SOP # FCX-15

FCX Department of Occupational Health and Safety Revision # 8

Supersedes Ver 2023 #7
X High
Medium
Surface Blasting Policy Task Risk Low
NA (North
America)
Approval Date: 7/29/2024 Original Date: 11/30/2011

Contents

Contents ........................................................................................................................................................ 1
1.0 Purpose and Scope............................................................................................................................ 3
2.0 General Requirements ...................................................................................................................... 3
3.0 Responsibilities and Duties ............................................................................................................... 3
3.1 Responsible FCX Employee ................................................................................................................. 3
3.2 FCX and Contractor Supervisors ......................................................................................................... 4
3.3 Mine Managers ................................................................................................................................... 4
3.4 Blockers and Sweepers ....................................................................................................................... 5
3.5 FCX Blasting Safety Steering Team (BSST) Requirements ................................................................... 6
3.6 Site Blasting Safety Steering Team (BSST) Requirements ................................................................... 6
4.0 Procedures .............................................................................................................................................. 7
4.1 Identification of Blast holes - Drilling and Sampling ........................................................................... 7
4.2 Pre-shift Team Meeting ...................................................................................................................... 7
4.3 Pre-loading Workplace Inspection and Blast Site Conditions ............................................................. 8
4.4 Explosives Storage............................................................................................................................. 10
4.5 Explosives Transportation ................................................................................................................. 13
4.6 Priming .............................................................................................................................................. 14
4.7 Loading .............................................................................................................................................. 16
4.8 Stemming .......................................................................................................................................... 17
4.9 Tie-in ................................................................................................................................................. 18
4.10 Pre-blast Meeting............................................................................................................................ 19
4.11 Clearing\Sweeping the Blast Area................................................................................................... 20

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 4.12 Securing and Holding Blocking Position .......................................................................................... 20
4.13 Blast Initiation ................................................................................................................................. 22
4.14 Post-Blast Inspection....................................................................................................................... 23
4.15 Blast Monitoring ............................................................................................................................. 24
4.16 Misfired Hole Procedure (CFR 56.6311) ......................................................................................... 25
4.17 Sleeping / Guarding Shots, Lightning Storms.................................................................................. 26
4.18 Lightning Storms/Red Alerts during Blasting Process ..................................................................... 27
6.0 Recommended Equipment and Software ............................................................................................. 29
7.0 Training and Competency (Future Development) .......................................................................... 30
8.0 Variance .......................................................................................................................................... 31
9.0 Definitions ....................................................................................................................................... 31

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1.0 Purpose and Scope

The purpose of this section is to outline the purpose and scope pertaining to the implementation of
and adherence to the Policy.

Purpose This policy outlines minimum requirements for surface blasting at all FCX
operations. This document provides standards to be addressed in site SOPs
(STANDARD OPERATING PROCEDURE).

Scope This policy applies to all FCX employees and contractors involved in blasting
activities.

Sites have varying levels of interaction with Blasting Contractors; these

policies apply regardless of the degree of contractor involvement. A
Responsible FCX Employee (exempt) will be accountable for all surface blasts
on site including project work.

2.0 General Requirements

The purpose of this section is to outline the general requirements pertaining to the implementation
of and adherence to the Policy.

General • Each site will clearly designate a Responsible FCX Employee

Requirements • Blasting ensures locations and expected blast time will be
communicated to affected work groups daily.
• Blast initiation devices will be serviced every 2 years or more
frequently if specified by the site.
• Each site will have an approved lightning detection system and
safety procedures in an approaching electrical storm. This system
needs to be able to cover the entire site and provide warnings of
potential lightening conditions.
• All blasting processes will be done safely and efficiently.
• There will be no implied haste.
• All blasting incidents need to be reported to the OI Blasting
representative in a timely manner.

3.0 Responsibilities and Duties

3.1 Responsible FCX Employee

Responsible FCX Employee and Responsible Exempt Employee will:

Blasting Process Provide field oversight of the entire blasting process. (Ensure delivery of the
blasting plan to the crew and monitors work to ensure SOPs are followed). The
exempt responsible employee will be present at the firing point to oversee the

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 blast clearing process. For all the sections of the blasting process prior to this
stage the responsible FCX employee does not have to be an exempt employee.

Blast Design Ensure the blast design has been reviewed by a qualified person to verify that
the initiation plan and hole timing are reasonable. If more than one shot is
planned, the initiation plan and delay between shots will be evaluated to
ensure that the shots do not interfere with each other.

All holes being timed in Shotplus software should be uploaded with actual GPS
(Global Positioning System) locations or actual measurements by field
verification. Holes determined to be too close in proximity (by site SME) can be
initiated with the same timing or eliminated; to prevent sympathetic
detonation, dynamic shock, or dead pressing.

Timing software will be used to design timing.

Compliance Be competent in ATF, MSHA (Mine Safety and Health Administration) and/or
other local blasting related regulations.

Understand and comply with the policies (this document).

Inventory Control Verify daily transactions of magazine inventories and conduct monthly
reconciliation comparing explosives in magazines with explosives in the SAP
system.
If contractor is controlling magazine inventories Responsible FCX person must
be conducting monthly reconciliation of explosives in magazines and document
this count.

3.2 FCX and Contractor Supervisors

Supervisors for both FCX and Contract companies will oversee the pre-shift meeting and:

Allocation of Assess the workload for crew members and allocate resources as appropriate
resources to minimize distractions and decision-making errors.

Accountability Supervisors will ensure that employees comply with this Policy and all site SOPs
and procedures.

Contractor Safety Contractors will also comply with the Health and Safety (H&S (Health & Safety))
Manual requirements in the BSST Policy and follow the Health and Safety policies of
each site.

3.3 Mine Managers

Be knowledgeable in and abide by the policies (this document) and champion safe blasting
processes.

Leadership Provide leadership that minimizes perceived haste.

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Audits Ensure internal audits are performed and action items are addressed. Audits
are required to be posted on the BSST(Blasting Safety Steering Team) NA/SA |
Audits from all Sites | Microsoft Teams

Staffing Ensure that sufficient and capable staff are available to oversee blasting
processes.

Ensure that where contract personnel are utilized, an FCX employee is

assigned as the FCX representative to oversee blasting operations.

Resources Ensure that sufficient resources (people, equipment, etc.) are available to
safely facilitate blasting processes.

3.4 Blockers and Sweepers

Blockers and Sweepers will be FCX employees (for production blasts and secondary blasts) whose
assignment begins at the pre-blast meeting. If required by contract, contractor employees may be
used as blockers and sweepers if they have been trained to FCX standards and this training is
documented. FCX will need to ensure that the contractor company will allow their employees to be
used as blockers and sweepers. Responsible FCX employee will supervise all blocking and sweeping
assignments for FCX and contractor employees.

Blocker Blockers are responsible for:

Responsibilities
• Blocking traffic at the assigned area
• Understanding and repeating back the assignment
• Following instructions without deviation
• Stopping the initiation process if a deviation to the blocking plan is
detected

Sweeper Sweepers are responsible for:

Responsibilities
• Proceeding from the blast site and clearing the area assigned
• Understands and repeats back instructions.
• Help close “back doors” (see section 9.0 for definition) for other
sweepers.
• Clear all equipment of personnel in the assigned area following site
SOPs for clearing personnel from equipment and/or buildings.
• Best practice for clearing personnel from equipment or buildings, for
example, during shovel PM’s. If there is concern, about the sweeper
not being familiar with the inside of a shovel then the responsible
maintenance personnel for that shovel PM (Preventative
Maintenances) will be contacted and he will be held responsible for
clearing personnel from shovel and will confirm that all his people are
clear.
• To ensure that all benches that have access to main haul roads are
physically cleared prior to the blast.

