A step-by-step guide on drill and blast safety audits

Effective and safe drill and blast operations are essential to a project’s success in the mining, quarrying, and construction spaces. If exceptional care is not taken, the repercussions can be immediate and severe, exposing companies to serious regulatory penalties, lengthy project delays, and potential harm to employees.

When diligently conducted, regular safety audits can mitigate much of this risk by helping companies identify critical gaps, enhance safety cultures, improve team coordination, streamline resource management, and minimise the degradation of explosive materials. When done properly, audits cover a wide spectrum of issues, ranging from verifying the correct usage of personal protective equipment and ensuring licences are always up to date, to inspecting the structural integrity of magazines where explosives are stored.

To guide clients in strengthening their safety standards, our safety specialists at Mining and Energy Acuity (MEA) have laid out five essential steps to help businesses conduct thorough, in-depth audits for drill and blast operations:

1.     Create and maintain comprehensive safety data documentation 

A Safety Data Sheet (SDS) serves as an essential reference for safely handling explosives, blasting agents, and any auxiliary chemicals involved in rock fragmentation. These documents highlight the specific hazards of each product, such as ammonium nitrate, fuel oil mixtures, or more specialised emulsions, and outline any chemical reactivity concerns.

Workers rely on the SDS to understand the risks associated with drilling fluids, explosive primers, and detonators, so they can implement the correct protocols for storage, use, and disposal. Additionally, by consulting the SDS, drill and blast teams learn about potential health impacts from inhalation of dust or fumes, as well as the proper use of personal protective equipment to reduce the chance of contact injuries or respiratory issues.

Safety data sheets are central to ensuring compliance with health and safety regulations, and should be updated and well maintained throughout operations, while ensuring that everyone involved is fully aware of the best practices for protecting themselves, their coworkers, and the surrounding community.

2.     Inspect equipment and the site environment for potential hazards 

Any comprehensive safety audit must include a systematic review of equipment and the broader environment in which drilling and blasting occur. This goes beyond verifying maintenance records and certifications for drilling rigs or compressors. Loose or damaged rock surfaces, evidence of misfires, or unidentified drill consumables must also be addressed before work resumes. A simple measure, like keeping a log of lost drill rods or bits, prevents unexpected detonations and costly downtime.

3.     Conduct risk assessments and green area meetings before each blast

Conducting a thorough risk assessment with all personnel before each blast is critical for preventing accidents and ensuring compliance. A successful risk assessment identifies all potential hazards associated with the upcoming task, along with the likelihood and severity of these hazards.

By including all personnel involved in the task, and encouraging each to contribute their observations, a more comprehensive overview of the potential risks can be formed. The team can then determine solutions with which to minimise the exposure to these hazards.

Equally important is hosting a ‘green area’ meeting, during which the details of the blast, such as scope, responsibilities, and relevant safety measures, are clearly explained. Keeping proof of both the risk assessment and the green area meeting participation – sign-off sheets and physical or digital records – further protects the organisation in the event of an incident investigation.

4.     Verify licences, permits, and training compliance 

Cutting corners on licences or staff training can lead to serious legal penalties and even site shutdowns. It’s essential to maintain valid permits for storing, transporting, and using explosives, and to beware that these often have expiry dates and strict renewal conditions. At the same time, all personnel, from the drilling crew to magazine keepers, should possess the requisite competencies and certifications. 

5.     Develop and refine a comprehensive blast plan 

As part of any audit, auditors and operational supervisors must keep an updated blast plan available on-site that covers everything from hole placement, quantity of explosives required per hole, site clearance and security procedures, right through to a chain-of-command for misfire reporting.

Any deviations from the plan, such as changes to hole depth or charge amounts, must be documented and explained. This maintains transparency while enabling teams to learn from real-world conditions and refine the plan for future blasts. Over time, audits of these deviations can reveal patterns in site conditions or equipment performance, helping companies adjust processes to become both safer and more efficient.

6.     Standardise and implement communication and coordination protocols

Even the most comprehensive safety procedures can fail if critical information isn’t relayed effectively. Audits should evaluate how teams communicate in the final stages before a blast. Is there a formal callout system? Who confirms that the area is fully cleared?

If staff rely on informal channels, formalising sign-off sheets or scheduled radio check-ins can be pivotal to preventing serious incidents.

7.     Schedule and follow up on regular internal audits

Finally, safety audits themselves must be ongoing. By scheduling them at regular intervals –either weekly, monthly, or quarterly, depending on operational intensity – companies can introduce and support a proactive, rather than reactive approach to maintaining blast safety protocols.

By grounding operations in effective procedures and consistently reviewing them, companies protect both personnel and timelines, while creating a workplace culture that values care over complacency. With MEA as a partner, you gain the strategic advantage of expert knowledge, customised training, and ongoing support from the best in the industry, ultimately ensuring that your drill and blast activities run smoothly and responsibly.