What happens to your blast fragmentation when you have excessive inter-row distance (burden)?

Introduction – Excessive Burden

According to Prasad et al. (2017), rock fragmentation size is a very important parameter for an economical point of view in any surface mining. Excessive inter-row distance, often referred to as an increased burden in blasting operations, can occur due to poor drilling operation (human factor, machine factor).

Applying Chapman–Jouguet (CJ) Condition:

The CJ condition holds approximately in detonation waves in high explosives. It states that the detonation propagates at a velocity at which the reacting gases just reach sonic velocity as the reaction ceases. In such case, excessive burden affects explosive energy distribution by diminishing the efficiency of the explosive shock wave travel, which impacts the creation of micro-cracks.

CJ Plane Theory

According to the CJ plane theory, an optimal burden ensures effective shock wave propagation and micro-crack formation, crucial for breaking rock.

With excessive burden, energy dissipates before adequately fracturing the rock, leading to poor fragmentation. This inefficient energy transfer disrupts the detonation process, reducing the effectiveness of the blast and resulting in larger, unbroken rock pieces.

Burden Distance Affects Rock Fragmentation

This article makes use of data from Prasad et al. (2017) to explain further the effect of burden increments from 2.5 to 3m. As shown by the regression line, the analysis revealed that the blast fragmentation size (D50 and D95) increases with more than 50% positive correlation.

This shows that, the larger the burden distance, the bigger the rock fragment generated from the blast. Having excessive burden with the same powder factor will definitely affect the fragmentation size and shape. To account for how your current burden is affecting your fragmentation, you should first assess your borehole condition before charging.

Furthermore, assess your blast results using image analysis software. WipFrag software is the most highly recommended blast assessment software, with a long history in addition to the latest technological innovation. The software offers significant advantages in assessing mine burden effects on fragmentation. Using the app on mobile phones allows for convenient, on-site analysis.

Deep Learning Capabilities

Deep learning capabilities save analysis time by quickly processing images. The boulder detection tool identifies oversized fragments, while the specification envelope helps correlate blast results with downstream primary crusher performance, ensuring optimal fragment sizes for efficient crushing and improved overall operational efficiency.

Follow for Part 3 – You can also find all three parts on Giant Miner’s Facebook page: https://www.facebook.com/GiantMiner

References

Prasad, S., Choudhary, B. S., & Mishra, A. K. (2017, August). Effect of stemming to burden ratio and powder factor on blast induced rock fragmentation–a case study. In IOP conference series: materials science and engineering (Vol. 225, No. 1, p. 012191). IOP Publishing.

Download WipFrag at https://wipware.com/get-wipfrag/

For Part 3 click here: https://wipware.com/effect-of-excessive-burden-distance-on-blasting-result/

Missed Part 1? Here you go: https://wipware.com/effect-of-excessive-burden-distance-on-blasting-result-part-1/

Excessive burden in blasting refers to having too much rock mass in front of the blast holes. This is relative to the designed blast parameters. The burden is the distance between a blast hole and the free face.

If this distance is too large, it can significantly impact the efficiency and effectiveness of the blasting operation. Here are some effects and consequences of excessive burden:

1. Incomplete Fragmentation:

When the blast design has too much burden distance between rows, the explosive energy may not be sufficient to break the rock effectively, leading to large, unbroken boulders or slabs.

2. Higher Vibration and Noise:

Relating ground vibration to this phenomenon, excessive burden can cause more energy to be transferred to the ground as vibrations, potentially causing damage to nearby structures and creating safety hazards (Blair & Armstrong, 2001).

On the other hand, inadequate burden can result in higher levels of air overpressure and noise, affecting the environment and nearby communities.

It’s worth noting that when there is excessive burden in blast design, the energy from the explosives is not used efficiently, leading to wasted explosive material and higher operational costs.

3. Flyrock Hazards:

Excessive burden can cause unpredictable flyrock, posing significant safety risks to workers and equipment.

4. Inefficient Loading and Hauling:

The resulting muckpile from an overburdened blast may have uneven fragmentation. This makes it harder to load and transport the material efficiently.

