Mine Road Workshop 2011 Roger Thompson PDF

GSFM AnIntegratedApproachto
MineHaulRoadDesign
RogerThompson
WesternAustralianSchoolofMines
CurtinUniversity
www.mining.curtin.edu.au
AimofPresentation
GSFM fourcomponentsof
mineroaddesign
GSFMandrollingresistance
interactions
Whatdoesroaddesignand
constructioninvolve?
Geometric
Structural
Functional
Maintenance.Design
components
Introduction
Poorroaddesignimpacts
safety,trafficmanagement,&
costpertonne hauled.
Ideally,SHMS/SOP
specificationsshouldincludea
formalapproachtoroaddesign.
Butwhatshoulddesign
considerand;
Howisitspecified?
Howisconformance
monitored?
Engineering &Mining Journal, vol 210,n5 June 2009. Mining Media Ltd.
RollingResistance
Primarymeasureofmine
roadperformance isoften
basedonrollingresistance
Frequentlythebasisofa
costbenefitevaluation,
but
whatisrollingresistance
andhowisitgenerated?
RollingResistance
Rollingresistanceisthe
resistancetotruckmotion
duemostlyto:
Roaddeformationunder
thetyre,
Tyre penetrationintothe
road,
Tyre deformationeffects
ontheroadsurface.
Roaddeformationundertyre pressure
Tyre penetrationintotheroadsurface
Tyre deformationeffectsontheroadsurface
RollingResistance
RR
RR%
GR% (+ve against the load)

(-ve with the load)
Totalresistance%=RR% GR%
PracticalApplication
Ramps
1%RR
10%KPH
Surfaceroads
1%RR
26%KPH
RR
Effect of rolling resistance on truck speed
Base case rolling resistance (RR) = 2%
Ramps
1%RR
10%KPH
25
Percent reduction in speed
per 1% RR increase (%)
Surfaceroads
1%RR
26%KPH
GR%
20
15
10
5
0
0 1 2
3 4
Performance Chart
Liebherr T282B 4.32kW(net)/tonne GVM

50/80R63 Tyres and 37.33:1 Drive ratio
Grade (%)
of ro
Full truck
(GVM = 592 tonnes)
Empty truck
(EVM = 229 tonnes)
8
ad
9 10 11
12
1400
1300
20
Retard
1200
Propulsion (trolley)
18
1000
16
Rimpull (kN)
14
800
12
700
600
10
500
400
300
200
2
1
100
0
0
10
20
30
40
50
60
70
80
Speed (km/h)
Effective grade (UPHILL) %

= Grade % + rolling resistance%
Effective grade (DOWNHILL)% = Grade % rolling resistance%
90
3% to 4% RR
Effective Grade (%)
1100
900
2% to 3% RR
Propulsion
4% to 5% RR
Rear dump truck (electric drive) with 4,27kW/t GVM
HaulRoadDesign
Howdowedeveloparoad
designwhich;
Maximises safety
Maximises utilityof
environment(materialsand
equipment),and
Minimises rollingresistance
andtotalroaduserscosts?
HaulRoadDesign
Fromasafetyperspective;
Geometricdesign
Excessiveshearforcesand
truckinstability.
StructuralDesign Damage
totyre andchassis,truck
instability,missalignment.
FunctionalDesign wet
slipperiness,tractionand
skidresistance,dust.
MaintenanceDesign
runningsurface.
HaulRoadDesign
Fromarollingresistance
perspective,minimise;
deformationundertyre
StructuralDesign
penetrationandtyre
deformation Functional
Design
roaddeteriorationrate
MaintenanceDesign
ImprovingMineHaulRoads
15
0.6
10
0.5
0.4
0.3
-5
0.2
-10
0.1
-15
0
0
0.5
1.5
2.5
3.5
Arbitrary time (s)

Measured truck response
Actual road defect
Road defect height (m)
Acceleration (m/s 2)
Unsprung mass acceleration due to two 100mm road defects

