proposed training program for shotcrete operators shotcrete...proposed training program for...
TRANSCRIPT
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
1
Proposed training program for shotcrete operators
To achieve a quality shotcrete system
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
2
Introduction
• Australian shotcrete industry• Advantages of a training program• Proposed training program• Case Studies• Recommendations• Conclusions
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
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
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
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
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
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
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
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
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
7
Training Program - Content• 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
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
8
Level 3 – nozzle operator
Training Program - Content
De s cripti o n 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 e r redu c er 5 hours W eek 23
Calculations of dosag e rates by w eight of ce m entatious mat e rial
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
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
9
• Level 4 - advanced nozzle operator
Training Program - Content
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
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
10
• Level 5 – project manager
Training Program - Content
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
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
11
Assessments
• Confirm Learning Outcomes• Accredited Assessor• Competency Standards• Elements• Performance Criteria• Statement of Attainment• Australian Qualification Framework
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
12
NorthParkesKey PointsKey Points::
••500m high block cave500m high block cave••8 extraction drives 8 extraction drives ••142 draw points142 draw points
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
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
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
14
Improved Core UCSSPRAYED
0
5
10
15
20
25
30 35 40 45 50 55 60 65 70 75
UCS(MPa)
NO
OF
EVEN
TS
Before training After training
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
15
Improved Core ResultsBATCH-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)
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
16
Improved In-situ Density In-situ Density
0
10
20
30
40
50
2200 2250 2300 2350 2400 2450 2500
Density (kg/m3)
No
of E
vent
s
Before Training After Training
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
17
20 % Improvement in Accelerator 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
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
18
Depth Probing
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
19
Peak Gold Mine
• Restarting shotcrete system• Shotcrete operators came back from
months in other roles • Temporary batch plant operated by
contractor
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
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
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
21
Recommendations
• Initial audit• Collect data• Review existing procedures• Analyse training needs• Monitor the shotcrete and training
systems• Seek continuous improvement
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
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.
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
23