ON THE JOB TRAINING GROUP REPORT

2ND BATCH
PHILEX MINING CORPORATION

AMOR, COLEEN JANN

Mindanao State University - IIT

BOSI, ELINITO. JOHN

Saint Louis University

CAJANO, FRINCESS JADE

University of Southeastern Philippines - Obrero

DEGAY. NATHAN JOSEPH

Saint Louis University

ESPACIO, JEMOEL JETT

Saint Louis University

SEPARA, KRIST JAN

University of the Philippines – Diliman

SEBUA, JOMEL
Caraga State University
ASSAY

FIG 1. Fire Assay Unit Operation for Gold Analysis

 Copper Concentration Analysis is done through Atomic Absorption Spectroscopy

(AAS)

Functions of Assay Laboratory

1) Ore Analysis
2) Water Samples Analysis
3) Oil Sample Analysis
4) Monitoring (Mill Quality Control)
5) Concentrate Analysis
CONTRACT MANAGEMENT & COST CONTROL (CMCC)

Tire Management

To ensure the safe, efficient, and environmentally-sound way of implementing tire management
program that provides effective monitoring and reduces downtime and overall tire cost

FIG 2. Parts of a Tire

Types of OTR Tires

 Radial (Steel)
- Commonly used in Open Pit Mines
- Good in terms of traction compared to bias
- Sidewall: Thinner, does not easily heat up
- Corrodes

 Bias (Nylon)
- Commonly used in Underground Mines
- Sidewall: Thicker, heats easily
- Sturdier

Fig 3. Tire Specifications

OTD – Original Tread Depth, mm
RTD – Remaining Tread Depth
Used Tread – OTD – RTD, mm
%Wear or %TUR - %Tread Utilization Ratio
60% - benchmark %TUR
PR – Ply Rating

L5S
L – Loader
E – Earthmover
S – Smooth / Sleek
5 – Extra Deep Tread, 4 – Deep Tread

Tread Wear Rate – Running Hours / Used Tread

Typical Defects

 Cut – Damage made by sharp objects (e.g. rocks, rock fragments). Also known as snag.

 Exposed Cord – Belt / Breaker, ply (usually nylon or steel) or other reinforcement and steel
chafer / bead area reinforcement that can be seen. Exludes fabric (usually nylon) chafer.

 Puncture – Any penetration of a tire’s air chamber by a foreign object resulting in loss of air.

 Separation – Parting of de-bonding of any adjacent parts of the tire (ply to ply, ply to rubber,
etc.)

 Bulge – An area of separation packed with rubber that has migrated from an adjoining area of
the separation.

 Chipping – Flaking or tearing away small bits of tread rubber

 Chunking – Tearing or breaking away pieces of tread rubber

 Cracks – Splits or narrow breaks in rubber compounds not caused by a foreign object. Also
known as a split
Out of Service Conditions

External Conditions

 Injuries too large, weather checking, stress cracks

a) Crown (Belt) Separations

b) Sidewall Separations
c) Weather Checking (Ozone Cracks)
d) Tread Chunking
e) Excessive Rust in Steel Plies
f) Petroleum Damage

Bead Damage

 Bent, broken, burnt, blistered or brittle rubber, chunked

a) Exposed Body Plies or Bead Wire

b) Bead Deformation
c) Bead Sole Damage

Internal Damage

a) Impact Breaks
b) Inner Liner Blisters
c) Run Flat – Inner Liner Damage
d) Sidewall Deformation

Improper or Failed Repairs

a) Repair units must not overlap

b) Any existing repairs found to be cracked or loose should be replaced

Cost Control

Accurate and timely budget allocation and monitoring of funds of the Mine Division to ensure the
continuous operation of the mine

To ensure the safe, efficient, and environmentally-sound way of preparing, implementing, and
monitoring the budget of the Mine Division

Key Factors for Cost Control

1) Budget
 A project’s budget lays out how much each of the various tasks should cost
 Production and Development Program
 MRSB (Major Requisition Screening Body)
 2) Monitoring Activities
 Monitor each contributor to keep the project on budget and on time
 Materials and Supplies Database
 Cost Variance Database

3) Damage Control
 The key to effective project cost control is being flexible enough to find solutions to
inevitable problems
 Cost Champions Meeting

