BCP 2 - Surface Initiation Systems

Blasting Competency Programme
Module 2: Surface Initiation Systems

1
Contents
Smartdets ............................................................................................................................... 2
Introduction .......................................................................................................................... 2
Smartdet Components ......................................................................................................... 2
Features and Benefits .......................................................................................................... 4
Surface Shock tube ............................................................................................................... 4
Introduction .......................................................................................................................... 4
Features and Benefits .......................................................................................................... 4
Description of Shock tube .................................................................................................... 5
Surface Shock tube Products............................................................................................... 6
Benchmaster Assembly ....................................................................................................... 6
Handimaster Assembly ........................................................................................................ 7
Handimaster Trunkline Delay ............................................................................................... 8
Noisemaster Trunkline Delay ............................................................................................... 8
Noisemaster Lead-in ............................................................................................................ 9
Common features............................................................................................................... 10
Common Benefits............................................................................................................... 10
Environmental Benefits ...................................................................................................... 10
Detonating Cord................................................................................................................... 11
Detonating Relays .............................................................................................................. 11
Capped Fuse ........................................................................................................................ 12
Introduction ........................................................................................................................ 12
Durafuse/Duraline System ................................................................................................. 12
Stopefuse 290/Stopeline System ....................................................................................... 13
Igniter Cord ........................................................................................................................ 13
AEL Electric Detonators...................................................................................................... 14
Types of Electric Detonators .............................................................................................. 14
Capacitor Discharge Shot Exploders ................................................................................. 15
Boosters ............................................................................................................................... 16
© African Explosives Limited, 2009

2
Surface Initiation Systems
Smartdets
Introduction
AEL Smartdet Electronic Initiation Systems are the most advanced initiating systems in the
market place. This state-of-the-art technology provides:
• flexibility in blast design,
• optimum blast results,
• safety,
• reliability,
• better control of vibration
and air blast, fragmentation,
muckpile profiles and
casting,
• better crusher efficiencies,
• cost-savings.
AEL Smartdet Systems are user-friendly, fully programmable and can accommodate
complex blast designs where flexible millisecond timing is required. The unique, patented
test-on-connect feature of the Smartdet system ensures successful deployment of the unit.
There are three AEL Smartdet systems:

1. The Narrow Reef System - This system is currently used in normal stoping and long-
hole stoping operations in Southern Africa. It is particularly suited to specific stoping
conditions which require flexible timing.
2. The Tunnel Blasting System - This system was developed specifically for
underground development and civil tunnelling applications.
3. The Universal Blasting System - This system is currently being used extensively in
quarrying, open-pit mining, underground massive mining, civil and construction, and
tunnelling applications.
Smartdet Components
Smartdet Electronic Detonator

The Smartdet Electronic Detonator assembly consists of:
• A base charge, greater than 8D making it compatible with any type of detonator
sensitive explosives,
• An integral printed circuit board (PCB) with a timing chip,
• An energy storage capacitor, ensuring total independence of detonators from
each other,
• Steel harness wires encased in an abrasion resistant plastic sheath,
• A waterproof connector filled with silicon grease,
• Unique factory assigned identity number for easy identification.

3
Rowpod
The RowPod facilitates communication between the detonators,
Logger and Blaster.
This small device functions as the memory module of the system and
stores the list of detonators as well as their assigned delays. Each
Rowpod can store data for up to 200 detonators - 4 Rowpods are
normally supplied with each Logger/Blaster kit.
The RowPod is used in conjunction with the Logger when hooking up, as well as with the
Blaster when initiating the blast.
Blaster
The Blaster is a handheld device used to test, program, arm and
fire the detonators. It provides the power to charge the capacitors
as well as the correct digital codes to initiate the blast.
The Blaster is password protected to prevent unauthorised use.
Universal Logger
This handheld device is used in conjunction with the RowPod to connect
up blast and assign the desired delay time to each detonator. This device
also tests each detonator to ensure functionality of each unit before
initiating the blast. It also allows for a complete test of the circuit once
connecting up is completed.
Detonators are connected in the reverse order of firing. The inter-hole

delay is pre-programmed in the Logger and can be changed as required.
The logger is inherently safe, operating at a voltage far below the firing voltage. Together
with built in electronic safety device in the detonator and the fact that the Logger is not
equipped with the necessary firing code, the Logger cannot initiate a detonator.
Harness Wire
Smartdet harness wire is of the correct gauge (thickness) and correct
insulation type to function correctly with Smartdets, Loggers and
Blasters.
Do not use any other type of harness wire to connect up Smartdets - the
wire may appear fine when logging, but when the blaster is connected
the wire may offer too much resistance to allow the blaster to function
correctly.

