COMPLETE PACKAGE RIG EXCEEDS EXPECTATIONS
How a steady team approach to drill and blast can lower costs, improve fragmentation.
Smart rig sets in-house record for manufacturer in number of metres drilled, fuel consumed.
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A TEAM-ORIENTED APPROACH TO DRILL, BLAST
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OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA
FEBRUARY 2019
BREAKING NEW GROUND FOR BORAL A new generation crawler rig is kicking goals for a drilling contractor at a Boral quarry.
IN THIS ISSUE FEBRUARY 2019
VOLUME 27, ISSUE 2
FEATURES 28 HOW FRAG ANALYSIS CAN ASSIST IN BLASTING Predictive models, photogrammetric techniques are proving vital to the optimisation of extractive operations.
32 MMU ARRIVES IN A SPLASH OF COLOUR A mobile manufacturing unit is helping to raise the profile of a NSW helicopter rescue service.
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TO THE POWER OF SIX A steady team approach to drill and blast can result in less costs, more fragmentation.
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33 FROM EXCAVATOR TO SURFACE DRILL COMPLETE PACKAGE A smart rig has set a new inhouse record in the number of metres drilled and fuel burn.
A renowned international manufacturer and supplier is offering a versatile alternative drill solution.
34 PROMOTING EXPLOSIVES SAFETY, SECURITY Peak body highlights explosives manufacturers' and suppliers' commitment to codes of practice.
35 INTEGRATED WEIGHING SOLUTIONS FOR EXCAVATORS How fleet management software coupled with weighing tech can turn excavators into mobile control centres.
36 VOLUME SCANNER MEASURES BULK FLOW
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DIGITAL PLATFORM Digitally connected tech promises continuously optimised blast outcomes.
COMPLETE PACKAGE RIG EXCEEDS EXPECTATIONS
How a steady team approach to drill and blast can lower costs, improve fragmentation.
Smart rig sets in-house record for manufacturer in number of metres drilled, fuel consumed.
30
A TEAM-ORIENTED APPROACH TO DRILL, BLAST
21
14
OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA
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BREAKING GROUND
A high tech, easy to use lidar system has been devised to measure material moving across a conveyor belt.
New generation crawler rig kicks goals for contractor at Boral quarry.
FEBRUARY 2019
BREAKING NEW GROUND FOR BORAL A new generation crawler rig is kicking goals for a drilling contractor at a Boral quarry.
COVER ADVERTISER: The Epiroc SmartROC C50 COPROD surface drill rig works in the 90140mm hole diameter range, features a COP 3060 CR rock drill, and is suitable for selective mining, aggregate and limestone quarrying. Visit: epiroc.com
EVERY MONTH 04 FROM THE EDITOR
38 IQA CALENDAR
06 FROM THE PRESIDENT
40 IQA NEWS
08 NEWS THIS MONTH
News from Queensland, South Australia and Western Australia
12 PRODUCT FOCUS
50 GEOLOGY TALK Celebrating a golden anniversary
Quarry February 2019 3
EDITORIAL
WILL THE GOOD SHIPS OF QUARRYING ENCOUNTER STORMY WEATHER?
W
elcome back! This time last year I speculated that Australia was, based on projections, entering a phase of amplified construction activity. I wondered if quarries and their suppliers were suitably equipped to meet this phase. My conjecture was confirmed throughout 2018 in economic forecasts, studies and surveys from BIS Oxford Economics, Deloitte Access Economics, the Australian Industry Group, and Cement Concrete Aggregates Australia (CCAA). The CCAA announced that the industry produced more than 30 million cubic metres of concrete in 2017 (see page 8). Deloitte Access Economics also reported of $324 billion of infrastructure projects in 2018, almost $50 billion up on 2016-17.
As we went to press, CommSec released its quarterly State of the States report. It revealed that Victoria is enjoying 38.2 per cent more residential, commercial and engineering work than the decade average. Construction activity in other states and territories also exceeds the decade average – New South Wales (+34.5 per cent), South Australia (+19.5 per cent), the ACT (+18.9 per cent) and Tasmania (+15.9 per cent). Employment, housing and equipment investment were also consistently high in these states and territories. Queensland (-16.5 per cent), the Northern Territory (-32.7 per cent) and Western Australia (-40.6 per cent) were below the decade average. While Tasmania and SA recorded high growth in construction on the previous year, the “boom states” of a decade ago fell well short. The verdict of the CommSec report was that NSW and Victoria have benefitted from population growth, construction and investment activity, and strong job markets. In line with other projections, it forecasts a steady stream of engineering construction activity in NSW and Victoria will offset a softening in residential builds. Based on the infrastructure projects
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in play – the Melbourne and Sydney Metros, Western Sydney Airport, Inland Rail, Western Distributor, NorthConnex, WestConnex, the Brisbane cross-river rail – there is an impressive pipeline. The hunger of such projects for construction materials should keep the extractive industry (at least in eastern Australia) busy well into the 2020s – but the pipeline has its pros and cons. The pro is it’s all happening in spite of Federal Government under-investment; therefore, a change of government shouldn’t weaken the pipeline. The claim of a “record $75 billion over a decade” in recent government TV ads ahead of the election amounts to a paltry $7.5 billion of investment per annum – well below state government expenditures, Infrastructure Australia’s recommendations and the feds’ own pledge in the 2014 Budget ($50 billion over six years – averaging $8.3 billion of investment per annum). The con is whether the demand of the pipeline projects can be met on time and budget. The approvals processes for new quarries and basic operational changes to existing sites will underpin how quickly these projects reach fruition. State governments are already playing “catchup” in securing the right lines of supply to cater for rapid population and urban growth. Further, as more development applications are lodged in the regions, will jurisdictions and proponents encounter resistance from locals who resent those reserves being diverted to the big capitals rather than towards local infrastructure? What impact could “lawfare” have on the delivery of the pipeline and on the industry? The “state of the states” is encouraging – but industry members should be wary of stormy patches against mostly blue sky. It won’t all be smooth sailing – but the weather is favourable. Welcome to 2019! DAMIAN CHRISTIE Editor
quarrymagazine.com Official publication of the Institute of Quarrying Australia Publisher Coleby Nicholson Associate Publisher Angela Han
CAN THE CONSTRUCTION MATERIALS INDUSTRY MEET THE DEMANDS OF PIPELINE PROJECTS - ON TIME AND TO BUDGET?
Editor Damian Christie damian.christie@quarrymagazine.com Journalist Tim Robertson tim.robertson@gunnamattamedia.com Advertising Sales Toli Podolak sales@quarrymagazine.com
Quarry is published by: Gunnamatta Media Pty Ltd Locked Bag 26, South Melbourne, VIC 3205 AUSTRALIA Phone: +61 3 9696 7200 gunnamattamedia.com info@gunnamattamedia.com Design & Production Manager Jo De Bono art@gunnamattamedia.com Accounts Paul Blewitt finance@gunnamattamedia.com Subscriptions info@gunnamattamedia.com Press releases damian.christie@quarrymagazine.com Copyright: All material appearing in Quarry is subject to copyright. Reproduction in whole or in part is strictly forbidden without prior written consent of the publisher. Disclaimer: The views and opinions expressed by authors are not necessarily those of the publisher. All statements made, although based on information believed to be reliable and accurate at the time, cannot be guaranteed and no fault or liability can be accepted for error or omission. Gunnamatta Media Pty Ltd strives to report accurately and fairly and it is our policy to correct significant errors of fact and misleading statements in the next available issue. Any comment relating to subjective opinions should be addressed to the editor where the opposing position may be published to encourage open debate. The publisher reserves the right to omit or alter any advertisement and the advertiser agrees to indemnify the publisher for all damages or liabilities arising from the published material.
PRESIDENT’S REPORT
GEARING UP FOR A BUSY 2019 IN PROFESSIONAL DEVELOPMENT The Institute of Quarrying
W
elcome to 2019! I hope you all had a safe and happy new year break and a chance to unwind in preparation for the year ahead. I’ve spent some time since returning from leave talking to the branch and sub-branch chairs about this year and what educational and networking events are planned, and it’s been great to see such enthusiasm for what I’m sure will be a very busy but successful year for the IQA and the industry. The end of 2018 saw a significant amount of change within the organisation, with our new CEO Kylie Fahey joining the team and the launch of the Australasian Academy of Quarrying. I’m pleased to see Kylie has hit the ground running and has transitioned well into our organisation, providing insight, strategy and execution to assist the IQA in working towards its strategic plan and organisational goals. I’m confident our members will see the benefits throughout 2019 and beyond, with focused effort resulting in sustainable growth for the Institute and longevity. This is also an IQA conference year, and we’re headed to Geelong, with the home of the Geelong Cats AFL club our conference venue. The conference theme is “The Future of Quarrying” – for which an exciting and engaging program is being developed. Some of the topics will include: the maximisation of limited natural resources through technology; the utilisation of the benefits of effectively managing diversity in the workplace; developments in emerging fixed and mobile plant technology; environmental and economic trends affecting the national quarrying industry; and many more. We’ve already received outstanding support and interest in the conference from industry sponsors.
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Australia
The 2019 conference will also see a revised Tuesday to Thursday format, a key change resulting from the 2017 post-conference survey. My thanks go to Brad Rooney, the 2019 conference chairman, for his hard work and commitment to date. I’m looking forward to what will no doubt be the premier industry event of the year. There has already been an increase in members seeking vocational education this year. The IQA is now well placed to provide Certificate III through to Diploma courses in surface extraction, along with other units of competency required by the various regulators for statutory positions through recently formed partnerships. Members wishing to inquire or enrol in these courses can contact Kylie Fahey via email: ceo@quarry.com.au It’s also worth a reminder that the IQA’s face to face professional development programs (PDPs) and webinar professional development programs (wPDPs) are still available to the industry. We are very lucky to have an excellent range of educational products, designed for the quarrying industry and developed with direct input from the industry. Significant effort has been deployed to review the content of many of the programs and to release new and relevant PDPs and wPDPs. A full list of PDPs and wPDPs can be found on the IQA’s website. I trust 2019 has started well for you all. I look forward to seeing you at an IQA event throughout the year. Have a safe and productive month ahead! CLAYTON HILL President Institute of Quarrying Australia
Educating and connecting our extractive industry
quarry.com.au THE IQA IS WELL PLACED TO PROVIDE A RANGE OF EDUCATION AND TRAINING INITIATIVES THROUGH RECENTLY FORMED PARTNERSHIPS.
The Institute of Quarrying Australia’s goals are: 1. To provide world class professional development for the extractive industries. 2. To establish an Australasian Academy of Quarrying. 3. To align service offerings with industry needs.
IQA CONTACTS: Chief Executive Officer Kylie Fahey PO Box 1779 Milton BC QLD 4064 Phone: 0477 444 328 ceo@quarry.com.au Company Secretary Rod Lester Phone: 0408 121 788 rgl@rlester.com.au Finance Officer Gemma Thursfield Phone: 0402 431 090 gemma@quarry.com.au Web Maintenance, Graphic Design, ePrograms, IT Support Ryan Spence Phone: 0422 351 831 ryan.spence@quarry.com.au General, membership and financial inquiries should be directed to admin@quarry.com.au or phone 02 9484 0577.
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NEWS
STRONG DEMAND DRIVES RECORD PRODUCTION YEAR ‘WE’RE NOT EXPECTING SHORTAGES, PROVIDED APPROVAL PROCESSES ARE RESPONSIVE TO KEEPING UP WITH DEMAND.’ KEITH SLATTERY CCAA CEO
The boom in public infrastructure projects, such as in Melbourne, has contributed to a record production year for the concrete, cement and aggregates industries.
More than 30 million cubic metres of pre-mixed concrete were produced across Australia in the 2017 calendar year, according to a survey commissioned by Cement Concrete Aggregates Australia (CCAA). The boom in public infrastructure projects, particularly on the east coast, and continuing strong demand for high rise residential buildings, have driven a record production year for the concrete, cement and aggregates industries. The sector has experienced steady growth in recent years. In the report commissioned from the industry research and forecasting company Macromonitor, the 2017 results eclipsed 27 million m3 produced in 2015 and 28.5 million m3 in 2016. “In essence, all of that material is
provided from Australian quarries,” CCAA chief executive Ken Slattery said. The industry directly employs more than 30,000 people, with another 80,000 estimated to be in industryrelated work, and contributes more than $15 billion per annum to the national economy, according to the CCAA. “The boom in infrastructure projects such as WestConnex and NorthConnex in Sydney and the West Gate Tunnel in Melbourne, is good news for the heavy construction materials industry and for the more than 110,000 Australians who are employed directly or indirectly in the sector,” Slattery said. Future growth is projected on the back of planned projects, again driven
by government-funded infrastructure projects on the eastern seaboard. A recent report by consulting firm Deloitte concluded that infrastructure projects worth at least $324 billion were in the pipeline, an increase of almost $50 billion over the past two years. Slattery said the building of the new Western Sydney Airport at Badgery’s Creek alone was expected to further lift demand for concrete and related products by at least another one per cent over the next five years. The Melbourne Metro rail project, which is currently under construction, would also lift demand for concrete by another two per cent, he added. Slattery expects that Australian quarries will be able to continue meeting demand. “That’s the big issue around all of this. Sydney and Melbourne have some particular challenges around how long it can take quarries to get approval. “We’re not anticipating any shortages, provided governments’ approval processes are responsive to keeping up with demand,” he said. On the back of a supply and demand study in 2016 that considered the state’s challenges to 2050, Victoria has launched a streamlined regulatory process for the management of basic operational changes. New South Wales has also engaged in recent studies considering supply constraints in the state and projections about the quantities and quality of aggregate required to 2036. •
PLANT MANUFACTURERS COMBINE FORCES Mobile plant specialist Anaconda Equipment has joined the McLanahan Corporation’s family of companies. McLanahan – which has been offering the global quarrying industry solutions in crushing, screening, feeding, washing and classifying, dewatering, fines recovery and tailings management since 1835 – has been distributing and selling the Anaconda line of tracked equipment in Northern Ireland since 2017. Founded in 2008, Anaconda Equipment has developed a range of mobile tracked plant, which includes scalping, screening, recycling and conveying equipment. The
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range is sold through a global dealer network. In Australia, Anaconda Equipment is distributed through Tricon Mining Equipment, in Somersby, NSW. Anaconda conveyors will be a key part of McLanahan’s new line of modular wash systems. Anaconda will also be adding larger size equipment, including trackmounted crushers. According to McLanahan, both companies share many of the same values and approach to doing business. “We looked into growing our line of tracked equipment in several different
Anaconda conveyors will be a key part of McLanahan’s new line of modular wash systems.
ways,” said Sean McLanahan, CEO of McLanahan Corporation. “Adding them to our family of companies seemed like a clear fit.” •
CONSENT CHANGES SOUGHT FOR DUNMORE QUARRY
There are plans to turn the site of a former Second World War training camp in Darley, Victoria, into a sand mine.
Boral is seeking a modification to the current planning consent for transport from its Dunmore Quarry in New South Wales.
