Proposed training program for shotcrete operators

Transcription

1 Proposed training program for shotcrete operators To achieve a quality shotcrete system 1

2 Introduction Australian shotcrete industry Advantages of a training program Proposed training program Case Studies Recommendations Conclusions 2

3 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 3

4 Advantages of a Training 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 4

5 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 5

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

7 Level 2 - pump operator Training Program - Content 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 7

8 Level 3 nozzle operator De s cripti o n Training Program - Content Est imat e d Ti m e Sc h ed ule d C om pletion Supplier c o mmuni c ation 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 L og o f fifty test p anels to r equired stand a rd 40 hours W eeks 7 to 11 Und e rstanding 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 o p erating pro c edures 5 hours W eeks 16 to 19 Senior first aid c ertificate 15 hours W eek 19 Adva n ced admixtures and dosages 5 hours W eek 20 Practi c al application of stabilizers 5 hours W eek 21 Practi c al application of ac c elerator 5 hours W eek 22 Practi c al application of w at er redu c er 5 hours W eek 23 Calculations of dosag e rates by w eight of 10 hours W eeks 24 & 25 ce m entatious mat e rial 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 8

9 Training Program - Content Level 4 - advanced nozzle operator 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 9

10 Training Program - Content Level 5 project manager 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 10 hours Weeks 13 to 16 crews Hiring procedures 10 hours Weeks 17 to 20 Retrenchment procedures 10 hours Weeks 21 to 24 10

11 Assessments Confirm Learning Outcomes Accredited Assessor Competency Standards Elements Performance Criteria Statement of Attainment Australian Qualification Framework 11

12 NorthParkes Key Points: 500m high block cave 88 extraction drives 142 draw points 12

13 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 13

14 Improved Core UCS SPRAYED 25 NO OF EVENTS UCS(MPa) Before training After training 14

15 Improved Core Results BATCH-SPRAYED UCS % 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% UCS-MPa sprayed (BT) batched (BT) sprayed(at) batched(at) 15

16 Improved In-situ Density In-situ Density 50 No of Events Density (kg/m3) Before Training After Training 16

17 20 % Improvement in Accelerator Dosage ACCELERATOR USAGE % lt/m3 BEFORE TRAINING AFTER TRAINING 17

18 Depth Probing 18

19 Peak Gold Mine Restarting shotcrete system Shotcrete operators came back from months in other roles Temporary batch plant operated by contractor 19

20 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 20

21 Recommendations Initial audit Collect data Review existing procedures Analyse training needs Monitor the shotcrete and training systems Seek continuous improvement 21

22 Conclusions Training has a significant and immediate impact on 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. 22

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