Training All blockers and sweepers must have documented training prior to being
assigned these responsibilities.

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Contractor Blasters All sites utilizing contractors for blasting will ensure that contractors
understand and comply with this policy.

3.5 FCX Blasting Safety Steering Team (BSST) Requirements

The FCX Blasting Safety Steering Team (BSST) will evaluate existing standards, set new policies, and
monitor site performance through audits

Required Members • Sponsor, GM (General Manager) level or Director Level

• Site champions representing all business units.
• A health and safety representative

Audit Requirements The BSST will conduct annual audits at mine sites to monitor compliance, look
for best practices, and provide feedback for continuous improvement.

Audits will include review of compliance with FCX policies, training, site SOPs,
and field practices. Follow-up audits may be conducted depending on site
performance.

A standard format will be used for the audits.

Annual Meeting An annual meeting will be held with all core members to review practices and
make recommendations for change where needed.

3.6 Site Blasting Safety Steering Team (BSST) Requirements

Each site will have a Blasting Safety Steering Team to ensure that the site is following FCX blasting
policies and monitor site performance. Internal audits will be posted on the BSST share point.

Required Members Sites will establish the site BSST consists of these members:

• Sponsor-Mine Manager
• The site champions.
• A geotechnical engineer
• A health and safety representative
• A member of the site blasting crew or fragmentation team
• Contractor representative (if contractors are utilized)

Blasting Operations Sites will include blasting operations as part of the risk assessments.
Records will be maintained according to the FCX – Records Retention Policy
for 10 years. Hard copies for 5 years (MSHA requirement) and electronic
copies 10 years.

Audit Requirements Sites will complete regular internal audits of blasting practices to ensure
compliance with this Policy. Action items will be tracked to ensure completion
and follow-through.

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 A standard question audit form is to be used. This form is found on the DOHS
(Department of Occupational Health and Safety) team site in the folder with
this policy and on the BSST Teams page.

Audit Frequency Site quarterly audits will be done quarterly and uploaded into BSST Teams,
Audit Document, Property location, Audit Type: Internal Audit.

BSST Teams - BSST(Blasting Safety Steering Team) NA/SA | Audits from all
Sites | Microsoft Teams

4.0 Procedures

4.1 Identification of Blast holes - Drilling and Sampling

This section ensures that holes are properly identified.

Numbered Stakes Numbered Stakes must be numbered consistently with the SOP (STANDARD
OPERATING PROCEDURE) of the site.

Drillers will place a numbered stake at each cuttings pile and verify that the
stakes are numbered correctly

Extra Holes/Holes Extra holes, “bad holes” or holes determined to not be loaded (drilled for
Not to be Loaded maintenance or any other reason) will be properly identified with a stake that
reads “Do Not Load” or similar language or instructions that indicate that the
hole should not be loaded. These holes will be stemmed or coned off prior to
laying out accessories (see section 9.0 for definition).

Site Procedures Each site will develop a process to inspect the pattern for unlabeled holes and
unsafe conditions and this will include steps to properly notify the responsible
FCX employee should something not be completed properly.

4.2 Pre-shift Team Meeting

A pre-shift meeting will be held by blasting crews each shift.

Requirements The pre-shift meeting shall include the following:

• Work locations
• Unique or continuing hazards/risks and the controls to mitigate.
• Equipment and personnel for assigned work.
• Hole specific loading instructions for a pattern (water, hardness,
product, etc.)

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 • List of amount and type of explosive products to be removed from the
magazine for each shot based on the blast plan (Daily Explosive
Worksheet) given to magazine manager daily.
• Identification of parties for communication and unique work being
done in areas adjacent to the blast site.
• Preliminary blocking locations
• The anticipated time of the blast
• Identification of the responsible FCX employee
• Other pertinent information

4.3 Pre-loading Workplace Inspection and Blast Site Conditions

This section ensures that the risks associated with the blast are identified and controlled.

Blast map and area A responsible FCX employee will verify that the blast plan map accurately
represents the blast pattern in the field (i.e., number of holes, hole locations,
problem holes). A map with the designed hole locations is to be used.

Blast plan map (Clearance map) includes unusual activities such as contract
drilling, equipment, shops, and projects taking place in blast area.

The FCX employee responsible (exempt) will determine the boundaries of the
blast area. The distance for equipment and personnel clearance will be
determined by each site based on site blast specifics (an example is 500ft for
equipment (150m) and 1,500ft for personnel (450m) are typical horizontal
distances but may need to be greater based on blasting practices and fly rock
potential). Vertical distance components may reduce the horizontal distance
above blast but increase horizontal distance below blast.

Inspection Blast site inspections shall be performed before any blasting process starts.
requirements This will be documented on the blast summary sheet or other appropriate
form.

Physical inspection of actual burden and spacing should be reviewed during

the inspection process. Make sure no holes are closer than designed burden
and spacing. Holes determined to be too close in proximity (by site SME) can
be initiated with the same timing or eliminated; to prevent sympathetic
detonation, dynamic shock, or dead pressing.

If the blast pattern is in an area where reactive ground “Hot Holes” are
suspected to exist, all holes will be checked with a meter and probe to check
on the bore hole temperature. These checks will be done with a proper
thermocouple device, not a temperature gun.

If the blast pattern is in an area where Low PH is suspected to exist, holes will
be sampled to check PH readings. Low PH will require different loading
products and practices. If PH measures 2 or below use other safe measures.

If any holes indicate a temperature of 130 degrees Fahrenheit (54.4 degrees

Celsius) or higher, they will not be loaded with normal products.

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 Holes indicating 100 to 129 degrees temperature should be primed, loaded,
and stemmed last.

In the event of reactive ground, it will be left unloaded and unprimed until all
other holes are loaded and stemmed. These patterns should be fired as soon
as loading, stemming, and tie-in have been completed.

It is highly recommended that buffered emulsion (inhibited) products be used

to load Low PH and/or hot holes. Technical questions about this procedure
should be discussed with your explosive's supplier.
Each site should have an SOP for dealing with reactive ground and know in
advance when they are going to be drilling into potentially reactive ground.
The pattern should then be shot as soon as can be safely managed.

During the inspection, blast site access and egress routes will be evaluated,
and appropriate actions taken to ensure safety prior to blast initiation.

Blasting All potentially affected personnel must be informed of blast times and
Notifications locations. This includes crews and personnel in potentially hazardous
situations outside of the blast area. This will be done by an “all channel call”
on the radio or other site-specific method approximately 30 minutes before
blast.

Determining The following items shall be considered when determining the boundaries of
Boundaries the blast area:

• Concussion of the blast

• Potential fly rock distance
• Fumes, ventilation, and prevailing wind conditions
• Air blast (see section 9.0)
• Subsidence (see section 9.0)
• Adjacent infrastructure
• Equipment locations including maintenance activities.
• Noise and vibration
• Geological features
• Adjacent underground or surface workings
• Hazards associated with the loading pattern.
• Weather conditions

Unlabeled Holes Unlabeled holes that are discovered will be accurately identified by the
responsible FCX employee using the blast plan map and labeled with a
numbered stake before loading.

