Tag Archives: Pybar Mining Services

Master Builders Solutions reinforces decline work at Hillgrove’s Kanmantoo

Base metals, Explosives and blasting, Mineral project development, Mining equipment, Mining services, Mining techniques, , , , , , , ,

Master Builders Solutions has helped the team at the Kanmantoo copper mine in South Australia speed up the excavation of its new decline portal by supplying fast-reacting, instantly thickening anchoring resin.

Kanmantoo, owned by Hillgrove Resources, is currently going through the initial stages of developing an underground operation at the former operating open-pit mine. It has employed a Komatsu MC51 to excavate a circa-500 m decline, with the continuous cutting trial focused on demonstrating the commercial viability of the machine and trial new materials handling and ground support processes.

One of these new processes includes the use of Master Building Solutions’ MasterRoc RBA 380 anchoring resin, which, according to the company, reacts in just three minutes.

This resin has been injected into 10, 9 m self-drilling anchors (SDAs) at the decline portal of Kanmantoo since mechanised cutting operations recently started up.

Master Builders Solutions explained: “Traditionally, cementitious grouts are used to encapsulate the SDAs, which can pose hazards such as dust inhalation and burns to contractors. In waiting for these grouts to cure, mining teams also lose critical heading for approximately 12 hours.”

In choosing the MasterRoc RBA 380, Hillgrove Resources was able to continue the safe excavation with the Komatsu MC51 after just five minutes, according to Master Builders Solutions.

Also involved in this project are Strata Consolidation and PYBAR Mining Services (now part of Metarock Group Limited).

Master Builders Solutions recently announced a planned transaction with Sika that would see the Switzerland-based shotcrete major acquire the company, formerly referred to as BASF Construction Chemicals.

Metarock set to leverage competitive contractor advantage

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Mastermyne’s contract mining growth ambitions became very clear in September when it proposed a buyout of contractor PYBAR Mining Services in a deal valuing PYBAR equity at A$47 million ($35 million).

The deal, which has just completed, sees Mastermyne, up until this point a company focused on the Australian coal sector, expand into the domestic hard-rock space through exposure to PYBAR’s gold, copper, zinc and lead-related revenues. In the process, it has been restructured under Metarock Group Limited.

The transaction is expected to create a leading Australia-based diversified mining services business with material scale, Mastermyne said, adding that the combined group will have a A$1.7 billion-plus order book and an active tender pipeline of A$2.7 billion-plus after completion. PYBAR will continue to operate as an independent business unit within the group with the existing management team.

Tony Caruso, Managing Director of Metarock (pictured), said the company had identified some time ago the need to diversify into “adjacent markets” to ensure its business retained “resilient and sustained earnings”.

“To be clear, we are very supportive of the coal industry, and we will continue to grow our coal business,” he told IM. “What we do know from 30 years of experience of operating in this market is it is very cyclic.”

When coal prices are strong, it is a great market to be a contractor, Caruso explained. Yet, when prices come down, contractor workforces or scope reductions often follow as mine owners look to cut their “flex costs”.

A diversified Metarock would be able to better cope with such a market dip.

“The theory (behind the PYBAR acquisition) is that when coal is down, other commodities will be up,” Caruso said.

In addition to increased commodity diversity, there are also a huge number of synergies that could be realised with the combination of the two companies.

PYBAR offers raiseboring services that can be used in coal, while Mastermyne offers ground support services (through its recently acquired Wilson Mining business) that can be used in the hard-rock space.

Both have registered training organisations that could share industry best practice across sectors, too.

What Mastermyne learned in the coal boom when it developed the “clean skin” training program, using a simulated underground coal mine with a bespoke program to train people for working in an underground coal mine, may have relevance in the hard-rock sector given the recent ‘boom’ perceptions, according to Caruso.

There are also more specific technology synergies that could benefit both hard-rock and soft-rock customers.

PYBAR has embraced automation and digitalisation with, for example, teleremote loading operations at the Dargues gold mine in Western Australia (pictured below, credit: PYBAR) and the use of Digital Terrain’s Simbio data entry and processing solution on its mining fleet.

Mastermyne has been running a similar project where real-time data is “taken off” machinery and, through proprietary software, converted into real-time dashboards for the operators to track performance against operational targets. Mastermyne used such a system with great success at the Narrabri underground operation, owned by Whitehaven Coal.

