Drilling Blasting Cost per Ton in Mining | Indian Minerology

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Drilling & Blasting Cost per Ton in Mining – Complete Technical Guide with Calculation Method (2026)

Drilling & Blasting Cost per Ton is one of the most critical performance indicators in both surface and underground mining operations. It directly affects mine profitability, production efficiency, fragmentation quality, equipment performance, and overall operating cost.

In this professional mining engineering guide, we will break down drilling and blasting economics using real-world formulas, technical logic, practical examples, and proven cost optimization strategies used across global mining projects.

Why Drilling & Blasting Cost per Ton Matters in the Mining Industry

Drilling and blasting is the first production stage in hard rock mining. Any inefficiency here multiplies cost across loading, hauling, crushing, and processing.

  • Controls rock fragmentation
  • Impacts excavator productivity
  • Reduces crusher energy consumption
  • Determines overall mine profitability

Globally, drilling & blasting contributes 15%–35% of total mining operational cost depending on rock hardness and mine type.

Lower cost per ton = Higher mine margin.

What Is Drilling & Blasting Cost per Ton?

It represents the total money spent on drilling and blasting activities divided by the total rock broken (in tons).

Basic Formula

Drilling & Blasting Cost per Ton = Total D&B Cost ÷ Total Tonnage Blasted

Where total cost includes:

  • Drilling equipment operation
  • Drill consumables (bits, rods)
  • Explosives cost
  • Detonators & accessories
  • Labor cost
  • Fuel & power
  • Maintenance
  • Safety compliance

Major Cost Components Explained (Technical Breakdown)

1. Drilling Cost

  • Rig ownership or rental
  • Fuel or electricity
  • Bit wear
  • Operator wages

Typical global drilling cost range: $2.0 – $6.0 per meter

2. Explosives Cost

  • ANFO / Emulsion / Slurry
  • Primers & boosters
  • Detonators (nonel/electronic)

Typical range: $0.20 – $1.00 per kg

3. Blasting Operation Cost

  • Charging labor
  • Safety arrangements
  • Blast design engineering

Step-by-Step Cost per Ton Calculation (With Example)

Mining Bench Data Example (Open Cast Mine)

  • Bench volume: 10,000 m³
  • Rock density: 2.5 t/m³
  • Total tonnage = 25,000 tons

Drilling Data

  • Total drilled meters = 3,000 m
  • Drilling cost = $4/m
  • Total drilling cost = $12,000

Explosives Data

  • Powder factor = 0.6 kg/ton
  • Total explosive = 15,000 kg
  • Explosive cost = $0.40/kg
  • Total explosive cost = $6,000

Other Blasting Costs

  • Labor + accessories = $2,000

Total Drilling & Blasting Cost

$12,000 + $6,000 + $2,000 = $20,000

Final Cost per Ton

$20,000 ÷ 25,000 tons = $0.80 per ton

Typical Drilling & Blasting Cost per Ton (Global Range)

  • Soft rock quarry: $0.30 – $0.70
  • Hard rock open pit: $0.70 – $1.50
  • Underground hard rock: $1.50 – $3.50+

Costs vary by:

  • Rock strength
  • Hole diameter
  • Explosive type
  • Fragmentation requirement
  • Depth and access

Practical Field Example – Underground Mining

In a gold underground mine with 2.8 t/m³ rock density:

  • Drilling meters per round: 120 m
  • Drilling cost: $5/m = $600
  • Explosives: 300 kg × $0.45 = $135
  • Accessories & labor: $165

Total = $900

Broken rock per round = 400 tons

Cost per ton = $2.25

Common Mistakes Increasing Cost per Ton

  • Poor blast design
  • Overcharging explosives
  • Incorrect burden and spacing
  • Excessive drilling depth
  • Low fragmentation control
  • Ignoring rock mass conditions

How to Reduce Drilling & Blasting Cost per Ton

Technical Optimization Tips

  • Use proper powder factor
  • Optimize burden & spacing
  • Match explosive to rock hardness
  • Use electronic detonators for precision
  • Improve drilling accuracy

Operational Improvements

  • Reduce re-drilling
  • Prevent blast damage
  • Monitor fragmentation size
  • Train blast crews regularly

Safety & Performance Enhancement

  • Controlled blasting reduces fly rock
  • Better fragmentation lowers crusher wear
  • Reduced ground vibration protects structures
  • Lower misfire risk

Frequently Asked Questions (FAQ)

What is a good drilling and blasting cost per ton?

For surface mining, $0.50–$1.20 per ton is considered efficient depending on geology.

How does powder factor affect cost?

Higher powder factor improves fragmentation but increases explosive cost. Balance is key.

Why underground blasting costs more?

Smaller holes, tighter space, higher labor intensity, and stricter safety controls.

Which explosive is cheapest?

ANFO is cheapest but not suitable for wet holes.

Can blasting reduce crushing cost?

Yes. Good fragmentation can reduce crusher power consumption by 15–30%.

Conclusion

Drilling & Blasting Cost per Ton is not just a number—it reflects the technical efficiency of your entire mining operation. By using proper blast design, smart explosive selection, accurate drilling, and continuous monitoring, mines worldwide are achieving massive cost reductions while improving safety and productivity.

Optimizing this single parameter can increase mine profit margins by millions annually.

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