As a result of a successful decline sinking project last year at the Lubambe copper mine, in Zambia, which is jointly owned by South Africa’s African Rainbow Minerals, Brazil’s Vale and Zambia Consolidated Copper Mines, mining contracting com- pany Murray & Roberts Cementa- tion has been awarded a new contract for trackless high-speed development at the mine.

This project is expected to extend to January 2014, says Murray & Roberts Cementation.

The original contract started in January 2011 and comprised a twin decline system on the mine’s eastern limb and ramps to access the orebody. This was completed ahead of schedule in October last year.

“Our team achieved 14 190 m and we remained ahead of target against the mining schedule for the duration of the contract,” says Murray & Roberts Cementation senior Lubambe project manager Wyllie Pearson.

The support regime extended to 0.5 m from the face and involved welded mesh, with split sets being installed by the drill rig operators after every blast from grade line to grade line.

“Additional work of the first contract included the installation of 75 m level tips – 6.1 m in diameter and 18 m in length – which were raise-bored. Construction of the tip and box-front infrastructure were subsequently also awarded to Murray & Roberts Cementation. Cover drilling, which was included in the contract to ensure safe and effective development, was undertaken using Kempe diamond drills, which covered advance development,” he explains.

The current contract involves all horizontal and inclined development for trackless high-speed technology in ramps 3, 4 and 5 on the mine’s eastern limb. The Murray & Roberts Cementation team will continue with the development of infrastructure for two conveyor belt systems and will maintain the owner’s fleet of equipment.

Pearson says his project team, comprising personnel from South Africa, Australia, the Philippines and Zambia, is once again exceeding the development target.

The first sand zone, which is 30 m wide, has been successfully negotiated using Titan soil nails, Becker Arch Sets, 5.6 mm welded mesh and shotcrete as support mediums. The second zone is currently being developed. Sand is excavated out of the face using a Hyundai 35Z7 mini excavator.

“Although the new employees gained experience with the mecha- nised equipment being used on this project during our first contract, it was necessary to elevate the competence level for the latest project,” he says.

Therefore, Murray & Roberts Cementation has extended its personnel training programme to include maintenance and rebuilding on the mechanical and electrical sides, civil and steel fixing and the efficient supply of services, as well as the development logistics required to achieve a depth of 1 450 m a month.

Underground vehicle training has been accomplished using the simulators supplied by mining equipment and service provider Sandvik. Final assessments and pass-out were undertaken in underground conditions.

The equipment bought for this contract was shipped to Durban harbour and transported by truck to the Zambian Copperbelt.

All equipment for the contract is being maintained by Murray & Roberts Cementation and is audited by the original-equipment manufacturers to ensure continued compliance with requirements. Murray & Roberts Cementation has also established an on-site workshop at the mine incorporating a three-bay facility, with a separate washing bay, two admini- stration containers and three store containers. Maintenance services are carried out during the day shift and drill rigs are brought in for a 12-hour service every week.

“Safety is the cornerstone of all Murray & Roberts Cementation projects and our vision is to develop a business culture that supports and delivers injury-free projects,” Pearson says.

Murray & Roberts Cementation employees are subjected to internal and Lubambe safety inductions. The foreign-supervision employees also received thorough safety training at the company’s Bentley Park group training facility, near Carletonville, in South Africa, before being sent to Zambia. All employees undergo job-specific safety training on site and, to date, the team’s safety record is 162 809 fatality-free shifts and 1 884 814 fatality-free hours.

Although transport logistics has at times posed a challenge, Murray & Roberts Cementation has the depth of experience in African logistics and has an established record, particularly in Zambia and in the Democratic Republic of Congo.