REVISED DRAFT TECHNICAL INSTRUCTION NO.

19

USE OF EXPLOSIVES FOR ROAD

CONSTRUCTION WORKS
1. GEN ERAL

Border Roads Organization handles and uses various types of explosives on large
scale for carrying out blasting operation for various construction works of roads,
tunnels, bridges, quarry operations etc. It is essential that on all the occasions,
blasting operation is carried out properly and c arefully. Indiscrimin ate blasting operation
may caus e disturbances to th e stability of existing hill slopes and cause irreversible
damage to environment. Unplanned blasting may result inloss of human lives and
damage to properties.

For construction of a road in hilly terrain, drilling and blasting are widely used for
the excavation of rocks. The main objec tive of blasting is to fragment and displace rocks
using explosives. The pavement layers are then laid over the displaced rocks. The
detonation of explosives within the hole yields dynamic stresses responsible for
rock-breakage. Only a small proportion (20 - 30 % ) of explosive energy is only utilized
for fragmentation and displacement. The remaining explosive energy (70 - 80 % ) is
lost to the surrounding environment or rock mass and is responsible for the
occurrence of unwanted nuisances such as ground vibr ations, air overpressure, over -
breaks, fly-rocks, etc. A skilled blast designer suitably tailors the blast designs in
accordance with the geo-environmental conditions to optimize the fragmentation and
control the damages caused by energy lost.

Vibrations originating from uncontrolled blasting of rock greatly disturbs the

stability of nearby hill side to a great extent. The over-breaks and the loose hanging
rocks from previous uncontrolled blasting operation sometimes fall over the men and
machines duri ng the subsequent operations. This also results in immediate and
delayed landslides and slip zones causing considerable damage to property. Explosive
energy is the cheapest energy available till -date for rock fragmentation. Further, the
linear progress obtained from a rock blasting is always greater than mechanical
means such as Rock breaker, Rock Splitter etc. With the advent of modern controlled
blasting techniques, blasting nuisances can be controlled to a greater extent without
compromising the progress in rock excavation. Now a days, the permission of
controlled blasting for excavation of mineral resources is easily granted up to a
distance of 100 m by regulating agencies. Blasting is integral and indispensable part
of hill road construction . However, rock blasting is hazardous in nature and often
highway or civil engineers are not trained to attain progress in rock excavation
without compromising the safety. Hence, it is firmly recommended that a highway

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engineer must be properly trained for executing s afe controlled blasting before their
deputation on blasting rocks for construction of hill roads.
DGBR Technic al Instruction No. 15 on 'Quarry Operation in BRO' bri efly covers the
use of explosives for quarry operation. BRO order s No. 1/93 and 2/ 97 have been issued
for safety and security of explosives.

The aim of present Technical Instruction No. 19 is to lay guidelines for selection of
explosives, technique of Rock Blasting operation and ensuring safety at all levels
while dealing with explosives. The present TI also lays guidelines for proper storage,'
transportation, handling, guarding , use of explosive for various construction activities in
BRO.

2. GUIDELINES

E xplosives must be properly stored, transported with due care and handled properly by
personnel duly authorized. Proper account of explo sives must be maintained daily at
each occasion of transaction/issue or consump tion by concerned staff. If explosives
are not properly handled (i.e., transported, stored, guarded and accounted) it may, at
times fall into the hands of anti -national elements and cause immense damage.

All the staff involved at all stages Le., Stores Company, RCC right from OC unit to
Personnel (including CPL ), must, therefore, be aware about the instru ctions for proper
storage, transportation and handling of explosives.
All the staff involved in rock blastin g work in RCC /BCC right from OC unit to
various personnel (upto CPL l evel). must, also be aware about the pr ecautions to be
taken for proper accounting and use of explosives, so that maximum output c an be
achieved with minimum quantity of e xplosives and with minimum blasting without
disturbance to the existing hill slopes and environment. All must be given necessary
training and consciousness regarding adverse e ffects as well as danger to life and
property due to uncontrolled rock blasting so that only controlled rock blasting is
practiced on-site.

Rock blasting must be properly planned and controlled. Rock blasting work for a
project must be planned in deta il at the stage of preparation of estimates. The blasting
work must be ca rried out under the direct supervision of a J unior Engineer or
trained Supervisor. Daily account must be maintained of rock blasting to be done,
explosives planned/expected to be used and actually used shall be under the direct
control of the Engineer and wherever there is 'any anticipated deviation in quantities
from that planned it should be checked. Only just sufficient quantity of explosive
should be issued in the morning for the day’s work and consumption justification
should be scrutinized at the close of day's work.

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 The depth of holes to be blasted is governed by the geo-environment conditions,
geological strength of rock, target progress, control achieved on blasting , slope stability,
proximity to inhabited structures etc . Similarly, the number of holes to be blasted at
a time are governed by the aforementioned factors . The blasting shall be done by
electric detonators, cord relays or delay detonators should be used in order to
disperse shock waves.

On hill roads-blasted material and debris rolling down should be avoided where
these are likely to result in destabilization of hillside, or cause soil erosion.
However, in unavoidable circumstances, the modern controlled b lasting techniques
capable of directing the throw of debris from a blast in specific direction, reducing the
momentum of debris fall, controlling the muck -fall on the down slope road etc. shall
be practiced. Subject to cost effectiveness, the debris should be moved to selected
safer places where these are not likely to be washed away. These should be kept in
such form as are likely to stabilize later.

3. NECESSITY OF ROCK BLASTING

3.1 Since, hilly regions in the country have predominance of rock varietie s in
some areas, blasting is rather a necessity in road construction activities. Blasting is
required for rock excavation in hill sides, through cutting and quarrying. Blasting of
ledge or half tunnel across a cliff face may also, sometimes, be necessary due to
economic reasons. Before deciding the exact alignment of the road and met hod of
cutting, the dip of the rock must be carefully examined to ensure that the completed
road would be stable. Particular care should be taken to detect faults, which often
provide planes of potential slips which may be dangerous. The methodology
(benching or horizontal blasting) for rock excavation shall be duly established
considering economy and slope stability. Extreme care shall be taken when blasting
with horizontal hole s. Blasting with horizontal holes will likely be more economical in
comparison to the benching in the most cases of widening or fresh cutting. However,
the former is more prone to damaging the slopes , hence, controlled blast design shall
be established after some trials for ensuring the minimum damage to the slope.

4. . MECHANISM OF BLAST ING

Blasting operation invariably require drilling of bore holes in

rocks/boulders to required depth. These bore holes are filled with explosives up to
one third to half depth. When fired, large volume of gases are released(5000 to 10,000
times the volume of explosive). Since. the gases are confined in small holes, the
pressure increases considerably. thousand times of the atmospheric pressure, which
causes breaking of the rock with explosion.

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 5. PROPERTIES OF EXPLOS IVES

Strength :- The most important property of an explosive is its strength. Relative

weight strength or relative bulk strength is the ratio of strengths of an
explosive to a standard explosive (Ammonium Nitrate Fuel Oil commonly referred as
ANFO). It is indicated in percentages. The relative bulk or weight strength of slurry or
emulsion explosives is generally greater than 1.

Velocity of detonation :- Detonation of an explosive is the rate whi ch the detonating

wave travels through a column of explosives and is of considerable importance since
shock energy of detonation increases rapidly with velocity. High velocity explosives
are preferred for special purposes such as plaster shooting and underwater work. Low
velocity explosives are most suitable where excessive shattering is to be avoided. The
velocity of detonation is also an indicator of explosives’ quality.

Density :-The density is important when selecting an explosive for a particular use.
Generally, higher the density of explosives, more breakage it provides.

Water resistance :-Explosives differ widely in resistance to water and moisture

penetration. While some explosives deteriorate rapidly under wet conditions, others
are design ed to withstand water for considerable periods. If blasting is to be done
under wet conditions, a water resistant explosive should preferably be selected. The
packaged emulsion and slurry explosives have a good water resistance.

Sensitivity :-An explosive must not be too sensitive in normal handling, shock and
friction, but it must remain sufficiently sensitive to be satisfactorily detonated and
capable of propagating satisfactorily, cartridge to cartridge even over short gaps,
such as may occur in practice. The very high sensitivity of gelatin explosives led to
prohibition of ‘gelatin’ as an industrial explosive in India.

Fume characteristics :-Explosives when used under stipulated ventilation

conditions should liberate minimum of harmful gases in the process of detonation.

Thermal stability :-Explosive combination should be such as to be stable under all

normal conditions of transportation, handling and usage. This is extremely important
as use of explosive itself depends on this characterist ic.

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6. .TYPES OF EXPLOSIVES

The choice of explosives and accessories depends upon the nature of strata and its
characteristics.

An explosive is a substance or a mixture of substances, which for the purpose of

transport, handling and storage is in stable equilibrium. The equilibrium is upset, if
subjected to severe shock resulting in violent release of energy in the form of shock
wave accompanied by extremely rapid conversion of the explosives into a large
volume of gases at high temperature and pressure. The necessary shock is provided
by combining detonator with the other blasting accessories such as detonating fuse.

6.3. The explosives are generally of two types i.e., 'low explosives' and 'high
explosives'. Low explosives possess, very low energy. These are initiated generally by
fire. Gunpowder is an example of low explosive. High explosives possess very high
energy and normally initiated by shock wave or detonating wave . The high explosives
are normally nitroglycerine and Ammonium Nitrate b ased. For road construction
works in BRO, generally high explosives are used. The use of nitroglycerine based
industrial explosives such as gelatin was completely prohibited by the regulating
agencies after the year 2003 as they are more prone to accidents caused by
vibrations and shock. Now a days, only ammonium nitrate based explosives can be
used for industrial rock blasting. However, it has been observed that the industrial
explosives used on-site are still erroneously referred ‘gelatin’ because the pac kaging
of ammonium nitrate -based explosives resembles to that of ‘gelatin’. Hence, the use
of word ‘gelatin’ for site explosives is a misnomer. For road construction, slurry or
emulsion explosives are generally used.

Explosives in common use :-The details of some explosives most

commonly used in road construction are given in Table 6 .1.

TABLE 6 .1 EXPLOSIVES IN COM MON USE

Name of Velocity of Normal density Nature of rock to be

explosives detonation (m/ s) gms/ cc blasted
Emulsion 4000-5200 1.40 Hard to very hard rock
Slurry 3500-5000 1.15 Hard rock
ANFO 3250 0.80 Laminated

The explosives are supplied in cylindrical cartridges of varying diameters, lengths

and weights. The drill machines use bits of varying diameter; hence, manufacturers
suppl y packaged explosives of varying diameters to provide a

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compatibility. Dimensions and weight of commercially supplied packaged explosives
in India are given in Table 6 .2 .

TABLE6 .2 DIMENSIONS AND WEIGHTS OF COMMONLY SUPPLIED

PACKAGED EXPLOSIVES

Cartridge D iameter Nominal length Nominal weight

(mm) (mm) (gm)
25 200 125
32 200 200
40 300 390
50 240 500
50 450 1000
60 460 1560
80 480 2780
90 420 2780

7. . DETONATOR S, FUSES, ACECESSORI ES AND MACHINARY

FOR ROCK BLASTING

7.1 High explosive requires some form of shock for initiation. Detonators
produce this shock. Detonators are small copper or Aluminum tubes of about 6 to 8
mm dia and 4 cm length filled with very sensitive explosive in small quan tity. By the
effect of fire, electric spark, friction or hammering these are exploded
instantaneously. These are stor ed with great care and prevented from shock and
friction. There are two types of detonators . Plain detonator, which are exploded from
a spit of fire transmitted by fuse coil and electric detonators, which are exploded by
an electric spark from the exploder.

7.2. Plain detonators :- These type of detonators are fired with a fuse. This
detonator consists of a small tube closed at one end. contain a base charge of PETN
(PentaErythrtolTetranitrate) an d a priming charge of ASA composition (lead azide,
lead styphnate and aluminum powder) in an aluminum tub e. (Fig 7.1 (a)) This type of
detonator is known as No.6 detonator and is commonly used for road Forks. Super
plain detonators of No.8 str ength, are also used for specific purposes. IFig.6.1: Plain
detonator

Electric Detonators :- These detonators are exploded from an electric spark from
exploders. These detonators consist of a base charge, priming charge and a fuse head
connected with leading copper wire, which transmit the electric charg e from exploder
to fuse head. These are of two types . Normally, Electric Detonators are also
manufactured in No.6 strength.
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 Ordinary electric detonators: An ordinary or instantaneous electric detonator is
essentially a plain detonator plus a fuse head coupled to a pair of leading wires and is
triggered by electric current. Fig 7.1

7.3.2. Delay detonators: Many blasting operations call for a series of shots to
be fired in a pre-determined
determined sequence, which can be achieved by the use of short
delay detonators. This detonator consists basically of an electric detonator with
appropriate delay element interposed between the fuse head and the priming charge.
There are eleven detonators in this range, numbered 0 to 1 0 (the number of delay
detonators of certain manufacturers has been increased to 16, numbered 0 - 15) with
nominal delay intervals of 25 milli seconds (increased in later numbers) between
consecutive numbers having leading wires of 24 SWG, PVC coated. Now a days, non-
electric (NONEL) detonators are also used but they are costlier than electric
detonators. Cord relay is a cheap alternative of electric delay detonator.

Sketch of various types of commonly used detonators and fuse head is given in
Fig. 7 .1.

Fig. 7.1. Detonators

(Electric ):- Detonator with 24 MS delay are known as short

Short Delay Detonato r (Elec
delay detonators. These are used for road works such as quarrying, open cut
excavations .
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 Long Delay De tonat or (Electr ic):- Detonator with a delay element of 300 MS delay
are used for specific purpose such as Tunneling, Half Tunneling, Shaft sinking,
drifting etc.

Detona t ing fuse:- It is supplied in the form of thin coils . It is a carrier of detonating
wave from detonator to explosives. It consists of a core of PETN with covering of
textile and plastic. It is initiated by No .8 detonator and detonates at a velocity of
approximately 6500m/Sec. It is generally used for simultaneous firing of multiple
charges a nd for mass initiating of large charges. N ormally it is supplied in 500 Mtr
length coils.

