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One of the biggest mistakes on haul roads is overwatering. Here’s how to avoid it.

Written by Janet Reznicek on . Posted in Article. No Comments on One of the biggest mistakes on haul roads is overwatering. Here’s how to avoid it.

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For most mining managers, road construction isn’t what they’re experts in. The roads just have to be good enough to get the dirt from the pit to the plant. This knowledge gap often leads to an over-reliance on water as a sole dust-control method.

However, civil engineering experts agree: water alone is a short-term fix that ultimately degrades road quality.

Alexander McHaffie
General Manager at Bind-X

“Once you apply water to a road, it evaporates quickly so you have to reapply it multiple times per day to keep dust down. This leads to overwatering.”

“The immediate impact is that it’s unsafe for haul trucks to travel on an overwatered road. But over time this overwatering also causes erosion, leading to potholes, rutting, and frequent maintenance cycles.”

The hidden costs of overwatering haul roads 

Mines often use plain water for dust control because it’s easy to apply and inexpensive. Yet, frequent watering can actually be more expensive and more time consuming. As water sinks into haul roads, it loosens surface particles, causing the finer materials to wash away and erode the roadbed. This erosion breaks down the road’s load-bearing structure and makes roads more susceptible to rutting and soft spots. Civil engineers caution that, without stabilisation, these weakened road surfaces make hauling slower and reduce mine productivity.

Overwatering harms roads and it also drains critical resources. The demand on water carts for repeated applications increases fuel use, labour hours, and vehicle maintenance. In areas where water is scarce, like many Australian mining regions, this approach quickly becomes unsustainable.

When mines adopt road stabilisation methods they can cut down on water usage and maintain stronger road surfaces.

How stabilised haul roads improve productivity 

Road quality has a direct impact on a mine’s operational efficiency. When haul roads remain stable and dust-free, trucks can travel faster, water carts come off the road, cycle times speed up, and fewer breakdowns occur. Stabilised roads reduce how often the upper wearing course needs to be re-laid, which means less frequent maintenance. 

Mining operations that adopt more advanced dust control measures see improvements that extend beyond the haul roads. There are new methods available that require fewer applications of water while creating more durable haul roads and longer maintenance intervals. 

“Many mining managers tried outdated dust suppression methods in the past, and only saw marginal benefits. But it’s 2024 now, there’s been a massive technology change in the past couple of years. There are better options out there that give you long-term production and environmental benefits,” says McHaffie. 

One of the newer categories of dust control products on the market is a biological-based approach first discovered at Murdoch University in Western Australia. Created for mining haul roads by Bind-X, it forms a solid layer like cement to hold the road materials in place, creating stability and significantly reducing dust.  

Mining operations that are already using the product have seen up to a 90% reduction in water usage on their haul roads, posing significantly less strain on water resources.  

Looking for other options

While water remains an easy fallback, it’s time for mines to look beyond ‘what’s been done before’ and do more to find ways to reduce water usage. Mines that have already chosen to stabilise haul roads with new dust control technology have found several advantages: 

  • Improved road durability: Roads retain their shape and support higher loads with minimal maintenance. 
  • Reduced water and resource use: Fewer applications lead to decreased water usage, less truck time, and lower carbon emissions. 
  • Enhanced productivity: Faster cycle times, fewer repairs, and clean audits from regulatory bodies reflect a well-managed, efficient operation. 

As McHaffie points out, plain water as a dust control method may seem effective at first, but it actually puts mining managers “in an endless maintenance cycle,” as it fails to strengthen the road surface. Mines that break this cycle with biological methods find themselves not only meeting — but often exceeding — their production goals, all while conserving precious resources. 

If you know haul roads, you know they need more than water to perform at their best. Wasting water on roads remains one of the biggest and most avoidable mistakes in the mining industry. By investing in methods that stabilise road surfaces, mining managers can take a critical step towards better roads, more loads, and long-term increases in throughput. 

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Water trucks on haul roads are an issue for a mine's productivity as they slow down traffic.

Are water trucks slowing down your haul road cycle times?

Written by Janet Reznicek on . Posted in Article. No Comments on Are water trucks slowing down your haul road cycle times?

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Water trucks substantially impact haul road cycle times—and yes, we can measure it. According to Tannant & Regensburg who wrote a manual on mining haul road design, road surface conditions and rolling resistance directly affect truck performance.

Impact on haulage time

Water truck slowdowns might seem minor at first glance, but they add up dramatically across your fleet. 

Think about a typical 15-truck operation. Each haul truck encounters water trucks 8-12 times per shift, with each interaction causing 45-90 seconds of delay. That’s 20-30 minutes of lost time per truck, per shift. Multiply that across your fleet, and you’re looking at 4-6 hours of total fleet delay every shift.