Unloadable Blast holes not intended to be loaded will be labeled “Do Not Load,” “Bad
Holes/Holes Not to Order (BO),” or similar language. They must be stemmed, coned, or
be Loaded barricaded before any product is laid out. Communicate information to
person timing, as soon as identified in the field.

Access to these holes will be restricted before blasting accessory distribution

to prevent accidental product distribution on them. This applies to production
holes only; presplit holes may be coned off.

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Addressing Questions or concerns that arise from the blast site inspection will be resolved
Questions or through consultation with the responsible FCX employee before the blasting
Concerns process starts

4.4 Explosives Storage

The purpose of this section is to ensure that explosives are stored in compliance with all regulations

Responsible Person A person or persons will be assigned responsibility for managing the
magazines for explosive storage.

Written instructions for the operation of the magazine are required (SOPs).

Two people are required to confirm ending inventory in each magazine daily.
They must both sign and date their verifications of ending inventory on the
daily magazine log sheets.

Fire Extinguishers The location of all fire extinguishers will be clearly marked.

Under no conditions should one fight a fire in an area near explosives except
as necessary to escape the area. These areas include the magazine, prill and
emulsion trucks/silos, powder trucks, and the actual blast site. In the event of
a fire, all personnel should be kept a safe distance away, as determined by
the site and the conditions.

Any fire involving explosives at any location, the safe distance to be cleared is
a minimum of 1 mile radius, for personnel. No one is allowed in the radius to
try to extinguish any fire involving any explosive product, until the fire is
deemed out.

Coordinate with your site Emergency Response Team or Site H&S Team
annually.

Construction of All outdoor magazines will be built to the Bureau of Alcohol, Tobacco,
Magazines Firearms (ATF) standards and sited to the American Table of Distances. If a
country’s laws or standards differ from those in the US, a more stringent
standard will be enforced.

ATF Website
MSHA Website

Lightning Protection All magazines will be fitted with a lightning protection system; a sufficient
grounding system will fulfill this requirement.

Yearly records of grounding checks are required and must be documented. 25

OHMS of resistance or less is considered satisfactory.

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Signage All magazines will be properly signed from each approach indicating contents
and have warnings such as:
• "No Smoking"
• "Explosives Stored Here"
• "Authorized Personnel Only"
• “No cell phones, electronic devices/non-intrinsically safe items, inside
magazine”
• “Radios must be turned off if taken into magazine.”

Signs will be placed so bullets fired at the signs will not impact the magazines.
These signs will be in the primary language of the country. A best practice
would be to also have signs in secondary languages that may be spoken in
that country.

Sparking Devices, Smoking, vaping devices, E-cigarettes, matches, open flames, and spark-
Cell Phones, and producing devices and tools, are not permitted within 50ft(15.2m) of a
Intrinsically safe magazine or Blast Site.
lighting
Only essential non-sparking equipment used for the magazine may be stored
with explosives.

Smart phones, cellular phones, smart watches, or other transmitting devices

are not permitted in the magazines. Any items used in magazines must be
intrinsically safe.

Only intrinsically safe lighting or flashlights are allowed in magazines.

Records All magazines will contain a book or similar method for the recording of all
explosive's movements in and out of the magazine and current inventories.
These books must remain inside the magazines for one year and onsite for 5
years hard copies (MSHA requirements) and 10 years electronically.

All magazines will contain an updated copy of authorization, permits, or

licenses.

All accessories must be inventoried and counted as each or units. The

exception is detonator cord, which is counted as spools or lengths.

When partial boxes are returned to the Magazine they will be recorded as
inventory and kept in the original boxes.

A reconciliation of the explosives in the magazine will be done daily after

partials are returned to the magazine and recorded on the Daily Explosives
Worksheet. This reconciliation will be done at the end of blasting for that day.
Variances from the daily blast sheet regarding expected explosive usage will
be documented and reviewed by the responsible FCX employee for each
blast.

A reservation in SAP must be created for used explosive products at the end
of the day or first thing next morning. GSC (Global Supply Chain) will review
and process reservations in SAP system timely, as per GSC Policy.

All contractors controlling explosives on FCX sites are held to same standards
listed under records, except requiring SAP system which is a FCX system.

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Magazine Location All magazines must be:
• located outside the corridors of power lines.
• made secure with either a lockable gate and fence or lockable storage
box for explosives, meeting the requirements of the applicable
agency.
• in areas configured to prevent vehicle impact to the magazine
• located in a proper manner to control surface drainage.
• All explosives' accessories must be stored safely and in accordance
with statutory regulations.
• Areas around magazines free of rubbish, brush, dry grass, and trees
for a minimum of 25ft(7.6m) in all directions

Bills of Lading (BOL's) and packing lists shall be kept in a secure location for
Bills of Lading the specified minimum period hard copies for 5 years (MSHA requirements)
and electronic copies 10 years per the FCX – Records Retention Policy. The
Bills of Lading for explosives are to be delivered to GSC on the same day they
are received.

GSC is responsible for following their GSC policy for receiving and
inventorying explosives.

Accurate Case The contents of all boxes of explosives will be verified for accurate case
Counts counts after being opened in the field and before distribution. In other words,
the contents of each case will be counted and verified before being placed
into the bags for distribution on the pattern. Any inaccurate boxes will be
returned and isolated in the magazine for further investigation.

Partial Boxes of If partial boxes are returned to the magazine, they must be re-issued as
Explosives partials. These partials should be re-issued as soon as possible and taken out
of inventory.

Partials from different boxes may not be combined. Unused explosives must
always be stored in the original packaging.

New cases must not be opened in the magazine. They should be moved to
the accessory truck as complete boxes and opened at the blast pattern.

Daily Explosive A Daily Explosive Worksheet will be created by the Responsible FCX Employee
Worksheet and given to the magazine manager during the pre-shift meeting.

Based on the Daily Explosive Worksheet the magazine manager will remove
explosives from the magazine first using remaining partials and then full
cases.

A reasonable amount of extra explosives should be removed from the

magazine to account for contingencies. This amount can be up to 10% and
should normally be one full case per pattern. For large patterns, the 10% limit
can require more than one full case.

All unused explosives at the end of the day will be returned to the magazine
as partials in their original box and recorded in the logbook. Mark quantity of
partials, initial, and date on original box.

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 The responsible FCX person must verify inventory, any +/- deviation from 10%
explosives taken to field and sign off on Daily Explosive Worksheet daily.
Any deviations from planned versus actual number of explosives being
returned must be documented for each blast.

Inventory Inventory will be reconciled daily by the magazine manager and verified by
the Responsible FCX Employee.

Once a month GSC will perform an audit of the magazines. They will reconcile
actual inventory on hand versus inventory in GSC SAP system, as per GSC
Policy.

Shortages A responsible FCX employee (“the discoverer”) will notify the manufacturer,
supplier, ATF, and local law enforcement within 24 hours of the discovery of
accessory shortages related to a site issue.

If the shortage is due to a manufacturer/supplier issue, only the

manufacturer/supplier needs to be notified.

All shortages will be documented and reported to supervisor, management

and GSC.

Overages In the case of overages, only the manufacturer and supplier need notification.
All overages will be documented and reported to supervisor, management
and GSC.

4.5 Explosives Transportation

This section ensures that explosives are transported safely and in accordance with regulations.

Transporting All explosives, detonators, and accessories will be transported in accordance

Explosives with statutory regulations (“day boxes,” Type 3 magazines).

Day boxes with explosives must be locked in transit.

