An introduction to the integrated design of surface mine haul roads

Abstract

The world-wide expansion of surface mining has led to the development of very large off-highway trucks currently capable of hauling payloads in excess of 160t. Typical axle loads ranging from 110 to 170t are applied to haul roads that have been, at best, empirically designed on the premise of “satisfactory” or “failed”, both in terms of structure and function of the road. The use of these empirical pavement design techniques will prove inadequate when high axle loads are encountered. Not only will the maintenance costs of existing haul roads of inadequate thickness increase, but vehicle operating and maintenance costs will also increase prohibitively. Under these conditions there is thus a clearly defined need for improved construction and management techniques for flexible mine haul roads, appropriate for the wheel loads of vehicles now in use. The aim of this paper is to introduce developments in haul road structural, functional and maintenance design and management which overcome the limitations associated with the previously empirical design techniques and to show how these developments are combined into an integrated design strategy combining construction techniques, available material and road maintenance equipment with hauler choice to realise a reduction in haulage and road maintenance costs. Future contributions will enumerate on the fundamental haul road structural, functional and maintenance design and management research from which these developments originated