Pre-Deployment
Calibration
Each shotcrete mix design requires a site-specific calibration curve established through beam end testing in accordance with ASTM C1074. Changes to accelerator dosage, cement type, or constituent materials require re-calibration. The validated curve is loaded into the platform and assigned to the relevant headings.
Operational Workflow
The entire sensor deployment takes under 30 seconds and requires no specialist skills. The operator activates the sensor, drops it in the hopper, and sprays as normal. From that point, monitoring is fully automated.
Daily Operations
Operator Tasks (Per Shift)
- Confirm sensor inventory is adequate for the planned spray schedule.
- Activate sensors immediately before each spray cycle — premature activation consumes battery life.
- Drop activated sensors into the hopper and spray normally. One or more sensors per heading depending on area size and site requirements.
- Verify sensor registration on the dashboard after each spray. The gateway auto-detects new sensors; the operator confirms heading assignment.
Dispatch Monitoring
- Monitor the real-time dashboard for heading status: Sprayed, Curing, or Cleared.
- Review predicted time-to-clearance for active headings to plan crew allocation.
- Receive automated clearance notifications when headings meet the design strength threshold.
- Log all clearance events in the shift record.
Re-Entry Approval
When the system indicates a heading is cleared, dispatch authorises re-entry. For headings where additional engineering judgement is required, the geotechnical engineer can place a manual hold — preventing automated clearance regardless of sensor data. All overrides and manual approvals are recorded in the audit trail.
Integration with Mine Systems
Data Flow
The Safecrete system connects to mine dispatch and fleet management platforms via the REST API. The integration supports:
- Automated re-entry scheduling: Clearance signals transmitted directly to dispatch enable crews to be assigned to cleared headings without manual communication.
- Status board updates: Heading status (Sprayed, Curing, Cleared) displayed on mine-wide status boards and control room displays.
- Shift handover reports: Curing status and expected clearance times for all active headings included in automated handover reports.
Audit Trail
Every clearance event is timestamped and archived with the full sensor dataset — temperature readings, maturity calculations, and strength estimates. This provides a complete compliance record for geotechnical review and regulatory reporting. Historical data supports analysis of shotcrete performance trends, curing time distributions, and mix design optimisation.