4) Considerations
 Monthly Operations Report

Reasons for Cost Overruns

1) Estimates
 A common reason for cost overruns is the inaccuracy of cost estimates. Such cost
overruns are due either to incorrect estimates or to changed conditions in the
marketplace

2) Design
 Sometimes, the designs or drawings that form the basis of the project are not realistic

3) Planning
 The project progresses according to a plan that assigns durations to project tasks. If the
projected durations can be too short, the project takes longer than anticipated and
cause cost overruns

4) Scope
 Changes in the scope of supply within a project frequently cause cost overruns. These
changes result from new requirements that the company may introduce

Realignment

 To utilize unused budget and guarantee that priority activities push through
 Prioritize
 Look for unused budget
 Budget from account charges which are least in their priorities
 Look for unused budget from other cost centers and seek approval with the respective
Department Manager
 In the event that the total remaining budget will not be enough to ensure, the continuous
operation of the mine, the Division will submit a proposal for additional budget to the Finance
and Budget Departments for review and approval
 CONTRACT MANAGEMENT

To ensure the safe, efficient, and environmentally-sound way of preparing and monitoring contracted
works

To ensure that all contractors follow the company’s set working standards

What is a contract?

 Document that contains the binding agreement between the company and the contractor

 Details the scope of work, company provisions, employee regulations, and other related
information

 Also includes the rates, the length / period of the contract, and payment terms as well as
deductions / retention fees

 Penal provisions and grievance mechanisms are also included

Contracted Activities

CAPEX OPEX

 Horizontal Driving  CBC Operation

 Rockbolting Activities  FBC Operation
 Fanhole Drilling Activities  CBC Maintenance (By Contract)
 Undercutting  FBC Maintenance (By Contract)
 Cablebolting Activities  Mine Draw Control – Subsidence
 Steel Set Activities Operation
 Concreting Activities  840 ML Ore Rehandling Operation
 Shotcreting Activities  LHD Operation
 UG Environment Enhancement &
Maintenance

Existing Contractors

Contractor Activities

Consolidated Explosives Group Face Driving

Corporation (CONEX) Rockbolting
B.B. Fischer & Co., Inc. Fanhole Drilling
Cablehole Drilling
Hanger Installation
Incremental Tramming
 Activities

Mine Trax Services
Nichol’s Construction
ED’s Construction _________________________
Nichol’s Construction
Dowel Installation
Concrete Forming and Pouring
Steel Set Installation
Widening
Backfilling
Shotcreting
Cable Bolt Installation
_________________________

Dowel Fabrication
Steel Wedge Fabrication
Base Plate (6” x 6”)
Base Plate (8” x 8”)
Used CHC Cable De-stranding
Concrete Panel Forming
Straightening of Used
Rockbolts
Rockbolts Fabrication

Activities

VB Gonzales Trucking Aggregates Hauling

UG Ore-Rehandling

GA Flores Construction Inc. Subsidence Backfilling

NETRUMA Inc. Tire Repair / Retreading

Banos Shayotao Construction Spillage Cleaning

PACE Corporation CHC / FBC Maintenance

QUINOPEZ UG Pest Control

 SURVEY SECTION (SS)

The Survey section conducts both surface and underground surveys to check adherence to the
standards set by the Mine Engineering Division. The section uses the local surface grid, Lagman
Stystem, as reference for establishing surveying control stations both in the surface and underground.
The Lagman System is based from the triangulation survey of Pul, Ulap and Matarik. Both the PRS92
and WGS84 are being used by the section.

Surveying operations may be classified into two: underground and surface. Mine surveying is
conducted underground for center line and grade line establishment, measurement of elevations,
bearings and distances, marking of fanhole patterns and the measurement of horizontal and vertical
drive dimensions. Permanent underground control stations were established through closed traverse
survey, using the data from the surface triangulation as reference. Each control station is placed 30
meters apart. After setting up the underground control stations, close traverse survey is done to
establish the center line.

With the use of the transit and electronic distance measurement, the
center lines are precisely marked using a thread connected to a spud.
Grade lines are painted on the side of the walls.

