Wet weather poses a significant operational risk for gold mining sites across Australia. Whether in the inland regions of Western Australia or the tropical zones of Queensland, rainfall events have the potential to bring production to a standstill—particularly when haul roads are not adequately engineered to manage water flow.
Haul roads often represent the first point of failure following a major rain event. Without proper drainage or stabilisation, these roads can rapidly deteriorate into muddy, rutted, and impassable surfaces.
For gold mining operations with extended haul distances, even minor disruptions can escalate into considerable productivity losses and financial impact.
At Dust-A-Side Australia, we recognise that rapid recovery following wet weather is critical. In high-grade operations, where each hour of lost haulage can translate into hundreds of thousands of dollars in lost production, the cost of inaction is significant.
Why Proper Haul Road Design Matters in Gold Mining
In Australian gold mining operations—where haul roads often span long distances across remote, arid, or seasonally wet terrain—road design is a critical factor in maintaining operational continuity.
A well-designed haul road network must not only withstand the high-frequency loads of heavy mining vehicles but also recover rapidly following rainfall events.
A key design parameter is two-way crossfall with a lateral slope of 1–4%. This facilitates surface water runoff into designated drainage structures. When implemented correctly, this approach delivers the following benefits:
- Prevention of standing water and pooling
- Reduction in rutting, potholing, and surface softening
- Shortened drying times—from days to mere hours
- Reduced dependence on reactive grading and rework
Preservation of the underlying road structure
In contrast, inadequately drained roads tend to absorb water and soften under load. The resulting degradation often necessitates reactive grading and dozing to restore usability. However, this process is unsustainable—each pass removes compacted material and weakens the structural integrity of the road, leading to a cycle of deterioration and escalating maintenance costs.
Illustration of two-way crossfall design that helps water drain off haul roads quickly
Bitumen Stabilisation: A Proven Approach to Wet Weather Performance
While drainage design is essential, the long-term resilience of haul roads can be significantly enhanced through bitumen stabilisation. By incorporating a bitumen emulsion—such our DAS Product solution—into the wearing course during construction or rehabilitation, gold mining operations can reduce wet weather impacts and increase haul road availability.
Bitumen-stabilised roads offer multiple performance advantages:
- Creation of a sealed, water-resistant crust that prevents water ingress
- Binding of fine particles to reduce dust generation and pothole formation
- Improved fuel efficiency through lower rolling resistance
Reduced maintenance frequency and associated costs - Enhanced structural durability under heavy traffic loads
Although the initial investment in bitumen stabilisation may be higher than traditional methods, the return on investment is realised rapidly—particularly in high-output operations where delays directly affect profitability.
Haul roads treated with DAS Product have demonstrated measurable improvements across key operational metrics, including:
- Up to 95% reduction in water consumption for dust suppression
- Improved visibility due to lower airborne dust levels
- Increased travel speeds, with typical improvements from 20 km/h to 60 km/h
- Extended tyre life and reduced puncture rates
- Lower fuel usage due to reduced rolling resistance
- Minimised road closures and unplanned maintenance interventions
Collectively, these improvements contribute to higher daily tonnage, improved site safety, and enhanced cost control—key priorities for modern gold mining operations operating in competitive and climate-sensitive environments.
Partnering with Gold mines for Long-Term Road Performance
Dust-A-Side Australia has a proven track record in the design, construction, and maintenance of high-performance haul roads across Australia’s gold mining sector.
Our integrated approach—spanning stabilisation, dust control, and road management—ensures operational continuity, environmental compliance, and long-term asset performance.
From remote Western Australian sites to high-rainfall locations in Queensland, we work closely with clients to address the specific demands of their haul road networks and site conditions.
Contact us on 1800 662 387. Or click here to request a consultation.
