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Tag: Road stabilisation

New research shows why dust reduction alone isn’t enough to evaluate dust suppressants

Written by Janet Reznicek on . Posted in Article.

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Researchers compared conventional and bio-based dust suppressants using two haul road materials from an operating iron ore mine in Western Australia’s Pilbara region. In controlled wind-tunnel testing, every commercial suppressant tested reduced airborne particulates by more than 99% compared with untreated soil.

The differences were clear when comparing how the treated materials performed under other stresses that matter on a haul road: abrasion, mechanical strength and exposure to water.

One finding was particularly significant. Abrasion resistance correlated with dust suppression performance, while indirect tensile strength did not.

The results suggest that mines evaluating dust suppression technologies need to look beyond how much dust a treatment initially suppresses and consider how well the road resists processes that cause dust to return.

Haul roads are under constant mechanical stress

Heavy haul traffic continually wears and displaces material at the road surface, while rainfall and runoff can weaken or erode the treated layer.

To understand how these different stresses affect dust suppression, Bind-X researchers developed a testing regime that assessed four characteristics: dust emission, abrasion resistance, indirect tensile strength and water erosion stability.

The research, presented as part of the proceedings at the 2026 Resource Operators Conference organised by the University of Wollongong, University of Southern Queensland and University of Queensland and published in the paper Bio-Based Dust Suppression for Haul Roads in an Arid Australian Iron Ore Mine, tested two Pilbara haul road materials with different characteristics: a sandy clay and a clayey loam.

Three bio-based treatments — Terrabind Select, Terrabind Max and Terrabind Ultimate — were compared with conventional treatments including bitumen emulsion, acrylic co-polymer emulsion and lignosulfonate, with water used as a control.

The objective was to compare treatment performance and determine which characteristics provide the most useful indication of dust suppression performance.

Dust suppression results alone didn’t tell the full story

To measure dust emissions, the researchers placed treated soil samples in a wind tunnel and exposed them to controlled wind speeds while measuring airborne particle counts across different size fractions.

All commercial treatments reduced airborne particulates by more than 99% relative to untreated soil across all measured particle-size fractions, including PM10 and finer particles.

There were still differences. Terrabind Select, Max and Ultimate reduced measured dust to background levels, while detectable particles remained with polymer, lignin and bitumen treatments, particularly among the finer particle sizes.

But the results also highlighted the limitations of assessing a treatment on dust emissions alone.

A treatment can suppress dust while the surface is intact. The question is whether that performance holds once the surface is repeatedly subjected to haul traffic.

Abrasion resistance provided a clearer indicator of dust performance

To investigate this, the researchers subjected treated samples to mechanical abrasion using a rotating-brush testing system capable of simulating loads corresponding to a 700-tonne haul truck.

Here, the differences were more pronounced.

Untreated and water-treated samples lost several grams of material during the test. Lignin, bitumen and polymer treatments reduced that loss, while Terrabind Select, Max and Ultimate recorded less than 0.1 g of material loss.

When researchers compared the abrasion results with airborne particle counts, lower abrasion correlated with lower dust generation.

That relationship matters because abrasion continually creates new loose material at the road surface. Even if a treatment initially suppresses dust, its effectiveness can deteriorate if traffic breaks apart the treated surface and exposes material that can become airborne.

Among the characteristics assessed in the study, abrasion resistance was the best predictor of dust suppression performance.

A stronger surface didn’t necessarily mean better dust suppression

The researchers also measured indirect tensile strength (ITS) to assess the breaking strength of the treated material.

Most treatments increased breaking strength relative to untreated material. But unlike abrasion resistance, ITS did not show a clear relationship with dust suppression. Treatments with similar breaking strength could produce different dust results.

A hardened surface is necessary for dust resistance, but hardness alone does not determine how that surface will behave under mechanical stress.

Layer thickness and cohesion are also important. A treatment may produce a firm surface layer that suppresses dust while intact. But if that layer is thin and susceptible to mechanical damage, cracking can expose loose material underneath and allow dust generation to resume.

The researchers point to previous work with lignosulfonate, where a hardened but thin layer provided dust suppression until it was subjected to mechanical stress.

For a haul road, retaining that structure under traffic is therefore as important as its initial strength.

Wet stability exposed another difference between treatments

The study also assessed whether the treated materials could retain their structure when exposed to water.

Build-in specimens were subjected to 45 minutes of simulated heavy rainfall and runoff, corresponding to water exposure of 10,000 L/m².

Terrabind Ultimate and bitumen emulsion were the only treatments that remained fully intact on both haul road materials.

Terrabind Select and Max provided moderate resistance on the clayey loam, while polymer and lignin showed limited resistance. On the sandy clay, only Terrabind Ultimate and bitumen demonstrated water resistance.

The results show why dry performance alone is not enough to assess a treatment intended for roads that may also experience intense rainfall.

The road material itself also affects performance

The differences between the two soils reinforce another point: dust suppressant performance cannot be considered independently of the material being treated.

The research identifies a range of interacting factors that can influence performance, including soil density and porosity, particle-size distribution, compaction energy, liquid and plastic limits, chemical composition, moisture content, water adsorption, temperature and humidity.

That makes it difficult to take the performance of a treatment on one material and assume the same result elsewhere.

This is particularly relevant when comparing products based on headline performance figures. The conditions under which those figures were produced — and how closely they reflect the road where the product will actually be used — matter.

So what does this mean for mine operators?

There is no single measure that can fully characterise dust suppression performance.

Dust reduction is fundamental, but the Bind-X results suggest mines should also consider whether the treated material can resist abrasion under traffic, maintain sufficient cohesion under mechanical stress, withstand the rainfall and runoff expected at the site, and perform with the specific road material being treated.

Of the characteristics investigated in this study, abrasion resistance showed the clearest relationship with dust suppression performance. The authors report that this relationship has also been observed across several additional soils outside the scope of the study.

Evaluate what happens after the dust has been suppressed

The research points to a broader lesson for mines evaluating dust suppression technologies.

All commercial treatments tested reduced airborne particulates by more than 99%. Yet abrasion, strength and water erosion testing revealed important differences in how those treated materials behaved under stress.

A headline dust reduction figure therefore only tells you how well a treatment performs against one measure.

The more useful evaluation is whether the treated road can maintain that performance under the traffic, road material and environmental conditions it will encounter in operation.

For mines comparing dust suppression technologies, that means looking beyond how much dust a treatment stops initially and assessing how well it keeps the road intact afterwards.

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Why haul roads lose wet stability and what to do about it.

Written by Janet Reznicek on . Posted in Article.

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This article explains why haul roads lose wet stability, where problems usually appear first, and what mines should consider when choosing a stabilisation approach that holds up after rain.

Why haul roads lose wet stability

A wet-stable road should hold firm after rain. It should resist rutting, deformation and washout, and remain trafficable with minimal recovery work before trucks can move safely again.