This significantly hurts production. A baseline cycle time of 22 minutes jumps to 28-32 minutes when you factor in water truck interactions. Over a shift, each truck in your fleet loses 2-3 complete cycles. And the disruption goes beyond just time loss. Water trucks create unpredictable bottlenecks, especially on ramps and at loading and dumping zones. When a water truck services these critical areas, queues of up to four trucks can form, triggering a cascade of delays.

These traffic flow disruptions hit hardest in high-congestion areas. Single-lane ramp sections see delays of 60-90 seconds when water trucks are present. Loading and dumping zones experience 2-3 minute delays during water application.

With haul trucks, every minute of delay hits your bottom line. Let’s look at a typical 1.6km haul on flat ground with 1.8 minutes combined loading and dumping time.

Tannant & Regensburg point out that on a well-maintained road with 4% rolling resistance, a loaded CAT 793C truck’s combined travel time is 4.7 minutes. However, when road conditions deteriorate to 10% rolling resistance, that same combined travel time nearly doubles to 9.5 minutes. This increases the total cycle time from 6.5 minutes to 11.3 minutes—a dramatic impact on productivity that can cost your operation millions in lost production annually.

Biological dust control creates stable roads and gets water trucks off mine roads

Getting water trucks off the road

But here’s the good news: there’s a better way. Forward-thinking operations like Eramet’s Grand Côte are getting water trucks off the road by implementing modern dust control strategies that use biocementation to strengthen the road. These long-lasting surface treatments can reduce water truck frequency by up to 90%.

What does this mean for you? Your operations teams don’t need to worry about strategic application timing, focused on night shifts and planned around peak production periods, to minimise interference with day shift hauling.

Operations that have made the switch report cycle time improvements across their haul road network. The results speak for themselves: cycle time improvements of 3-5 minutes and an additional 1-2 loads per truck per shift.

Implementation strategy for faster cycles

“In practice, many Australian mines are finding success with hybrid approaches,” says Martin Krehenbrink, Managing Director at Bind-X. “They’re using road stabilisers which keep dust down on main haul roads while maintaining traditional watering on temporary roads and around loading areas. The key is matching the method to your specific site conditions.”

He suggests you consider running a trial to see the benefits for yourself.

Measure and develop a test plan

“We suggest that you start by measuring and analysing your current situation,” says Martin. “Begin by tracking the frequency and duration of water truck encounters across your haul network.”

Document cycle time variations related to these interactions and identify your most problematic bottlenecks. Then calculate the production impact in terms of loads per shift to build a compelling business case.

“Next, select 2-3 km of your highest-traffic haul roads for initial testing with road stabilisation treatments,” explains Martin. Choose stabilisers appropriate for your site conditions and establish clear baseline metrics. Set measurable success criteria that focus on cycle time improvements and production increases.

Martin recommends you consider cleaner options now widely available, like biological dust control, which uses a biocementation process. This proven treatment employs naturally occurring microorganisms to bind soil particles together, creating a more stable road surface. Beyond reducing water truck requirements, biocementation is clean for the environment, unlike older technologies like crude-oil-based bitumen emulsions, salts, or polymer-based products.

Conduct controlled dust control trials

“When we run trials on site, we show operators how to apply the product and how to monitor performance,” says Martin. “Many are surprised when they go from applying water 15x per day, to then only spraying once every couple of days after they’ve applied Terrabind biological dust control.”

He suggests documenting all results carefully, including cycle times, dust levels, and operator feedback. Then, calculate your return on investment based on production increases versus implementation costs.

“During the trial phase, we train your operators on new procedures using existing water trucks and equipment already on site, and help you establish ongoing performance monitoring,” explains Martin.

Every minute saved in your haul cycle translates directly to improved production. By addressing the hidden impact of water truck dependencies, you can discover significant gains in operational efficiency. The question isn’t whether water trucks are slowing down your cycle times—it’s by how much, and what you’re going to do about it.

How is your site managing the balance between dust control and cycle time efficiency?

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Need to reduce water consumption? Start with dust control.

Written by Janet Reznicek on . Posted in Article. No Comments on Need to reduce water consumption? Start with dust control.

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One area all mine operations can look at to reduce water waste is dust control. Using only plain water for dust control uses billions of litres of water across the mining industry every year. But with increasing water scarcity and pressure from local communities to reduce wastage, this practice is becoming unsustainable. In 2025, new biological dust control technologies can dramatically cut water usage while being cleaner for the environment.

The growing role of water stewardship in mining

Mining companies are beginning to integrate water and dust management into their broader operational strategies. This shift reflects an industry-wide effort to reduce water inefficiencies and optimise the use of a scarce resource.

One miner leading the way in this area is BHP, which has developed a Water Stewardship Strategy to assess water-related risks at both operational and basin levels. It’s working towards a ‘water secure’ world by 2030 with public targets that aim to improve the management of water across their operations.

