not known when the blast design was made. The blaster should study the drill log and perform a thorough preblast inspection to determine if any loading adjustments may be required.
When changes in loading are made due to the conditions discovered during the preblast inspection they should be noted on the blast report. When these are done a meaningful post blast analysis can take place to support refinements to improve future blast designs.
WET BOREHOLES
Ideally the blaster wants all boreholes to be dry and free of water. Unwanted moisture regularly finds its way into boreholes between the time they are drilled and the time they are loaded with explosives. Water can enter from the surface through the broken ground formed by the subdrilling from the previous bench, or it may be found when the boreholes penetrate the level of static ground water in the area. In extreme cases, (tidal?) water on the top of the blast area fills the boreholes after a heavy rain, or as more commonly happens, several feet just simply seep into the borehole when the drill penetrates a few saturated cracks and seams in the subsurface material. Whatever its origin, water always creates extra problems for the explosives engineers and field loaders and will likely affect dry hole blasting results.
Water in boreholes creates limitations for the blaster. Explosive product choices are limited to those products that have adequate water resistance and sufficient density to sink, such as when using packaged explosives products. Thus the borehole loading procedures discussed in this chapter should be followed to ensure adequate column continuity for a full detonation of the charges. The blaster should remember that water in a borehole often contains sand, rock, and dust, all which increase the density of the water and make the sinking of packaged products more difficult. Displacing water from the borehole eliminates most product choices and loading concerns mentioned. Borehole liner selection criteria are discussed in chapter 24.
PRELOADING CHECKS
Preloading checks identify defects in the blast site that affect the blast plan. Loading, therefore, the blaster is responsible to perform the preloading checks provided in chapter 17 of this book. Defects should be corrected or compensated for to the greatest extent possible. When this cannot be done, they should be reported and appropriate safety and blast site security measures be taken.
Using Drill Log Information When Loading
Drill logs give the driller a written reminder of his pending borehole conditions after drilling the shot. Drill logs should be designed to communicate all the information regarding the rock condition at the blast site by the driller. This discussion presents basic rock information that can alert the blaster to modify the loading plan. The sooner the blaster can obtain the drill log the better the loading plan, so if explosive substitutions need to be made they can be available when needed. The drill log contains a lot of information about the rock at the blast site through the drill log.
Blasters need to know how to use the information on a drill log to properly load the boreholes in a blast. This knowledge comes from careful review of the information contained on the log and from understanding the driller equipment limitations (See chapter 18). Drill logs provide very valuable information for the prevention of flyrock and the maintenance of explosive confinement. In these regards, drill logs record valuable information such as: (1) the borehole collar condition (the area where many flyrock incidents originate); (2) the location of geologic anomalies and transition features (mud seams and pockets, geologic structures); (3) changes in rock hardness and quality; (4) borehole depth and diameter.
The driller can provide a wealth of information about the rock at the blast site through the drill log.
Borehole Collar Condition
One example of drill log information the driller reports on the log is the depth of loose and broken rock at the borehole collar as reported in figure 19.1 and illustrated in figure 19.2. This is very helpful information for the blaster to make stemming height and loading adjustments for top breakage and flyrock control.


With this information the blaster can appropriately apply a stemming calculation in equation 19.1 to load the proper stemming length for each borehole as illustrated below: Based on this calculation, the stemming at borehole no. 3 should be increased.
$$L_s = k \times B$$ <!-- VERIFIED -->
Equation 19.1
where:
- $L_s$ = Stemming length (meters) (feet)
- $k$ = a factor 0.7 to 1.0
- $B$ = the borehole burden (meters) (feet)
The stemming ratio, "k" factor in equation 19.1 is determined by many variables (e.g. geologic conditions, bench height, and distance to structures). Shorter benches use a value closer to 0.7, while taller benches use a value closer to 1.3.
EXAMPLE 19.1
Determine the level of stemming in a borehole in a short bench with a 6 foot burden using equation 19.1. Choose a stemming ratio of 0.7.
$L_s = k \times B$
$L_s = 0.7 \times 6$
$L_s = 4.2$
The stemming length is 4.2 feet.
Locating Geologic Anomalies and Rock Transition Zones
Another example of drill log information is the location of geologic anomalies and transition zones such as mud seams, cracks, and cavities. This is very valuable information for the blaster to ensure energy confinement and explosives performance.

