Rock Breaking in a Quarry Without Explosives

Spain

“We needed to break rock without using explosives and without causing problems for the surrounding area. CEMENTO 3E allowed us to work safely and with full control.”

A civil engineering and aggregate mining company contacted QUIMACER to handle a rock-breaking project at a quarry with strict operational restrictions.

The work site was located near sensitive areas, so the use of explosives was restricted or ruled out entirely due to safety concerns, permitting requirements, and vibrations.

The customer had tried mechanical methods using a hydraulic hammer, but performance was poor, machinery wear was high, and progress was uneven.

The rock contained large boulders that prevented the loading and transport of material from continuing.

The goal was to achieve controlled, safe, and economically viable fragmentation without harming the environment.

Problems Identified

  • It is practically impossible to use conventional explosives.
  • Poor performance of mechanical methods in massive rock.
  • Risk of vibrations, noise, and flying debris.
  • High hourly cost of heavy equipment.
  • The need to cut into small pieces with precision to facilitate later removal.

Our Intervention

  • QUIMACER analyzed the rock type, the volume to be fragmented, accessibility, the available drilling diameter, and the spacing between drill holes.
  • A chemical solution involving controlled expansion using 3E EXPANSIVE CEMENT was proposed.
  • A drilling pattern was defined based on the block size and the desired direction of fracturing.
  • It was recommended to adjust the mixture and application based on ambient temperature, drill hole diameter, and expected reaction time.
  • It was recommended to avoid using too much water, protect the boreholes, and allow sufficient expansion time to maximize the fracture.

Solution Implemented

  • Drilling of boreholes distributed according to rock volume and the desired fracture plane.
  • Mix 3E EXPANSIVE CEMENT with clean water until a fluid, homogeneous paste is obtained.
  • Immediate pouring into boreholes, avoiding air pockets and material loss.
  • Safety monitoring during the expansion phase, without vibrations or detonation.

Target parameters: drill hole diameter 32–45 mm, spacing 25–45 cm depending on hardness, depth equivalent to 80–90% of the block’s thickness.

Results and Improvements

Controlled rock fragmentation without the use of explosives.

Elimination of vibrations and a drastic reduction in noise compared to intensive mechanical methods.

Lower risk for workers and the surrounding area.

Reduction in the number of hours of hydraulic hammer operation required to complete the removal.

Reduced cost per cubic meter in an area where explosives were not a viable option.

Parameter Technical Details
Sector HDD / Civil Engineering
Soil Rock fragmentation
Method No explosives
Critical depth Hole diameters 32–45 mm; spacing 25–45 cm
QC Products

3E EXPANSIVE CEMENT
Recommended dosage

Based on the borehole design
Key Improvement

Controlled demolition without vibrations or explosive noise

WHY QUIMACER?

  1. It allows rock to be broken up without explosives.
  2. Precise control of the fracture.
  3. Greater safety for workers and the surrounding area.
  4. Lower environmental and operational impact.