Application of UAVs to Support Blast Design for Flyrock Mitigation: A Case Study from a Basalt Quarry

Blasting operations in surface mining pose a risk of flyrock, which is a critical safety concern for both personnel and infrastructure. This study presents the use of unmanned aerial vehicles (UAVs) and photogrammetric techniques to improve the accuracy of blast design, particularly in relation to controlling burden values and reducing flyrock. The research was conducted in a basalt quarry in Lower Silesia, where high rock fracturing complicated conventional blast planning. A DJI Mavic 3 Enterprise UAV was used to capture high-resolution aerial imagery, and 3D models were created using Strayos software. These models enabled precise analysis of bench face geometry and burden distribution with centimeter-level accuracy. The results showed a significant improvement in identifying zones with improper burden values and allowed for real-time corrections in blasthole design. Despite a ten-fold reduction in the number of images used, no loss in model quality was observed. UAV-based surveys followed software-recommended flight paths, and the application of this methodology reduced the flyrock range by an average of 42% near sensitive areas. This approach demonstrates the operational benefits and enhanced safety potential of integrating UAV-based photogrammetry into blasting design workflows.