5. Incomplete Detonation and Misfires:

Excessive burden can cause incomplete detonation of explosives. This leads to misfires and the need for re-blasting, which adds to safety risks and costs.

Conclusion

In their paper for the 2nd World Conference on Explosives and Blasting Technique in 2003, Onederra and Esen stated that there is usually a discrete element of time that has elapsed from the time of explosive detonation to mass burden displacement. This time is designated as the minimum response time (Tmin) and is dependent on the burden mass, explosive and dynamic material response to the explosive stimulus. Generally, but not always, Tmin can be decreased by employing small burdens, using higher energetic explosives or a combination of both.

References

Blair, D. P., & Armstrong, L. W. (2001). The influence of burden on blast vibration. Fragblast, 5(1-2), 108-129.

Onederra, I., & Esen, S. (2003). Selection of inter-hole and inter-row timing for surface blasting—an approach based on burden relief analysis. In Proceedings of the 2nd world conference on explosives and blasting technique, Prague. Taylor & Francis (pp. 269-275).

Read more – Part 2: https://wipware.com/effect-of-excessive-burden-distance-on-blasting-result-part-2/

Download WipFrag at https://wipware.com/get-wipfrag/. Assess your blasting results, spot regions with poor fragmentation and trace back to your drill and blast design.

Visit Giant Miner’s Facebook page for more information about WipFrag 4 capabilities: https://www.facebook.com/GiantMiner

A Quick Summary on WipFrag version 4 and its New Features

Overview

Mining is the extraction of valuable materials called ore or sometimes industrial minerals from the earth crust, using appropriate technology with the aim to provide raw materials for industrial use.

The materials exist in massive form and must therefore be broken into handable size through blasting operation or other safe and productive ways. The use of explosive to break rock into smaller sizes had been adopted several years due to it well know advantages.

Image analysis had been proven as the way forward to enhancing blasting and improving downstream operation efficiency through accurate visualization. Image analysis is a technique use to evaluate blasting output and to monitor material flow during mineral processing.

WipFrag Image Analysis software is a powerful tool for analyzing particle size distribution (PSD) in digital images collected from various blast muck-pile, including fresh phase muckpiles after blasts, time series stockpile samples, and even drone or UAV images.

Features and Advantages

Let’s delve into its features and advantages:
1. Instant PSD Analysis: WipFrag 4 provides instant PSD analysis of the captured images. Whether you’re assessing post-blast muckpiles or analyzing stockpile samples, this software delivers accurate fragmentation data.

2. Auto-Scaling Capabilities: With auto-scaling capabilities, WipFrag 4 ensures precise measurements. It’s a cost-effective solution that saves time and resources.

3. Cross-Platform Compatibility: Seamlessly analyze images across multiple platforms, including iOS, Android, and Windows. Share results effortlessly and optimize blast performance.

4. BlastCast Blast Forecast Module: This module, included in the software, helps predict fragmentation when used alongside WipFrag particle size data. It’s a valuable tool for blast planning.

5. Deep Learning Edge Detection: This amazing tool will increase accuracy from our previous Simple edge detection and almost eliminate the need to manually edit your images.

6. Integration with WipWare Photoanalysis Systems: WipFrag 4 also controls sixth-generation WipWare Photoanalysis Systems. Monitor conveyor belts or heavy-duty vehicles in real time, providing continuous particle size data to your portable device 24/7.

WipFrag Software Options Available

WipFrag 4 offers flexible licensing options to suit different operational needs, whether you require continuous blast fragmentation analysis or occasional assessments. Here’s a quick overview of what’s available:

1. Annual Subscription

Ideal for operations requiring consistent fragmentation analysis, the annual subscription allows up to 10 simultaneous device activations per license. This is a cost-effective solution for teams working across multiple sites or needing frequent analysis.

2. Pay-Per-Use (PPU) Option

For users who need WipFrag on a project basis or for occasional assessments, the PPU image credit is a great option. This model offers flexibility, enabling you to pay only when you use the software without committing to an annual plan.

3. UAV/Orthomosaic Image Analysis:

This is included in the annual subscription with unlimited analyses for the year. If credits are preferred, a minimum of 3 credits is required to unlock the analysis results. Number of credits is determine by hectare.

