company capability statement - mastermyne … · kpis it fosters and maintains a culture of...
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COMPANY CAPABILITY STATEMENT
CONTENTS
About Mastermyne .................... 3
Mastermyne Group .................... 5
Mastermyne Values .................... 5
How we manage our business .................... 8
HSEQ .................... 9
Roadway Development .................... 11
Outbye Services .................... 12
Chemical Injection .................... 13
Secondary Support .................... 14
Ventilation Control Devices .................... 16
Conveyors .................... 18
Longwall installation, relocations .................... 20
Innovation & Continuous Improvement .................... 21
Strategic Partnerships .................... 22
Why use Mastermyne .................... 23
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• Uniquely suited as a partner to improve the efficiency in the use of contractors across our Clients operations.
• Underground mine services; • Longwall support services; • Labour services;• Development mining labour and
management.
• Australia’s most experienced development mining contractor.
• Long term relationships with tier 1 mining companies.
• Demonstrated record of providing innovative commercial solution driving cost reduction.
• Proven project management systems.
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ABOUT MASTERMYNEMastermyne has grown by delivering high quality, competitive services for underground mining and has an established presence in all major coal producing regions on the east coast of Australia.
Today Mastermyne is listed on the ASX and employs in the region of 800 people operating across mine sites and other locations both in Queensland and New South Wales.
Mastermyne has an acknowledged reputation of “doing what we say we’re going to do”.
The Company has been strategically grown to incorporate an extensive range of services integral to the mining sector.
This broad range is of increasing importance to clients who are looking to consolidate their out sourced services and at the same time mitigate risk by engaging a contractor with a proven track record of Safety, Operational and HR and IR performance as well as systems that ensure compliance and sustainable outcomes.
Mastermyne continually generates repeat contracts through our transparent approach and focus on delivering optimum results for our clients.
This success is also down to our utilisation of effective, innovative systems and process managed by a highly skilled team of experienced personnel which continues to deliver added value to our clients.
Long term relationship
with tier 1 mining
companiesLength of contract relationship (years)
42 6 8 10 12 14
Vale
BMA
BHP Billiton
Rio Tinto
Anglo American
Glencore
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For the past 20 years The Mastermyne Group has been a leading provider of a range of specialist contracting services. Today Mastermyne is listed on the ASX and employs in the region of 800 people operating across mine sites and other locations both in Queensland and New South Wales.
Mastermyne has an acknowledged reputation of “doing what we say we’re going to do”.
The Company has been strategically grown to incorporate an extensive range of services integral to the mining sector.
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OUR VISION
OUR PURPOSE
To be a world class provider of contracting services.
We create value for our clients, our shareholders, our employees and the communities we work in.
Proactive & Passionate
Our team work together, are passionate about the business, are bold and encouraged to act, and take pride in what they do.
Delivering Customer Excellence
We build strong relationships with our customers by providing a reliable service of the highest quality.
Innovation & Continuous Improvement
We lead change to meet the needs of an evolving market and seek to improve what we do every day.
Safety Always
We are trained and competent to look after our environment, our workmates and ourselves, to ensure we all safely return to family and friends.O
UR
VALU
ES
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CONSUMABLESFLEETDIRECTIONAL DRILLINGLONGWALL RELOCATIONSDEVELOPMENTMAJOR PROJECTSCONVEYORSVENTILATIONSECONDARY SUPPORTOUTBYE SERVICESLABOUR SERVICESEMERGENCY STRATA SUPPORT
VENTILATIONDEVELOPMENT
CONSUMABLES
LONGWALL RELOCATIONS
EMERGENCY STRATA SUPPORT
DIRECTIONAL DRILLING
MAJOR PROJECTS
CONVEYORS SECONDARY SUPPORT
LABOUR SERVICES
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ACCESS SOLUTIONSPIPELINE SERVICESPROTECTIVE COATINGSPROGRAMMED MAINTENANCEFABRICATION, MACHINING CIVIL, STRUCTURAL, MECHANICAL, ELECTRICAL CONSTRUCTIONCONSUMABLESENGINEERING
FABRICATION PROTECTIVE COATINGS
MACHINING CIVIL, STRUCTURAL, MECHANICAL CONSTRUCTION
PIPELINE SERVICES
PROGRAMMED MAINTENANCE
ENGINEERING
LINE BORING
CONSUMABLES
ACCESS SOLUTIONS
DIRECTIONAL DRILLING
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HOW WE MANAGE OUR BUSINESSPeople ManagementSupporting and managing our people is a key differentiator of Mastermyne, we know from our extensive experience that to build a strong culture of safe and productive employees the employer has to take an active and visible role. We have proven this many times on our projects regardless of the commercial model under which we are engaged.