This drill log indicates a mud seam that as indicated in figure 19.4.

In addition, this drill log could indicate the mud seam as in figures 19.4 or 19.5. The driller can only report this information in one dimension (depth and thickness of the mud seam), and cannot report the lateral two-dimensional size of the mud seam.

The blaster needs to decide how to load these boreholes according to the rock conditions around this blast area. Blasters need to be thinking in three dimensions when reading a drill log. Using this same drill log, when checking the face, there is indication of a mud seam showing in the face between boreholes #2 and #3.

In the end, the blaster then needs to think three-dimensionally and visualize this mud seam as it could be from the top of the bench looking down as illustrated in figure 19.7, and load boreholes accordingly.

Identifying Changes in Rock Hardness
Another example of proper use of drill log information for loading is when the drill log records varying rock hardness as illustrated in figures 19.8 of seams of rock on the drill log, as in these next two examples.

The blaster then loads boreholes in this blast to prevent flyrock or loss of confinement to improve fragmentation as suggested in figure 19.9.



Based on the information provided in the drill log, the blaster can make decisions to modify loading prescribed by the blast design. Changes should be made to (1) ensure explosives confinement, (2) make loading adjustments for weak rock zones to prevent flyrock, and (3) adjust explosives energy to accommodate significant rock hardness or quality variations. Figure 19.11 illustrates how the blaster may load boreholes based on the information concerning rock hardness in the drill log. Adjustments to the loading plan based on drill log information often improve fragmentation and overall blasting results.
Borehole Depth and Diameter
Even though the driller records the diameter of the bit used and final depth of the borehole, the blaster should check both during the preblast inspection. Slight variations in diameter can cause significant variations in the loading density of bulk explosives. Borehole depth may not be as the driller finished drilling.
Using Checklists
The blaster is encouraged to use checklists to help ensure blast site and borehole conditions will permit the loading process to proceed according to the blast design and blasting plan. Sample checklists are included in chapter 17.
ELEMENTS OF LOADING
The borehole loading process consists of the eight (8) steps listed in table 19.1. When carefully followed, the blaster ensures execution of the blast plan and performance of the explosives products, and accurate blasting records. Proper execution of these steps minimizes the chance of a blast malfunction.
Steps In The Loading Process
Table 19.1 - Steps in the loading process.
Checking the Borehole
Checking the borehole is critical to ensure all boreholes are the correct depth, water conditions are identified, obstructions are discovered, and weak collar conditions are noted. Depending on the rock formation and drilling techniques, boreholes are sometimes checked for alignment and trauma with borehole mapping devices. Borehole mapping identifies borehole deviation that result in burden and spacing deviations. When deviations are identified, borehole loads can be adjusted to the degree possible, and blasting expectations can be modified.


Dewatering the Borehole
Water in the borehole can be a problem without proper preparation. When the blaster selects less water resistant explosives, wet boreholes must be dewatered to ensure explosive performance. If water can reenter the dewatered borehole, they should be lined with plastic borehole liners or loaded with explosives of sufficient water resistance. Several types of dewatering pumps are available to remove the water and they are discussed in chapter 24.
The smallest amounts of water can degrade most ANFO products. The smaller the borehole, the greater the amount of the ANFO column load will be degraded by moisture on the borehole wall. Degradation seriously affects ANFO's performance. The degrading effect of borehole wall moisture decreases as the borehole diameter increases.
When boreholes are dewatered, care must be taken that the discharged water does not reenter boreholes.