Similarly, Anglo American has a Sustainable Mining Plan to reduce freshwater withdrawals in water scarce areas by 50% by 2030. The company has designated water security as a principal risk as they acknowledge it’s “essential for our operations over the current life of mine and to support future growth.”

Teck Resources is another miner committed to becoming a net water-positive company by 2030. Proactively, they aim to contribute more water to the environment and communities than they consume through their Water Policy.

Despite these strong examples, inefficient water usage is still common throughout the industry. Some sites still rely on outdated systems where water sprays are manually activated, often spraying areas unnecessarily, such as empty stockpile zones.

Others spray only plain water to control road dust, which means water trucks continually run along roads—cycling up to 15 times per day. These practices not only waste water but also rely heavily on human intervention. The average Australian mine is estimated to use more than 2 million litres of water per day on roads, that’s more than 700 million litres each year at a single mine.

“The drum beats are certainly getting louder. Mining companies we’ve spoken to in Australia are centralising their water management approaches as a way to improve consistency and reduce waste across sites,” says Martin Krehenbrink, Managing Director at Bind-X.

“In the past, dust control often relied on running large water tanks and spraying plain water on the ground to keep dust levels down. While effective to some extent, this method is wasteful and increasingly unsustainable.”

A quick win: Use less water on roads

Fortunately, advancements in technology now offer mine sites a more sustainable way forward—saving water usage on haul roads by 90%.

“If mining operators look at how much water they waste on haul roads alone, they would be stunned to see how easy it is to save water,” says Martin.

“In the past, operations teams might have tried dust suppression products and only seen marginal benefits or have found them messy to use.”

Biological dust control is a new category of road stabilisers that can replace traditional dust control methods like polymers, lignosulfonates, and bitumen emulsions. Developed by Bind-X, the process is completely clean and environmentally safe. It massively reduces water usage while stabilising road surfaces.

Biological dust control uses naturally occurring biological processes that bond soil particles together to create a durable, long-lasting crust that prevents dust from being released into the air. It’s effective on mine roads, even high-traffic haul roads, as well as tailings and stockpiles.

What sets this approach apart is its drastic reduction in water consumption. Instead of water trucks running multiple passes per day, this can be reduced to once a day, or even every few days.

For mines in arid regions, this creates a significant opportunity to conserve thousands of gigalitres of water annually—water that can instead be allocated to operational processes or returned to the environment.

New tech is clean tech

Because biological solutions are non-toxic, they are completely clean for plants, animals, and surrounding waterways. This approach helps mining operations meet increasingly stringent sustainability requirements without compromising performance or safety.

These new, cleaner technologies are gentle on equipment, too. Operations can use their existing fleet of water trucks to apply them, and it won’t ruin pumps and render vehicles unusable, unlike some other traditional dust suppression options.

By applying biological dust control, mines can also cut down on fuel costs and labour associated with frequent water truck cycles. The longer-lasting nature of these treatments reduces the need for constant reapplication, in some cases from 15x per day to 1x per week.

Mining operations already saving water

Operations across Africa—in some of the driest and dustiest conditions—have successfully used biological dust control for several years, achieving dramatic reductions in water usage and improved compliance with environmental regulations. 

GCO Senegal, ArcelorMittal in Liberia, Jubilee Metals and other iron ore mines in South Africa, have reported significant cost savings while achieving more consistent dust control compared to traditional methods.

When more mines adopt modern dust control practices, it will have a big collective impact on water conservation for the industry. Mining companies operate in shared ecosystems where water is a scarce resource for communities, wildlife, and agriculture. By adopting new and proven technologies like biological dust control, the industry has the chance to gain some easy wins, and show how operational efficiency and environmental stewardship can go hand in hand.

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4 things to consider for tailings dust control

Written by Janet Reznicek on . Posted in Article. No Comments on 4 things to consider for tailings dust control

But there are lots of options available, all with conflicting product marketing claims, so how do you choose the right one?

There are four key factors to consider when selecting a dust suppression solution for your site’s TSFs.

  • Dust control effectiveness
  • Environmental impact
  • Efficiency of application
  • Rehabilitation impact

Let’s look at each of these in more detail:

  1. Dust control effectiveness

You want to be sure that the dust suppressant you use will effectively bind fine tailings particles and withstand the site’s environmental conditions year-round.

The first thing to think about is the product’s binding strength. Using methods that create a durable crust will help prevent wind erosion. “Technologies like polymers have a strong binding effect but binding strength alone isn’t enough. That binding agent needs to have decent longevity so you’re not having to constantly reapply it,” says  JC Le Roux, Head of Business Development – Africa at Bind-X.

“The best dust suppressants should last at least a year, but 6 to 12 months minimum,” he says.