“One thing I would say confidently is that wet stability is a real test of whether a road treatment is doing its job,” says Julian Musgrave, Head of Business Development Australia at Bind-X.

A haul road can look strong in dry conditions, but rain shows whether that strength remains when the surface is under moisture and load.

Rain affects a mining haul road in two ways: through the immediate condition of the surface and through the longer-term structural integrity of the pavement. The structural effects are often much more significant, and more expensive, than the visible mud and potholes.

Most mine haul roads are unsealed granular pavements. Their strength depends heavily on maintaining the right moisture content. When too much water enters the pavement, it changes how the aggregate, base and subgrade respond under heavy truck loads.

“Sometimes a stabilising product is not suited to the site material. Sometimes the product loading is too low. Sometimes the treatment depth is too shallow for the truck fleet, traffic volume or expected rainfall,” says Julian.

Drainage also plays a major role. If water sits on the road, runs too fast across the surface, or concentrates in low points, it increases the chance of softening, washout and deformation.

Effective stabilisation depends on good road design, drainage, maintenance, material compatibility, treatment depth and whether the stabilised layer has been designed for the loads and moisture conditions it will face.

Surface symptoms of wet instability

On an untreated haul road, the first changes are usually visible at the surface. Friction decreases, reducing tyre grip and increasing stopping distances. Water collects in depressions and wheel tracks, while saturated fines turn the wearing course soft or muddy.

Truck speeds may then be reduced for safety, immediately affecting productivity. Puddles, shallow rutting and potholes can also indicate that water is beginning to enter the pavement and affect the layers beneath it.

This is where the structural damage occurs

When water fills the voids between aggregate particles, friction between aggregate particles decreases. The pavement loses bearing capacity and becomes less able to support haul truck loads. Each wheel pass creates greater pavement deflection, which accelerates the loss of shape and strength.

Rainwater can also infiltrate through the wearing course and enter the base and subgrade. Saturation can dramatically reduce the strength of fine-grained materials, resulting in localised road failures, deep wheel tracks and rutting.

Another common failure mechanism on heavily trafficked haul roads is pumping. Repeated truck loads force trapped water upwards through the pavement. Fine material migrates towards the surface, progressively weakening the pavement structure and making the road rougher.

Flowing water creates a different type of damage. It removes fines and aggregate from the road surface and drainage system. Crowns, crossfalls, batters and ditch lines can deteriorate, while severe storms may wash out entire sections of road.

These failures are more difficult to correct than surface mud or isolated potholes because the road has not only lost its shape. It has begun to lose the structure that supports the fleet.

High-stress areas fail first

Not all sections of haul road cause the same level of stress. Julian explains that corners can be problem areas to maintain because trucks continually push material sideways when they turn. Over time, this creates rutting, channel formation and surface deformation, increasing the internal stresses on the tyres. Wet stability problems usually show up first where trucks place the greatest load, movement and shear force into the surface: corners, ramps, intersections, braking zones and loading areas. Corners are especially difficult. As trucks turn, they push road material sideways. If the surface has softened after rain, that force can quickly create rutting and channel formation.

“If I was designing a haul road treatment program, I would generally treat corners more aggressively than straight sections, because they’re often the first areas to go,” Julian shares.

Autonomous fleets can amplify this effect. While autonomous trucks vary their path slightly on straight sections, they tend to follow very similar lines through corners. The same sections of road receive repeated loading, which accelerates wear in concentrated areas.

The result is a surface that becomes progressively rougher and more difficult to maintain. Those localised defects might seem minor at first, but they create exactly the conditions that increase tyre flex, add additional abrasive material onto the road surface, generate heat, and shorten tyre life.

Once those sections lose stability, traction becomes harder to manage. Wheel spin is more likely, especially on ramps and corners. The tyre grinds against the softened surface, displacing more material and increasing deformation under load.

“Once one truck starts slipping, the whole fleet stops. Everything pauses until they can either grade the road or improve the conditions enough for the trucks to operate safely again.”

Wet roads increase rolling resistance

Even when the road remains passable, wet conditions affect haul truck performance. Tyres sink deeper into the softened surface, increasing rolling resistance and the amount of energy required to keep the truck moving.

As rolling resistance rises, fuel consumption increases and cycle times become longer. Tyre temperatures and wear can also potentially increase, while roughness, rutting and potholes place greater loads on truck suspension and structural components.

A useful rule of thumb in mining is that water almost always translates into higher rolling resistance. Rolling resistance then becomes a direct productivity and cost penalty across the fleet.

Grading can restore shape, but not always strength

After a rain event, the usual response is to send the grader through.

That may make the road look serviceable again and trucks can return to the route. But grading does not always restore the strength of the treated layer.

If the stabilisation has softened, washed out or failed to hold the road material together, the surface may look repaired while still being weak. Once haulage resumes, the same section can deteriorate again.

Julian has described this issue in relation to haul road maintenance more broadly: crews often restore the shape of the road without rebuilding the integrity of the road. That distinction matters after rain.

Where water has reduced bearing capacity, softened the subgrade or caused fines to migrate through the pavement, regrading the wearing course alone does not address the underlying failure.

Why good drainage is key

The biggest determinant of wet-weather road performance is often drainage, rather than road thickness alone. A well-built road must be able to shed water quickly before it infiltrates the pavement or remains trapped under repeated truck loads.

This requires an appropriate crossfall, adequate table drains and functioning culverts/drains, supported by a properly treated and compacted wearing course. A crossfall of approximately 2-4% may be used to help move water away from the running surface, depending on the road design and site requirements.

Where the drainage system is working effectively, the road can shed water and may recover within hours. Poorly drained, untreated roads retain moisture, soften and rut, and may require extensive regrading or rehabilitation before normal haulage can resume.

Drainage features also need to remain functional during the rain event. If table drains, culverts or crossfalls are blocked, damaged or poorly maintained, water will either find another path across or through the road or build up on the road.

Stabilise for wet performance

The answer is to stabilise the road properly for the conditions it will face. That means selecting a stabilisation method that suits the road material, rainfall exposure, drainage conditions, truck fleet, traffic volume and haul road geometry.

Designing haul roads for wet-weather performance

A uniform application across the whole road may not be enough. Straight sections, corners, ramps and intersections experience different forces. They may need different treatment depths, product, product loadings or construction methods.

In the past, a site might have looked to options like bitumen emulsion for high-strength haul road stabilisation. These products can be effective, particularly where the treatment area is limited and long-lasting surface strength is the priority. But product selection is changing.

Sites are now looking more closely at environmental performance, clean-up requirements, rehabilitation obligations and the full life cycle of the treatment, not just whether it can bind the road.