Wet boreholes generally indicate a flow of water through a seam of potentially loose rock inside the borehole or around the collar. Care must be taken when dewatering boreholes to lower and retrieve the dewatering hose and in a manner that does not cave the borehole or loosen rocks inside the borehole. In addition, make sure the discharge hose allows the water to exit the shot bench to eliminate residual water.
Priming the Borehole
The accepted definition of a primer is "a unit, package or cartridge of explosives used to initiate other explosives or blasting agent, which contains: (1) a detonator, or (2) detonating cord to which is attached a detonator designed to initiate the detonating cord" (IME SLP 12, 2007). Different types of boosters are discussed in chapter 12. Always follow the explosives' manufacturers priming recommendations.
This chapter will discuss primer assembly and use techniques.
A primer's effectiveness is determined by its booster characteristics as discussed in chapter 12. In addition, the efficiency of the priming system is related to other considerations including the size of the primer and the initiation system's compatibility with the main explosive charge.
Primer Assemblies
Different types of boosters may require specific types of initiating products. The blaster should consult the booster manufacturer's technical information sheet or representative for initiation system requirements. IME provides recommendations for primer assembly in IME SLP 4, 2009. These assemblies are shown below. Beyond these recommended assemblies, additional general primer assembly recommendations are listed in table 19.2.





General Statements Regarding Primer Assemblies
Table 19.2 – General statements regarding primer assemblies.
Several primer location techniques are used to ensure and optimize the explosive column performance. For example primer placement, location, and frequency in a borehole loaded with packaged explosives is important to ensure the results obtained from the explosive column. There have been many theories discussed about the correct placement of primers in all situations. The most common priming techniques are discussed below.
Bottom Priming
Most boreholes are primed in the bottom area of the borehole. Generally the bottom of the borehole is the area where the greatest amount of work must be done to break and move rock. The borehole bottom is also generally the area of greatest energy confinement. Thus when explosives are primed in this area the detonation gases are under maximum confinement and the explosives work is maximized.
When bulk explosives are loaded, primers are lowered into the borehole and pulled slightly off the bottom. This ensures the primer is not buried in drill cuttings or mud. Once positioned, the bulk explosives are loaded into the borehole to surround the primer. In the case of cartridged explosives, a cartridge is loaded into the borehole, the primer assembly is lowered on top of that cartridge and the rest of the borehole is loaded according to manufacturer's recommendations. The cartridge loaded on top of the primer must be lowered and not dropped, except under certain conditions as discussed in IME SLP 4 and in U.S. Mine Safety and Health Administration (MSHA) regulations.
Top Priming
Top priming is not often used in blasting situations. However, it is a rather common technique used in construction applications such as pipeline work. When a borehole is top primed, the top of the borehole explodes releasing gases and often causing air blast or possibly the overproduction of dangerous flyrock. The most widely accepted use of top priming or direct priming is in underground applications where instantaneous detonators are used. A special situation that has called for top priming a borehole is in "hot hole" applications where the primer setup (often a detonating cord bundle) is placed into a borehole just prior to initiation.
"Hot hole" situations are very dangerous and must be conducted by experienced personnel familiar with the explosive properties and this specialized application. Hot holes are discussed in chapter 10. Before any of these specialized applications are employed, the manufacturer and/or government agencies regulating the blasting situation should be contacted.
Center Priming
Center priming is often used when the bottom of the borehole contains very soft rock or mud conditions. The primer assembly is located in a more competent area of rock in the borehole.
Multiple Priming
This method, where additional primers are placed in a borehole is used for the following three reasons with insensitive explosives: (1) Ensure the explosive detonates the entire length of the borehole. This is extremely important in rough boreholes where column separation is a possibility; (2) Minimize cutoff boreholes because of earth movement; and (3) Help meet legal requirements imposed by some regulatory agencies. Some states require more than one primer in a borehole.




This is to reduce or eliminate the possibility of the primer being located in explosive materials that have been shock stressed from the previous column of explosive. The shock will not affect most cast boosters but could adversely affect other types of primer units.
Recommended Multiple Priming Conditions
Table 19.3 – Recommended multiple priming conditions.
Combination Priming
Combination priming or booster priming involves the use of a large diameter, waterproof packaged explosive in combination with a booster. The large diameter charge is primed with a booster and usually fills the cross section of the borehole. This combination primer is used to initiate ANFO or other less-sensitive ammonium nitrate based powder columns across their diameters, thus increasing the efficiency of that initiation.
Combination priming offers two significant benefits: (1) The first is when explosives are loaded in large diameter boreholes. A high detonation pressure booster charge helps the explosive column reach steady state velocity in a shorter distance. An explosives column is initiated more efficiently if the booster fills the diameter of the borehole. The easiest and most cost effective way to fill this diameter is with a primer and relief pot or emulsion combination. (2) The second is that a combination primer, usually placed at the bottom of a borehole, will also serve as a toe load for difficult blasting situations. This area of the borehole usually contains the most water and the greatest burden. The higher energy zones of explosive loaded immediately above the combination primer is therefore the most effective technique to break this toe burden. Basic priming application and safety rules are listed in table 13.4. Additional safety information is available in IME SLP 4.