Safety fuse: Safety Fuse consists of a thin core of specially prepared black powder
wrapped in layers of textile yam and waterproof coating. The burning speed of safety
fuse is controlled and is 100 to 120 seconds per meter. Safety fuse is used to
transmit fire from outside to the detonator for initiation of the explosive.

Charging and Firing accessories : Following accessories are required: -

Prick ers: - These are brass, aluminum or hard wooden bars of about 15 cm length
and 6mm dia. (fig 7.2) These are used for making holes in cartridges of explosive in
which detonator is inserted.

Scraper :- Made of brass (no other metal) for cleaning holes .

Stemming Rod :- The stemming rods made of wood (not metal)or PVC pipe to charge
and stem the hole .

6 mm

15 cm

Fig -7.2 : Wooden pricker

Crimpers : - These are used for crimping plain detonators on safety fuse. These are
made of non -ferrous, non-sparking material.

Ohm meter :- Ohm meter is used to test the electrical circuit and to measure its
resistance. Ohmm eters from an approved firm should only be used.

Exploder: When explosives are to be initiated electrically a portable exploder

for generating electricity is used. The exploders being manufactured in the
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 country, have a range of 50 shots to 200 shots in a series at a time. An exploder, i s
generally built on a metal chassis contained in a waterproof 'Bakelite' case. It
comprises of a dynamo which is operated by turning a handle. The A.C. Voltage
generated by the dynamo is stepped up by a transformer rectifier and used to charge
a condenser to a potential of not less than 1,200 volts. When the firing button is
pressed the condenser is discharged through the electric circuit firing the shots.

Shot -firing cable:- It is a well insulated cable used to connect the electric circuit
with de tonators. A well-insulated twin core cable (length 300 mtr and mix dia 0.46
max) should be used for this purpose. The insulation must be protected against
mechanical wear and tear.
Machinery Required for Rock Blasting on Roads

Air compressors of to 6 cu.m/min. capacity are generally used. The accessories

required with a compressor are as follows:

(a) J ack Hammer -1 to 3 Nos depending on capacity of the compressors

(b) Line lubricator - 1 to 3 Nos
(c) Air hose pipe - 100 m
(d) Hose pipe couplings - 8 No as required
(e) Drill rods
(i) 1 m - 6 Nos
(ii) 1.5 m - 6 Nos
(f) Grinder for sharpening - 1 No
(g) Essential spare parts for jack hammer
(h) B reakers
(j) Pusher leg
(Or)
Alternatively, pneumatic operated drill machines capable of drilling 32 to 64 mm
diameter holes are most suitable.

8. . METHODS OF BLASTIN G

High explosives are initiated by plain detonators in conjunction withsafety fuse,

by ordinary electric detonators, delay detonators or by detonating fuse.
Explosives can be blasted in many ways i. e., single hole blasting and multiple changes.
Single hole blasting is done by using safety fuse and ordinary detonator or electr ic
detonator. Firing of multiple changes us ing detonating fuse along with plain
detonators or with a circuit of electric detonators.

Prim er cartridge : - A cartridge of explosives containing a detonator is known as a

'primer' cartridge. Only one primer is required in any one shot hole, irrespective of the
number of other cartridges used therein. Where gelat in explosive is used, primer
cartridge is generally the top cartridge. (Fig 8. 1 )
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 Primer will not be made in Magazine or at a place where huge quantity of explosive
has been stored.

Before inserting the safety fuse in detonator, tap the detonator gently with the tube
inserted to remove any foreign material, such as saw dust etc . The safety fuse shou ld
not be exposed to sun. It may increase the burning rate of safety fuse.

Safety fuse should not be coiled too tightly and safety fuse coil should not be
twisted. This may cause kinking and give rise to misfire .

Cut a safety fuse of about 1 .20-m length by sharp edged clean knife. Length of the
safety fuse depends upon the time required by any person to reach at a safe place
after firing of the fuse coil.

Cut 3 to 6 cm from other end of safety fuse squarely with clean sharp knife to obtain
fresh surface before inserting into the detonator.

End of fuse should not get damp or come in contact wit h any oil orgrease.

Put the newly cut safety fuse into the detonator. Do not twist the en d ofthe fuse on
detonating compound because it can b last the detonator.

Crimp the detonator near open end with crimper to tight the fuse in detonator carefu
lly. Never crimp by teeth and also never crimp the detonator near the detonating
composition .

Open the cartridge at one end and make hole with the pricker. Push in the
detonator close the open en d, tie the fuse round the cartridge with a piece of
string so that detonator may not be detached from the cartridge while inserting it in
the hole.

8.3.10. High explosives are initiated by plain detonators in conjunction with

safety fuse, by ordinary electric detonators, delay detonators or by detonating fuse.

8.4. Prepari ng the 'Primer' Cartridge: All the saw-dust should be shaken
out of the detonator. The safety fuse should be cut straight across with a sharp clean
knife. The newly cut fuse should be pushed into the detonator holding it away and
the detonator crimped secu rely to the fuse with a crimper, ensuring not to crimp the
detonator tube on the part which contains the detonating composition. The length of
crimp should be 3 mm to 6 mm from the open end of the tube. The cartridge should
be opened at one end and a hole made with a pricker. The detonator should be
pushed in until it is burried, the open end closed and the paper tied round the fuse

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with a piece of string. The other end of safety fuse should be cut at an angle or scarp
for easy lighting. 8.4.3 Method described above is illustrated in Fig. 8. 1 .

Fig. 8. 1 . Fixing Detonator, Safety Fuse and Explosive Cartridge

The holes are drilled in rock with J ack hammer or pneumatic drill
machine operated with the help of a compressor. The holes are ge nerally 32 mm to
64 mm dia and depth of holes depend upon the excavation type (beching/horizontal
holes) and rock mass characteristics . The holes can be drilled vertical, horizontal or
at any angleas per the geotechnical characteristics to facilitate the e asy breakage.
The holes should be cleaned first with compressed air or scraper. However,
pneumatic drill rigs have an in -built mechanism to clear the holes. The diameter of
the hole should be at least 3 mm more than the cartridge diameter. The primer
cartridge should be made. Safety fuse shall be tested periodically for their burning
rate prior to blasting. Sufficiently long fuses sh all be used to enable men to get clear
danger zone of 300 m (at least) after lighting the fuse. If a total of say, three cartridges
are required in a hole, then two cartridges should be inserted followed by the primer.
The 'primer' cartridge is always the last. The base of the detonator should point
towards the full length of the charge. The cartridges should be pushed in one by o ne
with a wooden stemming rod.
After charging, the hole should be stemmed with sand or a mixture of sand and
clay. The first few inches of stemming should be tamped gently with the wooden
rod increasing the pressure as the shot holes get filled. Stemming material should
be free from sharp particles. The fuse should not be damaged or pulled while
stemming. It should be ensured that all personnel have taken shelter before going to
light the fuse. After lighting the fuse with a flame, moving to a place of safety away at
least 100 metres from the direction of the blast from the shot holes is essential.
One person should not light more than six holes at a time. For safety different
lengths of safety fuse are to be used. If a person is lighting more than one
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hole at a time, the length of safety hole in primer cartridge is suitably incr eased to
achieve adequate time for ensuring safety. Largest safety fuse is lighted first and in
that order lighting the shortest fuse at last. After lighting the fuse wi th a flame,
moving to place of safety away at least 100 meter from direction of blast from shot
hole is essential.

Count the number of bangs or explosions. If the explosion ofholes indicates lesser
number of holes having been operated, then it indi cates misfire

Electric shot -firing

This method of initiation is safer than blasting with safety fuse since the blaster is
definitely out of the way of danger at the time of the blast. Electric shot firing allows
upto 200 shots in series to be fired at a time and with this method the possibilities of
misfires are also remote.

8.5.2. Preparing the primer cartridge : The detonator leading wires should be
straightened. A hole should be made with the pricker in one end of the cartridge. (For
plain detonators the cartridge end is opened, but with electric detonator this is not
necessary). Th e detonator should be inserted i nside the hole until it is buried. The
wires are then hitched round the cartridge to prevent the detonator from being
withdrawn.

Charging and firing : For firing a single shot, the procedure Is very simple. The hole
should be charged with the requisite number of cartridges, inserting the primer last.
After the hole has been stemmed, the bare ends of the detonator lead wires should be
connected to the firing cable. Moving to the firing station, the other end of the cable
should be connected to the exploder and fired. Finally the firing key should be
removed and the cable from the exploder disconnected.

For firing two or more shots at a time, the lead wires are connected in a series
circuit. The series circuit is made by connecting one wire from each detonator to one
wire of the succeeding detonator and so on, thus forming a continuous circuit. The
free wires at either end are then connected to the shot firing cable and the circuit
tested with an ohmmeter prior to firing.

In damp conditions, each joint should be insulated to prevent current leakages

which might cause misfires and also as a safeguard against stray cu rrents.

Blasting with delay detonators

Short delay detonators are more suitable for blasting in road

construction, excavations and quarrying.

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 Charging and firing : The primer cartridge is prepared in exactly the same way as
with an or dinary electric detonator. With ordinary electric detonators, the 'Primer' is
inserted into the shothole last. With delay detonators however, the primer is inserted
first, followed by other cartridges. The base of the detonator should point towards the
mou th of the hole. The wires should be connected up in series. It does not matter
whether the leadwire of a No. 1 delay is connected with that of a No. 7 or a No. 2
delay; as long as the series circuit is properly made, the detonators will explode at the
appropriate intervals. Alternatively, cord-relays embedding the rows of detonating fuse
within them may be used for providing suitable delay interval. Cord relay is a device
containing pyro -technic delay detonator within the plastic case.

Advantages of short -delay blasting : The technique of short -delay

blasting offers a number of advantages over simultaneous blasting, particularly in
reducing ground vibrations and improving fragmentation as given below:

Reducing of ground vibrations :- The magnitude of vibrations produced

by delayed blasting is much less than simultaneous blasting.

Multi -row firing :- With delay detonators, many rows of holes can be simultaneously
fired, the second row after first row has been broken and the third row comes into
action after the first two rows have been displaced and so on.

Less back break :- With simu ltaneous blasting, the area behind the shot-holes is likely
to be cracked very badly , rendering the hill mass unstable. By using short delay
detonators, back break or back cracking can be reduced .

Blasting with detonating fuse

Detonating fuse is the simplest and safest accessory for blasting

explosive charges. It is not normally economical to use detonating fuse in short jack
hammer holes. In certain cases however, where speed is essential, the time required
for charging and blasting can be considerably reduced with the use of detonating
fuse. A large number of shots connected with detonating fuse can be initiated by a
single detonator, thus eliminating the length and complicated procedure of electrical
connections or of lighting fuses. The process of blasting with detonating fuse is
comparatively costly and its use may not be economical in some cases.

8.7.2. Preparing the primer cartri dge: A suitable hole should be made with a
pricker through the primer cartridge, longitudinally in the case of emulsions and
slurries. A piece of detonating fuse of suitable length should then be threaded
through the cartridge and the projecting end secure d to it by a knot or by taping it to
the side of the cartridge so that it cannot be pulled out. The methods for this are
illustrated in Fig. 8. 2 .

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 Fig.8. 2 Blasting with Detonating Fuse

8.7.3 Connecting and initiation detonating fuse : For charging the ho les, the
procedure is similar to that adopted for blasting with plain or electric detonators.
When the holes have been stemmed, about 15 to 25 cm of detonating fuse should
remain outside each hole. A long piece of detonating fuse known as a main line or
trunk line should then be laid alongside the holes and the short pieces of detonating
fuse connected to the main line. An 'L' joint or a clove -hitch joint can be used for
connecting branch lines to the main line. This can be initiated by all types of
detonators. The detonator secured to one end of the main line by adhesive tape,
should point towards the charges.

Blasting Technique / design of blasting

8.8.1. The design of an efficient blast depends upon the relationship between the
diameter and depth of hole, spacing, burden etc. In order to ensure that each
cartridge of explosives does maximum work for given working conditions, systematic
trials are essential to arrive at the best blasting technique. However, some important
general principles are given hereunder.

8.8.2 Drilling : It is necessary to have a free face of the rock forming a 'bench'
for ensuring effective utilization of explosives. This is done by developing a free face
first and then drilling rows of shot holes, parallel to the free face, 1.5 to 1.7 metres
deep and blasting them. The holes in the middle two rows are inclined so as to form a
wedge as illustrated in the Fig. 8. 3 . These inclined holes are blasted first, followed by
other holes, fired in sequence. The resulting excavation is ab out 1.5 metres deep and
can be deepened further using similar blasting pattern. The drilling pattern, depth ,
alignment of holes depend upon various constituents and nomenclature of rocks,
their bed settings, geological formations, dips of cleavages, folds and faults, hill face
slope etc. Unplanned blasting may disturb the adjoining loose boulder zones, rock
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beds, and this can create a serious disturbance to stability of hill slopes during
construction and maintenance on account of excessive slips.

Fig. 8. 3 . Drilling in Stages

8.8.3. Burden : This is the most critical parameter in benching. 'Burden' is the
perpendicular distance from shot hole to the nearest free face of the rock in the
direction in which the displacement is most likely to occur. Its actua l value will
depend upon a combination of variables including rock characteristics, the nature of
explosive and the diameter of explosive etc.

Depth of holes : The depth of a drill hole depends upon type of drilling equipment
and loading method adop ted. As a rule, the depth of hole should never be less than
the 'Burden'. In practice holes are drilled to a depth varying from 1.5 -2.5 times the
'Burden'. While deciding the depth of drill holes it must be borne in mind that depth
of stemming should not b e less than the 'Burden'; otherwise Line of Least Resistance
will be established in the direction of stemming and blasting may not be much
effective.

In general, a few deep bore holes are more efficient than large number of shallow
ones as the amo unt of material detached is proportional to the cube of the depth of the
charge. Also the vertical holes are easy to drill and normally give best results. They
should be so placed that the Line of Least Resistance is horizontal.

