Block caving is an underground mining method that involves the extraction of large blocks or

sections of an ore deposit from beneath the surface of the earth. It is a cost-effective method
that is well-suited for use in deep underground mines and deposits that are too large or too
difficult to mine using other methods. The basic principle of block caving is to allow the
material to break naturally under the influence of gravity, which reduces operational costs and
improves efficiency. This paper will describe the block caving method, including its
advantages, disadvantages, and applications in the mining industry, with references from
various sources.

Block Caving Method

Block caving is a mining method that involves allowing the rock to break naturally under the
force of gravity, which allows the minerals to be extracted without the need for explosives or
other costly machinery. In this method, a series of tunnels and vertical shafts are created to
allow the material to be removed from the ground. Once these tunnels are in place, the ore
body is undercut, or broken up, to allow the weight of the material above to cause it to
collapse. As the material falls, hydraulic shovels or loaders are used to recover the ore
(Engels, 2013).

The initial stage of block caving involves the creation of tunnels and shafts that will be used
to access the ore body. The tunnels are typically between 5 and 25 meters in diameter and are
created using mechanical excavation methods. Once the tunnels have been created, they are
reinforced using a variety of methods, including steel beams and shotcrete. The tunnels are
then used to create vertical shafts that provide access to the ore body, which is located deep
underground (Ebrahimi, et al., 2016).

Once the tunnels and shafts have been created, the next stage in the block caving process is to
undercut the ore body. This is achieved by drilling a series of holes into the ore body and then
blasting the material using explosives. Once the material has been blasted, it naturally falls
under the force of gravity, causing it to break further into rubble. The rubble is then removed
from the ground using a combination of hydraulic shovels and loaders, which are located at
the bottom of the ore body (McCarthy and Tucker, 2013).

Applications of Block Caving

Block caving is a mining method that is widely used in the mining industry, particularly in
the extraction of metals such as copper, gold, and silver. It is also used in the mining of other
minerals, such as uranium, nickel, and diamond. Block caving is often used in deep
underground mines where the ore body is too large or too difficult to mine using other
methods. It is also used in mines where the ore body is irregularly shaped or where the
deposit is located beneath a steep incline (Ebrahimi, et al., 2016).

One of the primary advantages of block caving is that it is a relatively inexpensive mining
method. Compared to other mining methods, such as open-pit mining, block caving requires
less capital investment, lower operating costs, and fewer personnel. This is because the
operation can be easily mechanized and automated, reducing the need for expensive
machinery and skilled workers. This, in turn, helps to reduce the overall cost of mining while
increasing the overall yield of the process (Engels, 2013).

Another advantage of block caving is that it has a lower environmental impact than other
mining methods. Because the ore is extracted in large sections, the amount of waste that is
produced is significantly less than that produced by other mining methods. This helps to
reduce the amount of waste material that must be disposed of while minimizing
environmental damage (McCarthy and Tucker, 2013).

Despite these advantages, there are also some disadvantages associated with block caving.
One of the primary disadvantages is the potential for cave-ins and collapses. Because the
material is allowed to fall freely under the influence of gravity, there is a risk that the roof
may collapse, which can be dangerous for mining workers and the surrounding environment.
This risk can be minimized by ensuring that the tunnels and vents are properly reinforced and
that the material is removed from the ground gradually and carefully (Ebrahimi, et al., 2016).

Another disadvantage of block caving is the potential for groundwater contamination. In

many mining applications, the ore body is often surrounded by water. As the ore is extracted,
there is a risk that the water may become contaminated with chemicals or minerals that are
harmful to aquatic life and the surrounding environment. To prevent this from happening,
mining companies must carefully monitor their operations and take steps to ensure that the
water is properly treated and disposed of once it has been used in the mining process
(McCarthy and Tucker, 2013)
Conclusion

Block caving is a popular and effective underground mining method that is well-suited for
use in large ore deposits, particularly those that are located deep underground. It is a cost-
effective method that is widely used in the mining of metals such as copper, gold, and silver,
as well as other minerals such as uranium, nickel, and diamond. While block caving offers
many advantages over other mining methods, such as cost-effectiveness and low
environmental impact, there are also some disadvantages that should be considered, such as
the risk of cave-ins and collapses and the potential for environmental damage. Despite these
challenges, block caving remains a popular and reliable method of mining valuable materials
from the ground.

Case Study: Grasberg Mine

The Grasberg mine, located in Papua, Indonesia, is one of the largest gold and copper mines
in the world. The mine is operated by Freeport-McMoRan, the US-based mining company,
and employs over 19,000 workers. The Grasberg mine is known for its use of the block
caving method, which has allowed the company to extract large amounts of valuable minerals
from deep underground at a low cost.

The Grasberg mine was discovered in 1988, and since then, it has undergone significant
expansion to become one of the world's largest mines. The mine is located in an area that has
long been known to contain large reserves of copper and gold ore. However, due to the
remote location of the mine, it was difficult to access the minerals. To overcome this
challenge, Freeport-McMoRan decided to use the block caving method to extract the
minerals.

The block caving method used at the Grasberg mine involves the creation of a series of
tunnels and vertical shafts that are used to access the ore body, which is located 4,000 meters
underground. The tunnels are created using mechanical excavation methods, and they are
reinforced using a combination of steel beams and shotcrete to ensure the safety of the
workers.

Once the tunnels and shafts have been created, the next step is to undermine the ore body.
This is achieved by drilling a series of holes into the ore body and blasting it using
explosives. This causes
the material to break up and fall under the force of gravity, which allows it to be extracted
from the ground without the need for costly machinery.

The block caving method used at the Grasberg mine has been highly successful, allowing
Freeport-McMoRan to extract large amounts of valuable minerals at a low cost. In 2019, the
mine produced over 800,000 metric tons of copper and over 30,000 kilograms of gold.

However, there have also been some challenges associated with the block caving method
used at the Grasberg mine. One of the primary challenges has been the risk of cave-ins and
collapses. To address this challenge, Freeport-McMoRan has implemented a variety of safety
measures, including the use of hydraulic jacks to support the tunnels and the use of seismic
monitoring to detect potential collapses.

Another challenge has been the potential for environmental damage. The Grasberg mine is
located in a region that is known for its biodiversity, and there have been concerns about the
impact of mining on the local ecosystem. To address these concerns, Freeport-McMoRan has
implemented a range of environmental protection measures, including the reforestation of
mined areas and the treatment of wastewater.

In conclusion, the use of the block caving method at the Grasberg mine has allowed Freeport-
McMoRan to extract large amounts of valuable minerals at a low cost. While there have been
challenges associated with this method, the company has implemented a range of safety and
environmental protection measures to address these challenges. The Grasberg mine serves as
an excellent example of the effective and sustainable use of the block caving method in the
mining industry.
References

Freeport-McMoRan Inc. (2020). Grasberg minerals district. Retrieved from

https://www.fcx.com/operations/grasberg

McCarthy, D., & Tucker, A. (2013). Best practices in cave mining using seismic monitoring.
Mining Engineering, 65(2), 35-39.

Ebrahimi, S., Xu, C., & Sagafi, M. (2016). A review of block caving mining systems. Mineral
Processing and Extractive Metallurgy Review, 37(6), 341–351.

Engels, J. (2013). Block caving – an inexpensive alternative to open-pit mining. Mining

Engineering, 65(7), 61–65.