Proposed training program for shotcrete operators To achieve a - - PowerPoint PPT Presentation

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Proposed training program for shotcrete operators

To achieve a quality shotcrete system

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Introduction Introduction

• Australian shotcrete industry
• Advantages of a training program
• Proposed training program
• Case Studies
• Recommendations
• Conclusions

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Austrlain Shotcrete Industry Austrlain Shotcrete Industry

• Australian Mining industry uses approximately

500,000 cubic meters of shotcrete per year

• Mines want 32 to 40 MPa UCS (Unconfined

Compressive Strength) at a minimum thickness of 50 mm and a cost of $650 to $750 per cubic metre

• Quality and cost is significantly affected by the

skill and knowledge of the shotcrete operator

• Australia does not have an accredited shotcrete
• perator training program

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Advantages of a Training Advantages of a Training Program Program

• The aims of a nationally recognised and

standardised training program are to

– Achieve a consistent quality of shotcrete – Ensure safe and rapid development – Recognition of employee’s skills – Transferable skills – Safer mining

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Proposed Training Program Proposed Training Program

• Level 1. Trainee shotcrete operator
• Level 2. Pump operator
• Level 3. Nozzle operator
• Level 4. Advanced nozzle operator (or

trainer-assessor)

• Level 5. Project manager

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Training Program - Training Program - Content

• ntent
• Level 1 - trainee shotcrete operator

Descripti on Est imat ed Time Schedule d Com pletion Overvi ew of training progr am 2 hours Week 1 QMITA B generic me talliferrous core induction progr am 10 hours Week 1 QMITA B generic me talliferrous elective induction program 5 hours Week 1 Introduction to shotcrete an d illustrated glossary 2 hours Week 2 Und erground communi cation 2 ho urs Week 2 Plan an d organise individual work 2 hours Week 2 Hazar d identification and risk assessment 3 hours Week 2 Site induction 30 hours Week 3 Site light vehicle ticket (equip ment manual) 10 hours Week 4 Concret e basics , including fibre 3 hours Week 5 Batch plant o perato r (theory and quality control) 3 hours Week 6 Site agitator ticket (equipmen t manual, for mal training component) 30 hours Week 7 Shotcret e Rig (equipment manua l, formal training com ponent) 40 hours Week 8 Maintenan ce and mino r repairs 10 hours Week 9 Consolidation of skills and allowa nce for scheduling 30 hours Weeks 10, 11 & 12

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Training Program - Training Program - Content

• ntent
• Level 2 - pump operator

Description Estimated Time Scheduled Completion Job safety analysis 3 hours Week 1 Crew communication 3 hours Week 1 Introduction to ground prepa ration 10 hours Week 2 & 3 Maintenance trouble shooting 10 hours Week 4 & 5 Electrical and hydraulic trouble shooting 10 hours Week 6 & 7 Mix trouble shooting 10 hours Week 8 & 9 Factors affecting mix performance 5 hours Week 10 Fibre balls 2 hours Week 11 Extra water 2 hours Week 12 Oversize aggregate 2 hours Week 13 Admixtures and dosages 5 hours Week 14 Quality implications 5 hours Week 15 Rejection of loads 5 hours Week 16

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Level 3 – nozzle operator

Training Program - Training Program - Content

• ntent

De scripti o n Est imat ed Ti m e Sc h ed ule d C om pletion Supplier c

• mmuni cation

5 hours W eek 1 Site specifi c ground aw are n ess course 10 hours W eek 1 Australian Standard s in testing 10 hours W eeks 3 & 4 Certification to sp ray test panels 30 hours W eeks 5 & 6 Log o f fifty test p anels to r equired stand ard 40 hours W eeks 7 to 11 Und erstanding

• f tensile strength

5 hours W eek 12 Flexural strength 5 hours W eek 13 Shea r strength 5 hours W eek 14 Bond strength 5 hours W eek 15 De v elop standard

• p erating pro cedures

5 hours W eeks 16 to 19 Senior first aid certificate 15 hours W eek 19 Adva n ced admixtures and dosages 5 hours W eek 20 Practi cal application