“And the tailings composition shouldn’t matter, it should be able to work with all pH levels and ore types in the tailings.”

Make sure to check the product compatibility with the water sources you have on site. Some suppressants require specific water conditions, while others work effectively with a wide range of pH levels (3-12) and brackish water.

2. Environmental impact

Tailings management teams are highly aware that the choices they make on site can impact people, animals, plants and water sources. Your choice of dust suppression methods is important to minimise these negative impacts. New technologies now mean you don’t have to make a trade-off between product effectiveness and environmental impact.

Start by checking whether the binding agent is non-toxic and opt for environmentally safe products to avoid contamination of local water sources and ecosystems.

“In the past you might have used polymers on your TSF, but now there are products that deliver the same binding effect as polymers, but are 100% natural and not a ‘white pollution’ plastic product,” explains JC.

Biodegradability is key. If you can use biodegradable suppressants, it prevents the long-term accumulation of synthetic materials.

Runoff control is a big part of that. Especially if your site is in a region with a significant wet season. Products like Terrabind, which is a biological binder, minimise the risk of leaching or contamination during heavy rainfall. 

“There might be a rain event right after you apply it on your TSF. With Terrabind there’s no issue, whereas with polymers you don’t want it to run off into waterways,” JC says.

A biological cap will also support hydroseeding and encourage new plant growth along dam slopes.

“You want to stabilise that area to control erosion to keep it intact for the wet season, so you can do hydroseeding and then rehabilitate that dormant area,” he explains.

3. Application efficiency

Your application method should be one of your most important considerations.

Why?

An easy and efficient application method can significantly reduce operational costs and timelines.
Products that use your existing site equipment, such as water trucks and standard pumps, allow for faster and broader coverage. “Our clients mention that they can apply a much bigger area per day with biological dust control. It allows them to use different equipment and different pumps that let them treat a much bigger section of the TSF.”

Coverage efficiency matters. A good suppressant should maximise treated area per unit volume. “It’s the difference between an application method like polymers which can take 60 days to cover the whole TSF, versus 15 days to do the job with biological dust control. It cuts the application time in half.”

And there’s the equipment clean-up to consider. “If you use a polymer, it’s a pain to apply because it needs special equipment and there’s a big clean up required to maintain that equipment. Sites I’ve been on have water trucks rendered unusable.”

4. Rehabilitation and future remining

Choosing the right tailings dust suppressant now can have long-term benefits for mine closure and future resource recovery.

Using the right tailings cap now can avoid a costly cleanup later — and that’s not just for mine closure. Some chemical suppressants can make tailings reprocessing more expensive. Opt for biodegradable, non-toxic methods to keep your TSF remains viable for potential future resource extraction.

Many mines focus on immediate dust control and overlook the implications for mine closure. “Many mines are trying to solve the immediate problem and manage immediate risk, but it’s worth thinking about the future and what tailings reprocessing might happen or what mine closure will look like.”

Find the right balance for your TSF

Selecting the right dust suppression method for your mine’s TSF requires a delicate balance of effectiveness, environmental responsibility, long-term site management, and operational efficiency.

Biological dust control methods offer a durable and environmentally friendly alternative to traditional methods like polymers. By considering these four key factors, environmental managers can make informed decisions that not only address immediate dust suppression needs but also support long-term sustainability goals.

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Meet our experts at the PDAC convention

Written by Janet Reznicek on . Posted in Article, Events. No Comments on Meet our experts at the PDAC convention

This year’s PDAC convention focuses on several key themes related to the principles of responsible mining. The convention will feature over 1,100 exhibitors, technical sessions, keynotes and numerous networking events. 

Biological dust control is a game changer

Bind-X with its new and proven technology of biological dust control is just in line with the principles of responsible mining. 

While water is becomeing more scarce, mines worldwide still rely on large volumes of water for dust control or on chemical alternatives.

This is not sustainable. And it’s also not necessary anymore.

With Bind-X’s biological dust control portfolio Terrabind, mines can achieve better  results while addressing environmental and regulatory challenges.

Book a meeting with our experts

Our team is looking forward to welcoming you at the Metro Toronto Convention Centre. Find us at the German Pavilion booth n° 6155N-6.

  • Dr. Luitpold Fried

  • Dr. Jan-Philip Merkl

Book a meeting

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Your guide to dust control methods in 2025. Which is best?

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We’ve already seen mines in other countries pause operations because of drought. It’s a global problem that is only going to get worse in the years ahead, as restrictions and shortages start to bite. In the short term, water isn’t doing your roads any good either. Giving the ground a regular soak increases mud and erosion which, unchecked, can destabilise the road and stop traffic. 

 These days, water isn’t the only option for dust suppression. More stable, sustainable and economical methods are available. Luitpold Fried, chief technical officer at Bind-X, says it’s worth looking again at what’s on the market, including completely new approaches, to see if your site could be doing better.  