Day boxes holding explosives will be used exclusively for explosive material
(No exceptions).

The truck transporting explosives will have a driver and a person to help load
and unload only, it is not to be used to transport people.

Signage Explosive transport vehicles will have the proper placards, visible in all four
directions.

Explosive trucks will display red or orange flags while transporting explosives.

Fire Extinguishers Vehicles must be equipped with two multipurpose dry fire extinguishers.

Under no conditions should one fight a fire in an area near explosives except
as necessary to escape the area. These areas include the magazine, prill and
emulsion trucks/silos, powder trucks, and the actual blast site. In the event of

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 a fire, all personnel should be kept a safe distance away, as determined by
the site and the conditions.

Day Boxes Day boxes must be securely fastened to the vehicle or confined within the
vehicle body to prevent spillage.

Must be made of non-sparking materials for container lining and fasteners

and must comply with all ATF standards for Type 3 magazines.

Detonators and boosters transported on the same vehicle must be stored in

separate, compliant day boxes.

No other materials will be transported in day boxes with explosives (No

Exceptions).

Day boxes must be locked on a pattern when products are not being loaded
or unloaded. Day boxes with explosives must be locked when unattended.
This means when there is no one by the truck, it will be considered
unattended.

Capacities The volume and quantity of explosives will not exceed the limits established
by regulatory authorities.

Vehicle loads must be within the rated vehicle carrying capacity.

Inventory Means to control the inventory of explosives in the field must be established.

Disposal Explosive refuse (empty boxes) must be inspected, broken down, and
disposed of properly on site.

4.6 Priming

This section ensures that detonators and primers are handled safely, and usage matches blast
design. This will allow for proper accounting of detonators and primers prior to loading.

Preparation All holes will be measured for depth and water level before priming. The
responsible FCX employee will be notified of any significant variance from
expected measurements before the hole is primed.

No blasting accessories are to be laid out on a blast pattern until the blast site
is secured, barricaded and/or all clean up with equipment is complete or
controls are in place to allow for safe distribution of explosive products.

All non-essential vehicles and personnel must be kept off the blast site before
blasting accessories are laid out.

Small vehicles should have a designated parking area out of the traffic pattern
for larger vehicles working in blast site.

Each site is responsible for small vehicle/equipment parking procedures for

parking inside blast sites.

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 Explosive products will be laid out in a careful, efficient, and well-coordinated
manner (between holes, on the outside of the cuttings pile and out of the
flow of traffic). Boosters and detonators must be separated with a minimum
of 1 foot(.30m) when laid out at blast hole.

Canvas stake bags will be used to carry explosives accessories while laying out
the accessories on the blast patterns. Ensure that people carry blasting
accessories, limit the total weight being carried to a safe limit, established by
site policy.

The blast site will be secured with yellow cones or yellow tape (or a
combination of both) and warning signs will be used to block all accesses to
the blast pattern to be primed and loaded. Documented permission (radio or
written) for entry must be given by the person in charge of the pattern.

Best practice of having everyone sign off on a workplace examination form,

HART form, JHA form or etc. is recommended to document anyone who
enters or leaves a blast site.

Inventory A physical inventory of boosters and detonators used for the blast will be
done in the field at each blast pattern and verified against the blast plan map
count. This count must be completed when all blasting accessories have been
distributed on blast site.

The responsible FCX employee will verify the detonator and booster inventory
after the products are laid out to ensure that the amount used matches the
blast plan for each pattern. Documentation of this check is required. If there
is a discrepancy, it must be resolved before any more activity is conducted on
blast site.

This inventory will be done before the accessory truck leaves the blast site.

Detonators and All detonators will be fully enclosed within the booster according to the
Boosters manufacturer’s recommended procedures.

An acceptable, standardized weight system must be used to ensure proper

placement of the booster in the explosives column when loading wet hole
products (pumped products). The use of rocks tied directly to a booster is not
acceptable. A mesh bag containing a rock or other type of (non-sparking)
weight along with rope or harness wire tied to bag and booster is
recommended for wet holes.

When down hole detonators are used, a redundant down line will be
required. At least one of the detonators will be an electronic type capable of
having its integrity verified from the surface.

Securing Downlines Downlines must be anchored securely into position at the surface in the
cutting piles. Wooden stakes or poles will be used.

Best practice of using rubber bands tied on downlines with minimum 1-foot
loop and attached to drill stake/pole is recommended.

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Primers Primers will be assembled only at the hole collar and will immediately be
carefully lowered into the hole. Priming will be done to facilitate efficient
advancement of the bulk loading trucks.

Issues Issues to normal procedures must be documented and reported to the

Responsible FCX Person.

4.7 Loading

The purpose of this section is to ensure that holes are loaded per the blast design and that
problems that arise during loading are dealt with appropriately.

Before Loading Loading personnel will know the upper weight limit of the product to be loaded
Holes and the planned stemming height of each hole. Each hole should be loaded
according to the blast loading sheet. Any extra amounts that are loaded will be
done with the consent of the responsible FCX employee.

Interruptions Interruptions in the loading process will be documented and communicated to

the responsible FCX employee.

Loading The powder column rise of each hole will be monitored until the stem height is
achieved or the maximum load is reached.

Any deviation from the expected column rise over a set amount during loading
will be immediately brought to the attention of the responsible FCX employee.
Each site is required to include this process in operating procedures.

Loading Trucks Loading trucks will wait to load holes until there are enough holes primed to
keep the loading process continuous. When loading with emulsion trucks, the
loading truck operator will follow their SOP for loading. This SOP must include
hole to hole moves, short and long distances moves on blasting patterns, to
prevent exposing ground personnel to line of fire of equipment.

If required, guides will be used to maneuver loading trucks around tight spots
on the patterns.

All loaded holes will be marked with unique color of spray paint, so everyone
knows the hole has been loaded.

Density checks on emulsion loading products must be done daily on every load.
These density checks must be documented. AN loading truck should have
density checks every 3 months, calibrated every 6 months, and documented.

All loading trucks will be parked off the pattern after loading is finished.

After Loading After loading, downlines must be checked prior to stemming to ensure that the
Holes booster and detonator are properly embedded in the powder column.

Upon completion of the loading process, the loaded hole count must be verified
against the blast plan and documented by the responsible FCX employee &
loading contractor.

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Pre-Logging Pre-logging to determine whether the electronic detonator has continuity, will
(Continuity be done after hole has been loaded with product.
Checks)
If the electronic detonator does not respond correctly, another set of primers
should be utilized with enough explosive loaded on top to secure the second
booster and detonator.

Person performing pre-logging is responsible for checking to make sure

downlines catch in powder column then check electronic detonators for
continuity and then paint drill/blast stake with unique color of spray paint, so
everyone knows the hole has been loaded, pre-logged (continuity checked) and
ready to be stemmed.

Best Practice - Document pre-logging by using report from logger to confirm it

was checked and number of holes match product laid out and loaded by SWE
(Southwest Energy).

Recordkeeping The required records must be kept for every hole loaded.

4.8 Stemming

The purpose of this section is to ensure that stemming activities are done in such a way to eliminate
cut downlines, “bridge overs” (see section 9.0 for definition) and help identify problem holes.

Material and Clean material (minimum fines), crushed gravel, as specified in the definition
Equipment of stemming, and sized for the diameter of the hole being loaded is required;
cuttings will not be used.

A side-dump articulating loader is the recommended equipment to load the

material. This loader will be used with the proper side dump bucket.

