Case study – Lafarge blast optimisation initiative H-5934-8001-01-A
How the Lafarge worldwide blast optimisation initiative improved safety and reduced costs In September 2013 world-leading aggregates producer and quarry operator Lafarge implemented a worldwide Blasting Standard Operating Procedure (BSOP) with an aim to reduce costs, increase safety, and lessen the impact on the environment. Through the use of Renishaw survey solutions as part of its innovative BSOP to optimise drilling and blasting operations, Lafarge is already realising significant measureable cost savings with the potential to save in the region of 10-25 million euros annually across its 600 sites worldwide. By increasing its understanding of fragmentation and the adoption of best practice, Lafarge has been able to reduce costs at every stage of the drilling, loading, and blasting process. Best practice includes the identification of experts, suppliers and equipment to improve the blasting process, as well as setting up procedures, and ensuring operator competency through training. The use of the Renishaw Quarryman Pro, a dedicated face-profiling system, allows the bench height, toe, crest, and slope angle to be accurately surveyed such that the maximum and minimum burden can be calculated. By mapping the rock face in detail, Lafarge can determine the actual burdens in front of each planned borehole to avoid excessive burden (vibration, oversize) or insufficient burden (flyrock, airblast).
3D face profiling using Renishaw Quarryman® Pro.
Quarry face profile.
The survey data acquired is used to design an optimised drilling and blasting plan, which specifies the desired burden and hole pattern required to produce a safe and efficient blast. Specialised blast design software is used to facilitate this and create detailed records of the blast design and survey parameters. It is critical that the blast design is stringently implemented if it is to be effective. Incorrect drilling can pose serious risk. Lafarge uses Renishaw’s Boretrak borehole deviation probes to check the depth and inclination of drilled blast holes before loading. Before loading explosives, check the depth and inclination of drilled blast holes using a Renishaw Boretrak®.
After implementing the BSOP and monitoring performance across several sites in Russia and Poland, Lafarge has seen measurable improvements in fragmentation and the associated safety, environmental, and cost-saving benefits. The company has calculated first-year measureable cost savings as follows: •
Up to 15% reduction in powder factor
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Up to 8% reduction in drilling costs per metre
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Up to 3% reduction in oversize
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Up to 5% reduced scalping
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Up to 50 t/hr increased plant throughput
Greater control of the quarry floor and faces is also observed, plus a reduction in blast-related vibrations and flyrock making for a safer and more efficient drilling and blasting process.
Client: Lafarge
Borehole geometry survey using Renishaw’s Boretrak.
Before: Blast optimisation enables you to avoid the kind of unpredictable and dangerous explosion shown here.
Project: Worldwide blasting optimisation initiative Laser system: Quarryman® Pro and Boretrak® Lafarge is the second-largest aggregates producer and one of the largest quarry operators in the world, offering a wide range of aggregate solutions, from general materials up to the most innovative recycled products. A world leader in its cement, aggregates and concrete businesses, it contributes to the construction of cities worldwide through the use of innovative solutions. With the world’s leading building materials research facility, Lafarge places innovation at the heart of its priorities in order to contribute to more sustainable construction and to better serve architectural creativity.
After: Initiatives such as Lafarge’s BSOP ensure safer and better-controlled blasting.
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*H-5934-8001-01-A* Issued: 0515 Part no. H-5934-8001-01-A