374t GVM RDT
First,youneedtoknowwhat
iswrongbeforeyoucan
decidedtofixit.
0 0 0 0 .0 0
0 0 0 .0 0
0 0 0 .0 0
Truck path
start
Defect 0.05 to 0.10m
Realtimemonitoringcanbe
usedtorecordthetruckand
tyreresponsetotheroad,
andwhenlinkedwithGPS,
givesthefirstindicationof
WHEREandWHATthehaul
roadproblemsare.
Thecureisnotnecessarily
justmorefrequent
maintenance.
Noamountofmaintenance
willfixapoorlydesigned
road.Eachcomponentofthe
roadinfrastructuremustbe
correctlyaddressedatthe
designstage.
Investigatetherootcauseof
theunder performance
before decidingona
remediationstrategy.
Followanintegrated
approachtoroaddesign,
examineeachdesign
component.
BASIC HAUL ROAD

DESIGN DATA
GEOMETRIC DESIGN
GUIDELINES
STRUCTURAL DESIGN
GUIDELINES
MAINTENANCE
MANAGEMENT
GUIDELINES
IS PERFORMANCE
OPTIMUM
AND
DELIVERING
MINIMUM TOTAL
ROAD-USER
COSTS?
CHEMICAL
PALLIATION OR
WATER-BASED
SPRAYING
MODIFY WEARING
COURSE MATERIAL
FUNCTIONAL DESIGN
GUIDELINES
MOST COST EFFICIENT SOLUTION TO HAUL

ROAD DESIGN AND OPERATION
IntegratedRoadHaulDesign
BASIC HAUL ROAD
DESIGN DATA
GEOMETRIC DESIGN
GUIDELINES
STRUCTURAL DESIGN
GUIDELINES
MAINTENANCE
MANAGEMENT
GUIDELINES
IS PERFORMANCE
OPTIMUM
AND
DELIVERING
MINIMUM TOTAL
ROAD-USER
COSTS?
CHEMICAL
PALLIATION OR
WATER-BASED
SPRAYING
MODIFY WEARING
COURSE MATERIAL
MATERIAL
FUNCTIONAL DESIGN
GUIDELINES

GeometricDesign
IntegratedHaulRoadDesign
BASIC HAUL ROAD
DESIGN DATA
GEOMETRIC DESIGN
GUIDELINES
STRUCTURAL DESIGN
GUIDELINES
MAINTENANCE
MANAGEMENT
GUIDELINES
IS PERFORMANCE
OPTIMUM
AND
DELIVERING
MINIMUM TOTAL
ROAD-USER
COSTS?
CHEMICAL
PALLIATION OR
WATER-BASED
SPRAYING
MODIFY WEARING
COURSE MATERIAL
MATERIAL
FUNCTIONAL DESIGN
GUIDELINES

StructuralDesign
BASIC HAUL ROAD
DESIGN DATA
GEOMETRIC DESIGN
GUIDELINES
STRUCTURAL DESIGN
GUIDELINES
MAINTENANCE
MANAGEMENT
GUIDELINES
IS PERFORMANCE
OPTIMUM
AND
DELIVERING
MINIMUM TOTAL
ROAD-USER
COSTS?
CHEMICAL
PALLIATION OR
WATER-BASED
SPRAYING
MODIFY WEARING
COURSE MATERIAL
MATERIAL
FUNCTIONAL DESIGN
DESIGN
GUIDELINES

FunctionalDesign
BASIC HAUL ROAD
DESIGN DATA
GEOMETRIC DESIGN
GUIDELINES
STRUCTURAL DESIGN
GUIDELINES
MAINTENANCE
MANAGEMENT
GUIDELINES
IS PERFORMANCE
OPTIMUM
AND
DELIVERING
MINIMUM TOTAL
ROAD-USER
COSTS?
CHEMICAL
PALLIATION OR
WATER-BASED
SPRAYING
MODIFY WEARING
COURSE MATERIAL
MATERIAL
FUNCTIONAL DESIGN
GUIDELINES

Costs
Minimum total
cost solution
Max
Min
Maintenance frequency
Rolling resistance
Min
Max
GeometricDesign
Geometricdesign;
Determinestheroadlayout
oralignment,both
horizontallyandvertically.
Practically,weoftenneed
tocompromisebetweenan
ideallayoutandwhatmine
geometryandhauling
economicswillallow.
Establish start and end

points of road.
Feasible (mine plan) and

economic route (topography)
selection.
Optimise truck performance

against route grades and
speeds and construction
costs.
Check additional road

geometric requirements
against ALL roadroad-user
vehicles.
Design horizontal and

vertical alignments. Check
sight distances throughout.
Assess junction and

intersection layouts and
associated safety
components.
Check drainage requirements
with topographic contours in
vicinity of route.
Survey and peg the route

