Advances in Controlled Blasting Techniques and Real-Time Monitoring: A Case Study from Navi Mumbai International Airport

Abstract

Controlled blasting plays a pivotal role in modern infrastructure development, particularly where excavation occurs near sensitive structures requiring precision, safety, and strict environmental compliance. This paper presents technological advancements in controlled blasting and real-time vibration monitoring, illustrated through a case study from the Navi Mumbai International Airport (NMIA) project, executed under Navi Mumbai International Airport Limited (NMIAL). The project involved extensive rock excavation in hilly terrain through a cut-and-fill operation where blasted rock was reused as engineered fill. The National Institute of Technology, Rourkela served as the technical consultant responsible for blast design, planning, supervision, and continuous monitoring. A unique challenge arose from the need to conduct blasting in proximity to freshly cast (“green”) concrete structures—within 2–3 hours of pouring—demanding stringent vibration control and high precision. The study integrates pre-splitting, precision charge control, electronic detonators, and real-time seismograph monitoring to ensure peak particle velocity (PPV) levels remained well within DGMS limits, while simultaneously achieving the desired fragmentation (≤300 mm and ≤100 mm fractions) for engineered fill. Experimental investigations, including comparative tests with and without pre-splitting, revealed that pre-splitting significantly reduces blast-induced ground vibrations, minimizing potential harm to nearby structures and enhancing overall environmental safety. The research highlights the fundamental relationships between pre-splitting parameters, rock characteristics, and ground motion behavior, offering practical design recommendations for vibration mitigation. The findings demonstrate that a combination of scientific blast design, data-driven supervision, and real-time feedback enables safe and efficient blasting in highly sensitive environments. Furthermore, the study underscores the role of pre-splitting as a proactive and sustainable technique for vibration control, contributing to the formulation of best practices and guidelines for environmentally responsible blasting operations—striking an effective balance between engineering efficiency and environmental stewardship.