Zhong Yin Group Australia is proposing to operate a near 16ha quarry at 48 Camerons Road, with access to the site via 222 Lerderderg Gorge Road.
The company has expressed concerns about the limitations in capacity for existing rail infrastructure and is seeking to modify the road transport limits from the quarry, for an extra 220 truck movements per day. The quarry produces 1.5 million tonnes per year of aggregate, with a maximum of 320 truck movements per day (160 loads), 24 hours a day. “There is no change planned to production. The modification seeks to remove existing restrictions relating to the method by which product is transported, being road and rail,” said a Boral spokesman. The NSW Environment Protection Authority (EPA) has stated that there are “clear environmental benefits” to minimising road transport in favour of rail, eg air quality and noise impacts. The Boral spokesman said the company’s preferred mode of transport is rail. “The limitation is the capacity of Boral’s freight terminals to handle the volume of quarry product
Boral is seeking to modify the road transport limits from its Dunmore Quarry (pictured).
being delivered by rail. Maximised production at our Peppertree Quarry (in Marulan South) means there is limited additional Boral terminal capacity in Sydney available to receive Dunmore Quarry trains.” Boral’s Peppertree Quarry produces up to 3.5 million tonnes per annum and is the only quarry in NSW that transports its product via rail. The modification request is already well into the assessment phase of the NSW Department of Planning and Environment (DPE). The Boral planning team recently responded to submissions from various government agencies to which DPE referred its application. •
SITE’S LIFE EXPECTANCY EXTENDED TO 2036 A northern NSW municipality has granted an application to extend the life of a Blakebrook quarry until 2036. The Lismore City Council granted consent last October to an application by Santin Quarry Products to extend operations at Rosehill Quarry in Blakebrook on the condition that: • The annual rate of extraction shall not exceed 23,000m³ annually. • The hours of operation of the quarry are to be restricted to 7.00am to 5.00pm, Monday to Friday. • The applicant must submit a Rehabilitation and Environmental Management Plan. • The site is to be inspected at the end of the consent period to ensure that rehabilitation has been carried out in accordance with the approved
WWII CAMP MOOTED AS A SAND MINE
Rehabilitation and Environmental Management Plan. • No topsoil above rock base shall be sold or otherwise removed from the site without prior consent of council. • A Stormwater and Erosion/Sediment Control Plan shall be submitted to council for approval with reference prior to recommencement of operations.
A public meeting was held at Bacchus Marsh Golf Club on 18 September, 2018. Andrew Helps, the project manager for Zhong Yin Group, provided information about the quarry’s operation to the local community. If Zhong Yin Group's application is successful, the lease will be for up to 30 years, with an output of more than 580,000 tonnes per year. Helps told the meeting there would be 53 truck movements per day, with each vehicle carting a 30-tonne load. Currently, the company has applied for a Work Authority to the Earth Resources Regulator, a portfolio supported by the Department of Economic Development, Jobs, Transport and Resources (DEDJTR). Zhong Yin Group is still yet to lodge a planning application with Moorabool Shire Council. Last September, Helps told Star Weekly: “When it comes to quarries, this one is about as benign as it gets. "There won’t be any blasting … We may have to [blast] in the future, but we’d certainly seek permission.” Helps did not respond to calls for more information as Quarry went to press. •
“The conditions probably suit the size of the quarry. It’s only 15ha – it’s a very small site,” said Michael Santin, owner of Santin Quarry Products. “I could’ve bulldozed it and sold it off as housing lots, but I’ve decided to keep it operating,” he said. Santin believes that there will still be enough material to be quarried after 2036, when the consent expires. •
Zhong Yin Group proposes to transform this location in Darley, Victoria into a sand quarry. Image courtesy of Google Maps.
Quarry February 2019 9
NEWS
DEVELOPMENT PLANS FOR BRISBANE’S EARLIEST SITE The area around Stephens Mountain, Brisbane, which includes the former Ekibin quarry, has been approved for future development. The Brisbane City Council recently approved the Coorparoo Neighbourhood Plan and published a draft of its key outcomes for the project. It is focused on “achieving a balance between growth in and around existing centres and the maintenance of character and low density residential development through the majority of the area”. The site also has 13 pre-1911 buildings and the council has assured the community they will be protected from demolition. This is in addition to 10 places that are already on the council’s heritage register. Prior to the plan’s release, a community bushcare group had called on the Queensland Government to scrutinise Brisbane City Council’s planning strategy. In the draft plan, the council has committed to “protecting environmental values and increasing the community’s access to bushland by rezoning 4.8ha of Stephens Mountain to conservation zone”. Ekibin Quarry was one of Brisbane’s earliest quarries. In the 1880s the site was quarried for road surface material. In the 1940s and 1950s, the quarry works were extended and a hot asphalt plant was added to its operations. In the late 1960s, Brisbane City Council stopped quarrying operations after the quartzite reserve was exhausted and the site has remained vacant since. •
Work at Ekibin Quarry, one of Brisbane’s earliest extractive sites, in the 1950s. Photo courtesy of The Courier Mail.
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SLATE PITS RECOMMENDED FOR WORLD HERITAGE STATUS AT ITS PEAK, THE WELSH QUARRYING INDUSTRY EXTRACTED 500,000 TONNES OF SLATE PER ANNUM
The quarries of northwest Wales have been nominated for UNESCO World Heritage Site status. A panel of experts in the past UK summer assessed the slate landscape around Gwynedd, in North Wales, and the nomination will be formally presented to the United Nations Educational, Scientific and Cultural Organisation’s (UNESCO) World Heritage Centre in 2019. A decision on the application will not be delivered before 2021.
Penryhn Quarry is one of the few active slate quarries in Wales today.
As part of the campaign to secure World Heritage Site status, school pupils have sent slate from northern Wales quarries to world leaders. Students at the Ysgol y Moelwyn bilingual secondary school sent a piece of slate branded with the Ffestiniog Slate Festival logo to more than 200 countries. Canadian Prime Minister Justin Trudeau and Prince Albert of Monaco were among 15 world leaders to respond. Trudeau said the campaign reflected the “admirable pride” the pupils had in their local history. In the 19th century, the quarries of North Wales were major providers of roofing materials and slate products throughout the world. Similarly, the associated technologies of quarrying and transport infrastructure were also exported worldwide. At its peak, the Welsh quarrying industry was extracting about 500,000 tonnes of slate per annum. Today, production is a tenth of that, as cheap, cement-based products have dominated the construction market. According to Dr Jana Horak, the head of mineralogy and petrology at the National Museum of Wales, slate has been used since the Roman occupation of Britain (circa AD77) and was exported during the Middle Ages. The industry took off at the height of the Industrial Revolution. “You can find it now in so many places,” Dr Horak told BBC News several years ago. “Even in Australia today they are replacing original slate roofs with more Welsh slate, to keep that look. It’s not just a ‘good slate’, it’s the best.”
Slate is a prominent feature of the Millennium Centre in the Welsh capital of Cardiff.
In the 19th century, the small mountainside village of Dinorwig was home to the second largest slate quarry in the world. In the mornings, thousands of men in flat caps hiked up the snaking path to the quarry huts perched high on Elidir’s mountainside. The quarrying industry helped foster traditional Welsh culture. As the quarries grew, so did the villages of Deniolen and Clwt y Bont, which were situated up the hill alongside Dinorwig Quarry. At its height, Dinorwig Quarry employed around 3000 men. Quarrying communities created their own democratic structures, including workers’ chapels, while contributing financial support to Bangor University. The business functioned through the medium of the Welsh language, making it unique within major capitalised British industries. Eventually the two world wars and the Great Depression took their toll on the slate industry, as did competition from roofing tiles. By 1960, Dinorwig’s workforce had been reduced to about 300 men. These days, the quarrymen have moved out and rock climbers, walkers, swimmers, divers and off-road runners have gradually moved in. •
LUXURY QUARRY HOTEL OPENS OUTSIDE SHANGHAI
DISCOVERY SHEDS LIGHT ON QUARRYING TECHNIQUE Recent discoveries have revealed how the ancient Egyptians moved stone blocks from the alabaster quarries of Hatnub, north of modern day Luxor, during the reign of King Khufu in the Fourth Dynasty.
Shimao Wonderland will host extreme sports, including bungee jumping and rock climbing.
After almost 10 years of construction, Shimao Wonderland, a luxury Intercontinental hotel built into a quarry at the base of Tianmen Mountain in Shanghai, China, has finally opened for business. The former quarry, first excavated in the 1950s but deserted in 2000, now houses the world’s first “groundscraper”. Sixteen of the hotel’s 18 floors are below ground, and the rooms on the bottom two levels are completely submerged with views of a 10-metre deep aquarium. The site has been transformed, with architects taking advantage of the natural surroundings and unique landscape. A waterfall, built into the rock face, is visible from the terraces of each of the 337 rooms. Almost all of the construction has been kept within the quarry pit. Even the grassed roof, which will provide a tranquil hangout for guests, has been designed to merge with the surrounding environment. The quarry will also offer a number of extreme activities to guests. A sports centre cantilevers over the quarry and will be home to bungee jumping and rock climbing, while another area will be dedicated to water sports. Another eye-catching feature of the hotel is a glass “waterfall”, which runs the height of the entire building, housing an indoor atrium.
and design firm led by former Atkins employee Martin Jochman. “This was a totally unique idea, to really do something special with a site that was forgotten and nobody knew what to do with, and to give it new life,” Jochman said. “I never lost my belief that it would be done one day, but it is here now, and I am really excited and amazed by the whole thing.” According to the hotel’s website, rooms have been available for booking since 20 November. They’re not cheap, with rooms starting from around 3394 yuan ($AUD666 or $USD487) per night. The maximum price for a suite is 71,068 yuan ($AUD14,000 or $USD10,243) per night, complete with butler service. •
A waterfall, built into the rock face, is visible from the terraces of the 337 rooms.
The initial idea of building a high end resort in such a unique location was proposed in 2006 by Xu Rongmao, chairman of Shanghai Shimao Group, a real estate development company. British architecture firm Atkins led the design for the hotel and was joined by JADE+QA, an architecture
Rooms start from 3394 yuan ($AUD666) per night.
Standing at 139 metres tall, the Great Pyramid was the world’s largest human-made structure for nearly 4000 years. However, it has long stumped Egyptologists just how the Egyptians managed to transport the enormous blocks across the desert. Now, archaeologists have discovered evidence of a sloped ramp with two sets of steps and numerous postholes on either side that they believe was used to hoist alabaster blocks from the quarry via a sled. With the help of manpower and ropes, the wooden posts appear to have been used to leverage the sled uphill. “The mission discovered a unique system to pull and transfer the stone blocks from the bottom of the quarry after removing the debris used to cover it,” said Dr Yannis Gourdon, the archaeologist who directed the joint mission of the Institut Français d’Archéologie Orientale and the University of Liverpool. “The moving system consists of the central ramp surrounded by two set[s] of stairs contain[ing] pole holes which help lift the alabaster stone block through at least a 20 per cent coarse ramp,” he told The Luxor Times. He added the ramp system could provide clues as to how the heavy limestone blocks were transported up the sides of the pyramids. •
The remnant of a stone ramp used by the ancient Egyptians to hoist alabaster blocks. Image courtesy of sun.co.uk
Quarry February 2019 11
PRODUCT FOCUS
To submit new product and equipment releases, email: damian.christie@quarrymagazine.com
MODERN WASHER OFFERS EXCEPTIONAL RESULTS Due to its modular, customisable design, the McCloskey SandStorm 620 is suited to most sand and aggregate washing applications. Built with power and durability, the SandStorm 620 design is novel and modern, offering up to three aggregates and two sand products and giving producers an exceptional quality product and finish. With its innovative features, the plant size has been kept to a minimum, while maximising access to serviceable areas. The choice of a 5m x 1.5m (16’ x 5’) or 6m x 2m (20’ x 6’) washing screen and a choice of single or dual sand output is available.
More information: 888 Crushing & Screening Equipment, 888cse.com.au MSC Group, msc.net.au
TOUGH, ROBUST TROMMEL The MDS M515 heavy-duty trommel is capable of handling rocks weighing up to a tonne, while delivering an output of up to 500 tonnes per hour. This tough, robust machine can process limestone, granite, steel slag, and demolition waste and remove sticky materials (eg clay) from rocks. The unit boasts a drum frame that houses screens with different openings that can be easily changed as per the application requirements. The entire MDS range utilises modern display panels that make set-up and operation of the machine very simple.
More information: OPS Screening & Crushing Equipment, opsaust.com.au Screenmasters Australia, screenmasters.com.au
HEAVY-DUTY MOBILE JAW The Lippmann-Milwaukee LJ-2950 is equipped with a heavy-duty, trackmounted crusher with 1270mm x 735mm single toggle jaw. It delivers maximum productivity through enhancements to the jaw box, including heavier flywheels and optimisation for all crushing applications. The LJ-2950’s jaw speed leads to better reduction and faster processing of material through the crushing chamber. Lippmann-Milwaukee has a reputation for design quality. The LJ-2950 crusher combines more power and productivity in one machine, with an impressive throughput and capacity and large stockpile height.
STRUCTURAL RIGIDITY, STABLE TRACK TRAVEL A new 23m tracked stacker has joined the Superior Industries line of portable conveying solutions. In keeping with Superior’s reputation for heavy-duty designs, the stacker is one of the heaviest models available in its class, weighing in at 15 tonnes. Each stacker is capable of handing up to 907 tonnes of material per hour while hydraulic power controls the tracks, folds and discharge height. The cross-bracing design is built into the undercarriage of the tracked stacker, which ensures structural rigidity and stable track travel. The stacker is equipped with Superior brand conveyor components like off-the-shelf idlers, pulleys and Exterra primary belt cleaners.
More information: Superior Industries, superior-ind.com 888 Crushing & Screening Equipment, 888cse.com.au
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More information: Tricon Equipment, triconequipment.com.au
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DRILL & BLAST
TO THE POWER OF SIX: PROMOTING A TEAM-ORIENTED APPROACH TO DRILLING, BLASTING Anthony Konya discusses a steady management approach to drill and blast that encourages employee buy-in and a dedication to improved techniques and efficiency. This can assist operators with reducing expenses and achieving better fragmentation.
A
common problem for quarrying engineers and consultants is the critical challenge of achieving proper blasting. Many of the problems faced come from operational inefficiencies in the drilling and blasting program. Most operators believe that better blast design will help save costs, improve fragmentation and decrease vibration, and while this is all true, none of it can occur if the design cannot be achieved with reasonable accuracy. By achieving this accuracy, before implementing better blast designs and processes, most quarries save upwards of 15 to 30 per cent on their blasting costs. There are many ways to achieve accuracy, such as designing for inaccuracies, automating jobs and blasting management.
