Muck-pile behavior plays a pivotal role in optimizing mining operations, as post-blast throw, drop, and lateral dispersion directly influence equipment selection and loading efficiency. The present study conducted a series of novel blasting trials to systematically evaluate the effects of different blast design parameters on key muck-pile characteristics. Principal Component Analysis (PCA) was employed to determine the most influential design variables for developing optimized blast configurations. The investigation comprised multiple combination blasts executed in four distinct phases at the OC1 RGIII mine of SCCL. Blast layouts were precisely developed using advanced blasting software and implemented in accordance with the parameters identified through PCA. Muck-pile properties were quantified using advanced AI-based analytical tools, yielding detailed and reliable insights.The findings revealed that a spacing-to-burden ratio of 1.35, stemming length equal to 0.9 times the burden, 1 m decking, and a V-pattern initiation sequence produced superior muck-pile conditions. This optimized configuration resulted in a reduction of drop by 3 m, a decrease in throw by 5.9 m, and an increased lateral spread of 19.3 m. These improvements contributed to smoother loader manoeuvrability, enhanced loading efficiency, and overall operational optimization.

In this study, UAVs played a crucial role in capturing high-quality muck-pile photographs, which were essential for characterizing key blast results such as drop, throw, and lateral spread. Principal Component Analysis (PCA), performed using XLSTAT, was instrumental in identifying and selecting the most influential blast design parameters affecting the blast outcomes. AI tool was effectively used to design blasts based on insights derived from the baseline study and PCA results A special AI tool within Strayos software was also utilized, which is unique in its ability to characterize key blast parameters, including throw, drop, and lateral spread. The results from this study unequivocally demonstrate that the V-firing pattern is the optimal choice for controlled rock fragmentation and efficient excavation. This results in well-sized fragments with a 3-meter drop, 5.9-meter throw, and 19.3-meter lateral spread, improving muck- pile stability and operational efficiency. The spacing-to-burden ratio of 1.35 optimizes energy distribution, balancing vertical drop (5 meters) with enhanced lateral spread (21 meters). This ratio reduces vertical energy dissipation, improving fragmentation and operational efficiency. A decking length of 1 meter further enhances performance by concentrating explosive energy in a smaller vertical zone, ensuring controlled fragmentation and a stable muck-pile. These findings underline the importance of combining the V-firing pattern, spacing-to-burden ratio of 1.35, and 1m short decking lengths to achieve the most efficient and economical blast design. Such an approach not only improves excavation efficiency but also contributes to the economic viability of the operation by minimizing the need for secondary blasting and optimizing loading cycles. The reduced vertical drop and enhanced lateral spread allow for efficient rock displacement, improving the overall productivity of the mining operation and reducing the operational costs associated with excavation and loading. Future research will focus on expanding the methodology to deeper benches and different rock types, integrating real-time blast monitoring, and developing AI-based decision tools capable of predicting muck-pile characteristics prior to blasting at mine-wide scale. This will enable continuous optimization of blasting operations, allowing dynamic adjustment of design parameters to further enhance productivity and sustainability in mining operations.

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