Successful Excavation with NexPand Large Hole: Regional Mall Project

When a regional mall required a new extension, the excavation team faced a clear constraint: the work area was surrounded by existing buildings, services, and overhead powerlines. Conventional blasting was not permissible. The project demanded a controlled, safe, and low-impact method to fracture and remove rock without compromising nearby infrastructure. NexPand Large Hole, a powerful rock breaking chemical designed specifically for use in large holes in quarrying, mining, and construction operations, provided the required solution.

Mall Excavation Project Overview

The excavation involved a foundation trench measuring 4 metres wide and 160 metres in length. Based on the site geology, drilling to a depth of 7 metres was required to reach the design levels. A 127 mm diameter drill was used throughout to ensure consistent performance and compatibility with NexPand Large Hole.

Key operational priorities included:

• Zero structural impact on adjacent infrastructure

• No damage or interruption to utilities

• No uncontrolled vibration, fly rock, or blast noise

• A safe and reliable, technically sound method suitable for a busy commercial environment.

NexPand Large Hole was selected for its ability to generate controlled expansion pressure within the drilled holes, enabling effective rock cracking without the risks associated with explosives.

Execution of Excavation with NexPand Large Hole

A drilling layout was designed to optimise crack formation and rock displacement. A spacing and burden of 1.5 metres was applied to align with the required depth, hole diameter, and rock conditions. This pattern ensured continuous breakage along the trench while maintaining control over fracture propagation.

Approximately 20 tons of NexPand Large Hole were used over the duration of the operation. After mixing to exact specifications and placement into the 127 mm holes, the expansion process was monitored and managed in defined sequences to maintain consistency along the full 160-metre length.

NexPand Large Hole’s controlled expansion generated uniform fractures, allowing the rock mass to break predictably. This enabled mechanical equipment to remove fractured material efficiently, without secondary breaking or unplanned overbreak into surrounding areas.

Results

The performance outcomes were aligned with the project’s technical and safety requirements:

• No measurable impact on nearby structures or services

• No vibration-related or noise-related complaints from tenants or neighbouring properties

• Clean, controlled breakage that supported steady excavation progress

• A cost-effective, environmentally friendly solution when compared with intensive mechanical breaking alone, particularly in terms of time, wear on equipment, and risk reduction

• The trench was excavated to design depth and profile within the planned schedule, while maintaining compliance with site restrictions and safety criteria.

Conclusion

The mall foundation project demonstrated the practical application of NexPand Large Hole for large-scale excavation in a sensitive commercial environment. Through correct hole design, accurate spacing, and controlled product use, the project team achieved precise, low-impact rock breaking where blasting was not an option.

For similar projects constrained by infrastructure, public proximity, or regulatory limitations, NexPand Large Hole provides a proven, technically robust solution for safe and effective rock excavation.