Stemming Operators Stemming operators shall:

• Safeguard against oversized material being accidentally introduced

down blast holes.
• Stemming operators must be trained in procedures used in case of a
lost, cut, or damaged downline, stemming operators shall inform the
responsible FCX employee of any problem holes

Before Stemming Stemming material shall be strategically placed at the blast site using a
spotter. Stemming piles should be wetted down to help prevent dust in
stemming process.

The stemming process will not begin until after the loading is far enough
ahead (loading trucks are advanced 3 holes) or to allow product being loaded
to expand properly and that stemming activities will not interfere with the
priming or loading process. Operator should always determine if safe to stem
holes, preventing dust impacting personnel on the ground, due to wind
conditions, etc...

Best practice of using rubber bands or Extreme i-Kons can be used as a

replacement for using downline attendant. Rubber bands can be used to tie
onto the downlines and anchor them to the drill stake with a minimum of a 1-

17
 foot loop for slack. (Using rubber bands or Extreme i-Kons eliminates safety
concerns of being in the line of fire of both stemming bucket and dust)

Downlines Detonator downlines will be positioned to minimize damage.

Downlines will be secured prior to explosives loading and stemming.

Stemming material shall be carefully poured down blast holes to minimize

downline damage and control dust.

Problem Holes The responsible FCX employee must address and ensure that all “problem
holes” are reported on the Blast Summary paperwork. Unloaded or “bad”
hole information should be included as well.

4.9 Tie-in

This section ensures detonation of all holes in the blast pattern and proper timing of all holes.

Before Beginning Tie-In The tie-in of pattern will begin only if it does not interfere with other blasting
processes and the blast site is free of distractions to those doing the tying-in.

Harness wire must be clipped in either using green wire or yellow wire; on top
of clip; but every hole clipped in consistently using the same site-specific color
on top of clip.

The tie-in pattern must begin at detonator 1 in the tie-in sequence designed
and follow the designed path. Reversing tie-in sequence is permitted but only
if sequence starts at last detonator and follows designed sequence
backwards. This is to prevent any potential misfires; the tie-in sequence is to
be followed exactly as designed.

All splices must be double clipped, and these clips taped with electrical tape;
to prevent clip from opening causing misfires during initiation process.

All personnel responsible for tie-in and logging should be listed in the blast
documentation.

Detonator Count Check Detonator count will be obtained from the data logger and a check made
against the field inventory of detonators and boosters recorded on the Blast
Summary Sheet (adjusted for “bad” or extra det’s used if necessary). Any
discrepancy must be reported to the responsible FCX employee and rectified
before moving into the blast initiation stage.

Blocker Notification A shift supervisor and\or shot blockers and sweepers should be notified at
least 30 minutes prior to completing tie-in, so that shot blockers and
sweepers can prepare for the pre-blast meeting.

18
Blast hole Diagram The responsible FCX employee shall generate a tie-in sequence diagram of
every blast hole.

This diagram will be included with the other blasting documentation required
from the daily blasting activities.

The responsible FCX employee shall review the sequence diagram with
personnel doing the tie-in. If contractor is doing this process, they must
review it with responsible FCX employee.

All “Harness Wire Splices” locations are to be documented on tie-in map

during tie-in.

Pre-splits or Secondary After tie-in is complete, the pattern must be independently checked by two
Blasting individuals, required if detonator cord is being used on surface. Make sure
every hole is tied in properly and verifying completeness, matching to the
blast map. Both shall initial the check on the Blast Summary.

Equipment Required Programmable electronic detonators with accompanying software and

hardware are required. Alternate methods may be used for pre-split and
secondaries if proper tie-in and timing are assured.

Using Programmable When using programmable delays, the blast crew will use the logger tests to
delays verify hook up reliability. If a “bad” detonator is encountered the back-up
detonator will be utilized. (See section 4.6 Priming: Detonators and Boosters)
Documentation of the situation and extra product usage on the Blast
Summary is required.

Final Checks Non-essential personnel should be removed from blast site prior to final tie-in
checks.

4.10 Pre-blast Meeting

This section ensures that all personnel involved in clearing and initiating a blast are clear about
assignments, properly equipped and knowledgeable of responsibilities.

Prior to Pre-blast Before the pre-blast meeting, uniquely numbered blue cones will be placed to
Meeting MARK the blocking position. Make sure no numbers/letters are
duplicated/legible on all blue cones. (Note: If Autonomous haulage site, then
Black cones can be used in lieu of Blue)

Attendance The responsible FCX employee will conduct the meeting.

This meeting will be a face-to-face meeting and will include all blockers and
sweepers. All blockers will remain at the meeting until the meeting is over.

This meeting must take place at the blast site or in the blast area, with view of
blast site when attainable.

NOTE: In particular, cases where FCX/Contractors are used for blockers and
they are restricted by long distances from attending, it is permissible for them

19
 to be told about assignments on a one-on-one basis by the responsible FCX
employee.

Best Practice Recommendation:Use a detailed guarding map with assignments

and routes marked, when assignments are given in advance.

Receiving Each blocker and sweeper will receive their assignment at the meeting and
Assignments the responsible FCX employee will ask them to repeat back the assignment,
their responsibilities, and ask if they have any further questions.

Document Blockers\Sweepers and their assignments must be documented.

Equipment Yellow cones will be provided for each blocking position to block the road's
full width.

Vehicles for Clearing All vehicles used for clearing and blocking will be equipped with a functional
and Blocking two-way radio and functioning beacons and/or flashers.

If vehicles are not used for blocking, a person with a flag (or suitable signage),
radio, and yellow cones is acceptable.

4.11 Clearing\Sweeping the Blast Area

This section ensures that the blast is perfectly cleared and that all affected personnel are notified.

Employee Clearing for a shot will be directed\supervised by a Responsible FCX

Requirements Employee who is an exempt employee.

Those clearing\sweeping for a shot must be qualified FCX employees who

have been trained. This training must be documented.

Contractor employees may be used for blockers and sweepers if they have
been properly trained and the training is documented.

Direction for Clearing Clearing an area for a blast will begin at the blast site and proceed outward.

Notification Required All affected personnel will be notified prior to clearing to allow for orderly
preparation and evacuation of the blast area.

Equipment All affected equipment will be positioned or relocated to a safe position to

prevent damage from fly rock or blast vibration.

All equipment in the blast area will be cleared of personnel following site-
specific procedures.

Guarding Entries During clearing, all entries previously cleared will be guarded to prevent re-
entry into the cleared area (“back doors” will be held).

4.12 Securing and Holding Blocking Position

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The purpose of this section is to ensure that blocking positions are never compromised, and clear,
concise communication is maintained between the responsible FCX employee and each blocker.

