Initiative #1881 Single Pass Ground Support (T4)

Initiative Description

Currently we use Type 4 ground support in our weakest rockmass conditions

underground to resist deformation and to provide stable working conditions. The T4 support
class consists of a thickened shotcrete shell (minimum 100mm thick) with encased mesh
reinforcement. (ie. 50mm shotcrete, mesh, additional 50mm shotcrete followed by spot
bolting).

Current T4 sequence in use:

1st pass with Spraymec, application of shotcrete min. 50mm
1 hour minimum wait for shotcrete hardening
1st pass with Jumbo, hangs and profiles mesh with minimum required bolts
2nd pass with Spraymec, application of shotcrete min. 50mm
1 hour minimum wait for shotcrete hardening
2nd pass with jumbo, pattern bolting of mesh through shotcrete
Grouting is undertaken in cycle maintaining grouted splitsets within 6m of the face at
all times.

Issues with the current T4 sequence:

The existing T4 sequence is time consuming to complete and equipment intensive,
and effectively results in a 48 hour drive cycle time. This compares to a T3 support cycle
(single shotcrete and mesh pass) which can be effectively achieved within 24 hours.

In effect we are delaying the application of our shotcrete by design in our poorest
ground conditions. This is counter-intuitive as we want our most effective support
element, the shotcrete, installed as soon as possible.
The mesh we currently use on site is standard 5.6 mm mine mesh, black or
galvanised, with smooth wires. This reinforcement ability of this small gauge mesh is
low due to small cross sectional area of strands and low friction smooth wire.
Once shotcrete cracks, which is a common occurrence in Kencana/Toguracis poor
and yielding ground conditions, mesh strands crossing the crack location become
point loaded.
Because the mesh is encased, the mesh sheet cannot stretch to distribute the loads
generated at the crack.
The point loads generated far exceed the capacity of the small gauge mesh strands.
The exposed wires fail in tension at the crack location.
Once ruptured, the mesh sheet ceases to be beneficial in resisting further
deformation of the shotcrete slabs.
Between cracks, the encased mesh does not see any load as the shotcrete prevents
load distribution through the mesh.
For this reason, encased mesh in yielding ground conditions is not considered to be
beneficial.
 Rather than the current system of 2 pass meshing and 2 pass shotcreting in our poor
ground conditions (T4), implement single pass T4.
At Kencana in particular this will result in a huge production improvement, and a better
geotechnical response.
To achieve the above production cycle improvements, we have already undertaken
QA/QC imrpovements together with training to make the required improvements to our
shotcrete. Cycle time improvements, equipment availability improvements, bolt consumption
improvements, geotechnical stability improvements

Note: An enabler to acheive 28m/day from Kencana.

Key Decisions and interdependencies

Reduced bolting with sacrificial bolts

1460 T4 Cuts per year at 28*365/2.8*40%=1460
Say 60bolts per heading saved @$20bolt
$1.7m Kencana

650 T4 Cuts per year at 20*365/2.8*25%=650

Say 60 bolts per heading saved @20bolt $0.8m TOG

Reduced equipment usage (single pass spraymec and jumbo) therefore increased machine
availability - not costed
Geotechnical stability improvements - not costed
Review bolt savings, drilling and consumables savings etc.

Cycle time is main benefit and extra cuts as a result additional value of cuts - Revenue not
included

How does this initiative change and improve our business performance :

Over the last 4 months, Kencana personnel have undertaken an excellent

improvement process regarding shotcrete delivery, shotcrete application and QA/QC. This
improvement at Kencana has been driven not just by the Geotech Dept. but has had
substantial buy-in and support from Production Superintendents, Underground Foremen,
Shift bosses and QA/QC Engineers.

With the recent change to higher performance fibres (Black R50), and improvements
in shotcrete QA/QC, supervision and thickness control, we are now well positioned to
change to 1 Pass T4 at Kencana.