Spacing of holes : The spacing between holes is dependent upon the nature of rock,
degree of fragmentation required and the method of firing. Where holes are fired
singly or with large intervals, the spacing may be twice the 'Burden'. However, where
shotholes are fired simult aneously, which is the most common practice, spacing
should not exceed 1.5 times the 'Burden'. In very hard and tough

15
 rocks, the spacing may have to be less than the 'Burden'. The optimum spacing
between drilled holes should be determined by trials.
Exampl e:- Drill Hole Diameter - 32mm
Depth of hole - 2m
Burden - 1to1.2m
Spacing - 1to1.5m

Calculation for Blasting and Volume of Rock Blasted

Volume of rock blasted: The volume of rock blasted is proportional to the depth
and spacing of dri ll holes and burden and is given by the formula:
Volume of rock blasted per hole (Cum) = Depth (m) x Burden (m) x Spacing (m)

For jack hammer holes it is not necessary to calculate the volume per individual
hole. The total volume to be blasted may be calculated as follows: -
Total volume of rock (Cum) = Average depth (m) x Total length of face (m) x Average
burden (m)

Charge Factor : The volume of rock broken by a unit weight of explosive is known as
“ Charge Factor". This ratio is usually exp ressed in "Kg of explosivesrequired to
fragment 1 cumec rock ". For blasting with emulsions and slurries, the following
charge factor may be adopted:-
Very Hard Rock –0.50 to 0.60 Kg/m3
Medium Rock - 0.25 to 0.50 Kg/m3

Quantity of explosives require d: The quantity of explosives required per hole or per
blast can be worked out as follows: -
Volume of rock (cu. m. )
Quantity of explosives(kg) =
Charge Factor (Kg/cu. m. )
Example: Ten jack hammer holes are expected to break 20 cu. m (solid) of medium
hard rock. What will be the charge per hole?
Volume of rock - 20 cu.m.
Charge Factor - 0.35 to 0.50 Kg/m3, taking a mean value of both (0.35+0.50)/2 =
0.425Kg/m3
Therefore, total charge in 10 holes – 20x0.425 = 8.5 kg
Therefore, charge in each hole = 8.5/10 = 0.85 kg
Hence, 6.8 (say 7) explosive cartridges of 25 mm diameter need to be charged in each
hole.

8.1 0 Secondary Blasti ng

Secondary blasting sometimes becomes necessary in the following cases:

(a) To break oversize boulders produced during the pr imary blast to suitable
size.
(b) To break oversize boulders in landslides causing road blockades.
16
8.10.2. There are two basic methods of secondary blasting viz. Pop Shooting and
Plaster Shooting.

Pop shooting : Pop shooting consists of drilling a hole just close to the centre of the
boulder to be broken so that the charge is centrally situated and depth of hole a little
more than half the thickness of the boulder. A hole is drilled either manually with the
help of a cold chisel or with a hand drill or compressor drill as the situation may
permit.

The charge varies with the size of the boulder, but for average conditions, a boulder
of size 1.4 m x 1.4 m x 1 m requires a charge of 1 25 gm i.e. one 25 mm diameter
cartridge of emulsion/slurry e xplosives for every two cu.m. of the boulder. The shots
can be fired by safety fuse alone or in conjunction with detonating fuse.

Machines/ equipment etc. deployed on the road near the site should be withdrawn to
safer distances, since there is co nsiderable scatter of rock when firing pop shots.

Plaster shooting (mud capping): Plaster shooting provides a ready means of

breaking even large boulders in circumstances where drilling is difficult due to
expediency, or due to non -availability of drilling tools/equipment at sites such as
isolated landslides. A charge of one or more cartridges is primed with a detonator and
safety fuse, and laid on the surface of the boulder. It is then covered with a shovel -
full of plastic clay which is pressed in to position by hand. It should be in good
contact with the surface around the explosive charge.

In plaster shooting, the charge used is about four times that required for pop
shooting, primarily depending upon the thickness of the boulder. Table 8. 1 gives a
guide to the quantity of explosive required for different boulder thicknesses although
it will vary with the type of rock blasted. Best results in plaster shooting are obtained
when the rock is -of a hard and brittle nature. Normally , plaster shooting consumes
more quantity of explosives than pop shooting and only utilizes shock energy for
fragmentation.

Table 8. 1 . Quantity of Explosives Required for Plaster Shooting

Thickness of Boulder Charge in gm

(cm)
Upto 40 100
40-70 200
70-90 300
90-110 400
110-140 400-700

17
 9. BLASTING METHODS FOR DIFFERENT ROAD CONST RUCTION
ACTIVITIES

Face attack :- When hill cutting is done from any face of hill, it is called
"cutting by face attack". Drilling is done along the section i.e., across the len gth of the
road. This type of hill cutting gives low output. The rock breaks up in a conical mass.
This type of blasting can cause appreciable jerk and vibrations, thus affecting the
stability of slope. This system of drilling and blasting produces lesser output. Refer
Fig 9.2 (a), 9.2(b), 9.2 (c).

Fig - 9. 2 (a) : X-Sec for face attack Fig 9.2(b) : Plan for face attack

Side Attack :- When drilling i s done from sides across the cross section of road, i.e.,
along the length, it is call ed "Cutting by side attack" as show n in Fig 9.3. The side
attack technique gives much better output with lesser vibrations. The blasted rocks
are always exposed at least from two sides, an d the burden may be kept as
required to get maximum output. As f ar as possible, this method of cutting of road
should be adopted

Fig - 9.2 (c) Sequence for blasting for Fig 9.3 Sequence for blasting side
Face attack attack

18
 Cutting in Rocks with dip towards hill side :- At certain stretches the rock layer are
dipping inside the hill. In such zones the cutting and b lasting should be started from
lower end 'A' as shown in the Fig 9.4 with holes drilled in middl e of a strata so as to
prevent ineffective blasting because of cleavages and joints in the strata. The blasting
sequence in such rocks is shown in Fig 9.4

Fig: 9.4 Hill Zone with dips inside

Cutting in rocks with dip outside :- At certain stretches, the rock layers are dipping
outside (or out wards) the hill. In suc h zones the sequence of blasting should start from
top layers as indicated in the figure 9.5.

Fig : 9. 5 : Blasting pattern in rocks dipping outside

19
 10. ROAD CONSTRUCTION WORKS INVOLVING _ROCK
_
BLASTING OPERATION

Pattern of Design :- The blasting technique in hilly areas and Rolling terrain vary
widely from those employed in the plains because of several constraints under which
the road construction work has to be carried out. Road construction activity in these
areas is usually associated with the following stages of operations.

(a) New Formation cuttin g

(b) Widening of existing formation of narrow roads or improvement of existing

formation of road comprising sharp curve/steep gradient.

(c) Maintenance of roads

Fresh cutti ng for n ew alignment : The blasting technique for fresh cutting depends
upon several factors like stability, availability of resources, economics, safety etc.
Blasting using horizontal holes will be generally more economical than benching.
However, benching will likely result in more stable slopes. Nevertheless, proper design
of controlled blasting operations can also yield stable slopes in i blasting with
horizontal holes also. The most convenient method is to drill vertical holes in several
parallel rows acr oss the roadside face of hill to obtain 'benching'. A series of benches
can be established to achieve the full height of the cutting. The height of the benches
will vary depending upon the type of the drilling equipment available and with jack
hammers it r arely exceeds 3 metres. For fast advance of the benches, multi -row firing
is often useful. The method is illustrated in Fig. 1 0 .1 .

Fig. 1 0 .1(a). Rock Excavation by Benching

20
 Fig. 10. 1(b). Distribution of bore hole position
for formation cutting in rock

Cuttings : There are two general types of cuts, a side hill cut where the excavation is
made on the side of the hill leaving a wall on one side only and a through cut, where
the excavation is made through a hill leaving a w all on bothsides. The procedure
is described below: -

(a) Side Hill Cuts : The first operation is the removal of soft over -burden.
This is carried out in advance of the rock excavation, to facilitate drilling of the
rock. When the rock has been exposed, a free face is established across the
width of the cutting. This is done by two or more parallel rows of vertical holes
and charging and firing them simultaneously. Once the free face has been
established, the work proceeds by blasting successive rows of hol es drilled
parallel to it. For deep cuttings. the desired level of road can be reached by
excavating in several lifts.

Fig. 10. 2 . Rock Excavation by Benching

21
 (b) Through cut : In case of through cut, a long cut can be opened up along
the centre line on either side depending on the slope of the surface. This face is
then worked as a quarry and pushed back laterally to the slope line. This
method can be repeated on successive lifts until the cut becomes too narrow.
After that, the through cut is wo rked in the normal manner that is, with the
shots extending to the full width.

Fig 10 .3 Typical drilling layout for blasting rock for a through cut

Half -tunneling : Half tunnels are made where the strata is particularly strong and
where construction of an open road would entail prohibitive amount of rock
excavation. The width and height of half -tunnels (and full tunnels) should also
consider future requirements of widening etc. as hill cutting later on will be very
inconvenient and too co stly. The half tunnel should be 7 m or more wide and 5 -6 m
high. Usually, such roads shall be widened to complete breadth in a single instance
without disturbing slope. J ack hammer drills fitted with air legs are most suitable for
drilling the horizontal h oles required for half-tunneling. For drilling holes in the
upper section of the cave, a portable staging with several platforms will be necessary.
Alternatively, where the half tunnels are not very high, the upper holes can be drilled
by standing on the d ebris produced by an earlier blast. Horizontal holes drilled
parallel to the hill-side should be 1.6 to 2 m deep and fired with short delay
detonators. Utmost care must be taken to prevent the disturbance in slope while
blasting. The fall of over -breaks caused by past uncontrolled blasting can be
hazardous during widening or future operations. A typical half tunnel face showing
hole placement and distribution of short delay detonators is illustrated in Fig. 1 0 .4 .

Precautions and procedure for cuttin g in Half tunnelling -:

Hill zones which have cleavages (dip) either vertical or inclined towards the
valley side of the road alignment, half tunnelling should be avoided because in such
zones rock mass may slide down without any prior indication resulting in serious
accident. However, thick hard rock strata with dips towards hillside can be stable
provided these do not have any other cleavages or plane of rupture. Half -tunnelling
22
can be constructed in fractured rocky zones also where joints are such that these are
not likely to slide. To achieve maximum output in half tunnelling the work of cutting
or blasting should be taken up from sides rather than from or across the length. Side
attack causes very less vibrations in the hill zones and results in little disturbances
of the rock joints materials and thereby does not disturb the natural stability of the
rocky strata.

Tunneling (full)/ drifting : A variety of drilling patterns are adopted in

tunneling work. The usual procedure is to fire several shots to break out a
preliminary cavity known as 'cut', in the centre of the cross section. This is further
widened by means of easer shots and final trimmer shots are fired to bring the tunnel
to the required finished size. The type of cuts commonly used include pyramid cut,
drag cut and burn cut depending upon the nature of rock.

Fig. 10.4 Section of Half Tunnel Face

These are described below:-

(a) Pyramid cut : A typical arrangement is given in Fig. 10. 5 . Due to the
inclination of the holes. the depth of the cut is generally restricted to half the
width of the drift.
(b) Wedge cut : A typical system is given in Fig. 10. 6 . The holes are inclined at
an angle not less than 45 0 towards the centre and almost meeting at the back
of the cut. In large tunnels a double wedge cut is often used i.e. a small wedge
followed by a larger one.
Note: Both pyramid and wedge cuts are suitable for uniform bedded hard
rocks. Explosives consumption is less than for other types of cut, but the depth
of pull is restricted by the width of the drift.
(c) Drag cut: This is mainly used in small drifts. A typical system is given in
Fig. 10. 7 . Wherever possible holes are inclined to the cleavage so that strata
23
 breaks along these planes. 'D' is not more than H/2 & 'h' is not more than H/3,
where D is depth of hole, H is height of cut and h is height of bottom most hole
from ground level.
(d) Burn cut : Typical arrangement is given in Fig. 10. 8 . While it is difficult to
drill more than half the width of the tunnel with a, b and c above due to angle
of drill hole, with the burn cut, advances equal to width of tunnel can be
obtained. Burn cut patterns comprise a number of parallel holes of the same
diameter, closely spaced, some of which are heavily charged and the remaind er
left empty to provide a free face.

It is necessary to have a series of charges firing at intervals. This is achieved either

by using delay detonators if fired electrically or cord relay, if fired with safety fuse.
Generally , emulsions or slurry explosives are best suited for this work. Consumption of
explosives generally varies from 0.25
0.25-0.65 kg/cu.m of rock broken depending upon
the nature of rock type and size of excavation.

Fig. 10. 5 . Pyramid Cut

Fig. 10.6 . Wedge Cut

24
 Fig. 10.7 . Drag Cut

Fig. 10.8 . Burn Cut

To expedite progress on a long stretch of half tunnel or tunnel, approach tunnels

may be driven at intermediate points, at right angles to the direction of the centre
line of proposed road. This will allow extra tunnel faces to be opened up.
Once the faces have advanced away from the tunnel the compressor and other,
equipment can be stored in the bye -end.

10. 6 Excavation of rock foundat ions: Excavation of foundat ions for bridges,
piers etc. forms an important part of the road building projects.

First a small pit should be formed by blasting and this can be later enlarged and
deepened to the desired limits of excavation. Several pairs of inclined holes should
be drilled in the form of a wedge. These holes should be drilled 0.9 to
1.2 m deep at 75 cm centre to centre and each hole should be charged with two or
three 25 mm x 20 cm emulsion cartridges.

25
 For excavation in low lying areas and river beds the depth of water normally ran ges
from 3 to 90 cm. Drilling in shallow water is rather difficult and the holes often get filled
up with sand and dirt. The depth of holes, therefore, should not be more than 0.9 m.
A number of holes should be drilled with 0.60 m burden, 0.9 m depthand3 m
spacing’s and each hole should be charged with emulsion cartridge of 25 mm
diameter at a charge factor of approximately 0.5 kg/m 3.

Detonating fuse may be used for under water blasting and the cartridges should be
taped on a thin strip of wood or b amboo. If electric detonators are used then all
joints should be properly insulated and kept out of water.

