The art of rock engineering design and the need for research
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- Created: Tuesday, 21 October 2025 11:02
- Written by F. Malan
Rock Engineers and mine personnel frequently disagree on design aspects. These disagreements can lead to poor designs or failures. A number of large collapses have occurred in the bord and pillar mines and open cast mines in the Southern Africa region in the last two decades. Can we learn from the decision-making that led to these collapses and improve? Philosophy offers the opportunity to adopt a reflective learning approach.
ChatGPT gave an interesting insight into this aspect of mine design. Rock engineering is less of an exact science than other engineering disciplines and it is suggested that rock engineering design is best described as a “science-based art”. The science provides the foundation and design is based on aspects such as rock mechanics principles (e.g., stress-strain behaviour, and failure criteria), empirical methods (e.g., Q-system, and RMR), numerical modelling (e.g., finite element, distinct element, and boundary element methods), monitoring and instrumentation (e.g., extensometers and stress cells) and geological and geotechnical data (e.g., boreholes, core logging, and lab tests). The designs are never purely scientific owing to reasons such as natural variability of the rock mass, the geology is complex and discontinuous, the uncertainty caused by incomplete or generalised data, decisions must often be made with partial information, when conditions change the designs must evolve, and balancing performance, cost, and safety is not purely technical.
Based on these considerations, it implies that “industry standard” criteria for design neither are always the best technical solutions, nor does it imply these criteria are correct. Davide Elmo and his co-workers explored this topic and examined rock engineering using a philosophical approach (Elmo et al., 2022) in Examining Rock Engineering Knowledge through a Philosophical Lens. Geosciences. They noted that rock engineering designs are shaped by cognitive biases, which over time have created a dogmatic barrier to innovation. Almost no attention has been given to the impact that subjectivity, human factors, and lack of scientific replicability have on the empirical design methods used in this field.
As a complicating factor, the modelling methodologies and constitutive codes typically used are difficult to calibrate and represent a universal challenge for the application of rock engineering models. As more complex numerical models are developed for the improved simulation of observed rock mass behaviour, more onerous requirements of model calibration and user expertise are required. This applies to boundary element models, finite element, and finite difference codes. Elmo et al. (2022) made the following important observation: “It is evident generally that if older and simpler solutions have a clear advantage in terms of durability and/or efficiency, even if this advantage is restricted to a limited purpose, they continue to exist and evolve.” In his 2003 Presidential Address: Rock engineering – good design or good judgement, T.R. Stacey recognised this problem and noted that rock masses are so complex that realistic modelling, even with sophisticated methods, is impossible. Simple elastic models with good engineering judgement may therefore continue to exist as one of the practical rock engineering tools.
As a first step to mitigate the uncertainty in rock engineering and the challenge described in this note, Elmo et al. (2022) emphasised that for research, critical thinking needs to be applied and the foundations of rock engineering as an empirical science should be questioned. Furthermore “replication” research should be conducted as a more rigorous form of review compared to the traditional peer review. A recent example of replication research is given by the Le Roux and Malan paper (2024). Researchers need to provide full information to allow others to replicate their work. Very often the assumptions used for numerical modelling of layout design are not given in design reports and these need to be included in the reports.
F. Malan
Journal Comment
Mining has historically been one of the most hazardous industries, a reality that has shaped the sector’s reputation for high risks and low margins of safety. Despite decades of progress in mechanisation, automation, improved ventilation, and the widespread adoption of personal protective equipment, accidents and occupational diseases remain serious and persistent concerns. Underground mining poses unique challenges because workers are confined to narrow spaces where they are exposed to unpredictable geological conditions, poor visibility, high temperatures, and dangerous gases. Beyond these acute risks are chronic health conditions that develop over time, including silicosis from prolonged inhalation of respirable dust, occupational hearing loss from exposure to high levels of noise, and musculoskeletal disorders resulting from heavy manual handling. The persistence of these problems highlights the complexity of mining safety and health, showing that technological improvements alone cannot eliminate them.
In the course of our engineering work on mining and metallurgical plants we are often called upon to evaluate the merits of different choices in process flowsheets, operating parameters and philosophies, raw material selection, and many others. The phenomenological complexity of the minerals industry usually means that each of these aspects is parameterised by a large number of variables, and there are also strong coupling effects between them – one changes a feed-rate setting here, and even though it fixes the immediate production problem over here, it also affects several other things over there in ways that one did not expect.
Just a couple of years ago the outgoing Chairman of the SAIMM Editorial Board, Dave Tudor, suggested that, as a previous metallurgical colleague, I should join the Board. Although I have been a member of the Institute for many years and was a previous Chairman of the Free State Branch, my knowledge of the management of the Institute was limited to attending some excellent schools and studying relevant journal papers.
Mining is big business. For many commodities, the orebodies are big and the best way to exploit them for maximum profit is on a large scale.
The mining industry is an exciting space, where the convergence of environmental stewardship, socio-economic responsibility, and technological innovation is reshaping the way we approach mine closure. As we navigate this complex landscape, the importance of mine closure planning is becoming more and more pronounced.
As the incoming President of SAIMM, I have been reflecting on my 34-year career in the mining industry and the lessons I have learned; lessons I can leverage to lead SAIMM and support the industry during my tenure. Writing this month’s journal comment provides an opportunity to share part one of some of these insights.
Mining has always been about more than just extracting minerals from the earth. It is about securing the future, balancing economic imperatives with environmental responsibility, technological innovation, and the well-being of those who power this industry. As we move forward, we must ask ourselves: are we truly mining with the future in mind?
This issue focuses on mine seismology, a discipline that has its roots in the South African mining industry. Gold was discovered near present-day Johannesburg in 1886. Mining related seismicity was first encountered in the early 1900s, when extensive stopes, supported solely by small reef pillars, reached depths of several hundred metres. In 1908, -the Government Mining Engineer appointed a committee to “inquire into and report on the origin and effect of the earth tremors experienced in the village of Ophirton” (Report of the 1908 Ophirton Earth Tremors Committee, Witwatersrand Earth Tremors Committee, 1915). The committee concluded that “… under the great weight of the superincumbent mass of rock [...] the pillars are severely strained; that ultimately they partly give way suddenly, and that this relief of strain produces a vibration in the rock which is transmitted to the surface in the form of a more or less severe tremor or shock.” Since then, strenuous efforts have been made to understand the phenomenon of mining induced seismicity, and to mitigate the harm that it causes through damage to mine workings and surface infrastructure, loss of production, and injury to mine workers and the public.