Basic Priming Application and Safety Rules
Table 19.4 - Basic priming application and safety rules.
Protecting And Securing Downlines And Legwires
The blaster must protect downlines and legwires from abrasion during the loading process. Damage to these often causes blast malfunctions. Securing the downlines and legwires at the borehole collar helps prevent them from falling into the borehole during the loading process. Whether tying these lines to a stake, or securing them to a rock, the blaster should take care not to damage them. Always provide extra slack in the downline or legwire to allow for explosive slumping in the borehole.

Loading
The blaster typically loads boreholes by one of two general methods. Whatever method is used, the practices discussed above should be followed. The two types of borehole loading methods are the conventional method and the mechanized method that uses the loading machines and systems described in subsequent chapters. Each method has its own loading issues and concerns. Regardless of the loading method used the loading factors in table 19.5 should be met.
Borehole Loading Factors
Table 19.5 – Borehole loading factors.
Since borehole coupling is an important factor in explosives performance, the loading method should be chosen for its ability to achieve the desired borehole coupling. A full discussion of borehole coupling is found in chapter 14. Full borehole coupling is the best way to ensure energy transfer to the borehole wall. Sometimes less than full borehole coupling produces the desired results such as in presplitting application. The two general methods are discussed below. The blast site environment, production requirements, and level of required blasting control usually dictates the loading method used.
In the event the detonator or detonating cord is dropped down the borehole, the blaster must use caution when retrieving the line. Simply lowering the measuring tape with lead weight and twirling the tape may "grab" the down line. A loading pole with non-sparking retriever may be used but care must be taken not to skin or tear the down line. If the line is not retrievable a new primer should be attached in the borehole.
Conventional Loading
Conventional loading refers to the manual loading process. Usually this is done with packaged explosives and bagged ANFO products. The conventional method occurs at a relatively slow speed. The explosive column must be checked to confirm that the product is rising properly and that obstructions have not blocked or bridged the borehole. Column rise is commonly checked with a weighted tape measure or a loading pole.
Properly packaged and sealed explosives can be loaded directly into water. A packaged explosive's density must be greater than the density of the water in the borehole if it is to sink and maintain package-to-package contact. It is imperative the blaster monitors column build up at each package is loaded to ensure column continuity and verify individual packages are not bridged. Small gaps between packages can stop the detonation front resulting in explosives detonating at lower order velocities or not detonate at all. Multiple priming may be required if gaps between packages occur. In event a package lodges, a loading pole with a non-sparking retriever can be used to job into the package and pull it out of the borehole. Care must be taken using retrievers to avoid damaging the detonator down lines or legwires. The integrity of the retrieved package may be compromised so, depending on the explosive type inside the package, the package may need to be used in a dry borehole.
Caution
Many jurisdictions forbid the extraction of explosives from a borehole.
If packaged explosives hang or bridge in the borehole, proper tools and procedures must be used to dislodge or remove the package. The blaster should never force or push on lodged packaged explosives.
In the event an explosive cartridge or package hangs in the borehole it can possibly be retrieved. A non-sparking retriever or hook can be used on the end of an appropriate loading pole to hook the package and pull it out of the borehole. In the process of extracting packages, extreme caution must be taken to protect the detonator or detonating cord down lines.
Bulk Loading
It is advisable for the blaster-in-charge to ensure the primer is in the explosive product and not at the bottom of the borehole stuck in mud or water or floating on top of the product. Rather than allowing the primer to rest on the bottom of the borehole it may be better to suspend the primer slightly off the bottom. When bulk loading begins, hold the down lines and pull the primer up slightly to ensure it is in the product and that the lines are not floating upward as the borehole is loaded.
When bulk loading with a pump truck, the position of the loading hose is important to ensure the primer is completely encased in explosive. Once the primer is locked in place, the loading hose should be slowly retracted to ensure water is not entrained in the explosives column. It is important to ensure that the loading hose is always in the explosive during loading. Pump loading too fast will churn the water and allow it to become entrained in the explosive column.
Bulk loading refers to the mechanized loading process that uses bulk trucks, pneumatic ANFO loaders, and cartridge air loaders discussed in detail in the following chapters. Mechanical loading methods usually take place at a faster rate than the conventional method. Thus, these methods are better suited in high production environments. For this reason, the blaster must pay attention to the column build up so the borehole is not overloaded and products are not loaded into voids or cavities. Mechanical methods all optimize borehole coupling by achieving 100% or nearly100% coupling in the case of the cartridge air loader.



