Proyecciรณn Virtual de Hormigรณn Proyectado
El ENFOQUE PRINCIPAL
CALIDAD DEL EQUIPO
EL DISEÑO DE LA MEZCLA CALIDAD DE EL LOS OPERADORES
ÂżRequiere profesionalidad?
ONSITE TRAINING (On the Job Training)
SIMULATOR TRAINING
INDUSTRY AVARAGE TRAINING TIME REQUIRED TO GAIN ACCEPTABLE LEVEL OF PERFORMANCE.
6-12 months
NEEDED RESOURCES
Ready mixed shotcrete materials, Concrete mixer and truck delivery, Shotcrete robot setup, Senior personnel and supervision, Testing equipment, Configuration of spray panels, Power, water and compressed air, Eventual ambulance personnel,
A classroom and a power plug. Fixed training cost.
DOWNTIME
Standing by for ready mix concrete delivery, Unexpected stoppages from trial-and-errors done in production, Unpredictable re-do rates due to low shotcrete compaction quality, Unplanned rebound quantity rates, Extra material waste caused by over-spraying, Cycle time variations due to performance and variation in quality between operators. Unforeseen repair costs through inadequate robot handling,
Drills and trial and errors done virtually, Practice and iterations done continuously without logistical interruptions, Measurable and thereby predictable performance rates, Rebound rate level mitigated based on the angle, nozzle distance, velocity, application technique and equipment manipulation applied by the operator. Over-spraying, inefficient equipment handling and are detected and rectified.
Manual quality sampling, Visual inspection, Subjective evaluation by a senior operator, Operators learn to adapt their technique as the situation arises in production. Bad habits are passed on.
PERFORMANCE VERIFICATION & QUALITY CONTROL
1-2 week
Objective evaluation and measurable results, Predictable performance rates. Training done on multiple types of rock surfaces, reinforcements and rock support.
El potential de la inversion
(
Machine
)( X
Chemicals
)( X
Operator
)
1) x (1) x (0,6) = 0,
Concrete spraying – cost distribution -
Labor 15% Equipo 15 % Shotcrete 70%
15 % 15 %
70 %
ÂżCual es el impacto de mejorar en desempeĂąo de lo operadores?
Switzerland
Marti Tunnelbau - Regensdorf site Sprayed concrete usage: approx. 60 000 m3 Sprayed concrete cost: 18 million EUR* Unnecessary cost: 3,2-7 million EUR *assuming a price of â‚Ź300 per m
3
– which includes everything like transport, additives, admixtures and so on
Sweden
LKAB – Kiruna and Malmberget sites Sprayed concrete usage: approx. 150 000 m3 yearly Sprayed concrete cost: 45 million EUR Unnecessary cost: 8,1-17,5 million EUR *assuming a price of €300 per m
3
– which includes everything like transport, additives, admixtures and so on
EL RIESGO DE CAPACITACIÓN • LA CAPACITACIÓN ES INTANGIBLE. • ”¿QUE PASA SI CAPACITO AL OPERADOR Y SE VA A OTRA EMPRESA?” • ”NO TENEMOS TIEMPO!” • ”CERTIFÍCAMELO Y YA!” • ”NO LO TENEMOS EN LA PROPUESTA.” • ”LA CAPACITACIÓN ES DEMASIADO CARO.”
13
LA METODOLOGÍA DE ENSEÑANSA
• • • • • • •
Safety violation warnings, Concrete hardening visualizations, Concrete thickness visualizations, System analyzer, Rebound rate feedback, Over-spraying feedback, Dropout and fallout feedback.
17
Qualification standard LEVEL 7 – Mesh, Slopes and Lattice Girders
LEVEL 3 – Robot Technique
TH EO RY
LEVEL 2 – Safety-, Startup and Shutdown procedures
LEVEL 1 – Foundational knowledge
AT O
SIM UL
LEVEL 5 – Shotcrete Adhesion and Rebound control LEVEL 4 – Systematic Spraying and Thickness control
R
LEVEL 6 – Overbreaks and Corner Spraying
“NO NOS PAGAN POR ENTRENAR LOS OPERADORES.”