For Julian, today his preference would be a clean biological stabilisation method that can deliver the required strength, while also performing under wet conditions. The aim is to build strength into the road structure without creating unnecessary environmental or operational issues later.

This is how he would approach a road designed for heavy mining traffic. “If I was using Terrabind Ultimate, I might stabilise straight sections to a depth of 150 millimetres, but increase that depth and product loading through corners because they’re higher-stress areas.”

The specific design would depend on the road, material and fleet. Wet performance has to be designed into the road from the start. Engineers should identify high-stress sections early. Drainage needs to be managed. The stabilisation product needs to be incorporated at the right depth and loading for the conditions it will face.

Crews must properly mix and compact the product throughout the treated layer. Choosing an appropriate product is only one part of the system. The road still needs suitable geometry, effective drainage, and construction and maintenance to ensure the pavement remains strong when wet.

Choosing the right stabilisation product

There is no single stabilisation product that suits every haul road. Some products perform well in certain material types but not others. 

“The goal isn’t to choose a product because it’s popular or the lowest upfront cost. The goal is to solve the problem in the right way that also aligns with your site’s operational and environmental objectives,” says Julian.

When weighing up stabilisation options, mines should ask:

  • Has the product been tested under wet conditions?
  • Does it maintain strength after heavy rain?
  • Does it resist washout?
  • How does it perform through wet-dry cycles
  • What treatment depth is required?
  • How does it perform under heavy truck traffic
  • Does it need different loading in corners, ramps or braking zones?
  • How soon can the road return to traffic after application?
  • What recovery work is usually required after major rain events?
  • How often does it need to be reapplied?
  • Does it create equipment clean-up issues?
  • What are the environmental, closure and rehabilitation implications?

These questions help you make a decision based on whole-of-life road performance.

Wet stability affects the whole operation

Large rain events are already disruptive. The aim is to stop road recovery from extending that disruption longer than necessary.

A haul road that holds together during and after rain can support safer traffic movement, more consistent haulage, fewer emergency grading interventions and faster return to production.

It can also help limit the increase in rolling resistance, fuel use, tyre wear, truck loading and cycle times that occurs when the running surface softens and becomes rough.

That is why wet stability deserves attention before the next major rain event. A stabilised road should maintain strength, shape and trafficability when conditions change.

That outcome depends on treating the road as a complete pavement and drainage system. The product, road material, treatment depth, compaction, geometry and drainage all need to work together.

If it cannot do that, your stabilisation strategy needs to be reviewed before the next storm exposes the same weakness again.

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Close-up of a haul truck tyre on a rough, dusty haul road

Poor haul road quality is driving up your tyre budget. Here’s why.

Written by Janet Reznicek on . Posted in Article.

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Sites that stabilise haul roads properly and maintain a smooth running surface can extend tyre life by upwards of 30 percent. Across an entire fleet, those savings really add up.

This article explores the connection between road quality, tyre heat and tyre life. And how some mines have reduced fleet maintenance costs just by improving the haul road surface.

Tyres are often the first place road quality costs show up

Tyres wear out naturally over time. That’s expected. What often shortens their life is heat build up.

“Road quality has a direct influence on how much heat a tyre generates,” explains Julian Musgrave, Head of Business Development Australia at Bind-X.

“The smoother the road, the less the tyre flexes, and the cooler it runs.”

Every time a haul truck travels over corrugations, potholes or uneven surfaces, the tyre deforms under load. That movement generates heat within the internal structure of the tyre.

Individually, those movements may be small. But across thousands of haul hours, the effect becomes significant.

Heat build-up also creates safety risks. Tyre overheating events can trigger extensive site response procedures, including exclusion zones, extended down time, cooling activities and inspections before equipment can return to service.

For that reason, tyre temperature is closely monitored across many operations.

Tyres are one of the easiest, yet most overlooked, places to see the cost of poor road quality. But they aren’t the only place it shows up. The same road conditions that shorten tyre life also increase dust, maintenance, water consumption, equipment wear and cycle times.

The most expensive road is often the one that isn’t treated

The financial impact of shortened tyre life is substantial. Julian points to one mining operation that focused heavily on haul road quality and road design. Before improving their road surfaces, their tyres lasted around 4,000 operating hours. After creating smoother running conditions and better road designs, tyre life increased to approximately 5,500 hours.

The exact numbers will vary from site to site, but the principle remains the same. Tyres are expensive and so is the maintenance to look after the fleet.

A haul truck tyre can cost $45,000 before freight and logistics are factored in, depending on the truck model and size. “A haul truck can easily be carrying a quarter of a million dollars’ worth of tyres underneath it,” explains Julian, who has worked in road stabilisation and dust control for nearly a decade.

“Tyres are often viewed as a necessary fleet maintenance cost. In reality, a lot of that cost is determined by the quality of the roads those trucks operate on every day,” he says.

Corners create some of the biggest challenges

Not all sections of haul road cause the same level of stress. Julian explains that corners can be problem areas to maintain because trucks continually push material sideways when they turn. Over time, this creates rutting, channel formation and surface deformation, increasing the internal stresses on the tyres.

Autonomous fleets can amplify this effect. While autonomous trucks vary their path slightly on straight sections, they tend to follow very similar lines through corners. The same sections of road receive repeated loading, which accelerates wear in concentrated areas.

The result is a surface that becomes progressively rougher and more difficult to maintain. Those localised defects might seem minor at first, but they create exactly the conditions that increase tyre flex, add additional abrasive material onto the road surface, generate heat, and shorten tyre life.

The problem starts when roads lose stability

In many cases, road surface deterioration begins with the loss of fines. A haul road relies on a mix of large aggregate, smaller aggregate and fine particles. The fines fill the gaps between larger particles and help lock the structure together. When roads become too dry, those fines are gradually lost as dust.

As the fines disappear, the larger particles begin moving against each other. The road surface becomes less stable, and defects start to develop.

This is when: potholes appear → corrugations form → loose material accumulates. And that rougher, looser surface creates more tyre heat and more tyre wear.

Most people notice the symptoms. Fewer people connect the root cause back to the fines that have already left the road.

As Julian puts it: dust is some of your hard-won profits blowing away.

Watering and grading don’t solve the problem

Most operations respond to deteriorating roads the same way: The grader smooths the surface → the water cart follows behind → the road looks good again.

But the challenge is that appearance and structure are not the same thing. 

“Are you restoring the shape of the road? Or are you restoring the integrity of the road?” he asks. Without addressing the underlying stability of the surface, the same deterioration process often returns within hours or days.

Water management creates a similar challenge. Roads perform best within a relatively narrow moisture range. Too little moisture and fines are lost as dust. Too much moisture and the road can soften, wash out fines and lose structural integrity. Maintaining that balance across an entire haul road network 24/7 is difficult, particularly when a small number of water carts are responsible for servicing a large fleet.