Caruso said on the latter: “We were looking at building out that software into other areas of our business – we used that in our production machines when we were cutting coal, but we were starting to look at bringing that across to a lot of the other support services we provide to customers as well.”

Should PYBAR come on board, Simbio could end up being used on its coal development machines, according to Caruso.

It works the other way round, too, with Mastermyne’s proximity detection expertise in coal having applications in the hard-rock space.

“Not only are these solutions OEM-agnostic; they are sector-agnostic,” Caruso said. “The same technology is applicable for coal and metalliferous markets.”

The benefits of the business combination do not stop here.

Growth in the coal space has mostly been tied to sustaining capital projects – the overall production levels have remained flat, if slightly increased – whereas, in the hard-rock sector, brownfield and greenfield projects have been the order of the day, catalysed by higher prices and projections of increased demand.

This means the pressure dynamics around skilled labour are slightly different between the two.

Mastermyne has, to this point, benefitted from the ongoing trend of majors exiting their thermal coal businesses to deliver on ambitious ESG targets, with smaller companies taking on these assets and outsourcing work to contractors. Mining contracts at Crinum (Sojitz Blue Pty Ltd) and Cook (QCoal) in Queensland are two examples of the company taking advantage of this trend.

This type of sustaining growth capital expenditure in the coal sector is very different to the greenfield growth witnessed in 2010-2012, Caruso said. “The significant volume increase in greenfield expansion, which drove real pressure on labour, is not there,” he said.

In the hard-rock space, the dynamic is much more reminiscent of that boom a decade ago.

“There are a lot of new projects in Western Australia opening up so there is a lot more pressure on resources because the demand is far outstripping the supply in the hard-rock labour pool,” he said.

While there has not, typically, been a transfer of labour between the coal and hard-rock contracting sectors, if Metarock is able to facilitate such a shift, it could gain a competitive advantage over peers scrabbling for talent that are focused wholly on the hard-rock mining space.

“We have a workforce of 2,000-2,500 people at the moment, and we want to have a fluid workforce that can move across sectors,” Caruso said. “This will enable us to send our best people to projects to make sure we replicate good performance at these operations, regardless of where they are, geographically, or what type of work they are doing.”

Not only could this provide Metarock with the ability to shift employees between sectors, but it could also allow them to offer employees long-term security beyond the current Australian coal demand horizon.

Komatsu MC51 gets cutting at Hillgrove’s Kanmantoo copper project

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The world’s first portal cut using “transformational continuous mining technology” is now underway with the help of Hillgrove Resources’ team at the Kanmantoo copper mine in South Australia and Komatsu’s MC51 machine, powered by DynaCut tech.

The underground decline at Kanmantoo commenced last Friday, just over a month after Hillgrove announced that the South Australian Government had awarded it a A$2 million ($1.5 million) grant to trial the new underground mining technology.

The continuous mining technology, which is also being tested at Vale’s Garson mine in Ontario, Canada, and has previously been trialled at Newcrest’s Cadia mine, removes the need for blasting, providing the potential to transform the traditional underground development process and result in improved safety and operational performance, Hillgrove said.

On top of this, the Komatsu MC51 technology is 100% electrically powered, providing a mine development option for companies pursuing zero-emission mining.

The Komatsu MC51 will be used to develop a portal and a circa-500 m underground decline at Kanmantoo, a former-operating open-pit mine that is transitioning to underground operations. This transition is permitted and benefits from having all existing infrastructure in place, including an operational 3.6 Mt/y processing facility and tailings storage facility, Hillgrove said.

The continuous cutting trial will focus on demonstrating the commercial viability of the machine and trial new materials handling and ground support processes. Ground support assistance is to be provided by PYBAR Mining Services.

“The underground decline has multiple benefits to Hillgrove, including the development of underground drilling platforms which reduce drilling cost as Hillgrove continues to expand and infill drill the existing Kanmantoo Underground resource,” the company has previously said.

It could also help bring forward potential first copper production and reduce future development costs, Hillgrove added.

Hillgrove CEO and Managing Director, Lachlan Wallace, said the development of the underground decline and establishment of underground drilling platforms was a key milestone in the Kanmantoo Underground development program.