Water-spray dust control

In the past, water’s main advantage was it was cheap and easily accessible. Even though it’s an increasingly limited resource, more than 70% of mining operations still use it as their primary method of dust suppression.

The problem with water is it requires frequent re-application, multiple times per day, meaning you not only churn through tonnes of water, but you also have to pay for fuel,increased wear on mining vehicles, and labour costs to respray. This means more trucks and more lost time. Luitpold says the real costs tend to be hidden.

“Because you have to apply it five to 20 times a day, when you think about the square meterage, it becomes highly cost intensive,” Luitpold explains.

“Most mines are just thinking about the upfront costs, they’re not thinking about it over the whole life of the mine.”

These costs are only going to get worse, long-term. Water is already scarce in many countries, including large parts of Australia. It’s a pressing problem in Chile, where mining operations were shut down for months by a severe drought in 2022. And more than half of all copper mining worldwide is at drought risk with climate change, according to a recent report by PWC. Long-term use of water can also destabilise the terrain, creating the need for more frequent road maintenance.

Pros:

​​✔​ Cheap and easily accessible for now

Cons:

​​✘ ​Requires frequent application

​​✘ ​High environmental cost due to water usage

​​✘ ​High operational costs over time

Bitumen emulsions for dust control

Bitumen emulsions tend to be used for primary roads with a lot of heavy traffic. It’s not hard to see why. When applied, it sets quickly and provides a solid, stable and long-lasting base. Luitpold says this longevity is both a plus and a minus. 

“Bitumen emulsions do a good job, but they are crude oil-based and not degradable. If you get it on your shirt, you’ll never get it out, it’s really ugly stuff.” 

However, it’s not just about the oils. Because applying hot mix bitumen isn’t always possible at remote sites, you’ll need to treat the soil with bitumen emulsions containing solvents and other toxic chemicals. And while it lasts forever in the soil, it tends not to last too long on the shelf, meaning you won’t always get your money’s worth from a bulk purchase. 

Pros: 

​​✔ ​Established and trusted method 

​​✔ ​Provides good performance and road quality 

Cons: 

​​✘ ​Oil-based 

​​✘ ​Persistent in the soil for thousands of years 

​​✘ ​Requires emulsification with other chemicals 

Polymers for dust control

Synthetic polymers provide a flexible and durable layer to keep the dust down, by binding particles together. Unlike some other methods, they work well in a range of climates and remain durable in the wet. They only require a thin film to work effectively, but they do require regular reapplication. Luitpold says concerns about “white pollution” (solid waste from plastic products), along with rising costs, means many mine sites are starting to phase polymers out.

“Polymers are not as good in performance as bitumen emulsions and they are more expensive. Also, unless you’re using bio-based polymers, they will stay in the soil forever.”

Pros:

​​✔ ​Can provide good performance

​​✔ ​Work in a range of climates

Cons:

​​✘ ​More expensive than other methods

​​✘ ​Polymer film is only a thin layer, requiring frequent reapplication

​​✘ ​Environmental concerns around persistence in soil

Dust control with lignosulfonates

A waste product of the paper industry, the main appeal of lignosulfonates is that they tend to be cheap. If you’re working in a dry climate, they can also be effective. In wetter climates they tend to be less effective, because they aren’t water-resistant and might need to be reapplied after every rainfall.

“You have to use a lot of product, maybe 1.5kg per square metre,” Luitpold says. “If you’re building a road with 10,000 square metres, you’re going to need a lot of stock.”

That stock might be cheap but may not always be easy to access. Changes to the paper industry will have knock-on effects and reduce future affordability, unless you still have a mill nearby.

Pros:

​​✔ ​Cheap and stable in arid conditions

Cons:

​​✘ ​Introduces sulphur into the soil

​​✘ ​Requires frequent reapplication in wet climates

​​✘ ​Availability issues due to factory closures

Salts for dust control 

Salts — or chlorides — are also cheap, but again you’ll need to use a lot of them. Because they work by sucking water out of the air and into the soil, they can have a destabilising effect on the terrain. The buildup of salts also tends to make soil poisonous to any vegetation.

“It gets into the groundwater, which is a big issue,” Luitpold says. “But it’s super cheap, which is the reason some people in Australia and North America are using it.”

Ultimately, the sheer volume of salt needed for effective dust suppression — and the associated transport and storage issues — often sees them fall out of favour with sites.

Pros:

​​✔ ​Very cheap

Cons:

​​✘ ​Not environmentally friendly, toxic to plants

​​✘ ​Washes out easily with rain

​​✘ ​Requires high application rates

Biological dust control

Biological dust suppression is the new kid on the block. Instead of relying on chemicals, this method uses naturally occurring microorganisms that react with dust and dirt to create a solid layer as hard as cement. This means greater stability in any climate, fewer applications and much less wasted water (up to 20 times less than other approaches). Available in powder or liquid forms, it’s easy to store and simple to apply. 

