S 679 .M5 Copy 1 Clearing- Land ^ Rocks ior Agricultural and Other Purposes By J. R MATTERN Published by The Institute of Makers of Explosives Room 902, io3 Park Ave., New York Clearing Land of Rocks for Agricultural and Other Purposes By J. R. MATTE RN Published by The Institute of Makers of Explosives Room 902, 103 Park Ave., New York Copyright, igi8 By Institute of Makers of Explosives INSTITUTE OF MAKERS OF EXPLOSIVES Organized July 15, 1913 MEMBERS AETNA EXPLOSIVES COMPANY, Inc. New York, N. Y. ATLAS POWDER COMPANY Wilmington, Del. AUSTIN POWDER COMPANY Cleveland, Ohio E. I. DU PONT DE NEMOURS & CO. Wilmington, Del. EGYPTIAN POWDER COMPANY East Alton, 111. EQUITABLE POWDER MFG. CO. East Alton, 111. EXCELSIOR POWDER MFG. CO. Kansas City, Mo. THE GIANT POWDER CO., Cons. San Francisco, Cal. THE GRASSELLI POWDER CO. Cleveland, Ohio HERCULES POWDER CO. Wilmington, Del. ILLINOIS POWDER MFG. CO. St. Louis, Mo. KING POWDER COMPANY Cincinnati, Ohio MONONGAHELA POWDER CO. Fairmont, W. Va. SENIOR POWDER COMPANY Cincinnati, Ohio STANDARD POWDER CO. Philadelphia, Pa. UNITED STATES POWDER CO. Terrfci-Haute, Ind. MAY 24 1918 How weeds and briars grow up about a boulder in a field. In this case the stone itself is not very large, but the total land area put out of business is three times as much as the stone covers. INTRODUCTORY THIS bulletin is published by the Institute of Makers of Ex- plosives. The aim is to give the united conclusions and the sum of the experience to date of nearly all makers of explosives and of farmers who have dealt successfully with the problem of boulders and ledges in their fields. The material has been classified and assembled so any phase of it will be available easily and quickly. Uncertainties have been eliminated as much as possible in favor of known facts and formu- las established by actual experience. It is offered as a manual or handbook for farmers, home and road builders, contractors, park makers and others who must remove rocks from land, and as a textbook for students of agriculture. Readers will find that the recommendations are impartial, and that the suggestions on that part of the work which can be done best with explosives are particularly complete. Boulders and Ledges of Rock Eight generations of farmers have picked stones off the fields of a great many farms in this country, and in these same fields all the boulders too big to be moved by the direct strength of men and horses still arc dodged by the present farmers. Some land cleared and farmed as long ago as the Revolu- tionary War has not had the "niggerheads" removed to this day. Those stones that project above the surface of the ground can be avoided, but those hidden underneath are more serious trouble makers. The man who works his own land for years gets to know where they lie, and can escape them to a certain extent, but it is by broken plowshares that a new plowman learns their location. In former years, before the value of land began to increase as it has of late years, farmers found more profit in locating a new acre that had fewer stones or none at all than in removing those from a stony acre. But that time is past. Farm land today can be made to pay without removing the boulders, but not the full hundred cents from each dollar earned by the work and ex- pense put on it. Stony farms can be sold, but not for big prices. Thoughtful farmers remove the rocks. It is surprising how much there is to know about the disposal of boulders. Too often this work has been attempted in ways that were crude and wasteful of energy and time, and considering these items, very expensive. This is partly due to the lack of published data describing easier, simpler ways. The up-to- date farmer will not tolerate methods that are wasteful or unprofitable. He may find the information he wants in the following pages. The Profit and Loss Account of Boulders The interference of boulders and rock ledges with farming operations and profits takes many forms, and its cost can be estimated from a glance at a few of them. This is the sort of perpetual tenant which pays no rent, and on which this bulletin declares war. 4 On ground where a cultivated crop is grown, each boulder causes the waste and loss of about half an hour per year of the time of a man with a team, worth five dollars a day. Four seasons' loss will remove the Time Lost . stones. They ",eat their heads off" as the saying goes, ten or more times during the active lifetime of the average generation. In addition, the breakage and damage to tools and machines may amount to as much in total loss as that from waste of time. This is particularly true of those farms where modern heavy implements are used, as, for instance, the heavy disc harrows for four or more horses, the gang plows, and all the tillage tools pulled by traction engines. Tractor plows and harrows are sure to be broken in stumpy or rocky land. It is impossible to make good time with gang plows or harrows among boulders, because of the constant stopping necessary, and besides, the work done is bound to be poor. Ten to twenty boulders to the acre are just about as bad as 100 for the man with the engine imple- ments — they make good work and speedy work impossible. About each rock that sticks above the surface some weeds are sure to grow. There never is the stone, or log, or stump, on or in Weed Breeding the ground but where you can find a thistle or two, or several specimens of other equally noxious plants, growing close to the edge or out from under it. These single weeds re-seed entire fields. Another feature of the loss sometimes caused by tight stones in fields is the injury to horses and men caused by the sudden strain and jerks. Horses sprain leg joints, shoulders, hips and backs. Many Danger to Horse spavins have their beginning in the ugly twists sustained, and Men Brood mares often are caused to lose their foals prema- turely. The baffling for which stones are responsible is one of the most common causes of balkiness of farm horses. A team can be ruined in a short time by such treatment. The danger to men is not so common, but when it does come it comes heavily. The records of the past generation show that many a farmer was struck with a plow handle when the plow point encountered a stone that was tight. Sometimes the result is a broken arm or hip, or rib, or worse still, a rupture. The newspapers frequently report accidents caused by the driver of a mowing machine being thrown from the seat into the knives, or under the heels of the horses, when the machine suddenly struck tight obstructions such as stones. The direct loss of crops which would grow on the land occupied by the boulders need not be stated in figures. Every farmer knows that the loss of corn, wheat, or hay on a square rod amounts to 1 5 to 50 cents a year. Tight stones on a farm are bound to keep its selling Low Land Value value down. One of the first things a shrewd buyer of and Increase land will want to know is whether the soil is free of rocks that interfere with cultivation. One of the easiest and surest ways of increasing the value of land, for selling, for actual use, and in the estimation of other people, is to clear away the boulders. The stones themselves may not be without value when they are broken up in pieces small enough to handle. It is well for every farm to have a pile in seme convenient place, where they can be had any Value of Stones time they are wanted. They are valuable for building material, and in drains and walks. At the rates prevail- ing in many places it is easy to collect fifty dollars' worth of stone right 5 near where it Is needed and save both the cost of the stone and most of the expense of hauling. Some of the more common purposes for which stones are valuable on farms are for blind drains, for lining ditches along roads or in fields, where the water gouges out the sides or bottom on account of a grade or turn, for road founda- tions, for repairs to walks, for constructing steps, chimneys, walls, etc., for fill- ing in concrete construction, and for building garages, houses, barns and silos. Clearing land of boulders should not be regarded as an expense, like taxes, or like the cost of shoes to wear. It is an investment, like the purchase of Government bonds, or like the purchase of shoes by a storekeeper, to sell again. When money is spent for removing boulders by a farmer, he is buying something — the clean land — that at once begins to pay back the cost of the work. It pays for itself within three or four years and then keeps right on pay- ing dividends year by year. Kinds of Rock and Their Nature It helps if you know your rock when you go to break it up, for many different kinds exist as boulders and ledges on farms and in roads. In some sections the term "hardhead" is used to describe one kind of boulder. Another term is "niggerhead." It is better to know the rocks by the names which designate their real nature. Rock Qualities What does make a difference is that some stones are easy to break and others are not. To understand why, a study of the stones is necessary. Their resistance depends on their comparative hardness and toughness. These two qualities must not be confused, for they are not the same. Hardness and To illustrate, window glass is hard, but not tough. It will Toughness scratch very hard steel, but will shatter under a light blow. Untempered iron is tough, but not hard. It can be ground away rapidly by a stone, or scratched with glass, but it is extremely difficult to break by pounding or twisting. To some extent stones possess the same qualities, and in addition almost all of them have one or more lines of weakness. Most rocks have a grain, not unlike the grain of wood, and will split more easily along the grain, and less easily in any other direction. It is safe to say that all rocks have joints running in one direction, and some rocks have two sets of joints running at right angles. The joint lines may not be visible, but the force of a blast or of a sledge will find them. There is still another sort of weakness in rocks with which the blaster should be famil- iar. This is the bedding plane, or layer — with lines running at right