„Quarry6 –
Hightech for the raw material extraction“

The Quarries Trade Association (StBG) awards prizes to particularly innovative manufacturers, which, for example, clearly increase the safety during blasting or decisively improve the course of work. Prizes are not awarded to manufactures every year but only if outstanding innovations justify the award. This year it goes to geo-konzept GmbH (Fig. 1) for blast design. This company stands for exact surveying, quick planning and safe controlling of large hole blasting. The methods used reach from high-precision terrestrial laser scanning, software for planning and controlling to blasthole surveying and the integration of GPS data. The manufacturer prize 2009 of StBG is awarded for the integration of the entire flow of work into one software, i.e. from planning and controlling up to blasting. Thus, not only the flow of work in the quarry is enormously improved but also the safety is clearly increased.

Two things are important in a quarry – safety and profitability. Both can be enormously improved by means of the comprehensive system from geo-konzept. The individual components and their interplay in an integrated workflow are described in detail as follows:

Surveying of the quarry face

Exact data of the quarry face are the basis for each individual step of work. All following steps are based on a reproduction of the real circumstances as exactly as possible. A hand-operated laser is sufficient for a two-dimensional sectional survey as the simplest version. Of course, a three-dimensional survey of the quarry face offers more accurate data. On request, this can even be supplied as an automatic system. The software Quarry6 processes all data and can be adapted modularly to the requirements. For example, the module QuarryPocket logs the face data on a handheld and passes them to the computer for further processing.

Data processing and planning

Quarry6 (Fig. 2), the software which was awarded the manufacturer prize, processes the data to a quarry face model. The software has a clear structure. Even laymen will understand the individual steps of work, functions and tools, which can be used quickly and efficiently. There are various tools and possibilities of analysis to plan the line and positions of blastholes (Fig. 3). Parameters, such as drilling angle, depth and direction, subdrill as well as the desired offset angle, can be optimized at the same time in the profile view, plan view and in the three-dimensional view. In the first step, however, ­
Quarry6 ­calculates the ideal course of the blastholes. Furthermore, the familiar “BurdenMaster” function ensures high safety. Critical offset angles along the entire face are reliably detected.

The decisive advantage, when preparing the drilling pattern, is that the calculation is based on an exact reconstruction of the reality, i.e. exact offset-angles and the real course of the quarry face. Quarry6 provides exact data as regards the position of the collar, the inclination and depth of the blastholes. In order to really find the calculated point, the software is able to issue GPS coordinates. Thus the starting point on the floor can be marked to the exactness of a centimetre.

Accurate staking out

To mark the collar exactly at the right point, only a high-precision GPS receiver and a mobile hand-operated computer are needed. The software leads the driller exactly to the calculated point and he can mark the collar with an exactness to a centimetre. He is supported by a map displaying a view of the present position. What about the different levels of the floor? Eventually, a face model cannot represent the floor. The solution: The level and length coordinates are recorded simultaneously when setting out and marking the blastholes. If it is not possible to drill at the desired point, the driller may determine an alternative collar for the blasthole. In this case, the new data simply become an integrated part of blast design. Thus, a wrong depth of a blasthole due to the level error is excluded. No residual toe will be left and strong vibrations due to subdrill are eliminated.

The integration of high-precision GPS data into blast design represents a real innovation in the quarry. So far position and level data have not been used though they decisively improve planning, safety and success.

Optimization of planning

Now Quarry6 calculates the optimum drilling depth based on the new data as regards the position and, above all, the level of the collar. The authorized blaster no longer depends on speculations and comprehensive experience but can plan the drill pattern in a carefully controlled way, based on exact data. Another advantage is the documentation of his work – the proof of good and correct planning is available at the touch of a button. The program generates a great variety of standardized printouts, maps and tables comprising all relevant data according to BGV C24 §46 (trade association rules).

Checking the real blastholes

Planning is good, control is better. Rock hardness, inclusions, caverns and caves seldom adhere to planning, there are always deviations. To be on the safe side, geo-konzept also offers a system for controlling the holes drilled. Using rugged blasthole probes, e.  g. “Blasthole Probe MK3”, precise data on the real course, the real angle and the real depth of the blasthole are provided within minutes.

Optimization of blasting

The software Quarry6 also acquires the data of the real blast-hole and the blast design is completely recalculated. Thus, the risk, which is represented by experience values, estimations and ignorance, has been prevented. Furthermore, the entire course of work is precisely documented. Each individual step – from surveying, planning, controlling and optimization up to blasting – is documented. Planning of blasting is based on the best and most effective surveying technology offered at present. Large hole blasting cannot be planned, documented and carried out in a better way.