Duties of Securing and holding of blocking positions will be overseen by the

Responsible FCX responsible FCX employee (exempt). A responsible FCX employee (non-
Employee Exempt exempt) may be used to perform the duties below if directly supervised by
the responsible FCX employee (exempt) unless otherwise stated. Duties
include:

• Prior to pre-blast meeting, determine blocking locations and place a

uniquely numbered blue cone at each location. (Note: If Autonomous
haulage site, then Black cones can be used in lieu of Blue). This is to
mark the blocking location NOT to block the road. The best practice
is to place these cones out as early in the morning as possible so
traffic will know blocking areas when it is time to clear blast area.
• The clearance map for each blast will be the responsibility of the
responsible FCX Exempt employee.
• Maintain a blocker checklist and use it to verify completion of
assignments.
• Complete a redundant check with each blocker prior to the last blast
warning.
• Instruct each blocker to hold their position if a delay occurs.
• At the end of the delay, check with each blocker before continuing
with the last blast warning.
• Document any unplanned situation during any part of blocking and
securing procedures

Duties for Blockers Blockers will:

(also see Section 3.4
Blockers and • Be trained to FCX standards and the training documented.
Sweepers) • Drive to assigned blocking location identified by the
corresponding uniquely numbered blue cone. (Note: If
Autonomous haulage site, then Black cones can be used in lieu of
Blue)
• Turn vehicles or equipment used for blocking perpendicular to
the flow of traffic (if vehicles are used)
• Use a minimum of three yellow blast cones to block all the road.
• Have contact with the responsible FCX employee via radio.
• Communicate to the responsible FCX employee, in detail, actions
taken to clear the area (if sweeping) and that the blocking
position is secure.
• Not permit entry to the secured area by anyone without
permission of person in charge of the blast

Duties for Sweepers Sweepers will:

(also see Section 3.4
Blockers and • Sweep and clear equipment and pick up personnel in assigned
Sweepers) area.
• Assist other sweepers with “holding back doors” while benches
are cleared.
• Clear all the way out to the assigned blocking location.
• Communicate to the responsible FCX employee, in detail, actions
taken to clear the area and that the blocking position is secure (if
blocking)

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4.13 Blast Initiation

This section ensures all detonators are communicating, the blast area is clear, and all blocking
positions are secure.

Direction/Supervision Blast initiation will be directed/supervised by a Responsible FCX Employee

(Exempt Employee).

Blasting Time The Responsible FCX Employee will determine if enough time remains before
sunset so that, there will be enough natural light to conduct a post-blast
inspection.

Blast Initiation Blast initiation will take place from a location safe from hazards resulting
Location from blasting and where the blast can be viewed.

The blast initiation location will be a safe distance from electrical

interference (e.g., power lines, power cables, radios).

Radios/Drones/Sirens or any equipment that could cause electrical

interference with the initiation system, must be kept a minimum of 25 feet
(7.6m) from blasting equipment during the initiation process.
Best practice: Keep drone or truck radios a minimum of 50 feet(15.2m) away
from blasting box, to prevent interference.

Firing/Initiation The remote box on the pattern can be armed or turned on and the dongle
System can be removed and taken to the firing point when the Blast Site has been
cleared and the guard has been removed. The firing dongle is not to be put
into the firing box unless told to do so by the responsible FCX employee and
the blast area has been cleared.

The firing/initiation system will always be in the possession of the blasters

and under control of the responsible FCX employee.

The firing/initiation system will be connected by the responsible FCX

employee (exempt) or a person under his/her direct control. The responsible
FCX employee overseeing the blasting process must be at the firing location.

Radio Two-way radio communication between the responsible FCX employee and
Communication all blockers will be maintained throughout the clearing, blocking and
initiation processes.

Communication The responsible FCX employee will ensure that all electronic detonators used
Devices/Errors in a blast continue to “communicate” with the blast initiation device
throughout the blast initiation process.

The “communicating detonator count” will be checked against the

“detonator used count,” verified during priming and loading.

22
 Shooting “through errors” or “with errors” (see section 9.0 for definitions) is
forbidden.

All blasts must be videoed unless weather or conditions are unsafe to do so.

Failure to Detonate Blasting personnel will be competent in safe practices if a blast fails to
Procedures detonate.

If the pattern must be “re-entered,” the blasting equipment must be “Safe”

(dongles removed and in the possession of the person re-entering the
pattern). Site procedures or SOPs must address this procedure and be
followed.

The waiting period for a shot that has been aborted during the arming
process, whether it has electronic and/or pyro detonators, is 5 minutes. For
misfires, the wait time is 30 minutes for Electronic Detonators and
Pyrotechnic Detonators.

4.14 Post-Blast Inspection

This section ensures that the blast holes have been detonated and that the area is safe for re-entry.

Requirements A post-blast inspection will be performed under the supervision of a

Responsible FCX Employee and documented.

After a successful blast, the Blast Area may be entered after a 5-minute wait
period and when the dust clears.

Secondaries and pre-split Blast Site will be walked for post-blast inspections
if detonating cord is used, to make sure all the product has fired.

There will be enough natural light to conduct a post-blast inspection.

The post blast inspection must be done by conducting a visual inspection

around blast site perimeter; driving around blast site perimeter is acceptable,
if safe to do so. Walking the shot is also allowed by qualified personnel and

23
 only if a spotter is used at the blast site with radio communication. A list of
items to identify the possibilities can be found in the definitions section.
Site specific other visual means can be used “Only if access has been
compromised” such as:
• binoculars,
• looking over the high wall
• zoom cameras.
• drones or video
• other acceptable means

Electrical Storm In the event of an electrical storm, a visual drive around blast site is
permitted; you do not have to get off vehicle to clear blast site.

If the blast site must be walked, wait until the warning system has indicated
an “all clear” before re-entering the blast site.

Blockers All blockers will remain in place during the post-blast inspection.

Completing the Yellow cones will demarcate the blast site until the post-blast inspection is
Inspection complete and the responsible FCX employee gives the “all clear.”

Re-Entering Blast Site A minimum of 5 minutes must elapse before re-entry into the blast area.

Do not re-enter if noxious fumes or excessive dust clouds are present, wait
until they dissipate.

Care should be taken not to endanger personnel.

4.15 Blast Monitoring

This section ensures blast vibration data is recorded and used to manage slope stability.

Viewing Blasts will be viewed from above if possible.

Monitoring system A blast vibration monitoring system-utilizing seismographs must be instituted

and actively managed and utilized by both Blasting and Slope Stability
personnel.

The seismograph reading records must be available, up to date and shared

with appropriate personnel.

24
 Information from seismograph readings pertaining to signature holes must
be used as recommendation/implementation for timing of blasts.

4.16 Misfired Hole Procedure (CFR 56.6311)

This section ensures that personnel involved in blasting and operations processes are trained to
recognize a misfire and are familiar with the procedures for dealing with it.

Blasting Personnel Blasting personnel must:

Duties
• Know the definition of a misfire hole, live hole, bad hole, &
problem hole.
• Be familiar with the blasting products used.
• Be familiar with what a misfire looks like.
• Know how to determine if there is a misfire.
• Be familiar with the waiting period for a suspected misfire, which is
30 minutes before you can enter Blast Area.

Process for Misfire If there is a misfire or live hole, blasting personnel will:
and Live Holes
• Restrict access.
• Document and handle them properly.
• Mark in the field in an easily recognizable manner
o Minimum 30 foot (9.1m) in diameter with red or
appropriate flagging attached to Lathes and signage
stating barricading reasons.
• Enter the hazard into shovel/loader computer GPS systems (if
used) to alert shovel and loader operators of the location.
• Notify all supervision/management who will be affected by the
hazard area.
• Inspect bench floors for evidence of any misfired product
remaining after mining through.
• Safely dispose of misfired (recovered) products following site
SOP’s.
• Offset future drilling locations 5 feet (1.5m), to prevent from
drilling into explosives remaining in the bench floor.

Training and Annual A safety session on unfired powder column and blasting component
Refreshers recognition will be part of all mine personnel, training including annual
refreshers.

Reporting Misfires Misfires/Live, holes occurring during the shift shall be reported to mine
management no later than the end of the shift.