angles to both joint-lines mentioned. Some knowledge about the joints and natural cleavage planes makes the breaking of rocks easier. Even the most massive rocks are divided into blocks of varying sizes, making them split in some direc- tions easier than in others. The cracks will tend to stop short and splinter out or to run entirely through the stones, depending on the toughness of the rock, while the blocks will or will not crumble much according to their hardness. Description of Rocks In these brief remarks we will make no attempt to give the geological classification of the rocks, but will try to identify the typical rocks found as boulders and ledges by names which are used most generally, and to make 7 How the seam and joint lines crisscross in most stones. A little inspection of a stone nearly always will show a spot where the force can be applied to break it with much less force or greater effectiveness than if the stone is attacked at solid spots. Two fields which will cost $50 to $200 or more an acre to clear of stumps and stones. If the land can be used for residential purposes or for some form of intensive farming like trucking or fruit growing, it will pay to clear such places, but it will not pay to clear them for general farming and pasture purposes. clear their nature. Common names for different kinds of rock or stone are not always satisfactory because the common name applied generally to one kind of rock in certain localities in numerous instances is applied to an entirely different kind of rock in other localities, but it is hoped that any confusion will be limited. These three classes of rock seldom exist as boulders, though they some- times interfere with cultivation in the form of ledges close Talc, Gypsum to the surface of the ground. In this shape they nearly al- and Shale ways are full of two sets of joints, and lie in thin beds. Some- times the seams are so close together that the rock breaks up into blocks only an inch or two square. They are fairly tough, are inclined to crumble rather than split or crack, when struck with a sledge hammer, and are easy to drill. Usually takes the form of flat boulders on the surface in fields or of ledges which project almost to the surface or above the surface several Limestone feet. Limestone generally has two systems of joints. It also has bed lines wide apart — a foot or more. This kind of stone nearly always is tough, breaking off, rather than splitting far. Its hardness varies. The boulders of this class frequently are nearly round. Slate rock is char- acterized by a thin shingle structure. The leaves are less than a quarter Slate of an inch thick. There are joints as well. The stone is tough, break- ing only a short distance (but splitting on cleavage lines easily), soft, and inclined to crumble. Occurs as boulders of every shape and size, and as ledges of all sorts. The ledges usually are stratified — that Is, in beds of a thickness of one, 2, 3 or more See picture on preceding page feet. It has frequent joint lines running in two directions, and it breaks up into irregular sized blocks of more or less rectangular shape. The Sandstone sand particles which compose the stone are very hard. When the cementing material is silica the stone is blue or white, and much harder than when of an iron origin, making a brown or red stone. For purposes of drilling, blue sandstone must be classified as a hard rock, and brown sandstone as softer rock; and for breaking purposes, both kinds may be listed as soft. It crumbles easily, and is rather tough. These rocks and others like them in structure lie Lava, Mica Rocks, in layers from 2 to 100 feet thick. They have no Feldspar other bed lines, but they have infrequent joint lines. Lava, excepting that of the pumice type, is hard and brittle. The boulders split fairly easily into pieces of irregular shape and size. A mixture of various rocks, such as slate, sandstone and the like, often in the form of pebbles cemented together, making a rock that lies in beds. It may be crystalline and very hard — even flinty — or it may be Conglomerate only medium hard. The boulders are rather brittle than tough. Joints in one direction are located wide apart. Boul- ders of conglomerate rock sometimes have a ball-like structure, with layer after layer 1 to 6 inches thick, and joints every 2 to 4 inches. The layers of such rock crack off like the skin of an onion. Occurs often as boulders, though frequently there are granite Granite ledges. Granite is of a layer structure, with frequent joints. It splits easily. It is not particularly tough, and is hard to drill. Some granite breaks easily while other is difficult to shatter. These rocks are very different and can only be classified together when referring to methods of breaking them. They Marble and other hard, are fine-grained, and have no distinct bedding tough rock, such as planes. They do not break up in layers. They Quartz, Trap, Porphyry do break along joint lines. They are sometimes quite hard, but not very tough, and except trap rock, which is tough, often shatter easily. The boulders are numerous in some sections of the country, and ledges are not infrequent. Seme rocks are full of irregular cavities resembling General Features bubbles, and these generally make the breaking easier. The cavities interfere with the regular joint lines and cause the splitting to take place along new lines of weakness. The amount of force required to break a rock depends on its hardness and its relative toughness, and on the lines of weakness or cleavage which run through it. Hard rocks usually crumble less easily than soft rocks, but generally split better when once started. Tough rocks are hard to split into small pieces, while brittle ones shatter to bits under a proper blow. The point at which the force should be applied for the most and quickest breakage depends on the structure of the rock and the direction and frequency of bedding and joint lines. 10 Eight Methods Methods of Clearing Away Rocks Rocks too large to be pried out and loaded for hauling by hand, and tight ledges, must be broken. Following is described eight methods of breaking them. Each method has advantages under certain conditions, but some are much more serviceable, convenient and easy than others under most circumstances. List of Methods Hauling: Consists of either dragging with chains or loading on sled or wagon. See page 31. Sledging: Consists of hammering them into pieces small enough to handle. See page 14. Burying: Needs no description. Seepage 14. Breaking with fire: It is possible to break many kinds of rocks in this way. See page 14. Plug and feather breaking: Intended for splitting out building stone. Consists of drilling a series of small holes in a line across a boulder, and then driving into these holes special steel wedges. Blasting by drilling: Called "blockholing" when referring to boulders. See page 23. Blasting by undermining or underdrilling: Called "undermine blasting" or "snakeholing." See page 19. Blasting by mudcapping: Also called "doby shooting," "plastering" or "blistering." Seepage 15. Choice of a Method In the practical handling of rock clearing, the elements to be considered are the costs of labor and material re- quired. These are governed by the nature and amount of rock to be broken. Time is also an important factor. The softer and more brittle boulders, if they are not large, may be dis- posed of by any of the above methods. Very hard and tough rock cannot be Cost, Men, Time and other Factors How a boulder can mar the appearance of a farm from the roadside view. Such a stone leads possible buyers of a place to think that the field contains many such. '■■rrmr. 1' *'')|fV«pipa[?^ The disposal of this partly buried boulder called for rolling it out of its bed in the ground without breaking it, and then mudcapping it. It was rolled out with one stick from the position shown in the first picture, and (see next page) sledged into pieces successfully. When such rocks are to be blasted they should be drilled (blockholed) rather than mudcapped or undermined. Ledges of rock always should be broken up by blasting drilled holes. The limits of size of rock at which mudcapping becomes impracticable are explained on page 1 5. Labor conditions are important. On some farms men are very scarce and wages are high. At other places there are periods when laborers are practically idle and can be put to disposing of stones, without much extra cost. In the former case it is wise to let explosives do all the work possible with no more drilling, sledging, handling and hauling than absolutely necessary. In the latter case the amount of explosives used should be kept down, and the idle men left to do the resulting extra work. The time element is equally important. If nothing else demands the at- tention of the men on the farm, a slow method is all right, but when stones must be removed in a hurry, the quickest method probably is the cheapest in the end. When the cost must be kept down as much as possible, and when easier and better methods are not available, burying and breaking by fire may be resorted to, provided there is labor available at little cost. Sledging, when practicable, is a cheap method if labor and time are not considered, provided good sledges are available. But it is slow, hard work. This applies to any way of disposing of rocks except blasting. If the conservation of energy as well as of time and men is desirable, the use of high explosives is the only method to consider. Mudcapping is the easiest way to blast boulders in most instances, but takes the most explosive of the three blasting methods. It seldom should be attempted with boulders containing more than 15 cubic yards of stone unless they are thin slabs, and is expensive with trap rock or other very hard and tough material. Rocks should be flat rather than round, or at least should have a flat side on which the charge can be placed. mudcapped a few days later with five sticks with the result shown in the second picture. Note that the entire rock has been reduced to small fragments requiring no further handling. Undermining or " snakeholing " has practically the same effect as mud- capping, though it requires less explosives and, usually, a little more work. Blockholing, though effective and economical, requires time and tools to drill the holes. Mudcapping and undermining are pre-eminently the methods to use where there are only a few boulders to dispose of, since one man can do in an hour by these methods what it would take much longer to do by any other method. Stones that are deeply imbedded should be under- mine blasted lightly to roll them out, or at least to loosen them, before they are mudcapped. Some very large stones should be both undermined and mud- capped, with two or more charges fired simultaneously with an electric blasting machine. Other combinations of methods will suggest themselves to a resourceful blaster. Study the rock. If it is imbedded, roll it out by undermine blasting as above directed, and examine it on all sides. Usually you will find that an undermined or mudcap blast, unless the charge of explosive has been small, will break up the boulder and make blockholing unnecessary. 