“It’s applicable with standard equipment, so the mine does not have to change anything,” Luitpold says.  

“This is important if a mine does not want to make a huge investment upfront.” 

One disadvantage is that it can take a little longer to work its magic than old school fixes such as bitumen emulsions. The microbes initially need six hours to turn the dirt into stone but have the advantage of creating a long-lasting stable crust that’s more solid than the surface films other methods offer. 

Pros: 

​​✔ ​Better water stability than bitumen emulsions 

​​✔ ​Can be applied with standard equipment 

​​✔ ​Binds small dust particles effectively 

​​✔ ​Flexible powder formulation can be stored for up to two years 

​​✔ ​Environmentally sustainable and bio-based 

Cons: 

​​✘ ​It takes six hours to reach full strength for road stabilisation due to biological activation (Although, dust suppression works with immediate effect) 

​​✘ ​The application method requires initial training 

No matter how you deal with dust today, it’s worth thinking about how you could do it better tomorrow. Water shortages will continue to make mining more expensive and difficult in many regions. So, if you’re just pouring water on your roads to keep the dust down, now is the time to look at other options. There are new and more effective methods out there, giving you a chance to get smarter about suppressing dust, improving road quality and – most importantly – keeping the trucks moving. 

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Is bitumen still a safe option for dust control?

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However, when it comes to environmental sustainability, there are some clear problems with using bitumen emulsion on mine roads.

In this article, we examine why it’s so widely used and suggest some cleaner options that have the same performance.

“The reason bitumen has traditionally been used for haul road stabilisation is that it lasts so long,” says Luitpold Fried, Chief Technical Officer at Bind-X. “It’s flexible, so you can drive huge loads along it and it won’t break — it’s like chewing gum in the soil.”

Bitumen may be effective at stabilising roads — which is particularly important on heavy use haul routes — but changing attitudes and regulations around the environment mean it’s worth looking at what else is out there.

The ugly side of bitumen emulsion

Even on its own, bitumen is “ugly stuff”, Luitpold says. It’s difficult to handle and almost impossible to clean up. Splash it on your clothes and it will never come out. As a crude oil-based product its production generates high levels of CO₂. Industry attempts to make it easy to transport and liquified have led to the emulsion being diluted with toxic chemicals.

“For the mining industry, bitumen emulsion is commonly blended with other waste streams,” Luitpold says. “Mostly they’ll add a polymer, a biopolymer or sugar to mix it down. Pure bitumen emulsion is better, but the cheaper version will do the job.” These additives mean bitumen might still be used because that’s what has always been done, but it’s not necessarily safe. “The bitumen blends always have at least three to six different hazardous symbols on the packaging, so you know there are a lot of poisonous chemicals in there. You’re looking at toxins and acids that are being brought into the environment.”

The impact can be disastrous, effectively sterilising the soil by killing essential bacteria and organisms. If the chemicals aren’t seeping into the dirt, they risk evaporating into the air, from where they can easily end up contaminating groundwater. Chemicals, crude oil products and increasingly scarce water supplies don’t go well together. That staying power can make clean-up jobs an expensive and complicated prospect when mines close — and can get in the way of future mining if there’s a need to dig up the ground where bitumen roads have been laid.

“If the water is close by, this is a serious issue,” Luitpold says. “Lots of communities are unhappy having bitumen works nearby, because you don’t want to have poisonous stuff in your drinking water.”

Water pollution can be an expensive business. There are examples from overseas of mines having to be closed down, Luitpold says, after drinking water has been contaminated by their activities. Nearer to home, Alcoa has had to commit $15 million towards researching the impact of its mining upon West Australian water catchments, after the government found nine out of 15 major drinking water catchments had been affected by toxic run off. A fix was priced in the order of $2.6 billion.

Less messy alternatives

Given that high price tag, it’s understandable that large mining companies across the globe are looking for a less toxic solution to dust suppression.

Biological dust control methods offer a proven and increasingly popular alternative that removes the risk of contamination. The natural process uses micro-organisms to react with dust and dirt to create a solid layer as hard as cement. It’s easier to ship and store than bitumen and far less messy to apply. It also means less water wasted, fewer applications and a reduced risk to the local flora and fauna.

“The ingredients in these biological binders are bio-based and also biodegradable, meaning that organisms within the soil can consume it,” Luitpold says.

These claims of biodegradability aren’t made lightly, he insists. While some plastic bags are touted as degrading naturally, they tend to require the sort of temperatures unlikely to be found in ordinary or even compost conditions — sometimes as high as 70 degrees centigrade.