• f stabilizers

5 hours W eek 21 Practi cal application

• f ac celerator

5 hours W eek 22 Practi cal application

• f w at er redu cer

5 hours W eek 23 Calculations of dosag e rates by w eight of ce m entatious mat erial 10 hours W eeks 24 & 25 Justifying rejection of loads 5 hours W eek 26 Limits o f a d mixture quantities 5 hours W eek 27 Consolidation of skills 40 hours W eeks 28 to 36

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• Level 4 - advanced nozzle operator

Training Program - Training Program - Content

• ntent

Description Estimated Time Scheduled Completion Supervisory communication 10 hours Weeks 1 to 4 Leadership and motivation 10 hours Weeks 5 to 8 Introduction to contract management 10 hours Weeks 9 & 10 Supervisor for up to 24 hour, 7 day operation 40 hours Weeks 11 & 12 Parts of Certificate IV Workplace Training and Assessment 30 hours Weeks 13 to 24 Consistent procedures (quality control) 15 hours Weeks 25 to 28 Implement and maintain standards on site 10 hours Weeks 29 to 32 Consolidation of skills 10 hours Weeks 33 to 36

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• Level 5 – project manager

Training Program - Training Program - Content

• ntent

Description Estimated Time Scheduled Completion Client communication 10 hours Weeks 1 to 4 Advanced contract administration 10 hours Weeks 1 to 4 Advanced site administration procedures 10 hours Weeks 5 to 8 Consistent procedures across all sites 10 hours Weeks 9 to 12 Supervisory level in charge of a 24/7 operation with 4 crews 10 hours Weeks 13 to 16 Hiring procedures 10 hours Weeks 17 to 20 Retrenchment procedures 10 hours Weeks 21 to 24

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Assessments Assessments

• Confirm Learning Outcomes
• Accredited Assessor
• Competency Standards
• Elements
• Performance Criteria
• Statement of Attainment
• Australian Qualification Framework

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NorthParkes NorthParkes

Key Points Key Points: :

• 500m high block cave

500m high block cave

• 8 extraction drives

8 extraction drives

• 142 draw points

142 draw points

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NorthParkes Issues NorthParkes Issues

• Inexperienced staff
• Experienced staff moving on to mining crews
• Training was limited to what the operators could pick up in a

two week handover

• Poor practices were being passed on as standard work

procedures

• Shotcrete was transferred underground from a large agitator to

a smaller more manoeuvrable rig underground via a slick line.

• Excessive rework to rectify poor shotcrete
• Shotcrete was not meeting the required specifications

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Improved Core UCS Improved Core UCS

SPRAYED

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 UCS(MPa) NO OF EVENTS Before training After training

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Improved Core Results Improved Core Results

BATCH-SPRAYED UCS

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 30 35 40 45 50 55 60 65 70 75 80 85 90 90+ UCS-MPa % sprayed (BT) batched (BT) sprayed(AT) batched(AT)

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Improved In-situ Density Improved In-situ Density

In-situ Density

10 20 30 40 50 2200 2250 2300 2350 2400 2450 2500 Density (kg/m3) No of Events Before Training After Training

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20 % Improvement in Accelerator 20 % Improvement in Accelerator Dosage Dosage

ACCELERATOR USAGE

0.0 20.0 40.0 60.0 80.0 100.0 19 20 21 22 23 24 25 26 27 28 lt/m3 % BEFORE TRAINING AFTER TRAINING

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Depth Probing Depth Probing

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Peak Gold Mine Peak Gold Mine

• Restarting shotcrete system
• Shotcrete operators came back from

months in other roles

• Temporary batch plant operated by

contractor

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Peak Results Peak Results

• Increase in UCS from 32.5 to 35 MPa (7.6%)
• A saving in excess of 40 litres per heading in accelerator

usage

• There was a improvement in the quality of the shotcrete

applied underground

• There was a improvement in the performance of the

shotcrete operator’s

• Improved operator understanding of the use and control of

the Maxijet including concrete pump speed and pressure, accelerator pump setting and engine speed setting

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Recommendations Recommendations

• Initial audit
• Collect data
• Review existing procedures
• Analyse training needs
• Monitor the shotcrete and training

systems

• Seek continuous improvement

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Conclusions Conclusions

• Training has a significant and immediate impact
• n the performance of a mine’s shotcrete system.
• Monitoring the shotcrete systems performance is

an essential element of, monitoring the effectiveness of training and reducing the cost of shotcrete.

• Training is an essential step to developing and

improving a quality shotcrete system.

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