Normet SmartScan Technology: Real-Time Monitoring of Shotcrete Application
Dhyanendra Mani Tripathi General Manager – Project Operations (India), NormetIn recent years, shotcrete technology for underground rock support has seen significant advancements, particularly with the integration of digital technologies like SmartScan and other IoT-based innovations. SmartScan, a cutting-edge digital system, offers real-time monitoring and analysis capabilities during shotcrete application processes.
One notable innovation is the incorporation of laser scanning technology (Light Detection and Ranging), allowing for precise measurement and mapping of the tunnel profile. This enables operators to identify irregularities and adjust shotcrete application, accordingly, ensuring uniform coverage and optimal rock reinforcement. Additionally, SmartScan facilitates immediate feedback on the thickness and quality of applied shotcrete layers, minimizing the risk of over-spraying and reducing material wastage.
Moreover, SmartScan's data analytics capabilities provide valuable insights into shotcrete performance and adherence to safety standards. By monitoring variables such as material consistency, thickness sprayed and desired profile etc., operators can make informed decisions to enhance efficiency and effectiveness in rock support operations.
Shotcrete-based rock support challenges
Determining the necessary thickness of concrete for rock support in underground operations is a complex task, heavily reliant on the expertise of the operator. However, there are notable variations in the quality of application among operators, posing safety concerns for such a critical task.
Unfortunately, cost-effective and efficient methods for assessing concrete layer thickness are lacking in the market, despite being indispensable for tunnelling operations. Ensuring a minimum concrete layer thickness is essential for safety underground, yet excessive spraying to meet this requirement incurs additional costs and time. Moreover, such over-spraying may deviate from the tunnel's intended profile, necessitating costly removal measures. These factors often lead to delays and incomplete project documentation, adversely impacting both the contractor's ability to bill for completed work and the client's satisfaction with the operation.
Normet SmartScan Technology
Normet SmartScan represents a cutting-edge measuring system tailored for convenient measurement and monitoring of applied sprayed concrete thickness. Employing state-of-the-art scanning technology, it is specifically engineered to thrive in demanding underground settings such as tunnel sites, caverns, and mining operations. Utilizing 3D LiDAR technology, it eliminates unsafe manual probing methods for determining layer thickness beneath fresh concrete, thereby enhancing the efficiency of concrete spraying processes, and ensuring the safety of underground personnel.
Operated with the touch of a single button by the nozzle operator, it initiates measurement effortlessly. The onboard computer promptly calculates concrete thickness in near real-time, presenting results in customizable colours on the screen, providing immediate feedback to the nozzle operator regarding the recently sprayed area. Its user-friendly touch screen interface makes learning and operation uncomplicated.
Moreover, the accompanying SmartScan Desktop software enables swift and advanced report generation, along with secure storage of profile data for comprehensive data analysis. Achieving the required concrete layer thickness swiftly before relocating the concrete spraying machine eliminates the necessity for return visits to re-spray areas, significantly boosting efficiency, preserving quality, and minimizing material waste.
SmartScan Hardware
The hardware components of the SmartScan system have been carefully selected for use in harsh underground environments, such as tunnel construction sites, caverns, and mining operations. They come with at least IP65 protection and withstand dust and often high humidity, temperatures, and vibrations. The measuring unit is protected by a robust protective housing against concrete rebound during spraying and splash water during cleaning of the machine. For an optimal field of view and access, the SmartScan system is mounted on the front of the concrete spraying machine. The operator interacts with the measurement system via a scratch-resistant touchscreen. The rugged vehicle terminal provides the necessary computing power for fast data processing of the sprayed concrete layer and display on the screen in 3D.
SmartScan Live
The user interface has been designed with focus on ease of use and speed. After the project parameters have been entered using the software keyboard, the operator starts the first scan with a single touch. The tunnel profile is captured by the scanner and immediately presented on the display for checking. After the application of sprayed concrete, the operator initiates another scan, from which the applied concrete layer thickness is determined in a short time and displayed in configurable colours in 3D. The operator thus receives immediate feedback on the effectively applied layer thickness. The coloured areas allow the operator to re-spray sections with insufficient concrete until the required layer thickness is achieved, eliminating the need to return to the previously sprayed area for expensive rework.
Key Features
- Easy to operate one touch operation.
- Simple interface for project parameters
- Fast data processing.
- User configurable colour coded 3D visualization.
- Automated generation of spraying reports.
- Advance algorithms for alignment of scans.
- No targets or illumination required.
The Retrofit Kit
Exhibit 3: Sprayed Concrete Thickness ReportThe SmartScan retrofit kit allows new or existing sprayers to be equipped with the latest LiDAR measurement technology to measure and monitor the applied sprayed concrete thickness in underground construction. The kit, which is easy and quick to install, includes all the necessary components to increase the technological level of the concrete spraying equipment fleet, thus enabling even older equipment to be used in demanding projects with little effort. The SmartScan system does not require calibration after installation and is ready for immediate use. Normet offers an installation service for the scanner system and training for the use of the system. SmartScan retrofit kits are currently available for all Normet underground sprayers.
Key Features of Kit
- The kit includes all components for easy and quick installation
- Economical option to upgrade older machines with the latest LiDAR technology
- Great savings potential thru minimized and expensive over spraying and less wastage
- Installation service and training provided by Normet
SmartScan has revolutionised the sprayed concrete (shotcrete) operations across the globe. Normet remains dedicated to advancing technological innovation and achieving excellence, with a strong focus on enhancing customer satisfaction and promoting sustainable operations. Normet's commitment lies in “Defining the future of underground” and the company is steadfast in its pursuit of excellence to contribute to a better world ahead.