4. MailFrag Single or UAV/Orthomosaic Image Analysis:

MailFrag is our online service when customers need a third party to analyze their images. Single image analysis is 3 credits and UAV/Orthomosaic image analysis is a minimum of 9 credits based on hectare. MailFrag is only available for use with credits. It is not included as an option with the annual subscription.

Which License is Right for You?

If you’re unsure which license best fits your needs, contact us to discuss your application and explore the best solution for your operation. Whether you need continuous monitoring or occasional analysis, WipFrag has an option that works for you!

Remember that credits can be transferred to other WipWare Account users. Additionally, UAV/orthomosaic images must be analyzed with the Windows version and be in GeoTIFF format.
In summary, WipFrag 4 offers a cost-effective and accurate solution for fragmentation analysis, making it an essential tool for professionals in various industries.

Multiple Language Options

WipFrag 4 has multiple language options available for our customers. The following nine languages are now available:

Anglais, français, espagnol, allemand, portugais, russe, chinois, italien et hindi.

Pour modifier votre préférence de langue dans WipFrag 4, veuillez suivre ces étapes :

Click on your Profile Icon

Cliquez sur le bouton Paramètres

In Settings, click on Language to access the drop-down menu

Dans le menu déroulant, 9 options de langue sont disponibles

Pour plus d'informations sur notre logiciel d'analyse d'images WipFrag 4, veuillez visiter notre Page WipFrag.

How Low Can You Go?

One of the most common questions we receive is, “How small can you analyze?” The answer depends on multiple factors, but with the right imaging, WipWare’s systems can measure down to micron levels. However, when analyzing material on conveyor belts, additional considerations impact the minimum particle size that can be accurately measured.

Over the years, we’ve worked with a vast range of conveyor belt applications from highly quality-controlled 10-inch belts to massive run-of-mine conveyors that are several metres wide as is normally found in global copper, iron ore mine operations. Our fully adjustable frames are customized before shipping to ensure seamless integration into your operation.

Key Considerations for Conveyor Belt Analysis

When it comes to analyzing material on conveyor belts, a few fundamental factors come into play:

• Fixed Camera Position – The camera is mounted at a consistent distance from the belt, usually within a metre or so (a few feet).
• Controlled Lighting – Conveyor belt environments generally offer stable lighting conditions, improving image accuracy.
• Material Spread – The material stream typically covers a predictable portion of the belt rather than the entire conveyor surface, allowing the camera to focus specifically on the material.
• Controlled Flow – Conveyed material has a known source and destination and moves at a controlled speed and direction, making variables easier to control.

With these stable conditions, WipWare’s systems can precisely determine the size ranges they analyze for each application.

Real-World Examples

Let’s explore two real-world examples using WipWare’s Solo system:

From the comparison table above, we see that ABC Company’s larger conveyor widths require the particle sizing system to be mounted higher to capture the full material spread. This setup means the system focuses more on coarser size fractions than fines – which is good: If a 3-metre belt is in use, and the material is raw primary crusher output, it’s unlikely that the material is 100% fines.

In contrast, Company XYZ deals with crushed and pre-screened materials, meaning the belt carries smaller particles. Since the conveyor is smaller in width, the system mounting height is closer to the material and can therefore analyze smaller size fractions.

Note: These are real-world examples with their own unique challenges which affect the detectable size range and goals which determine the focus of data collection. Your own application could have very different detectable size ranges depending on similar factors at your operation.

Expanding the Size Range: What are the options?

If you need to adjust the minimum or maximum detectable particle size, consider the following:

1. Calibrate for Unseen Fines – Using sieve data and manual belt cuts to measure unseen and unresolvable fines and calibrate the system output accordingly. This is good for known and predictable material streams.
2. Reduce the Field of View – Narrowing the system’s focus by adjusting the position or changing the type of lens used to view a smaller area. This in turn may limit the ability to capture coarser sizes.
3. Increase Camera Locations – Using multiple cameras on the same material stream to capture different ranges of material, ie. a “fines” camera and a “coarse” camera.
4. Tailored Solutions for Your Operation – The technology itself can change for your specific needs, such as increasing the camera resolution or changing the mounting solution.