DESIGNING FOR INACCURACIES How does one design for inaccuracies in blasting? This is a common question when inaccuracies are encountered, because engineering out these inaccuracies is one of the easiest options with the least capital cost. 14
Quarry February 2019
However, this approach is extremely costly in the hidden costs of drilling and blasting. One of the first people to study drill deviation on a large scale was Ulf Langefors, who documented his extensive results from dozens of mines in his book The modern technique of rock blasting and discussed ways to “engineer out” drilling inefficiencies.1 He did this by analysing the average errors in drilling from: Collaring location – the drill setting up in the wrong place, causing the hole to begin in the wrong location. Alignment inaccuracies – including drilling improper angles and the deviation inside of the borehole when drilling. When Langefors studied a multitude of blasts in Sweden, he concluded that, on average, improper collaring locations accounted for 101 millimetres (or four inches) of deviation, and alignment inaccuracies were about one millimetre for every 30 centimetres (or 0.04 inches per foot) in bench blasting. To most, this may seem insignificant, but this is almost ±15cm (or ±6 inches) on a 12m
P10
P50
P80
No deviation 40mm
No deviation 302mm
No deviation 448mm
Langefors 101mm
Langefors 302mm
Langefors 498mm
Forsyth 51mm
Forsyth 302mm
Forsyth 701mm
Table 1. Fragmentation comparison.
P10
P50
P80
No deviation 40mm
No deviation 302mm
No deviation 448mm
Langefors 61mm
Langefors 190mm
Langefors 335mm
Forsyth
Forsyth 101mm
Forsyth 0.8mm
Not within accurate modeling
Table 3. Engineered fragmentation.
(40-foot) bench. This means the spacing between the two holes may be reduced by 300mm (one foot) and the burden increased by 152mm (0.5 feet).
Drill Deviation Impacts on Fragmentation
Passing Percent
1 0.8 0.6 0.4 0.2 0
0
5
No Drill Deviation
10 15 20 Fragmentation (inches) Langefors Deviation
25
30
Forsyth Deviation
Figure 1. Drill deviation on fragmentation.
Forsyth, Deen and Sterk studied this same problem and reported up to three millimetres for every 30cm (0.12 inches per foot) on longer blast holes with a 196mm (7¾ inch) drill bit.2 As the drill bit is reduced, the drilling errors are larger, based on the stiffness of the drill steel. In this case, both studies were with larger drill bits. To determine the significance of this, we can look at a fragmentation prediction method called the Kuz-Ram model – a way to predict fragmentation before a blast that has a variable to define the drillhole deviation.3 To analyse the drill deviation with an example blast in limestone, you would use the following specifications: • Drillhole diameter – 101mm (4’). • Explosive – ANFO. • Burden – 2.4m (8’). • Spacing – 3.5m (11.5’). • Bench height – 12m (40’). • Sub-drill – 762mm (2.5’). • Stemming – 1.7m (5.6’). From Figure 1, one can observe the actual impact of drill deviation. In this graph, the horizontal axis is the fragmentation (screen size) in inches from the blast, and the vertical axis is the per cent passing that screen size. Table 1 has a summary of these results, with the term Px meaning the screen size that “x per cent” of the material would pass through. This table shows that, with increasing deviation, the fragmentation oversize significantly increases, which will raise crushing costs as well as secondary breakage costs. To overcome this drill deviation, Langefors suggested reducing the burden to account for this divergence. He suggested the actual design burden should be the optimal burden subtracted by the deviation per 30cm (or foot). This is what is meant by “engineering out” deviation from drilling. While this can be a good method, it has some drastic ramifications.
By engineering out deviation, not only will the burden change, but all blasting parameters have to be modified. To analyse this effect, the Kuz-Ram model will again be used for the design in each of these situations: A few problems are brought to light instantly when analysing these patterns, even before looking at the fragmentation, ie: 1. The small burden will cause face blowouts, scattering rock across the entire pit. 2. The large powder factors of the “engineered patterns” can cause large air overpressure. 3. The cost will significantly increase (to be analysed later). When analysing the fragmentation in Figure 1 and Table 3, one can see the extreme results this can have. One can observe that, in terms of the fragmentation, Langefors’ method works well with his drill deviation, but with a larger deviation such as Forsyth it becomes impractical and costly, with a large
SOLUTION
increase in fines and boulders, with relatively little good material. How much does this “engineering out” method cost a mine? Three sets of figures show the cost for blasting a bench that is 18m (60’) long by 6.7m (22’) wide, based on a drilling cost of $AUD7.00 per 30cm ($US5 per foot for drilling) and $AUD0.42 per 453 grams ($US0.30 per pound) of ANFO: • No deviation = $AUD1635 ($USD1186). • Langefors = $AUD2812 ($USD2040). • Forsyth = $AUD5969 ($USD4329). One can see that by engineering out the solution, the cost is increased drastically. If better fragmentation is achieved, some of these costs can be offset in reduced crushing and better product. But what if large deviation, like in Forsyth above, is displayed at the quarry?
SIX SIGMA BLASTING Large mines are moving to autonomous drilling, with claims of improved accuracy. However, the drills are only as accurate as the GPS and instrumentation available and not error-free. In drilling, a significant portion of the drilling deviation occurs when the steel is in the borehole (see Figure 3 overleaf). These autonomous machines do not control this deviation, and, while they can reduce it, most quarries do not have the capital for the improved drilling set-up location. To improve its blasting, a quarry must employ management techniques. Even with engineering out a blast, deviations must be minimised to achieve proper breakage. Six Sigma is a management technique used to improve drilling, blasting and fragmentation.
No deviation
Langefors
Forsyth
Drill diameter
101mm
101mm
101mm
Explosive used
ANFO
ANFO
ANFO
Burden
2.4m
1.8m
1.2m
Spacing
3.5m
2.6m
1.8m
Bench height
12m
12m
12m
Sub-drill
0.7m
0.5m
0.4m
Stemming
1.7m
1.3m
0.9m
Table 2. Engineered out solution.
Quarry February 2019 15
DRILL & BLAST
Figure 2. Engineered-out fragmentation.
The goals of this program include: • Employee buy-in. • Reduction of drillhole deviation. • Improvements in loading technique. • Improved efficiency in blasting. Without proper employee buy-in, projects generally are unsuccessful and results are not as expected. This is the same with improving a drilling and blasting program, so how can management, engineering and the driller/ blaster all work together and buy in to the project, especially when it has increased workloads for all levels? According to Maslow’s hierarchy of needs4 (illustrated in Figure 4), a person is motivated at a higher level by belonging, self-worth, accomplishment and personal growth. In most cases, quarry employees at all levels have safety, a job, insurance, food and water. In general, people are longing for an increased belonging and accomplishment. This is where the Six Sigma effect has large benefits. Six Sigma functions as a team role, where all levels of management, engineering and the drillers and blasters work together to accomplish these goals. This team is composed of: • The sponsor (management) – Those who oversee the project at a high level and ensure obstructions from above do not impact the team. • The leader (any level willing to lead the team) – This person will check in with the entire team, report results and help lead the team in the direction of its goals. • The black belt (an expert in the field of improvement) – This person will need a deep understanding of drilling and blasting, generally someone who is extremely technical in the area or a consultant. • The green belt (those knowledgeable in 16
Quarry February 2019
Figure 3. In-hole deviation (photo by T Sinkala).
the field) – Drillers, blasters and engineers to help the team collect data, make interpretations and suggest improvements. • Team members – This role can range from showing up at monthly/fortnightly meetings to reading the report, or to helping the team in other aspects. By having all levels involved in the team, all members will feel a belonging and want to improve their work, and that of others, to ensure team success. Little wins for the team will give all members a sense of accomplishment and continue to motivate them towards the goal of improving. In cases where contract drilling and blasting is done, management should require that the contractor attend these meetings and achieve certain parameters. If these parameters are not met, the contractor should have a financial responsibility for unsatisfactory performance. This will ensure the contractor will listen – although most contractors will have solid knowledge and experience that can assist the quarry, and it would not be in their best interests to cut corners. Good communication between parties is critical and will result in better performance. This team generally functions under the DMAIC approach (Figure 6), which means the group will: • Define the objectives of the program. • Measure the inputs and outputs of the blast. • Analyse using statistical means how the inputs are influencing the outputs. • Find ways to improve these inputs. • Ensure these inputs are controlled to within limits for desired outputs.
DEFINE PHASE At this stage, the team will need to devise the goals of the program. These could be topics
Figure 4. Maslow’s hierarchy of needs.
such as: • Reduce all vibration at a nearby neighbour to “x.xx” millimetres per second (mm/s). • Have a P80 from blasting of “x” millimetres. • Decrease the cost of blasting (an increased drill and blast efficiency can result in an ability to expand the pattern). Clear goals are needed, and multiple goals can be decided on, with an order of importance. For example, one quarry had the following goals: • Decrease the cost of blasting by 30 per cent through increased blasting performance. • Have a P80 of 152mm to 203mm (six to eight inches). • Increase the speed of drilling and the loading of the bench. Once the goals are established, the next step is to define key performance indicators (KPI) for the drill and blast program. These are for both the inputs and the outputs of the program. Examples include the following: Inputs. • Borehole depth to intended depth.
SIX SIGMA TEAM Sponsor
Leader
Black Belt
Green Belt
Team members
Figure 5. The make-up of the Six Sigma team.
• Borehole location to intended location. • Borehole path to intended path. • Actual burden to intended burden. • Actual spacing to intended spacing. • Actual sub-drill. Outputs • Fragmentation size (P80, P50, P10). • Air overpressure. • Ground vibration. • Cost to blast. • Time to drill/load. • Muckpile height and throw. • Crusher power output.
MEASURE PHASE The measurement stage of the program is when the driller, blaster, engineer and supervisor will take field measurements for the KPIs. There are many ways to now effectively and quickly measure these KPIs, including:
1. Borehole depth. The simplest way to ensure the proper borehole depth is reached is to get a tape measure that has the length of the borehole +10 per cent and tie a five- to 10-gram lead weight on the end (fishing sinker). This can be let down the hole until the bottom is felt and the depth can be recorded. The depth is important in many places, such as: • Measuring immediately after drilling to determine the depth drilled. • Measuring immediately before loading to determine the slump into the hole. If the depth of the bench is known, this method can be used to analyse the depth of the sub-drill (borehole length – bench height). The sub-drill is often critical in leaving a toe and fragmentation throughout the shot. 2. Flashlight test. The flashlight test is a relatively primitive
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Figure 6. The DMAIC approach.
method of determining borehole deviation, but can be useful and provides valuable information for quarries with limited capital. This involves tying a flashlight onto the end of a rope with 152mm to 304mm (½- to one-foot) increments marked. The flashlight is then put into the borehole with the light shining out so one can see it. This is lowered until the light no longer shows (caused by drill deviation) and the depth is recorded.
DRILL & BLAST
3. Burden and spacing (tape measure). The burden (toe burden) and spacing are critical parameters in blasting and need to be field verified to ensure proper placement. This can be done by simply taking a tape measure and measuring the distance from the centre of one hole to the other. 4. Burden and spacing (GPS). For a slightly more accurate, more expensive and quicker way to measure the burden and spacing, a GPS surveyor can be purchased and used to get the exact location of each borehole. These can then be imported into a CAD program and easily measured. 5. Burden and spacing (drone). Another method to very quickly and accurately obtain the co-ordinates of the borehole is to use a drone to capture the locations. This is normally more expensive than other methods, but has a payback in the
Figure 7. Analysis of a muckpile.
time to analyse. This can also be contracted out to another company, and videos of blasts can also be monitored to see what is happening.
they are lowered. When loaded into a CAD program or other software, one can see the exact path of the borehole, including angles, curves and length.
6. Borehole tracker (borehole length and deviation). A more accurate method to determine the length and deviation of a borehole is a borehole tracker. These devices are inserted into the borehole and take co-ordinates as
7. Face profiling system. Many laser and photogrammetric face profiling systems exist, which allow quarries to create a point cloud of the face of their blast. This can be combined with options such as the borehole tracker and drone to
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Our rental fleet includes the latest equipment from the world’s leading manufacturers. create a 3D image and calculate the exact parameters of all variables. 8. Boulder counting. One quick and easy way to measure the fragmentation performance of a blast is to use a boulder count. This is counting the number of boulders over a certain size on the muckpile. To refine this method, the loader operator can count boulders throughout the pile. This method can be deceptive and doesn’t accurately display fragmentation, but will accurately assess the secondary breakage reduction of blasting. 9. Fragmentation analysis (WipFrag, WipWare). If fragmentation is a key output to the quarry (which it normally is), the WipWare systems are a great way to accurately measure the fragmentation (see Figure 7). I have used this at many quarries to help identify fragmentation. This involves taking a picture of the muckpile, in several locations, and using the software to determine the fragmentation of the muckpile. At least nine images at varying locations on the muckpile should be used per muckpile. 10. Fragmentation analysis (reflex system). To simplify this process and achieve more accurate results, WipWare has introduced a reflex system that uses stationary cameras to take pictures of almost the entire muckpile. The camera can be placed on a dump point (crusher), a point all trucks dump, or the front of a loader/shovel.
ANALYSIS The next step is to analyse all inputs and determine which key inputs are relied upon to achieve the desired outputs. This can take many blasts to determine and often the bad blasts are more important than the good blasts for this. By monitoring both, one can determine the changes in different parameters. This, along with pre-blast simulations of performance, can be used to carefully manipulate variables to determine the key inputs. Important topics to look at in the statistical determination of blasting parameters include: • The mean. • The medium. • Standard deviation. • Normality of data. • Correlation to outputs. IMPROVEMENTS After the analysis phase is complete and the key inputs are mapped and correlated to the outputs, the improvement phase begins. Improvement is the most difficult step and can be handled in many ways by the quarry. In certain situations, it is training an employee on proper techniques for drilling or loading. It might be providing employee motivation to achieve measureable goals – or purchasing new equipment or technology to help achieve the goals. The improvement phase is the area in which the black belt will need to take the lead, using help from the green belts, to determine the exact way the quarry will improve a system. This can come from engineering implementations as well. Like Langefors’ suggestions, if minimal deviations exist, other engineering methods include: 1. Designing holes to be drilled slightly deeper (304mm, or one
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DRILL & BLAST
foot) and measured before loading. If slumping has partially filled these holes to the proper loading depth, loading is done. If they are a little deep because no slumping has occurred, the blaster can kick in some drill cuttings to fill the hole to the desired load depth. 2. If burden and spacing are commonly an issue, parameters such as burden setbacks can be used along with timing changes to alter the direction of movement. 3. If drilling is consistently a problem, having the driller fill in the bad hole and drill a new hole can also be used (if a contractor driller, this is done at no additional cost).
