In the mining industry, the efficiency of haul cycles is a pivotal factor for increasing production. Solutions for improving the quality of haul roads will not only result in maximised output, but also lead to reduced maintenance costs and downtime, while increasing safety.

This article delves into strategies that mining operations can adopt to enhance haul cycle times, focusing on optimising haul road design, road stabilisation, and utilising road binders for dust control purposes.

The Importance of Correct Haul Road Design

 Careful planning and engineering are essential in designing haul roads to guarantee fast cycle times. As outlined in our Haul Road Construction eBook, the most effective strategy is to design and construct haul roads correctly from the outset.

 At Dust-A-Side Australia, we understand that the foundation of a productive mining operation lies in the quality of its haul roads. Poorly designed roads lead to increased wear and tear on vehicles, higher fuel consumption, and frequent maintenance interruptions. By focusing on proper road design, we help mining operations achieve smoother, safer, and more efficient haul cycles.

A well-designed haul road includes factors such as optimal gradient, appropriate width, and effective drainage. By incorporating these elements, we ensure that haul roads can withstand the heavy loads and high traffic typical of mining sites. Our approach results in reduced vehicle strain, lower operational costs, and improved overall productivity.

For instance, our work with a fleet of 48 Komatsu 930E haul trucks demonstrated a 15.5% improvement in tyre life over a 24-month period. This enhancement in tyre longevity is just one aspect of the overall productivity gains achieved through proper haul road management, which also includes:

• Up to 75% reduction in the water cart fleet
• Up to 70% reduction in grading
• Increased electric motor life by up to 2.5 times
• Reduced downtime
  

Boosting Production Through Road Stabilisation

Enhancing haul road quality is a strategic move necessary to increase production efficiency. While the high cost of replacing haul road tyres—comparable in price to a luxury vehicle—impacts operational expenditures, superior road conditions directly boost production levels.

Dust-A-Side Australia has pioneered the use of a stabilised running surface, comprising a 50-75mm bonded wearing course with a bitumen seal layer utilising our bitumen emulsion solution, DAS Product. This innovation minimises the loss of fines and prevents water ingress, ensuring a less abrasive haul road surface. Robust data supports our approach, with a notable 37% decrease in the International Roughness Index (IRI) within two months of implementing our techniques. This improvement in road smoothness translates to faster and more efficient haul cycles, enabling higher productivity.

Furthermore, a 32-week study revealed that a haul road treated with our DAS Product registered a Roughness Defect Score (RDS) about one-third of those recorded on untreated roads. This dramatic reduction in road defects means fewer interruptions for maintenance and more time spent hauling.

By focusing on creating more durable and less abrasive haul roads, Dust-A-Side Australia extends the lifespan of critical equipment like tyres and enhances overall mining operation efficiency. This strategic focus on road quality leads to uninterrupted production cycles, showcasing that efficient haul road management is a cornerstone of increased mining productivity.

Minimising Downtime by Reducing Water on Haul Roads with Road Binders

Haul roads require constant watering to suppress wheel-generated dust. However, reducing water on haul roads is critical to improving production, as wet conditions can lead to increased wheel slip, decreased traction, and more frequent tyre damage due to the softening of rubber and enhanced cutting action from rocks.

Dust-A-Side Australia’s range of dust binder products ensures that haul roads stay drier and more stable, leading to operational excellence, faster production, and increased revenue. These binders work by binding dust particles together on the road surface. Sprayed via the water cart, the water evaporates leaving the solid content of the product behind as it dries. This binds the soil particles together, sealing them onto the road surface.

Supplied in a liquid form, our range includes treatments such as lignosulphonate-based binders, bitumen emulsions, and synthetic polymers. These formulations are much more effective at suppressing dust than plain water and can reduce water usage by up to 90%.

Without constant over-watering, the haul road network becomes sturdier, requiring less maintenance. This equates to fewer interruptions and more frequent and faster haul cycles. The cost saving for the mine on grading, general surface repairs, and road re-sheeting can be substantial.

Creating a stronger road network enables the mine to reduce its fleet size of water carts, even redeploying water cart operators to perform other, more high-yielding activities.

Additional Operational Benefits

Efficient haul road management extends beyond direct tyre and water savings. It encompasses broader operational improvements such as:

• Extended strut and suspension life
• Enhanced braking efficiency and brake life
• Reduced road maintenance and rebuild frequency
• Decreased operator fatigue and injury risk
• Elimination of the need for 4WD in certain conditions
• Improved drainage, allowing for continued work during wet conditions and quicker restarts after rain
• Longer life for equipment parts and consumables

By adopting Dust-A-Side Australia’s comprehensive haul road solutions, mining operations can experience significant improvements in productivity, safety, and cost-efficiency. Our commitment to innovative road management practices ensures that our clients achieve optimal performance from their haul roads, driving success in the mining industry.

Contact Dust-A-Side Australia to Learn About Trialling Our Solutions

If poor cycle times are an ongoing issue at your site, the team at Dust-A-Side Australia can help. Click here to request a no obligation sales call or technical consultation.