centre lines. Test soil
properties for Structural
Design phase
GeometricDesignVertical
Alignment
Alignmentoftheroadin;
Thevertical plane here

wedesignforsafeand
efficient;
Stoppingandsight
distances(howreliably
canwedeterminethese
values??),
Optimumrampgradients
andverticalcurve
transitions.
Alignment
Stoppingdistances;
Truckmanufacturersand
sitetestingshouldconfirm
thedistancesrequiredto
bringatrucktoastop
undervariousconditionsof
load(NBempty),speed,
gradeandtraction wet,
dry,wearingcourse(s).
Alignment
Sightdistances;precautions
shouldbeappliedwhensight
distancefallsbelowstopping
distance;
Benchedgeobstructionsrequire
laybacksorbatter,
Verticalcurves crestsoften
requireflatteningtoimprove
sightdistances,
Useaminimumverticalcurve
lengthof150mandradiusof
1500mfordesignwork.
Applyspeedlimits.
Alignment
Sightdistancesandmachine
factors;
Inadditiontosightdistances
alsoconsiderdriverblind
spots wherethedriverhas
limitedornosightofpartsof
theroad.
Final Report Blind Area Study Large Mining Equipment, Contract Report
200-2005-M-12695, CDC/NIOSH, USA, 2006.
GeometricDesignHorizontal
Alignment
Alignmentoftheroadinthe
horizontalplane herewe
designforsafeandefficient;
Roadwidth,
Curvatureandsuper
elevations,
Crownorcrossfall.
GeometricDesignHorizontalAlignment
Ramp
5
RampW
W5
Ramp
RampW
W44
50
m
m
50
Ramp
Ramp W3
W3
Ramp
1 (W)
Ramp W
W1
(W)
Ramp
Ramp W1
W 1 (E)
(E)
50m
50m
Main
Main haul
haul road
road
Alignment
Widthofroad;
Sufficientfortherequired
numberoflanes
(pavementwidth),and
shoulders(carriageway
width)andallthe
associatedsafetyand
drainagefeatures
(formationwidth).
3.5W why?Effectof
largervehicles.
Thewidestvehicles
proposeddeterminethe
pavementwidth.
TheTablesummarizesthese
designroadwaywidths.
Truck images courtesy Caterpillar Inc
Alignment
Curvesandswitchbacks;
Designedwiththe
maximumradiuspossible
andbekeptsmoothand
consistent.
Changesincurveradii
(compoundcurves)should
beavoided.Alargercurve
radiusallowsahighersafe
roadspeedandincreased
truckstability >200m
minimumradiusideal.
Superelevation;
Bankingappliedonthe
outsideofacurvetoallow
thetrucktomaintain
stabilityinthecurveat
speed.
Shouldnotexceed5%7%,
unlesshighspeedhaulageis
maintainedandthe
possibilityofsliding
minimizedbyusingmedian
berms tosplitsuper
elevations.ReferTable.
Alignment
Crossfall(usewithextreme
caution),crownorcamber;
Critical tothedesignand
successfuloperationof
mineroads.
Ensureswaterdoesnot
gatheronandpenetrate
intotheroadsurface.
Alignment
Crossslopeshouldbeused
withcaution,possibilityof
collisionincreasesorrunoff
benchedge.
Largedeflectionberms
shouldbeplacedattheroad
centerandedge.
Crossslopeeasierto
maintain.
Camber
(crown)
example
Center-line
2-3%
2-3%
Drain
Drain
Cross-slope
example
2-3%
Drain
GeometricDesign
Safetyberms;
A'crest'orroadedgeberm
willnoteffectivelystop
trucks(especiallyhigh
speedladenorunladen
trucks)fromleavingthe
road.
Atbest,theywillprovide
limiteddeflectionand
warningtothedriverthat
thetruckpathneeds
correcting.
GeometricDesign
Berm slopeshouldbeassteep
aspossible(1.5V:1Hideally),
butensurestabilityand
maintenanceofheight.
Section A-A
Outslope
Conventional berm
Median berm
Forlargehaultrucks,theberm
heightshouldbeatleast50%
66%ofthetruckwheel
diameter.
Steepberm sideaidsdeflection.
Flatterberms allowthetruckto
climb andoverturn.
Medianberms considertraffic
managementimplications.
Bench face
Section on A-A
Median berm
Downgrade unladen
Conventional berm
Height
Outslope
GeometricDesign
Alsoincludedinthe
geometricdesignisdrainage;
Nomatterhowgoodthe
design,waterwillalways
damageamineroad. Keep
waterOFFtheroads orat
theveryleastleadwater
offtheroadassoonas
possible.
Investigategeometry AND
localtopographicdrainage
patterns.
BASIC HAUL ROAD
DESIGN DATA
GEOMETRIC DESIGN
GUIDELINES
STRUCTURAL DESIGN
GUIDELINES
MAINTENANCE
MANAGEMENT
GUIDELINES
IS PERFORMANCE
OPTIMUM
AND
DELIVERING
MINIMUM TOTAL
ROAD-USER
COSTS?
CHEMICAL
PALLIATION OR
WATER-BASED
SPRAYING
MODIFY WEARING
COURSE MATERIAL
MATERIAL
FUNCTIONAL DESIGN
GUIDELINES