Surveyors also meticulously measure the bearing and azimuth

of draw crosscuts, as this data is used as a basis to preserve the
bullnose and camelback of the opening. Surveying is also essential in
vertical driving. For an advance less than 10 meters, conventional
FIG 4. Center line and grade raising is made, wile for an advance more than 10 meters, the Alimak
line in a horizontal drive raising machine is used.

The quality of drives is measured through the use of the

sunflower offset, a series of horizontal, inclined and vertical
measurements. Surveyors measure the overbreaks incurred by
blasting or widening, and the data collected is used as a basis for the
billing of service contractors.

For surface operations, topographic surveys are made for ore

inventory and the maintenance of subsidence gradient. For ore
inventory, a robotic total station records several points from the ore
stockpile delivered by trucks. The total station then computes for the
Center line

total volume of ore delivered, and is subsequently used for contract

billing and liquidation purposes.
FIG 5. Sunflower offset
Surveyors must also closely monitor the pit floor gradient, to ensure
that the gradient is greater than -4% to avoid ponding, and less than -7% to avoid scouring of backfill
material.

Pipe-outs on the pit floor are also surveyed. The diameter and depth of the pipe-out is recorded as
well as the date and time of occurrence. Using the data provided by the survey, the corresponding
underground location of the pipe-out will be relayed to the Draw Control Section. The following are
the blocks at the subsidence area, and their corresponding locations underground:
 Underground Level
North Block Partly 782 ML, 840 ML, 867 ML
Central Block 782 ML
South Block 908 ML, 890 ML
South Extension Active block 908 ML

Amount of precipitation is also measured by the Survey section through the use of udometers located
at several stations in the surface, including : Core house, Survey Office, Mill Office, Pond #3,
Subsidence Area, and Museum. The intensity of rainfall is then interpreted using the data obtained
from the rain gauges.
DEVELOPMENT, PLANNING, AND DESIGN/ MINE OPERATIONS – DEVELOPMENT

/ ROCK MECHANICS SECTION (DPD/ RM)

Driving of Underground Openings

Horizontal Driving

Heading Finished Dimensions

(Width x Height)
Draw Crosscuts (DXCs) 3.5 m x 3.0 m
Undercut Lines (UCLs) 3.5 m x 3.5 m
Production Lines (PLs) 4.0 m x 3.5 m
Ventilation Crosscuts / Drifts
Drilling Drifts / Crosscuts
Access Ramp from PL to UCL
Conveyor Drifts 4.0 m x 5.0 m
LPT Access 5.0 m x 4.0 m

FIG 6. Draw Cross Cut Drive Segments

 Sequence of Driving for Opening a Draw Crosscut

1) Segment A

FIG 7. Segment A Driving

2) Segment B

FIG 8. Segment B Driving

3) Segment C

FIG 9. Segment C Driving

4) Segment D and D1

FIG 10. Segment D Driving

 If the balance remaining is below 10 m driving should be done on the other side following the
same opening sequence

 Maximum allowable over break is 0.15 m at the sides and the back of the heading

 Blast Efficiency should at least 90% of the depth of the hole

FIG 11. DRILLING AND BLASTING PATTERN FOR PRODUCTION LINES

Total No. Of Holes = 31

FIG 12. DRILLING AND BLASTING PATTERN FOR UNDERCUTLINES

Total No. Of Holes = 29
 FIG 13. DRILLING AND BLASTING PATTERN FOR DRAW CROSS CUTS
Total No. Of Holes = 29

 For Production Lines: Install two hangers at 0.50 m apart at 2m intervals at a depth of 0.30 m
 For all other openings: Install one hanger on each shoulder at 2m intervals at a depth of
0.30m

Vertical Driving

Heading Finished Diameter

Drain Raise 2.5 m
Slot Raise 2.5 m
Pilot Raise 2.5 m
Access Manway 2.5 m
LTR / STR 3.0 m
Ventilation Raise 3.0 m

 If vertical drives are greater than 10 m, use raise climber

 Minimum of 18 holes per blast
 Blast efficiency of at least 90%
 If raise will connect to an operning, the driving of raise must stop once the face is 3 m from the
connectiing opening. The driving will continue from the opening above the raise