Of course, it’s that very strength that is also one of bitumen’s shortcomings. Once bitumen emulsion has been sprayed on the ground, it’s almost impossible to get out again. Being biodegradable, biological dust control doesn’t need the same exhaustive cleaning regime. It can be safely broken up when needed, but while in use has the added bonus of getting stronger with each application. The big question, of course, is whether biological dust control methods can deliver the same stability that has made bitumen so reliable.

“It has similar performance to bitumen in the strength parameters and wet stability — and does slightly better than bitumen blends,” Luitpold says. “For maintenance, a small amount of product is sufficient to capture fugitive dust, which then produces another stable layer, closing any cracks that might have developed.”

Importantly, biological dust control doesn’t come with a high upfront cost, being cheap to source and easy to apply with equipment you probably already have on site.

Phasing out bitumen emulsions

“There are already lots of reasons to stop using bitumen emulsion, but we know it will be more expensive in future,” Luitpold says. “Prices will increase due to CO₂ taxes, the high energy need and the reduced availability of fossil fuel sources.”

Chemical companies are already researching how to cut back on the amount of bitumen in their products, substituting chemicals that might not yet be regulated. Some companies are even investigating biologically based bitumen, made out of renewable organic sources such as cashew nuts. As environmental regulations toughen in different parts of the world, Luitpold says it isn’t hard to imagine a near future in which the use of bitumen is banned entirely.

“It’s ugly stuff and it might very soon be coming off the market.”

Sticking with bitumen for dust suppression on haul roads is anything but a safe bet. In the short term, it’s difficult to handle, messy to apply and brings the risk of a costly clean-up bill. But in the longer term, it means investing in a product that — after a strong and steady run — might soon be reaching the end of the road.

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Should your dust control strategy change for the wet season vs dry season?

Written by Janet Reznicek on . Posted in Article. No Comments on Should your dust control strategy change for the wet season vs dry season?

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Your mine road dust control approach will need adjustment to avoid serious impact on your cycle times and productivity. By adapting your dust control strategy to your region’s distinct wet and dry seasons you can boost productivity and avoid costly setbacks.

Why does rainfall matter for roads and dust control?

Haul roads are the backbone of every mining operation and their condition is heavily influenced by weather. In the dry season, dusty roads can obscure visibility, accelerate vehicle wear, and breach environmental regulations. In contrast, heavy wet season rainfall saturates and erodes roads, making them unstable and slippery for haul trucks.

As Johan Smit, Dust Control Application Manager at Bind-X explains, “Managing haul roads effectively through seasonal changes is not just about compliance—it’s about productivity. A well-planned approach to dust control and road maintenance supports faster haul cycles, reduces downtime, and conserves critical resources.”

Dust control methods that work in the dry season often require adjustments—or a completely different approach—in the wet season. Ignoring these seasonal shifts can lead to road degradation, higher maintenance costs, and reduced productivity.

Dry Season vs. Wet Season: What is the best dust control strategy?

Dry season dust control

What is the best dust control strategy for your haul roads during the dry season? Here are four practical tips:

1. Use dust-binding agents

We recommend you use a biological dust binder which will bind surface particles in place, reducing the frequency of water applications. Dust binders not only control dust but also strengthen road surfaces, extending maintenance intervals. Johan explains, “Dust-binding agents work on the principle of locking dust particles together, significantly reducing airborne dust and the frequency of water spraying.” There are other dust control options available but he cautions that you should always consider the effect of these products on the plants, animals, and surrounding waterways. Some will be cleaner for the environment than others.

2. Optimise water usage

Avoid overwatering by applying water sparingly and only where it’s needed. Pairing water with stabilisers can make this possible. “A good binding agent will reduce your water applications by up to 90%,” says Smit. “In 2025, there’s no need to waste so much water on your roads when there are now biological road stabilisation options available. With water being so scarce now, we should be saving it for other areas of the mine where it’s needed.”

3. Focus on road surface maintenance

Regular grading and compaction helps maintain smooth surfaces and reduce dust fallout, supporting faster haul cycles and lower fuel consumption. “Make sure that your road surface is clean. Instead of just applying a product, make sure that your road is clear of contamination by sweeping or blowing away rocks or loose material,” explains Smit.

4. Adopt a biological approach

“Biological dust control can reduce watering frequency from five times a day to just once, eventually extending intervals to every 4-5 days. This minimises damage and improves road stability,” says Smit. Biological binders can also be mixed as a slurry for patch repairs, or churned into the soil as you would mix a concrete solution for surfaces that require increased stability.

Wet season dust control

In the wet season, saturated roads are prone to erosion, potholes, and softening. Here are four considerations to stabilise your roads during this time of year:

1. Ensure proper drainage

Proper camber and high walls with drainage channels allow water to flow off roads instead of pooling. Shoulders must be level with or below the road to prevent standing water.