13 Detailed Directions for Disposing of Boulders Small boulders, weighing only 100 pounds or so, may be dug out and rolled into wagons on planks, or dragged off the field with chains. With Digging Out larger stones, hauling is slow business, and is likely to result in injury to men. The hard straining required to lift the rocks, added to the danger from the falling of heavy stones, makes what would seem to be one of the simplest and safest of jobs an exceedingly hazardous one. A practicable method of disposing of rocks is to break Sledging Rocks them up with sledges. Use heavy sledges -the heavier the better. 1 he tough rocks are almost impossible to break in this way. It is impractical to sledge up large rocks of any kind. Pay particular attention to the direction of the grain and the lines of cleavage. A blow right at a vital point often will break a rock in two when you could hammer away an hour at another part without much effect. When you sledge rock, there is much danger from flying bits of stone, and it is a good plan to wear gloves. Tie your coat sleeves over the gloves or the gloves over the sleeves, turn your collar up, wear a cap which pulls down over the ears, and wear goggles. If you have no goggles, be careful to shut your eyes when striking the rock. One way is to dig a pit alongside the stone, and tip it over. This is suit- able for stones that can be pried over. Large stones must Burying Rocks be undermined and let sink down slowly. Let each end down separately. Extreme care must be used in this oper- ation to prevent the rock from rolling on the man who digs. Burying heavy stones is a dangerous operation, and has crippled and killed many a man. Burying rocks is open to the objection that at some time the work may have to be done over again, on account of not getting the top low enough. Frost, erosion, and other forces gradually have the effect of bringing the stones to the surface. If the rock is large, it will interfere seriously with the growth of anything planted over the spot. Buried stones are beyond your reach if needed for building purposes. Dig a trench round the stone to be broken, as deep as the stone goes, or somewhat deeper. Gather a cord or two of wood to start with. Have plenty of large pieces^logs and the like. Build your fire, and see that it gets intensely hot. After it burns four or five hours, and the stone is thor- Fire Breaking oughly heated all through, suddenly draw away the fire and throw on several buckets of cold water. It will snap and crack. Pieces will shell off the surface. Rake these away and renew the fire for another several hours, and repeat the water application. Gradually you will be able to wear the rock down and crack it entirely through. After two or three of such burnings you will be able to pry open the cracks that are formed and sledge up the remaining large pieces. Be careful to keep out of the way of flying fragments when you throw on the water. Stones also often break with a loud crack when the fire gets very hot. See that none of the pieces strike you. In addition to their force, they will burn like melted iron, for they are almost red hot. One small piece in your eye may destroy the sight. The easiest way of breaking stones is to do it with high ex- Blasting plosives. The directions for this work are given in full detail, with careful attention to mudcapping, blockholing and undermining or "snakeholing," and to combinations of these. In order to do the matter justice it is placed in a separate chapter. 14 Blasting Boulders and Ledges All of the methods described in the preceding chapter are more or less useful, but in actual practice the disposal of boulders or ledges nearly always will be impractical unless you use explosives. Mudcapping Rock Briefly, mudcapping rocks consists in placing the explosive in a neat pile on a face of the rock, covering it with about 6 inches of stiff wet clay, and ex- ploding it. When done right, the force of the explosion breaks the rock. It is the enormous speed of the gases which accounts for the success of such a blast — the time element. Mudcap blasting is made possible by the intensely fast shattering action of some of the modern high explosives. It can- not be done satisfactorily with black powder nor with the slower kinds of high explosives. Owing to the resistance of the air and the inertia of the material in the mudcap, the gases strike the rock like an enormous sledgehammer swung at a rate faster than the eye could follow. Such a blow, if in proportion to the size and strength of the stone, is sure to shatter it. Of the three distinct methods of blasting, mudcapping is Description the best one to use when the boulders to be broken are flat and brittle and smaller than 5 or 6 feet across. Probably the most economical mudcapping per cubic yard of rock is in blasting sandstone boulders having flat sides, and containing 4 to 6 cubic yards. Some sandstone is brittle, yet hard to drill, therefore should be broken by mud- capping. Shale, slate, conglomerate and other such rocks break very success- fully under mudcap blasts. Mudcapping is less satisfactory, owing to greater quantity of explosives required, when very hard and tough rocks such as trap, etc., are to be broken. In fact, mudcap blasting had better not be attempted on hard, tough rocks that are more than 3 feet in diameter unless no drills are to be had, and the stone must be removed immediately. If the stone lies free on the surface, it is ready for the placing of the ex- plosive. If it is buried in the ground more than a foot, it is a good plan to dig or blast away the dirt before attempting the mudcap blast. One way to do this is to dig a trench round the stone, to within a Preparing the Rock few inches of its bottom. Another way is to place one or more small charges down alongside the stone and to loosen up the dirt or throw it away from the sides, but in such a way as to leave the ground firm and undisturbed underneath. A third, and probably the best way where the stone is almost buried, is to explode a slightly larger charge down under one side of the stone to roll it out of its bed, and onto the surface of the ground. Then it is ready for mudcapping. In determining the best point at which to place the explosive, considera- tion of the principles of rock structure, as outlined on pages 7 and 9, should be the basis. Study the make-up of the rock and de- Locating the Place termine the directions in which it will split the easiest. for the Charge Look for and work for the hair-thin but far reaching seams. Clean the dirt or dust from likely-looking places. The joint lines most of the time will be hardly visible, yet they are important if the most complete and economical breaking is to be secured. Some workers say that they put the explosive where they would hit the stone with a sledge if it would be possible to break it with one blow. The big 15 thing is to get the explosive at a vulnerable point on the rock, whether this is top or sides. It may be necessary to support the explosive and its covering of mud with a banking of dirt, or with props from the ground, if the charge has to be located down along the side. It is better to place the explosive in a depression or hollow on the stone, or at least on a flat face, than on a round or bulging surface. A round face acts to some degree as an arch, and resists the blow of the explosive much more than a flat face. A depression gives the explosive some confinement that en- ables it to do better work. In placing the explosive it sometimes is well to deepen crevices or de- pressions with a drill or cold chisel, in this way making what might be called a semi-mudcap out of the blast. Such a blast is more efficient than when the explosive is placed on a flat or rounding surface. If it is desired to break the boulder or rock into pieces of certain shapes and sizes, make channels across the face with a chisel or mason's hammer and place the explosive in these channels. The process is like breaking ice by chopping channels across it. This treatment gives rough dimension pieces, but it may increase cost. The charge of explosive ordinarily should be placed in a low cone at the point selected on the rock. If less than four sticks are to be used, it is well to take all the explosive, except ^ 2 stick for priming, out of the paper wrapping and press it into place. If the charge is large, one or Putting the more of the sticks can be left intact and bedded in loose Charge in Place explosive. Sometimes the sticks bed-in better when cut in two. The explosive should not cover much area on the stone, since widely spread charges tend to distribute their force and have lower breaking ability. Sometimes it is a good plan to place the explosive in a How a mudcap charge is pressed down on a flat side of a boulder, with fuse projecting from the mud, and how a boulder is broken up. This charge was placed properly and was of the right amount. Note that none of the pieces were thrown far, though the stone is well broken up. 16 long, narrow mass— if there is a long depression, or crack, or the rock is much longer than it is broad. Thin