Fuel & CO2

Water & Dust

Machinery & Costs
Reduce all of the above with a

simple change to operating procedures

How? - Smarter Ground Improvement

Before

After
SEALS Group - Reduce Your Costs

Major benefits of stabilising haul roads

✓ Less fuel consumption and tyre wear

✓ Less road maintenance and dust
✓ Less water consumption
✓ Lower CO2 emissions
 Improving Ground - With PolyCom Stabilising Aid

Improved sub-grade benefits

✓ Improved sub-grade extends pavement life
✓ PolyCom improved sub-grade delivers a high degree of weather immunity
✓ Improving sub-grades means designed pavement thicknesses can be reduced
✓ Sub-grade strengthening saves on natural resources, significantly lowers project costs

Improved wear courses benefits

✓ Stabilised wear course reduces road deformation and displacement
✓ Stabilised road surfaces ensure much easier dust control
✓ Lower quality materials may be utilised for wear courses
✓ Improved wear courses mean much less maintenance and stoppages after rain

It’s about improving and preserving the dry strength of the available material
 Sub-grade Improvement - PolyCom

Stronger more consistent sub-grades

• Water resistance - internally and externally

• Workability to material previously cut to spoil
• Remediates dispersive soils
• Reduces the requirement for capping materials
• More economical pavement designs
• Significantly reduces project costs
• Extends pavement life
 Wear Course Improvement - PolyCom

Same equipment and methodology

• Stabilised in-situ material that is re-workable
delivers increased strength and flexibility
• Less maintenance and easier dust control
• Less downtime after rain events
• Smoother running surface
• Reduces road deformation and displacement
Mining & Gas - Clients and projects

Queensland Gas - Road stabilisation and dust control of main office and gas plant
Natural ground construction of drill access roads
Natural ground construction of seismic pad
Origin Energy - Sub-grade stabilisation for gas plant & R.O plant construction
BMA Crinum Mine - Stabilisation of heavy equipment lay down area
Minerva Mine - Haul road stabilisation and ongoing dust control
Southern and Northern haul roads
Wksp area and access roads
Jellinbah Coal - Haul road stabilisation and ongoing dust control
Stabilisation and dust control of Haul roads ‘A’ and ‘F’
Deep compaction stabilisation to haul roads ‘A’, ‘B’ and ‘F’
Kestrel Coal - Stabilisation and dust control of all surface roads
Stabilisation of underground roads
BHP Cannington - Stabilisation and ongoing dust control of the main decline
BMA Blackwater - Capping and stabilisation of go lines and shut down pad
New Hope Coal - Acland - Stabilisation of roads and coal pad at train load out
Yarrabee Coal - Upgrade and stabilisation of road train haul road shoulders
Stabilisation of gravel work areas
Xstrata Copper - Dust control of the main decline
 Validation Example - Jellinbah Mine

Validation of improved road

performance

• Dynamic modulus of haul road running surface

Dynamic Modulus measured using Light Weight Deflectometer

Test (LWDT) indicates a considerable improvement following
HIEDYC™ Compaction and PolyCom Stabilisation. The
comparison of mean dynamic modulus before and after ground
treatment (compaction and stabilisation) is provided below. LWDT Results
Running Surface Compaction and Stabilisation Project, Jellinbah Mining Limited
Seals Group and Infra Tech
Road dynamic modulus results before and after Ground Note:
Dimensions relating to road and

Treatment
bern width are nominal values
Haul Road Direction of truck

Test Location 2 To dump

15m
Status of running surface Test Location 1

Mean dynamic modulus (MPa)

22 21 20 19 18 17 16 15 14 13

12m
Centre berm
1 2 3 4 5 6 7 8 9 10 11 12

In as presented status (prior to ground treatment) Keep Left sign

10m 5m
Test Location 1

38.8 To mine
Test Location 2

Following the ground treatment Reference Line

Haul Road Direction of truck
Distance X

69.0
(via Keep Left sign)

Test point Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

The results relating to the road that underwent the complete

Distance X 47.4 463.8 506.4 550.0 594.0 638.0 681.6 723.0 764.6 805.7 848.0 890.0 903.0 803.0 703.0 603.0 503.0 403.0 303.0 203.0 103.0 3.0

LWDT Results - Test Location 1

41.8 49.4 33.9 38.8 41.9 30.9 30.1 32.0 41.3 51.7 28.4 47.6 31.3 42.4 30.7 42.9 37.8 19.7 44.3 47.1 45.9 45.4
(Prior to Treatment)

ground treatment (HIEDYC™ Compaction and PolyCom LWDT Results - Test Location 1
(After Treatment)
80.9 104.5 104.2 86.4 74.2 59.9 66.6 86.1 49.9 78.9 40.2 68.0 73.0 75.6 58.8 91.2 70.2 73.1 59.9 63.3 59.2 77.7