Rock Bolt Installation

Material Used Deformed Bars

Length 7 ft (2.1 meters)
Diameter ¾ inches
Base Plate 6” x 6” plate
3/16” thickness
¾” diameter hole
Nut ¾”hexagonal
Cemextra Capsules 30 cm long
25mm diameter
 Heading Dimension Rockbolt per ring
Draw Crosscuts 3.5 m x 3.0 m 7 bolts
Undercut Lines (UCLs) 3.5m x 3.5m 7 bolts
Ventilation Drifts / Crosscuts 4.0 m x 3.5 m 9 bolts
Drilling Drifts / Crosscuts 4.0 m x 3.5 m 9 bolts
Production Lines (PLs) 4.0 m x 3.5 m 9 bolts
Access Ramps from PL to UCL 4.0 m x 3.5 m 9 bolts
Conveyor Drifts 4.0 m x 5.0 m 11 bolts
LPT Access 5.0 m x 4.0 m 11 bolts

Number of Cemextra per 7 ft rock bolt:

Bit Diameter Automatic Roof Bolter Jackleg

38 mm 12 cartridges 10 cartridges
41 mm 15 artridges -

 Cemextra capsules must be soaked for two to three minutes only

 Plates should be tightly in contact with the rock surface

Cable Bolt Installation

Material Used Used CHC Cable Wire

Length 6.30 m
Base Plate 8” x 8” plate
3/16” thickness
¾” diameter hole
Lock Barrel Wedge Lock
Grout Hose ½” diameter plastic hose
Grout Mix Water to Cement ratio should be maintained at
0.30 to 0.35 (Add 14 liters of water to every bag
of 40 kg cement)

Particulars Pattern
Draw Points 11 bolts at 2m spacing
Other horizontal openings needing cable 3 pcs at the back spaced 2m apart per
bolts cable bolt ring
Breaker Station 2 m x 2 m spacing

 Exposed cable should be 0.3 m from the base / face plate

 FIG 14. Trenching Fanholes

Shotcreting (With Plastic Fiber)

1 MIX
10 BAGS OF CEMENT : 40 kg per bag
1,200 kg CRUSHED SAND
1 BAG PLASTIC FIBER: 5 kg per bag
3.5 LITERS OF PLASTICIZER
ACCELERATOR: 22.46 LITERS / MIX : 8% by weight

 Initial Shotcreting Thickness: 2 inches

 Final Shotcreting Thickness: 4 inches
 Shooting Distance: 1 m to 1.5 m
 Water – Cement Ratio must be reduced to 0.3 if we add 3.5 Liters of Plasticizer

Dowel and Steel Sets Installation

Dowels

Drill Steel Diameter 38 mm (wedge type dowels)

Hole Depth 2 feet
Dowel Dimensions
Diameter 25 mm
Length (with one end slit for Steel Wedge) 1.2 m (4 feet)
Exposed Length when inserted 0.6 m (2 feet)
Dowels Required 1 dowel per sq. meter at 1 m spacing
Steel Set

 Steel post foundation should be excavated at a depth of 0.30 m

 Provide stiffener (1/2” thick plate) for spliced steel post which should be perpendicular to the
steel post and fully welded
 9 required

FIG 15. Steel Set Design

Concreting

Reinforcing Bars Installation

INSIDE STA. FE FAULT OUTSIDE STA. FE FAULT

Single Reinforcing - 0.3 m x 0.3 m
(Horizontal x Vertical)
Double Reinforcing 0.3 m x 0.3 m 0.4 m x 0.4 m
(Horizontal x Vertical)

 #16 GI Wires as tie wires to support reinforcing bars

Forming
 Concrete forms should be installed at the same depth as the base of the steel post
 One dowel shall be installed per square meter of concrete forms installed
 Dowels shalle be anchored in the rock mass at a depth of 24 inches
 Pouring

Steel Reinforcing
Inside the Sta. Fe Fault Double Reinforcing (Side & Back)
Outside the Sta. Fe Fault Single Reinforcing
Double Reinforcing 0.5 m to be concreted
Single Reinforcing 0.25 m to be concreted
Concrete Ratio = Cement / Sand / Gravel 1:2.5:0.75
480 kg: 1200 kg: 360 kg
Water – Cement Ratio 0.3 with plasticizer
Plasticizer 3.5 L per mix

Rock Mechanics

Padcal’s main orebody is the Sto. Tomas which measures 700m in height and 500 m in width and is a
massive, pipe-like, Andesite Porphyry.