Business Support SystemsWith Pronto, an industry regarded ERP system, as its business management system coupled with the Mastermyne Group Operating System (MOS), TM1 as a forecasting tool and INX for document control, Mastermyne Group runs an Integrated Business Management system to deliver clients complete, accurate and timely reporting for effective contract management.
HR/IRMastermyne’s proven ability to fulfil human resourcing requirements in line with project demand means that we can be relied on even when the competition for labour is at its highest. Mastermyne’s employment and industrial relations platform will promote flexible work practices and drive a culture of safety and productivity.
Local PresenceThe Group has approximately 800 personnel across the Bowen Basin, Hunter Valley and Illawarra Region.
Innovation & Value AddingMastermyne has a continuous improvement policy which looks at delivering value adding services to our client. Innovation & Continuous Improvement is a core component of our business and can result in positive gains for our Clients.
Umbrella ServicesMastermyne is Australia’s largest underground mining contracting company, experts in mine services and much more.
From mine services, to labour hire, conveyors to consumables, Mastermyne can assist our Clients to reduce cost and improve efficiency across their entire operations.
Mastermyne are experienced in all aspects of underground mining, including:
• Roadway Development,
• Outbye Services,
• Ventilation,
• Conveyor installation & relocation,
• Secondary Support,
• Longwall installation & relocation, and
• Directional Drilling.| Page 8 |
The Mastermyne Group has developed our own HSEQ Index which measures numerous safety statistics, predominately leading indicators such as safe talks and hazard reporting. By linking this HSEQ Index to Senior and Project management KPIs it fosters and maintains a culture of ownership and accountability for systems implementation. This idea is a simple tracking device that reports the level of participation in HSEQ activities.
Mastermyne’s goal is to deliver safe projects and services and to support the achievement of this goal, we have a fully integrated Health & Safety, Environment and Quality (HSEQ) Management System, AS4801 accredited.
Quality remains one of the cornerstones of the overall HSEQ Management System and ISO 9001 Quality accreditation is held across all divisions of the company.
Our Environmental Management System and Policy is certified to ISO14001 and is underpinned by rigorous Hazard Identification, Risk Assessment and Control Processes.
HSEQ
Quality ISO 9001
EnvironmentISO 14001
Project ManagementMastermyne once engaged as the Contractor for the procurement, construction, commissioning and performance testing of the proposed works, sets up a specific Project Management Plan.
The Project Management Plan identifies the needs of the project and sets out how Mastermyne will structure the project to manage deliverables.
The project objectives encapsulate the following:
a) To ensure the works are performed safely, without injury/incident.
b) To make sure the plant is available by the planned date and within the agreed budget.
c) To perform the work of the highest standard and quality in the most efficient manner possible.
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Mastermyne has established a reputation amongst Tier 1 operators for delivering industry best practice Underground Coal Development services on time and to budget. Our project understanding technical experience and our design and construction management capacity have proved invaluable on major projects such as the Kestrel Mine Extension for Rio Tinto, Broadmeadows for BMA, and Moranbah North for Anglo American.
These industry leaders in coal have each repeatedly utilised Mastermyne for their projects and we believe this is the greatest testament to our proficiency. Mastermyne is incredibly proud of its ability to build and maintain strong relationships with our clients and to continually deliver at the highest level. Our bundled service offering enables more effective use of human resources through priority resource allocation, resource leveling and cross skilling. Consolidating all outsourced services under a single Mastermyne Project Management Team can reduce cost to any operation.