4
Features and Benefits

Smartdet Features
• Inter-holes delay flexibility
• Versatility
• 100% factory tested
• Immunity to electromagnetic radiation
• Immunity to stray currents
Smartdet Benefits
• Improved fragmentation
• Maximum face advance
• Increased blast cycles due to better muckpile distribution, resulting in a major
decrease in cleaning time.
• Saving of up to 30% in number of holes drilled, due to the ability to stretch
existing blast design criteria.
Surface Shock tube
Introduction
Shock tubes are small diameter, hollow plastic laminated tubes
that are internally coated with a very thin film of reactive material.
When initiated by either a detonator or detonating cord, a low

energy shock wave is transmitted at around 2 000 m/s inside the
shock tube to a detonator crimped onto one end, or both ends.
The function of the detonators (crimped) on either ends of the
Shock Tube system, is to initiate the explosives in the hole (in-
hole detonator) and to transfer the firing signal to the next sequential Shock Tube (out-hole
detonator). The tube is coated with a tough outer layer which provides superior, abrasive,
tensile and oil resistance properties.
Features and Benefits
Benefits of Shock tube

• Shock tube can be used in all temperature conditions.
• Shock tube systems are suited to a number of applications underground including
development, narrow reef stoping and ring blasting.
• The main benefits are sequential firing, minimal misfire rates, optimum
fragmentation and improved muckpile characteristics.
• The product is oil and degradation by UV radiation resistant and will withstand
temperatures of -20 to +60 degrees.
• Shock tube product has no memory and therefore coil and uncoil easily and can
withstand tensile loads exceeding 350 Newton.

5
Description of Shock tube

The shock tube is a narrow bore hollow plastic tube containing a light dusting (18 ± 4 mg/m
or, in layman terms, about a teaspoon per kilometer) of an explosive mixture of HMX and
aluminium powders. HMX is a powdered high explosive developed by the British military and
paint fine aluminium is mixed with it as a sensitiser.
When initiated by either a detonator or detonating cord, a low energy shock wave is
transmitted at around 2 000 m/s inside the shock tube to a detonator crimped onto one end,
or both ends.
Shock tube detonator

The detonator used for initiating the explosive (or a primer) with shock tubes is crimped to
one end of the shock tube and sealed by a rubber sleeve. The tube sits on a conductive
isolation cup (the conductive characteristics of this cup give an added measure of safety
against accidental generation of static discharge during assembly or handling) above the
detonator delay element.
Where a sealer element is present (in detonators with delays of 150 ms and up) there is an
external crimp part way down the detonator tube to prevent movement of the delay element
and ensure sealing. This sealer element has a slagging compound which seals the delay
element as it burns and allows the starter element (in detonators with delays of 400 ms and
up) and main delay element to burn in a closed pressurised atmosphere.
The lead azide/styphnate primary charge is pressed into a witches hat configuration to
minimise the amount of azide in contact with the detonator wall. There is approximately 0.78
g of PETN in shock tube detonators, which makes it number 8 strength.
Handimaster Block
The Handimaster Block is a Bunch Block specifically designed for Handimasters.
It contains the out-hole detonator which is the same as the in-hole detonator except for the
different delay. It accepts up to 6 strands of shock tube.
Cobra Clip
Where detonating cord is to be used to initiate the shock tube it is important that the tube be
connected at right angles to the detonating cord if the tube is to be reliably initiated by the
cord in both directions.
Cobra clips are used primarily in underground applications on Tunnelmasters but may be
used in surface applications. The Cobra clip is designed to connect the shock tube at right
angles to detonating cord (Powercord or Cordtex 10).

