BHP BILLITON – Olympic Dam, Australia

Minova repaired Olympic Dam ore chamber walls using high‑performance Rappass shotcrete, restoring impact resistance and supporting safe mine operations.

Sector / Application

Metal & Non-Metal Mining, Mining

Overview

Minova were contacted by BHP Billiton in March 2012 to assist during the April Clark Shaft shutdown to repair and rehabilitate the badly damaged walls within the ore pocket and chamber below the Clark Crusher. Olympic Dam was a major gold, copper, silver and uranium‑producing mine in Northern South Australia, located approximately 600 km north of Adelaide.

The walls of the chamber had been severely damaged by the continuous impact of ore dropping into the circular chamber from the crusher several metres above. The original concrete wall material had been worn away to, and in some areas past, the original steel reinforcement. In certain locations even the reinforcement itself had worn away. Minova’s experience with similar issues allowed us to quickly organise and implement a solution ahead of the imminent shutdown.

Solution

Minova recommended Rappass as the solution for BHP. Rappass was a specially formulated cement product engineered to deliver exceptional impact and abrasion resistance. It could be manufactured in a pourable grade, as a wet‑mix shotcrete, or as a dry shotcrete. For the repairs at Olympic Dam, a dry shotcrete mix was selected. This provided high early strength, extremely high final strength, and the ability to achieve high build in a single pass with very little rebound.A two‑man crew carried out the application (one pump operator and one nozzleman) using a Reed pump. Approximately ten pallets of Rappass were used in the repair. Including preparation of the area, such as cleaning and exposing the damaged surfaces, the application was completed over two shifts to lower the level of remnant ore in the chamber and expose further areas of wear.Minova were praised for an efficient and successful product application that helped maintain the safe operation of the Olympic Dam mine.