TMALL 0141 Presentation v 1.0
Kompetensutveckling av bergarbetare
Thomas Dalmalm Trafikverket
The following slides are from The Swedish Transport Administrations (STA) The slides are excerpts from an internal presentation developed by the STA. The presentation compares the two Swedish tunnel projects “Norra Länken” (North Link Project), which did NOT have a training and certification requirement in place for sprayed concrete operators, with the project E4 Bypass Sthlm that requires training and certification for sprayed concrete operators.
Sprutbetong Ex från
The presentation shows sprayed concrete lining examples from the 21 project “Norra länken” (North link
Överförbrukning på 89% Krav 75 mm verkligt utfall 141 mm
The STA conducted 227 measurements measuring the thickness of the sprayed concrete in the North Link project. The set requirement was 75 mm – 22 instead in average the thickness was 141 mm. This
Återstuds Medel förbättring 3,3%, ger 10 000 m3 på Förbifarten
Rebound: Looking at the rebound improvement of 18 different operators, the average improvement is 23 3.3%, which gives approx. 10.000 m3 of savings
Exempel: Sprutbetong
Tjocklek, Norra länken
Besparing FS Minskad översprutning 89% (10%) Minskad återstuds 3,3 %
Återstuds, Förbifart Stockholm
30 000 m 3 10 000 m 3
Summa besparing efter utbildning:
40 000 m3 Looking at the total saving for the E4 Sthlm Bypass in terms of reduced overspraying (10%) and rebound (3.3%) the total 24 amount of saving after the sprayed concrete training /
National - Sweden Nationally recognized certificate in Sweden • The Swedish Transport Administration (STA) established certifications for sprayed concrete, injection and bolting operators in 2016 in conjunction with planning of the project E4 Stockholm Bypass. It was then called a “project certification”. • The reason was that they had had huge quality, costs and safety issues in previous projects. • Those certifications have now transformed in to the national standard in Sweden. • The one for sprayed concrete is called “Concrete spraying on the STA’s projects” and is now required in all major tunneling projects.
E4 Stockholm Bypass
National - Sweden Nationally recognized certificate in Sweden • The certificate is valid for 5 years. • In order to attain the certificate, individuals need to: • Attend a theory course incl a concrete test methods session. • Pass a theory test. • Go through training and evaluation on a concrete spraying simulator. • Hand in document showing work experience. Theory course
38 hours
+
Theory test
0,5 hour
+
Practical course (simulator training and tests)
20-40 hours
+
= CERTIFICAT 2 months experience E
WestConnex - Australia WestConnex The requirement is set by the main contractor; the sprayed concrete operators should go through Edvirt’s online theory and test, 18 assignments on the simulator, as well as do an assessment on site. All training is outsourced to Edvirt. The simulator training is done near site.
•
• •
Theory + Test online
8 hours
+
Practical course (simulator training and tests)
20-40 hours
+
On site assessment
8 hours
= ELIGABLE
Hinkley Point C – United Kingdom Hinkley Point C The requirement is set by the main contractor; the SCL operators should have the EFNARC certificate, and as well as go through 18 assignments on Edvirt’s VR Shotcrete Simulator™. The project rented a simulator and had a trainer employed who personally did the assessments and who ran the simulator training and evaluations.
• •
EFNARC certificate
+
Practical course (simulator training and tests)
20-40 hours
= ELIGABLE
USA – PLRP Approved Shotcrete Certification. PURPLE LINE LIGHT RAIL PROJECT All shotcrete operators have to go through 3 days simulation training and 3 days onsite training for Mechanized Shotcrete operation.
•
Boliden Mineral – Sweden Boliden
• • • •
They have established an internal certification scheme for their sprayed concrete operators. Certification courses three times per year, arranged by Edvirt. Three mines send participants each time The certification consists of theory and test, a concrete test methods session and simulator training and evaluations. Theory course + Test
12 hours
+
Lab
4 hours
+
Practical course (simulator training and tests)
20-30 hours
= CERTIFICAT E
EFNARC C2 Curso EFNARC C2 (Módulo 1-4) Módulo
1
2
3
4
5
Descripción
Sesión Teórica
Examen Teórico
Formación Virtual
Sesión Practica
Experiencia laboral
Duración
1 Día
1 hora
3 Días
1 Día
Day
1
1
2-4
5
5 dias
>40 dias