6
Surface Shock tube Products

There are five shock tube products specifically designed for surface operations:
• Benchmaster Assembly
• Handimaster Assembly
• Handimaster Trunkline Delay
• Noisemaster Trunkline Delay
• Noisemaster Lead-in
Benchmaster Assembly
Uses
• Quarries
• Open cast/open pit mines
• Civil engineering projects
• Provides an in-hole delay detonator which is initiated
by detonating cord on surface connected with a cobra
clip
Features
• High strength detonator with delay time printed on aluminium shell
• Orange cobra clip indicating delay time and tube length
• AEL shock tube of variable length
o Yellow colour
o 45 kg minimum break load
o Resistant to hot and cold temperatures
o Functional after immersion in oil containing explosive products under standard
mining conditions
• Reliably initiates Pentolite boosters, cartridged explosives and cap-sensitive high
explosives
Benefits
• Accurate and precise pyrotechnic delay timing
• Rugged, abrasive resistant tubing
• Easy and simple to use
• Highly visible components – greater safety
• Immune to hazards of radio frequency radiation, stray currents and static
discharge
• Shock tube does not tangle
• Reliable

7
Handimaster Assembly
Uses
• Quarries
• Open cast/open pit mines
• Civil engineering projects
• Pipeline and utility trenching
Features
• New HANDIMASTER® enhanced connector
o Blocks are colour coded by delay
o Printing on block indicates delay time and length
o 6 tube capacity – can contain 1 to 6 shock tubes
o Low shrapnel and low noise design
o Contains optimally charged detonator for shock tube initiation in both
directions
• In-hole detonator
o High strength detonator with delay timing printed on shell
o 500 ms delay
• AEL shock tube
o Yellow colour
o Functional after immersion in oil/fuel containing explosive products under
standard mining conditions
Benefits
• Accurate delay sequence
• Rugged, strong, abrasive resistant tubing
• Quick, simple and secure connections
• Highly visible components - greater safety
discharge
• Reduced noise levels as compared with detonating cord
• Eliminates detonating cord and relays
• Economical, reduced inventory

8
Handimaster Trunkline Delay

Uses
• Surface mining
• Quarrying
• Civil engineering operations
Features
• New HANDIMASTER® enhanced
connector
o Blocks colour coded by delay
o Printing on block indicates delay time
and length
o 6 tube capacity – can contain 1 to 6 shock tubes in connector block
o Low shrapnel and low noise design
o Contains optimally charged detonator for shock tube initiation in both
directions
• AEL Exel shock tube
o Green colour
• Orange cobra clip indicating delay time and tube length
Benefits
• Combined trunk-line and delay
• Rugged abrasive resistant tubing
• HANDIMASTER® connector has a low shrapnel and low noise design
• No requirement to cover HANDIMASTER® connector
• Quick and simple connections
discharge
Noisemaster Trunkline Delay

Uses
• Surface delays with detonating cord or shock tube down lines
• Quarries
• Surface mines
• Civil engineering and demolition
Features
• Bunch block connector
o Colour coded for each delay time
o Positive locking cover
o Accepts shock tube or detonating cord

9
• AEL Exel shock tube

o Green colour
o 45 kg minimum breaking load
• Orange cobra clip printed with delay time and tube length
• No 6 strength initiating detonator
Benefits
• Accurate delay timing
• Easy to use
• Flexible blast design
• Eliminates noisy surface detonating cord
discharge
Noisemaster Lead-in
Use
• Non-electric blast pattern initiation
Features
• Bunchblock connector
o Purple colour
o Accepts shock tube or detonating cord
o Positive locking cover
• Spooled for easy off-reeling
• Shock tube
o Red colour
Benefits
• Easy to use
• Cost effective
• Reduced noise
• Positive initiation control
• Immune to the hazards of radio frequency radiation, stray currents and static
discharge

10
Initiation
NOISEMASTER ® Lead-in assemblies can be initiated by any of the following initiation
products:
• Electric detonators
• Detonating cords
• HANDIMASTER® trunk-line delays
• NOISEMASTER® trunk-line delays
Common features
All AEL shock tube products have the following features in common:
• Closed flame design.
• Fixed nominal delay. – Very accurate.
• Fast delays.
• Fixed burn front.
• High strength in-hole detonator. – 8D detonator can directly initiate blow loaded
ANFEX.
• Bunch block with 6 tube capacity and low shrapnel design – Reduces risk of
cutoffs
• 45 kg Minimum break load on the shock tube which is also resistant to hot and
cold temperatures.
Common Benefits
• Accurate delays
• Brightly coloured components
• Quick and simple connections/hook-up
• Connectors are robust and easy to hold
• Connectors can accept up to 6 lengths of shock tube
• Low risk of fumes
• No open flames
• Low risk of cutoffs
• Reduced inventory
• Rugged, strong, abrasive resistant tubing
• Rustproof aluminium detonators
Environmental Benefits
When used in place of detonating cord, Shock Tube systems can solve environmental
problems and provide major technical advancements in delay blast initiation. These include:
• Bottom-point initiation.
• Down-the-hole delays.
• Individual hole firing.
• Increased surface delay ranges.

