Solving Shotcrete Challenges at an Australian Tin Mine
When an Australian tin mine faced significant annual costs due to pump failures, they turned to PumpEng for a solution. This case study highlights how PumpEng's problem-solving approach and specialised equipment transformed a critical dewatering challenge into a success story. Michael Spargo (Mick), Business Development Manager, shares the journey from identifying problems to finding long-term solutions.
The Challenge
Q: How did you first learn about the mine's dewatering problems?
The mine's Continuous Improvement Manager contacted us about their serious dewatering issues. The mine site manager explained how shotcrete fibre damage was causing significant pump turnover. They needed a solution to improve pump life and relieve pressure on their maintenance personnel. Our team went on-site and assessed the crews' underground challenges firsthand.
Q: What did you learn from that underground site visit?
The situation was severe. The cost of repairs on their existing pumps was substantial and had the potential to be a long-term financial drain. They continuously purchased new pumps because the Shotcrete was causing extensive damage. The mine crews had attempted various preventative measures, including adding screens and erecting barriers, but these efforts failed to reduce pump turnover. Nothing they tried effectively addressed the root problem.
Impact on Operations
Q: How did the pump failure impact the mine site operations?
The effects were widespread across their operation. They reported significant downtime and consequent disruption to production. Their maintenance teams described the frustration of repeatedly getting service crews to change pumps. There were also substantial follow-on impacts, like the warehousing and freight costs from transporting pumps to repair facilities. It wasn't just one isolated issue - the entire mine operation was suffering because they weren't using the right pump for these challenging conditions.
Q: How long did their old pumps last?
Some pumps lasted only 7 to 14 days before failing. Imagine the resource drain of replacing critical infrastructure every two weeks.
The PumpEng Solution
Q: What solution did PumpEng provide, and when was it implemented?
In July 2024, we delivered two 10kW JetGuard® pumps. JetGuard®'s unique features reduce the wear typically seen in standard pumps, and the pump's quality/durability provides a long life in tough applications. The results speak for themselves - these pumps have been operating continuously for nine months in those difficult underground applications, areas that previously required pump replacement every two weeks.
Q: What results has the mine experienced since implementing PumpEng's solution?
The Continuous Improvement Manager is impressed with the pump performance and is working on a plan to change out the other pumps for JetGuards®.
Q: How has this affected the mine's maintenance operations?
Having those two reliable pumps in previously difficult locations has allowed their service group to focus on development rather than worrying about constant pump replacements. It has freed up time for them to perform their intended duties, like working with ventilation systems, supporting drilling operations, and focusing on production.
Addressing Challenges
Q: Were there any issues that came up during the implementation?
We did encounter some initial teething problems. After receiving photos from the site, we could see the pumps weren't being used as intended. Once we addressed those operational factors, the pumps ran smoothly. I've now visited the site twice to gather feedback and discuss expanding the number of JetGuard® pumps on site. We're gradually increasing our pump fleet because JetGuard® has proven its toughness operating in minewater containing Shotcrete.
The PumpEng Difference
Q: How does this experience reflect what PumpEng is about as a company?
For many years, standard dewatering pumps that were not explicitly designed for modern Australian mining conditions have been used in Australia. JetGuard® has an innovative design reflecting how PumpEng develop solutions that target the challenges of Australian underground mining.
This is why I wanted to join PumpEng in the first place. We genuinely want our customers to have a good day at work, and that means providing solutions that solve their problems for the long term. If an issue arises, we're there to resolve it promptly. Beyond the technical solution, this project has been a powerful example of "The PumpEng Way"- our philosophy of using the right pump for the job.
Conclusion
The Australian tin mine case demonstrates how PumpEng's specialised equipment and dedicated problem-solving approach turned a million-dollar problem into a success story. By understanding the specific challenges of shortcrete contamination and deploying purpose-built JetGuard® pumps, PumpEng has helped the mine dramatically reduce maintenance costs, increase operational uptime, and allow staff to focus on productive work instead of constant repairs. Nine months after installation, the pumps continue to perform in conditions that previously caused failure within two weeks - a testament to the value of using the right equipment for challenging environments.
"They are over the moon with what has been achieved." – Michael Spargo, Business Development Manager.