If you’re wondering how effective a WipWare analysis system would be for your operation, Nous contacter! Our technologies have helped mining operations worldwide achieve better process control.

Have a unique application? We love a challenge — send us the details, and we’ll be happy to assist!

WipWare’s fragmentation analysis technologies have been widely applied across various mining operations to solve critical challenges. These were associated with material flow, fragmentation consistency, energy use, and overall process efficiency. I came across Tom Palangio‘s works on numerous case studies highlighting the effectiveness of WipWare‘s tools. These tools optimized blasting practices and downstream processing. This review presents a summary of several influential studies and industrial applications of WipWare technology.

Photographic Fragmentation Analysis

Selbaie Mine, Joutel, Quebec, Canada

In the mid-1990s, Selbaie Mine utilized photographic fragmentation analysis using WipFrag to assess explosive performance and optimize blasting patterns. The integration of WipWare technology enabled the mine to monitor and control several key performance indicators. Some of these indicators included energy consumption for crushing, loading rates, haul truck payloads, secondary blasting costs, and maintenance expenditures. Fragmentation data revealed a more comprehensive understanding of the effects of blast results on overall mining cost structures. This information allowed the mine to better manage ore processing operations. They could quantify the true cost of mineral handling based on fragment size.

Significant Pattern Optimization

INCO Coleman Mine, Sudbury, Ontario, Canada

INCO’s Coleman Mine used WipFrag during a detailed study in 1994, resulting in significant pattern improvement. The original tight blast pattern (5ft x 10ft) yielded a characteristic size (Xc) of 0.617 m, with substantial oversize material requiring re-blasting. Progressive expansion of the blast pattern to 6ft x 10ft and eventually 7ft x 10ft not only improved fragmentation (Xc = 0.318 m) but also reduced oversize entirely. WipFrag data was instrumental in determining optimal fragmentation, with INCO realizing up to 40% blast pattern expansion and 80% cost savings. Additionally, the technology allowed for reductions in fines generation, further streamlining ore handling and improving crusher feed quality.

Correlate Ore Fragmentation and Hardness with Mill Performance

Highland Valley Copper, Logan Lake, British Columbia, Canada

At Highland Valley Copper (HVC), the team used WipWare tools to correlate ore fragmentation and hardness with mill performance. WipWare’s WipFrag software, Reflex vehicle analysis system and Solo conveyor analysis system played a central role in tracking ore size distributions from the pit through to the mill feed. This enabled real-time optimization of crusher and mill settings. The mine’s dispatch system integrated fragmentation data to guide stockpile management and minimize feed segregation. WipFrag analysis revealed that feed consistency across the grinding lines could be improved by adjusting feeder ratios. This capability to quantify fragmentation effects allowed HVC to perform cost benefit analyses and optimize the balance between blast quality and mill throughput.

Detonator Timing Accuracy and Improved Fragmentation using WipFrag

Bartley and Trousselle – Ogdensburg, New York, USA

At Benchmark Materials Quarry, Bartley and Trousselle demonstrated the link between detonator timing accuracy and improved fragmentation using WipFrag. Digital programmable detonators yielded superior blast uniformity and reduced vibration levels. WipWare’s image analysis facilitated the evaluation of blast performance improvements by providing accurate fragmentation size distribution data.

The Effects of Improved Fragmentation on Mechanical Performance and Power Usage in the Crushing Circuit

Lafarge Canada Inc. – Exshaw, Alberta, Canada

Lafarge’s Exshaw operations applied WipFrag to examine the effects of improved fragmentation on mechanical performance and power usage in the crushing circuit. A redesigned blast using 102 mm holes led to more uniform fragmentation. This resulted in a 16% increase in crusher throughput and a 30% reduction in power consumption. WipWare data also informed decisions related to equipment selection (e.g., drill bits) and wall control, leading to improved safety and reduced vibration impacts on neighboring communities.

