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

Proposed training program for shotcrete operators To achieve a quality shotcrete system QuickTime™ and a TIFF (Uncompressed) decompressor 1 are needed to see this picture.

Introduction Introduction • Australian shotcrete industry • Advantages of a training program • Proposed training program • Case Studies • Recommendations • Conclusions QuickTime™ and a TIFF (Uncompressed) decompressor 2 are needed to see this picture.

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 operator training program QuickTime™ and a TIFF (Uncompressed) decompressor 3 are needed to see this picture.

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 QuickTime™ and a TIFF (Uncompressed) decompressor 4 are needed to see this picture.

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 QuickTime™ and a TIFF (Uncompressed) decompressor 5 are needed to see this picture.

Training Program - Training Program - Content ontent • Level 1 - trainee shotcrete operator Descripti on Est imat ed Schedule d Time 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 QuickTime™ and a TIFF (Uncompressed) decompressor 6 are needed to see this picture.

Training Program - Training Program - Content ontent • Level 2 - pump operator Description Estimated Scheduled Time 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 QuickTime™ and a TIFF (Uncompressed) decompressor 7 are needed to see this picture.

Training Program - Content Training Program - ontent Level 3 – nozzle operator De scripti o n Est imat ed Sc h ed ule d Ti m e C om pletion Supplier c o 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 of 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 op 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 of stabilizers 5 hours W eek 21 Practi cal application of ac celerator 5 hours W eek 22 Practi cal application of w at er redu cer 5 hours W eek 23 Calculations of dosag e rates by w eight of 10 hours W eeks 24 & 25 ce m entatious mat erial 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 QuickTime™ and a TIFF (Uncompressed) decompressor 8 are needed to see this picture.

Training Program - Training Program - Content ontent • Level 4 - advanced nozzle operator Description Estimated Scheduled Time 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 QuickTime™ and a TIFF (Uncompressed) decompressor 9 are needed to see this picture.

Training Program - Training Program - Content ontent • Level 5 – project manager Description Estimated Scheduled Time 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 10 hours Weeks 13 to 16 Supervisory level in charge of a 24/7 operation with 4 crews Hiring procedures 10 hours Weeks 17 to 20 Retrenchment procedures 10 hours Weeks 21 to 24 QuickTime™ and a TIFF (Uncompressed) decompressor 10 are needed to see this picture.

Assessments Assessments • Confirm Learning Outcomes • Accredited Assessor • Competency Standards • Elements • Performance Criteria • Statement of Attainment • Australian Qualification Framework QuickTime™ and a TIFF (Uncompressed) decompressor 11 are needed to see this picture.

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 • QuickTime™ and a TIFF (Uncompressed) decompressor 12 are needed to see this picture.

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 QuickTime™ and a TIFF (Uncompressed) decompressor 13 are needed to see this picture.

Improved Core UCS Improved Core UCS SPRAYED 25 20 NO OF EVENTS 15 10 5 0 30 35 40 45 50 55 60 65 70 75 UCS(MPa) Before training After training QuickTime™ and a TIFF (Uncompressed) decompressor 14 are needed to see this picture.

Improved Core Results Improved Core Results BATCH-SPRAYED UCS 100% 90% 80% 70% 60% 50% % 40% 30% 20% 10% 0% 30 35 40 45 50 55 60 65 70 75 80 85 90 90+ UCS-MPa sprayed (BT) batched (BT) sprayed(AT) batched(AT) QuickTime™ and a TIFF (Uncompressed) decompressor 15 are needed to see this picture.

Improved In-situ Density Improved In-situ Density In-situ Density 50 40 No of Events 30 20 10 0 2200 2250 2300 2350 2400 2450 2500 Density (kg/m3) Before Training After Training QuickTime™ and a TIFF (Uncompressed) decompressor 16 are needed to see this picture.

20 % Improvement in Accelerator 20 % Improvement in Accelerator Dosage Dosage ACCELERATOR USAGE 100.0 80.0 60.0 % 40.0 20.0 0.0 19 20 21 22 23 24 25 26 27 28 lt/m3 BEFORE TRAINING AFTER TRAINING QuickTime™ and a TIFF (Uncompressed) decompressor 17 are needed to see this picture.

Depth Probing Depth Probing QuickTime™ and a TIFF (Uncompressed) decompressor 18 are needed to see this picture.

Peak Gold Mine Peak Gold Mine • Restarting shotcrete system • Shotcrete operators came back from months in other roles • Temporary batch plant operated by contractor QuickTime™ and a TIFF (Uncompressed) decompressor 19 are needed to see this picture.