A solution that empowered site teams and reduced supervision costs, delivering real results for the local community
At Dust-A-Side Australia, we pride ourselves on delivering practical, effective dust control solutions that meet the unique challenges of mine sites across the country.
This case study highlights how our team helped a mining operation located adjacent to a regional town deploy the system to gain visibility, reduce dust, and operate more confidently without the need for full-time on-site personnel, through a simple, self-sufficient and cost effective solution.
The Situation
A regional mine operating near a township, with the local school located just 200 metres from the mine boundary, was seeking a better way to manage dust emissions and improve road conditions across its haul roads. As the mine expanded, increased road traffic and material handling on-site led to significant dust generation. This dust was not only impacting the worksite but also creating challenges for the surrounding community — with dust encroaching into residential areas and, notably, towards the school grounds.
The site faced recurring issues with a water-only suppression strategy, which delivered limited results and led to excessive water consumption. Over time, the constant application of water degraded the running surface, reducing road integrity and contributing to the formation of potholes. This deterioration required frequent repairs, driving up overall road maintenance costs, increasing downtime which impacts production levels.
Additionally, with limited capacity to supervise the system full-time, the client needed an autonomous solution that could deliver reliable results and provide remote visibility on performance and consumption.
Further challenges included coordinating the deployment of personnel and equipment, which at times can result in delays. However, the combined efforts of the client and Dust-A-Side Australia teams ensured these hurdles were overcome to deliver a successful outcome. The site also faced heavy rainfall events, including approximately 75mm in a single day, which temporarily paused works and tested the resilience of the program.
The Solution
Dust-A-Side Australia proposed and delivered a Remote Supervision dust suppression package for rapid setup, minimal disruption, and long-term performance. The system required minimal integration with the site's infrastructure and was fully operational shortly after delivery.
What we supplied:
- Storage Tank – Robust, chemical-compatible tank for safe on-site storage
- Unloading Pump – Allows for safe, direct bulk transfers
- Dosing Pump – Precisely doses volumes into water carts without external inputs
- Hoses and Pipes – Delivered pre-fitted for immediate use
- Remote Telemetry – Real-time monitoring of usage and tank levels
- HydroTac Product – Organic dust suppressant that reduces water usage and binds fine particles. Click here to learn more about HydroTac.
The strategic dosing point was selected to target haul roads with the highest traffic volumes, and the system was configured to allow for flexible expansion as the site evolved.
The trial phase demonstrated that the product worked over the specified trial road networks utilising the purpose built dosing station. Encouraged by these results, the client expanded the dust suppression setup across more of their road network.
Photo of access road post rip/blend and application
Photo of treated areas showing application techniques and site preparation
Implementation and Support
Once delivered, the client installed the system with minimal assistance. The solution also incorporated operator training, condition monitoring, and performance assessments. Site visits were conducted at agreed intervals to:
- Check and maintain equipment
- Assess road conditions and advise/adjust dosage
- Train water cart operators on best application methods
- Ensure preventative maintenance was in place
- Manage product logistics and delivery schedules
- Provide reporting on performance, usage, and savings
Operator training was delivered using a “ride-along” approach, where Dust-A-Side personnel joined water cart operators to guide dosing rates and reading road conditions. This hands-on method helped reduce trial and error, resulting in faster learning and better outcomes.
Where necessary, areas were treated using scarification or heavier spray-only establishment methods, depending on how surface materials responded to initial applications.
The treated area expanded significantly, ultimately covering over 106,000 sqm including haul roads, access roads, ROM pads, and workshop aprons.
Mobilisation of equipment at the site included:
- 68,000L Self-Bunded Rectangular Tank
- Garpen 10HP Trash Pump
- HydroTac Pump
- 1 x IBC of water for flushing
- All required hoses
- Solar-powered telemetry system for remote monitoring
Photos of expanded treatment areas post establishment
Maintenance and Inspections
Regular inspections ensured system uptime and allowed for proactive maintenance. Faults were addressed promptly, and remote telemetry provided continuous visibility into system performance.
Site inspections confirmed that client objectives were met, including:
- Reduced dust levels
- Improved safety
- Lower water consumption
- Decreased reliance on water carts
- Reduction in dust-related complaints from nearby residents
Although quantitative data (e.g. % dust reduction) wasn't captured, the client reported visibly improved road conditions and fewer neighbour complaints.
Asset Performance Summary:
From a site report after implementation, all equipment passed inspection, including:
- Tanks (valves, locks, drip trays)
- Hoses and stainless-steel fittings (no spills)
- Pumps (secure, no leaks, functioning E-stops)
- Telemetry system (restored successfully post-fault)
- PPE, fire safety, signage, and documentation on-site
No major service issues were identified. Some minor improvements were recommended, such as relabelling switchgear and updating risk registers.
Snapshot of asset table from site report post implementation.
Challenges and Learnings
One of the key challenges during implementation was the site’s limited water access. The water source location made it logistically challenging for the team to fill water carts efficiently during initial deployment. However, once the system was installed and running, it proved easy for the client to manage on an ongoing basis.
Another challenge involved surface material variability, which required on-the-fly adjustments to dosing and establishment methods. By actively monitoring and adapting treatments, Dust-A-Side Australia was able to ensure consistent results across different parts of the site.
The program also demonstrated resilience in adapting to weather events and operational constraints, such as crew changes and resource availability during challenging conditions.
Outcomes
Within weeks, the client observed visibly improved road surfaces and a reduction in dust-related complaints. Key benefits included:
- Reduced water usage
- Less wear on roads and equipment
- Improved operational confidence
- A system that worked without daily oversight
- Enhanced reporting and visibility through remote telemetry
The Remote Supervision package enabled the client to cover over 106,000 sqm of critical site roads, with scalable deployment across the network. The system continues to operate effectively and is supported by Dust-A-Side through scheduled site visits and ongoing advisory services.
Looking for Smarter Dust Control Solutions?
Our Remote Supervision package delivers simplicity, autonomy, and results — even when we’re not there. Let’s talk about how we can implement this solution at your site.