Cost-Effective and Reliable Fragmentation Assessment Tool

Barkley and Carter – Evaluation of Optical Sizing Methods

Barkley and Carter evaluated WipFrag as both a cost-effective and reliable fragmentation assessment tool. Their work highlighted that previous blast optimization efforts were constrained by the lack of efficient sizing techniques. In contrast, WipFrag enables meaningful decision-making in blast modeling, mining method selection, and economic planning. The study underscored the significance of image-based sampling frequency, particularly in varied muck pile conditions, to derive actionable insights on crusher performance and feed consistency.

Assess Fragmentation and Stemming Uniformity

Chiappetta, Treleaven, and Smith – Panama Canal Expansion

During the expansion of the Panama Canal, WipFrag was employed to assess fragmentation and stemming uniformity in complex geological and logistical conditions. The integration of WipWare into blasting operations enabled engineers to both track blast outcomes and support adaptive design decisions in real time. In a project characterized by not only marine traffic but also saturated zones and tight deadlines, the technology provided essential support in achieving controlled fragmentation and predictable material handling.

Conclusion

These reviewed case studies emphasize WipWare’s critical role in improving the efficiency and economics of mining operations. Through accurate and real time fragmentation analysis, WipWare technologies facilitate optimization across the mine to mill value chain. From reducing energy consumption and equipment wear, to improving blast designs and minimizing fines, WipWare’s technologies offer robust solutions to a range of material flow problems in both surface and underground mining environments. These outcomes underscore the value of fragmentation analysis in modern mining practice, unquestionably supporting data-driven decision making and continuous process improvement.

By Blessing Taiwo

From a dusty DOS computer to AI-powered, real-time fragmentation analysis systems… WipWare has been at the forefront of fragmentation analysis for over 30 years of innovation, transforming how the world measures particle size.

The Beginning

From humble beginnings to global impact, we’ve come a long way. This year, we’re celebrating over 30 years of innovation in fragmentation analysis. Along the way, we’re taking a look back at the milestones. These milestones shaped us and the journey of making particle size analysis smarter, faster, and easier than ever.

Before WipWare was WipWare, our founder Tom Palangio was in the field with North Bay DuPont. He was tackling real-world challenges with innovative thinking and a practical mindset.

Below is a photo of Tom from our archives. He was working on a project that would spark the idea for our very first product in fragmentation analysis: WipFrag.

Solving a Global Problem

Traditionally, describing blast results in mines and quarries was limited to vague terms like “good,” “fair,” or “poor.” Manual sieving and particle counting were too costly and impractical until a team of passionate pioneers changed the game.

WipFrag was born in 1986 from groundbreaking collaboration between Franklin Geotechnical, DuPont/ETI, and the University of Waterloo. It was the world’s first digital image analysis software for measuring rock fragmentation.

Leveraging advancements in imaging and computer processing, they created a revolutionary tool. A digital method to analyze muckpile photos or video frames to produce a detailed fragmentation size distribution curve.

The name itself carries the legacy: Waterloo Image Enhancement Process for Fragmentation or “WIEP,” later shortened to just “WipFrag.”

Since then, our journey has been marked by bold ideas, hard-earned field experience, and a commitment to excellence that has brought us to where we are today. Tom Palangio, with his explosive expertise, innovative leadership, and close collaboration with Dr. Norbert Maerz and Dr. John Franklin laid the groundwork for much of what we now take for granted in automated material analysis.

First Trials

Thanks to real-world testing in 1980s-1990s at INCO’s Copper Cliff and Coleman underground operations and Highland Valley Copper in BC, WipFrag proved its worth boosting productivity, reducing oversize, and optimizing blast patterns. Results included a 40% pattern expansion and 10% increase in mill throughput milestones that cemented WipFrag’s value in the mining industry.

We owe this innovation to the visionaries who asked, “What if we could measure fragmentation automatically?” and then made it possible. Hats off to the original developers and researchers whose dedication paved the way for what WipWare is today, 30 years strong and still leading the future of photoanalysis technology.

WipJoint and System 1

In 1990, WipJoint was introduced for measuring in-situ rock apparent block size and joint orientation.

