Proposed training program for shotcrete Shotcrete...Proposed training program for shotcrete operators To achieve a quality shotcrete system QuickTime and a TIFF (Uncompressed) decompressor

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    1

    Proposed training program for shotcrete operators

    To achieve a quality shotcrete system

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    2

    Introduction

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

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    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

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    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 employees skills Transferable skills Safer mining

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    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

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    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

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    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

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    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

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    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

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    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

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    11

    Assessments

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

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    NorthParkesKey PointsKey Points::

    500m high block cave500m high block cave8 extraction drives 8 extraction drives 142 draw points142 draw points

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    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 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

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    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)

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    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

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    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

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    Depth Probing

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    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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