CONTROL Finally, the control phase is implemented to ensure the parameters are met. This is normally in the form of quality control charts with maximum acceptable and minimum acceptable limits. Periodic monitoring should be done (much
less than the measure phase) to ensure everything is consistent. In many cases, the outputs can be monitored, creating an easy, successful control plan. Without the control plan and excellent documentation in place, quarries may implement this process and spend a lot of time on it only to have new people come in and change it. One of the benefits of the Six Sigma team is that an entire team will rarely leave the site at the same time. This ensures knowledge can be passed down, and the quarry’s drilling and blasting can be maintained. Improper drilling and blasting procedures can result in major blasting costs, which go relatively unnoticed. Design changes and new products will not be beneficial unless proper drilling and blasting management is in place. While some corrections can be made to the design to “engineer out” inaccuracies, a steady management system is one of the only ways to consistently ensure desired performance. The Six Sigma drilling and blasting
approach has proven itself in the trenches. Based on teamwork at all levels, clear goals and measurements of systems, and a control system, it can help quarries achieve excellence in their drill and blast programs. • Anthony Konya is a project engineer with Precision Blasting Services, Missouri, USA. Email: Anthony@ idc-pbs.com Article courtesy of Aggregates Manager (US). REFERENCES & FURTHER READING 1. Langefors U, Kihlström B. The modern technique of rock blasting (3rd edition). Wiley, New York, 1978. 2. Forsyth W, Deen J, Sterk P. Assessment of perimeter blasting at the Homestake Mine. Proceedings of the 23rd conference on explosives and blasting technique. International Society of Explosives Engineers, Las Vegas, NV, 1997: pp 437-445. 3. Cunningham CVB. The Kuz-Ram model for prediction of fragmentation from blasting. In: Holmberg R, Rustan A (eds). Proceedings of the first international symposium on rock fragmentation by blasting. Luleå Tekniska Universitet, Luleå, Sweden, 22–26 August, 1983: pp 439–453. 4. Maslow AH. A theory of human motivation. In: Psychological Review 50 (4), 1943: 370–396. http:// psychclassics.yorku.ca/Maslow/motivation.htm
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DRILL & BLAST
Donnelly Blasting Services’ Epiroc SmartROC T40 smart rig, fitted with silenced kit boom, at Fulton Hogan’s Blue Rock Quarry.
COMPLETE PACKAGE RIG EXCEEDS EXPECTATIONS
A drill rig has set a new in-house record for the manufacturer with the number of metres drilled and litres consumed in one shift. Damian Christie spoke to Daniel Kirwan, of Epiroc, and father and son Jason and Dan Donnelly, of Donnelly Blasting Services, about their SmartROC T40 smart rig.
D
onnelly Blasting Services (DBS) is headquartered in Jimboomba, in southeast Queensland. The Australianowned, family-run business conducts work in numerous quarries and construction and dam projects in southeast Queensland and northern New South Wales, with about 80 per cent of its clients being quarries. The company offers the full rock on ground service. To quote Dan Donnelly, “we do everything in-house – the surveying, markout, boretrack design, shotfiring, monitoring, and drilling”. His father and company founder Jason added: “We float our rigs, mark our own holes, survey, drill our own holes, load the fire, do all the reporting, all the surveying and all the blast monitoring ourselves. For our explosives, we use Orica as a contractor but we also have our own explosives trucks.” Jason started the business 20 years ago after he spent 10 years as a shotfirer for Orica Mining Services. He wanted to pursue
a career as a part-time contract shotfirer but ultimately formed a business that today employs 30 staff, including around 20 drill operators, and keeps him busy full-time. DBS has a modern fleet of Epiroc smart rigs and specialised rigs that can be configured for special project requirements. Added to that are mobile manufacturing units (or ANFO trucks) with augering and blowloading capabilities, a 25-tonne excavator with rock breaker and a 30-tonne widening tri-axle low loader. Jason said the company has built its reputation on flexibility, which is “we’re able to do what the customer wants”. “We have GPS guidance on our rig – a lot of the larger rock on ground services don’t have that,” he said. “We can control the whole outcome because we do the whole job. We put the extra holes in, we control the drilling [with machine guidance] – we understand what’s going on with the drilling. We have the latest technologies in the drills,
so we’re saving our customers money. Some other companies can use up to 400 or 500 litres of fuel a day – we’re down to below 200. We work with our customers for a better outcome.” DBS’s association with drill rig manufacturer and supplier Epiroc covers nearly the whole lifetime of the business. “We started with Ingersoll-Rand, which was bought by Atlas Copco,” Jason recalled. “It’s been a long association but we’ve probably used Atlas Copco [now Epiroc] for 15 years. We ended up changing to them from another brand for the technology, fuel burn, operator comfort, reliability and product support.”
SOUND OF SILENCE DBS’s 20-strong Epiroc/Atlas Copco drill rig fleet comprises manual-operated PowerROC T35s, as well as numerous smart rigs that operate via machine guidance including ROC D7Cs, ROC D9Cs, and up to six SmartROC T40 rigs. The contractor has also recently Quarry February 2019 21
DRILL & BLAST
TECHNICAL DATA – EPIROC SMARTROC T40 RECOMMENDED HOLE DIAMETER
64-127mm (2.5”-5”)
DRILL ROD/TUBE DIAMETER
45mm or 51mm (1.7” or 2”)
HYDRAULIC ROCK DRILL
COP 2540, COP 2560
ENGINE TYPE/OUTPUT
Caterpillar C7.1 ACERT (Tier 3) – 168kW@1800 rpm Caterpillar C7.1 ACERT (Tier 4 Final) – 168kW@1800 rpm
OPERATOR CABIN
Air conditioning, clear laminated glass (10mm front and roof windows and 8mm side windows), clear toughened glass (8mm side windows), rear view mirror, cab heating, electric combined engine inclination and hole length instrument in main computer display.
CERTIFICATE
ROPS and FOPS
TRANSPORT LENGTH
11.6m
TRANSPORT HEIGHT
3.4m (7.4m at feed height)
WEIGHT
15 tonnes (15,000kg)
OPTIONS
Silence conversion kit, HNS, MWD, ROC Manager
taken delivery of some SmartROC C50 COPROD rigs. Some of the DBS rigs are also equipped with sound suppression for environmental drilling restraints (eg noise pollution), reducing the noise factor by about 10 decibels. “I can be 20 metres away from it and I can pick up my phone and ring you and you’d hear background noise, and that’s all,” Jason
22
Quarry February 2019
said. “The silenced kit takes the ringing, the high frequency out of it – it reduces that steel on steel sound.” “It doesn’t echo down the valley like a traditional drill rig would,” Dan added. One of these sound-suppressed (or silenced kit rigs) – a ROC D9C – has been working at Fulton Hogan’s Stonemaster Quarry, on the Gold Coast, on an integrated
program devised by Cement and Aggregate Consulting Services (CemAgg) to raise the quarry’s productivity by as much as 20 per cent. DBS has successfully collaborated with CemAgg and Fulton Hogan on a program comprising drone surveillance, quarry design, machine control and site-based GPS surveying to extract Stonemaster Quarry’s remaining reserves. An in-depth explanation of this service has been explained in a previous issue of Quarry.1 The second silenced kit rig – a SmartROC T40 – has been recently working on a greenstone deposit at Fulton Hogan’s Blue Rock Quarry, at Cedar Creek, also in southeast Queensland. According to CemAgg, Blue Rock has a more challenging geology than Stonemaster Quarry, coupled with new development works that require careful planning so that future production is not constrained by limited supply of higher raw grade feed.2 The SmartROC T40 is equipped for hole diameters in the 76-127mm range, with maximum hydraulic pressure of 220 bar and a maximum impact rate of 44 to 53 Hz. It features a folding boom system, aluminium profile feed beam, hydraulic cylinder feed beam and a carousel-type rod handling system, with 1 + 7 rods. The 15-tonne unit is powered by a 168kW, turbo-charged Tier 3 or Tier 4 Caterpillar C7.1 ACERT engine at 2200 revolutions per minute and features an Atlas Copco OIS K-36-C111 GD screw compressor, with a maximum working pressure of 10.5 bar and free air delivery of 153 litres per second. The engine and compressor speed is self-adjusting, according to demand. Three variable hydraulic pumps lower engine speed during non-drilling periods and tramming. Automatic cooler and dust fan controls are standard.
BEST RESULTS Epiroc’s optional machine guidance systems on the T40 comprise the Measure While Drilling (MWD), Hole Navigation System (HNS) and ROC Manager software. The HNS in particular manages hole position, inclination, correct aiming and the required hole length (as defined in the prepared drill plan) via the global navigation satellite system (GNSS). As a result, it can decrease the drill and blast cost per every cubic metre produced. “We utilise site navigation, so the driller can walk in and utilise the boom as much as possible,” Dan said. “The machine’s not
moving the carrier, it’s moving the boom to the next hole. And with the navigation, we can use the automatic set-up, which means we can get great accuracy.” It was at Blue Rock Quarry that the silenced kit T40 recorded some of the best results in relation to penetration and fuel usage. Daniel Kirwan, Epiroc’s regional manager for the Brisbane and Mackay regions of Queensland, remotely monitored the performance of the rig and according to that data, the T40 drilled 487m in one shift (of around 11 to 12 hours’ duration) at total drill power and capacity, burning through just 187 litres of fuel – exceeding regular performance expectations. “It’s a pretty good record – to do that many metres in day,” Kirwan explained. “When you start looking at the fuel usage, it pretty much works out as 0.4 litres per metre drilled, which is really good. Normally, the T40s will burn through 0.5 or 0.6 litres per metre. That equates to around 15 litres per hour.” “It far exceeded our expectations,” Jason said. “Years ago, if we got 200 metres a day,
DRILLING STATISTICS DAY
TOTAL DRILL METERS
DRILL METERS PER ENGINE HOUR
1 DAY
487.7
45.8
12/11/2018
487.7
45.8
According to Epiroc's Certiq data, the T40 drilled 487m in one shift - at full drill power and capacity.
FUEL CONSUMPTION STATISTICS DAY
TOTAL LITERS
LITERS PER HOUR
TOTAL co2 EMISSION
1 DAY
187
17.6
557.3
12/11/2018
187
17.6
557.3
The T40 used up just 187 litres in the one shift - a significant saving on previous drill models.
that was a good day on the previous drill and you would burn 400 litres of diesel. This is how far technology has taken us in such a short period of time.” “It was amazing,” Dan added, “since the industry average is a litre per metre – the rule of thumb – and there are a lot of machines that are well over a litre per metre.”
Kirwan attributed Epiroc’s 64-127mm T51 speed rods at a 3.6m length as a major factor in the metres per litre drilled. “By having our rod, [DBS was] able to up the impact pressure on the rock drill,” he explained. “Essentially, they’ve been able to increase the impact rate on the drifter to get more metres. And to do that you need to
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DRILL & BLAST
DBS’s ROC D9C smart rig at Fulton Hogan’s Stonemaster Quarry is equipped with a silencer kit on the mast for reduced noise emissions.
have drill strength capable of standing up to the increased pressure. “With our shanks and rods there wasn’t breakage and because of the rod quality they could run the drill harder, whereas lesser quality rods would break when you put that much pressure up. So that was definitely a big part of it – being able to increase the performance of the rock drill and have the driller consumables to match it.” Kirwan said it was a testament of Epiroc’s history and expertise. “Epiroc’s been making rods for the best part of 100 years. It manufactures premium rods at a premium price. What we have is probably the longest lasting, highest quality rod.” All the parties agree that for these results to be replicated by another rig in another quarry setting, there needs to be a combination of factors. “As the operator was getting more comfortable with the rig and winding more power into it,” Jason said, “we could see the metres going up and up. That was the thing that was really great about his performance on that shot, it was a good designed shot, good bench preparation, all the stars aligned on it.” “It’s an example of a customer that’s using all the features of the Epiroc machine,” Kirwan said. “Some customers may just buy 24
Quarry February 2019
the rig for the fuel savings or may just take a silencer kit. But DBS has purchased the whole lot: the silencer kit, the HNS and the fuel burn all working together with the rod package. They’re using the whole Epiroc package to get the best results.”
AT THE LEADING EDGE DBS and Epiroc have reported positive feedback about the performance of the smart rigs. Jason Donnelly said that quarry operators were genuinely surprised by the drilling results. “When we take the T40 into a quarry, the quarry manager comes around and asks, ‘How many metres did you do today?’ And the operator will say, ‘150, 170’. The manager will go ‘Really?’ and then they’ll go back and check the fuel book and they come back and confirm the next day that it wasn’t a one-off. And they’re like, ‘Wow! I’m glad we’ve got this now!’ They realise that, compared to other drill rigs, 160 metres drilled in a day represents a lot of savings!” “The bulk of the customers using the T40 are drilling a 89mm hole size and it seems to be the drill of choice, particularly when it comes to penetration rate, fuel burn and then having the technology options on it,” Daniel Kirwan said. “It’s also sort of future-proofed for changes if quarries
want to go down the hole navigation path. “There’s a bigger emphasis in the industry on technology, reducing your fuel burn and having all capabilities built into the machine, so if you go to a site where they want to invest in using hole navigation, you have that capability. “It comes down to your hole size and capacity, and what you actually want to drill,” Kirwan continued. “The Donnelly guys have set up the T40 and now they’re almost going beyond that to the C50 COPROD to do bigger hole sizes, the 102-115mm holes. If you’re doing the 89-102mm hole size and want to reduce your fuel bill, and potentially look at ways of getting technology into your business, the T40 is definitely a machine to consider. “We’ve had a lot of success with the T40 on that smaller hole size (89-102mm). We have some newer products like the T45 and the C50, which are the ‘big brothers’ of the T40. Donnelly’s are starting to use some of those machines at the Hanson quarry at Wolffdene to great effect. They are at the leading edge of picking up new technology, trialling new things, which is really good for the market – to challenge the status quo.” The T40’s positive results at Blue Rock Quarry have prompted DBS to replace the D9C rig with another sound-suppressed T40 at Stonemaster Quarry. The company is gradually replacing the ageing parts of its drill fleet with the smart rigs for its quarry assignments, and its older, more manually operated rigs (such as the PowerROC T35) are being assigned to construction jobs where the need for survey control and estimates has already been determined. Working with CemAgg and Fulton Hogan on the integrated program at Stonemaster Quarry has also resulted in better machine utilisation for DBS across the board. “The way we conduct our rock on ground is the same but our design is completely different,” Jason said. “We have a path that we take that’s aligned more to pit design. We have a roadmap, we know where we’re headed.” “We can plan all our maintenance better, we plan our blasting dates further in advance, and we’re not reacting to things in the quarry,” Dan Donnelly added. • REFERENCE & FURTHER READING 1 Franklin S. The digital quarry: An integrated technical approach. Quarry 26(8); August 2018: 2429. quarrymagazine.com/Article/8782/The-DigitalQuarry-An-integrated-technical-approach 2 Ibid.
DRILL & BLAST
MODERN CRAWLER RIG TRIALLED ABROAD
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lobal explosives producer MAXAM has optimised its drill and blast works in the Polish market through the acquisition of SmartROC T40 drill rigs, equipped with the COP 2560 rock drill, Hole Navigation System (HNS) and remote control function. In a single year, MAXAM drills about a million metres of blast holes in Poland. It has had as many as 20 Epiroc drill rigs distributed across Poland, providing services to quarries producing granite, dolomite, sandstone, basalt, and melaphyre aggregate, as well as limestone for cement production and other components for construction chemicals manufacture. In Poland, quarry walls may have a thickness of 12 to 28 metres. Popular hole diameters are 89mm, 95mm and 102mm. In purchasing new rigs, MAXAM was committed to reducing total operating costs.
