African iron ore mine achieves 30% less water truck trips on haul roads
Client:
An Iron ore mine
Location:
South Africa
Challenge:
Water scarcity
Use-Case:
Haul road stabilisation and dust control

The regulatory environment intensified the need to look for alternative options as the site faced warnings from South Africa’s Department of Mineral Resources and Energy (DMRE) due to excessive dust levels.
They knew that if they continued exceeding dust fallout limits, the DMRE could halt operations entirely. Faced with these challenges, the Mining Manager began to look into a more sustainable, cost-effective alternative that could control dust and reduce water use.
Researching alternative dust control methods

The mine operates in an arid region and access to water is limited. Anything that could reduce the amount of water on the roads was something the Iron Ore mine seriously considered.
“It’s a very water-scarce area. They’ve got a set amount of potable water that they can utilise across the whole mine. So anything that can reduce the amount that’s being sprayed onto the roads is worth considering because that’s put to better use in the process plant,” says Alex McHaffie, General Manager, Bind-X.
Initially, the mine considered continuing with their existing options: lignosulfonates and bitumen blends. While these methods offered decent performance, they brought several limitations. Bitumen emulsions stained the water trucks, added wear and tear to equipment, and became cumbersome to apply.
Costs also posed a challenge: bitumen, being a crude-oil-based product, is deeply connected to the oil price which continued to rise, adding budget strain to an already cost-sensitive operation.
Although lignosulfonates helped stabilise roads, they required frequent reapplication and high volumes of water, both of which clashed with the mine’s commitment to conserving water in their community.
The Mining Manager explored newer technologies and found a biological dust control method by Bind-X which addressed each of these challenges. With Terrabind, the mine site could reduce daily dust suppression applications by 30%, conserving water and lowering labor costs.
The product’s application also proved simpler, required less frequent attention, and left no staining or residue on vehicles. And from an environmental perspective, it was clean for plants, animals, and waterways.
Soil testing and compatibility

First, Bind-X conducted soil sample tests to confirm compatibility with the mine’s iron ore haul roads. With positive results, they chose to move forward, providing training on the product’s application methods. As Alex explains, “They initially queried whether less water and fewer applications would mean reduced effectiveness, but they were thrilled when we achieved the opposite: better dust results with less water.”
A biological approach also aligned with the mine’s strict budget and commitment to environmental safety. Instead of multiple daily sprays with high water volumes, the team could now apply a concentrated solution at less frequent intervals. This adjustment helped the operation reduce water and labour costs, optimise haul road durability, and prevent vehicle staining and equipment wear.
30% less water truck trips
With the new dust control method in place, the mine experienced substantial and immediate improvements. By reducing dust suppression applications by 30%, they cut water usage significantly, which allowed the operation to redirect water to essential mining processes. As a result, the haul roads required less maintenance, improving cycle times and production targets.
Moreover, they began to consistently meet the DMRE’s strict dust fallout regulations, ensuring the mine operated without regulatory interruptions. “Since switching to Bind-X, we haven’t faced any DMRE warnings in over 20 months,” reported the Mining Manager.
He also noted that vehicle maintenance had declined as the new dust control solution left no residue.

“It allowed us to achieve outcomes that meet or even surpass those from previous products. The application aligns perfectly with our environmental safety goals and also safeguards our equipment. We’re seeing superior dust control at lower costs, with the added benefit of reducing our carbon footprint. Each regulatory visit confirms our full compliance, and we’ve set a new benchmark for dust control on site.”
A South African iron ore mine
By implementing a biological dust control method, the mine addressed critical water and dust control challenges head-on, and made their operation more environmentally responsible at the same time. The mine’s success exemplifies how strategic, sustainable choices can drive operational excellence, allowing the mine to set a new standard in water efficiency, regulatory compliance, and long-term productivity.