The result is a cycle of watering, grading, deterioration and rework that many operations struggle to escape.

The goal is a smoother, more stable road

The best solution is stabilisation. Whether that’s achieved through mechanical stabilisation, lignins, polymers, salts, bitumen-based products or biological stabilisers, the objective is the same: preserve the integrity of the road structure for longer.

A stable road retains fines, resists deformation and maintains a smoother running surface under traffic. Once that happens, many of the secondary benefits follow naturally:

  • Tyres run cooler
  • Dust generation decreases
  • Water demand falls
  • Maintenance intervals extend
  • Equipment experiences less vibration and wear
  • Visibility and safety improve
  • Cycle times become more consistent

As Julian explains, “The road remains in good condition for longer, it reduces the need for constant intervention, and lowers the damage being done to the equipment using it.”

Choosing the right stabilisation approach to extend tyre life

As we’ve shown, addressing road stability and surface smoothness on your haul roads can have a big impact on tyre costs.

When you’re evaluating stabilisation options, look beyond the initial application and consider the full life cycle of the product.”

Consider things like water use, maintenance demands, reapplication frequency, environmental impact, and rehabilitation requirements, as these all influence long-term value.

Carbon footprint is increasingly important as well. In their reporting, many operations are beginning to assess the upstream footprint associated with the products they use. As Julian notes, decisions made today should be made with the next five-to-ten years in mind, not just the next five-to-ten months.

Many mines now find that biological dust control options like Terrabind address all of these factors and improve road stability.

They treat road quality as both a maintenance issue and an operational performance issue to unlock savings and benefits across their operation.

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Water truck spraying a wide fan of water beside a haul truck

Why water-based dust suppression fails in dry and windy mining conditions

Written by Janet Reznicek on . Posted in Article.

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The fundamental failure begins with high evaporation rates. In environments where humidity is low and temperatures are high, water sprayed onto the surface does not penetrate deeply enough to create a lasting bond. Instead, it sits on the surface and vanishes within minutes. This creates a “vicious cycle” for mine management: to maintain compliance and safety, water trucks must be deployed in a near-constant rotation. This not only consumes millions of litres of a finite resource but also fails to address the underlying cause of dust generation.

Furthermore, water lacks a residual binding effect. Once the moisture evaporates, the fine particulate matter (PM10 and PM2.5) is left in a state often more volatile than before. The constant wetting and drying cycles can actually break down the surface integrity of haul roads, leading to “potholing” and the creation of more loose fines, which are then easily picked up by the next gust of wind or heavy vehicle.

The wind factor: Mechanical displacement and the “strip-off” effect

While evaporation removes the moisture, wind provides the kinetic energy that renders water-based dust suppression completely ineffective in open-pit environments. In windy mining conditions, the surface of a haul road or tailings dam is subject to constant shear stress. Because water provides no physical or chemical structural reinforcement, it cannot prevent the mechanical displacement of fine particles once the surface layer dries.

This leads to what is known as the “strip-off” effect. In high-wind scenarios, even a recently dampened surface is quickly stripped of its moisture-laden top layer. Without a specialised binding agent to create a cohesive crust, the wind effectively “sieves” the material, lifting the smallest, most hazardous dust particles into the atmosphere. These fines are often carried over long distances, impacting neighbouring communities and violating environmental regulations despite the continuous presence of water trucks.

Moreover, the lack of surface crusting means that wind-borne erosion is not just an environmental hazard but a threat to the infrastructure itself. As the wind removes the fine “matrix” material that holds larger aggregates together, the road surface begins to ravel. This creates a loose, gravelly texture that increases rolling resistance for heavy machinery. In a dry and windy climate, water is simply too lightweight a solution to anchor the massive volumes of dust generated by industrial activity, leaving the site vulnerable to constant erosion and diminished visibility.

Operational and economic consequences: The hidden costs of inefficiency

The failure of water-based dust suppression in dry and windy conditions is not merely an environmental or safety concern; it is a significant drain on operational profitability. When a mining site relies on water alone, it inadvertently commits to a high-cost, low-yield logistics chain.

The most immediate impact is found in increased cycle times and reduced productivity. To combat rapid evaporation, water trucks must operate in high frequency. This creates a “congested” haul road environment, where the movement of multi-million-dollar haulage fleets is frequently interrupted or slowed to accommodate the watering schedule. Furthermore, the over-application of water, a desperate attempt to maintain moisture, often leads to “slick” road conditions. This forces operators to reduce speeds for safety, directly impacting the site’s tonnes per hour (TPH) metrics.

 

From a maintenance perspective, the “wet-dry” cycle is destructive. Constant watering leaches out the natural binders in the road material, leading to:

  • Surface degradation: The formation of potholes, corrugations, and rutting.
  • Increased rolling resistance: As the surface softens and loses its structural integrity, fuel consumption for the haulage fleet increases significantly.
  • Mechanical wear: Loose fines that are not effectively suppressed find their way into the air intake systems and moving parts of expensive machinery, leading to premature filter clogs and increased engine wear.

In water-scarce mining regions, the opportunity cost of water is perhaps the most overlooked factor. Every kilolitre of water used for ineffective dust suppression is a kilolitre that cannot be used in the processing plant or for community hydration. In many arid jurisdictions, strict water quotas mean that inefficient dust management can literally cap a mine’s production capacity.

Moving beyond traditional suppression

To overcome the inherent limitations of water, the industry is shifting toward new and proven biological solutions that address the root cause of dust generation. Bind-X specialises in this transition, moving away from temporary wetting and toward permanent soil stabilisation through Bio-Cementation.

Unlike water-based dust suppression, which relies on weight and surface tension, Bind-X methods, such as Terrabind™, utilise biological processes to create a long-lasting, robust surface crust. This process involves the application of organic binders that facilitate the bonding of fine particles into a solid surface layer. This “bio-crust” is specifically engineered to withstand the dual pressures of extreme desiccation and high-velocity winds.

The advantages of Bind-X biologicals:

  • Longer-lasting durability: Once applied, the biological bond is not subject to evaporation. It remains active and effective for significantly longer periods, even in the most intense heat.
  • Significant water savings: By eliminating the need for constant re-application, Bind-X solutions can reduce a mine’s water consumption for dust control by up to 90%*.
  • Erosion resistance: The bio-cemented surface acts as a physical shield against wind. It prevents the “strip-off” effect, ensuring that hazardous fines stay locked in the ground rather than becoming airborne.
  • Operational optimisation: Harder, more stable roads lead to lower rolling resistance, reduced fuel consumption, and fewer maintenance interventions for the haulage fleet.
* These figures reflect outcomes from a project at the GCO mine in Senegal

Optimise your operations with Bind-X

In the modern mining landscape, “more water” is no longer a viable strategy. It is an environmental burden and an operational bottleneck. Bind-X provides the expertise and the technology to transform dust management from a constant struggle into a streamlined, sustainable process. By leveraging the power of biology, we help mines protect their people, their machinery, and their local environments.

