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How Does Hard Rock Breaking Chemical Work?

Author: Sunny

Jul. 14, 2025

Rock Breaking Without Blasting - Rock Busters

Rock breaking has traditionally been associated with explosive techniques that require careful planning and execution. However, advancements in technology have paved the way for non-explosive methods that are safer, more precise, and environmentally friendly. In this blog, we will delve into the world of rock breaking without blasting, exploring the various techniques and tools that are revolutionizing the industry.

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Expanding Grout

How Expanding Grout Works

Expanding grout is a chemical compound that expands when mixed with water, exerting immense pressure on the surrounding rock. The process begins by drilling a series of holes into the rock, similar to the methods used with hydraulic splitting or chemical rock-breaking agents. The expanding grout is then carefully poured into these boreholes, where it penetrates the fissures and cracks within the rock mass.

Advantages of Expanding Grout

Expanding grout is an excellent choice for rock breaking due to its many advantages. It guarantees safety as a non-toxic and non-hazardous option. Precision is achieved with controlled fracturing, minimizing damage. The reduction of noise and vibrations makes it ideal for urban areas. It is environmentally friendly, producing no harmful gasses or pollutants. Cost-effectiveness is achieved through minimal equipment and reduced material waste. Finally, its versatility allows for its application in various rock types and projects. Overall, expanding grout offers a safe, precise, eco-friendly, cost-effective, and versatile solution for rock breaking.

Chemical Rock Breaking

Chemical rock breaking involves the use of chemical agents to weaken the rock structure, making it easier to break. One commonly used chemical agent is expansive mortar, also known as non-explosive demolition agent (NEDA). NEDA is a powdered substance that, when mixed with water and poured into pre-drilled holes, expands with tremendous force, causing the rock to crack. This technique is ideal for applications such as mining, construction, and quarrying.

Chemical rock breaking offers several advantages. Firstly, it is a non-percussive method, which means there are no vibrations or shock waves generated during the process, minimizing the risk of structural damage to nearby buildings or infrastructure. Secondly, it provides precise control over the size and direction of the fractures, allowing engineers to achieve the desired results with accuracy. Additionally, chemical rock breaking is relatively silent compared to explosive techniques, reducing noise pollution in residential and urban areas.

Hydraulic Splitting

Hydraulic splitting utilizes hydraulic pressure to fracture rock formations. The process involves drilling a series of closely spaced holes in the rock, into which hydraulic wedges are inserted. These wedges are then driven into the holes using a hydraulic pump, generating immense pressure that forces the rock to split along predetermined lines. Hydraulic splitting offers precise control over the direction and size of the fractures, making it suitable for delicate operations, such as in urban areas or near existing structures.

Hydraulic splitting provides several advantages over explosive techniques. Firstly, it eliminates the need for drilling and blasting, reducing the potential hazards associated with explosives. Secondly, it is a quiet and vibration-free method, making it suitable for use in noise-sensitive areas. Additionally, hydraulic splitting produces clean fractures without flyrock or airborne dust, ensuring a safer and healthier work environment.

Mechanical Rock Breaking

Mechanical methods rely on mechanical energy to break rocks. One commonly employed technique is the use of hydraulic breakers, also known as rock breakers or hammers. These heavy-duty tools are mounted onto excavators or backhoes and utilize a powerful hydraulic system to deliver repeated impacts to the rock surface, effectively fracturing it. Mechanical rock breaking is versatile and widely used in various industries, including mining, road construction, and demolition.

Mechanical rock breaking offers several advantages. Firstly, it provides high productivity, allowing for rapid and efficient rock fragmentation. Secondly, it can be used in various rock types and sizes, making it suitable for a wide range of applications. Additionally, mechanical rock breaking offers precise control over the breaking process, enabling engineers to achieve the desired fragmentation size for downstream processing or disposal.

Thermal Spalling

Thermal spalling is a non-explosive method that utilizes high-temperature differentials to break rock. By applying a controlled heat source, such as a flame jet or induction heater, to the surface of the rock, thermal stress is induced, causing the rock to expand. Subsequent cooling or rapid cooling through water application creates thermal stress gradients that result in spalling or flaking of the rock surface. Thermal spalling is particularly effective for breaking large boulders or concrete structures.

Thermal spalling offers unique advantages in certain applications. Firstly, it can be used in confined spaces or areas where vibrations and noise need to be minimized. Secondly, thermal spalling is a relatively low-cost method compared to other rock-breaking techniques, making it an attractive option for projects with budget constraints. Additionally, thermal spalling is a non-chemical method, which means it does not involve the use of potentially harmful substances, making it environmentally friendly.

Furthermore, thermal spalling allows for precise control over the depth and extent of the fractures. Engineers can adjust the heating and cooling parameters to achieve the desired results, whether it’s breaking the rock into smaller, manageable pieces or creating controlled fissures for excavation purposes. This level of control ensures greater safety and efficiency during the rock-breaking process.

The Future of Rock Breaking

Rock breaking without blasting has emerged as a safer, more precise, and environmentally friendly alternative to traditional explosive techniques. Chemical agents, hydraulic splitting, mechanical methods, and thermal spalling have revolutionized the industry, offering engineers and construction professionals a wide range of options to tackle rock-breaking challenges.

These methods not only increase safety for workers and nearby communities but also reduce environmental impact, noise pollution, and vibration. As technology continues to advance, we can expect further innovations in rock-breaking methods, paving the way for a more efficient and sustainable future in the industry. Whether it’s using chemical agents to induce controlled cracking, utilizing hydraulic pressure for precise splitting, employing mechanical tools for rapid fragmentation, or harnessing thermal differentials for controlled spalling, the art of rock breaking has entered a new era of safety, efficiency, and environmental consciousness.