Our journey into real-time automated analysis systems began in 1998, led by Thomas W. Palangio, the founder’s son, as he joined the company and introduced our first hardware systems. System 1 was released in 1998 with one camera for online analysis: a well-received innovation for the mining industry. The very next year, System 2 was rolled out, boasting the capacity to integrate 12 cameras for real-time analysis.

Then another year later in 2000, WipFrag 2 was developed, building on the success of the first WipFrag.

In this 2007 photo, WipWare team members gather around the first Solo system — a major step forward in automated material analysis. Originally built for conveyor belts and later adapted for vehicle loads, this early unit was the seed of what would become today’s Solo 6 et Reflex 6 systems — smarter, faster, and tougher than ever.

Pictured here are two faces still leading WipWare forward today:

• Thomas Palangio (right), now our Chief Technical Officer and Vice President of Technology
• Kevin DeVuono (back right), now our Head Programmer

WipFrag 3 joined the arsenal in 2014 with drone and GIS capabilities, serving as HMI for our real-time analysis systems. With WipFrag now in the palm of your hand since 2016, WipWare makes it easier than ever for field personnel to assess blast fragmentation instantly, anywhere, anytime and share it across platforms for end-to-end mine-to-mill optimization.

WipFrag Goes Mobile

In 2016, WipWare brought WipFrag to mobile devices — putting fragmentation analysis directly into the hands of field personnel.

For the first time, users could capture and process muckpile images using the camera on their phone or tablet, with the option to sync and share results across devices for further analysis.
This leap in accessibility made data collection faster, easier, and more flexible — using tools people already carried with them.
Designed for the real world — and it redefined the standard.

Pit to Plant Fragmentation Analysis

In 2018 Tom Palangio, President of WipWare enjoyed an interview with Les Crownsmen Partners at the CIM in Vancouver. During this interview, Tom discussed how innovation, being a disruptor in the early years and providing excellent leadership has shaped WipWare into the company it is today.

WipFrag 4 Released in 2020

In 2020, WipFrag became easier than ever for field personnel to assess blast fragmentation instantly, anywhere, anytime and share it across platforms for end-to-end mine-to-mill optimization.

Fast forward to today, under the technical direction of Thomas Palangio (CTO), the company continues to redefine industry standards. His creativity, technical drive, and future-forward thinking have powered the evolution of Solo, Reflex, and WipFrag, now enhanced with Deep Learning Edge Detection for unparalleled accuracy across all environments.

From a garage in Bonfield, to a global leader in real-time fragmentation analysis – 30 years of innovation and engineering smarter solutions for the world’s toughest industries.

Since 1995, we’ve been shaping the future of mining technology with groundbreaking tools like WipFrag, Solo, and Reflex. Along the way, we’ve helped change how the industry collects and understands data. Today, we’re using edge-powered, AI-driven systems on conveyors and vehicles, even underground.

WipWare continues to provide the industry with powerful tools to help companies monitor, measure and manage their materials the smart way. Our state-of-the-art arsenal of analyzers measure particle size, shape, volume and colour data in real-time on conveyor belts and vehicles. Our comprehensive software is useful anywhere to instantly determine particle size and shape distribution without using a scale object.

Always Evolving, Always Innovating

But we’re not done — today our tools continue to evolve.

We’re enhancing the way our systems capture material composition and volume — bringing deeper insights to operations of every size. Plus, we’re refining how data becomes decision-making power. And now we’re working to bring that same clarity everywhere from underground to outer space.

Thank you to our technical team, whose work ensures every system and line of code is field-ready and rock solid.

Thank you to the innovators whose commitment, structure, and continuity make every innovation sustainable and scalable!

And most importantly, to our clients, resellers, and partners around the world — thank you for 30 incredible years. Here’s to what’s next. YOU are the reason our WipWare Team continues to push boundaries. Your trust, feedback, and collaboration fuel the team purpose. Whether you’re analyzing underground ore, surface muckpiles, aerial drone images, conveyor material, or vehicle loads, your success is our mission.

Here’s to 30 years of innovation, reliability, and excellence… And to the next decades of digital transformation in mining and material handling.

Vitrine minière du Nord de l'Ontario North Bay & District Chamber of Commerce CIM/ICM Northern Gateway Branch MineConnect