TITLE:
Comparative Analysis of the Conventional Blasting Technique to the Double Saver Plugs Technique Based on Pit Floor Conditions and Cost Evaluation
AUTHORS:
Akuba Bezeba Yalley, Francis Hackman
KEYWORDS:
Saver Plugs, Conventional Blasting Techniques, Pit Floor Analysis, Explosives, Open Pit Mining
JOURNAL NAME:
Journal of Geoscience and Environment Protection,
Vol.14 No.7,
July
28,
2026
ABSTRACT: This study evaluates the performance of double saver plug blasting relative to the conventional blasting method at the Huni Pit Cutback of Abosso Goldfields Ghana Limited, Damang mine with emphasis on cost efficiency and pit floor quality. The motivation for the study stems from operational challenges associated with conventional blasting, including high explosive consumption, hard digging, uneven fragmentation, and poor pit floor conditions. A comparative case-study approach was adopted using operational data collected between May and November 2022. Three conventional blasts and three double saver plug blasts were analysed. Cost analysis was performed using Microsoft Excel based on drilling geometry, explosive consumption, and saver plug costs, while pit floor analysis was conducted using Geovia Surpac 2021 from post-mining survey pick-ups and Digital Terrain Models. The results indicate that the double saver plug method reduced the explosive column from 7.0 m to 5.5 m and lowered the powder factor from 0.61 to 0.47 kg/m3. Across the three blasts analysed, total blasting cost decreased from US$44,683.481 for the conventional method to US$37,780.451 for the double saver plug method, representing a saving of US$6903.030. On average, this corresponds to a saving of US$20.667 per hole and approximately US$2300.919 per day, with a projected annual saving of US$773,108.784 under similar operating conditions. Pit floor analysis further showed that both methods achieved acceptable floor conditions within the mine’s tolerance of ±0.3 m; however, the double saver plug method performed better, with 98% of the floor area rated as good compared with 95% for the conventional method. Overall, the findings demonstrate that double saver plug blasting offers a more cost-effective alternative to conventional blasting while also improving pit floor quality. The study therefore recommends the continued application of saver plugs, subject to proper installation and supervision, and further investigation into their effects on fragmentation and environmental performance.