Loading Hot Boreholes
The blaster must be sure that the temperature in the borehole is not hot enough to constitute the hazard of prematurely initiating explosives being loaded. Heat is generated from the friction of the drill bit as it penetrates the rock, but it may also originate from underground fires in coal beds, or from sources not generally recognized, such as the presence of hot, broken drill steel in the borehole and corrosive reaction. Stick-across temperature probes at various temperatures or coolants in other situations may come into play.
No explosives should be loaded if temperatures in excess of 65°C (150°F) are encountered. Cooling the borehole by flooding it with water is an acceptable method, provided the explosives to be used have the necessary water resistance. Special precautions are required when loading ammonium nitrate-based explosive materials into iron sulfide-bearing ores. Chemical reactions that occur between these materials (such as AN/FO) and the iron sulfide compounds can generate excessive thermal energy resulting in high temperatures in the boreholes. Melted boosters and shock tubing, and premature detonations, have resulted.
Decking
Decking is a technique to either divide explosives charges to comply with regulations, or prevent explosives loading in weak areas of the rock. Decking is a mid-borehole stemming technique. Mud seams and voids can create poor fragmentation and be the cause of flyrock. The drill log is an invaluable document to help the blaster know where these unconsolidated areas are located. The blaster should deck with inert material through the seam or void to eliminate the explosive loss of energy and gasses.

Stemming
Proper stemming helps confine the explosive energy in the borehole. Stemming may be located in two areas of the borehole, the top and within the column to form decks as discussed above. Thus, stemming is a very important part of the loading process. Ideally boreholes should be stemmed with a small crushed aggregate stone. The sharp angular edges of the crushed stone help lock the stemming and confine the explosive energy in the borehole. Good confinement helps prevent the energy from blowing out or ejecting the stemming. Personnel employed to stem boreholes should be educated and trained in their critical role. The stemming may be loaded slowly to ensure it does not bridge, create a blockage, or damage downlines or legwires. Insufficient stemming can result in excessive air blast, poor fragmentation, or flyrock. If the event drill cuttings must be used, stemming lengths may need to be increased, as they do not lock in the borehole as well.
Also, stemming lengths may need to be increased in the collar area in the event of wet boreholes when they are loaded with cartridges or bulk, pumped explosive. In these cases, the water is displaced to the top of the explosive column. If drill cuttings are used, stemming heights should be increased as the saturated drill cuttings have lesser ability to lock the energy in the borehole.
In some instances, it may be necessary to remove stemming from a borehole. This practice should be carefully reviewed by the blaster-in-charge to prevent possible damage to the initiation system and explosive charges. Caution must be exercised to prevent injury to personnel by flying stemming materials.
Cleaning Up
Prior to tying-in the shot all hoses, wrappers, and empty packaging must be cleared from the site. Local, state, and federal ordinances must be followed in the proper disposal of such packaging.
ADDITIONAL RESOURCES
Institute of Makers of Explosives (IME). 2009. Safety Library Publication 4, Warnings and Instructions, October. IME, Washington D.C.
Institute of Makers of Explosives (IME). 2011. Safety Library Publication 12, Glossary of Commercial Explosives Industry Terms. IME, Washington D.C.
Mine Safety and Health Administration (MSHA): Code of Federal Regulations (MSHA), Title 30, U.S. Department of Labor, Washington, D.C.