If a misfire is uncovered while loading shot material, the loading equipment

should be moved to a safe loading location until the misfire can be thoroughly
investigated, during daylight hours.

Investigation/ Treat it as a serious event and investigate causes for all misfires/live holes.
Documentation Develop and share action plans.

25
Faces & Muck Piles Faces and muck piles shall be examined for misfires after each blasting
operation.

Work in Affected Area Only work necessary to remove a misfire/live hole and protect the safety of
miners engaged in the removal shall be permitted in the affected area until the
misfire is disposed of in a safe manner.

No Safe Disposal When a misfire/live hole cannot be disposed of safely, each approach to the
Possible area affected shall be posted with a warning sign at a conspicuous location to
prohibit entry, and the condition shall be reported immediately to mine
management

Checking for Firing If it can be safely fired, all equipment and personnel must be moved out
Ability further than the normal clearance limits. Clearance limits are site specific and
are determined by the responsible FCX employee.

In most cases, it is much safer to dig out a misfired powder column following
site procedures or SOPs. Also, ensure site procedures are followed when
removing any boosters or detonators from a misfire.

Misfire Explosive If an explosive product such as a booster with detonators is found or

Product Handling recovered, that product will remain intact and be destroyed at the site's
Procedures earliest safest convenience. The detonators must not be tested, and they can
only be walked to a safe location for disposal and cannot be transported in any
vehicle.

In a case where a booster and detonator are found at night and cannot be
disposed of properly, follow all procedures for sleeping a shot and red alert
procedures will apply.

If an explosive booster is found only, this product can be transported and

stored until it can be destroyed safely.
If explosive products such as ANFO or Emulsion are found without detonators
or boosters, this product can be flushed with water to dissipate the product.

4.17 Sleeping / Guarding Shots, Lightning Storms

The purpose of this section is to ensure shots slept overnight are safely managed. Each site will have a
procedure for sleeping shots.

Overnight Shots can only be slept overnight for these reasons:

• breakdowns rendering equipment immovable.

• weather
• darkness
• environmental or social reasons

Physical Guard Shots slept overnight will be guarded by at least one person and barricaded to
prevent unauthorized access to the blast pattern.

26
Variance signatures Variance for shots slept will be signed off on by the Mine Manager using the
DOHS Site Ops Management of Change-Short Term HS Variance and General
Manager will be notified. If after normal operating hours electronic
confirmation for signatures will be accepted as sign offs on variance forms.
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Longer than 72 hours If blasting of a loaded hole may be delayed for more than 72 hours, the
operator shall notify the appropriate MSHA district office.

Harness wire If a shot is slept all harness wires will be disconnected, if can be done safely.

Sleeping a shot during If a shot is being slept and a red alert warning is activated, all clearing and
red alerts blocking procedures for a regular blast must be followed.

A detailed guarding plan must be made by the responsible FCX employee and
communicated face to face with the oncoming mine operations shift
supervisor. The plan must consist of detailed guarding locations (maps) and
instructions of what areas need to be cleared to meet all safe distances for a
blast zone. All blocking positions must be marked in daylight hours with
uniquely numbered blue cones and the guarding sheet provided with all
numbered blue cones locations. All aspects of the blast must be communicated
to the mine operations supervisor, who will oversee clearing, blocking, and
lifting of guards when determined safe to re-enter the area when the red alert
is lifted.

4.18 Lightning Storms/Red Alerts during Blasting Process

This section ensures shots are safely managed during electrical storms or red alerts. Each site will have
a site-specific procedure for red alerts during blasting process.

Detection system Each site must have a lightning detection system in operating order.
• Have a site-specific SOP detailing procedure, settings and how their
systems are used and maintained.
• The detection system must be capable of measuring potential and
actual lightning strikes.
• Each site is responsible for determining their boundaries for yellow
alerts, and red alert, due to lightning strikes. Recommended distances
are red alert within 5 miles (8km), yellow alert within 10 miles(16km)
for blasting sites.

Red Alert for lightning During the approach and progress of an electrical storm that causes a red alert,
strikes Surface blasting operations shall be suspended, and persons withdrawn from
the blast area by responsible FCX employee and blasting crew.

If the Responsible FCX employee or blasting crew determines at any time that
there is the potential for lightning strikes within the blast area (with or without
warnings from lightning detection systems), they may suspend operations and
withdraw personnel from blast area.

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Clearing Procedures In the event of an approaching electrical storm, the responsible FCX employee
(exempt) will be responsible for clearing the blast area in the same manner as
clearing for a blast.

People will be cleared to the boundary of the blast area by normal blasting
clearing and blocking procedures.

Any vehicle carrying explosive products and loading trucks will be left on the
blast site and all personnel cleared from the blast site and blast area.

Initiation of blast Initiation of the blast is allowed under a red alert if the following conditions are
during Red Alerts met.
• Supervision has been notified, and they have given you permission to
initiate a blast.
• No personnel must get out of their shelter area to do anything to
commence initiation of blast.
 This would include such tasks as cable work, having an
operator get off piece of equipment, and/or connecting
initiation systems. Anything that could put personnel in
danger should prevent blasting crew from initiating a blast.
• All guards are in place and all equipment have been cleared the proper
distances from blast.

Post blast inspections Post Blast inspection under red alert

during Red Alerts • Enter blast area only after 5-minute wait and blasting boxes indicate
all detonators have been fired successfully.
• Do not walk onto pattern if under red alert or visual lightning is taking
place. You can drive to the perimeter of the blast site like normal
clearing of blast site. Once it looks like everything fired, only then can
you declare blast area “Clear.”
• If detonating cord is used, you cannot walk pattern during red alert so
keep blast site barricaded.

5.0 Records

This section ensures accurate records are kept as required by regulation.

The following • Employee training records

records must be • Equipment inspection records
retained according • Variance documents
to the FCX-Records • Daily FCX magazine inventories transactions shall be recorded, and
Retention Policy paperwork stored for each blast. This will include all blasting products
inventories, BOL’s and consumptions.
• Magazine physical inventories shall be checked for accuracy at least once
per month by GSC and verified inventory matches SAP ending inventory.
Any discrepancy shall be immediately investigated and documented.

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 • When Contractors control magazine physical inventories, a Responsible
FCX employee shall conduct a physical ending inventory count at the end
of each month. (Note: Contractor inventory must match your monthly
usage and ending inventory, for monthly billing purposes)
• FCX supervision will conduct a physical inventory count of magazines
quarterly and document. Any discrepancy shall be immediately
investigated.
• A yearly close out and starting inventory will be conducted and
maintained as part of the permanent records required by the regulatory
agencies (FCX verification is required).
• Each site shall maintain daily blasting documentation (Blast Summaries)
that contain information such as load amounts, blast diagrams, timing
configurations, post-blast data uploads, “bad” or “problem” holes, and
other “out of the ordinary” or pertinent information.
• Licensees and permit holders must keep all records pertaining to
explosives, in permanent form, for not less than 10 years.
• License and permit documentation shall be kept current and displayed in
conspicuous areas. Records of Employee Possessors and Responsible
Persons must also be maintained and updated quarterly by Blasting
Supervision or delegated personnel.
• Any changes pertaining to new and/or dismissed employees aimed at
licensing and permits, must be sustained according to BATF rules and
regulations relating to licensing. These deviations are the responsibility of
each site's Blasting Supervision or delegated personnel.
• Each site is responsible for developing SOPs for training, certification and
licensing of employees that handle explosive products. This includes
contractors. Copies of these records will be kept by the Drilling and
Blasting department or training department.
• Each site is responsible for developing SOPs for reporting explosive
procurements, transportation, and usage to the appropriate government
agencies on a jurisdiction-specific basis.
Falsification of explosives records or documentation is a crime and
may be punishable by fine and jail sentence.