FAQ: Frequently asked questions about dust suppression in mining

  • 1. Why is water-based dust suppression considered ineffective in arid mining regions?

    Water-based dust suppression relies entirely on temporary moisture-induced cohesion between fine particles. In arid regions, high evaporation rates remove this moisture almost immediately. Without a binding agent, the dust returns to its volatile state, requiring constant re-application which wastes water and labour without providing long-term stabilisation.

  • 2. How does wind impact dust control on mine haul roads?

    Wind-induced shear forces can exceed the cohesive forces between surface fines, causing particle entrainment and dust lift-off. Through wind erosion, the dry top layer of fines is progressively removed from the road surface. Bind-X solutions mitigate this by creating a bio-cemented crust that physically anchors the particles, making the surface resistant to high-velocity wind erosion.

  • 3. What are the primary environmental benefits of using Bind-X biotechnology over water?

    The most significant benefit is the significant reduction in water use for dust control, often up to 90%. Additionally, by creating a more durable surface, Bind-X reduces emissions associated with water truck operations, fuel consumption, and haul road maintenance frequency. Our solutions are also designed to be environmentally friendly and biologically safe.

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Haul truck in a heavy dust cloud on a mine road

Dust is your road disappearing: here’s why that matters

Written by Janet Reznicek on . Posted in Article.

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Most sites respond by applying water and grading more often. But that approach tends to accelerate the degradation cycle rather than fix it. And as temperatures increase, plain water is less efficient for dust control and it wastes a limited resource.

So, what does dust really mean for your roads, why do mines persist with high-maintenance approaches, and what’s the key to breaking the cycle?

What dust is actually telling you about your road

Julian Musgrave, Head of Business Development Australia at Bind-X, sees the same pattern across sites. Significant effort goes into building and compacting haul roads, only for that work to slowly undo itself in operation.

“Dust is your road surface blowing away. People spend significant money building roads, and every time it dusts up, they’re watching it disappear but they don’t connect the two.”

A well-built haul road relies on a mix of material sizes. Larger aggregate provides structure, while fines fill the gaps and bind the surface together. When those fines are lost as dust, that structure starts to open up.

The surface loosens. Larger stones begin to move under load. What starts as a stable running surface quickly turns into potholes, corrugations, and loose material. From there, the problem compounds. Loose rock spreads across the road and contaminates stable sections. Each truck pass accelerates the breakdown.

Left unchecked, it becomes a self-reinforcing cycle: the more fines you lose, the faster the road deteriorates. The ripple effect impacts safety, haul efficiency and tyre wear.

Two haul trucks working in a quarry

How the road maintenance cycle makes this worse

As conditions decline, maintenance ramps up with more grading and watering. But this is where many sites get stuck.

Under time pressure, grading is often a quick cut rather than a full rebuild. Material is pushed into the windrow instead of being properly reincorporated. This gradually strips fines from the running surface and exposes coarser layers underneath.

The result is a weaker road that breaks down faster and pulls crews back into the same cycle within days.

Water adds to the problem. It delivers short-term suppression, but once it evaporates, dust often returns quickly. This drives repeat application, which further disturbs the surface.

The cycle becomes continuous:

 Wet → dry → dust → reapply → degrade → repeat

Why this shows up across your whole operation

Haul roads are production assets. They should be maintained the same way you would a conveyor or processing system because they directly affect output.

As road conditions deteriorate, rolling resistance increases, haul speeds drop, and equipment wear accelerates.

But the impact doesn’t stop at the road.

“Excessive dust and poor road conditions quickly translate into higher maintenance costs across the fleet. Driving through heavy dust loads clogs air filters and on large haul trucks, those filters are significant components that require constant cleaning or replacement,” says Julian.

At the same time, rough roads increase stress on suspension systems, drive higher vibration through the chassis, and speed up wear across critical components.

If the road is dusty, it’s usually not performing, and that cost shows up across the operation.

Too many mines stay stuck in this loop

In many ways, this is a legacy problem.

As Julian points out, the industry has relied on the same approach for decades. Water was cheap, readily available, and effective enough at the time. As a result, it became standard practice. But the operating context has changed. Haul trucks are now larger and heavier. Production demands are higher. Environments are harsher. And water is now a scarce, contested resource across most mining regions.

Yet the approach to dust control hasn’t kept pace.

Aerial view of a loaded haul truck on a road through an open pit

Dust control should be about stabilising the road

Most dust control methods focus on suppressing dust after it appears. But the real objective should be to stop it leaving the surface in the first place.

There are multiple ways to stabilise haul roads, from mechanical compaction to traditional binders like lignins, polymers, salts, bitumen-based products, and newer technologies like biologicals. What works best depends on the material, climate, and traffic conditions on site.

But the principle is consistent: keep the fines locked into the structure so the road holds together under load.

“Road stabilisation technologies have progressed in recent years,” Julian explains. “Introducing the right additive changes how the material behaves. You want the fines to bind into the matrix, creating a more stable, consistent running surface.” 

Biological stabilisers like Terrabind™ take this a step further. Rather than coating particles or adding temporary cohesion, they trigger a natural biocementation process within the soil. This forms a crystalline structure between particles that strengthens the road throughout the wearing course, not just at the surface.

Loaded haul truck on a mine road

Under heavy haulage, the wearing course holds together, fines stay in place, and the surface resists the breakdown that leads to potholes, corrugations, and loose material.

Operationally, that stability changes everything. Sites grade less because the road isn’t constantly degrading. Water use drops, often from multiple applications per shift to a single pass per week. And with a consistent surface, trucks can maintain speed.

As Julian notes, when you reduce grading, water use, and road damage, the benefits flow across the operation. The sites that do this see lower maintenance hours, reduced water consumption, longer tyre life, less equipment stress, and more consistent cycle times.

Reduce road maintenance with a modern approach

When dust is looked at in isolation, it’s easy to justify short-term fixes: more water, more grading, another pass. But when you consider downstream factors like higher maintenance, increased water use, equipment wear, and lost haulage efficiency, that approach becomes far more expensive than it appears.

Instead of constantly chasing dust, focus on road integrity at the source. It’s then that you’ll start to reduce long-term cost and improve haul road performance.

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Water truck spraying beside a haul truck in an open pit

Why water doesn’t actually work for dust control

Written by Janet Reznicek on . Posted in Article.

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In hot, dry conditions, that water evaporates within minutes. The road shifts from wet, to briefly optimal, to dry and dusty again. To keep up, your operators have to reapply water constantly, chasing conditions that never stabilise.

Over time, that approach wastes water. And from an operational standpoint, it softens the road surface, breaks down the wearing course, and accelerates the loss of fines that hold the road together.