StructuralDesign
Structuraldesignrefersto
theloadcarryingcapacityof
theroad;
Betterpavementresponse
toappliedloads,
Reduceddeflectionon
surface,betterwearing
courseperformance
Eliminatedeformationin
subgradeorinsitu.
StructuralDesign
Twoapproaches;
Mechanisticdesign
approachusingpavement
layerlimitingverticalstrain
criteria&
CBRcovercurveapproach
usingpavementlayerCBR
values.
StructuralDesign Mechanistic
Mechanisticdesignapproach
usingpavementlayer
limitingverticalstrain
criteria;
Limitingstraincriteria
tailoredtotrafficvolumes,
typeandlifeofmineroad
(ramp,pitormainhaul).
Wearing course
Selected blasted
waste rock
(structural) layer
In-situ
The strains resulting from

the truck wheel loads
decrease with depth
except where these strain
fields overlap. Here, higher
strains are found and if
more than 2000 microstrains
the in-situ material is liable
to collapse leading to
structural failure.
Limiting pavement layer vertical compressive strain
values for mine haul road structural design
Haul Road Category

CategoryI
Permanentlifeofmine
highvolumemainhauling
roadsandrampsin and
expit.Operatinglife>20
years
CategoryII
Semipermanenthigh
volumeramproadsinpit.
Operatinglife>10years
CategoryIII
Semipermanentmedium
tolowvolumeinpitbench
access,expitdump,or
ramproads.Operatinglife
<5years(>50kt/day)or<10
years(<50kt/day)
Limiting microstrains
10000
Category III Haul Road
Category II Haul Road
Category I Haul Road
1000
100
0
40
80
120
160
200
240
280
Traffic volume (kt/day) x performance index
320
Maximum permissible vertical strains can also be

determined from (kt/day x performance index).
Where performance index is defined as;
1
Adequate but fairly maintenance intensive,
2
Good with normal maintenance interventions,
3
Outstanding with low maintenance requirements .
Whenabaselayerofselected
blastedwasterockisusedin
thestructure,amechanistic
approachismoreappropriate.
Theselectedwasterocklayeris
locatedunderthewearing
course,
Roadperformanceis
significantlyimproved,
primarilyduetotheload
carryingcapacityofthe
wasterocklayer.
Mechanistic
Designchart(examples)are
basedonafullyladenhaul
truck,atmaximumGVM,(tons)
withstandardradialtyres,
inflatedto800kPa.
Theroaddesignincorporates
200mmofsheetingwith
CBR=80%,aselectedblasted
wasterockbaselayer,builton
3mofinsitumaterialwiththe
indicatedEmodulusshownon
thecharts.
CAT789C Base Layer Thickness Design

800kPa tyre pressure, fully laden truck at OEM GVM
For limiting strains of 2000

1400
1200
Thickness (mm)
1000
Wearingcourse
200mm
E=350MPa
800
Baselayer
thickness
E=3000MPa
600
400
Insitu
Thickness
3000mm
200
0
10
100
Eeff Modulus
of In-situ(MPa)
material (MPa)
E Modulus
Category I
Category II
Category III
1000
CAT789C Base Layer Thickness Design