KESTREL MINE EXTENSION
170 metres average rate
268 best weekly metres
3.0 m/hour average
MORANBAH NORTH
236 metres average rate
285795
3.99,938
best weekly metres
monthly average metres
m/hour average
metres driven in FY2014
1,272 best monthly metres
KESTREL
160 metres average rate
2.9 m/hour average
4,451 6 months drivage
DENDROBIUM
3.0 m/operating hour
100 cut hours achieved (119 hours peak)
219795
best weekly metres
best monthly metres
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Roadway Development
Mastermyne commenced its first development contract 14 years ago at the former Gordonstone Mine in Central Queensland. Since that initial project, we have driven more than 150km of roadways on 12 sites across Queensland and New South Wales.
OUR OPERATIONAL CULTURE• Positive and supportive interaction
between supervisors and employees• No barriers between workforce and
management• Relevant communication with crews at
start of shift, during work and a debrief by supervisors at the end of each shift
• Compliance and standards are mandatory
• Crews are managed by interaction, motivation, review and a consistent and fair disciplinary procedure
• Management are required to get out of the office and into the workplace
• Planning for each task is critical• We set realistic goals and beat them• We take pride in our reputation as one
of the country’s leading underground coal roadway development contractors
• Site teams sequence, plan and execute with a high degree of accuracy and compliance
• Our service is backed up with strong systems around planning, maintenance and reporting
• We have equipment such as 3 Continuous Miners, 1 Place Change Miner, shuttle cars, breaker feeders and electrical equipment.
Notable contracts:
Carborough Downs Drivage
Moranbah
North Mine Drivage Contract
Appin 516
Development Drivage
and Outbye Services
Kestrel North
Roadway Development
Crinum East
Roadway Development
Dendrobium
Mine Services Labour
Kestrel Mine
Expansion Roadway
Development
Grosvenor
MineDrivage Contract
best monthly metres
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Outbye Services
Mastermyne is a specialist in all forms of outbye services including
• Roadworks;
• Pumping;
• Conveyor maintenance, and
• Service extension/retractions. We have performed these services at many mines throughout QLD and NSW.
Client Site Scope of Services
Anglo Moranbah North Mine
Concrete works, road works, transportation of supplies and materials, stone dusting, cleaning, conveyor maintenance, water control and pipe installations, sump construction and cable recovery.
Rio Tinto Kestrel SouthRoad works, salting, transportation of supplies and materials, stone dusting, cleaning, conveyor maintenance, water control, pipe installation and drift cleaning.
South32 Appin Roadworks, transportation of supplies and materials, pipe installation.
Anglo Grosvenor Mine
Concrete works, road works, transportation of supplies and materials, stone dusting, cleaning, conveyor maintenance, water control and pipe installations, sump construction and cable recovery.
BMA CrinumRoad works, transportation of supplies and materials, stone dusting, cleaning, concrete works, water control and pipe work.
BHP Dendrobium
Concrete works, road works, transportation of supplies and materials, stone dusting, cleaning, conveyor maintenance, water control and pipe work, sump construction and cable recovery.
BHPWest Cliff and Appin Area 9
Concrete works, road works, transportation of supplies and materials, stone dusting, cleaning, conveyor maintenance, water control and pipe work, sump construction and cable recovery.
Rio Tinto Kestrel SouthRoad works, transportation of supplies and materials, stone dusting, cleaning, conveyor maintenance, water control and pipe work.
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Chemical InjectionMastermyne has recently partnered with Dywidag Systems International (DSI) to offer an alternative supply of chemical products and support to Underground Mines. Mastermyne are the licensed installer and DSI are able to offer a complete suite of Chemical Products including Phenolic Cavity Fill, Urea Silicate and PUR for applications in Longwall Recovery, Longwall Relocations, Strata Consolidation and water management.
Mastermyne have recently completed the longwall take off pre-consolidation at Anglo American’s Moranbah North Mine.
Mastermyne differentiate ourselves from the current chemical providers primarily by having the labour for the application embedded within our existing work crews. Chemical rates would only be applied for chemical pumping, with all the drilling and initial setup completed at the lower rates.We have adopted a similar approach with our other contracts in the Moranbah region and we currently have enough embedded personnel on these contracts to be able to support a 24/7 pumping event for extended periods of time.
Mastermyne have also invested heavily in R&D projects to optimise the pumping delivery system.
In addition to our partnership with DSI, Mastermyne have strong working relationships with both Minova (Orica) and Wilson’s.