6.0 Recommended Equipment and Software

This section's purpose is to aid in standardizing the types of stemming equipment, blast timing, and
seismic tools used at our various sites.

Stemming Process For the stemming process, it is recommended to use rubber tired, or rubber
track loaders equipped with a side-dump bucket, small enough to easily
maneuver through the holes on blast patterns.

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 Blasting For blasting, an electronic, programmable detonator system is mandatory at
all FCX sites. The i-kon products from Orica are most commonly used.

Seismic Sites are using standard technology tools to monitor blast vibrations for
every blast initiated and communicating these results with Drilling and
Blasting Departments.

7.0 Training and Competency (Future Development)

All employees and contractors who participate in drilling, sampling, blasting, or support blasting activities shall be
trained to effectively perform expected duties. This training shall be documented.

30
Required Skills Sites will develop a list of required skills and evaluate individuals to verify competency
prior to participating in or support blasting activities without direct supervision. The skills
shall include:

• Staking drill holes

• Duties of Responsible FCX Employee
• Duties of a Lead Blaster and magazine manager
• Duties of a sampler
• Conducting a pre-loading site inspection
• The identification of unique hazards for blast patterns
• Hole loading practices for routine and non-routine holes
• Magazine inventory control
• Safe transport of explosives
• Field inventory control
• Inventory reconciliation
• Guarding a shot overnight
• Establishing evacuation areas for blocking
• Effective blocking for a blast
• Post blast inspections
• Managing misfires or discovered explosives.
• Lightning storm precautions \ actions

Annual Blaster Best Practice: Each site should consider having Annual Blaster Refresher training for their
Refreshers employees. This refresher can be used to update new practices or procedures and be
used for line of progression for each site.

Best Practice: South America personnel are given a card which indicates what they are
tasked trained on at site. They keep this card with them at all times while at the mine, so
anyone would know what they are task trained on before assigning a task.

8.0 Variance

If any part of this policy cannot be followed, an approved Variance is required.

Variance It is expected that all sites will follow this FCX policy. However, periodically
there may be extraordinary circumstances due to site-specific issues that do
not allow all aspects of this policy to be completely followed.

If any part of this policy cannot be followed, a variance form must be

completed per the DOHS Site Ops Management of Change-Short Term HS
Variance
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9.0 Definitions

Definitions

Air Blast The noise produced by a blast that travels through the air and is scaled by
decibels

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Back Door Phrase used to describe access to a bench connected to a haul road. This “Back
Door” will be guarded by a sweeper until another sweeper has gone onto the
bench and ensured that it is clear of personnel

Blast Area The area in which concussion, flying material or gases from an explosion may
cause injury to persons or damage to property.

Blast Site The area where explosive materials are handled during loading includes the
perimeter formed by the loaded blast holes and 50 feet (15.3 meters) in all
directions from loaded holes. A minimum distance of 30 feet (9.1 meters) may
replace the 50-foot requirement if the perimeter of loaded holes is marked
with a barrier.

Clearance Limits These cannot be standardized for all the mines, as there are so many variables
at each mine it must be the responsibility of the Responsible FCX Person to
decide the distance, as the vertical distance increases the horizontal distance
may decrease. Again, this is the responsibility of the Person in charge to
determine.

Direct Control Having face-to-face contact to ensure clear and concise communication.

Explosives Transport The vehicle that carries blasting accessories (powder truck).
Truck

Intrinsically Safe Refers to a device that has been designed to be incapable of producing heat or
spark sufficient to ignite an explosive atmosphere, even if the device has
experienced deterioration or has been damaged.

Misfire The complete or partial failure of explosive material to detonate as planned.

The term also describes the explosive material that failed to detonate.

Misfire Hole • Attempted to fire no evidence of detonation on all or part of the blast
patterns.
• Known or suspected failure to detonate.
• Product found during mining process.
• Software aborted fire command

Bad hole A “bad hole” has no product.

• Bridged over
• Too close to crest
• Too close to an adjacent hole
• Any hole in pattern not loaded.
• Too short to load or voids present.

Close Holes Two or more blast holes that are of close distance from one another;
determined by sites. Advise these type of blast holes be initiated with the
same timing or eliminated; to prevent sympathetic detonation, dynamic shock,
or dead pressing.

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Problem Hole A “problem hole” has received product and

• May or may not be fired.

• Has a “bridge over” condition after priming or loading takes too much
or too little stemming.
• Has lost, cut, or damaged downlines.
• Is not identified in the blast plan.
• Has column subsidence
• Has other inconsistencies
• No replies

Live Hole A “Live hole” is a blast hole that:

• Has product and will not be fired.

• Cut downlines, lost downlines.
• Cannot tie-in by any means

Identifying misfire Look for areas of the blasted pattern, which look flat and/or have not been
when walking the lifted or displaced from fired blast holes.
shot
Look for product such as detonating cord, boosters or Senatel (Emulsion
Chubs) on pre-splits or secondary shots. Cord can also be discovered when
using cord to booster; downhole.

During a blast if you have a good visual of blast pattern and you see potential
holes not fire, these holes or areas can be checked visually. Visually inspect the
ends of the pyro detonators, these ends have a built-in indicator that shows it
has been burnt, to confirm the pyro detonator has been fired.

Responsible FCX Blasting Supervisor, Blasting Engineer, Lead Blaster, or other “qualified” person
Employee who is an employee of FCX. The person in charge of the clearing process will
always be a qualified exempt employee. Contract personnel may not be the
responsible FCX employee.

Stemming Rock crushed to 80% 1 inch to 1 ¼ inch with a maximum size of 2 inch (based
on 10 5/8” hole diameter, varies according to hole size). There should be no
fines.

Subsidence The downward movement of the earth from blasting, earthquakes, or other
causes

Sweeping/Clearing/ Ensuring all personnel are removed from the blast area and restricting entry
Blocking before detonation of the blast(s).

Distributing The process of distributing Primers, and Detonators to each hole to be loaded
Accessories and shot

With Errors This is to continue with the initiation process even though the blasting box
presents a message that says “with Errors” the box will also display a code that
shows where the error is. It is forbidden to fire with errors.

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10.0 PRILL TANKS

Prill Tank silos • Conduct yearly inspections

Inspection • Housekeeping of area including spills and vegetation
• Silos in decent shape with no visible damage on silo walls and hopper;
such as rust, cracks, rusty bolts or missing bolts, welds intact
• Access ladders, cages, and railing in good condition, barricaded and
signed properly
• Silos roof sealed properly to prevent water from entering tanks
• Fill pipe in good working order for off-loading AN into tanks and vents
are working correctly/not plugged on top of tanks
• Vibrators secured and in working order
• Properly grounded and grounds in good condition
• Properly signed and signage in good readable condition
• Cross bracing and all tie off points in safe working order and no visible
rust or deformation on anchoring points or fall protection cables
• Waste barrels with lids; accessible and properly marked
• Base foundation system; concrete slab has no major damage
• Columns and baseplates are in good condition and mounted correctly
• Silos level and ground structurally solid
• Insulation on emulsion tanks in good condition

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