Convergence Monitoring

FIG 16. Convergence Monitoring Triangle

Done using an extensometer. Movements in the studs reflect compression or extension of

access / drifts.

Rock Mass Rating (RMR)

RMR = S1 + S2 + S3
S1 = Intact Rock Strength (IRS) (140 MPa)

S2 =
S3 = , where
A – Slightly Undulated (Large Scale), B – Striated / Rough (
Fragmentation

1) Primary Fragmentation – Fragmentation after primary blasting

2) Secondary Fragmentation – Fragmentation caused by abrasion by initially fragmented ores

Undercutting Sequence

 Pre-undercut Caving

Undercuts are developed first before production lines

 Advance Undercutting Caving

Undercutting is done before trenching

 Conventional Caving / Post Undercutting

Trenching is done before undercutting

Drawzone Spacing

FIG 17. Closely spaced Draw Points

 FIG 18. Overly spaced Drawpoints

MINE UNDERGROUND ELECTRICAL SERVICES DEPARTMENT (MUESD)

FIG 19. Underground Transformer Circuit

Electrical Stations are located at 908 ML, 773 ML, and 745 ML
MINE VENTILATION

FIG 20. Ventilation Circuits – Intake and Exhaust

MILL DIVISION
FIG 21. Simplified Mill Process Flow
MINE OPERATIONS – PRODUCTION
FIG 22. Simplified Ore Flow
DRAW CONTROL AND SUBSIDENCE

Draw Control Operation

In the draw control section we were able to understand the role and the importance of it in
relation to development, production and most especially in the safety and stability of the mine. The
three principles of DC are:

1. Obtain the best ore grade and tonnage

2. Minimum Dilution
3. Safe Operation

Hence, the Draw Control section does:

 Sampling
 Draw Audit
 Order and Issuance

Grab sampling, done in every shift and is taken from 9 random points in every draw point and
should be approximately 3 kg, is to mainly compare theoretical and actual grade obtained. The
sample took should be able to represent the whole ore characteristics of the draw point. The draw
control also conducts draw audit in which aims to evaluate the situation in the draw point in order to at
least determine the possible situation of the back of a trench. The draw audit considers several
factors including:
 Fragmentation or the size of rock in the draw point which can be fine, medium, coarse or very
coarse.
 Percent Dilution associating the percentage of soil occurrence in the draw point which can be:
Fresh, Slightly Diluted, Moderately Diluted, Highly Diluted, and Brown Ore. Preventing dilution
is associated with proper sequencing and regulation of draw.
 Water Content in the draw point which can be dry, wet, dripping water, or flowing water.
 Fluidity of Ore

The draw order given to the Production is basically based upon the results of the grab sampling
and draw audit made in each draw point. To obtain a profitable tonnage to be brought to the mill, the
need of an efficient ore blending is considered. Ore blending is also the draw control’s responsibility,
thus the draw order has three classifications, Priority 1, Priority 2, and Priority 3. However, the result
of the draw audit has been taken into consideration whenever giving a priority to a draw point to
ensure worker’s efficiency and mine stability. For every priority, there is a corresponding tonnage to
be drawn for every shift; the maximum tonnage to be drawn for a day is around 300T and the least is
around 20T per day.

The mining methods used in the Padcal Operations are:

1. Block Caving (908, 782 and 798 MLs)

 Multi lift, different level in mining
 Conventional, PL and UCL are developed together followed by trenching and blasting of UCL
then drawing of ore.
 Pre undercut, develop the UCL first then blast the UCL then you develop the PL and then
trenching and drawing.
 BLOCK VS PANEL, the first have different sub block in each level while the latter illustrates a
joint commission where in dilution is controlled.
 2. Sublevel (840/867, 760/ 730/ 700)
 Usually in 30 mete interval
 2.5-meter distance per fan holes
 5-meter advance in the upper drift to avoid collapse

Accordingly, to schedule the best tonnages to extract from draw points for set period of time, there is
a need to incorporate the mining sequence affected by: cave ability, ore body geometry, induced
stress, primary fragmentation, grade distribution, production requirements, influence of geological
environment, and mud inflows; rate of opening new draw points, extraction rates, and the depletion or
the rate of caving. Also, the factors affecting the vertical mining rate are the rock mass characteristics,
the rock mass fragmentation, cave propagation, the draw point availability with respect to hang-up
incidence and the frequency of secondary blasting, and the production constraints.
The draw section is related to development such that after undercutting, the draw control section
draws the swell tonnage that is approximately 2,500T and turn overs and gives draw order to the
Production.