Stabilisation) shows an increase in the dynamic modulus of LWDT Results - Test Location 2
(Prior to Treatment)
45.4 38.1 37.8 41.0 39.0 31.9 29.1 36.4 34.6 39.9 30.4 70.6 32.5 32.1 31.3 51.9 37.9 29.8 45.0 39.3 37.9 38.1

78%. LWDT Results - Test Location 2

(After Treatment)
62.5 72.2 73.5 72.3 67.5 61.3 50.0 95.3 29.3 54.9 47.3 78.5 74.0 73.2 69.9 84.4 74.4 60.3 60.8 60.1 50.2 62.2
 Validation Example - Jellinbah Mine

Validation of rolling resistance improvement

• Haul road rolling resistance

Rolling resistance is one of the major components of the total resistance against
truck movement.

Main components of the resistance to truck movement are;

1. Resistance due to grade (grade resistance) – (RG)
2. Rolling resistance (acting on truck tyres from the running surface) – (RR)
3. Resistance of transmission components when on neutral – (RT)
4. Wind resistance – (RW)

Above 1 and 4 are negligible with level surface and low wind speeds, while above 3
is considered to be similar for both pre and post ground improvement situations.
Considering RR to be the significant component, the calculated resistance against
truck movement was considered as rolling resistance.

The results of calculated parameters are shown below.

Pre Compaction and Stabilisation

R - Total Resistance (kN) 79.1850
Coefficient of Friction of Running Surface (µ) 0.260

Post Compaction and Stabilisation

R - Total Resistance (kN) 67.4958
Coefficient of Friction of Running Surface (µ) - 0.221

This is a 15% reduction in resistance against truck movement (approximated to rolling

resistance).
 Diesel & CO2

Rolling resistance improvements of 15% as shown are substantial and equate to a

diesel saving of 4-6% for haul traffic - This is considerable in yearly budget
terms as truck haulage costs can account for up to 50% of total operating costs

An equivalent saving in CO2 emissions is also realised and this is possibly a more
meaningful result given the climate debate. A 4-6% CO2 reduction for haul road
traffic is considerable as this traffic accounts for a sizeable percentage of mine
emissions

For every litre of combusted diesel there are 2.7Kg of CO2 produced and an additional
0.783Kg of CO2 is produced in the manufacture of every litre of that diesel

A typical haul truck will burn approx 300,000 litres of fuel a year so a saving of 5% in
fuel and also CO2 emissions equates to a net yearly CO2 saving of 52,245Kg for each
truck. This is substantial and measurable
Water & Dust

Typically, PolyCom stabilisation in the construction stage realises a 30-50% water

saving compared to neat water and more when compared to older stabilisation
techniques

Follow on water savings are realised as future maintenance requirements are

reduced

Still further savings can be achieved if the treated area is managed for reduced
dust emissions thus delivering extended wear course durability and considerable
reductions in water usage for dust control (as much as 90%)

Roads and work areas managed properly for dust control are cost negative
 Machinery & Costs

Standard construction plant can be utilised for 90% of the ground improvement
work requirements eliminating the need for complicated and expensive stabilising
machines and spreader trucks

Improvement of in-situ material means less trucking of material to site and less
machinery on site for removal and replacement or capping tasks

Stronger and more durable roads and work area require less machinery less often
for maintenance work and less trucks for watering of roads

All of the above equate to cost savings in machinery and fuel

Dollar value of fuel savings of 5% per haul truck based on rolling resistance reductions
$16,500/annum - at a fuel price of $1.10/litre
SEALS Group - Client Site Assistance

Site assessment including roads, ramps, pits, dumps and access areas

Recommendations on construction material efficiencies

On site management and overseeing of all ground improvement work

Validation of all work including strength and rolling resistance improvements

Road grading, maintenance and watering action plan

Delivery of instruction and information lectures to relevant personal including best

practice road shape and grading techniques, watering techniques and general
information fully explaining how and why these methods work
 Summary

SEALS Group will deliver improved strength and water resistance to roads and wear
courses

We will deliver measurable and provable reductions in diesel use, CO2 emissions, water
use and dust emissions

Additional improvements to operator conditions, tyre wear, chassis and engine damage
are follow-ons from vastly improved roads and management of these areas

PolyCom stabilising aid is not magic but it’s a very handy tool. It’s use coupled with good
old fashioned know how and the education of operators and key staff provides a further
‘small step’ advancement which goes a long way to improving how we do things -
financially, socially and environmentally

Thank you for you time

For Further Information

SEALS Group
P.O.BOX 525
BEAUDESERT
QLD, 4285
Australia
P. +61 7 5543 1053
Ops Manager 0422 020 385
info@sealsgroup.com
www.sealsgroup.com