It proceeded to trial a T40 rig at a granite quarry in Rogoznica, in the southwest. The trial comprised two grids of holes spanning 2000m, allowing for a reliable assessment of the drilling costs and the actual tool wear. Until the trial, most blast holes in Poland were designed without consideration of the wall profile or verification of completed hole quality directly after drilling. The use of HNS helped to maintain the depth level of all drilled holes and to avoid uncontrolled excess drilling. The drilling parameters sampled with the MWD system enabled the estimation of quality and possible adjustments (via generation of a table of drilled hole bottom deviations in relation to the planned position) immediately after completion of the grid. In addition, the SmartROC technology indicated that holes could be drilled at nearly half the cost.
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The results exceeded the MAXAM personnel’s expectations. During the trial, the T40's average drilling progress was 1.1 metres per minute (m/min), compared to 0.8m/min on a ROC F9C. The T40’s fuel consumption was 0.5 litres per metre (lpm) of hole; the ROC F9C varied from 0.9 to 1.1 lpm. The results of the trial convinced MAXAM that the T40 was a worthwhile purchase and there was significant promise of a return on investment in time and fuel savings. The Epiroc technology has further modernised MAXAM’s drill and blast works and presented opportunities for more precise projects with greater quality. It has also reduced total costs by more than 30 per cent (through reduction of the consumption of fuel and explosives, the lack of additional edges and the drop of seismic vibrations during blasting). • Source: Epiroc
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DRILL & BLAST
DIGITALLY ENABLED BLASTING
PLATFORM SETS OUT TO OPTIMISE OPERATIONS A next generation software program promises continuous improvement of blasting outcomes through data insights and integration via digitally connected technologies throughout the drill and blast process.
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rica, one of the world’s largest manufacturers of commercial explosives and innovative blasting systems, has released the latest version of its BlastIQ digital blast optimisation platform to the Australian mining market. It is designed to optimise blasting outcomes by integrating data and insights from digitally connected technologies across the drill and blast process. Solutions enabled by BlastIQ can deliver predictable and sustainable improvements that can reduce the overall cost of drill and blast operations, improve productivity and safety, and facilitate regulatory compliance. Orica chief commercial officer Angus Melbourne described how Orica’s digital technologies would assist operators. “The downstream impact of variable and poorly controlled blast outcomes today can impact as much as 80 per cent of the total mine processing costs. This presents a significant opportunity for the industry. The new BlastIQ platform enhances blast performance and outcomes for customers by seamlessly connecting data under a single platform,” he said. “Soon the platform will link geoscientific, blast modelling and design data with measured field operations data, optimised blast delivery and advanced learning for continuous improvement. “Orica wants to transform how drill and blast unlocks mining value for our customers, utilising digital and automated technologies to create safer, predictable and more productive blast outcomes. BlastIQ enables us to collaborate with customers to realise this transformation. 26
Quarry February 2019
BlastIQ’s information management component provides a secure, centralised online location for users to collate and collaborate on data from across the drill and blast process.
“Building on more than 140 years of experience and innovation in blasting, we have enhanced our ability to deliver value for our customers by adding world-class digital expertise and solutions to our existing suite of market-leading products and services. We believe Orica is uniquely positioned to unlock the value that digitally enabled blasting can deliver.”
SECURE, CENTRAL LOCATION According to Orica, the suite of enhanced technologies in the next generation BlastIQ empowers mine managers and engineers to make better decisions and increase control of blasting outcomes across mining and quarrying operations. The platform’s information management component provides a secure, centralised online location for users to collate and collaborate on data from across the drill and blast process. This accelerates planning, analysis and auditing of blast data to satisfy regulatory requirements. Optimised blast designs are developed using Orica’s SHOTPlus 3D design and modelling software. Evolved over 30 years, the advanced design tool has the capability to manage both simple and complex blast designs and initiation sequences. Orica’s global digital product manager Angelo Labriola outlined the key
benefits of the new digital platform. “Our SHOTPlus design tool improves productivity by integrating seamlessly with the BlastIQ platform,” he said. “This allows blast loading instructions and rules to be communicated in near real-time to field operations, ensuring the right explosive type and quantity is used in the right place and subsequently initiated at the right time, every time. “Improved in-field blast quality control and assurance is achieved using the new BlastIQ mobile device, enabling the efficient capture of auditable data direct from the bench. Blasthole condition data is captured with the BlastIQ mobile device in near realtime, allowing data to be shared between operations and engineering personnel from anywhere on-site, at any time, empowering rapid decision-making and improved operational efficiencies.” Labriola said the complete blast control solution, enabled by the BlastIQ Platform, offered a complete integration between the explosives delivery control system, blast design and quality management systems. “In a world-first, accuracy and efficiency of explosives delivery is significantly enhanced through the new BlastIQ-enabled delivery system, with loading and delivery to design now fully integrated,” Labriola said. “Orica’s Mobile Manufacturing Unit delivery
Australia’s leading designer and manufacturer of rubber torsion spring motor bases. systems, in particular the recently released Bulkmaster 7 unit, can be integrated into BlastIQ to wirelessly receive blast designs updated with near real-time blasthole quality data, while on the bench. “Using this data, Orica’s connected, smart delivery systems load the correct explosive type and quantity according to the original design, adjusted based on blasthole condition measurement data and the automated application of a defined set of rules managed by the drill and blast engineer. “This unique, direct integration with the delivery control system automates process control, thereby eliminating errors in manual product selection, process control and incorrect logging of loading actuals, as well as, importantly, reducing overall explosives loading times.” Where a BlastIQ-enabled delivery system is not available, a BlastIQ mobile device can be used to capture and record asloaded data during the delivery process. The system still updates instruction to the delivery system operator based on updated processing of design and in-field blasthole condition measurement that precedes loading. “The powerful new insights and analytics engine incorporated into the BlastIQ platform presents near real-time, hole by hole, blastrelated data visually to the multiple users across the drill and blast process,” Labriola said. “Delivering the necessary insights and analytics helps the drill and blast team to easily monitor and manage key blasting KPIs, providing with them an essential tool to optimise blasting outcomes.”
CUSTOMER SUCCESS PROGRAM In addition to the new technologies, functionality and enhanced user experience in the next generation BlastIQ Platform, a comprehensive training, support and customer success program has been introduced. It is aimed at tailoring each BlastIQ implementation specific to an operator’s needs, increasing the speed of implementation and, importantly, maximising their ability to realise productivity, cost reduction and regulatory compliance benefits. The new platform has been integrated into several operations around the world, with operators experiencing its benefits and rewards. Through easy integration into existing operational systems and processes, the BlastIQ Blast Control solution can improve blast quality control through autonomous and seamless data transfer and insights. This results in the elimination of rework, and the reduction of excess drilling and explosives consumption. Multilingual support was to be introduced to the BlastIQ Platform in late 2018, as well as a new capability to optimise blast fragmentation through integration of drilling data, blast modelling and automated fragmentation measurement. In early 2019 the platform will connect third party mine planning, drilling and predictive modelling to deliver more blast control and optimisation for operators. The scope for data-driven optimisation in the drill and blast segment of the mining value chain is significant and the next generation BlastIQ will continue to evolve rapidly to meet the growing demands of customers. Orica will launch the next generation BlastIQ platform to the quarry industry in July 2019. • Source: Orica Australia
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DRILL & BLAST
HOW FRAGMENTATION ANALYSIS CAN ASSIST IN BLASTING
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he basic aim of all blasting operations is to fragment the rock mass in a suitable granulometric distribution, and obtain a shot pile formation and bulking of the material. The resulting fragmentation can significantly affect later stages of the operation. In this regard, successfully loading, crushing and milling the material would reduce energy consumption and, in consequence, the total cost of the operation (Figure 1). For this reason, quantifying the resulting fragmentation through photogrammetric techniques combined with predictive models is a fundamental stage in the continuous improvement process for all mining operations. The energy released when detonating the explosive charge generates a powerful shockwave that is transmitted to the surrounding rock mass, and is continued by a violent gaseous expansion. Although some of the energy released in the detonation is lost in ineffective work, most is concentrated in two distinct phases: (i) dynamic, dominated by the action of the shockwaves; and (ii) semi-static, dominated by the action of the gaseous expansion in the rock mass. The high pressures generated by the detonation of the explosive column are transmitted to the rock through shockwaves during the dynamic phase. These propagate radially through the rock mass by means of concentric compression pulses that attenuate as they move away from the load centre. The dynamic state the rock was subjected to recovers its almost static state once the shockwaves have passed. The static properties of the rock mass begin to manifest themselves more effectively due to the appearance of a semi-static field of voltages corresponding to the pressure of the gases in the walls of the blast hole. This is how the combination of both phases brings about a very specific granulometric distribution, bulking and shot pile format. The assessment of blasting fragmentation is a recent, effective advance. The volume of the samples to be screened, according to industrial sampling rules, would imply that this assessment would be physically 28
Quarry February 2019
Figure 1. An estimate of the average energy impact in each unit operation.
Figure 2. Fragmentation curves.
unfeasible due to the financial, human and time costs involved. However, new photogrammetric techniques are widespread, both in mining and in the ore processing industry, allowing the aforementioned obstacles to be overcome and offering almost immediate results in a convenient, economical manner. Photometric analysis software can work with images collected using conventional fixed and mobile video cameras, photo cameras or digital files, plus orthophotos obtained with drones. These use automatic algorithms that identify individual blocks by defining contours. Whenever necessary, the images can be manually re-edited to improve the digitisation of each of the blocks. The flexibility of the series allows several
A shot pile after blasting on the Toowoomba Second Range Crossing project.
types of reading in accordance with the requirements of each operation, including accumulated distribution charts, histograms and continuous flows, in order to set out any product quality variations quickly in different time periods (see Figure 2). The need for continuous improvement in all extractive operations makes it necessary to apply measuring models that can, in the design phase, predict the impact of fragmentation on the subsequent phases of the production cycle. It is therefore possible to, after comparing predictions to the actual results, establish the optimal energy configuration in each blast. • Source: MAXAM Australia
DRILL & BLAST
INNOVATION AWARDS CELEBRATE SILVER ANNIVERSARY, DRIVE SOLUTIONS
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AXAM, the global technology company specialising in energetic materials in mining, quarries and civil works, recently celebrated the 25th edition of its Santa Barbara Innovation Awards, an initiative in the blast solutions industry that promotes a culture of innovation at all levels of the organisation. Some of MAXAM’s solutions – such as the RIOBLAST design and simulation software and the RIOSENSOR device – blossomed from these awards. The awards are aimed at the company’s 6500-plus workforce in 80 industrial facilities and subsidiaries across more than 50 countries on five continents. They are open to any employee who can identify and propose new ideas and solutions that generate a differential value for the company and its customers. “MAXAM’s professionals in the field face complicated and extremely differing environments such as a mine in Siberia in -40 degrees, underwater blasting machines in Panama, or projects in sub-Saharan Africa in more than 40 degrees of heat,” MAXAM’s chief technology officer Miguel Àngel Flórez said. “It is they who can quickly detect any new challenge to improve the security and efficiency of operations. Thanks to them, to the non-conformist, innovative spirit of our teams, some significant technological advances have emerged from Santa Barbara that respond to the specific needs of our customers.” Fernanda Cardama, the company’s global head of people and resources, said: “Innovation is one of our fundamental values as a company and a distinguishing mark of each and every one of MAXAM professionals. “We have a global, multicultural and diverse team that drives us to innovate every day. Constantly exploring new paths and possibilities is the only way we know to continue creating value for all our stakeholders, while still contributing to the progress of society.” In its 25-year history, the Santa Barbara Innovation Awards program has been the starting point for some of the company’s
Maxam MSU trucks deliver RIOFLEX bulk watergel to an extractive site. The trucks evolved from mobile assembled explosive units first proposed as part of the Santa Barbara Innovation Awards.
important technological advances. In the past 10 years, the prototypes of innovative developments have featured in the awards, aimed at increasing the efficiency, precision and security of blasting solutions for mining and civil engineering. For example, technologies such as RIOBLAST and mobile assembled explosive units played key roles in MAXAM’s successful Panama Canal extension project, completed in 2015. Both innovations evolved from the presentations of MAXAM employees at the Santa Barbara Innovation Awards. Other significant developments arising from winning ideas have included the BER system for the real-time visual inspection of boreholes and the RIOSENSOR device, which contribute to clear security, efficiency and productivity improvements in mining projects. RIOBLAST is a blast design and simulation software package for managing a one-off blast or complete campaign. It enables the optimisation of explosives and initiation systems, and accurately predicts aspects such as the fragmentation that will be obtained, vibrations in the field and reach, allowing the delimitation of the security perimeter. Additionally, it can be used to analyse results and generate blast reports with details of fragmentation and vibrations.
RIOSENSOR is a device designed by the company’s technicians to identify and measure deviations in blastholes before proceeding with the blast. It means corrections can be carried out or the effects of deviations on the final result can be anticipated, therefore improving operational productivity. BER is a visual and real-time borehole inspection system that can remain inside the borehole while the explosive is loaded, unlike other devices where it is necessary to extract and clean it. In addition, this system transmits real-time images that can be seen from anywhere in the world. Information obtained on every borehole via the BER allows adjustments to be made before executing the blast, contributing to improvement of the end result. During works for extending the Panama Canal, part of MAXAM’s technical team developed a device for packaging the stored explosive on trucks that pump the bulk product into the boreholes. This conversion of trucks into mobile explosive units generates significant economic savings for the customers, and significantly increases the security of an operation. It enables the use of an assembled product in unstable areas or areas with difficult access for pump trucks. • Source: MAXAM Australia
Quarry February 2019 29
DRILL & BLAST
CONTRACTOR BREAKS NEW GROUND WITH “INTELLIGENT” RIG The latest rendition of an all-encompassing crawler rig is kicking goals for a drilling contractor at a Boral quarry. Tim Robertson reports.
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axfield Drilling has been working closely with Boral in Tasmania for the past 30 years, but it was only in January last year that the companies partnered for their first project on the mainland. “We have a great relationship with Boral,” said Dean Maxfield, the general manager at Maxfield Drilling. “We’re very proud that they’ve shown the confidence in us to give us work in Victoria – a new state – so we’ve set up a workshop and office in Victoria and hopefully it’ll grow from there.” Established in 1984, Maxfield Drilling is primarily a blast hole drilling contractor for quarries, open-cut mines and large-scale civil construction projects. It also conducts grade control drilling services and is currently working on about 46 sites across Western Australia, Tasmania, Victoria and Tasmania. The company has always placed an emphasis on keeping abreast of the latest technological developments, to ensure it remains at the forefront of the industry. This shared vision has led to a close partnership between Maxfield Drilling and Sandvik Mining and Rock Technology. The relationship has gone from strength to strength since 2004, when Maxfield Drilling purchased its first piece of Sandvik equipment – a Pantera 1100 crawler rig. Since then it has bought more than 25 machines and its fleet now includes 20 Sandvik drills. Now, in a first for Australia, Maxfield Drilling has been operating Sandvik’s Ranger DX900i surface drill rig at Boral’s Lysterfield Quarry, in the southern foothills of Mount Dandenong in Melbourne’s south-east. “We’d been talking to Sandvik for some years about getting a machine that was versatile in reach and movability, as well as being capable of achieving high production
30
Quarry February 2019
The Ranger DX900i drill rig is equipped with a revolving upper structure that offers a 290-degree drilling reach and 55m2 coverage.
rates. When the DX900i was released, we thought it was a machine that could hopefully achieve both these tasks,” Maxfield said.
