Our approach to developing and producing Blast-Hole Liners is based on Quality, Safety, Survivability and Advancement (QSSA). The concept of QSSA is derived from our background in the Geo-membranes (Synthetic Lining/Containment Systems) field. It was developed to ensure installation and long-term survivability of these critical systems. The QSSA initiative has been applied to our SafetyBlast® product line as follows:
Quality
All Layfield Group Limited manufacturing plants are ISO 9001:2000 certified and accredited. ISO (International Organization for Standardization) is renowned for being the world’s foremost authority on quality standards. We only ship product that meets or exceeds the agreed upon or published specifications. We test for conformance during every step of the manufacturing process. We even test incoming raw materials. Every liner produced is assigned a unique identification number. Additionally, we insert an operator quality identification tag in every Blast-Hole Liner pocket that identifies 5 quality operator checks, as well as shift, date and operators initials. This audit process allows us to back track production and test data specific to any liner produced in any of our factories.
As an example of the quality and effectiveness of our product; we have large surface, deep hole/angled hole mining customers who shifted from using emulsion and blend products to 100% ANFO in combination with our Single Wall and Double Wall liners.
Safety
Layfield has conducted extensive research in the area of anti-static control. Our products are specifically formulated to reduce levels of static build-up that could potentially ignite a methane pocket within a blast-hole.
Survivability
Product survivability is a key component to performance. Over the years, Layfield has studied, trialed, and tested many adaptations of what is currently our product line. The basic platform is built on Single Wall and Double Wall Blast-Hole Liner technology.
- We only use first-quality grade virgin raw materials and additives to produce our Blast-Hole Liners. Our Blast-Hole Liner product blend has been specifically engineered for optimum strength, tear resistance and puncture resistance.
- Our Double Wall Liners are similar in concept to the Double Hull construction technique used on Oil Tankers – a tank within a tank – a tube within a tube. The outside liner protects the inner liner through the rigorous down-hole installation process, ensuring the integrity of the inner liner remains intact. The concept of independent layers, rather than homogeneous structures, has been proven far superior. Because of its effectiveness, the concept is adapted to many different design applications. In the 1970’s, ICI’s Canadian Division, then named CIL, developed a double wall polyethylene shipping sack for export shipments. Testing showed a 35% + increase in puncture strength, as compared to a single layered film of the same resin blend & equal combined gauge.
- To optimize loading survivability, Double Wall Liners come complete with 2 bottom seals plus a fold over and a 3rd seal on the inside liner, all of which are staggered for optimum shock absorption. Our Single Wall Liners come with 2 staggered seals.
- SafetyBlast® Double Wall Blast-Hole Liners are designed to deliver high levels of performance in demanding environments (deep holes, long sleep times, wet conditions). Our Single Wall Blast-Hole Liners are designed for moderate sleep times in dryer - wet conditions.
Advancement
As a company that prides itself in innovative thinking, Layfield is always searching for better solutions in all areas of its business, including product development and manufacturing. Below are some examples of our current efforts and past successes.
Product Development
- To further increase the performance of our liners, we have recently developed a pocket that will ensure the liner is not left hanging above the hole-bottom. A liner left hanging could be subjected to supporting loads in excess of 10,000 lbs (in a hole deeper than 200'). This is something we identified as a key issue when studying installation methods and once again drew on our geo-membrane know-how to create a solution.
- We are also currently in the process of developing a Double Wall Blast-Hole Liner with leak detection capabilities. To do so, we will be applying conductive materials to the inside liner. This innovation will create a superior tool in terms of managing blast performance.
- We have developed a liner for coal blasting operations that is complete with tear-away functionality. This functionality allows for the removal of material in the area being stemmed, therefore limiting the potential for contamination.
Manufacturing
The Layfield Group has developed and perfected a number of proprietary, inline, automated manufacturing processes to produce both Single Wall and Double Wall Blast-Hole Liners. We have recently increased capacity for Single Wall & Double Wall Blast-Hole Liners to service our USA initiative.