Result

Even the most exacting blasting can be carried out safely, quickly and economically using the system from geo-konzept, above all, due to the integration of an exact GPS. Loosened rock with a poor size range, waste of explosive, flying rock and unnecessary vibrations are virtually excluded. Optimum blasting is getting nearer and nearer using the products from geo-konzept GmbH based on exact data and a reliable software for calculation. More productivity due to high planning exactness! Incidently only one person is needed for the operation. He can carry out all steps without any special knowledge of surveying. Also in this respect the system is user-friendly and economic.

StBG not only recommends the advantage of safety and profitability and awarded the prize to the supplier, quarry operators buying the modular system of geo-konzept also get financial support: for every module StBG grants an allowance of 30 %!

Further advantages

When the system has been installed in the quarry there are further possibilities of use. For example, projection mapping, additional equipment and further software can be continuously adjusted without any additional expenditure.

The GPS unit can also log positions, e. g. of vibration measuring instruments, and integrate them into existing plans. The laser scanner can also be used to survey stockpiles and calculate exact volumes.

ZKG INTERNATIONAL talked with Dipl.-Geogr. Martin Herkommer, product specialist for the surveying system of geo-konzept GmbH regarding the awarded project in the category manufacturers prize.

ZKG: How did it occur to you to develop the suggestion for improvement?

Martin Herkommer: Since 1992 geo-konzept GmbH has been dealing with terrestrial laser surveying. Since that time we have also worked in quarries with this method where we have learned a lot as regards the operational procedures and, above all, the requirements. The analysis of poor blasting has shown us where the sources of error are located. We found that, above all, the exact position and height of the borehole starting point is a decisive factor for successful blasting. Wrong borehole lengths lead to the familiar problems: vibrations, left residual toes, uncontrolled flying rock. To eliminate these problems motivated us to improve our system.

ZKG: How was the suggestion developed, has it already been implemented in your company?

Martin Herkommer: As far as our system is concerned, it is a long time ago that it was a mere suggestion. The GPS-aided blasting planning has been successfully on the market for more than a year.

The reason for the development was that the quarry floor could not be calculated. However, this would be very helpful for work and safety in quarries. But how should you get exact data of locations and heights in a quarry? A type of GPS for blasting operations – that’s what was needed! This way was obvious since geo-konzept has also been dealing with high-precision GPS for agriculture since its foundation. As you perhaps know, the “normal” GPS has a precision to only about 30 metres – this is of no use in a quarry. We already had the technology and the know-how how to work with it with a precision to a centimetre. Thus, the integration of GPS into the planning of blasting was the logical step and the solution for many of the shortcomings of blast design. With geo-konzept it is now possible to survey the exact height and position when staking out boreholes. Thus, height errors are simply eliminated.

Other benefits followed automatically so to speak: The time-consuming manual staking out becomes unnecessary. Handheld computers including map and exact coordinates lead the driller to the exact place where the borehole must be according to an exact calculation. Furthermore, the driller cannot only determine the real course of the boreholes by means of probes. The system of geo-konzept is able to process these data again to adapt to planning of blasting to the reality.

ZKG: How much time did you invest from the first idea to the finished suggestion? How many co-workers took part in this process?

Martin Herkommer: The development from the idea to the first marketable product took about two years. At the beginning two co-workers implemented the ideas. After the success the department now consists of four staff members. However, such a process is never really finished. There are always new ideas, requirements and technologies, which we integrate. For example, currently we are working on a planning tool for the simple and safe preparation of ignition plans.

The most important motor for the further development is the customer. We do not want to miss the market with amazing features. We want to offer exactly what is really needed. Only practical technology will be used. And what is more useful than technology that makes quarries more economical and safer as well?

ZKG: What are the benefits of this suggestion for your staff and your company?

Martin Herkommer: It goes without saying that we, as a company, are interested in working economically and our success shows that we are right. However, it is more than only a question of economic success. It is important for us to see that we are on the right track with our solution. We plan for the future. This is not least reflected by the award, which is something of which we are naturally very proud.

ZKG: What about your role as the trailblazer for other companies?

Martin Herkommer: We travel a lot for our customers and potential customers both nationally and internationally. Through our partners we get in touch with many companies. Again and again we find out that this innovative and easy technology is not known, in part, or is not used.

Then often it is a great surprise for blasting companies when they realize what is possible with minimum expenditure. With our free of charge presentations we frequently preach to the converted, because we offer what many blasting companies would like to have already had for years. It turned out that safety and profitability, as a package, are convincing. More than 90  % of the quarries, where we present our system, buy it. Not least the contribution of 30  % granted by the Quarries Trade Association for better safety is a good business card.

If we look at our competitors in the market, we are in the fortunate position to score as a technology leader. There is nobody worldwide who could offer a similar system with comparable prices or quality. Other companies have to cut their coat according to their cloth.

ZKG: How do you rate this event (Award Work-Safety-Health)?

Martin Herkommer: It is the highest award and recognition we could receive for our work in the last few years.   

www.geo-konzept.de