ROTATING COVERAGE At the rig’s Australian launch in April 2018, Sandvik personnel said the DX900i had potentially the widest drilling coverage available in its class, with its revolving upper structure offering a 290-degree drilling reach and 55m² coverage. Despite the rig’s ability to rotate, it maintains maximum stability through a counterweight structure opposite the boom. Its low centre of gravity and high tramming power also allow it to remain mobile. “In a conventional rig, your reach from one spot to where you tram is only the boom movement and the areas of a few square metres maximum,” IIkka Lahdelma, Sandvik’s global director of product management for surface drilling and exploration, told Quarry. “So basically, in this kind of drilling pattern, you are able to reach two holes, if you are tramming to a row of holes. “Because the [DX900i] has a 290-degree turning upper structure, we are able to reach four-hole rows from the one set-up.”
TECHNICAL DATA SANDVIK RANGER DX900I Recommended hole diameter
89-140mm* (3”-5.5”)
Drill rod/tube diameter
51mm or 60mm (2” or 2.3”)
Hydraulic rock drill
RD927L, RD927L-C (27kW)
Drilling coverage
55m2
Engine type/output
Volvo Penta TAD852VE (Tier 3) – 210kW@1800 rpm Volvo Penta TAD872VE (Tier 4) – 210kW@1800 rpm
Flushing air capacity
9.5m³/min, 335 cfm up to 10 bar
Operator cabin
iCab
Certificate
ROPS and FOPS
Transport length
12.4m
Transport width
2.45m
Transport height
3.3m (4.4m with safety cage, 4.4m with noise silencer)
Weight
19.6 tonnes (19,600kg)
* If larger than 127mm holes drilled, consult factory.
During his presentation, Lahdelma also outlined how the Ranger DXi series is equipped with the latest versions of “Sandvik intelligence”, including full hole automatics, troubleshooting functions, iTorque drilling control system, full radio remote control and optional extras available for hole navigation, on-board data collection, wireless data transfer and drill plan creation and analytics.
IN THE FIELD Since becoming operational at Lysterfield, Maxfield told Quarry the rig has been performing well. “From a movability and reach point of view, it far outperforms anything else we’ve used. Its penetration performance has met expectations and so far we’re very happy with the Volvo engine package. Fuel burn has been really good too.” Sandvik’s publicity for the Ranger DX900i has emphasised that fuel consumption can be reduced by as much as 15 per cent on previous models.
Dean Maxfield (left) receives the keys to the DX900i from Sandvik’s Australian surface drilling and exploration business line manager Scott Wright at the rig’s Australian launch in April last year.
“As with most new model machines, you can have some teething problems, but Sandvik have addressed all of them and have been very proactive in resolving any ongoing issues,” Maxfield said. Feedback from the client, Boral, has also been positive. “From my perspective, it’s been good,” said Rodney Krins, the drill and blast manager for quarries in Boral Construction Materials & Cement’s southern region. “We haven’t had
any major issues. The versatility of it is good. Availability-wise, it’s been good, and the operator certainly seems to like it.” While the Ranger DX900i hasn’t even finished its first assignment, it seems it will be only a matter of time before it starts appearing on more Australian sites. Based on what Maxfield Drilling has experienced in this short time, it is increasingly likely the company will consider more additions to its drill rig fleet in the future. •
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DRILL & BLAST
MOBILE MANUFACTURING UNIT ARRIVES IN A SPLASH OF COLOUR
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rica’s Bulkmaster 7 – which was launched 12 months ago – recently arrived in the New South Wales coal region with a splash of colour. A new Mobile Manufacturing Unit (MMU), donning the red and yellow livery of the Westpac Rescue Helicopter Service to raise funds and awareness, was unveiled at the service’s Broadmeadow base and is now operating on-site at Yancoal’s Moolarben coal operations. The vehicle’s traditional colours are blue and white. Orica has been a supporter of the Westpac Rescue Helicopter Service since 2015, contributing more than $500,000 to the service over that time. “The Westpac helicopter service is a vital lifeline for the community,” Orica’s AustraliaPacific vice-president Todd Peate said. “We’re so proud of our partnership with the service that we’ve painted one of our Bulkmaster 7 trucks in their colours, to lend support and spread awareness.” Peate said Orica had operations at sites throughout the Hunter Valley and northern New South Wales, from Newcastle to Gunnedah, and it was “reassuring to know that this life-saving service is there for us and the community”. He added the red and yellow 47-tonne Bulkmaster 7 was an expansion of a partnership underpinned by the generous contributions of Orica employees over many years, through Orica’s “Dare to Share” payroll deduction program. Orica matches its employees’ donations on a dollar-fordollar basis. Richard Jones, CEO of the Westpac Rescue Helicopter Service, said support from companies such as Orica was critical to the service’s operations. Each year the service undertakes more than 32
Quarry February 2019
The Bulkmaster 7 fully integrates with LOADPlus, a BlastIQ-enabled smart control system technology.
1200 missions across the Hunter, Central Coast, Mid North Coast, New England and north-west regions of NSW. “No one ever pays to be assisted by the service, but its value is priceless,” Jones said. “We truly appreciate the long-term and valued support from Orica. This is an incredibly creative promotional push for our service. We are fortunate to have many people support us in so many diverse ways. We know the great history of Orica’s colours and we’re humbled and privileged that Orica has chosen to support our service this way.”
EXPLOSIVES DELIVERY SYSTEM Designed for use in the open-cut mining sector, the Bulkmaster 7 is part of Orica’s delivery system technology, offering an increased payload, loadout rates and bin flexibility for more productivity and safety on bench. The first Bulkmaster 7 unit began operation in February 2018 at the Fortescue Metals Group’s Solomon operations, in the resourcerich Pilbara region of Western Australia. Orica has cited significant performance improvements through a series of technical innovations in the new generation
delivery system, including: • A proprietary bin shape to optimise ammonium nitrate flowability, minimise weight, evenly distribute stresses and lower the centre of gravity. The Bulkmaster 7 is designed to significantly improve reliability, stability and safety, and increase total bulk explosives product holding capacity to up to 21 tonnes of Fortan and 22.5 tonnes of Fortis. • Specially designed augers and significantly increased power capacity to improve delivery rates and allow for new material metering methods. It allows for accurate Fortan and Fortis delivery rates of 1100kg/ min and 550kg/min respectively. • State-of-the-art integrated hydraulic, sensor and control system technology that optimises usability and formulation quality at high speeds. The Bulkmaster 7 fully integrates with LOADPlus, a BlastIQ-enabled smart control system technology, to deliver products transparently and accurately in accordance with site requirements. BlastIQ delivers a range of technology solutions to improve productivity, save time and reduce the overall cost of drill and blast operations. As the extractive industry moves ever closer to automating the entire mining value chain, the release of the Bulkmaster 7 is considered a milestone in Orica’s overall technology vision. This vision includes WebGen, the world’s first truly wireless initiating system, the BlastIQ system and an advancement of Orica’s bulk product range and delivery methods to revolutionise drill and blast operations. The Bulkmaster 7 is being rolled out in Australia, providing a competitive advantage to operators adopting the new technology. • Source: Orica Australia
SPECIAL DRILL &REPORT BLAST
FROM AN EXCAVATOR TO SURFACE DRILL
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renowned international manufacturer and supplier is offering a versatile, alternative drill solution to the quarrying industry. The Montabert CPA blast hole drilling rig is an excavator-mounted drill that offers numerous advantages over the conventional crawler drill, such as drilling multiple holes from one position, pre-splitting and toe holes, which provide safety advantages, and easy travel and versatility over rough terrain. It effectively transforms any suitable excavator into a surface drilling machine and enlarges its application range, while retaining all of the excavator’s usual benefits, eg the long reach boom, mobility, cabin view, etc. From the Montabert Micro CPA, the smallest unit to suit machines ranging from five to 10 tonnes, up to the Montabert CPA X-tend, the largest unit, which is mounted on a 30-tonne machine, operators have economical and effortless options for their drilling needs. The CPA can drill holes up to 28 metres deep and 140mm in diameter, using a wide range of rods (from the Hex 22/25 to T60). For maximum safety, a CPA can be equipped with an automatic rod changer (up to seven rods) and a dust collector. The swing can also be rotated by 45 degrees to allow easier positioning (in one version, the Micro CPA 360 can go up to 180 degrees). The CPA can be operated from the excavator cabin or from outside with a remote control.
INDONESIA
MALAYSIA
On top of drill and blast in quarries, as well as long or high reach drilling, the CPA can be used in a wide range of applications including excavation, anchorage, bolting and drainage. The drill circuit on the excavator can also run a rock breaker should oversize breaking be required, or back to bucket work, which enables the owner to maximise 100 per cent availability. Montabert drifters have been mainstays of the quarrying industry globally since the 1970s. One of the most notable benefits of the Montabert drifter is the piston shape. Its trapezoidal design allows the drifter to deliver constant power with a high efficiency ratio; no energy is wasted. Every single kilowatt supplied to the drifter will be used at its best, and converted into drilling power to provide the best penetration rates, and the lowest costs per metre. Drifters also provide savings on consumables. Dampening systems and reverse percussion greatly improve shanks and bits lifespan. High quality raw materials and treatments, and reliable manufacturing processes grant these drifters a very high life cycle, minimising maintenance. The drifters are mounted on the Montabert CPA drill attachment but can also be used to replace an old drifter (not necessarily a Montabert) on regular surface or underground drilling machines. • Source: Komatsu Mining
SINGAPORE UNITED KINGDOM
+65 +65 9799 9799 5497 5497 sebastian@trimaxmachinery.com sebastian@trimaxmachinery.com
Trimax Tri Machinery
www.trimaxmachinery.com
SIMPLY BETTER CRUSHERS
SPECIAL DRILL & BLAST REPORT
INDUSTRY BODY PROMOTES IMPROVED SAFETY, SECURITY OF EXPLOSIVES
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he Australasian Explosives Industry and Safety Group (AEISG) was originally formed in 1994 as the Australian Explosives Manufacturers Safety Committee. In 2004 a formal constitution was developed, and the association was formally incorporated under the New South Wales Associations Incorporation Act. Since formation AEISG membership has expanded to include all significant explosives manufacturers and suppliers in Australasia. The membership includes (but is not limited to): Applied Explosives Technology; BME Australia-Asia; Davey Bickford Enaex Australia; Downer EDI Mining-Blasting Services; Dyno Nobel Asia Pacific; Hanwha Mining Services Australia; Johnex Explosives; Maxam Australia; Nitro Sibir Australia; Orica Australia; Platinum Blasting Services; Redbull Powder Company; Solar Mining Services; and Thales Australia. AEISG’s company members elect a committee chairman on an annual and rotational basis, and employ a chief executive officer and an industry liaison officer to progress the group's activities. Its primary goal is to continuously improve safety and security throughout the manufacture, transport, storage, handling and use of explosives and their precursors (eg ammonium nitrate, ammonium nitrate emulsions) in Australasia. The roles of AEISG and its members have been incorporated into its constitution, ie to: • Create an environment for open exchange of opinions/ideas on explosives industry matters. • Disseminate information about explosives industry issues (eg accidents, incidents, security, environmental, technological advances in safety and security). • Represent the explosives industry nationally and internationally to regulatory bodies on safety, security and other matters. • Liaise with national and international organisations to progress improved safety and security in the explosives industry. • Develop and promote industry Codes of Practice (minimum acceptable standards). • Promote consistency in legislation covering the explosives industry. • Promote community perception of a
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The AESIG’s Codes of Practice include steps to reduce NOx fumes produced by ANFO.
competent and responsible industry. In undertaking the above roles, AEISG members hold meetings four times per year, with further meetings to address specific technical issues as necessary, including the Codes of Practice. Further, AEISG, through the CEO or member representatives, is represented on national and international regulatory meetings where it can provide input to effective outcomes on safety and security issues involving explosives. The current AEISG Codes of Practice include: • Blast guarding in an open-cut environment. The use of explosives to break rock is an intrinsically hazardous process. On a mine or quarry site the potential hazards are increased by the need to manage the blasting procedure to protect personnel, contractors and the public from exposure to foreseeable, if unintended, adverse consequences of a blast. This code provides practical guidance on meeting regulatory requirements on explosives and mine/quarry safety. • Mobile processing units (MPUs). This code sets out requirements for the design and operational management of MPUs used in the manufacture and blast-hole delivery of explosives in surface and underground blasting. • Ammonium nitrate emulsions, suspensions or gels. This code sets out requirements and recommendations to control the risks (to people and to the environment) arising from the storage, handling (including transfer operations), transport and security of ammonium nitrate emulsions,
suspensions and gels conforming to UN3375. These materials are collectively referred to in this code as ANEs. • Prevention and management of blastgenerated nitrous oxide (NOx) gases in surface blasting. These guidelines assist the safe use of explosives in situations where a specific additional hazard may arise due to the generation of NOx within the post-blast gases. • Elevated temperature and reactive ground. This code aims to enhance the safety of explosive suppliers and their customers when handling explosives and charging in elevated temperature and/or reactive ground conditions. • Segregation barriers for transporting mixed loads of detonators and high explosives. The code covers the safe and secure transport of explosives as per as the Australian Explosives Code (AEC) and provides additional guidance to satisfy the segregation requirements outlined in chapter seven of the AEC regarding transportation of detonators and other high explosives on the same vehicle. • On-bench practices for open-cut mines and quarries. This code has been developed to provide practical guidance for those on-bench activities that must be considered as part of the risk assessment process, and during the development of a safety management plan and associated operating procedures and work instructions. Such codes are developed, with both industry and regulatory input, to establish acceptable safety and security requirements in the handling of explosives, and AEISG members are committed to following such requirements. Some have either been adopted into legislation or accepted as “approved codes” by regulators. While these codes are, and remain, copyright, AEISG makes them freely available on its website – at aeisg.org.au – for use by any interested parties. The AEISG is always keen to receive constructive comments on improving any of its codes. • Bob Sheridan is the CEO of the Australasian Explosives Industry and Safety Group Inc.