Fig. 10. 9 Typical grid for a short -delay in sinking cut

Well-sinking
Since conditions in sinking are normally wet, it is important t o use high density,
water resistant, emulsion and slurry explosives. The principle in sinking is same as
in tunneling. An initial cavity is created by blasting a ring of holes inclined towards
the centre as to form an inverted pyramid. The subsequent ring of 'easers' and
'simper' holes which are succeeding less inclined than the preceding holes, fire into
this cavity. The charge factor is about 0.45 - 2 kg/m3 solid rock broken.
Use of blasting in maintenance of roads

Hill roads are sometimes blocked by slips/landslides and also by large boulders
sliding down hill. Smaller pieces can be bulldozed away but the large ones often
require to be blasted. Both pop shooting and plaster shooting can be applied tobreak
up large boulders.

26
 11 . BLASTING IN ADVERSE WEATHER C ONDITIONS

11.1. Special measures have to be adopted when blasting in unfavorable

weather conditions.

2 In very cold weather: Low - freezing type explosives can be stored and
used up to 00C or even at lower temperatures if the exp osure is of short duration.
Prolonged exposure to lower temperatures may, however, cause the explosives to
freeze. On freezing, explosives lose their plasticity and become hard. In frozen state,
some types of explosives are very sensitive and liable to pre mature explosion.

All types of detonators and detonating fuse remain unaffected by low temperatures.
The outer coating of safety fuse will freeze in sub -zero temperature conditions.

4 Precaution to be taken to explosives from freezing: The following

precautions should be taken: -
Store all explosives in well constructed magazines until required for use.
Stack cases of explosives on wooden trestles clear off the ground.
Cover cases of explosives with tarpaulin when awaiting us e in the field.
Use up the contents of the case quickly once it has been opened.
Return all unused explosives to a magazine at the end of the day.
Explosives should not be left exposed in the open for longer than is absolutely
necessa ry.
As a general rule, explosives should be issued from a magazine on a 'first-in
first-out' basis.

5 Precautions to be taken with frozen explosives: The precaution to be

taken are:-
Frozen explosives should not be used for blasting.
Pricker should not be forced into a frozen cartridge of explosive.
Attempt to soften a frozen cartridge of explosives by pressing it in the hand or
rolling it on the ground should not be resorted to.
Attempt to thaw frozen-explosives by heating them over an open fire should not
be done.
Frozen explosives should be thawed by placing them in the sun.

6 Precautions to be taken with frozen safety fuse: The outer coating of

safety fuse is likely to crack if it is stored and unco iled in very cold weather. Moisture
or water may enter through these cracks and affect the black -powder core.

7 In wet weather: Emulsion and slurry explosives are water resistant and
can be kept submerged in water for at least 24 hours. Ordinary deton ators and safety

27
 fuse can be used in wet holes provided the crimps have been treated with cap sealing
compound.
Blasting with safety fuse cannot be practi ced when it is actually raining. Electric shot
firing may be carried on provided all the joints have been properly insulated.
The most suitable method, of course, is to use detonating fuse for blasting in very
wet weather. If the holes contain water, a knot should be tied in the fuse in such a
way that about 8 -10 cm of fuse extend beyond the knot. A cap sealing compound
may be required when holes are likely to contain water. The junction between
the fuse and detonator should be properly coated with this compound.

8 During thunderstorms: Blasting should be stopped and all men must

leave the blasting site, when an electric storm is approaching. An electrical shot firing
circuit, if struck by Lightening may detonate despite all precautions. Lightening
several kms away may produce electrical charges sufficient to fire electric detonators.
In case the storm is not severe, then the charges primed with detonating fuse can be
initiated by plain detonator and safety fuse.

9 In foggy weather: Shot firing should be suspended during dense fog.

Due to poor visibility , it becomes difficult to ensur e that the danger area has been
cleared of men and animals.
11.9.1. In foggy weather it takes a long time for the fumes to clear and workers
should not return to the work site until the smoke and fumes have disappeared.

0 In high w ind: ln high wind, as difficulty may be experienced in lighting

fuses with ordinary matches, special matches and lighting devices available for this
purpose should be used.
12. . CONTROL BLASTING

12 .1 Need of control blasting

Control blasting is a technique to direct maximum explosive energy in fragmenting
rocks and minimize the nuisances associated with the blasting. Different nuisances
associated with rock blasting for construction of roads are entailed below:
12 .1.1 Ground vibrations
Ground vibrations are the most prev alent blasting nuisance. The stress waves
generated from the detonation of explosives travel through surrounding rock -mass
inducing vibrations within it and structures located above. The propagation
characteristics of ground vibrations are similar to earth quake-induced ground
motions. Hence, they are also referred as seismic waves. Ground vibration is also a
major cause of slope failures. Excess ground vibration is also responsible for causing
damages in the nearby structures. However, the ground vibrations can be easily
restricted within the permissible limits using proper instrumentation (seismographs)

28
and apt blast design. Ground vibrations originating from blasting are measured in
the terms of ‘Peak Particle Velocity (PPV)’. Damaging potential of a blast vibration is
directly dependent on the frequency. At low frequencies (less than 25 Hz), frequencies
of ground vibrations resonate with the structure’s frequency , hence, augmenting the
potential to cause damage. Safe limits of vibration (PPV) for different types of
structures are specified in Table 1 2 .1 . Blasting can be executed nearby a structure
only if the safe vibration limit is not exceeded. If blast vibrations exceed the safe
limits, blast designs must be suitably corrected to fall within the limit.

Table 1 2 .1 : Safe limits of blasting vibration for different type of structures

Type of structure Peak
< 8 Hz 8-25 Hz > 25 Hz
(A)B uildings/structures not belong to the owner
1. Domestic houses/structures 5 10 15
(Kuchcha, brick& cement)
2.Industrial buildings 10 20 25
3. Objects of historical importance 2 5 10
and
(B )B uildings belonging to owner with limited span of life
1. Domestic houses/structures 10 15 25
2.Industrial buildings 15 25 50

.2 Sound/ Air over -pressure

Excess air over -pressure generated from a blast result in loud sounds which can in
turn damage and crack the window panes of houses. It is recommended that the
sound from a blast must be restricted within 134 dB. If the sound exceeds the
specified limit, blast design must be corrected suitably.
3 Fly -rock
Fly-rock is an uncontrolled throw of rocks fragmented during blasting and is the
main cause of damage to nearby structures and humans. Fly rocks can be controll ed
using proper blast design. Additional precautions of blasting mats or rubber tyre
muffling may be used for effective control on fly -rocks. Blasting mats are heavy large
mats in various sizes and can be made from 2 to 4 cm manila rope or old steel wire
rope or old rubber tyres etc. These mats catch or arrest the fly rock. Holes should be
somewhat under-charged in order to avoid fly rock. Only two or three shot holes
should be fired at a time, with minimum quantity of explosive just to crack/break the
rock.
4 Over-break and slope damage

The inappropriate blast design s for excavation of roads can damage the rock mass
beyond the periphery of desired excavation boundary. This excess breakage beyond
the desired boundary is termed as over -break. Sometim e, poor blasting practices
damages the rock beyond the desired periphery by inducing new damage cracks and
29
opening the width of existing cracks. These cracks reduce the geological strength of
rockmass and many times results in slope failures , formation collapse or delayed
landslides. Hence, blasts must be designed to yield a controlled excavation with
minimum damage.

5 Fragmentation

The size of rock fragments resulting from a blast can be regulated by designing the
blasts accordingly. Over-size boulders are difficult to handle, require re -handlingusing
rock-breaker or blasting. Hence, more time is consumed and poor progress is
achieved. Further, with the advent of modern blasting technique it is possible to
obtain the desired fragment size for feeding within the crusher or to be used in
pavement layers. It is recommended that the mean fragment size of blasted muck
shall be less than shovel’s bucket size for effective progress and economy.
In an efficient blasting, maximum possible length or quantity of rock shall be blasted
with minimum nuisances. Big blasts are more economic than several small blasts
because of fuel saving incurred by reduc tion of the marching frequency and
maneuverability of machines on the patch. Following guidelines should be adhe red to
for effective control of fly rock.

Blast hole location/ charge configuration : - To avoid the regularities in the front row
burden, it is important to ensure that the holes are correctly collared with respect to
the back break/ initiation to the face and that digging alongside the initiation face well
controlled. The charging of the f ront row holes should be critically determined.

Stemming Depth : - The collar region is usually fr actured forehand due to back
break from previous blast or due to sub-grade blasting from bench above. The holes
should be effectively stemmed with stemming material and stemming material should
not be less than whole burden.

Initiation pattern/ sequence : The fly-rock could be fairly controlled by adopting the 'V'
pattern of initiation with adequate inter row delay interval as compared to the
commonly used 'in -line open loop' pattern. The maximum inters row delay interval
consistent with the absence of cut off helps in minimizing the fly rock formation. As a
general rule, an inter -row delay of 6-8 ms/m of burden could be used for this purpose.
Adequate care should be taken while connecting the delay devices in holes/rows and
the initiation sequence should be properly checked before firing to avoid initiation of
blast holes out of sequence

Protective mats : Protective covering of blast with blasting mats can be used when
there is a serious need to dras tically reduce or even eliminate the incidence of fly
rock, such as in built up areas . However this method should be limited to small
blasts only. The protective mats can be made from 2 to 4 cm manila

30
rope or old steel wire rope or old rubber tyres etc. These mats catch or arrest the
flying of rock pieces. Alternatively sandbags can also be used.

Fig. 12.1 (a) Inadequate burden Fig. 12. 1(b) Inadequate burden in
the toe the collar region region

Fig. 12.1(c) Fly rock generation due to Fig. 12.1(d) L:W<1.5 increases fly
Stemming depth reduction rock generation

31
 Fig: 12. 1(e) Staggered ‘V’ pattern of initiation (L:W>3 reduces fly rock)

13. . MISFIRES
In case the proper method of blasting is used, the occurrence of misfire will be very
rare. However, explosive accessories may have some manufacturing defect within
them resulting in misfires. Occasionally, however, the shot firer may encounter a
misfired shot and it is important that he should know how to deal with it. It is a
general practice to wait for 30 minutes, when blasting with plain detonators, before
returning to blasting site and 5 minutes when using electric detonators or delay
detonators.
Cause of misfires: These are explained below along with precautions for their
prevention:

S/ No. Cause How to prevent

a) With safety fuse and plain detonators:
(i) Black powder core becoming Store fuse in cool, dry place. Use
damp. waterproof fuse in wet holes.
(ii) Cracking of fuse by uncoiling Warm frozen fuse at 20 0 to 250for eight
in very cold weather. Moisture hours before uncoiling.
can enter through these
cracks.
(iii) Water entering detonator. Crimp tightly. Use cap sealing compound.
Dip the joint in the compound and allow it
to dry before making up the primer. Do
not use grease for water proofing.
(iv) Fuse damaged during Use fine material for stemming and stem
stemming gently using a wooden rod.
(v) End of fuse may have absorbed Use freshly cut fuse only
moisture.
32
(vi) Fuse cut at an angle may
double back inside section a
detonator.
(vii) Air gap between detonating
compaction and fuse and saw
dust or dirt inside detonator.
Cut fuse straight across with a sharp
knife.
Remove all saw dust and dirt from
Detonators. Make sure that the end of the
fuse is in close contact with the detonating
compaction.

(viii) Fuse and detonator may have Fix fuse securely and test by pulling
been pulled out of the primer. during stemming.
(ix) Fuse may have come out of Use a proper crimper. Done not crimp
detonator. with tooth or ordinary pliers.
(x) Fuse may not have lighted. Be sure that each fuse is burning before
lighting the next fuse.
(xi) Damp detonator Store detonators in a dry place. Do not
blow into a detonator to remove sawdust.
b) With Electric Detonators:
(i) Detonator damaged, or lead Store in a dry, well ventilated place.
wire corroded due to damp.
(ii) Broken lead wire Do not pull or jerk lead wires.
(iii) Detonator pulled out of primer. Stem gently.
(iv) Poor connection causes partial Make clean, firm joints and keep them
misfire in round. dry.
(v) Faulty exploder or faulty Check exploder regularly and see that it is
operation of exploder. capable of firing the required number of
shots. Keep exploder dry. Use full force
when turning the key.
(vi) Insulation scraping off causing Avoid sharp particles in stemming and
short circuit. stem gently.
(vii) Lead wire touching rails, pipes Keep wire of blasting circuit away from
etc. Cause earth leakage and metal objects.
short circuit.
(viii) Bare joints lying in water or on Insulate all joints and keep them above
wet ground. wet ground.
(ix) Wrong wir e connected with Make proper series connection and check
each other with ohmmeter.
(x) Cut off with delay detonators Place primer cartridge at the back or
bottom of the hole when using delay
detonators.
(xi) Faulty cable Check cable regularly with ohmmet er.

33
 3 Detecting of misfired shots: While blasting with safety fuse it is easy to
locate the misfired shot by simple visual exam ination. When firing electrically,
however, the procedure described below has to be adopted to find the faulty shot.

4 Where the electric detonators are connected in series, the first step is to
divide the circuit at the face in half, connecting one half to the shot firing cable and
testing it from the firing point, all men having been withdrawn from blasting site.
This procedure will indicate in which half of the circuit, the defect lies. The defective
half of the circuit is again halved, the test repeated and the faulty quarter of the
circuit discovered. By further repetition of this method, the faulty shot will be final ly
located. The remaining shots can be fired after taping the leading wires from the
defective shot to a suitable marker. A search should be made afterwards for
undetonated cartridges and detonator, assuming that the misfired hole has been
dislodged during the blast.

5 Dealing with misfired shots: Where a misfire occurs with safe tyfuse,
the exposed fuse should be examined after a lapse of thirty minutes. If a sufficient
length of sound fuse is found projecting from the hole, then it should be relighte d.
Where the fuse has burnt to a point inside the stemmed hole, the procedure given
below should be adopted. This procedure will also apply to misfires with electric
detonator.

Recovering the charge by removal of stemming: Attempts should be made to

remove the stemming by blowing out with compressed air or flushing out with water.
The air blast or water should be introduced through rubber or non - ferrous metal
pipe. No tools should be used for digging out stemming since there is the risk of
detonation of the charge by friction or shock. After the stemming has been removed,
it may be possible to withdraw remaining cartridges in the shot hole.