“We are also excited to advance the mine development in a way that leads the industry towards zero-emission mining, which is without question the way of the future,” he said.

On top of the A$2 million grant from the South Australian Government, Hillgrove says it has secured favourable payment terms from Komatsu, which sees no payments until funding for the mine development is secured. The deferred and contingent nature of the agreement and grant funding results in minimal cash outflow to Hillgrove while the company focuses on the drilling program.

Mastermyne looks for hard-rock exposure with PYBAR Mining buy

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Mastermyne has accelerated its hard-rock mining strategy with an agreement to acquire PYBAR Mining Services in a cash and share deal that comes with an expected equity purchase price of A$47 million ($35 million).

The acquisition for PYBAR Holdings, owner of PYBAR Mining Services, will see Mastermyne, a metallurgical coal-focused contractor, exposed to PYBAR’s gold, copper, zinc and lead-related revenues, it said.

The deal is expected to create a leading Australia-based diversified mining services business with material scale, it said, adding that the combined group will have a A$1.7 billion-plus order book and an active tender pipeline of A$2.7 billion-plus after completion.

To reflect the changing make up of revenues, Mastermyne is proposing to change its name to Metarock Group Ltd.

Mastermyne MD and CEO, Tony Caruso, said: “The PYBAR acquisition is highly complementary to Mastermyne’s existing underground business and expands the combined group’s addressable markets to support ongoing growth, in addition to increasing the earnings resilience of the group by diversifying our commodity exposure.”

PYBAR Mining Services was established in 1993 and has gone on to become one of Australia’s largest underground mining contractors, serving the likes of Glencore (Black Rock mine), Diversified Minerals (Dargues gold mine), Gold Fields (Hamlet North mine), Evolution Mining (Cowal gold mine), OZ Minerals (Carrapateena) and more.

It has a large fleet of equipment, which includes Sandvik DD421 and DD421i series drills, a fleet of Cat R1300, R1700, R2900 and Sandvik LH621i LHDs, Cat AD45V-AD60 sized trucks and several Sandvik TH663s haul trucks. It provides services such as mine development, raiseboring, mine production, shotcreting, cable bolting and production drilling.

Mastermyne says PYBAR will continue to operate as an independent business unit within the group with the existing management team should the deal go through.

Subject to Mastermyne shareholder approval and the satisfaction or waiver of other conditions associated with the transaction, Mastermyne anticipates the deal completing by the end of the year.

Emesent takes drone autonomy to another level with AL2

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Emesent says it has announced a major breakthrough in the journey to fully autonomous drone flight systems, with the launch of Autonomy Level 2 (AL2) for Hovermap, the world’s first plug-and-play payload for industrial drones that provides autonomous beyond line of sight, GPS-denied flight.

Building on Emesent’s Hovermap simultaneous localisation and mapping autonomous (SLAM) flight system, AL2 enables compatible drones to fly beyond communications range and venture beyond line of sight into unmapped areas, it says.

“The AL2 technology enables companies to rapidly map, navigate, and collect data in challenging inaccessible environments such as mines, civil construction works, telecommunications infrastructure, and disaster response environments,” Emesent said.

Andrew Rouse, Chief Technology Officer at PYBAR Mining Services, a user of the Hovermap payload, said: “AL2 is a game changer for us. It takes Hovermap into places that even the most experienced pilots would fear to venture, enabling us to obtain critical data in real time without risking the machine. We’re already seeing great benefits to our workflow and operational efficiency from using the new technology.”

PYBAR has previously collaborated with Emesent to test automated drones at the Dargues and Woodlawn operations, in Australia.

Emesent’s technology builds on a decade of award-winning research by CSIRO’s Robotics and Autonomous Systems group into drone autonomy and 3D LiDAR-based SLAM techniques.

Customers around the world have been using Hovermap’s Autonomy Level 1 capability for almost two years, safely mapping challenging GPS-denied areas within line of sight. Moving to AL2 means the drone can self-navigate and avoid obstacles beyond line of sight, while being operated from take-off to landing from a safe distance, the company explained.