WEIGHING SYSTEMS
INTEGRATED WEIGHING
SOLUTIONS FOR EXCAVATORS
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combination of a fleet management system (FMS) and hydraulic on-board weighing technology can transform quarry excavators into mobile control centres for increased productivity. Intelligent positioning technology provider Position Partners has announced a new solution for excavators working on quarry and mine sites that combines Topcon’s iVolve FMS with RDS hydraulic excavator scales. The technology enables accurate weighing of material onto trucks, transforming the machine into a control centre for loading operations. The iVolve FMS solution provides high precision machine guidance for excavator and dozer operators to mine to a preprogrammed design without having to wait on supervisors and surveyors. It offers real-time positioning information across the machine fleet on an easy to use, comprehensible interface inside the machine cab. iVolve FMS enables excavator operators to accurately excavate even the most complex designs and maximise their accuracy from the digging and loading phases at a glance, using key information on a single screen. It also eliminates over- or under-excavation and associated rehandling, reduces fuel usage and machine wear, minimises intervention from surveyors and supervisors, and makes the operators more effective, reducing the workload on other quarry personnel. Producers can also monitor and record all aspects of the haul truck load cycle, including tonnage, load pass details, material, load and dump location, activity/delay and loader vehicle state. Topcon’s Loadex 100 RDS excavator loader scales technology stores accurate load information, especially in difficult conditions and terrain, to ensure road trucks are loaded consistently and within approved
weight limits. It can also be customised to accommodate a wide range of earthmoving applications and attachments and a variety of other active tasks. Operators can set individual product targets or make automatic product selections, set alarms for overload thresholds, make quick and easy calibration adjustments to match site reference (eg a weighbridge), load accumulation for up to 10 attachments (eg buckets, grab tools) and manage recordkeeping, traceability and stock management – all from a single screen. The Loadex 100’s features include a colour touch-screen display, dynamic weighing technology using inclinometers and mechanical sensors, memorised preselections for repeat job set-up, GPRS and Wi-Fi connectivity, SQL database functionality and XML data output, a printer option with configurable output, an internal audible alarm, calibration “nudge” and a system “pause” button. For haul trucks already fitted with truck scales, the combined iVolveFMS/RDS excavator scales system acts to validate and compare truck tonnage. If trucks do not have on-board weighing technology, the excavator can store and transmit loading information to the truck, allowing site managers to consistently and reliably track material movement across the site. “By bringing together iVolve FMS and RDS excavator scales, we can offer managers an exciting productivity tool that maximises an excavator’s capacity by making it the centre of loading operations,” Position Partners’ national manager for mining Andrew Granger said. “In consultation with our customers, we identified a need for this solution in the quarrying and mining industries. Having supported a similar solution in construction for some time, we were able to work with our
suppliers to create a tailored system that is specifically designed to meet the needs of Australian mine sites.” Position Partners’ announcement of the combined iVolveFMS/RDS excavator scales system coincided with the company receiving the top prize for construction at the Topcon Xperience dealer conference in San Antonio, Texas, in December 2018. Along with this accolade, the company also received awards for the top five excavator sales and top five year-on-year sales growth. “We are privileged to receive Topcon’s dealer of the year award among all of Topcon’s successful distributors,” Position Partners CEO Martin Nix said. “It’s a great reflection of the support our customers give us as they strive to increase productivity and safety by pushing the boundaries with intelligent positioning systems in the construction industry. “These awards are accepted as a recognition of the combined efforts of our teams and employees, who continually do their utmost to deliver exceptional customer service.” Topcon executive VP and general manager of the construction and retail groups Jamie Williamson said: “The Position Partners team has always exhibited strength and dedication in providing the most innovative technology and service to their customers. That spirit has been notably evident in their performance, which makes Position Partners a superb choice for dealer of the year.” With about 270 people in offices Australiawide, in south-east Asia and New Zealand, Position Partners is the largest Australianowned company focusing entirely on the distribution and support of intelligent positioning solutions for geospatial, construction and mining projects. • Source: Position Partners
Quarry February 2019 35
WEIGHING SYSTEMS
VOLUME SCANNER FOR MEASURING, REPORTING ON BULK MATERIAL FLOW
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oadscan, a global leader in payload profiling systems, has released the conveyor volume scanner (CVS) – a high tech, easy to use tool that allows users to see how much material is moving across their conveyor belt. Loadscan systems provide 3D images and insightful data in real-time for every load, equipping users to optimise loading, productivity and profitability. The CVS is an above-belt lidar laser measurement system. It is ideal for production management because it provides unambiguous data, including 3D profiling, in real-time or period reporting. The Loadscan belt scanner gives users a clear understanding of their inventory production rates (or contract crushing quantities) in volume and tonnes. Its specially designed scan-head, with single laser, continuously scans the full width of a conveyor belt at high angular resolution to capture accurate volumetric measurement of material flowing by. “We are really excited about this product,” said Carey West, the owner and director of Loadscan. “The concept of a belt scanner has been around for a while – customers have been asking for it – and now we can deliver a well designed solution that’s easy to install and affordable, that has a software interface that is stacked with functionality, and that’s user-friendly. “The CVS is the perfect complement to our load volume truck scanners and will complete our customers’ volumetric production tracking. It could also solve production management headaches for many companies, and industries, that have never used volumetric scanning before. I can see it being adapted to a variety of industry applications.” West said that, unlike other optical belt scales, which provide some data but don’t integrate easily, the Loadscan CVS has been designed to provide hassle-free, insightful reporting. It has extensive functionality options, with an on-board application programming interface (API). The API enables the user to easily set up a list of jobs, instructing their dispatch system 36
Quarry February 2019
The Loadscan CVS is an above-belt lidar laser management system that scans any belt from 400mm to 2000mm wide.
to deliver specified job quantities (which can be reported direct to the loader operator’s cab) and allowing the job run to be initiated by the loader operator. The Loadscan conveyor volume scanner works across all conveyor belts. The standard scan head is simply fixed to the appropriately sized frame, which expands or contracts, for a secure fit to the user’s belt. With the correct size frame, the CVS can run on any belt from 400mm to 2000mm wide (and can be custom-mounted on belts up to 3000mm). It can also be used on deep belts, supplying accurate measurement for material quantities that were previously thought to be too great for bulk-flow volume scanning. Loadscan has been at the forefront of volumetric measurement over the past decade, ensuring easy, accurate load management with its load volume scanning (LVS) systems for trucks and trailers. The Loadscan LVS and CVS systems both utilise laser-scanning technology combined with proprietary Loadscan software to
measure the exact volume of the material (either loaded in a truck/trailer bin or flowing on a conveyor belt). The CVS continues Loadscan’s history of high build quality. It is a robust product that will withstand a wide temperature range in harsh environments. The high spec lasers used in the CVS are class one eye-safe, meaning users do not require extra protection. West and his team at Loadscan have built upon the volumetric scanning technology his father originally pioneered, and are now fielding global interest for their innovative product. “Whether you’re talking about optimising truck loads or measuring bulk material flow across a conveyor belt, we’re chasing the same outcome: greater efficiency and, ultimately, improved profitability for our customers,” West said. • Source: Loadscan
STACKERS
IRON ORE PROJECT BOASTS WORLD'S LARGEST STOCKYARD MACHINES
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hyssenkrupp's industrial solutions business has been awarded one of the largest fabrication and construction projects the company has ever handled in Western Australia. Under the contract, thyssenkrupp will design, supply, construct and commission large-scale stockyard machines – possibly the largest in the world – for the BHP South Flank iron ore project in WA's central Pilbara region. The contract is valued at $AUD237.5 million. The project is targeting first ore extraction in 2021. With an output of 80 million tonnes per year, it will fully replace production from BHP's Yandi mine, which is reaching the end of its economic life. The project will create many opportunities for WA suppliers.
“South Flank will be one of the largest iron ore operations worldwide,” said Torsten Gerlach, CEO of the mining technologies unit at thyssenkrupp Industrial Solutions. “We look forward to contributing to this project by combining long-standing global expertise in the mining business with local experience. “Our strong partnership with BHP extends globally, but the Pilbara region is a core area where we have provided material handling solutions for decades.” thyssenkrupp will supply two stackers that deposit iron ore into stockyards, and a reclaimer for loading the ore onto rail to Port Hedland. The machines will have a capacity of 20,000 tonnes per hour and their designs incorporate the latest Australian Standards
requirements and technology improvements centred on safe construction, operation and maintenance activities. thyssenkrupp Industrial Solutions' mining technologies business unit supplies a full range of machinery, systems, equipment and services for the extraction, processing, storage and transportation of raw materials. In collaboration with customers in the mining and minerals sectors globally, the mining technologies business unit develops custom, forward-looking solutions that enhance productivity and allow natural resources to be used responsibly and efficiently. • Source: thyssenkrupp Industrial Solutions
AUSTRALIAN CRUSHER REPAIRS
ONE-STOP CRUSHER SHOP
• Crusher Systems • Site Maintenance • Site Electrical • Mobile Crusher Servicing • Fabrication • Spare Parts • Machine Shop
Mark: 0407 934 727 Greg: 0448 634 896 Tony: 0432 225 343 admin@acrpl.com.au 3 Enterprise Drive Berkeley Vale NSW 2261
www.acrpl.com.au 02 4388 1011
2019 IQA EVENTS ACT BRANCH 15 March Dinner meeting (Venue TBA) 12 July Dinner meeting (Venue TBA) 15 Nov Dinner meeting (Venue TBA)
QUEENSLAND BRANCH 19 Feb Technical and dinner meeting, Moda Events Portside 21 March WIQ Queensland Conference, Brisbane 2 April Site visit to Brisbane Airport’s second parallel runway 17 May IQA Annual Golf Day, Oxley Golf Club 14 June Quarrying Safety & Health Conference, Bris 7 Aug Dinner meeting & AGM, Bris Sept CMEMC 2019
CENTRAL QUEENSLAND SUB-BRANCH 13 March Technical meeting, Rockhampton 19 July Annual Golf Day, Rockhampton
NORTH QUEENSLAND BRANCH 12 Feb Technical and dinner meeting, Nth Qld Club, Townsville
12 March Technical and dinner meeting, Cairns 14 May Technical and dinner meeting, Cairns 21 May Technical and dinner meeting, Mackay 19 June Safety & Health Seminar, Townsville 26 July Annual Golf Day, Cairns 13 Aug Branch AGM, Townsville 13 Sept Annual Golf Day, Townsville 8 Oct Technical and dinner meeting, Townsville 30 Oct Technical and dinner meeting, Cairns 15 Nov Christmas Party, Townsville
SOUTH AUSTRALIAN BRANCH 24 May Technical and dinner meeting (venue TBA) 12 July WIQ SA Conference, Adelaide Pavilion 30 Aug AGM/dinner, National Wine Centre 8 Nov Dinner Meeting, Pullman Adelaide Hotel
VICTORIAN BRANCH 19 Feb 1 March 16 May
Summer technical night Annual golf day Student presentation night
WESTERN AUSTRALIAN BRANCH 22 March ‘Bowling Stone’ Challenge, Lawn Bowls Challenge, South Perth Bowling Club 8 May Breakfast meeting, Beaumonde on the Point, East Perth 28 June Brikmakers clay brickworks site visit and sundowner 7 Aug Breakfast meeting, Beaumonde on the Point, East Perth 3 Sept AGM and dinner meeting, Imperial Court Restaurant 22 Nov Annual golf day, Joondalup Resort
All dates and venues for the above branches are correct at time of press. Not all branches had confirmed their activities/ dates. For further information about IQA branch activities, contact your local branch representative (see IQA branch contacts on page 41) or visit quarry.com.au
PDP WEBINARS & EVENTS Unless specified otherwise, the activities below are webinars open to all IQA members and other interested parties. To register, visit: quarry.com.au/education
IQA 62ND ANNUAL CONFERENCE Geelong Football Club, Kardinia Park Geelong, Victoria 1-3 October (Tuesday to Thursday), 2019 “The Future of Quarrying” will be the theme of the IQA’s annual conference which this year will be hosted at the home of the Geelong Cats AFL Football Club. The conference program will focus on numerous topics, including: the maximisation of limited natural resources through technology; the benefits of effective management of workplace diversity; new developments in emerging fixed and mobile plant technology; environmental and economic trends impacting on the industry; and much more. In a first, the conference program will be hosted on a Tuesday, Wednesday and Thursday. For more information, visit quarry.com.au
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TRAINING AND VERIFICATION OF COMPETENCY 12 February 2019 Personnel in quarry and extractive industry operations must be adequately trained and verified as competent for the tasks that they are responsible for performing. This is not only a legal obligation, but it makes sound business sense. This wPDP provides participants with an introduction to the core principles of training and verification of competency (VOC) required for safe and efficient quarrying operations. It is suitable for quarry managers, quarry supervisors and key support personnel with management responsibility.. For more information, visit https://quarry.page.link/TVOC
DEALING WITH NEIGHBOURS AND THE COMMUNITY 15 February 2019 The public are seldom happy with living near
a quarry. Dust, noise and environmental damage are genuine concerns, not only at the development application stage, but during the life of the operation. This webinar will provide tips on how to communicate effectively with neighbours and the community at large, what needs to be done to maintain the "social licence to operate", and how to co-exist with other land users in the surrounding community. It is suitable for quarry managers, supervisors, community liaison officers and environmental officers. The facilitator is Wayne Scott. For more information, visit https://quarry.page.link/DWN
CONCRETE STRUCTURES & BUILDING TECHNICAL SEMINAR Oaks on Market, Melbourne 21 February 2019 The Concrete Structures & Buildings Technical Group of the Australasian Corrosion Association (ACA) has produced a
The Institute of Quarrying Australia
technical program that focuses on pragmatic considerations and practical and optimised solutions for reinforced concrete structures. This event will draw from the presenters’ and audience members’ experience, the lessons they have learnt through real life case studies, and openly explore successes and failures. This one-day event – from 8.30am to 5.00pm – will bring together all stakeholders to discuss various corrosion issues across the concrete structures and building industries. The presenters on the day will be Fred AndrewsPhaedonos (VicRoads), Michael Heathwood (Laing O’Rourke), Luke Thompson (SMEC), Glenn Brewster (Transurban), Frédéric Blin (AECOM), Dave Charters (DCL Consulting), Chris Jones (Boral), David Johnstone (AkzoNobel) and Darren Smith (SIKA). The seminar will conclude with networking drinks. Admission is $300 (inc GST) for ACA members and $340 (inc GST) for non-ACA members. To book, visit events.corrosion.com.au/events/concretestructures-and-building/
EFFECTIVE RISK MANAGEMENT 22 February 2019 The IQA and the quarrying industry at large recognise the importance of managing safety risks. Effective risk management processes are fundamental in realising significant gains in safety performance. When these processes are ineffective you send the wrong message to your workers and do little to improve safety at your site. This webinar will assist operators in ensuring their risk management processes are effective. It will consider why risk management processes fail, identify risk profiles, provide advice on effective risk management processes and cover some incident investigations. Participants will also be given practical examples of how smallscale quarries have achieved significant safety improvement through effectively managing risk. Managers, supervisors and key support personnel are the primary target group for these webinars. There is a good opportunity to ask questions in an informal environment. Numbers are kept small to provide an opportunity for everyone. The facilitator is Wayne Scott. For more information, visit https://quarry.page.link/ERM