7 Displacement of charge by relieving holes: If it is not possible to fire

the charge by inserting a fres h primer, then a relieving hole, not more than 90 cm
deep should be drilled parallel to and at least 45 cm away from the misfired shot.
After firing the relieving shot, the debris must be carefully searched and the
undetonated cartridges and detonator reco vered.

8 Misfired shot containing detonating fuse: With charge in large

diameter holes primed with detonating fuse, the stemming should be removed to
expose a short length of detonating fuse. A primer should then be secured to the fuse
and fired. This will most likely detonate the misfired charge. If, however, the fuse
cannot be exposed, then relieving holes, not more than 38 mm diameter and 90 cm
depth should be drilled and blasted in such a way that the rock is benched away
from around the misfire.

34
 The explosive requirement must be carefully planned to consume the explosives
within the shelf life and unnecessary excess hoarding shall not be permitted.
Generally, the explosives have a shelf life of 6 months.

Caution : Explosives and accessorie s are sensitive materials and hence blasting
operation has inherent risk and danger unless the entire operation is handled with
security and safety as prime factor. Utmost care and caution should be exercised in
handling and use of explosives and laid down procedures strictly
adhered to.

14. . DETAILED BLAST REPORT (DBR)

14.1 J unior engineers shall note down the blast related information and
progress as mentioned in Appendix ‘E’ for every blast. The information mentioned in
the DBR shall be communicated to the office of Chief Engineer periodically through
the proper channel.

15. . SAFETY PRECAUTIONS

These guidelines shall be followed in conjunction with IS 4081-2013

(Reaffirmed 2018)-Blasting And Related Drilling Operations — Code Of Safety (Second
Revision ) and IS 10386 (Part 4 ): 2013 (Safety Code for Construction, Operation and
Maintenance of River Valley Projects (P art 4- Handling, Transportation and Storage o f
Explosives) (First Revision ), all the relevant central, state and local laws and rules and
regulations framed there under shall be complied. Loading, unloading and handling
of explosives shall be supervised by qualified personnel. At the time of loading or
unloading of explosives, no electrical switch should be operated.

2 Transportat ion of Explosives

Containers - For carrying small quantity, (upto 5 kg of explosives) specially

designed insulated containers may be used. These containers shall be
constructed of finished wood not less than 50 mm thick or plastic material not less
than 6 mm thick or pressed fiber not less than 10 mm thick. Metal components,
including nails, bolts, screws, etc., shall not be used in the construction of the
containers, which shall be waterproof and provided with lids. The containers shall be
provided with suitable non -conductive carrying device, such as rubber, leather or
canvas handle or strap. Each explosive container should be clearly and indelibly
marked to indicate:

(a) manufacturer’s name or trade mark,

(b) name of the explosive,
(c) lot number,
(d) date of manufacture,
35
 (e) expiry date, and
(f) the words ‘ EXPLOSIVES, HANDLE WITH CARE’

Containers used for storing explosives or detonators shall be used for that item only.

Vehicles - The vehicles used for transporting explosive shall be driven only by an
experienced driver who is physically fit and is familiar with the precautions to be
taken while carrying the explosives in his vehicle. All vehic les used for transporting
explosives shall be maintained in good working condition and all systems of same
must be checked before starting move of vehicle. The vehicles should preferably
be enclosed type with locking arrangements and body -work leak-proof.

In open body vehicle the floor of the vehicle carrying explosive shall be leak proof.
The sides and ends shall be of sufficient height to prevent the explosive from falling
off the vehicles.

The interior of the body shall not have any expo sed metal parts, except those of
copper, brass and other non -sparking metals and shall preferably be lined with wood.

The chassis of the vehicles shall be well sprung. The tyre pressure shall be
maintained as per the requirement of the Indian Explosives Regulations.

All electrical wiring and equipment of vehicles shall be adequately insulated and
protected against mechanical damage to prevent short circuiting.

Two carbon dioxide fire extinguishers, each of not less than 3 kg capacity,
conforming to IS:2878 -1986, shall be carried on each vehicle. The
extinguishers shall be securely mounted on the vehicles in such a manner that they
can be readily removed for use in an emergency.

A motor vehicle carrying explosives shall not b e refueled except in emergencies and
even then only when the motor has been stopped and other precautions have been
taken to prevent accidents.
The quantity carried, in any single vehicle should not exceed 75% of its rated
capacity or 3600 kgs, whi chever is less.
Safety Precautions in Transportation: Safety precautions outlined below shall be
observed for transportation of explosives.
No metals except approved metal truck bodies shall be allowed to come in contact
with cases of explosiv es. Metal, flammable or corrosive substances shall not be
transported with explosives. As far as possible, transportation of any other material
along with explosives shall be prohibited.

36
 Smoking shall be prohibited in the vehicle carrying explosive s and in its vicinity
upto a distance of 30 m.

No unauthorized person shall be allowed in the vehicle carrying explosives.

Explosives and detonators of blasting caps shall not be permitted to be transported

in the same vehicle.

Detonators and other explosives for blasting shall be transported to the site of work
in the original containers or in securely locked separate non -metallic container and
shall not be carried loose or mixed with other materials. Furthermore , the detonators
and explosives shall never be transported in the same vehicle.

Care shall be taken while loading and unloading of explosives, like inside of vehicle
body must be free from grit, oil rags etc., unloading should not be done near exhaust
of pipe, explosi ve protected from rain/prolonged exposure to sun, engine of vehicle
switched off and no refueling permitted while unloading etc. The filled containers
shall not be handled roughly or dropped.

Drivers shall not leave the vehicles unattended while tr ansporting explosives.

The speed of the vehicle shall not exceed 25 km/h on rough roads and 40 km/h
elsewhere.

Vehicles, transporting explosives shall not be taken into a garage, repair shop of-
parked in congested areas, public parking or s imilar places.
Explosives shall not be transported in trailers. Further, any trailer shall not be
attached to a motor truck or vehicle when it is being used in transporting explosives.

Explosives shall not be transported on public highways during darkness, except in

emergencies and even then only when the approval of the concerned authorities
has been obtained. Such vehicles shall be fitted with adequate warning lights on
both ends, while operating in darkness.

Explosives shall not be transferred from one vehicle to another on public highways,
except in cases of emergency.

When explosives are carried in a convoy, the distance between any two vehicles
will not be less than 75 metres.

Precautions during Use : Following precautions during handling and use of explosive
should be strictly followed:-

37
 Never use tools made of iron or steel for opening cases. Use hard wood or copper
implements.
Never store explosives in the sun.

Replace the cover of the ca ses closing it properly after the ! requiredquantity has been
taken out.

Explosives should not be carried or transported in pockets.

Never make primer near the large stacks of explosives.

Never insert anything other than fuse coil in the detonator, otherwise it may blast.

Do not remain near explosives during a storm or thundering nor these should be
transported during storm or thunder. All working persons should move to a place of
safety.

Never use damaged or deteri orated explosives and accessories.

Never break open explosive cartridges.

Never use explosives without a proper and valid license nor make their transactions
with any unlicensed, person.

Precautions while drilling and charging :- Following precautions during drilling

and charging of explosives should be followed.

Never start drilling before it is sure that the rock face contains no unfired explosive.
Never drill into the explosive.

Check the condition of hole with st emming rod before inserting the cartridges.

Excessive force should not be applied while placing cartridges in the holes.

Never keep large unwanted stocks of explosives near shot holes.

15.6.5 Cut detonating fuse from the rear immediately after the primer has
reached the bottom of the hole. Insert only freshly cut fuse in the detonator.

15.4.6 Never force the detonator excessively into the cartridge. Make a hole in
the cartridge with a prickers or wooden round piece.

38
 Precautions while stemming the hole: Following precautions while stemming will be
strictly observed.

Never use metallic rods for stemming. Use only wooden or brass rods. The end of
the rod should be kept square by sawing of fthe pointed end periodically.

Never stem the primer, always put a few inches of stemming material dry soil after
the primer is in position inside the hole.

Never use sharp or pointed particles in the stemming.

Never damage the fuse, lead wires or detonating fuse by stemming.

Precautions while firing with safety fuse.

Never use short length fuses. The minimum length should be3 ft. or 1 metre, make
sure that there is sufficient time lag after charging the fuse to reach a place of safety
before the explosion.

Always use only approved crimpers for fixing detonator on a fuse.

Always use fuse lighters only. While using matches, slit theend of fuse, hold match
heads in the slit and rub the side of an empty matchbox against the match head.

Never use cartridges for lighting a fuse. This practice is extremely dangerous.

Precautions while firing with electric detonators.

Never use electric detonators during dust storms or near any other source of heavy
charge of stat ic electricity.

Always keep the firing circuit insulated from ground, bare wires, rails, pipes or any
other paths of stray currents.
Always test firing circuit with an Ohm -meter or a circuit testers from the firing point.

Make always sure that all the joints are firm clean and dry.

Always keep lead wires short circuited until it is ready to fire.

39
 Precautions before and after firing.

Never fire until you have made sure that all surplus explosives have been removed
and all persons, vehicles and equipments are at a safe distance.

Red flags will be installed on both sides of the blast site and prior whistle warning
must be given before lightening the fuse or firing with exploder.

All the persons involved with blasting such as driller, persons stemming and
charging the holes, DES, Workshop persons and supervisors or any officer
supervising the hill cutting works will wear the helmets. Also Eqpt & Plant should be
far from site and protected with ballies etc.

16. . STORAGE OF EXPLOSIVE S

Storage of explosives is regulated by Indian Explosives Act 1884 and provision there
under should be strictly observed, unless exempted under section 14 of the Act.

Explosives shall be stored only in a magazine, which is clean, dry, well ventilated,
well illuminated where electricity is available, reasonably cool, correctly located
(more than 100 mtrs from living accommodation) and protected against
lightening if explosive is one ton or more in acco rdance with Indian Electricity Act
and Indian Explosives Act. The magazine should be located on well drained sloping
ground and away from built -up area/highway but approachable with all -weather
road. In case of new storage accommodation for explosive, the local Inspector of
explosive or other licensing authority should be consulted and care should be taken
to ensure that the statutory distances from other buildings and property are
observed.

All major dumps as well as dumps in disturbed area having e xplosive of

3 ton or more should be fenced with double fencing of barbed wire. Similarly, all
precautions of security must also be taken for safe storage of explosives.
Explosive cases should not be stacked in more than five tiers and should be stacked
in such a way that ends of the cases showing the date of manufacture are visible,
which will facilitate use of stock early.
Explosives upto 4 kgs should be kept in a securely locked container away from fire
and detonators/capped fuses should be ke pt in separate containers. While storing
explosive upto 20-25 kgs a small store/magazine should be built. In case of storage
for large quantity, following guidelines be followed.

40
 Building should be specially constructed for this purpose situated aw ay from
residential/industrial area and highway.

About 2.42 sqm floor area should be considered for each ton of explosive. While
stacking cases, each stack should not have more than 5 tiers and a working space of
1.22 m must be left between two stacks.

Where quantity of explosive exceeds 20 ton a separate building for storage of

detonators must be built and for les ser quantity detonators can be stored in an
annexe, which is built as integral part of main building but has a substantial
partition with an air space between them. As a rough guide a double partition of 2 cm
each with 45 cm air space between them will suffice the purpose of storing 10,000
detonators.

Blasting caps, electric blasting caps, cord relays or primers shall not be stored in the
same box or room with other explosives in big dumps. However, in small dumps sand
bag revetments of appropriate thicknesses and height will be used to segregate
different zones of explosives.

Explosives, fuse or fuse lighters shall not be stored in a damp or wet place or
near oil, gasoline, or near radiators, steam pipes or other sources of heat.

Smoking and use of matches, naked lights and readily flammable articles or open
fire/flame shall be prohibited within the fenced area around it. Similarly, explosives
should be kept away from electric contact, fuse boxes and switches.

An area upto a distance of not less than 50 m on all sides of a magazine shall be
maintained free of all vegetation, debris and combustibles.

Metals, metallic objects and metal tools that are capable of producing sparks
shall not be stored or used inside or in the immediate vicinity of the magazine.

Boxes of explosives shall not be thrown down or dragged along the floor and may be
stack ed on wooden trestles.

Package containing explosives shall not be allowed to remain in the sun.

Empty boxes, packing materials or any combustible material shall not be stored
inside or in the vicinity of the magazine.
Adequate quantity of water and firefighting equipment shall be provided near the
magazine. Guards shall be properly trained in handling such equipment.

Signboards reading "DANGER -HIGH EXPLOSIVES", "PROTECTED

AREA", "NO SMOKING" etc. shall be prominently displayed In front of the magazine.
41
 Well trained preferably armed guards shall be posted to guard the magazine.

The following shall be hung up in the lobby of the magazine:

(a) A copy of explosive rules, 2008
(b) A statement showing the stock in the magazine, and
(c) Certificate showing the last date of testing of the lightening conductor

Magazine shoes, without nails, shall be kept at all times in the magazine and a
wooden tub or cement trough, approximately 300 mm high and 450 mm in diameter,
filled with water shall be fixed near the door of the magazine. Persons entering the
magazine shall put on the magazine shoes provided for the purpose and shall not be
allowed to touch the ground outside clear floor with magazine shoes. Persons with bar
e feet before entering the magazine shall dip their feet in water and then step direct
from the tub on to the clean floor.

For continued blasting operations, the magazine shall be located at a safe

distance near the work site and actual requirement of explosives for each blast may
be drawn and transported to the site and left -over, if any, must be immediately
returned to the magazine. Where the blasting operations extend to several scattered
sites and/or one for a short duration, portable magazines shall be used. Each such
magazine shall be located at a safe distance from the work site, enclosed in a fence
and properly guarded.

The storage should be done in such a way that the first store should be used first
and to have this facility, the explosives should be stored in sequence.

Blasting caps, electric blasting caps or primers shall not be stored in the same box,
container or room with other explosives.

If nitroglycerine from deteriorated explosives has leaked down onto the floor of the
explosive magazine, the floor shall be desensitized by washing thoroughly with an
agent obtained before hand from the supplier of the explosives. For this purpose,
desensitizing agents and the instructions for using them shall always be obtained
along with the supply of nitroglycerine.
A brush or broom shall be kept in the lobby of the magazine for cleaning the
magazine on each occasion it is opened for the receipt, delivery of inspection of
explosives.