edges of the mass should be pressed in and made steep and square. Before all of the charge is in place, put in the cap with fuse or the electric blasting cap. See pages 34 and 41. The best way is to prime a part of a stick of explosive in the usual way and bed this in the Inserting Cap loose explosives. If you decide to do this, stand the primed powder on end, with fuse or wires projecting from the top, and the closed end of cap pointing toward the center of the whole charge and then press the rest of the loose explosive about it. If a primer of this kind is not used, the cap must be inserted directly in the charge. To do this punch a hole a little larger round than the cap about one-third of the way down in the top of the charge. The cap should be in the upper third of the charge. To place the cap deep in the mass might lower the efficiency of the blast. Use the handle of the cap crimper or a blunt-pointed stick for punching the hole, as directed on page 38, and see that the cap is pushed to the bottom of the hole and that the explosive is pressed closely around it. The covering of mud should be put over the charge carefully. Be sure that the cap is not pulled out of the explosives during the covering operation, or later. The mud cap should be, preferably, of stiff wet clay. If clay cannot be got conveniently, use the heaviest earth you can find. The Mud Covering Sand is the least satisfactory material, but can be used if made thoroughly wet. In any case, the mud- cap must be MUD and not dust. At least 6 inches of mud cover should be placed over the explosive. This means 6 inches of covering in all directions over all of the charge. If the charge is 6 inches broad, then the mudcap would cover at least 18 inches of the rock, with the charge centered under it. To make a mudcap when the surrounding ground is dry, it is a good plan to gather and mix the mud in an old dishpan or box. Then to apply it on the rock simply turn the pan or box over at the right place and press the mud down so that no possible air spaces remain be- tween it and the explosive or the stone. Be careful that there are no stones in the mud covering. They fly like bullets when the charge is fired. The amount of explosive to use depends on the size and shape of rock and on its toughness and hardness. Below is a table which will serve to guide the blaster. These figures should be high enough to Amount of Explosive cover tough stones. Less explosive may be used for rocks that are easier to break. Rocks smaller than one cubic yard require more explosive than their size-proportion. Approximate Number of Pounds of Explosives Required for Mudcapping per Cubic Yard of Rock Sandstone, slate and similar soft or easily broken rock . I lb. Limestone and other intermediate rock II-4 lbs. Marble, trap, granite and similar hard tough rock. . . .2 lbs. While this table serves as a bsais for calculating the amount of explosive required to break boulders, it is only approximate, as the weight of the charge does not continue to increase according to the number of cubic yards in the boulder. Some blasters may prefer the following table, which gives the approxi- mate number of sticks required for each diameter of stone. 17 Number of IJ4 x8 Inch Sticks of Explosive Required for Mudcapping Boulders of Different Sizes Sandstone slate and similar soft, Limestone and other Marble, granite, trap more easily broken rock intermediate rock and hard, tough rock IHft. greatest dia. ^4 sticks 1 3/^ sticks 2}/^ sticks 2 " " 132 " 2 3 2^ " " m " 23^ " 33^ •' 3 " •' 2 2^-3** 4 4 " •' 4-5 " 5-7 " 5 " " 7-10 " Charges in mudcap blasting may be fired by either Firing Charges fuse and caps or by the electric method. The advantages of each method are discussed on pages 50 and 55. The electric method is the only one that can be used when more than one charge is to be fired at the same time. The kind and grade of explosives best to use for mudcapping rocks is one having a very quick action of great shattering or disruptive power. The best explosive for this purpose is one of 40*;;, 50' , or 60', strength. The straight nitroglycerin dynamites or powders are a little quicker in Kind and Grade action than the "extra" or ammonium nitrate explosives, of Explosive and for mudcapping should be the first choice. See page 44. But the ammonium nitrate dynamites or powders are equally powerful, when of equal percentage strength, and though they are slower in action, tending to break the rock into larger pieces than nitroglycerin explosives, their work is satisfactory for mudcapping. When another explosive than those recommended above is on hand on account of some other use, it may be used for mudcapping with success, though its use may be more expensive. Almost any dynamite or high explosive powder, for farm, mine or quarry work, may be used in an emergency. Even the 20 '"^ high explosives that are best for soil blasting can be made to break rocks in this way, though their performance will not be very satisfactory. When these lower percentage explosives are used, particularly if of the ammonium nitrate type, the quantity must be increased greatly. The use of such explosives will result in cracking the stones into a few large pieces rather than into many fragments. Whenever there is much mudcapping to do it will pay to get the proper explosive. In cold weather, use only the low freezing grades of these explosives. The only tools necessary for mudcapping are a shovel, a pocket Tools knife and cap crimper, though an old dishpan or similar receptable and a water pail often can be used to advantage. Breaking average sandstone boulders by blasting by the mudcap method on some jobs has cost fifteen to twenty cents per cubic yard. Granite, limestone, marble and trap rock boulders have been broken for slightly Cost and Time more. Mudcapping costs per cubic yard of rock run up fast when the boulders are very large, say larger than 6 to 8 cubic yards each. Trap and other tough rocks are expensive to mudcap. The shape of the rocks has much to do with the cost and practicability of break- ing them in this way. The approximate cost of mudcapping can be computed on the basis of the amount of powder required as given in table on page 1 7. The time required to mudcap rocks is very little. When wet ground for the mudcap is at hand, a man can have a stone lying round in pieces within 10 or 15 minutes after he 18 gets on the ground. Many practiced blasters use no more than 5 minutes for each boulder. Three feet of fuse burns about a minute and a half and under ordinary conditions is enough to permit the firer to reach a place of safety. If an electric blasting machine is used, the operator should stand at least Suggestions 250 feet away, and should watch for and dodge any flying piece of rock coming in his direction. Avoid standing behind a shelter that may let stones through, as the branches of a tree. See page 55 for dis- cussion of misfires. A rock will often break better if it is jacked or pried from the ground and allowed to rest on small stones under the ends or corners. Sometimes odd shaped rocks, particularly if they are long, are broken better with two or more mudcap charges placed at different points and fired simultaneously by the electric method, than by one charge. Usually it will be best to locate such charges on opposite ends of the rock, though this rule is not good every time. Sometimes one may be a mudcap and the other a snakehole or undermine charge. Before proceeding with any mudcapping, read the chapter of this bulletin beginning on page 43, about the nature of explosives, detonation, tamping, freezing, thawing, etc. The result to be expected from a successful mudcap blast is to break the stone into a great many pieces, none of them too large to handle. If a heavy blast is used on a small brittle stone, half or more of the stone may be almost powdered, and few or none of the pieces may be much larger than a man's fist. Two pictures : How a proper undermine blast can be made to break a stone that is partly buried. Two charges of 50 per cent, ammonia explosive were used under this stone, and fired simultaneously, with the result shown. Undermine or Snaliehole Blasting To break a stone by the undermine blast method, the charge of explosive is placed against the under side or bottom of the stone with the solid ground as its backing. Less explosive is required than with a mudcap. Description since the confinement is better, owing to the earth backing and the weight of the stone. This method is superior to mudcapping because less depends on the shape of the stone under the ground or the depth it is buried, which are always hard to determine with certainty. 