As pressures on the minerals sector continue to grow, operators are facing a pivotal question. How can quarries unlock more value from the reserves they already have? With planning permissions becoming harder to secure and replenishment rates falling, the industry is increasingly focused on getting the most from every tonne beneath the surface.
This challenge set the scene for a recent IQ Derbyshire Branch technical evening, where attendees gathered to hear from Brian Duthie of Nova Geo Consulting. The presentation explored how innovative geotechnical thinking and practical design changes can significantly extend quarry life while maintaining compliance with the Quarries Regulations.
Brian centred on three detailed case studies which demonstrated how a combination of geotechnical assessment, engineering controls, and revised excavation strategies can significantly extend the operational life of quarries.
Case Study 1: Enhanced Stability to Unlock Greater Depth
At the first quarry, the introduction of presplit blasting, mechanical scaling, and robust rockfall control improved overall face stability. These changes allowed the removal of benches and rock traps, creating an opportunity to work an additional 77 metres in depth. This adjustment has the potential to extend the quarry’s life by more than 20 years.
Case Study 2: Reassessing Historical Faces to Release Additional Reserves
The second quarry showed how the careful review of historical faces can support steeper and safer design options. Working within the requirements of Regulations 22 and 12, the revised design released approximately one million tonnes of additional rock. This demonstrates the value of revisiting older excavation data to unlock reserves that may previously have been considered inaccessible.
Case Study 3: Mechanical Extraction as an Alternative to Blasting
The third example highlighted how alternative extraction methods can influence quarry design. By using mechanical techniques that reduce reliance on blasting, the operator was able to work with steeper faces and narrower benches. This approach significantly increased the amount of recoverable material, showing how changes in method can deliver both operational and geological benefits.
Looking Ahead: The Role of Integrated Geotechnical Data
The evening concluded with a discussion on future opportunities for research and innovation. Brian emphasised the importance of integrating site geotechnical data, including information collected during drilling and blasting, into quarry design processes. By combining real time data with thoughtful engineering, operators can continue to identify new efficiencies and maximise the reserves already available to them.
This session highlighted how site-specific assessment and innovative thinking can make a substantial difference to long term resource planning.
As planning constraints become more demanding, these approaches will play an increasingly important role in supporting the future sustainability of the industry.
The Value of IQ Branches and Volunteer‑Led Events
Events like this are made possible through the commitment of the Institute of Quarrying’s nationwide network of volunteer‑run branches. These branches play a vital role in supporting professional development by creating regular opportunities for members to hear directly from specialists, share experiences with peers, and stay connected with industry developments.
Branch technical evenings are more than learning sessions. They help build local professional communities, encourage the exchange of practical knowledge, and offer a platform for open discussion on industry challenges. The volunteers who organise these events give their time to keep the industry informed, engaged, and progressing, and their work underpins the Institute’s commitment to lifelong learning.
Regular attendance not only supports these volunteers but also ensures that members continue to benefit from up‑to‑date insight, best practice, and a stronger professional network.
View the latest upcoming events here: https://www.quarrying.org/iq-upcoming-events