The system processes data on-board in real time to stream a 3D map of the environment back to the operator’s tablet, providing instant and detailed insights into the surrounding area, as well as any potential hazards. The entire mission from take-off to landing is conducted by interacting with the live view 3D map, allowing stopes to be mapped with just a few taps, Emesent claims.

AL2, according to Emesent, will give industrial customers:

  • Improved safety, with the ability to fly beyond line of sight keeping workers away from hazardous environments and better data insights informing how to make mines and other environments safer;
  • Cost optimisation, as it is quicker to scan environments and the technology requires less skill to operate;
  • Reduced downtime, with the drone able to quickly and easily map inaccessible underground excavations, with minimal disruption to production;
  • Enhanced visibility into environments, with real-time point clouds delivered directly to the pilot’s tablet, enabling them to interact with and explore the scan data as they operate the aircraft; and
  • Ease of operation due to its “Tap-to-Fly” and “Guided Exploration” functionalities, and various fail safes, including automatic return to home on low battery and automatic landing at critical battery level.

AL2 is currently compatible with several DJI Enterprise drones including the new DJI Matrice 300 RTK, according to Emesent.

“Emesent has worked closely with DJI to ensure close compatibility and integration of autonomous functionality such as AL2 with the drone’s flight controls,” it said. “Further compatibility with other drone models is planned following the launch.”

Dr Stefan Hrabar, CEO and co-Founder of Emesent, said: “This is a huge step forward for drone autonomy and a massive benefit to industries like mining, civil construction, and emergency response.

“With the intelligence to navigate environments without a prior map, customers can use the system to carry out complex missions, secure the safety of personnel, and drive greater efficiency in their operations.”

Dargues gold mine on the road to production: DRA Global

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DRA Global says it is in the final stages of the implementation of the engineering procurement and construction (EPC) of the gold concentrate plant for Diversified Minerals’ Dargues gold project, in New South Wales, Australia.

The engineering company was awarded the EPC contract back in January 2019 after detailed design for the project commenced in March 2018. At this point, first ore was expected to be processed in early 2020.

As of March 2020, the plant construction and wet commissioning has been completed, DRA said. Hot commissioning is planned to take place soon and expected to be completed in early April. After this, the DRA team will hand over the 330,000 t/y plant to the client’s operations team, it said.

Dargues, owned by Diversified Minerals, an associated company of PYBAR Mining Services, was previously expected to have a 355,000 t/y capacity gold processing facility comprising crushing, milling, flotation and filtration circuits to produce a sulphide concentrate for export. This could see Dargues produce an average of 50,000 oz/y of gold in the first six years of production.

The mine, which will be operated by PYBAR, is also set to incorporate tele-remote loading. In December, Diversified Minerals took delivery of a second new Cat R1700 underground LHD following commissioning of the first loader during August.

The new machines are equipped with Caterpillar’s next generation Command for Underground technology, giving them automation capabilities that will allow them to be driven via tele-remote from the surface from early-2020. This will realise significant productivity, efficiency and safety gains, according to PYBAR.

Members of the Austmine Board were recently invited to a tour of the Dargues gold mine (pictured).

PYBAR takes Command of Dargues automation with new Cat R1700 LHDs

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PYBAR has taken a step closer to advanced underground automation at the Dargues gold mine in New South Wales, Australia, with the arrival of a second new Cat® R1700 underground LHD at the Diversified Minerals-owned site.

The new loader visited the PYBAR head office in Orange, en-route to the mine site, where it was met by executives and senior management from PYBAR and WesTrac.

The first of two new R1700s purchased for Dargues from WesTrac was commissioned at the mine during August and the company, in November, announced that the underground loaders were undergoing staged testing that will see them move towards improved automation in early 2020.

Dargues is owned by Diversified Minerals, an associated company of PYBAR Mining Services. The mine is expected to have a 355,000 t/y capacity gold processing facility comprising crushing, milling, flotation and filtration circuits and produce a sulphide concentrate for export. This could see Dargues produce an average of 50,000 oz/y of gold in the first six years of production.

The new machines are equipped with Caterpillar’s next generation Command for underground technology, giving them automation capabilities that will allow them to be driven via tele-remote from the surface from early-2020. This will realise significant productivity, efficiency and safety gains, according to PYBAR.

Command is part of the Cat Minestar™ integrated suite of offerings designed specifically for mining, PYBAR said.

