Mining technology developer Maptek reports that it launched its PerfectDig software program to the global mining market at the end of June, following successful field trials at coal mines, in Australia.

Maptek’s PerfectDig software combines three-dimensional (3D) modelling, laser scanning and handheld communication devices, and provides access to detailed spatial analysis on the progress of a surface mining operation, which enables the effective monitoring of the excavation progress through comparing actual surfaces to designs, either in the field or remotely.

“By sharing the information in an easy-to-use and easy-to-view graphical 3D mine environment interface, PerfectDig sup- ports near real-time decision-making and, thus, removes the communication barriers often faced by engineers, surveyors, supervisors and operators,” says Maptek Australia GM Peter Johnson.

PerfectDig automatically combines mine plans and design information from Maptek’s design software program, Vulcan, with laser scans of working areas, captured by a Maptek I-Site 8800 or I-Site 8810 laser scanner.

“A Maptek I-Site laser scanner captures surfaces while mining continues, which means that there is no need to stop equipment to scan an area,” says Johnson, adding that PerfectDig automatically determines the location and registers the scanned data against the mine-survey grid at a given location and perspective at any time.

Thereafter, the user can launch PerfectDig on a tablet or smartphone to compare scanned surfaces with the design imported from Vulcan.

Different coloured layers can be selected for display, enabling the user to instantly view detailed sections, photos, volumes and other data.

“Based on specified tolerances, the degree of conformance to plan can be assessed, the excavation adjusted and the design updated,” explains Johnson.

The use of PerfectDig can result in significant operational savings through the targeted use of excavation equipment and less rehandling or overdigging. This ensures that better angles are more consistently met in the pit, resulting in improved wall stability or pit-surface characteristics.

PerfectDig can be applied to a range of surface mining operations that require increased accuracy in production activities, or reduced variation or costs in digging.

“The software can, thus, reduce dilution or ore loss owing to overdig, under dig or poor drill and blast results,” notes Johnson.

Further, haul fleet use can be improved, as only the relevant material is loaded. The quantity of blasting products required is also reduced, owing to a more accurate generation of pit-surface conformance to the design.

Johnson explains that, traditionally, a design compliance check is completed after an excavation has been completed, which does not solve the issue of poor excavation. PerfectDig, however, provides feedback about the design compliance during the digging.

While providing a digital audit trail of the excavation progress, the software also enables operators to identify what part of the excavation needs cleaning up or adjusting to better conform to design before excavation is completed.

“This saves time and money and, in most cases, results in improved wall stability and safety,” notes Johnson.

Meanwhile, PerfectDig is simpler to use and requires fewer steps than similar systems on the market, he adds.

Johnson also stresses that current machine guidance practices, in creating pit surfaces adherent to design, involve either the manual placement of flags by surveyors to define dig limits or the programming of limits into equipment guidance systems.

He notes that using flags on the surface to define dig limits conveys a rudimentary representation of a design intention to a machine operator.

Meanwhile, equipment guidance systems show only a basic view of design and require calibration and training on how to use them optimally. Subsequently, there is almost always some variation between as-built and design, with significant time and effort spent to control the development and the accurate delivery of designs.

A key aspect of Maptek technology is to add value to existing processes and workflows in a mine.

“PerfectDig does not significantly change the operational work of excavation, as there is no need to change the truck and shovel scheduling or dispatch operations.

“Instead, the system enables faster, more accurate communication and feedback on the conformance of the excavated works to the design, including indications to the shovel operator of the deviation that has occurred and how this may be improved,” explains Johnson.

Meanwhile, compiling production progress reports has also become a significant part of surveyors’ work – with about 10% of the digging time spent measuring and setting out or adjusting targets for digging – to improve conformance to design.

“Where work surfaces are approaching design surfaces, it is estimated that surveyors may spend at least one hour of a 12-hour shift measuring progress against the design and providing feedback for production,” notes Johnson.

PerfectDig, however, reduces this time to about 15 minutes, which means that digging can continue confidently and accurately.

Johnson says the communication and implementation of mine plans across the planning and production divide is a large source of cost overruns and that, while tools to measure and analyse them exist, there are always delays and difficulties in communicating this to the production crews tasked with digging the mine.

Maptek, however, is uniquely positioned to combine a range of technology and data to enable miners to quickly and easily track the accuracy of a mine’s design, as well as its progress at any time.

The value of this ability is easily justified by the reduced equipment movements, dilution and ore waste, and in the reduced reworking or rehand- ling of ore, which significantly improve mine profitability.

Johnson says that, with many companies embarking on the in-house removal of overburden and mineral excavation, products such as PerfectDig, which directly targets operating costs and the efficiency of excavation equipment, are likely to be in demand in the market.

“In times of low confidence, it is even more crucial for professionals to use tools that help increase productivity and maintain high-quality operations.

“The value gained by a mining opera- tion from the benefits of using PerfectDig is enormous,” says Johnson.

Maptek products are sold directly in Africa from Maptek’s offices, in Johan- nesburg and the UK, which also offer local training and sales support, concludes Johnson.