19 Undermining or snakeholing works better when the stone to be broken has a flat side down, and with flat boulders rather than round ones. To shatter a stone by this method, as by other methods, due attention must be given to the hardness, toughness and seams. Locating the Holes as outhned on pages 17 and 19. When a boulder is well buried the first thing to do is to probe about it with a sharp quarter-inch steel rod, to learn the shape of the under side and the condition of the ground. In any case, the charge of explosive should be placed as near as possible underneath the center of weight of the rock. Holes for the explosive can be made with a crowbar and sledge or with a dirt auger. The crowbar likely will be the most serviceable. If the hole is not large enough to hold all the explosive required at the right Making Holes point, you can make use of a scraper to enlarge the hole at the bottom. See page 31 for description. In blasting very large rocks, small tunnels can be shoveled out. The practice of enlarging the bottom of the hole by "springing" with an inch or so of a stick of explosive, is seldom to be recommended in undermine blasts of stones, on account of possibly enlarging the cavity too much and forming cracks extending into the surrounding earth. The explosive should be placed as nearly against the rock as possible. When the rock is undermined by digging, the explosive should be packed in a compact bulk, as in a mudcap charge. If you get the Placing the Charge charge an inch or two away from the rock with dirt between, its breaking effect on the rock will be re- duced. Read the directions for loading a hole, on page 28, and for placing a mudcap charge on a rock, page 16. The stick of powder containing the blasting cap should be the last or next to the last to go in. The cap should not be against the rock. Inserting Cap but if possible in the outside portion of the charge. The business end of the cap should be pointing directly toward the center of the charge. The charge must be thoroughly and tightly tamped. If there is not good firm resistance all the way round it will blow the dirt out from under the rock without doing any stone breaking at all. It is a good plan sometimes to tamp the dirt the whole way round the stone before the charge is exploded. Never use a metal tamping rod in the hole or near the charge of explosive. It may strike sparks from the rock or from small pieces of stone, and cause a premature explosion. Firing the charges may be done either by the cap and fuse method or with electric blasting caps and blasting machine. Each method has its advantages and adaptations to certain conditions as fully explained on pages 50 Firing and 55. How to prepare charges, including the fixing of the fuse and cap, inserting and tying them in the stick of explosive and other de- tails, are told on pages 33 and 42. The amount of explosive required to shatter rocks by the undermining method depends on the size, shape, toughness and hardness of the rock. The table here will serve as a guide. These figures Amount of Explosive should be high enough for average tough rock, but it must be remembered that the amount of explosive required does not always change according to the size of the rock to be blasted. 20 Approximate Number of Pounds of Explosives Required for Shattering Boulders " Snakehole " by Undermine Blasting, per Cubic Yard of Rock, Sandstone, slate and similar soft or more easily broken rock M lb. Limestone and other intermediate rock 1 lb. Marble, granite, trap and similar hard, tough rock 13^2 lt)s. Some blasters may prefer a table based on the diameter of the stones. Such a calculation can be used satisfactorily, but in this case, too, a great deal depends on the shape of the boulder. Approximate Number of \^i by S inch Sticks of Explosive Required to Shatter Boulders of Different Sizes by Undermine Blast Limestone Sandstone }/2 ft. greatest dia. 1 stick 2 " " \H " 21/2 " " ^V2 ' 3 .. .. \H " 4 '« •• 3-4 " 5 " 6-7 ' and other tough rocks 13^ sticks IM " 2 4-6 " Marble, granite, trap and similar very hard, tough rock 2 sticks 3 If larger sizes are to be broken, better calculate the amount of ex- plosives required by the cubic yard basis. Your figures will be more accurate. When rocks are to be rolled out without shatter- ing, comparatively small charges can be used. The following table will give an idea of the amount of explosive necessary. Approximate Quantity of Explosive Required to Roll Out Buried Boulders dia 14 stick • ?4 .1 .2 l^ft. 2H " 3 " 4 " 5 " Larger sizes than listed require proportionately increased charges. The extent to which the boulder is buried and the nature of the ground also influence the amount of explosive required. Probably the most economical explosive for breaking rock in this way is 30% to 50% strength dynamite or powder of either the nitroglycerin or am- monium nitrate class. On account of the better confine- ment secured in this method, stones can be broken more effecti'^ely and successfully with slower and less power- ful explosives than by mudcapping. 20% to 40% strength 21 A striking illustration of the action of a proper under- mine blast. The rock is lifted a few feet and cracked, but is not thrown far. Look closely and you can see the cracks where they had begun to form at the instant the picture was made. Kind and Grade of Explosive explosives often will prove satisfactory. Any standard strength of nitroglyc- erin, ammonium nitrate or gelatin dynamite will do the work. To roll stones out without breaking them, the high percentage explosives can be used successfully, but they are not as well suited to the purpose as the slower ones, such as 20' ,' ammonium nitrate dynamite or powder. If you are buying explosives for breaking rocks, however, buy those best suited to the actual breaking, and do the rolling out of the stones with the same explosive. The tools needed in snakehole or undermine blasting of boulders are the testing rod or probe already mentioned, a shovel for handling dirt, a crowbar or dirt auger, a wood tamping rod V/l inches in diameter, and a cap Tools crimper. Several other items in the tool list can be made use of to good advantage where there are many stones to undermine. One is a 3-inch fence post, to tamp the ground tight about the edges of the stone. Another is the scraper, for enlarging the bottom of an auger hole. Undermine or "snakehole" blasting is a slightly cheaper method than mudcapping when conditions are favorable. It is often found that the cost per cubic yard increases with stones smaller than one cubic yard, and is very much less with stones containing several cubic yards. Sandstone Cost and Time has cost ten to fifteen cents per cubic yard to break in this way, and the other kinds in proportion. This is one of the most serviceable and satisfactory methods of blasting boulders. The cost can be calculated by referring to table on page 21. Add labor cost to the total for explosives. Sandstone and other such easily broken material can be broken up cheaply, while marble and trap come higher. Although the cost of explosives is somewhat less than with the mudcap method, this is partly offset by the additional labor required in making the holes in the ground. Ordinarily a man can make a hole and place a charge under a stone in 1 5 to 20 minutes. Combinations of snakeholing and mudcapping sometimes are effective with stones that lie on the surface of the ground or are imbedded only a little. ^^^/ ^TOff/V FUSE : FUSE /^/IVHED ' DANGEROUSLY JAMMED "^D/PT BETWEEN STICKS OF POWDER ^AIRSPACES'.-'':'' . \ ; ' <--4, A combination of evils. Such loading could not result in breaking a boulder. Note the seven faults. 22 To make use of the advantages of such a combination an elec- Suggestions trie blasting machine to produce simultaneous exploding is nec- essary. It is not wise to attempt the combination of top and under shots when a stone is buried deeply. Better roll it out first. Two points of caution are desirable. Beware of misfires. See page 55. Remember that snakehole or undermine blasting may throw pieces of rock with considerable force and range, but the danger can be reduced Cautions to a minimum if proper precautions are taken to see that every person and animal is out of range of flying rock and fragments. It is not unusual in snakehole or undermine blasting to see pieces of stone thrown more than 100 yards. Blockholing This method of breaking rock with explosives consists in drilling a hole into the boulder, putting the explosive at the bottom, tamping tightly, and firing in the usual way. It is remarkable how small a charge of explosive will break a big boulder, even of the hardest and toughest kind, when placed in this way. One stick of explosive in a drill hole 18 or 20 inches deep in a rock will do more damage than several sticks on the surface. The blockhole method of blasting is the best way of break- Description ing large, tough boulders that are not too hard to drill and which do not break well from a surface blast. Drilling and blasting in a similar way is nearly always the only practicable method of blasting ledge rock. The nature of the rock has a good deal to do with the point at which it is best to place the explosive. Ordinarily it will be found that the charge should be located somewhere near the center of the Character of Rock and boulder, though different kinds of rock require Placing of Explosives different depths of holes. A brittle rock which does not split well and a tough rock such as trap, must be drilled deep in order to break it right, while a shallow hole will give satisfactory results in a rock which is easy to split, or which crumbles apart like slate. A rule that may be applied to all rock is that the deeper the drill-hole, down to 3^ or 3 5 the way through the rock, the less explosive will be required, and the greater will be the execution of the blast. In boulders that are very hard, and so big that they require a large charge, it once in a while pays to drill a very small hole, and then spring this hole at the bottom by exploding at that point a small charge of explosive, using no tamping. Such a practice will be needed rarely in boulder blasting, though it is often useful in blasting out ledges. Holes may be drilled by one man alone, or by two or Drilling Facts more men. One-man drilling usually is the cheapest when holes are made by hand. The drilling can be done with ordinary hand hammer drills, with churn drills (finishing deep holes), or with machine drills. A hand drill is just a straight piece of drill steel, which is medium hard and very tough, with one end shaped into a proper cutting bit. This bit is ^ to 3^2 or more wider than the shank of the drill, with the Hammer Drills cutting edge somewhat rounded up to the corners and sharpened in the form of a "v," the angle of which should be long and thin or short and thick, according to the kind of rock to be drilled. In soft rock use a long thin cutting edge; in hard rock a short, thick edge. 23 You can buy drills of different lengths and diameters from mine supply houses or hardware dealers anywhere. Or you can buy the steel from hard- ware stores and make them. Drill steel comes in :>8-inch, " s-inch and other diameters, in bars up to 20 feet long. If you plan to make your own drills, be sure to have on hand a good length of it, for even if you have only a dozen boulders to blast you will need several drills as they require sharpening fre- quently. If one man is to do the drilling, the hand hammer should weigh 3 or 4 pounds; if two men, 8-pound sledges are about right. All hammers should, of course, be flat faced. The drill should be turned about