PYBAR Chief Technology Officer, Andrew Rouse, said: “With the second loader now on site we will complete the tele-remoting set up in time for stoping early next year.

“Our intention is to be able to tele-remote from the surface from the outset when both loaders go into full operation. It’s a milestone all three teams (Caterpillar, PYBAR and WesTrac) have been working towards and will deliver.”

The new loaders were purchased after trials at the Vivien gold mine in Western Australia during 2017, PYBAR said. These trials delivered impressive results, including quicker bucket loading, faster cycle times, greater payloads and less fuel burn, according to PYBAR.

PYBAR said: “These benefits were further highlighted when the Cat R1700 was tested against the R1700G at Vivien (owned by Ramelius Resources) in June 2018, prompting PYBAR to place the order for the new loaders.”

Rouse added: “We were extremely impressed with performance of the new loader during testing. With the knowledge gained from the activity at Vivien, we were able to carry out a rigorous analysis around the loader combinations required for the Dargues operation with the R1700 proving to be the most cost effective.”

Since the first new loader has been put into operation, PYBAR has been preparing for advanced automation through the use of the traction control and Autodig features on the new machines, it said. The feedback has been very positive with full buckets consistently being achieved, the company added.

“The Command technology enables remote operation from the surface or underground, providing productivity and efficiency gains, improved safety of personnel, more accurate tunnel navigation, and reduced machine damage,” PYBAR said.

Caterpillar’s Commercial Manager for Underground Technology, Randy Schoepke, said PYBAR has long seen the value of being on the “leading edge of technology” as a contractor and an owner miner.

“The new Cat R1700 loader will be a huge complement to their technology portfolio leveraging the most advanced features in the industry,” he said.

“The R1700 features of traction control, live payload, Autodig, and ride control will not only provide operator comfort and productivity but also be leveraged by Caterpillar’s latest generation of Command for Underground, Caterpillar’s remote and autonomous control system.”

Schoepke concluded: “When there is a requirement to remove the operator from the underground environment, the technology allows safety and utilisation to be taken to the next level. We look forward to our continued work with PYBAR on this project.”

WesTrac General Manager of Mining Sales, Jody Scott, said this development was the culmination of more than two years work with PYBAR to “identify and test the technology that will have the most impact and benefits for them and their clients”.

He added: “Extensive testing has enabled us to fully evaluate the challenges posed by the harsh underground environments in which the machines are required to operate. It has also allowed us to set up the machines to get the most out of their automation and tele-remote capabilities.”

Pybar starts underground mining at Heron’s Woodlawn zinc project

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Pybar Mining Services has started up underground mining at Heron Resources’ Woodlawn zinc project in New South Wales, Australia, ahead of full commissioning by the end of the year.

The company entered into a four-year underground mining contract with Pybar in February and the contractor has now kicked off mining. This includes the ground support of box cut walls and the first portal blast of the decline.

Heron said the overall project, as of the end of August, was 73% complete, with earthworks substantially concluded, equipment purchasing at 98%, concrete almost complete and offsite fabrication 92% signed off. Sedgman is the EPC contractor.

Woodlawn is envisaged as a 1.5 Mt/y operation able to produce 40,000 t/y of zinc, 10,000 t/y of copper and 12,000 t/y of lead at steady-state production over a 9.3-year mine life. This is based on a reserve base of 2.8 Mt at 14% ZnEq from underground and 9.5 Mt at 6% ZnEq from reprocessed tailings.

The operation is set to use an IsaMill™ to treat the zinc-rich reclaimed tailings, as well as polymetallic primary ore in different processing modes. The 3 MW 10,000 IsaMill comes with an IsaCharger™ media delivery system, as well as commissioning services from Glencore Technology.

Heron’s Managing Director Wayne Taylor said: “Exploration over the last four years has defined a very high-grade, high-quality resource and reserve position, and the access which has now commenced will enable us to deliver underground ore into the processing plant in 2019.

“Once underground, our geological team will focus on further expanding the known mineralised positions to build upon the excellent and cost-effective work they have undertaken to date.

“Elsewhere on site, I am pleased to report that good progress continues to be made with all aspects of the build, and that works remain on schedule for the commissioning by the end of the year.”