This leads to a cycle of more watering, more grading, and more equipment damage just to try and maintain basic performance.

Here we look at why that cycle persists, what it’s really costing operations, and why stabilising the road, not just wetting it, is the key to breaking it.

Haul truck on a gravel haul road raising dust

What happens on baking hot haul roads

On a hot haul road, the problem isn’t just that water doesn’t last. It’s how quickly it disappears.

“I’ve measured road temperatures in the Pilbara at over 70 degrees,” says Julian Musgrave, Head of Business Development Australia at Bind-X. “You put water on that and it’s gone in minutes.”

Even under good conditions, the window is short.

“You get a short window, maybe 10 to 25 minutes, where it’s perfect. Then it’s too dry again. So you’ve got this cycle: too wet, then just right then too dry. And you’re chasing it all day,” he says.

But it also means conditions are never stable. Dust levels rise and fall throughout the shift, and operators constantly have to react to changing conditions rather than focus on ‘shifting dirt’.

It’s not just maintenance costs

As the road’s wearing course deteriorates, rolling resistance increases, the surface corrugates and haul speeds drop, impacting your production cycle times.

At the same time, the rough surface is harsh on equipment. Loose material and exposed rock increase stress on tyres and components, and you need to grade more often to keep roads serviceable.

Dust adds another layer of hidden costs. Air filters clog more often, and trucks experience more wear when they operate over uneven surfaces.

Water isn’t always cheap, especially when you add up the cost of applying it. At large operations, haul roads alone can consume millions of litres per day just to maintain basic dust suppression. And if your water carts run continuously, labour and fuel costs increase.

Why this approach persists

Water has been the standard for decades because it’s readily available, easy to apply, and delivers an immediate short-term result. Under the right conditions, it’s “good enough” to meet basic dust control requirements.

But today, mining operations have changed.

Haul trucks are now significantly larger, with payloads now reaching 280 tonnes, and the total weights upwards of 450 tonnes. Heavier loads place far more stress on haul roads, while heat and accelerated wear, amplify the impact of surface instability.

Tyres run hotter, surfaces break down faster, and roads are worked harder with every pass.

At the same time, the expectations on mining operations have shifted. Everyone is under more pressure to maximise productivity, while water availability is now constrained in many regions – you have to balance the needs of local communities, Traditional Owners, farmers, and neighbouring mines.

So the plain water approach persists. Not because it’s effective, but because it’s familiar.

Before and after: dusty road beside a bound red road surface

A modern approach: stabilise the road first

Modern dust control methods focus on stabilisation rather than suppression alone.

“When you control the fines, you control the road quality,” explains Julian, who has spent a decade helping mining operations suppress dust and stabilise their roads. “If the fines stay in the road, you don’t need to keep chasing your tail.”

That shift changes how the road behaves under load.

Instead of a surface that constantly breaks down and needs rewetting, the road holds together. Fines remain bound within the matrix, which reduces material loss and limits dust generation at the source while increasing tyre life.

“You may not eliminate road grading completely, but you can make primary haul roads more efficient, which frees the graders up to do a better job elsewhere and helps keep your trucks out of the maintenance bay,” says Julian.

Biological stabilisers, like Terrabind Ultimate, trigger a natural biocementation process within the soil. It forms a binding structure between particles, locking fines into place.

It creates a more wet-stable road surface that performs consistently for weeks and months, without the constant cycle of watering and reworking.

In practice, that means less water use, lower maintenance demands, and more predictable road performance.

Stop chasing the cycle

Water may currently have a vital role on mine roads. But on its own, it doesn’t solve your problems.

It evaporates quickly, fails to retain fines, and with repeated use, degrades the road faster. That’s why many mines use more and more water every year while their road conditions continue to decline.

When you switch your focus to a long-term approach starting with road stability, you don’t have to react to dust control every shift and manage fluctuating results.

That shift reduces water use, improves road performance, reduces downtime and lessens mechanical wear—delivering more consistent results across the operation.

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Wet coal stockpile with mining equipment on the bench

Designing a year-round dust control plan

Written by Janet Reznicek on . Posted in Article.

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Mining operations never stand still. Haul roads, stockpiles, and work areas are constantly exposed to changing weather conditions, heavy traffic, and environmental pressures. That means dust control can’t be treated as a one-off task – it requires a proactive, year-round plan that adapts to the seasons.

“Dust control isn’t just about reacting to dry or wet conditions. It’s about planning for the whole year,” says Johan Smit, Dust Control Application Manager at Bind-X.

A well-designed dust control strategy doesn’t just reduce emissions. It improves road safety, lowers maintenance costs, protects water resources, and supports compliance with environmental and social standards.

Here’s how to think of dust control as a continuous process rather than a seasonal scramble.

1. Understand your site conditions

Every mine is different, and your dust control plan should reflect that. Start with a comprehensive understanding of your site’s conditions:

  • Climate and seasonal patterns: does your region face long dry spells, heavy monsoon rains, or frequent seasonal shifts?
  • Soil type and composition: clay, sandy, or gravelly soils behave differently under stress and moisture. Assess gradation, fines content and plasticity index (PI), as these influence binder bonding and dust potential.
  • Traffic and layout: road length, gradient, and vehicle frequency all influence dust generation.
  • Community and compliance context: what regulations and local expectations shape your operation?

Johan emphasizes, “Every site is different. Knowing your soil, traffic, and climate is critical before choosing a dust control strategy.” Getting these factors right helps you choose prevention and control methods that are effective and cost-efficient. A good road design and preparation drastically reduce long-term costs and maintenance intervals.

2. Prevention first: road design and preparation

Drainage pipe discharging onto dark rock beside a road

The most successful dust control doesn’t begin when a binder is sprayed or water is applied—it starts with proper road design and preparation.

Grading and camber: Ensure adequate runoff and reduce erosion.

Strong base: Achieve >95% MDD compaction density to minimise surface breakdown. Moisture conditioning before binder application improves penetration and adhesion.

Drainage and buffer zones: Use ditches, culverts, and vegetated areas to manage runoff and protect nearby ecosystems.

Binder selection: Choose a product suited to your soil chemistry and climate to avoid premature degradation and rework.

3. Seasonal adaption

Dust challenges shift with the seasons. A flexible plan ensures consistent performance throughout the year.

Dry conditions: Preserve moisture, extend binder life

When rainfall is scarce and traffic is high, roads dry out quickly, leading to dust, raveling, and surface degradation.

  • High dust levels demand effective binders and careful water use. Smart binder use can reduce water consumption by up to 90% and maintain road safety.
  • Road watering alone is unsustainable and costly.
  • Schedule applications based on traffic and weather patterns for maximum impact.

“During dry periods, the biggest challenge is keeping haul roads safe without overusing water,” Johan explains. “Smart binder use can make a huge difference.”