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Secondary Support
Mastermyne is one of the leading installers of secondary support in Australian coal mines. This includes the installation of:
• Strata support such as, mega bolts, hi tens, cable bolts, roof bolts, rib bolts, meshing and shotcrete
• Quality controlled and well developed tracking systems
• Significant experience in fall recovery
• Specialised equipment to support secondary support work, air tracks, QDS bolters and hand held equipment
• Polymeric strata support products and services.
MORANBAH NORTH workfronts3
GROSVENORworkfronts2
DENDROBIUMworkfronts4
WEST CLIFF / AREA APPIN 9 workfronts4
KESTRELworkfronts2
Mastermyne peak strata control workfronts
CRINUM 2015
2,700+8.1m TG Bolts
160+6m JSS cable bolts4664m JSS cable bolts
240+1.8m cuttable bolts
1770+1.2m steel bolts (rib)
200+2.1m steel/roof bolts
70010m JSS bolts (spiles for PDRR)
300+9m Self drilling bolts (spiles for PDRR)
WESTCLIFF 2015
2,5008m Mega Bolts
37510m Mega Bolts1,2503m Mega Dowles
455 psi seals
3 month average, planned task completion 103.2%
8m Mega Bolts
2120 psi seals
WESTCLIFF 2014
5,2008m Mega Bolts
76010m Mega Bolts1,2503m Mega Dowles
375 psi seals
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4664m JSS cable bolts1500Rib bolts
2,1008.1m TG Bolts70010m JSS bolts
(spiles for PDRR)
CRINUMFY2015
PDRR SUPPORT
24/7 crew coverage 5/4 roster
7 man crews (1sup + 6op)Completed injury & incident
free
Mastermyne’s high standard of execution contributed to
Crinum Mine record longwall take-off.
Completed in approx. 7 weeks due to production constraints
Completed with the use of hand held bolters & QDS
bolting rig.
Installation of tin canning support & geotechnical
devices
Reduced cure time for fly-ash grout down to 60 days compared to 90
daysIntroduced the use of 9m self-
drilling bolts (spiles for block side). Reduced installation time &
double handling.
Predriven Recovery Roads
Through our Mine Services contract at Crinum, Mastermyne completed the final three pre-driven recovery roads (PDRR) at Crinum Mine. The PDRR method at Crinum was refined over 4 year period with Mastermyne contributing to this continuous improvement process. The result provided greater strata stability, improved safety and significantly decreased Longwall Relocation time.Mastermyne has also improved our performance and quality of PDRR’s over the past 3 years. Pre-driven Recovery Road 27, the final to be completed at Crinum, was completed in record time (7 weeks) and for significantly lower cost, ($400k) than previous averages.
PDRR27 Highlights
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Ventilation Control Devices (VCDs)Mastermyne manufactures and installs ventilation control devices (VCDs) either as primary projects, part of an umbrella contract or as ancillary works to drivage at many underground operations. An extremely accurate planning and scheduling regime for construction as well as product control and supply has been developed over our extensive history of VCD works.
The Mastermyne Group business Mastertec, manufacture and supply:
• Quality VCDs
• Regulators, man doors, air locks, coffin seals, overcasts, undercasts
• VCD consumables
• Brattice, grout, plaster, pogos
From our facilities in Gladstone and Newcastle we design and manufacture independently certified, pressure rated VCDs.
Design
Mastermyne have a wide range of VCD designs to service our existing customers. In most cases, these designs have been customaries to the mines specifications. Examples include different seal types, machine doors and regulators and overcasts.
Certification and Engineering
VCD certification and engineering is completed in-house by our engineering department. We also have relationships with multiple RPEQ certified contractors for peer review.
Manufacture and Supply
Our Client’s customised VCD’s can be manufactured through Mastermyne’s fabrication workshops and sourced through direct import from emerging markets. This option has recently seen a number of our customers realise significant cost savings. Mastermyne also distributes MynePlaster (Falcon Plaster).
Quality Assurance
Quality Assurance is completed by industry leading experts in our support team. Steve Jones and Kevin Dine have a combined 60+ years of ventilation experience and regularly complete QA for Mastermyne installed VCD’s.
