2155 project was that being involved from the problem identification stage (e.g., participating in the mine’s innovation committee meetings) through to trial execution allowed the team to preempt many potential implementation problems. It also built trust that the solution was genuinely addressing the mine’s needs, not just showcasing a product (Trinh and Macedo, 2020). 4.3 Impact on sustainability and future developments The improvements in efficiency and reduction in waste also carry positive sustainability implications. The ICS approach at Inmaculada reduced shotcrete rebound, which means less concrete waste to dispose of and more efficient use of cementitious material. Given that cement production has a significant carbon footprint, using less shotcrete for the same support effect is beneficial from a sustainability standpoint (Garcia et al., 2018). Additionally, by accelerating development, ICS can help mines reach ore zones faster, potentially reducing the overall time machinery is running underground, and thereby lowering energy consumption per meter advanced. Although these environmental benefits were not the primary driver of the project, they align with broader industry trends to improve the sustainability of mining operations. In future implementations, further enhancements could be explored, such as incorporating supplementary cementitious materials (slag, fly ash, or newer alternatives) to lower the carbon footprint of the shotcrete, or using accelerator formulations designed to minimize specific substances. Digital monitoring could also augment ICS benefits: using sensors to track shotcrete strength gain in real-time, or linking the shotcrete application schedule with blast scheduling software for optimal coordination. The success at Inmaculada opens the door to applying ICS in other mining projects. It will be important, however, to tailor the approach to each situation: taking into consideration factors like mining method (e.g. cut-and-fill vs. long-hole stoping), advance per round, and equipment availability will influence how ICS can be integrated. Finally, the economic aspect bears discussion. The trial showed a modest reduction in cost per meter (5-8%), which is noteworthy given that many new technologies initially increase costs. The positive economics in this case were a result of the efficiency gains overtaking the higher material costs of the accelerated mix. For mines evaluating ICS, this demonstrates that the business case can be justified if productivity gains are significant and if secondary benefits (like improved safety and less rework) are factored in. Importantly, Hochschild Mining acknowledged the success of the Inmaculada ICS trial as part of its operational efficiency initiatives, noting that it contributed to increased ore extraction rates in 2022 (Hochschild Mining, 2022). This kind of endorsement from mine management is crucial for the broader acceptance of such innovative practices in the industry. 5. CONCLUSION The implementation of in-cycle shotcrete at Inmaculada Mine has shown that it is possible to accelerate underground development cycles by on the order of 15% while maintaining high safety standards. By introducing a carefully engineered, fast-setting shotcrete as immediate ground support, the mine achieved faster re-entry times and increased monthly advance rates. Equally important, the case study highlights the value of a collaborative, holistic approach to technological innovation in mining. Rather than treating shotcrete as a commodity product, the project treated it as a system. This is done by combining mix design optimization, modern application techniques, alignment with the mine’s operational workflow and rigorous monitoring of the sustainability of the results. This system approach, enabled by the partnership between mine and the solution provider, was instrumental in avoiding pitfalls (such as incompatible materials or scheduling conflicts) that could have undermined the effort. Inmaculada Mine now benefits from a cycle time reduction that can translate into reaching ore zones sooner and potentially extending the mine’s economic life through faster development of reserves. The safety improvements (immediate support, less exposure to unsupported ground) and reduced material waste further strengthen the case for ICS beyond just productivity. While each mine will have unique conditions, the lessons learned here are broadly applicable: early engagement with stakeholders, rigorous testing, and training, and a focus on compatibility and quality are keys to successfully deploying in-cycle shotcrete. Future work will continue to monitor the long-term performance of the shotcreted development headings
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