Wet season priorities:

  • Heavy rain can wash away treatments, create potholes, and make roads unsafe.
  • Adjust curing times for moisture and temperature.
  • Wet-stable road stabilisers and binders become essential.
  • Inspect roads regularly after storms to catch issues early.

“Heavy rain can undo months of work in just a few hours,” Johan notes. “Choosing the right stabiliser before the wet season is essential.”

Transition periods:

The shift between seasons is often when roads are most vulnerable. Early inspections and adaptive scheduling prevent damage during seasonal shifts.

4. Application & technology

Water truck spraying a road surface evenly

How you apply a solution is just as important as what you apply.

Spraying techniques: Make sure the binder is applied evenly and mixed properly to ensure effective binding and reduce the need for reapplication. Use the correct nozzles, nozzle size, spray pressure, and dilution ratio. Keep a steady speed when applying the product on the road for optimal binding.

Timing: Apply after grading, ahead of extended dry periods, or before the wet season when more stable binders are needed.

Monitoring tools: Dust sensors, drone surveys, or even basic logbooks help move from reactive to proactive management.

“It’s not about spraying more often. It’s about applying correctly and at the right time,” Johan says. “That’s where biological binders really shine.”

With biological binders, effectiveness comes from correct application and timing — not frequency. Because they create durable bonds, fewer applications are needed compared to water or salts, even across seasonal shifts.

5. Monitoring & KPIs

You can’t improve what you don’t measure. Tracking the right indicators allows you to evaluate effectiveness and adjust strategies as needed:

  • Dust levels (measured or reported).
  • Water consumption for dust suppression.
  • Road maintenance costs and frequency.
  • Number of binder applications per season.
  • Community complaints or safety incidents related to dust.

“Measuring results is just as important as applying the solution,” Johan adds. “Without tracking dust, water use, and road condition, you can’t improve your strategy.”

Keeping a seasonal log or digital dashboard ensures decisions are based on real data rather than assumptions.

6. Building a long-term strategy

Dust control works best when it’s part of a long-term plan rather than a short-term fix:

Budgeting as investment: Dust control reduces vehicle wear, accidents, and environmental risks – saving money in the long run.

ESG alignment: Dust reduction improves environmental performance and supports social license to operate.

Continuous improvement: Reviewing data annually ensures strategies evolve with site conditions.

Conclusion

A year-round dust control plan combines prevention, adaptation, monitoring, and long-term thinking. By tailoring strategies to site conditions and seasonal shifts, mines can reduce costs, improve safety, and operate more sustainably.

“‘A year-round plan protects not just the operation, but the people and environment around it,’ Johan concludes. “That’s the real value of proactive dust control.”

At Bind-X, we help mines design dust control solutions that work in every season – with biological binders that last longer, use less water, and protect the environment. Talk to our team about how to create a tailored dust control strategy for your operation.

Case Insight: Sustainable impact in practice

This approach is not just theoretical. At an open-pit mine in South Africa’s Northern Cape, implementing a seasonal dust control plan with the biological binder Terrabind™ reduced water consumption by 90% and extended road lifespan by 85%. The proactive strategy improved air quality, reduced vehicle wear, increased tyre life, lowered maintenance costs, and strengthened community trust—demonstrating the tangible benefits of planning dust control for the full year.

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damaged water bowser used to control dust with bitumen emulsion

One switch transformed dust control at a manganese operation

Written by Janet Reznicek on . Posted in Case study.

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Dust control wasn’t the problem. But maintenance was losing its grip.

The manganese operation had been managing its haul roads with a familiar choice: a bitumen emulsion blend. The haulage roads were in a decent condition, the dust levels down, and the product was widely available. But beneath that apparent success, operations were paying the price.

Clogged tanks. Thick residue on trucks and equipment. Cleaning cycles for equipment and tanks caused delays of up to two weeks. The blockages meant the mine lost control over its road maintenance, and the roads themselves began to suffer.

“Bitumen emulsions may initially appear to be an attractive dust control solution, but they often lead to significant operational challenges and additional hidden costs. In mining, operations rarely run perfectly, and the added burden of cleaning out chemical tanks, managing cleaning logistics, and falling behind on essential road maintenance is best avoided,” says JC Le Roux, Head of Business Development Africa at Bind-X.

Loooking for performance — without the problems

The mine’s Mine Planning Engineer understood there had to be a better way. The mine wasn’t just seeking something more environmentally friendly. They required a solution that maintained the same road performance without causing downstream damage.

That’s when they tested Terrabind™ Max, a biological dust control product whose advanced solidification process creates robust, high-compressive strength roads capable of withstanding the harshest conditions, reducing maintenance requirements and extending the lifespan of both equipment and infrastructure.

“What stood out about this team was their willingness to challenge the status quo,” JC says. “They weren’t only looking for something ‘green’. They wanted something better operationally.”

Clogged water bowser tank with bitumen emulsion

Immediate impact, measurable change

The biological solution matched the dust control performance and road stability, without the complications:

  • No tank blockages
  • No equipment buildup
  • No unplanned maintenance
  • No off-site tank cleaning
  • No delays in product deliveries

Even during extreme conditions on site, the team could respond quickly, without any of the old bottlenecks. Reapplication was simple and immediate, without delays or cleaning logistics.

One year later: reliable, efficient, and clean

One year into using Terrabind™ Max, the mine reports significantly improved road maintenance operations. No equipment damage. No tank cleaning.

“This isn’t just about sustainability,” JC concludes. “It’s about uptime, asset longevity, and freeing up resources. The mine made a smart, forward-looking move — and it’s paying off.”

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Dusty mine site with reduced visibility

Is dust control risking your license to operate?

Written by Janet Reznicek on . Posted in Article.

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In areas like Western Australia’s Pilbara, groundwater is a shared resource, relied on by local communities, Indigenous custodians, farmers, and ecosystems. And while your site might be compliant, that’s no longer the whole story.

“Staying within your licence isn’t enough anymore. You can still lose support on the ground,” says Martin Krehenbrink, from Bind-X. “We’ve seen the impacts of this recently in the Pilbara in Western Australia.”

Groundwater under scrutiny

Earlier this year, the Robe River Kuruma people raised serious concerns about the impact of groundwater extraction from aquifers in the Bungaroo Valley, water connected to sacred sites.

The ABC News report says that mining operations have drawn up to 10 billion litres a year from the area since 2014. Groundwater levels have dropped by half in just a decade. The result? Dry riverbeds, dead trees, and damage to culturally significant landscapes.

While dust suppression isn’t named directly, it’s part of the picture. And one of the easiest areas to target for immediate water savings.

“We can’t just talk about compliance anymore,” says Martin. “We need to demonstrate that we’re thinking about long-term water stewardship and cultural heritage.”

Dust control: A silent water drain

Dust suppression is often treated as a background task. But it’s a thirsty one.