If generator is used for lig hting purpose, it shall be kept at least 10 m away from the
magazine premises to avoid any spark from silencer of the generator.

42
 17. SILENT EXPLOSIVE

Silent explosives are non -exploding compounds. They do not cause any noise, firing,
toxic fumes or vibrations etc. The silent explosive are basically expanding cements,
whose volume increase on setting. The fracture of rocks is caused due to tensile
stress set up by the expansion of cement.

The silent explosives are to be used in built up area s, where normal types of
explosives cannot be used. The silent explosives maybe used for following works in
built up areas: -
(a) Breaking of boulders
(b) Trenching:
(c) Excavation near foundation of existing bridges or building setc.
(d) Demolition of mass concrete.
(e) Demolition of false piers, etc. below the bridges.

The silent explosives are normally supplied in two forms.

(a) Powder form
(b) Cartridge of about 200 mm length of 30 mm dia

Method of Use: Silent explosive is to be mixed with water. The water to be mixed is
about 30% by weight of silent explosive. First, the requisite water in the bucket is
taken and explosive powder is added gradually. The mixture is stirred till the full
quantity of explosives is mixed with the water and a slurry is formed. The slurry is
then poured in to predrilled holes as soon as possible within 5minutes. The slurry is
filled up to about one centimetre below the top. The filled holes are covered with a
sheet to avoid spurting of the explosiv es. After 24 to 48 hours, the cracks initiate and
develops into length and width. The secondary breaking of rocks is done by using
crowbar /splitters.

Mechanism of Blasting: The silent explosive functions by exerting stresses

generated due to expans ion of the slurry. This stress is much greater than tensile
fracture strength of rocks. The tensile fracture strength of rocks ranges from 40 to
150 Kg/sq.cm.
Designing of holes for use of Silent explosives: The designing of hole pattern may
depend on type of rocks to be broken.
(a) Loose Boulders: The depth of the hole should be kept 80 -90% of the
boulder depth or at least 20 times the hole dia. In case of shallow
boulders, inclined holes may be drilled for a more effective breaking of
boulder. Table 17.1 gives the recommended design of holes.
Table 17.1 Hole design for Loose boulders
43
Holes can be drilled either in cross pattern or in hexagonal pattern as shown in Fig
17.1

Fig 17.1 Hole pattern for loose boulders

(b) Benching: For benching operation also, the design of holes can be done as per
table 17.1 above. In addition to vertical holes, horizontal holes may also be drilled to
help developing separation in the horizontal plain. In case cleavages are already
present in rock in h orizontal plain, only vertical holes are sufficient. (Fig 17.2)

Precautions while using silent explosives :

The cost of explosives and requirements of drilling in case of silent explosives are
much more than conventional explo sive. It must be used only in the areas where the
conventional explosive cannot be used such as built up areas,

44
bridges. Silent explosive must be procured only from a reputed manufacturer. The
explosive bags if kept open or stored for a long time should no t be used.

Only potable water is used to make the slurry. If mixing temperature exceed 32°
C, then cold water should be used for making slurry.

Only a limited quantity of explosive should be used to make slurry, which can
be poured into the holes within five minutes of mixing.

During hot weather, it is preferable to use silent explosive, during cooler part of the
day.

Silent explosive may not be fully effective during very cold Feather. Crack may take
larger time to init iate i.e., 48 to 72 hours, as such its use in very cold weather should
be avoided.

Operator must use protective item like goggles, helmet, hand gloves etc while
handling explosive.

Any part of the body coming in contact with explosive mus t be washed with plenty
of water.

18 . ACCOUNTING OF EXPLOSIVE

Explosive is a Cat 'B' constructional store and its accounting in auditable ledgers is
done only at Task Force level as per laid down procedure. Great care must be
exercised at all levels while accounting of the explosives.

Procurement of explosives should be done in small quantities, preferably quarter-

wise. Issue to RCC's will be done in small quantities.

For issue of explosives to the site no explosive will be issued t o a person below the
rank of a supervisor. The supervisor will be personally responsible for use and
accounting of the explosive issued to him. The C P L's will not be allowed to
handle the explosives without supervision. The detailed instructions for acc ounting of
explosives have been given in Appendix "E".

45
 Appendix ‘A’ to DGBR TI No. 19
(Refer para 16.3)

GUIDELINES FOR TRANSPORTATION

OF EXPLOSIVES
1. Project authorities will issue standing operating procedure the elaborate
instructions, keeping in view the existing situation in the area/project from time to
time.

2. Adequate security of explosives must be ensured while transporting explosives

including following aspects. .

(a) Vehicles : - Only Govt/Depa rtmental vehicles will be used for

transportation of explosives. Under no circumstances, vehicl es of any private
party or transport contractors will be used for transportation o f explosives.
(b) Armed escorts : Armed escorts should be detailed to accompany the
convoy (carrying explosives) special ly in the disturbed areas .
(i) Security of explosives during transit: - Armed guards shall be
provided from factory to destination by the manufacturer of explosives
along with van carrying the supply of explosive as a precaution against
theft, pilferage and org anized attack to loot the explosive in transit.
(c) In the terrorist affected areas the explosives in bulk must be transported
in vehicles only with proper protection of Police/Army/Para military forces
(d) Supervision: - Convoy in charge should be at least a J Co/S S Grade -
I/Supvr Gde -I

3. Detailed instructions, pertaining to transportation of explosives (in bulk and

small quantities), are given in the succeeding paragraphs , on the following aspects.
(a) Vehicles
(b) Loading and unloading of vehicles
(c) Instruction to vehicle dri vers
(d) Escort commander.

VEHICLES FOR TRANSPORTATION OF EXPLOSIVES

4. Only Govt/Departmental vehicles should be used for transportation of

explosives shall be maintained in good working conditions and all systems of it must
be checked before starting move of vehicle.

5. The vehicles used for transporting explosive shall be driven only by a licensed
driver who is physically fit and is familiar with the precautions to be taken while
carrying the explosives in his vehicles. All vehicles used for transporting explos ives
shall be maintained in good working condition.
46
6. The body-work of each vehicle shall preferably be of the completely enclosed
type with a properly fitting door and locking arrangement. The body -work shall be
leak-proof. In open bodied vehicles, the floor shall be leak-proof, the sides and ends
shall be of sufficient height to prevent the explosives from falling off the vehicle and
the explosives shall be covered with a waterproof and flame resistant tarpaulin.

7. The interior of the body shall not have an y exposed metal parts, except those of
copper, brass and other non -sparking metals, and shall preferably be lined with
wood.

8. The exterior of the body shall be conspicuously marked on both sides and
ends, with the word ‘ EXPLOSIVES ’, painted in not less tha n 100 mm high letters in
white over a red background in English and local language.

9. AIl electrical wiring and equipment of vehicles shall be adequately insulated

and protected against mechanical damage to prevent short circuiting.

10. Two carbon dioxide fire extinguishers, each of not less than 3 kg capacity,
conforming to IS 2878, shall be carried on each vehicles. The extinguishers shall be
securely mounted on the vehicles in such a manner that they can be readily removed
for use in an emergency.

11. A motor vehicle carrying explosives shall not be re -fuelled except in

emergencies and even then only when the motor has been stopped and other
precautions have been taken to prevent accidents.

12. All motor vehicles used for transportation of explosives shall be caref ully
inspected at the beginning of the day’s work to ensure that:
(a) the vehicle is in good condition in all respects for safe transportation of
explosives;
(b) the chassis, engine and body are clean and free from surplus oil and
grease;
(c) the fuel system of the vehicle, including the fuel tank(s) is free from
leakage;
(d) all electrical wiring and equipment are in sound condition;
(e) lights, brakes and steering mechanism are in good working order;
(f) the fire extinguishers are serviceable and in position on the vehicle; and
(g) driver is trained in the use of extinguishers on his vehicle.

47
 INSTRUCTION REGARDING LOADING/ UNLOADING
OF VEHICLES

13. The quantity of explosive, carried in any vehicle should not exceed 75% of rated
load carrying capacity of that vehicle or 3600 Kg whiche ver is less.

14. Loading/unloading of explosives will be carried out under the direct

supervision of a responsible person not below the rank of J C O/ SS Gde -II.

15. During loading/unloading of explosives, all person will observe necessary

precaution for preventio n of accidents by fire or explosion.

16. No smoking will be permitted within 30 meters of the vehicle and no fire or
naked light will be allowed within 50 meters of the vehicle.

17. Before commencing loading of explosives, the interior of the vehicle will be
thoroughly cleaned. Inside of the vehicle body must be free from grit, oil, rags etc.

18. Engine of the vehicle should be switched off while loading/ unloading of
explosives.

19. No refueling of vehicle be permitted while loading/unloading explosives etc.

20. Explosives will be protected from rain or prolonged direct exposure to sun
during loading/unloading.

21. After loading/unloading has commenced, the work will be completed without
interruption as far as possible. If the work is interrupted, the vehicle will not be lef t
unattended.

22. Explosives and detonators shall not be permitted to be transported in the

same vehicle.

23. No metals, except approved metal truck bodies, shall be allowed to come in
contact with the cases of explosives. Metal, flammable or corrosive substance s shall
not be transported with explosives. As far as possible, transportation of any other
material along with explosives shall be prohibited.

24. Detonators and other explosives (in small quantities) for blasting operation
shall be transported to the work s ite in the original containers or in securely locked
separate non-metallic containers. Same shall not be carried loose or mixed with other
materials.

48
25. No unauthorized person shall be allowed in the vehicle carrying explosives.

26. Explosives shall not be tra nsported in trailers. Further, any trailer shall not be
attached to a motor truck or vehicle when it is being used in transporting explosives.

27. Explosives shall not be transported on public highways during darkness,

except in emergencies and even then only when the written approval of the project
authorities has been obtained. Such vehicles shall be fitted with adequate warning
lights on both ends, while operating in darkness.

28. Explosives shall not be transferred from one vehicle to another on public
highways except in cases of emergency.

29. Care shall be taken, while loading and unloading of explosives. The filled
containers of explosives shall not be handled roughly or dropped.

30. The tail board of the rear of the vehicle will be well secured before starting.

31. Unloading of explosives from the vehicle should not be done near or behind
exhaust pipe of vehicle. Explosive be protected from prolonged exposure to sun.

INSTRUCTION TO DRIVERS OF ROAD VEHICLE TRANSPORTING

EXPLOSIVES

32. Driver of the vehicle (carrying ex plosives) has to take all precautions for
ensuring safety of life and property. Driver of the vehicle carrying explosives will
ensure that
(a) Driver of vehicle will check all the systems of the vehicle for serviceability
and maintain it in good working condi tion and refuel the vehicle before
commencement of loading explosives in vehicle.
(b) Fire extinguishers of suitable size are carried in the vehicle fitted in
handy position. Driver of vehicle will familiarize with use of fire extinguishers
fitted on the vehicle.
(c) Red flags are fitted/displayed on both sides of the cabin and at the rear
of the vehicle.
(d) No explosive is carried in the driver's c abin.
(e) No person other than the driver and the escort is allowed on the vehicle
(even for short distance) except for the purpose of loading/ unloading .
(f) No smoking is allowed in the driver 's cabin (by anybody including vehicle
driver and escort) or any place near the vehicle within 30 meters.
(g) No fire is lit near the vehicle .
49
(h) No fuel is kept on the vehicle except in the fuel t ank of vehicle.
(i) Lighter, matches, smoking material if any, and those of escort are placed
in the metal box supplied, which is to be carried unop ened in a safe position,
within the cabin of the vehicle.
(j) When th e vehicle is loaded or unloaded, the electric I gnition system
should be switched off and if the engine is provided with magneto ignition, it
should be grounded. No refilling of fuel tank will be allowed.
(k) The vehicle is not at any time left unattended (Le. Either the driver or th e
escorts on the vehicle be close to it) even for short duration, while transporting
explosives.
(l) The speed of the vehicle should not exceed 25 Km/hr on rough road and
30 Km/hr elsewhere.
(m) When explosives are carried in a convoy, the distance between any two
vehicles will not be less than 75 meters but in the case of fir e on any vehicle,
the distance will not be less
(n) than 275 meters.
(o) Vehicle transporting explosives shall not be taken into a garage, repair
shop or parked in congested area, public parking or similar places.
(p) E xplosives shall not be transport ed on public highways, during
darkness, except in emergencies.
(q) The vehicle is stopped before passing any unguarded level crossing and
started only after ascertaining that it is safe to proceed further.
(r) Any defect if found in vehicle on inspection (every day before
commencing journey or en route at time of short halt) is rectified before he
proceeds further on th e journey.
(s) The journey is completed without un necessary halts and the vehicle is
not put up in any building or stopped in any populated area except when
absolutely necessary.
(t) In case of accident and where the GRE F explosives involved can
reasonably be suspected to have been rendered dangerous, no action will b e
taken to keep together and/or set aside any packages or its contents, which
might have been thrown about as a result of th e accident. Such explosives will
be left in situ till the arrival of competent person, who will decide, as to what
further action taken to warm in coming traffic of the danger in the event of a
vehicle being entangled with another or with an y object or structu re. No
attempt will be made to disentangle the same until the lo ad (of explosives) is
removed from site of accident to another pl ace 75 meters away from the vehicle
or any habitation. Inh abitants and other vehicles will be warned of the danger.
(u) The foregoing does not however prohibit action at the discretion of the
escort Commander or other responsible person on the spot, which he may
consider essential to avert immediate danger to life or property.

50
INSTRUCTIONS TO DRIVERS/ ESCORT COMMANDER OF VEHICLES
TRANSPORTING EXPLOSIVES

33. The escort will normall y travel in the cabin of the vehicle in addition to the
driver.

34. If a fire breaks out on the v ehicle, ACT QUICKLY .

35. Prevention is better than Cure: Before driving off, check fire.

36. If engine, petrol or oil system, catches fire get busy with fire extinguisher, first
closing the cut off, if fitted. If vehicle catches fire, get busy with the extinguisher and
any water you can get.

37. If fire is detected early , the prompt application of the fire extinguisher may
prevent the development of a serious fire and consequent explosion . extinguisher, See
that it is filled, ready to use and in good working order.