What is rock blasting? - Superior Performance

Rock blasting is the process of drilling holes in a rock mass at depths, and spacing to allow an explosive to fracture the rock. In this process, the rock must fracture enough to be broken down to the size intended.

It is practiced most often in mining, quarrying, and civil engineering such as dam, tunnel, or road construction.

But how exactly does this process work and what does it involve?

Let's dive into everything you need to know about rock blasting.

How does rock blasting occur?
How is rock blasting performed?
Is rock blasting precise?
What explosive is used for rock blasting?
Is rock blasting safe?
Why do mining companies blast?
Do I need an engineer to plan rock blasting?

How does rock blasting occur?

After detonating, chemical energy from the explosive is released, causing the explosive to transform into a glowing gas with large amounts of pressure. In a densely packed hole, this pressure can exceed 1,500,000 psi.

The high pressure released is what shatters the area surrounding the drill hole and exposes the rock beyond to high levels of stresses (and strains), stresses, and strains that cause the rock to crack.

While under pressure, the cracks in the rock extend, and the rock in front of the drill hole yields and move forward. If the distance of the hole to the closest surface is not too great, the rock in front of the hole will break free.

How is rock blasting performed?

Rock blasting is performed to fracture rocks so that these can be excavated for construction, extracting through mining operations, or quarried for processing.

This process is completed by discharging explosives in a confined manner (for instance mud capping) or confined in a borehole.

The explosives used for blasting are usually commercial grade and formulated to provide a controlled amount of energy release as it is detonated. The explosive itself has little effect on the way in which the rock fractures, but instead, the geometry of the drilled hole and the manner in which it is loaded with explosives affects this.

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For instance, a deeper hole will produce a larger fracturing radius and a higher explosive concentration will cause the rock to break into smaller pieces.

Is rock blasting precise?

Rock blasting's design is not an exact process, but an iterative process of designing the blast hole layout and estimating the number of explosives needed to blast the rocks. This process requires professional assistance and experience.

Therefore, it is possible to produce the desired result in all rock blasting situations (considering the unique rock formations).

When blasting is designed correctly, the minimum number of explosives can be used, which will reduce costs and minimize the environmental impact of blasting.

Also, it’s important to take into account that blast vibrations may affect surrounding buildings and structures if not carefully monitored and controlled.

What explosive is used for rock blasting?

Ammonium nitrate fuel oil (ANFO) is used as an explosive in mining, quarrying, and tunneling construction.

Ammonium nitrate can be transported and stored and mixed with fuel oil when needed. ANFO is made of about 94% ammonium nitrate and 6% fuel oil.

Over the years, consumption of ammonium nitrate explosives has grown because of its safety advantage over other products such as dynamite.

Is rock blasting safe?

Over the years, the United States Bureau of Mines (USBM) and the Office of Surface Mining (OSM), universities, and private groups have conducted extensive research about rock blasting.

Research findings have led to the development of acceptable vibration standards that greatly reduce the risk of off-site impacts. Ground vibration levels have been set by law to avoid off-site damage and should feel the same as a loaded truck or bus going 50 to 100 feet away.

One of the greatest challenges of rock blasting is to accurately determine the bounds of the blast area. This is particularly true in geologically disturbed rock that is to be blasted. The determination of the bounds of the blast area is the first step in ensuring safety.

Mine operators prevent injury to people or damage to equipment when a scheduled blast is detonated by having a blast area security system. Most blasting accidents occur during scheduled blasting and are due to inadequate blast area security.

With today's technological advances in the civil engineering industry, operators can now explore blasting areas remotely using drones. This can help them locate potential hazards and ensure that blasting is done safely and accurately.

Why do mining companies blast?

Blasting is the most cost-effective technique for breaking rock. As a result, blasting lowers the costs of manufactured goods like as electricity, sand, gravel, concrete, aluminum, copper and other minerals extracted from the ground. “If it can't be cultivated, it must be mined” has never been more accurate.

Blasting is also the most efficient method for creating ore access tunnels and haul roads. These are essential in a mine to ensure the safe and efficient movement of personnel and equipment while providing access to mineral deposits.

Finally, rock blasting is used as part of environmental remediation projects by breaking down hazardous waste sites or landfills in order to facilitate their proper treatment and disposal.

Do I need an engineer to plan rock blasting?

Yes, you will need to hire a civil and or structural engineer. A professional engineer/blaster is required to use the latest technology and techniques in order to determine the precise amount of explosives needed for a particular blasting project. This includes calculating safe vibration levels for nearby structures, creating computer models, or carrying out a pre-blast survey of the site. The engineer/blaster must also design the blast to minimize ground vibration and airblast, as well as other potential hazards associated with blasting.

A professional engineer/blaster can help you save money by minimizing explosives usage and ensuring that a safe, efficient rock blasting job is done correctly. Rock blasting can be a cost-effective way to achieve your project goals, but it must be done carefully and correctly. Using a professional engineer/blaster is essential for this.

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References

Blasting - https://www.britannica.com/technology/blasting

Explosives and Blasting Agents - https://ihsmarkit.com/products/explosives-and-blasting-chemical-economics-handbook.html

208 Rock Blasting - https://www.dot.state.oh.us/Divisions/ConstructionMgt/OnlineDocs/MOP/200%20Earthwork/208/208%20Rock%20Blasting.htm

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