Fines Reduction Project at Wendling Bowser Quarry
Document type: Case Study
Categories: Case Study

FINES REDUCTION PROJECT AT
WENDLING BOWSER QUARRY

PROJECT SUMMARY
IMPROVING OPERATIONS WHILE REDUCING
COSTS
The goal of the study was to achieve the best possible
fragmentation with chemical blasting for costs and for
bank ton yield from reduced fines. Customer had
attended Quarry Academy (QA) and saw opportunity for
applying principals discussed at QA to improve his
operation and reduce costs.

BACKGROUND
 The Wendling accounts are serviced by Quick Supply &
DYNOCONSULT IS CALLED IN TO FIND Bennet Explosives. In 2009, the General Superintendent
OPTIMUM CRUSHING PLANT PARAMETERS of Operations for Wendlng attended the Quarry
The project began in May, 2010 and was concluded by Academy. Due to what he learned there, he wanted to
the end of September 2010. During the course of the improve the competitiveness and efficiency of the
project, 9 production blasts were studied. The first four Wendling operations. blasts were baseline blasts to calibrate the fragmentation
model and to decide which future improvements could About this time, the competition was attempting to win
be compared. The initial site visit was to obtain geologic over Wendling quarries. In conversations with Wendling,
information and drilling information for calibration of the Olsen representatives stated they could help Wendling
fragmentation model to the local site conditions. Once achieve their goals. Wendling then contacted
the fragmentation model was calibrated, various blast QuickSuppply/Bennet Explosives to see if they could
design parameters were modeled to guide the blast offer a similar program. Quick/Supply Bennet Explosives
designs and produce the desired muckpile contacted DynoConsult to ask for assistance the project. fragmentation.

were modeled to guide the blast offer a similar program. Quick/Supply Bennet Explosives
designs and produce the desired muckpile contacted DynoConsult to ask for assistance the project. fragmentation. During this same time, sieve analysis was It was felt that, should the competition initiate such a
performed on samples taken from the discharge of the project with Wendling, they would win over Wendling
crushing plant. By separately quantifying the fines quarries. produced in the blasting and crushing, it was possible to
determine the optimum crushing plant parameters to
reduce the fines produced in the crushing.

Wendling Quarries has expanded operations to include PROJECT GOALS
14 counties throughout Eastern Iowa and Western
Illinois.
 WENDLING QUARRIES SEEKS TO IMPROVE
Wendling Quarries currently operates approximately 100 COMPETITIVENESS AND EFFICIENCY
quarries and employs an average of 200 employees that 1. Primary Objective - Reduce the percentage of
are dedicated to superior customer service. Along with material less that ¾ inch output by crushing plat.
the production of crushed stone, sand, gravel, and 2. Secondary Objective – Maintain or reduce historic
asphalt mix, a growing portion of the business has drill and blasting costs
become the processing of recycled concrete and 3. Tertiary Objective – Maintain historic production rates
asphalt.

Disclaimer: This case study is provided for informational purposes only. No representation or warranty is made or intended by Dyno Nobel or its
affiliates as to the applicability of any procedures to any particular situation or circumstance or as to the completeness or accuracy of any information
contained herein, and, to the full extent permitted by law, Dyno Nobel expressly disclaims any liability arising from the use of this document or the
information contained herein. User assumes sole responsibility for all results and consequences. ©2020 Dyno Nobel

FINES REDUCTION PROJECT AT
WENDLING BOWSER QUARRY

TECHNOLOGY APPLIED
A WIDE RANGE OF TECHNOLOGY IS APPLIED
TO INSURE OBJECTIVES ARE ACHIEV
 • Fragmentation modeling used to guide blast designs
 to achieve desired muckpile fragmentation.
 • Sieve analysis study looking into changing plant
 operational parameters to determine optimum
 operation for desired results.
 • Employment of DigiShot® electronic detonators to
 control muckpile fragmentation.
 • DigShot Electronic Detonators
 • TITAN® 1000 SD
 • FAS-Blast fragmentation modeling
 • WipFrag photographic fragmentation analysis

VALUE ADDED
 IMPRESSIVE SAVINGS AND INCREASED
 SALEABLE PRODUCT
 • $24,000 annual savings in D&B savings at the Bowser
 Quarry
 • Potential of $390,000 in D&B costs if techniques
 employed at other Wending operations.
 • Reduced total fines in plant output from 73% to 58%.
 • Increased saleable product by 30,800 tons/yr at
 Bowser Quarry alone.
 • Expanded drill patterns by 58%.