An investigation into opportunities for improvement of surface mine haul road functional design, construction and maintenance

Abstract

Haul road pavement condition has long been considered as having a significant influence on the efficiency of haulage in surface mining. However limited literature exists relating wearing course condition with performance, resulting in mine operators not maximising the potential value of their haul road assets. This project focuses on defining current issues associated with the functional performance of haul roads, through a case study involving three iron ore mines in the Pilbara region of Western Australia. Consequently attempts are then made to relate material properties to performance so that existing criteria can be verified or refined. Cementitious stabilisation and naturally occurring gravels found adjacent to the mines involved in the case study are then trialled via laboratory testing, show promise and lead to a recommendation of subsequent field trials. Pavement lifetime costing is finally completed with the Pilbara environment as the basis, utilising the most appropriate models currently available for pavement condition and vehicle operating and maintenance costs. This resulted in a lack of variability due to material properties, with maintenance variables having a greater effect. Lastly it is found that potential production loss values (net reduction in ore hauled) outweigh expenditure on improved maintenance practice or even material treatments.