Spraying plain water on haul roads can quietly consume millions of litres each week. At some sites, it accounts for more than 30% of total water use. Yet it’s rarely monitored or reported on separately.

That creates a blind spot, not in your compliance report, but in public perception.

“The real risk isn’t about breaking the rules,” Martin explains. “It’s about losing trust. If you’re not in front of the issue, someone else will be.”
In a region where every drop is becoming increasingly scarce, it’s what you do with each litre that counts.

From compliance to conservation

According to Martin, a molecular microbiologist who works closely with mine sites around Australia, it’s time to treat dust control not just as a maintenance task, but as a conservation opportunity.

“Dust control has to align with your broader sustainability strategy,” says Martin. “It can’t be the exception.”

Water spraying might feel like business as usual, but it’s wasteful, short-term, and increasingly hard to justify. Other options are available, and some newer technologies on the market are achieving good results.

Biological road stabiliser used on a haul road

A smarter way forward

Some mining companies are already proving what’s possible.

At one site, ArcelorMittal switched to a biological dust control method using a clean, biological product called Terrabind. Instead of regular water sprays, this solution binds fine particles on the haul road, keeping dust down for longer with significantly less water.
The impact? A 75% reduction in water use for dust suppression. You can read the full case here.

The approach doesn’t just conserve water. It also extends the life of haul roads, reduces fuel and maintenance costs, and shows a proactive commitment to environmental responsibility.
It’s a cleaner alternative to older technologies like polymers, and bitumen emulsions, which come with their own challenges. It’s worth considering the newer wave of dust control alternatives out there.

Haul road dust suppression may not be the biggest issue on your ESG radar. But it’s one of the few where you can make a visible, measurable improvement—quickly.

Every litre saved sends a message that your site takes stewardship seriously.

Where to start: Key questions for your site

  • Are you tracking water use for dust suppression separately?
  • Have you benchmarked usage per kilometre of haul road?
  • When did you last assess alternative control methods?
  • Are Indigenous water concerns part of your site’s risk assessment?
  • Do your sustainability reports reflect haul road water usage?

Dust suppression doesn’t need to be a blind spot in your sustainability strategy.

Your licence to operate depends not just on legal compliance, but on leadership. Especially when it comes to visible, localised impacts like water use.

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Water truck on a haul road with a treated surface in the foreground

More water trucks won’t fix your dust problem

Written by Janet Reznicek on . Posted in Article.

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Across Australian and African mine sites, operations continue to rely on untreated water as their primary dust control method, despite clear evidence of its limitations. Plain water evaporates within hours, creating a costly cycle of reapplication that strains resources without delivering lasting results.

“The mining industry has historically defaulted to ‘just add more water trucks’ when dust problems persist,” notes Martin Krehenbrink, CEO at Bind-X. “But forward-thinking site managers are now questioning whether plain water, regardless of application frequency, is fundamentally the right tool, given increasing water scarcity.”

Why spraying more water falls short

On paper, watering haul roads might appear low-cost and straightforward. But its effects wear off fast, often within 20 to 40 minutes. This creates a constant, resource-intensive loop with high fuel and water use: 3 to 4 trucks per shift, especially during the dry season.

The problem doesn’t stop at inefficiency. Plain water on its own damages road surfaces, compromises safety, and disrupts operations. Too much water means operators face slippery conditions, wet ruts, and potholes. Tyre wear increases. Maintenance teams are left fixing the very roads the water is supposed to protect.

“Water trucks are out in force, but they’re not solving the root problem. In many cases, they’re making it worse by degrading the roads,” says Martin. “We’ve seen haul speeds drop purely because of wet, greasy conditions.”

One method doesn’t fit all

Each part of your site has unique dust dynamics. In-pit areas may respond well to water. But static surfaces, like bunds and stockpiles, require longer-lasting suppression. And heavy-traffic haul roads benefit from stabilisation rather than repeated wetting.

Yet many sites still rely on one method, spraying plain water, as the primary dust control method, regardless of traffic volume, dust generation rate, or reapplication effort. It’s easy to default to water trucks. They appear to get the job done. But in reality, you’re spending time, fuel, labour and water, just to chase a problem around the site.

“Smarter dust control starts with zoning,” says Martin. Not every part of the site generates dust the same way. “In-pit at the active face, plain water with cannons works, sure. A well-timed wetting strategy can keep things under control.”

“But when it comes to your high-traffic haul roads, and areas like bunds, stockpiles, ROM edges, or rehab zones, these aren’t places you should be hitting with a water truck every few hours,” he says.

For those zones, you need a set-and-forget approach. Ideally you would use biological binders or soil stabilisation products that create a crust or binding layer that lasts for weeks or even months, depending on conditions.

“But it should be environmentally safe and re-minable at a later time,” explains Martin.

“When we see sites step back and treat dust control the way they treat any operational risk, by assessing cause, exposure, and impact, better decisions follow. The progressive ones are already doing this.”

You spend less, get better results, and free up your crews to focus on higher-value work.

Stronger roads and less dust with Terrabind

A smarter approach

Newer technologies now offer the same durability as older methods like bitumen emulsions, salts and polymers, without the environmental downsides. One example is Terrabind, a biological dust control method that uses natural  processes to form a solid cement-like layer on the wearing course. It keeps dust in place without oil, polymers, or synthetic resins.

Once applied, it penetrates the surface and holds dust down through heat, wind, and even rain. It’s biologically safe and scalable.

“We’ve helped sites cut water usage by 75%, and some up to 90%,” says Martin. “Removing water trucks from haul roads not only reduces water use, it eliminates unnecessary interactions with dump trucks and speeds up haul cycles.”

Eramet reduced road water usage by 85% with a biological dust control approach at their Grande Côte Opérations (GCO) in Senegal. In 2022, the mining services team realised they were spraying over 242,000 litres of water per day on the roads just to keep dust under control. They wanted to reduce water consumption, so the business proactively decided to test other options. The team found that Terrabind reduced water usage by 85% and created a three-fold drop in dust fallout. You can read more about that story here.

Measure first. Then take action.

Before you default to more water, pause and assess what’s really happening onsite. With the right data, you can make smarter, targeted decisions:

  • Use dust monitors to pinpoint hot spots
  • Schedule your drones to regularly assess surface conditions and track dust movement
  • Conduct visual audits to measure effectiveness by zone
  • Stabilise haul roads with environmentally safe binders

“Smart sites are moving from firefighting to forward planning,” says Martin. “They’re using technology like dust monitors, drones, and data to decide where and when to act.”

The solution isn’t just running water trucks, it’s a new mindset. Treating dust control as a strategic process instead of a reactive routine opens the door to better performance, lower costs, and safer roads.

Because if you’re just spraying water, you’re not solving the problem. You’re delaying it.

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