CCAA ACADEMICS FORUM 2019 26 February 2019 Pullman Sydney Airport Hotel The Academics Forum, organised by Cement
Concrete Aggregates Australia, is designed to provide a platform for leading product specialists from the Australian cement, aggregates and concrete industries to meet with principal academic researchers from around Australia. In doing so, both can be informed of the issues current in the industry, and learn of the breadth of research being undertaken into cement and concrete in Australia. Industry participants will gain insights into the work being undertaken in major Australian universities, the specific expertise residing in these institutions and whom businesses should contact about specific technical issues. Throughout the day – which commences at 9.00am and concludes at 5.00pm participants will be able to hear of the current directions for the concrete industry in market development, and also hear the thoughts of major concrete users and specifiers as to where they see the issues and challenges for the industry. For more information, contact Warren South, the CCAA’s director of research and technical services, tel 02 9667 8313, email warren. south@ccaa.com.au or visit the ‘Events’ page of the CCAA website: ccaa.com.au
PROJECT MANAGEMENT PRINCIPLES 1 March 2019 Projects exist throughout the life cycle of quarries, eg exploration and development projects, capital works and construction projects, and operational improvement projects, to name just a few. Multifaceted, capital-intensive projects will (and should) be led by a dedicated project management team but less complex projects are often managed by line managers and supervisors in the course of their “day jobs”. This webinar is designed to introduce the principles and practices of project management and the skills required for project success. It is suitable for quarry managers, quarry supervisors or other employees with responsibilities for planning, executing and controlling projects in the quarrying environment. The facilitator is Hamish Beattie. For more information, visit https://quarry.page.link/PMP
WORKER HEALTH 15 March 2019 Managing hazards associated with worker health is critical in establishing and implementing an effective safety management system. This area of health and
safety is getting added attention within all regulatory jurisdictions due to the increasing incidence of death and serious illness from work-related exposures. This webinar provides information on site worker health hazards including dust, noise, hazardous substances and psychosocial hazards, exposure monitoring and health surveillance, effective management of worker health hazards, and what should be in a worker health plan (in line with a relevant jurisdiction’s mining legislation, WHS legislation and duty of care requirements). It is suitable for managers, supervisors and key support personnel. Visit https://quarry.page.link/WH
MANAGING PSYCHOSOCIAL HAZARDS IN THE WORKPLACE 22 March 2019 Bullying, harassment, stress and physical violence are far too common in modern workplaces. Creating and maintaining a supportive workplace culture is critical to identifying and managing these hazards in the workplace. This webinar will provide tips on how to identify these problems in the workplace, what needs to be done to address them, and how to create and maintain a supportive environment that does not tolerate unacceptable anti-social behaviour. It is suitable for quarry managers, supervisors, human resource officers, and health and safety officers. The facilitator is Wayne Scott. For more information, visit https://quarry.page.link/MPH
HAZARD IDENTIFICATION PRINCIPLES 29 March 2019 Hazard and risk source identification are key steps in risk management. If these problems are not identified and acted upon early, they can spiral out of the organisation's control and impact on its day to day activities. Robust identification and initial appreciation of hazards and risks are therefore critical steps in comprehensive and effective risk management processes. This webinar will outline definitions and interpretations, benefits of comprehensive hazard and risk source identification, potential consequences of inadequate hazard and risk source identification, common hazard and risk source identification methodologies, and an introduction to alternate hazard and risk source identification methodologies. The facilitator is Hamish Beattie. For more information, visit https://quarry.page.link/HIP
Quarry February 2019 39
IQA NEWS QUEENSLAND NEWS Branch premium supporters The Queensland branch is pleased to confirm the appointment of two additional branch premium supporters for 2019 – Scope Engineering and Groundwork Plus. The branch committee thanks its branch premium supporters for their continued support, enabling the branch to host meetings and events at affordable rates. Technical meetings The first technical and networking meeting for 2019 will introduce a new format. It will be held at Moda Events Portside on Tuesday, 19 February, starting at 4.00pm with a technical presentation by Gregory Glennon, the eastern region operations manager for Otraco International, part of the Downer Group of companies. Greg will report on an extensive review of tyre maintenance-related fatalities and life-threatening injuries in the industry, the causes, and the controls that need to be implemented to eliminate them. The technical presentations will be followed by a networking function, concluding at 7.00pm. Complimentary on-site parking is available for a maximum of four hours. Please book tickets online at quarry.com. au or contact the Queensland branch secretariat, email qld-admin@quarry.com.au
WIQ conference The 2019 Queensland Women in Quarrying conference will be held at the Glen Hotel on Thursday, 21 March. Michelle Connelly from the CPR Group (the WIQ Queensland branch’s major supporter) and the other members of the conference planning committee (Karen Normanton, Anita Waihi, Rob Sloman, Tegan Smith) are finalising the conference program under the theme #quarriesrocktomorrow. Full details are available on the IQA website: quarry.com.au Date claimers – 2019 Further branch meetings are planned for the following dates: • 13 March: Technical and dinner meeting, Rockhampton. • 21 March: WIQ Queensland Conference, Brisbane. • 2 April: Site visit to Brisbane Airport’s second parallel runway.
tel 0419 782 688 or email qld-secretariat@ quarry.com.au
• 26 July: Annual Golf Day, Cairns.
By Jennifer Milward
•1 3 Sept: Annual Golf Day, Townsville.
NORTH QUEENSLAND BRANCH NEWS Christmas party The North Queensland branch’s Christmas party was full of its usual cheer, with 80 guests enjoying the end-of-year celebration at The Brewery in Townsville. Jeff Reibel from the North Queensland Cowboys was the special guest speaker. Ritchie Bros Auctioneers sponsored Christmas gifts and Lincom sponsored the lucky door prize – a Johnathan Thurston-signed Cowboys jersey.
•3 0 Oct: Technical and dinner meeting, Cairns. •1 5 Nov: Christmas party, Townsville. For further information about the above meetings, contact the branch secretariat, tel 0419 782 688 or email qld-secretariat@ quarry.com.au By Jennifer Milward
SOUTH AUSTRALIAN BRANCH NEWS
New SA associate members receive their certificates: (l-r) Kevin Whelan, Julie Ann Day, SallyAnne Heinrich, Sarah Pennington and Matt Stopp.
Dinner meeting More than 100 guests attended the South Australian branch’s final function for 2018 – a dinner meeting at the Pullman Adelaide Hotel, on Friday, 16 November. The Lincom Group’s Erwin Koch presents the signed Cowboys jersey to lucky winner Mark Collins (Hy-Tec Industries).
Date claimers – 2019 Further branch meetings are planned for the following dates: • 12 Feb: Technical and dinner meeting, North Queensland Club, Townsville. • 12 March: Technical and dinner meeting, Cairns. • 14 May: Technical and dinner meeting, Cairns.
• 14 June: Quarrying Safety & Health Conference, Brisbane.
• 21 May: Technical and dinner meeting, Mackay.
For further information about the above meetings, contact the branch secretariat,
• 19 June: Safety & Health Seminar, Townsville.
Quarry February 2019
•8 Oct: Technical and dinner meeting, Townsville.
Staff from Burdekin Quarry pose with Santa Claus.
• 17 May: IQA Annual Golf Day, Oxley Golf Club.
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•1 3 Aug: Branch AGM, Townsville.
The evening was a great opportunity for everyone to mingle and network in a relaxed atmosphere. Once the formalities were done, membership certificates were presented by branch chairman Andrew Wilson to new Associate members Kevin Whelan (Boral), Julie Ann Day (Groundwork Plus), Sally-Anne Heinrich (SC Heinrich & Co), Sarah Pennington (SA Department of State Development) and Matt Stopp (Hanson). The guest presenters for the evening were Tristan Throup (Penrice Quarry & Mineral and SA Young Members co-ordinator) and Clint Hart (MSP Group’s Kulparra Quarry). They provided an insightful and entertaining presentation on the Young Member Network study tour of New Zealand in July 2018. This included a blend of industry and cultural learnings.
The Institute of Quarrying Australia
The NAGA Award and now keenly soughtafter stainless steel spades (sponsored by Drew Martin from Blast It Global) went to Lincom, represented by Rebecca Jenkinson, Craig Lorimer, Michael Harrington and Brad Neil, with one of the lowest ever NAGA scores of 79.
The victorious team from Hanson: (l-r) Damon Case, Simon Blow, Stefan Kelemko and Michael McCallion. SA branch chairman Andrew Wilson presents raffle winner Frank Pedretti with a model Metso Nordberg H4 crusher.
the pin, straightest drive and beat the pro, as well as first to sixth places and last place (the NAGA). For the first time, there was also a launch monitor on the course, measuring the club head and ball speed of every golfer teeing off on the Quarry 9 hole. Sponsors that “manned” their holes also had plenty of prizes on offer, with business card draws, and RUD Chains introduced a chipping competition on its tee box that was very popular and competitive.
Tristan Throup and Clint Hart provided an entertaining presentation on the Young Member Network study tour of New Zealand.
Acknowledgement was also given to Mark Bevan, who was awarded the Retracom Quarry Operator of the Year Award at CMIC18 in September. The branch extends its appreciation to Andy Gough (Metso), who kindly provided a Nordberg H4 model as a door prize. This was raffled at the dinner and raised $377 for charity beyondblue. A big thanks to everyone who bought tickets. The winning ticket belonged to Frank Pedretti (Boral) – congratulations! The SA branch thanks its sponsors for their continued support – it goes a long way to ensuring that the branch remains relevant, vibrant and effective for its members. By Marie Cunningham
There was also a pictorial quiz question on each tee box that tested everyone’s golf knowledge (and very probably their Google search abilities!). The victorious team from Hanson finished with a gross score of 61 (net 58.625), including one eagle, nine birdies, seven pars and not a bogey in sight. In second place was Darryl Burton and his team from WesTrac, with a gross score of 63 (net 58.688), and in third place was the Brooks Hire team.
IQA BRANCH CONTACTS ACT
Peter Hewson: 0429 001 476
NSW
Gemma Thursfield: 0402 431 090
Northern Gemma Thursfield: 0402 431 090 Hunter Gemma Thursfield: 0402 431 090 Illawarra
WESTERN AUSTRALIAN BRANCH NEWS Branch golf day About 212 players took to the field in high spirits on 23 November, 2018, for the WA branch’s annual golf day. As usual, it was not all about the standard of play (for most) but about how much fun you could have. As a result, this highlight of the WA calendar once again hit the mark. There was a lot going on around the course, with the opportunity for players to win lots of prizes, including for longest drive, nearest
Dylan Treadwell: 0418 632 057
Central West Mitchell Bland: 0428 462 987 NT
Darren McKenna: 08 8988 4520
QLD
Jennifer Milward: 0419 782 688
Gladstone Jennifer Milward: 0419 782 688 Townsville Jennifer Milward: 0419 782 688 Cairns SA
Chris Wilson: 0438 134 752 Marie Cunningham: 08 8243 2505
Tasmania Nicholas Palmer: 0418 126 253 Victoria
Eli Carbone: 03 8637 4723
Vic Sub-branch Craig Staggard: 0407 509 424
WA
Celia Pavri: 0417 027 928
Bruce Hardy from Hanson was one player who could not be ignored – his fashion style surpassed all others on the field and won him the title of best-dressed golfer! Unlike other years, there was no followup dinner to the golf day. Instead, the branch hosted a two-hour sundowner with presentations, and everyone was home in time for dinner. The branch will be seeking feedback from members to see if this worked for everyone. The branch extends its thanks to the golf committee, comprising Grant Menhennett and Stephen Elliott, for their help behind the scenes, to Royce Sallur for MC duties, Orica for sponsoring the drinks carts and Boral Quarries for sponsoring the sundowner. A complete directory of all the event sponsors is on quarry.com.au and the branch is grateful to them for making the 2018 IQA golf day such a great success. By Celia Pavri
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Quarry February 2019 41
GEOLOGY TALK
CELEBRATING A GOLDEN ANNIVERSARY
Ancient Egyptian artisans lavishly decorated tombs with gold and gold objects, such as on Pharaoh Tutankhamun’s mask (front and rear). It is fashioned from two layers of high carat gold.
Bill Langer this month commemorates a milestone in his personal life – but will his wife Pam accept his golden gift?
T
his month my wife Pam and I celebrate our 50th wedding anniversary – our golden anniversary. I spent a lot of time trying to think of something gold to give to Pam. Instead, I have decided to take the lead from Your Song, recorded by Elton John in the 1970s. To paraphrase, the lyrics go something like this: My gift is my [article] And this one’s for you … And you can tell everybody this is your [article] … Let me explain why I have resorted to this simple gift. Even though gold is relatively scarce in the earth, more than 2700 tonnes (or 3000 US short tons) of gold is mined every year. Gold is concentrated by geologic processes to form commercial deposits of two principal types: lode deposits and placer deposits. Lode deposits are the targets for the “hard rock” prospector seeking gold at the site of its deposition from mineralising solutions. Placer gold is the stuff people “pan” for. Concentrations of gold eroded from lode deposits are carried downstream as flakes, grains or nuggets, and subsequently are concentrated in pockets containing stream bed sediments, where the current slackens.
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Quarry February 2019
Gold can survive being eroded from rock and carried downstream because it is a “noble” metal – it does not oxidise under ordinary conditions. In addition, pure gold is relatively soft and is the most malleable of metals. Because of these special properties, gold does not have to be smelted to be used, and was among the first metals to be mined and turned into useful objects. More than 5000 years ago, artisans in Egypt lavishly decorated tombs and temples with gold and golden objects. In ancient America, gold had both symbolic and spiritual meaning in Aztec society. This was strange, though, because the word for gold in Aztec dialect is teocuitlatl, which means “excrement of the gods”! Gold has a variety of applications. In 2015 about 41 per cent of the gold consumed for commercial products was for jewellery. But I would not dare buy jewellery for Pam without her approval, so gold jewellery is out. About 34 per cent of gold is used in solidstate electronic devices. These devices use very low voltages and currents that are easily interrupted by corrosion at the contact points. Gold is a highly efficient conductor that does not corrode, so it is used to plate the metal contacts on integrated circuits.
A 1999 Mexican teocuitlatl 1.4g gold coin.
Pam is quite happy with her flip-phone, so electronics are out. Ten per cent of gold was used for official coinage. No way would a gold coin make an appropriate anniversary gift. Three per cent of gold is used in dental and medical applications. Gold alloys are used in dentistry for fillings, crowns and bridges because it is chemically inert and non-allergenic, and because less inert materials might have an adverse effect on long-term health. I doubt a gift certificate to the dentist is what Pam has in mind. And speaking of health, one of the most ingenious uses of gold is to remedy a condition where a person cannot close their eyes completely. The condition is treated by implanting small amounts of gold in the upper eyelid. Gold is very heavy and weighs down the eyelid, helping it to fully close. Hmmm ... nope, I can imagine Pam rolling her eyes right now! The remaining two per cent of gold is used for things such as making glass red, coating the visors on astronauts’ helmets, gold nanoparticles and so forth. They even put gold on ice cream cones and in champagne. Uhmmmm … nope! So, Pam can tell everybody this is her article. Happy anniversary, my dear! •
Bill Langer is a consultant geologist. Email bill_langer@hotmail.com or visit researchgeologist.com
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