800kPa tyre pressure, fully laden truck at OEM GVM
For limiting strains of 2000

1400
Thickness (mm)
1200
1000
Wearingcourse
200mm
E=350MPa
800
Baselayer
thickness
E=3000MPa
600
400
Insitu
Thickness
3000mm
200
0
10
Eeff
100
Modulus
of In-situ(MPa)
material (MPa)
E Modulus
Category I
Category II
Category III
1000
StructuralDesign
CBRCoverCurve
CBRcovercurvedesign
approachusespavement
layerCBRvalues;
Thicknessofsuccessive
layersbasedonCBR
(strength)ofunderlying
layerandtruckwheelload
(tonnes).
CaliforniaBearingRatioCBR(%)
1
55
10
CoverThickness(mm)
40
25
15
500.0
1000.0
TruckTruckwheel
GVM(t)load(t)
1500.0
9015
150 25
240 40
320 55
390 65
450 75
510 85
570 95
630 105
2000.0
2500.0
3000.0
3500.0
4000.0
4500.0
CBR (%)
Modulus (Eeff)(MPa) . 10
14
21
.
100
0.0
28
35
41
55
8 . 10
69
20
104
40 60 80 100
138
207
276 345
.
414
Wearing course CBR 80%

Base CBR 55%
Sub-base CBR 30%
Compacted In-situ CBR 13%
In-situ CBR 7%
BASIC HAUL ROAD
DESIGN DATA
GEOMETRIC DESIGN
GUIDELINES
STRUCTURAL DESIGN
GUIDELINES
MAINTENANCE
MANAGEMENT
GUIDELINES
IS PERFORMANCE
OPTIMUM
AND
DELIVERING
MINIMUM TOTAL
ROAD-USER
COSTS?
CHEMICAL
PALLIATION OR
WATER-BASED
SPRAYING
MODIFY WEARING
COURSE MATERIAL
MATERIAL
FUNCTIONAL DESIGN
DESIGN
GUIDELINES

FunctionalDesign
Wearingcoursematerial
selection.Designfor;
Improvedtraction,skid
resistance,reduceddust,
Reducedrollingresistance
throughreducedwearing
coursedefects,
Reduceddeterioration
ratesandmaintenance
frequency.
Inthiscase thewearing
coursehastoomuchfine
materialanditformsa
slipperysoftlayeronthe
road.Carryover?
Here,thestonesinthemix or
aggregate istoobig thiscant
easilybegradedandifitis,the
largestoneswillcomeloose
seeding potholesanddamaging
trucktyres.
FunctionalDesign
Thisisprobablyagoodmixof
crushedrocktouse,everything
smallerthan40mminsizeand
nottoomuchfinematerial
(<20%smallerthan2mm).
Watchoutforsmoothround
alluvialaggregateinthemix.
Thiswillnoteasilyinterlock
andwillraveloutofthe
wearingcourse.
FunctionalDesign
Asmalljawcrushercanbeused
toprepareblastedrockasa
wearingcourseaggregate,
ofteninamixofoneormore
othermaterialstoformthe
finalproduct.
Itisalsousefulforcreatinga
fineaggregatefromwasterock
tobeplacedasadressingin
loadingareas toreducetyre
damageintheseareas.
FunctionalDesign
Reduceroadrolling
resistance through
reducedwearingcourse
defects &
Reduceroaddeterioration
ratesandmaintenance
frequency.
400
Shrinkage Product .
Correctwearingcourse
materialselectionwill;
Wearing Course Selection
350
300
Dustiness
250
Slippery w hen w et
200
150
100
Loose stones
Tyre damage
50
Loose material
Corrugates
0
0
10
15
20
25
30
35
40
45
50
Grading Coefficient
Recommended (1)
Recommended (2)
FunctionalDesign
Wearing Course Selection
Shrinkage Product .
400
350
300
Dustiness
250
Slippery w hen w et
200
150
100
Loose stones
Tyre damage
50
Corrugates
Loose material
0
0
10
15
20
25
30
35
40
45
50
Grading Coefficient
Recommended (1)
Recommended (2)
550
500
450
400
S h r in k a g e p ro d u c t
Wet skid resistance
Dustiness
350
300
250
200
150
100
Loose
stoniness
50
0
0
10
Loose material
2
1
Corrugations
20
30
Grading coefficient
Dry skid resistance