11
Detonating Cord
Uses
• Lead-in lines
• Tie-up and initiation of shock tube detonators
• There is a range of detonating cords to satisfy a
variety of applications
• Connection to trunklines may be by using cobra
clips, detonating cord connectors, clove hitch
knots and double clove hitch knots
• Cords may be extended by use of reef knots
• Consider 8 g/m coreload for booster and
detonating relay initiation
Features Benefits
• Each detonating cord consists of a core • Relatively insensitive to detonation by
of pentaerythritol tetranitrate (PETN) friction, shock, electrostatic discharge
enclosed by a tape, wrapped with yarn or other forms of electricity
and sheathed in plastic • Excellent resistance to side penetration
• VOD 6 500 m/s by oil or water
• Highly visible colours • Flexible
• Reliably initiated with a 0.6 g PETN • Uniform coreload
detonator • High tensile strength
• Easy to handle and tie knots
Cutting Detonating Cord

When cutting detonating cord make sure that you use a sharp, clean,
smooth blade which must be cleaned afterwards.
Detonating Relays
Use
• As surface delays for detonating cord
Features Benefits
• 25 ms and 40 ms delays available • Bi-directional
• Colour coded by delay • Quick and simple connection
• Compatible with 8 g/m and higher • Easy to use
coreload detonating cord

12
Capped Fuse
Introduction
Capped fuse is a generic term used to describe any type of pyrotechnic black powder based
fuse which has been capped with a detonator at one end and a connector assembly at the
other. AEL currently manufactures two types of capped fuse, namely Durafuse and
Stopefuse 290.
Stopefuse® 290 is used for blasting in stoping application and Durafuse® for development
and tunnelling applications. These are underground applications, but capped fuse is
occasionally used for surface applications as well.
Each fuse is used with a corresponding igniter cord - together the fuse and igniter cord make
up the initiating system.
Durafuse/Duraline System
The Durafuse/Duraline system ensures the
reliable initiation of development rounds in
adverse mining conditions experienced
underground .
Durafuse evolved from the original standard fuse
with which all capped fuse products were made
until recently. It is a high quality plastic finished
safety fuse product and consists of a tough
polyethylene sheath extruded over conventional
semi-fuse. It exhibits greatly improved water
resistant characteristics over conventional fuse
and is impervious to diesel and ammonium
nitrate.
Durafuse burns at a rate of 99-121 s/m and is recognised by the green flexible polyethylene
(also called alkathene) sheath surrounding the core. Standard lengths range from 1.8 m to
3.0 m in increments of 0.3 m. Non-standard lengths up to 4.2 m
are available on request.
Duraline is a high carcass strength igniter cord which prevents

cross ignition of shot holes and thus ensures correct firing
sequence in tunnelling application. It is constructed using the slow
igniter cord composition which gives it excellent water resistance
characteristics.
Duraline is also green and is constructed of standard slow cord
igniter cord with an iron wire alongside it, providing additional
carcass strength to the igniter cord. The fuse burns at a rate of 30
- 45 s/m and is covered by a green polyethylene sheath.
Duraline used to be known as Duracord.

13
Stopefuse 290/Stopeline System

Sequential firing of a large number of shot holes
is an essential requirement for narrow reef
stoping. The Stopefuse 290/Stopeline system
guarantees sequential firing by slowing down the
blasting process.
The method of manufacture, the wet spun
process, enables safety fuse to be manufactured
at slower burning rates. This technical
development allows the highly reliable Stopeline
twinned slow igniter cord to be used with 0.9 m,
1.2 m or 1.5 m fuses in stoping. Prior to the
introduction of Stopefuse a range of faster
burning igniter
cords were
manufactured to
match the faster standard fuse. These igniter cords included
IC57 and Medium cord, both of which were inferior to Slow
cord in terms of water resistance and robustness.
Stopefuse burns at a rate of 260-320 s/m and is coloured

red.
Stopeline cord has a burning rate of 30-45 s/m and is

covered in a red plastic sheath .
Igniter Cord
Selecting the right igniter cord for a given fuse type and length is important for achieving
good blast results:
Stopeline Stopeline 9 Slowline Duraline
Used with Stopefuse 290 in stoping Used with Durafuse in Development

applications applications

14
AEL Electric Detonators
Types of Electric Detonators
Carrick Statsafe • Fiery Coal Mines

• Low chance of accidental
initiation by a stray current
• Accurate delay
• Reliable initiation
• But not of methane/air mixtures
• Delays from 0 to 300 ms
IED – • Initiating primary blasts - fire