J/g of a revolution at each stroke of the hammer so as to keep the hole round. The more regularly this is done the nearer true the holes will be and the faster the bit will cut. The holes can be started with a short drill — say 8 or 10 inches long — easier than with a long drill. The right diameter for a hole in a boulder usually will be about one inch. It is well to keep the hole as small as possible, for it takes a good deal longer to drill a big hole than a small one. For instance, it takes Size of Holes about four times as long to drill a 2-inch hole as one an inch in diameter. If the 1-inch hole will contain enough explosive it should be the size selected. But it must be remembered that as the hole goes down, the ears of the drill bit will wear off and the hole will grow smaller, so that in hard rock it is well to start a hole that is to go deeper than a foot or so, with a drill 3<4 inch larger than is wanted at the bottom. In boulders con- taining more than 6 or 8 cubic yards of material it is best to drill inch or inch and a quarter holes. The holes should be kept wet by pouring in water as the drill goes down. In this condition, the drill cuts much faster than in dry holes. It is necessary to keep the holes clean. The sledge, as the ground-up rock is called when mixed with water, can be taken out with a scraper which is shaped somewhat like a very small garden hoe, or with a spoon rod, which is a small wood rod with a disc of tin on each end. The discs should be of different sizes, and at Pressing in the tamping after a charge of explosive has been seated in the bottom of a blockhole 24 one point they should be cut to the center and one of the cut edges bent down, so that when the rod is revolved in the bottom of the hole the edge will scoop up some of the sludge. Another good way of cleaning out holes is to use a spiral hook, or drag twist, like an old-fashioned rifle cleaner. Rags or hay can be used on this to wipe the hole. A hickory or willow stick with the end split into many small pieces, or broomed, is also a good thing for getting dirt out. When this is dipped in the sludge, the material sticks to it, and can be lifted out and knocked off against the outside of the stone. A leather or rubber washer, or some old rags, should be fixed round the drill just above the level of the stone, to prevent the sludge and dust from fly- ing up into the face of the driller. This is particularly necessary when churn drilling. A churn drill is a piece of drill steel from 5 to 6 feet long, often having bits at both ends. It is used without a hammer — a man raises and drops it into the hole. Holes cannot well be started with it. It will cut Churn Drills holes faster than a hammer drill under favorable conditions, but owing to the way it is worked its use should not be at- tempted in holes less than 6 or 8 inches deep. For deep holes and in soft rock it certainly should be considered. A good churn drill for 1 -inch holes should weigh about 10 pounds. Bits should be kept sharp, for dull drills do only a fraction of the work they should. To sharpen bits costs about five cents each. It may be done in a blacksmith shop or, in emergencies, with a file or on an emery-wheel or grind- stone. They should be made as sharp and hard as Sharpening Drill Bits they can be used in the rock to be drilled without either dulling too fast or chipping. The angle of bevel that is best generally will be about 90 degrees for hard rock and 45 to 60 degrees for soft rock. Your blacksmith will give you the proper kind of bevel if you give him the necessary information. Good drill steel is not tool steel. Before attempting to sharpen a drill the shape of a new bit should be observed. Heat the drills to cherry red, and do not hold them long at that temperature. Work to get them hot without delay, then take them out of the fire promptly for dressing. The bit should be hammered to shape on the anvil, with the shank of the drill held so that it has 1 foot rise to 2 feet of length. You likely can use a file to advantage to help shape the edge, while the steel is hot. When the bit is shaped, it is ready to be put back into the fire and reheated for tempering. The tempering should be started when the steel is at a temperature of 430 degrees F. You can tell the temperature by the shade of the surface or color film that forms on the surface as the steel is being heated. Tempering Drills When the bit has been heated slowly until the surface has nearly a cherry red shade, take it from the fire and hold it in the air till it gets a very pale yellow. Rub it on a stone to remove the scales so the color can be seen unmistakably. If it seems to take too long to reach this color in the air, plunge it into the water and out again at once to start the cooling. Then watch the colors by standing in a dark corner. They should advance parallel to the edge. If they don't, hold the hot corner or side in the water an instant to even up the entire bit. As soon as the very pale yellow color is noticed, stick the bit into cool water and leave it there, stirring it about till most of the heat has left the steel. 25 Temperatures of the steel that are indicated by the colors are as follows: Very pale yellow 430 degrees F. Straw color 470 Brown 490 " " Purple 530 " " Full Blue 560 " " Dark Blue 600 " " Cherry Red 900 " " How a proper blockhole blast will shatter a boulder into pieces of all sizes. Note how completely the stone is broken throughout its entire volume and not just at one side or corner. The time in which two men with hand drills can make holes in rock can be told best by stating the number of minutes it takes per inch of hole in different kinds of rock. For beginners, when two men are drilling holes an inch in di- ameter in rock such as sandstone, about 1\<2, to 3 minutes per inch in depth is required; in limestone 3 to 3J-; minutes; in granite 4 Time for Drilling minutes; in mica schist 5 minutes; in marble and trap rock 6 to 8 minutes. Single hand drilling (one man) proceeds about two thirds as fast, except that in soft rock the rate is upwards of three-fourths as fast and in very hard rock only half as fast. These figures change greatly according to the experience of the workers and the condition of the sandstone, limestone, granite, schist, marble or trap rock that is drilled. The cost, including sharpening of drills, will run about 25 cents a Cost foot in the easily drilled rock up to 70 cents in the very hard, tough rock. Machine drilling is very much faster than hand drilling, and much cheaper where there is enough drilling to do to justify the pur- Machine Drilling chase of an outfit. Since there are many owners of large acreage which requires clearing, also many contractors in stump and stone removing who will use this handbook, some of the data about machine drilling will be useful. 26 In clear rock, or rock not checked, machine drilling is 5 to 15 times as fast as hand drilling. In some sandstone it is possible to go down at the rate of a foot in 5 minutes (instead of an inch or two as in hand drilling); and Speed in trap rock at the rate of a foot in 10 or 12 minutes. In limestone the rate is even faster than in some blue sandstone, there being records of instances where a foot has been drilled in 3 minutes. Hard granite and flinty rock often drills at the rate of a foot in about 7 minutes. Blockhole blasting is more economical than undermining, the cost depend- ing partly on how difficult the rock is to drill. Large rocks of a hard Cost and tough nature, cost pretty regularly around 16 to 17 cents per cubic yard of stone to break by this method. Blockholing requires a smaller amount of explosive and larger amount of labor and time than mudcapping or "snakeholing." The cost of machine drilling usually is much lower than of hand drilling — ■ often it is about one-fourth or one-third, of course not including depreciation or interest on the cost of the outfit. This is much or little per foot of hole drilled, according to how steadily the oufit is used. It may amount to only a fraction of a cent, or it may run the total cost up higher than that of hand drilling. There are some power machines which it is claimed will drill at a cost of 6 cents per foot. Others drill at a cost of 10 cents per foot, but 1 cents is high. How a boulder can be broken into pieces small enough to handle easily without shattering it into fragments, with proper charges of 20 per cent, ammonia explosive placed in a blockhole, or by 40 per cent, explosive used as a mudcap. This stone shows by its breaking how joint and bed lines run. There are two types of machine drills operated by steam or Machines compressed air — the small jack hammer and the large tripod drill. The jack hammer drill is the best type of machine for use on boulders. Jack drills are portable and easily handled. Tripod drills are heavy. The tools needed in blockhole blasting, aside from drills Other Tools and hammers, are a pocket knife for cutting fuse or scraping wires, a cap crimper and a wood rod for tamping. Crowbars are often useful. 