40
50
550
500
S h r in k a g e p ro d u c t
450
400
350
300
250
200
150
100
50
0
0
10
20
30
Grading coefficient
40
50
DustPalliatives
Dustiscausedthroughloss
offines,soconsider
specifically;
Wearingcoursematerial
selection;
Sizedistribution,clay
content,
Restraintoffines,
Trafficvolumes,
Climaticconditions.
DustPalliatives
Allsuppressionsystemsaim
tominimise erosivity ofthe
wearingcourse.Options
include;
Improvedwearingcourse
material,
Regularwatering,
Useofchemical
suppressants.
DustPalliatives
Chemicalpalliativesavailable
include;
Water/wettingagents,
Hygroscopicsalts,
Lignosulphonates,
Modifiedwaxes,
Polymers,
Tar/bitumenproducts,
Sulphonated oils,
Enzymes.
DustPalliatives
Useofchemicaldust
suppressants;
Shouldbeconsideredonlyas
anadjuncttoother
methods,
Chemicaldustsuppressants
havealimitedlifeandwill
requireregularapplications,
Variousgenerictypesto
choosefrom,basedmainly
onclimaticconditionsand
wearingsurfacematerial.
DustPalliatives
Trialachemicaldust
suppressantfirstbefore
makingafirm
commitment,
Carefulattentionshouldbe
giventowholeoflife
costingbeforeusinga
chemicaldustsuppressant.
DustPalliatives
Locality Data
Themostappropriate
selectionandmanagement
strategyshouldconsider;
Safetyandhealthbenefits,
Roadmanagement
philosophy,
Improvedcostefficiency.
Road, Climate, Wearing course parameters

Hours per day of dust control required
Equipment Data
Productivity and operating costs of road (re)-construction, maintenance and (spraying) equipment
Set Maximum Dust Defect Allowable
Palliative Data
Water Data
Cost ($/litre) and application rates

(establishment and rejuvenation)
Cost ($/kilo-liter) and application

rates (l/m 2)
Determine Cost of Establishment
Determine Cost of Rejuvenation (reapplication) and Interval
Determine Wearing Course

Maintenance Interval and Cost with
Palliative Applied
Determine Cost of Water-based

Spraying

Water-based Spraying
Summarise Annual Costs (Application and Road Maintenance)
Method selection
Locality Data
Road, Climate, Wearing course parameters
Hours per day of dust control required
Equipment Data
Productivity and operating costs of road (re)-construction, maintenance and (spraying) equipment
Set Maximum Dust Defect Allowable
Palliative Data
Water Data
Cost ($/litre) and application rates

(establishment and rejuvenation)
Cost ($/kilo-liter) and application

rates (l/m 2)
Determine Cost of Establishment
Determine Cost of Rejuvenation (reapplication) and Interval

Palliative Applied
Determine Cost of Water-based

Spraying

Water-based Spraying
Summarise Annual Costs (Application and Road Maintenance)
Method selection
BASIC HAUL ROAD
DESIGN DATA
GEOMETRIC DESIGN
GUIDELINES
STRUCTURAL DESIGN
GUIDELINES
MAINTENANCE
MANAGEMENT
GUIDELINES
IS PERFORMANCE
OPTIMUM
AND
DELIVERING
MINIMUM TOTAL
ROAD-USER
COSTS?
CHEMICAL
PALLIATION OR
WATER-BASED
SPRAYING
MODIFY WEARING
COURSE MATERIAL
MATERIAL
FUNCTIONAL DESIGN
GUIDELINES

MaintenanceManagement
Maintenancedesignand
management;
Routineroadmaintenance
asaresultofprogressive
wearingcourse
deterioration.
Asatisfactoryroaddesign
willrequireminimum
maintenance.
Toofrequent
maintenance?Review
designdatatofindrootof
problem.
Costs
Minimum total
cost solution
LOW VOLUME
SURFACE
ROADS
Costs
Minimum total
cost solution
Max
Min
Rolling resistance
Min
Max
Minimum
total
cost solution
- RAMPS
Costs
Max
Min
Rolling resistance
Min
Max
Max
Min
Rolling resistance
Min
Max
Percent change
Percentage increase in total road-user costs with

maintenance interval
40
35
30
25
20
15
10
5
0
0
Days between maintenance
B02
B03
B05
S Ramp
B04
10
PracticalApplications
Whyisthesegment
maintenanceintensive?
Poordesignand/orbuild
specs;
Geometrics,
Structure(layerworks
andmaterials),
Functional(wearing
course surfacing
materials).
BenchmarkingRolling
Resistance
Roadperformance
evaluation,
Usedefectdegreeand
extenttodetermineRR%.
Defect extent
% road area
effected
Extent
score
<5
Intermittent
6-15
Regular
16-30
Frequent
31-60
Extensive
>60
Not seen or isolated only
Defect
Potholes
Corrugations
Rutting
Loose material
Stones - fixed
Degree Extent Degree