38. It the fire cannot be put out, thing and ACT QUICKLY . Send the escort to
alarm the area and to get the news to the police and any service coming as quickly as
possible. With the help of passersby, stop traffic and keep the road and vicinity clear
of all unnecessary personnel for 300 meters from the vehicle.
39. Drive the vehicle into open country if possible so long as the is not actually
affecting the packages and there is no immediate danger.

51
 Appendix 'B' to DGBRTI No. 19
(Refer para 16.4)
GUIDELINES FOR STORAGE OF EXPLOSIVES

1. Indian Explosives Act 1884, Explosives rules 1940 and Magazine Regulations
regulate storage of explosives. The provisions under the aforesaid should be strictly
observed, unless exempted under section 14 of Explosive act. For storage of
explosives, guidelines will be observed as indicated in succeeding paragraphs.

2. Explosives shall be stored only in a magazine, which is clean, dry, well

ventilated, well illuminated , reasonably cool, correctly located (more than 100 Mtrs
from living accommodation) and protected against ligh tening (if explosive is one tone
or more) in accordance with the provisions of Indian Electricity Act and Indian
explosives act. The / magazine should be - located away from built up area/highway,
but approachable with .all weather road and it should be loc ated on well drained
sloping ground.

3. Construction of Explosive Magazine : Following be kept in view:

These guideline shall be followed in conjunction with IS 10386 (Part 4): 2013 (Safety
Code for Construction, Operation and Maintenance of River Valley Pro jects) Part 4
Handling, Transportation and Storage of Explosives): -
(a) The magazine should be kept away from residential buildings, railroads
or highways, transmission lines, dams and their appurtenant works.
(b) The safe distance required under the Explosives R ules, 2008 depends
upon the storage capacity of the magazine and should be carefully planned
taking into account the rate of consumption and the frequency of
replenishment.
(c) The best site for a magazine is on well drained sloping ground. The
selected site should be accessible by road and it is advisable to make sure that
the existing tracks are usable throughout the year. If there are overhead power
transmission lines in the selected area, the distance between these overhead
power transmission lines and the magazine building should not be less than 92
m.
(d) The construction and approval of the magazine shall be based on
Standard Indian Practice as governed by the Indian Explosives Act, 1884 and
Explosives Rules, 2008 as amended from time -to-time.
(e) Under no circum stances, magazine be erected within half kilometers of
any working kiln or furnace.
(f) From installation / building (Le. sub -depot/group office, store house,
sub-fire station, watch tower, sub -canteen, rest shed etc.) distance should not
be less than 100 mtrs.
(g) From electric sub -station and high voltage over headline, distance should
not to be less than 100 mtrs.
52
 (h) From overhead telephone line distance should not be less than 10 mtrs.
(i) Distance between magazines should be 5 to 15 Mtrs .
(j) Distance from outer fencing/ compound wall of area not less than 25mtrs.

4. All major dumps as well as dumps in disturb ed area having explosive of 3 ton
or more, should be fenced with double fencing of barbed wire. Similarly double
fencing will also be provided for the explosive dump of Base Depot / Transit Depot /
Sub Base Depot / Unit irrespective of their holding.

5. An area up to a distance of not less than 50 mtrs on all sides of a magazine

shall be maintained free of vegetation, debris and combustibles.

6. Signboards reading "DANGER-HIGH EXPLOSIVES", .''PROTECTED AREA", ''NO

SMOKING" and use of overshoes etc. Shall be prominently displayed in front of the
magazine. Copy of lighting conductor test certificate should also be kept in magazine.
A warning sign for trespassers should be dis played outside.

7. Well trained preferably armed guards shall be posted to guard the magazine.

8. The following shall be hung up in the lobby of the magazine.

(a) A copy of explosive rules
(b) A statement showing the stock in the magazine
(c) Certificate showing the last date of testing of the lighting conductor.
(d) Standing order on fire fighting (in area around magazine and in
Magazine).
(e) Standing order for handling/taking over for security guard and
maintenance of record.
(f) Standing order for daily check by duty J CO/Supvr.

9. Adequate quantity of water and fire -fighting equipment shall be provided

near/in the magazine. Guards shall be property trained in handling such equipment.

10. Magazine shoes (without nails), shall be kept at all times in the magazine.
Persons entering the mag azine shall put on the magazine shoes provided for the
purpose and be careful not to allow the magazine shoes to touch the ground outside
clear floor. Wooden tub or cement tub . (approximately 300-mm high and 450-mm in
diameter) filled with water shall be f ixed near the door of the magazine. Persons with
bare feet shall, before entering the magazine. dip their feed in water and then step
down from the tub over the barrier (if there is one) on the clear floor.

53
11. Guard register will b e maintained and proper handing/taking o ver between
guards and sentries will be carried out on every occasion. Guard change will be done
under the supervision of a J CO/ Supvr will initial record of guard change of each
occasion.

12. Area surrounding the magazine should be kept free of inflammable materials to
avoid fires. Bushes and vegetation should be trimmed regularly.

13. Persons entering the magazine should be se arched for cigarettes/matches or

other inflammable material with th em.

14. Tools for opening explosive boxes must be of wood, brass, copper or bronze.
Use of tools made of iron, steel or other sparking materials is prohibited .

15. Proper and accurate record of 'receipt' and 'Issue' o f explosives should be
maintained.

16. It should be ensured that proper turnover of explosives is made i.e. by making
issue from the lots received first or manufactur ed on earlier dates before explosives
received subsequently can b e issued.

17. In case of storage of explosive in large quantit y following guidelines will be

followed :-
(a) Magazine building should be specially construct ed for this purpose
situated away from residential /industrial area and highway.
(b) Design of Magazine should be such that th ere is an internal volume of
not less than 0.4 cum per 100 Kg of explosive stored.
(c) While stacking cases, each stack should not have more than 5 tiers. 15 -
cm air space should be allow ed between the cases and wall for free circulation
of air.
(d) Detonators should not be stored with other i tems of explosives.
Detonators exceeding 44000 will have to be stored in a separate storage place
of magazine and inter distan ce between two should be ma intained (5-15 Mtrs).
(e) Where quantity of explosive exceeds 20 ton, a separate building for
storage of detonators must be built. If the quantity of explosives is lesser than
aforesaid, detonators can be stored in an annex, which is built as inte gral part
of main building (magazine) but has a substantial par tition (0.6 M thick) with
an air space (1.0 M wide) between them. As a rough guide a double partition of
20 cm each with 45 em air space between them will suffice the purpose of
storing 10,000 detonators.

54
18. Explosive cases should not be stack ed in more than five tiers rd should be
stacked in such a way that ends of the cases showing re date of manufacture are
visible, which will facilitate use of stock manufactur ed first.

19. Explosive up to 4 Kgs should be kept in securely locked container away from
fire and detonators/ca pped fuses should be kept separate containers . While storing
explosive upto 20-25 Kgs a small store/magazine should be built. .

20. Stocking of explosives should be done in accordance with magazine regulations

as far as practicable in the fi eld.

21. Different categories of explosives and accessories will be stored together but
segregated. Under no circumstances will detonating fuse, (cordtex) and gelatine be
kept together in explosives dumps at Base Depot/Sub Base Depot/Unit/Work Site.

22. Blasting caps, electric blasting cap s or primers shall not be stored in the same
box or room with other explosives in big dumps. However, in small dump, sand bag
revetments of appropriate thickness and height will be used to segregate different
zones of explosives.

23. Explosives, fuse or fuse lighters shall not be stored in a damp or wet place or
near oil, gasoline or near radiators, steam pipes or other sources of heat.

24. Smoking and use of matches, naked lights and readily flammable articles or
open fire/flame shall b e prohibited WIth in the fenced area around it. Similarly
explosives should be kept away from electric contact, fuse boxes and switches.

25. Metals, metallic objects and metal tools that are capable of producing sparks
shall not be stored or used inside or in the immediate vicinity of the magazine.

26. Boxes of explosives shall not be thrown down or dragged along the floor and
may be stacked on wooden tresties.

27. Package containing explosives shall not be allowed to remain in the sun.

28. Empty boxes, packing materials or any combustible material shall not be
stored inside or in the vicinity of the magazine.

29. For continued blasting operations the magazine e shall be located at a safe
distance near the work site and actual requirement of explosives for each blast may
be drawn and transported to the site and left-over if any, must be immediately
returned to the magazine. Where the blasting operations extend t o several scattered
sites and/or one for a short duration, portable magazines shall be used. Each such
magazine shall be located at a safe distance from the work site, enclosed in a fence
and properly guarded.
55
 Appendix 'C' to DGBR TI No. 19
(Refer para 16. 5)

INSTRUCTIONS FOR ENSURING SAFETY AND SECURITY OF

EXPLOSIVES IN HANDLING AT ALL THE STAGES IN BRO
GENERAL

1. Border Roads Organization , is entitled for exemptions as provided under

section 14 of the Explosiv es Act 1984, being integral part of Armed Forces of Union of
India. This calls for additional diligence . within the Department by BRO. Measures
required to be taken for ensuring safety and security, are given as under:
(a) Utmost care and precautions ar e taken by all concerned to ensure that
explosives procured for normal construction works do not get into the hands of
terrorists / anti-social elements and adequate safety measures are taken to
plug loop holes, if any, in handling / accounting of explosives. .
(b) Safety/Security measures, normal surprise checks are the sole
responsibility of the Chief Engineers Project and Commanders at various levels
including Officer Commanding Depot / Units and Officer -in-charge Platoon /
Detachments, where th e explosives are kept.
(c) Guarding :- Explosive dumps must always be ade quately guarded and
sited in protected areas. In case of emergency of unsettled / disturbed
conditions, the strength of security guard must be suitably increased for strict
vigilance at all levels and implementation of standing orders on the subject
need hardly any more emphasis.
(d) Some of the points, which should be acted upon, are given in the
succeeding paragraphs as g uide to all concerned.
(e) Issue of Standing Orders: - To meet the requirement of Safety and
Security of explosiv e in accordance with the existi ng local condition as
prevailing in area from time to time, standing order will be issued by concerned
authorities [I.e., Project S tanding order, BRTF Standing Orders / Unit Standing
Order etc.).

2. Explosive is a Category 'B' stor es item in BRO and i ts ,accounting in th e

auditable ledgers is done only at Task Force level, as per the laid down procedure. It
being sensitive stock, strict control to be exercised over tis procurement, storage,
issue and utilization. Following guidelines are, therefore, laid down :-
(a) Supply Order will be linked with the an nual works plan approved by Dte
GBR (Resources) and vetted by the concerned Accounting Officer.
(b) Procurement will be done in small quantities preferably every quarter.
However, while ordering, utilization of full capacity in terms of explosive vans
will be kept in view.
(c) In terrorist affected areas, the explosives in bulk must be moved only
with proper protection of Police/Army /Paramilitary Forces.
56
 (d) Mandatory vigilance checks will b e carried out frequently.
(e) Issue to RCCfs will be done in small quantities based on their monthly
demand. Only in exceptional cases, stock up to a period of three months can be
held by RCC with the approval of Chief Engin eer.
(f) Strict Administrative control will be maintained for its storage a nd
expense, where in report and returns on the ,subject would be scrutinized
thoroughly at each level.
(g) For issue of explosives to the site, no explosive will be issued to any
person below the level of Supdt B/R -1. Supdt B/RI in turn will ensure th at
explosive is not given to CPL s without supervision . Supdt B/R -I will be
personally responsible for expending explosive. He will personally issues a
certificate for the usage of the explosive issued to him .
(h) Other instruction as issued from tim e to time will be strictly followed.

3. Order on Safe Custody : Following action should be taken for ensuring safety
and security of explosives.
(a) Officers Commanding Base Depot/Transi t Depot/Sub Base Depot / Unit
will be personally responsible for the safe custody of explosives and
accessories. Officers Commanding Depots /
(b) Unit will carry out weekly inspecti on and they should sign in the regi ster
maintained in the magazine to ensure that standing ord er covering explosives
are being complied with by all concerned.
(c) E xplosive dumps will be inspected by duty J CO / Supvr d etailed by OC
Depot / Uni ts for this purpose. Daily counting and check of explosive boxes in
the stacks will be carried out. Record o f such inspection will be maintained in a
register in the explosive dump.
(d) Opening stock of all explosives for the day should be displayed on the
tally cards inside the explosive dump/ magazine.
(e) The Depots/Units will ensure that quantiti es of explosive issued to the
units / sub-units. are struck off from their ledgers a nd removed forthwith by
the units from the concerned depot pr emises.
(f) Issue vouchers will always be prepared and return of the receipted copies
of the same from the consignees are insisted upon within two weeks from the
date of preparation of the issue voucher.
(g) No explosives will be issued to PWD . Army or any other
Organization/agency outside the BRO either on loan or perm anent transfer /
sale / issue without the prior sanction of the Govt.

4. Reporting of losses / recoveries: Following actions should be taken for

reporting of losses / recoveries of explosive :-
(a) It will be ensured that reports of all cases of losses / recovery of explosive
are made to HQ DGB R by signal immediately on occurrence / d etection. Report
of such losses will also be made to the District Supdt. of Police a nd nearby
57
 Army Formation if any. A court of Inquiry will be h eld immediately and the
responsibility fixed on the individual concerned.
(b) In case of any recovery of explosives. the same will be reported in
accordance with Army Order 90/7l.
(c) Where cases pertain ing to theft and pilferag e are not being pursued
vigorously by the state police au thorities to a concluding point, DG police/Chief
Secretar y Intelligence Bureau of the State concerned should be intimated.