Subsidence Backfilling Operation

The primary objectives of the backfilling operation are:

 Prevent recurrence of destructive mud rush in the mine underground. Preventing mud
rush is ensuring the safety of the man power assigned underground; also it is protecting
the equipment from the unwanted damages and destructions. Furthermore, it is to
sustain a safer and more environment-friendly mining operation.
 Maintain a clean and green environment within the surrounding area and its nearby
municipalities and sitios. Maintaining this means being able to discharge clear water to
downstream areas, keep a good and harmonious relationship with the community and
reforest in feasible areas.

The backfilling activity includes the ripping, stockpiling, benching, loading to dump truck, hauling,
dumping and spreading of 4Tons backfill materials in every 1Ton drawn from the underground. The
backfilling materials consist of in-situ materials which need to be ripped in order to be excavated and
loaded and talus materials that have been eroded and are readily available for loading and hauling.
The sources of these materials are the Albian, Albian Main canal, Old Batching Plant, Post 1, Pokis
A-B3, Silt Pond, Alan Cut, Wedge 1&2.

The backfilling operation prevents ponding and the seeping of meteoric water towards the
underground mine. The gradient maintained in backfilling is -4 to -7% in order to prevent ponding and
scouring respectively. The subsidence area has 4 active blocks and has corresponding active ML
underground which are the following:

 South Extension – 798 Active Block

 South Block – 908 and 890 ML
 Central Block – 782ML
 North Block – Partly 782 and 840 and 867 ML

One of the problems encountered in the backfilling operation , the depression in the pit floor of at
least 1meter deep caused by massive displacement of materials underneath, pipe-out. There are two
possible reasons for piping out, first of which is due to void infill which is the effect of faster draw rate
than the caving from a draw point, secondly, due to mud rush also caused by fast draw rate due to
the infilling from softer materials. Thus the regulation of draw orders has a great effect on the
steadiness of the subsidence area.
MINE CRUSHING AND ORE HANDLING DEPARTMENT (MCOHD)

Two Types of Conveyors

FBC – Feeder Belt Conveyor

Used primarily underground from loading stations to collecting bins and is made of rubber with
rubber ply. Run by drive pulley attached at the end of conveyor and is supported by rollers.

CHC – Cable Hauled Conveyor

Used to transport ore from collecting bins to the mill. Estimated Length is 2.3 km. Made of
rubber with steel wire ply. Attached to a cable rope, supported by pulleys, and run by the drive and
snob pulley located at the drivehouse.

Underground Crushing Plant

2-4 (773 ML) – hang-up slab problem, under repair.

4-4 (773 ML) – under rehabilitation

MINE LOGISTICS DEPARTMENT

Logistics – aspect of military science dealing with procurement, maintenance, and transportation of
material, facilities, and personnel

Explosives – substance especially prepared chemical, that explodes or causes explosion

ANFO – Ammonium Nitrate Fuel Oil (ANFO). 96% AN (Oxidizer) & 4% FO

 Cap Sensitive Explosives are classified as High Explosives
 One ANFO mix is completed in 15 min.

Materials Unloading

Men Required At least 2 people

Tools Tag Line
Rigid Hook

Explosives Handling

Men Required At least 3 people

Tools Fire Exinguishers
Explosive Sign
Wood Matting
Tarpaulin
MINE MOBILE EQUIPMENT SERVICES DEPARTMENT (MMESD)

FIG 23. Parts of the LHD bucket

FIG 24. Parts of the LHD Body

MINE MECHANICAL RELATED SERVICES DEPARTMENT (MMRSD)

FIG 25. Parts of a Rock Breaker

FIG 26. Simplified Rock Breaker Circuit