Engineering Performance of Data-Driven Powder Factor Optimization in Tunnel Blasting Under Complex Geological Conditions

Yusoof, A; Mohamad, ET; Saidin Misnan, M; Afrazi, M; Jahed Armaghani, D

Engineering Performance of Data-Driven Powder Factor Optimization in Tunnel Blasting Under Complex Geological Conditions

Yusoof, A Mohamad, ET Saidin Misnan, M Afrazi, M Jahed Armaghani, D

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Publisher:: MDPI
Publication Type:: Journal Article
Citation:: Geosciences Switzerland, 2025, 15, (11)
Issue Date:: 2025-11-01

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Field	Value	Language
dc.contributor.author	Yusoof, A
dc.contributor.author	Mohamad, ET
dc.contributor.author	Saidin Misnan, M
dc.contributor.author	Afrazi, M
dc.contributor.author	Jahed Armaghani, D https://orcid.org/0000-0001-8171-6403
dc.date.accessioned	2026-02-11T00:19:12Z
dc.date.available	2026-02-11T00:19:12Z
dc.date.issued	2025-11-01
dc.identifier.citation	Geosciences Switzerland, 2025, 15, (11)
dc.identifier.issn	2076-3263
dc.identifier.issn	2076-3263
dc.identifier.uri	http://hdl.handle.net/10453/193408
dc.description.abstract	This study introduces a cohesive and flexible methodology for optimizing tunnel blasting in the Gambang Tunnel 1 project, located in Malaysia’s geologically intricate tropical setting. The study examines the intrinsic difficulties of attaining safe and effective rock fragmentation in weathered, fractured, and large rock conditions commonly found along the tunnel alignment. The study utilized established rock mass classification methodologies, specifically the Q-system and Rock Mass Rating (RMR), to classify the tunnel face into specific geological zones. The optimization of the blast design aimed to determine appropriate powder factor ranges for each rock class by connecting rock mass quality with actual blast performance and fragmentation results. The results indicated that weathered zones (Q-value < 1.0) efficiently responded to powder factors of 0.65 to 0.85 kg/m<sup>3</sup>, whereas fractured zones (Q-value 1.0–4.0) attained optimal fragmentation with powder factors ranging from 0.85 to 1.10 kg/m<sup>3</sup>. The study emphasizes that incorporating rock mass categorization into blast design increases technical accuracy, minimizes over break and vibration, optimizes mucking efficiency, and fosters safer working environments. Furthermore, the methodology complies with regulatory standards established by authorities, ensuring that blasting activities are secure and subject to audit. This study offers pragmatic recommendations for forthcoming tunneling endeavors in analogous geological contexts, illustrating the significance of data-informed, site-specific blast design in fulfilling engineering, safety, and environmental goals.
dc.language	English
dc.publisher	MDPI
dc.relation.ispartof	Geosciences Switzerland
dc.relation.isbasedon	10.3390/geosciences15110441
dc.rights	info:eu-repo/semantics/openAccess
dc.subject	0403 Geology, 0907 Environmental Engineering, 0909 Geomatic Engineering
dc.subject.classification	3705 Geology
dc.subject.classification	3706 Geophysics
dc.title	Engineering Performance of Data-Driven Powder Factor Optimization in Tunnel Blasting Under Complex Geological Conditions
dc.type	Journal Article
utslib.citation.volume	15
utslib.for	0403 Geology
utslib.for	0907 Environmental Engineering
utslib.for	0909 Geomatic Engineering
pubs.organisational-group	University of Technology Sydney
pubs.organisational-group	University of Technology Sydney/Faculty of Engineering and Information Technology
pubs.organisational-group	University of Technology Sydney/Faculty of Engineering and Information Technology/School of Civil and Environmental Engineering
utslib.copyright.status	open_access	*
dc.rights.license	This work is licensed under a Creative Commons Attribution 4.0 International License (CC BY 4.0). To view a copy of this license, visit https://creativecommons.org/licenses/by/4.0/
dc.date.updated	2026-02-11T00:19:11Z
pubs.issue	11
pubs.publication-status	Published
pubs.volume	15
utslib.citation.issue	11

Abstract:

This study introduces a cohesive and flexible methodology for optimizing tunnel blasting in the Gambang Tunnel 1 project, located in Malaysia’s geologically intricate tropical setting. The study examines the intrinsic difficulties of attaining safe and effective rock fragmentation in weathered, fractured, and large rock conditions commonly found along the tunnel alignment. The study utilized established rock mass classification methodologies, specifically the Q-system and Rock Mass Rating (RMR), to classify the tunnel face into specific geological zones. The optimization of the blast design aimed to determine appropriate powder factor ranges for each rock class by connecting rock mass quality with actual blast performance and fragmentation results. The results indicated that weathered zones (Q-value < 1.0) efficiently responded to powder factors of 0.65 to 0.85 kg/m³, whereas fractured zones (Q-value 1.0–4.0) attained optimal fragmentation with powder factors ranging from 0.85 to 1.10 kg/m³. The study emphasizes that incorporating rock mass categorization into blast design increases technical accuracy, minimizes over break and vibration, optimizes mucking efficiency, and fosters safer working environments. Furthermore, the methodology complies with regulatory standards established by authorities, ensuring that blasting activities are secure and subject to audit. This study offers pragmatic recommendations for forthcoming tunneling endeavors in analogous geological contexts, illustrating the significance of data-informed, site-specific blast design in fulfilling engineering, safety, and environmental goals.

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http://hdl.handle.net/10453/193408