27 The kinds and grades of explosives that can be used for blockhole blasting are many. In fact, rock can be broken by this method with almost any blast- ing explosive. But certain facts should be understood by blasters. One is that the use of a high strength quick-acting explosive. Kinds and Grades such as 50% or 60% powder or dynamite will shatter of Explosives rock into small pieces, while the use of slower explosives such as 20' , strength will crack and split it into larger pieces. Ammonium nitrate dynamites or powders are considered somewhat superior to nitroglycerin explosives for this purpose. For the ordinary breaking of boulders into pieces small enough to handle easily, there is nothing better than 20% to 40% ammonium nitrate powder or dynamite. In blasting in quarries, 5 tons of rock often are brought down per one pound of explosive. It is difficult to maintain this Amount of ratio in the field, unless it be with very large rocks, or Explosive Required ledges with an open or free face. Small boulders often require more explosives per cubic yard than large ones. The shape of the boulder Is also an important point, so the follow- ing tables can only be considered as approximate. Approximate Number of Pounds of Explosives Required to Break Boulders by the Blockhole Method, per Cubic Yard of Rock Sandstone and other more easily broken rock M It). Limestone and other medium rock H It). Marble, trap and similar hard, tough rock 3^ lb. Figuring on the basis of the diameter of the stones and the number of sticks of explosives required, the tabulation is: Approximate Number of Sticks of Explosive Required to Break Boulders of Different Diameters Limestone and Marble, Granite, Trap, other medium and similar hard, rock tough rocks Sandstone, Slate and similar easily broken rock \y>h. dia. 34 sticl 2 " H ' 2K2 ' Vz ' 3 ' H ' 4 ' 1 5 ' 13/2 ' 7 ' 6 K2 M 2 stick stick Often from experience, an observant man will learn just how much ex- plosive is required to crack a stone and lay it apart without excessive throwing of pieces, danger and waste of explosives. All water should be wiped out of the holes. If the holes are smaller than the sticks of explosive the paper wrapping of the sticks will have to be removed and the explosive pressed into the hole so that there are Loading Charges no air spaces. The cap should be placed in the charge near the top. Tamping of damp or wet clay or other earth should be placed solidly over the explosive to the mouth of the hole. Results of the blast with the smallest charges will be poor unless there is at least 6 or 7 Inches over the powder. 28 An undermine blast that was too heavy was used here to break a very hard, tough boulder As a consequence the rock is broken only into large pieces and these are thrown long distances. A better way would have been to have used a very heavy mudcap blast on top of the rock, or. stiU better, a proper oiocKnole blast. The firing of blockhole charges may be done either with fuse and cap or by the electric method. If more than one charge is to be fired, the Firing electric method will enable you to put them all off at once. Electric firmg is of much advantage in blasting out ledges, and also in firing the very small charges sometimes used to break stone to certain dimensions. Sometimes what may be called a " semi-mudcap " blast can be used in very hard stone, or in stones that are difficult to drill. Drill a hole into the stone for 3 to 8 inches, fill with explosive, let the rest of the charge of explosive pile up on top of the rock as you would a mudcap charge, in a low cone with steep edges. Cover this with 6 inches or more of wet clay. Boulders that are buried may be thrown out of the ground before they are blockhole blasted. When the earth is supporting them on Suggestions all sides they may not break quite as well. Digging round them or raising them off the ground with a jack or pry. and letting them rest on small stones placed under the ends or corners, helps to break them up better. Blasting in drilled holes is practically the only method that is effective in breaking up ledges of rock, either underground or above the surface. Drill a line of holes along back of the edge or face of the ledge Breaking Ledges above the surface. It is not necessary to dig or blast away the dirt from a ledge. The quantity of explosive required can be gauged by the table giving the amount to use per cubic yard of rock. Use half again as much explosive in a ledge blast as in a boulder. Measure the distance from the open side or face of the ledge back to the drill holes, and compute the number of cubic yards that should be broken off. Ordinarily on farms or in roads it is desirable to break up ledges to a depth of about 2 feet below the surface. To do this the holes should be put down slightly more than 2 feet and should be located 2 or 3 feet back from the face of the ledge. To break ledges deeper, drill deeper holes farther back from the 29 face and charge heavier. The deeper holes can also be farther apart. Two- foot holes usually can be 5 feet apart in soft, brittle shale and slate. 4 feet apart in limestone, and 3 feet apart in harder material. The spacing between the holes should be about the same as their distance back from the face. The details of charging holes, drilling, tamping, firing, etc.. that have been giving for boulder blasting apply equally to ledge blasting. Blockhole blasting is perhaps the most efficient method of breaking rock that is known, and from it you can expect perfect results. If you use a proper charge of a quick explosive, the rock will be shattered Results to Expect into small pieces. If you use a slow explosive, the rock will be broken into larger pieces. In any case, the use of the charges recommended here will result in the satisfactory breaking up of any rocks you may have to deal with. How boulders are shattered into fine pieces by heavy mudcap charges of 60 per cent, nitroglycerin explosive. Note the amount of stone that is so small it will not need to be hauled away. General Considerations The information on boulder blasting, and particularly on the breaking of ledges of rock, applies to quarrying limestone or road material, gravel, etc. In quarrying. It Is better to drill larger holes than one inch. Quarrying Proper loading In Inch and a half holes, drilled to depths of 6 or 8 feet, and 5 or 6 feet back from the edge of the quarry ledge will loosen large quantities of rock. It does not pay to dig hard-set gravel or sand by hand, for in such material the holes are easy to drill, and comparatively small charges of explosive will loosen great quantities. For quarrying use 40' ,' ammonium nitrate explosive unless the rock is wanted in large pieces, when 20' ;. ammonium nitrate grades will be better. For the semi-rock, hard gravel, etc., use 20'; explosive, the granular powder known on the market as R.R.P., or if the work is dry, black blasting powder. Medium tough rock can be quarried at a cost of 50 cents per cubic yard. Including the cost of drilling but not of crushing, screening and hauling away the stone. 30 Emphasis should be placed on the possibility of using explosives as a labor substitute. To illustrate, take the disposal of a 4-foot sandstone boulder. To drill this with an inch hole 32 inches deep would require about ]}/2 hours, or slightly lesS; for two men. But one man can smash the same boulder within 10 minutes by placing a proper mudcap blast. In the Explosives as a first case the breaking of the boulder is achieved with Labor Substitute greatest economy in total outlay, but in the latter case it is broken by one man, and broken without interfering seriously with other work. On many farms there is so much to do and men are so scarce that to take the \} o hours for the boulder's removal is out of the question, and the boulder remains in the field — unless it can be broken up with little labor and loss of time. When a boulder that is nearly all buried is rolled out and blasted, there likely will be room in the hole for many of the large pieces, deep enough to put them all below the plow line, but it is not well to bury Disposal of Pieces pieces larger than 6 inches in diameter, as the broken rock will be valuable for building purposes, for road making, lining ditches, etc., and should be kept in the stone pile until needed. It costs about 35 cents a cubic yard to haul pieces of stone away, figuring on the average haul. Solid rock of average density weighs about 2 tons to the cubic yard and loose material as it falls weighs about 1 ^ 3 tons to the cubic yard. It is better to put a stone rack on a wagon if a wagon is used. Hauling Such a rack can be made of 2 or 3 inch plank. To get heavy pieces of stone on the wagon, use planks to skid or roll them up. If the pieces are very heavy, use a "stoneboat " instead of a wagon. It is better for short hauls because it saves so much lifting. An average load of stone is about a ton and a half, and two men will handle this in about half an hour, including loading and unloading. The holes from which boulders have been taken should be filled level, to avoid a low place in which water will gather during wet weather. To fill the depressions, a horse drag scoop such as is used in excavating Filling Holes dirt is a useful thing. If this is not available, a good thing to use is an ordinary road drag, or a split log. By standing on the drag or log it can be made to gather a lot of ground, and the dumping can be done by taking off or shifting your weight. In addition to various tools described under the separate headings on methods, blasters of boulders will find a heavy crowbar and an iron wedge to be useful at times for prying apart pieces of rock. Some blasts will be found steel bar for making boles. SoU auger — note long point. not quite heavy enough to throw the stones apart. Tools and Appliances though they will crack the rocks through and through. These stones can be reduced with a sledge, but a little prying will accomplish more than a whole lot of hard hammering. If the bar cannot be forced into the crack use the wedge and sledge it in. Be careful that the wedge does not strike solid rock at a bed or joint line running at right angles. The wedge should be a slim piece of tough steel, 6 inches long and an inch or two thick at the base. 31 The best tamping material is damp clay. Tamp the hole full, while working in the tamping with the stick in one hand, hold the fuse or the electric wires out of the way with the other hand. It is easy to damage fuse Tamping and wires by breaking the insulating with a pebble, or with the edge of the tamping rod. It is also easy to pull the cap out of the primer charge unless the fuse or wires are held firmly against the rock. Many misfires are due to carelessness at this point. In lighting a fuse, stick the flaring head of a burning match right against the powder in the end. See page 4 1 . This will work in any wind. The fuse always gives a pronounced spit as soon as it is lighted. Do not leave before the sparks and smoke begin to spit out regularly. It may be safe to stand 100 to 150 yards away from a blast that is not overloaded, but this is a matter which each blaster will have to decide for himself. So much depends on the proportion of the charge to the boulder, its location, and as to whether the stone is solid. The right Flying Pieces charge will not throw stone far, but a charge that is too heavy, or in the wrong place, will throw large pieces for long distances. In fact, this is one of the ways in which you can tell whether or not you are using too much explosive. In any case, to be safe, keep an eye on the blast and dodge any flying fragments coming your way. Use every care to keep everybody beyond the range of danger. The man who fires the charge should keep his eyes open for stones coming down several seconds after the blast and at distances 100 yards or farther away. They are dangerous. See page 55 for discussion of Watch Misfires their cause and remedy. How a large granite sandstone or limestone boulder can be shattered with a mudcap blast. At the point next the explosive the stone is broken into small fragments, but at the other side it is left in large pieces, though it is well cracked in every direction. 