(1-5)
(1-5)
x
Extent
5
3
3
5
5
1
3
5
2
2
Total score
5
9
15
10
10
49
3,25%
49
Percent change
Percentage increase in total road-user costs with

maintenance interval
40
35
30
25
20
15
10
5
0
0
Days between maintenance
B02
B03
B05
S Ramp
B04
10
Resources
Formoreinformationonissuedraisedtoday;
http://mining.curtin.edu.au/people clickonRJTfor
furtherlinkstohaulroadpublications
www.edumine.com searchforhaulroaddesignand
construction Uni BritishColumbiaandABET/ISO/IACET
accreditedselfstudycourse.
www.smartmines.com/mhroad/guidelines.pdf haul
roaddesignguidelines(2000)forOilSandsMines
(AlbertaCanada).
Resources
www.cdc.gov/niosh/mining/pubs searchfor
IC8758.pdf 1977USBMhaulroaddesignguidelines
www.mhsa.gov/readroom/handbook searchforph99I
4.pdfdesignandauditguidelinesformineroads
SMEMiningEngineering
www.smenet.org
Handbook,ThirdEdition,2011,Ch10MineHaulRoads
Copyofpresentationandfullsupportingnotesavailable
throughDEEDIMinesSafetyandHealthwebsite.

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GSFM AnIntegratedApproachto

GR% (+ve against the load)

Liebherr T282B 4.32kW(net)/tonne GVM

Effective grade (UPHILL) %

Rear dump truck (electric drive) with 4,27kW/t GVM

Arbitrary time (s)

Actual road defect

Road defect height (m)

Unsprung mass acceleration due to two 100mm road defects

Defect 0.11 to 0.20m

Defect 0.21 to 0.30m

Defect 0.31 to 0.40m

Defect 0.41 to 0.50m

BASIC HAUL ROAD

MOST COST EFFICIENT SOLUTION TO HAUL

MOST COST EFFICIENT SOLUTION TO HAUL

MOST COST EFFICIENT SOLUTION TO HAUL

MOST COST EFFICIENT SOLUTION TO HAUL

MOST COST EFFICIENT SOLUTION TO HAUL

Establish start and end

Feasible (mine plan) and

Optimise truck performance

Check additional road

Design horizontal and

Assess junction and

Survey and peg the route

Thevertical plane here

Truck images courtesy Caterpillar Inc

MOST COST EFFICIENT SOLUTION TO HAUL

The strains resulting from

Haul Road Category

Traffic volume (kt/day) x performance index

Maximum permissible vertical strains can also be

CAT789C Base Layer Thickness Design

For limiting strains of 2000

CAT789C Base Layer Thickness Design

For limiting strains of 2000

Wearing course CBR 80%

MOST COST EFFICIENT SOLUTION TO HAUL

Wearing Course Selection

Wet skid resistance

Dry skid resistance

Road, Climate, Wearing course parameters

Set Maximum Dust Defect Allowable

Cost ($/litre) and application rates

Cost ($/kilo-liter) and application

Determine Cost of Establishment

Determine Cost of Rejuvenation (reapplication) and Interval

Determine Wearing Course

Determine Cost of Water-based

Determine Wearing Course

Summarise Annual Costs (Application and Road Maintenance)

Set Maximum Dust Defect Allowable

Cost ($/litre) and application rates

Cost ($/kilo-liter) and application

Determine Cost of Establishment

Determine Cost of Rejuvenation (reapplication) and Interval

Determine Wearing Course

Determine Cost of Water-based

Determine Wearing Course

Summarise Annual Costs (Application and Road Maintenance)

MOST COST EFFICIENT SOLUTION TO HAUL

Percentage increase in total road-user costs with