Manufacture
Installati on
Q
ualit
y Assu
rance
Engineering
Certi f cati on
Design
Mastermyne VCD
Capability
As well as being an industry leading VCD installation contractor, Mastermyne has the in-house design, engineering and manufacturing processes to complete an end to end solution for Broadmeadow.
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MORANBAH NORTH
DENDROBIUM
ULAN WEST
BULLI SEAM OPERATIONS (APPIN WEST/EAST/NORTH)
NORTH GOONYELLA
WAMBO
CRINUM
KESTREL SUPPLY OF VCDs
Design and installation of Longwall sealsMastermyne design seal resulted in cost savings to the clientBuilt within time framesQuality Assurance checks conducted
8 years on site Fully integrated client/contractor planning and schedulingFull Quality Assurance requirements undertaken on installationsSupply and installation of all VCD’s including all fabricated devices and 120psi plug seals at both Appin West and North operations
9 years LTI free to date Design and installation of rated stoppings, overcasts, machine doors and regulator doorsQuality Assurance checks conductedFully integrated client/contractor planning & scheduling
LTI free to date Supply and installation of rated stoppings, overcasts, machine doors and regulator doorsDesign specialised longwall goaf seals to assist in cost saving measuresMaintain & test tube bundle systems
13 years on site (relocated from Crinum to Crinum North and now Crinum South9 years LTI free achieved in 2011Fully integrated with BMA planning and schedulingSite project managed suppliers and stock
Supply intermediate services and ventilation control devices to the following sites:• Moranbah North• Grasstree• North Goonyella• Grosvenor• Carborough Downs.
Fully integrated client/contractor planning and schedulingFull Quality Assurance requirements undertaken on installations75 VCD’s installed during 2014
From the opening of the operation Mastermyne has supplied ventilation and outbye services including, longwall seals, fabricated VCD’s, bolting and general outbye duties.
Design, supply and installation of rated stoppings, overcasts, machine doors and regulator doorsDesign specialised longwall goaf seals to assist in cost saving measuresProvide production labour
Ventilation Experience
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Conveyors Conveyor work is a core competency on which the Mastermyne Group was founded.
• Our expertise and experience includes installations, recoveries, extensions, belt moves and upgrades.
• Turnkey Civil, Mechanical and Electrical conveyor services are all carried out in house.
• Installed >300 Trunk, Maingate, Development and Drift Conveyors across underground mines in Queensland and NSW.
• Strong track record of delivering on time, within budget and to a high quality.
Across QLD and NSW Underground Mines Mastermyne
has installed over 300 trunk, maingate, development
and drift conveyors.| Page 18 |
Recent projects undertaken for BMA at BroadmeadowsServices undertaken included Project management, detailed planning, of civil, electrical and mechanical through to commissioning.Description NotesBroadmeadows MG9 Longwall Conveyor Upgrade 2013/2014 $5.4 million
Installation of a conveyor haulage system at BMA’s Broadmeadow mine capable to support the long wall operations. Removal of the existing conveyor system, replacing it with a higher capacity system and upgrading the reaming system.
Broadmeadows MG10 Longwall Conveyor Upgrade 2015 $4.7 million
Installation of a conveyor haulage system at BMA’s Broadmeadow mine capable to support the long wall operations. Removal of the existing conveyor system, replacing it with a higher capacity system and upgrading the reaming system.
Broadmeadows MG13 Conveyor Installation 2015 $3.6 million
Installation of a conveyor haulage system at BMA’s Broadmeadow mine capable to support development utilising a full underground conveyor system, extending the life of mine by 10 years.
KESTREL MINE EXPANSION
1400 cubic metres of concrete placedIncluded sumps, conveyor drive base, foundations, roadways and general concrete works.
7.5kmsof conveyor
structure installed
Included Main trunk conveyor, MG401 development, MG401 production, MG402 development and 3 Jiffy conveyors.
8.2kmsof conveyor
structure removedIncluded MG401 development, B-Heading conveyor and Jiffy conveyors.
8.5kmsof pipe work installation
Included 6’ and 8’ pipe, valving, droppers, services points, air, water and de-watering, and pressure reducing stations.
10kmsof tube bundles
Completed installation in both drifts and pit bottom, plus commissioning.