Instantaneous trunk lines of detonating cord
• Initiating secondary blasts
• Low cost and reliable
• Blasting cables can be re-used
SPD and LPD • SPD – Short Period Delay

o 15 delays: 25 - 375 ms
o Ring blasting applications
• LPD – Long Period Delay
o 12 delays: 0.5 - 6.0 seconds
o Tunnelling and Shaft Sinking
• Easy circuit testing
• Easy to prime and charge
• Simple and flexible
Vulcan • Initiation of Blasting Gunpowder
Fuseheads • Dimensional Stone Quarries
• Circuits easily tested
Shurstart Electric • Initiation of igniter cord

Starters • Clip to securely hold initiating
cord next to initiating charge
Energy Requirements of Electric Detonators

In practice it is rare for a DC current to be used for firing blasting circuits today except for
capacitor discharge shot exploders. The only other source of DC current likely to be available
is a battery and using these is illegal under South African mining and civil blasting
regulations.

15
However, when using other forms of power supplies such as AC mains supply and capacitor
discharge exploders, calculations are done to determine their steady DC current equivalent
when analysing blasting circuits.
Capacitor Discharge Shot Exploders
Like AC power supplies, capacitors differ from DC

current in that the voltage supply (and hence the current
and energy delivered) decays with time.

16
Boosters
Uses
To initiate non-cap sensitive explosives in
packaged or bulk form in the following applications:
• Open cast operations
• Quarrying
• Underground ring blasting
• Vertical Crater Retreat stoping
• Development applications
Features
• Cylindrical Pentolite, PETN and TNT
cast boosters
• 1,68 g/cc density
• VOD 7 500 m/s
• 30 g booster for use with plain detonator
• Detonation pressure of > 21 GPa
• Virgin grade TNT used
• Excellent shelf life due to stability of explosives
Benefits
• PETN rich pentolite composition for pick-up reliability
• 150 g boosters fully protects the detonator
• 150 g booster have saddles for protection against damage to shock tubing or
wire and/or damage to detonating cord
• Optimum diameter to length ratios for effective loading and initiation of explosives
• Completely waterproof
• Cylindrical shape ensures easy loading with no bridging of bulk explosives in the
hole
• A range of boosters that can be initiated by electronic, shock tube, electric and
capped fuse detonators. Detonating cord >8 g/m may also be used
• Easy to use

BCP 2 - Surface Initiation Systems

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Blasting Competency Programme

Module 2: Surface Initiation Systems

© African Explosives Limited, 2009

Surface Initiation Systems

There are three AEL Smartdet systems:

Smartdet Electronic Detonator

© African Explosives Limited, 2009

The Blaster is password protected to prevent unauthorised use.

Detonators are connected in the reverse order of firing. The inter-hole

© African Explosives Limited, 2009

Features and Benefits

Surface Shock tube

When initiated by either a detonator or detonating cord, a low

Features and Benefits

Benefits of Shock tube

© African Explosives Limited, 2009

Description of Shock tube

Shock tube detonator

© African Explosives Limited, 2009

Surface Shock tube Products

© African Explosives Limited, 2009

© African Explosives Limited, 2009

Handimaster Trunkline Delay

Noisemaster Trunkline Delay

© African Explosives Limited, 2009

• AEL Exel shock tube

© African Explosives Limited, 2009

© African Explosives Limited, 2009

Cutting Detonating Cord

© African Explosives Limited, 2009

Duraline is a high carcass strength igniter cord which prevents

© African Explosives Limited, 2009

Stopefuse 290/Stopeline System

Stopefuse burns at a rate of 260-320 s/m and is coloured

Stopeline cord has a burning rate of 30-45 s/m and is

Stopeline Stopeline 9 Slowline Duraline

Used with Stopefuse 290 in stoping Used with Durafuse in Development

© African Explosives Limited, 2009

AEL Electric Detonators

Types of Electric Detonators

Carrick Statsafe • Fiery Coal Mines

IED – • Initiating primary blasts - fire

SPD and LPD • SPD – Short Period Delay

Shurstart Electric • Initiation of igniter cord

Energy Requirements of Electric Detonators

© African Explosives Limited, 2009

Capacitor Discharge Shot Exploders

Like AC power supplies, capacitors differ from DC

© African Explosives Limited, 2009

© African Explosives Limited, 2009

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