5. Accounting of Explosive at Work sites : Officer in the. Charge /Command

should be instructed to strictly observ e the following instruction with regards to
receipt holding and further issue of explosives. The chance of explosives finding their
way to unauthorized hands deliberately or through neglect are m uch more at work
sites than while in stock. It is therefore essential that comprehensive instructions on
the handling and accounting of explosive s at work site are also drawn up and
observed strictly. Following guidelines ar e made for incorporating in the detailed
instructions to be issued by Project authorities for handling of explosives by the
ground executives.
(a) Explosives dump at work sites must be p roperly guarded and individuals
detailed for this purpose should not be given additional duties.
(b) Issues of explosives should be made against the signature of the
officer/J CO/Supvr in -charge of blasting and a daily register (baby ledger) be
kept for accounting of explosives issued at work sit es. Issues should be made
to a limited number of men specially authorized through a unit Daily Part I
order and directly associated with blasting. under no circumstances issues of
explosives should be made to any civilian laborers/ representatives of
contractors. Issues should be restricted to minimum essential quantities
required for the blasting on the particular day.
(c) At the close of day's work, a check will be made at the work site to
ensure, that no unused explosives are left behind. Unused explosives will be
returned to the explosive dump same day and accounted for accur ately,
Officer/J CO/Supvr/NCO incharge work site explosives dump must tally at the
end of each day, the explosives drawn. consumed and returned unused to the
dump by various work sites and maintain a record thereof.
(d) The work of officer/J CO/Supervi sor in-charge, who is directly
responsible for proper maintenance of records should be strictly monitored
regularly and counter checked by arranging surprise checks by the senior
officer.
(e) Explosives, if and when found with unauthorized persons, will be
confiscated from them and apart from normal reporting of such cases to
various authorities, investigations and disciplinary proceedings initiated
without delay.

58
 Appendix 'D' to DGBR TI No. 19
(Refer para 16.6)

GUIDELINES FOR RECEIPT OF EXPLOSIVES

THROUGH RAILWAYS

(Note : Project authorities will issue 'Standing Operating p rocedure' with

elaborate instructions keeping in view the existing situation in the
area/ p :roject from time to time)

1. As per IS 4081:2013 ( Blasting and Related Drilling Operations -Code of Safety,

(Second Revision)), for transportation by rail, unless otherwise permitted, quantity of
explosive in any wagon shall not exceed 4 500 kg. The minimum gross wagon load
(inclusive of mass of packing cases) shall be 3 000 kg, which is approximately equal
to 102 cases of explosives if packed in wooden cases or 114 cases if packed in fiber
board cases.
2. At times explosives are received by BRO Project authorities directly from the
indigenous sources (Le. manufacturers etc) with DGBR markings. These explosives
are dispatched by the firms in covered wagon without escort. Thorough checks are
required to be exercised while receiving explosives.

3. On arrival of the wagons containing explosives at the destination, various

actions as indicated in the succeeding paragraphs t o be taken meticulously.

4. Inspection of wagon :- Carry out the usual inspection of the wagon for correct
wagon number. There should be no sign of any breakage or tempering etc. with the
body of the wagon such as cutting holes(in the bottom of wagon or side s/top of the
wagon) or rewelding it after cutting etc. (In bottom/sides/top/door of wagon).

5. Inspection of Doors. Seal and Padlocks etc . :- Carryout further visual

inspection of wagon. There should be no sign of tempering with the door,
seal/padlocks etc a nd genuineness of the seal. If any doubt arises, it should be
checked with the railway staff. The seal should bear the stamp of dispatching station.
There may be cases, where seals of an intermediate station may have been used. The
corresponding wagon numb er from which the explosive transshipped and
genuineness of the new seal should be checked with the local railway staff.

6. Receipt of Consignment :- After thoroughly checking the consignment of

explosives in the wagon in the presence of railway staff (immedi ately after opening
wagon by them) the delivery should be taken in their presence. The details of
discrepancies, if any, be informed to railways and firm simultaneously. If there is any
loss of explosives, action as laid down in Army order 90/71 will be fo llowed.

59
7. Shortages :- In case of tempering of body of wagon (i.e. cutting holes etc or re -
welding again at holes etc) or broken seal or tempering with the seal etc, open
delivery in the presence of railway staff and Railway protection Force must be
insisted upon. Shortage of explosive, if any, should be recorded in the Railway
Delivery Book immediately. Railway short certificate be obtained and claim be
referred without delays as the explosives are dispatched at Railway risk.

8. Discrepancies :- In case wagon seals are intact, but discrepancy in receipt

comes light on checking the contents of the wagon or the boxes appears to be
tampered with, the matter should be immediately brought to the notice of Railway
staff and delivery of explosives, should be taken in their presence. The firm should
also be informed if there is any discrepancy.

9. BRO team :- In all the cases, the explosives wagon will be opened in the
presence of a suitable team of BRO headed by an officer of BRO and discrepancies be
recorded by officer personally.

10. Under no circumstances explosives will be transported from Railway station

through vehicles of transport contractor. Explosives will be transported through
Govt./Departmental vehicles, After receipt of explosives, it will be loaded direct into
Govt. transport an d it must be dispatched to its immediate. destination under proper
escort/guards.

11. A tally card of boxes as loaded in each vehicle, be made at the time of dispatch
from Railway station as well as the time of unloading at the explosive du mp. Proper
convoy note should be prepared and convoy in -charge should be properly briefed
about his responsibilities.

60
 Appendix 'E' to DGBR TI No. 19
(Refer para 20.3 to TI)

GUIDELINES FOR ACCOUNTING OF EXPLOSIVES

INTRODUCTION

1. Explosives as received by Project and units under command must be properly

accounted for immediately after receipt, issue and consumption after carrying out
thorough check of quanti ty and quality. All the connected documents and
transactions with all d etails must be completed properly after occurrence same day
and concerned staff and officers must sign the documents same day. These
instructions are general guidelines and Chief En gineers. BRTF Comma nder and OC
units may issue their own Standing Operating Procedur e covering all points keeping
in view the ground situation. The instructions cover the following aspects.
(a) Receipt/issue at Base by Base Depot/Rear Stores Company.
(b) Receipt/Issue by S tore Coy/Platoon from stock of BR TF.
(c) Receipt/Issue by RCC/BCC.
(d) Accounting of consu mption of Explosive by RCC/BCC.
(e) Receipt/Issue/Consumption by platoon/Detachment and maintenance
of daily account of consumpt ion of explosives.

BULK RECEIPT AND ISSUE BY BASE DEPOT OR CONCERNED UNIT

AUTHORISED BY PROJECT CHIEF ENGINEER

2. Collection and distribution of explosives on behalf of Project/ BRTF will be

centrally done by Base Depot or by any o ther unit (or Rear Stores company) as
specifically directed as per Pro ject Standing Orders. From the time of receipt of
explosive at the Railway Station by the aforesaid unit, till these are issued to
concerned BRTF/ stores Company/stores Platoon , the responsibility for accounting
security and preservation will rest with the unit which has recei ved explosive initially.

3. Board of Officers ordered by Chief Engine er or BRTF Commander will check

explosives. In case of any discrepancy in the explosives, while receiving at Railway
Station, discrepancy will be recorded in the Railway Delivery Book.

4. Proceedings of Board of Officers will be submitted to HQ Project/BRTF within

48 hours from the time of arrival of explosive at Railway Station.

5. All holdings at the explosive dump at Base Depot (or Rear Stores Company) will
be accounted for in appropriate ledgers supported by relevant receipt and issue
vouchers. For accounti ng of explosives, following procedure will be strictly adhered
to.
61
 (a) All the items taken on charge and receipt vouchers cleared within 24
hours.
(b) No explosive will be released without a release order from project.
(c) Issue to BRT F/Stores Company/RCC will always be in full boxes, and
never in loose condition.
(d) BRTF HQ will be intimated the date for collection of explosives well in
advance by Base Depot (or Rear Stores Company as the case may be).
(e) Issue will be made only after verification of identity and specimen
Signature of representative so detailed by BRT F / RCC in response to the
intimation given in (c) above.
(f) Signature of the BRTF/Stores Company / RCC representatives will be
obtained in the Convoy Note and on all copies of issue voucher as prepared at
the issuing end. BR TF/ Stores Company/Unit concerned will clear these
vouchers within 24 hours of receipt.
(g) Convoy Note will bear reference to the issue voucher and vice versa.
(h) All copies of vouchers will bear the following details : -
(i) No, Rank and Name in block capital s and Signature (indicating
date) of the person issuing the explosives on behalf of receiving unit.
(ii) No, Rank and Name in block capitals and signature (indicating
date) of the Incharge of party in token of correct receipt.
(iii) A transaction will only be conside red complete after the officer of
receiving unit have signed receipt voucher and given the number of
issue & receipt voucher over the voucher.
(i) Upto-date tally card will be maintained all the time with the Signature
/initials of the stores holder. This shou ld be checked and initialed periodically
by Officer In-Charge detailed by the unit OC.

6. Surprise Check: - From time to time, surprise check of bulk stock of explosives
will be ordered by Chief Engineer and proper record of surprise check will be kept. A
register for record of check will be kept at explosives dump, which will be under
custody of guard commander, duty J CO /Supervisor. Duty Officer detailed for the day
will carry out surprise check and count the explosive boxes in stock daily and record
the results in the register accordingly. This register will be produced, when asked, for
inspection of Staff Officer to CE Project visiting that location.

ACTION BY STORES COY/ PLATOON ON BRTF

7. OC Stores Coy/Platoon will prepare its own standing order incorporating these
points within the general framework of Stores Company /Platoon. These orders will be
got approved from BRTF Commander.

62
8. On receipt of 'Release Order' for explosives from the project HQ, the Stores
Company/Platoon (on behalf of BRTF) will arrange collection as per following
procedure :-
(a) In-Charge collection party will not be below the rank of J CO/Supervisor.
(b) Authority letter with the specimen Signature of In -Charge party will be
sent to place of stock.
(c) In-Charge collection party to be asked for foll owing action.
(d) Entries on Convoy Note and voucher will be checked for its correctness.
(e) Record of explosives held in each bunker will be kept in Tally Card and
displayed on each dump item-wise. This must be maintained upto -date.

9. Accounting and Issue of Expl osives :- Holding of the Stores Company

/Platoon will be entered in appropriate ledgers and all the entries of the same will be
supported by relevant issue/receipt vouchers. Issue will only be effected a fter
'Release Order' have be en issued by HQ BRI'F. Ex plosives will under no
circumstances be issued to anyone below the rank of J CO/Supvr. Action on all the
points as given in preceding paraNo.2 to 6 will also be taken meticulously.

ACTION BY RCC/ BCC

10. Explosive are collected by authorized representative of unit as per BRTF

Release Order and same will be checked at receiving end same day before keeping in
explosive dump and accepting the explosive.

11. Immediately, same day, explosi ves will be taken on ledger charge and all the
entries initialed by an o fficer. If issue vouchers are not received, the explosives will be
taken on ledger charge on the authority of Convoy Note While initi aling the ledger
entry, the voucher / convoy note will also be si gned by the officer and the voucher,
cleared within 24 hours.

12. Stock Tally Cards will be maintained in the explosive bunkers and kept upto
date by the explosive in-charge.

13. Issue of detachments by RCC/BCC : Procedure to be followed for issue of

explosive to Detachment which does not maintain dump, will be as given in the
succeeding paragraphs.

14. Issue of Explosive to De t t Dump : OC unit will periodically issue Daily Part I
order fixing the limit of holding explosive by the detachment. Following procedure will
be maintained :_
(a) Explosive to other detachment / platoo n etc will be issued from the
detachment on the authorit y of release order issu ed in writing from HQ
RCC/BCC duly signed by OC/21C of same unit.
63
 (b) In-charge of explosive dump in detachment will maintain one copy of
requisition slip.
(c) In-Charge of explosive dump in Detac hment will sign the requisition as
having received the items of correctly and will taken item on detachment
ledger/register charge. Entries will also be signed and initiated by the Dett
commander personally.
(d) Once a month, all detachment register/ledger wil l be sent to RCC/BCC
HQ through a responsible Supervisor to check the correctness of all
transactions. These checks will be carried out by the OC unit who will also
initial the last entry of Dett ledger, as a token of having checked the explosive
accounts and found correct.

15. Accounting of Explosive at work Site: 'Work Diaries" are being maintained at
each site for the J obs' where explosive are utilized: Person authorized to handle
explosive will be nominated by name in Unit Part -I orders. Only authorized person
will draw explosive from 'RCC's main Dump' or 'Dett Dump' and sign for the same in
a register to be maintained for this propose. Explosives in -charge will also record in
the work Diaries the explosive issued on a particular day. At the end of the day, when
the blasting operations are over, entries will be made in the 'Work Diaries' indicating
the consumption of explosives. This entries will also be signed by the explosive
incharge and he will strike off the item consumed from his ledger and obtain the
initial of Dett Commander or in case of unit main dump of the officer authorized by
the OC against all the entries. Register of issue of explosives will be maintained up to
date and all entries initialed / signed by all concerned.
16. At the close of the day’s work, a check will be made at work -site to ensure that
no unused explosives are left behind.
17. For proper accounting of usage of explosives at site, following form should
be filled: -
Fresh Cutting/widening(tick the appropriate) at the ..............................road
Date: Time of blast: KM:
BLAST DESIGN: To be neatly drawn in the box

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 (A) Drilling Qunatity Details (B) Charging Details
S Parameters Quan Unit S No. Parameters Quan Unit
No. tity tity
1 Hole Depth m 1 Charge/Hole Kg
2 Bench m 2 Length of m
Height or Detonating Fuse
Face Height consumed
3 Hole mm 3 Total Explosive Kg
Diameter
4 No. of Holes 4 Manufacturing
date/Batching
date of
explosives
5 No. of Rows 5 Explosive type
6 No. of 6 No. of detonators
Holes/Row used for
initiation
7 Burden * m*m 7 Length of safety ms/no
Spacing fuse consumed s.
8 Top m 8 Cord ms
Stemming Relay/Delay
Detonator
9 No. of deck Nos. 9 No. of cord
and their andm relays/delays
length used
10 Rock M3 10 Charge Factor Kg/m3
Volume

Charging Firing

65
Output

Linear output : Damage to the slope

Volumetric output : Comments on excess
vibration
Cumulative Drilling Comments on air
length/Blast : overpressure/sound
Blow out of Explosive from Comments on fly
holes : rock
Mean Fragment size : Total drilling time
(uninterrupted)
Over-break : Total loading time
(uninterrupted)
Damage to existing Total Mucking time
formation : (uninterrupted)
Complaint from local Sockets
inhabitants/administration:

,(

J unior Engineer

66