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longwall moves completed by Mastermyne
Longwall installs, salvages, mini-builds, monorail moves, in-situ remedial work
Actively engaged in up to
Minor equipment to support
longwall work
Longwall move-related projects per year
530+
Longwall installation, relocationsMastermyne has, over a long period of time, been successfully completing longwall relocation projects throughout Queensland and New South Wales. This experience demonstrates our capability in this sector but it should also signal that by engaging Mastermyne you can be assured that the project will be successful as you draw on our experience, our people and our equipment, which together have repeatedly delivered successful projects.
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Innovation and Continuous ImprovementWe recognise that to perform at the highest level we need to be safe and continue to add value to our client operations through innovation.
Mastermyne have a strategic focus on expanding our value offering to our customers. Through this approach we attempt to bundle together multiple services to provide significant savings to our customers through more efficient project management, resource levelling and transfer of labour and value discounts.
Innovation through using new technologiesDustless pump
Mastermyne is currently working with a long-term ventilation plaster manufacturer to manufacture a sealed delivery system for pumping ventilation plaster and shotcrete. The unit is currently in phase one concept testing with the aim of having a test unit available for site trial in 2016. The unit will eliminate the airborne dust which is created by loading plaster or shotcrete into pumps and expelled from the pump while operating. Dust from this equipment can cause delays and limit working hours. The new pumps will allow continuous pumping operations in any single area.
Shotcrete alternative
Mastermyne now have access to technology that allows existing ventilation installation equipment to be used to apply a shotcrete type product. Reducing the requirement for specialised shotcreting machinery and materials, therefore significantly reducing the cost of application.
Innovation Mastermyne design and manufacture of VCD’s
Utilising the Mastermyne design, construction material and construction methods could offer a savings of up to 25% on current construction rates as well as a reduced requirement for product.
Mastermyne have recently completed the construction of their Plug Seal in longwall 901 and Appin North, the introduction of this seal has delivered cost saving and reduction in time to build as compared to Appin’s traditional design VCD. Certification for the seals can be designed to suit customer specific requirements. Mastermyne currently has designs and certification for various 20, 50 and 120psi plug seals with differing factors of safety, head of water and convergence capabilities.
Savings are predominately realised through reducing the depth of plaster that is required to seal the stopping.
Type Current South32 Design Stopping Depth
Mastermyne Design Stopping Depth
2psi Stopping 5.2 x 3.0 meters
100mm 85mm
5psi Stopping 5.2 x 3.0 meters
150mm 110mm
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Strategic Partnerships
McConnell Dowell – Mastermyne Joint Venture
McConnell Dowell & Mastermyne have formed a highly capable team to enable the delivery of the underground infrastructure including the Cut & Cover, Drift Driveage and Ancillary Works.
Mastermyne - DSI RelationshipMastermyne has recently partnered with Dywidag Systems International (DSI) to offer an alternative supply of chemical products and support to Underground Mines. DSI are able to offer a complete suite of Chemical Products including Phenolic Cavity Fill, Urea Silicate and PUR for applications in Longwall Recovery, Longwall Relocations, Strata Consolidation and water management.
Mastermyne - Reliable Conveyors RelationshipMastermyne has recently partnered with Reliable Conveyors and are now able to offer conveyor splicing, major pulley relagging and major conveyor changeout services through this relationship.
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Significant track record in resourcing large scale projects
Significant track record in resourcing large scale projects
We can offer a complete umbrella services package
We can offer a complete umbrella services package
Capable and experienced management team with local knowledge
Capable and experienced management team with local knowledge
Long term relationship with Tier 1 contractors
Long term relationship with Tier 1 contractors
Demonstrated Recruitment and Retention Processes
Demonstrated Recruitment and Retention Processes
Why use Mastermyne?
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Business:Mastermyne Pty Ltd Level 1 Riverside Plaza45 River StreetMackay QLD 4740
e:t:f:
[email protected](07) 4963 0400(07) 4944 0822
ABN: 71 069 346 247www.mastermyne.com.au
Contacts:David Sykes EXGM Underground e: [email protected] m: 0407 186 871
Steve Jones Mining Products Manager e: [email protected] m: 0409 113 054
Daniel RyeTender Manager e: [email protected] m: 0429 361 605
Patrick McCoyOperations Manager NSW e: [email protected] m: 0418 337 417