32 Preparing Charges of Explosives for Firing A charge of explosives for the purposes of these directions is considered to be all the explosives needed for a single hole with cap and fuse or electric blasting cap properly inserted in the stick of dynamite or powder (see pages 36 to 37) and tamped in the hole, ready What a Charge is to fire. The preparation of charges is practically the same for all sorts of farm blasting. The slight varia- tions advisable to suit different kinds of work are not enough to call for separate treatment, since the principles are all the same. All who use and buy explosives should read the next chapter, beginning on page 43, on the nature and actions of explosives. It is only the man who understands all the facts mentioned there who will be able to load and blast with greatest ease, speed and results. Scope of This Chapter It is important for everyone who blasts to understand why he does things, as well as how to do them. For that reason the following discussion of the preparation of charges is made full and complete, with due attention to all the important factors involved. Details of any particular part of the operation can be found quickly by referring to the heading desired, as given in the index. Readers who may not desire a full discussion are referred to the following brief outline of the process. Be careful that explosives, cap and fuse are in perfect condition. Cut a length of fuse sufficient for the hole to be loaded, making the cut clean, with- out dragging ends, at a slight slant of, say, 30 to 45 degrees from right angle. Pick a cap from the little tin cap box, carefully, with your fingers, and slide it gently on the end of the fuse. With a proper cap crimper fasten the cap securely to the fuse, making the crimp close to the open end of cap. Avoid twisting or punching the end of fuse against the bottom of cap as well as draw- mg it away from the bottom. For wet work waterproof the joint of cap and fuse with tallow, soap or other material. Do not use thin grease or oil. Next punch a hole at a long slant in the side of the stick to be primed. Better use a wooden punch for the purpose. The handle of the cap crimper may be used. Insert the cap in the hole made as described, tie the fuse in place, and, for wet work, waterproof all openings in the stick. You then are ready to load. Provide space enough in the hole at the proper point to hold the required amount of explosives in a bulk that is not too long. Be sure before you start to press in the sticks to the bottom of the hole (see page 28) that there is enough clearance to permit their easy and certain entrance. Tamp fully and firmly up to the top of the hole. The charge is now ready to fire, which may be done by pressing the burn- ing or flaring head of a freshly scratched match against the powder in the split end of the fuse. Carrying Explosives and Supplies The place to keep the explosives is in the magazine or storage place, and not with you in the field. Carry with you in warm weather only enough for the job or the day, or in cold weather only as much as can be Protection ^^P\ warm and in condition for firing until you are through of Explosives '°^<^'"g' ^^^P explosives separate from caps. ^ A good way to carry the caps, fuse and small tools is in a basket. Put a piece of blanket in the bottom, to keep 33 out dampness when the basket is on the ground. Some blasters use an explosives box for the purpose, putting a wood handle or double wire bale on it. The tight wood box probably is a little better than the basket because it affords somewhat more complete protection to the contents. Whatever the method of carrying the explosives, it should be well pro- tected. This consists in keeping the hot sun off it, keeping rain and fog off it, keeping it away from dampness of the ground, and keeping it safe from meddlesome people and animals. Many blasters prepare charges before going to the field, but it is better practice to carry along the tools and materials, and to put them together or make the primers on the spot after all the holes are made in the ground or rock, and when everything is ready for the firing except to put the explosive in place. These remarks are given as reminders. Full discussion of proper handling and storing of explosives can be found on pages 58 to 60 respectively. Tools and Materials Required The first step in preparation of charges is to assemble the following: as many sticks of explosive (or parts of stick, if charges are to be less than full sticks) as there are holes to be primed; an equal number of caps; a sufficient quantity of fuse; some string; a wood punch with an end the size of a cap for about 3 inches; a pair of cap crimpers; a pocket knife. If the holes are very damp or full of water you also will need some tallow or other waterproofing material. In certain cases a sharp hatchet or axe and a block of wood will be worth having. The purpose and use of these items will be made clear later. A handy box for carrying supplies to field. Putting Caps and Fuse Together {Making Primers) Fuse is described as to sizes and properties on page 57 and caps on pages 56 and 57. Readers who are not familiar with them should turn to those pages at this point. Unroll the fuse and cut off a length that will be enough, since fuse burns about 2 feet in a minute (there are variations — see page 58). Three feet will give you 13^2 minutes or a sufficient time to get beyond danger under ordinary conditions. The fuse, of course, must be long enough to reach out of the mouth of the hole when the The Fuse charge is in place. Measure the depth of the hole before you cut the fuse. Warm cold fuse before attempting to bend it. It may be taken into any warm room for the purpose but should be subjected to no heat greater than 1 10 degrees. If for any reason you have doubts about the con- dition of your fuse, cut off a foot or more and try it without any cap or explo- sive. If it will burn properly it is all right. Be sure to get fresh ends both for the match and to put into the cap. If fuse has been cut for some time into lengths, it is well to cut off short pieces from the old ends in order to bring fresh powder right to the tips. 34 Cutting the Fuse Cut the fuse off at a very slight angle or bevel — say 30 to 45 degrees, as shown in the diagram. This slant is for the purpose of giving a little space between the actual end of the powder and the explosive material in the bottom of the cap, to enable the spark to spit into material. The only way to regulate the space is to cut the fuse as directed and let the long tip rest gently against the bottom of the cap. The spark has a better chance to ignite the explosive material in the cap when it spits from the end of the fuse than when it merely burns up to the end without any space to spit into. The end of the fuse where cut off should be clean and free from dragging ends and threads. If it is not cut off clean, part of the covering may double over the end of the fuse in the cap and keep the spark away from the explosive, causing a misfire. Be careful to keep both ends of fuse off damp ground and out of puddles of water. If the fuse has been mashed, or is too thick to go into the cap easily, do not peel off any of the covering. Reduce the diameter by squeezing it with the cap crimpers or by rolling it on a smooth surface under a knife blade or other smooth implement. Sometimes you can reduce it by rolling it between the thumb and finger. The very best way to cut fuse is on a block of wood with a sharp knife. The blade can be pressed right through the fuse and will make a clean cut. Another good tool is a sharp axe, to be used on a block of wood. The method of cutting is of small importance, just so the actual cut is made smooth and even enough. If you do use other tools, have a knife with you to trim up ends that are not true. Be careful to avoid twisting, pinching or otherwise knock- ing the freshly cut end of the fuse about, for you may shake out the powder back far enough to cause a misfire. The powder should come out flush with end. To get one cap out of the tin box in which they came, tilt the box up on edge till some of the caps slide forward, and then pick the cap up with your fingers. Don't attempt, on penalty of losing a hand, to take a cap out of a box by running a nail or a little stick or the fuse into it in the box. Be care- ful you do not drop a cap to the ground or floor. Turn the cap upside down, to make sure there is no dirt in it, and gently slide it on the fuse till the end of the fuse just touches the bottom of the cap. Do not ram, press or twist the end against the bottom. Hold the fuse with capped end up, to keep the cap from sliding off, and crimp the cap fast. This you do with the special plier-like tool called a cap crimper. The "crimp" is made by pinching the open end of the cap tight to the fuse. It Crimping should be made with- in the last quarter inch of the open end of the cap. Never make it toward the closed end because you might disturb the explosive material in the bottom of the cap and cause it "Crimp" or fasten caps to fuse with a regular crimp- {._ ^vrkln<-lo/e.- w/nedm sen'es, m a /to/c. w/re^tn G^ fi/ckmg up separate ftofes /*oe so ^oo