2. Plan for post-rain grading

Frequent grading after heavy rains helps restore road profiles and prevent rutting, though repair costs are higher in wet conditions. Johan advises, “Grading is essential after rains, but timing it correctly can prevent further damage and control costs.”

3. Monitor road conditions

Engineers and safety managers should assess road conditions daily. Toolbox talks can address speed adjustments and braking distances to ensure safe operations.

4. Use road stabilisation agents

The last thing you need is slippery and unstable road conditions. Apply road stabilisation agents like Terrabind which creates a hard, cement-like layer to stabilise the soil during periods of heavy rain. “When it’s applied in the right ratio, it will improve your soil structure and reduce erosion of your road over time,” says Smit.

Seasonal transitions and how to adapt your dust control

As seasons change, so do the demands on haul roads. Smit says “It’s essential that you get your soil tested so you know the right volume of binding agent to get the best results as conditions change.” A proactive approach to transition between wet and dry seasons includes:

  • Conduct pre-season inspections to identify vulnerabilities. 
  • Test the soil and adjust dust control products and application schedules to match anticipated conditions.
  •  Train staff on seasonal best practices for road maintenance and dust suppression.
  • Develop a seasonal haul road dust management plan to streamline efforts and reduce expenses. This plan should include:
  • An annual schedule for inspections, treatments, and maintenance activities. 
  • Clear guidelines on when and how to apply dust-control agents. 
  • Metrics to evaluate the effectiveness of dust control measures, such as water savings, reduced downtime, and maintenance costs.

By adapting your dust control strategy to each season, you can break the cycle of reactive road maintenance, optimise haul road performance, and ultimately achieve better roads, more loads, and a stronger bottom line.

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Water scarcity makes mining more difficult. Why do we waste so much on dust control?

Written by Janet Reznicek on . Posted in Article. No Comments on Water scarcity makes mining more difficult. Why do we waste so much on dust control?

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Cape Town in South Africa famously endured five years of water scarcity, with inhabitants limited to 50 litres each per day – just enough for a quick shower, two litres of drinking water, one sink of dishes or laundry, one cooked meal, two hand washings and a toilet flush. Just this year, we saw similar shortages in places as diverse as Spain, Mexico and Zambia.

The global mining industry is already facing the consequences of growing water scarcity. In Australia, there is mounting community and government pressure for mine sites to use less water and manage it better.

In Chile, several mines recently had to stop operations altogether and find costly alternatives when a drought made fresh water unavailable.

More than half of all the world’s copper mines will be at risk of being shut down by drought by 2050, according to a report by PricewaterhouseCoopers LLP. Lithium and cobalt are at even higher risk of drought exposure — 74% of sites are expected to be affected.

Martin Spitznagel
Chairman of the Board and Founder at Bind-X

“We have to prepare for the fact there are going to be another billion people added to the planet over the next 10 to 15 years, which will make it even more tricky to manage water in all areas of society and business,”

The need to act now to avoid future pain 

Martin Spitznagel, Chairman of the Board and Founder at Bind-X, says we in the mining sector need to be taking action to cut down on wasting water before it gets more expensive and more threatening to day-to-day operations.

“We have to prepare for the fact there are going to be another billion people added to the planet over the next 10 to 15 years, which will make it even more tricky to manage water in all areas of society and business,” Martin says.

“It’s going to be the most precious resource. That obviously affects mining, because water management is already one of the most important aspects when you’re running an existing or setting up a new project.”

While new projects are having to account for water savings, existing sites have less and less water available.

It doesn’t help that water allocation prices in Australia are shooting up and that more frequent water scarcity and drought is likely to drive water prices even higher for miners. Water entitlements across New South Wales increased in value from around AU$29 billion in 2021 to an estimated AU$34 billion in 2023 — a 17% increase in two years. If water wastage isn’t curbed, existing mines may struggle to keep their licence to operate and new projects will become unviable. 

Martin says that, while many key operations on a mine are always going to be water hungry — most process plants require large amounts of water, for example — there is one area where savings can be made right now.  

Billions of litres of water wasted on dust control

“Depending on the conditions of the mining area, dust control can be the main consumer of available water and is a key area where we could be using less. When you use plain water to keep the dust down, you may need to spray your roads and other areas up to five or six times a day. We’re talking billions of litres of water wasted every year.”

Most miners see water as the default option for dust suppression on roads, a hangover from a time when water was plentiful and cheap. Estimates suggest 70% of Australian mines are still using water alone, even as shortages loom and prices rocket. When you consider that the average site has between 50 and 100 km of roads, the amount of fresh water being thrown on the ground looks staggering.

It’s also not hard to come up with a realistic estimate. Using conservative numbers, let’s say the average site has only 50 km of roads, each 10 metres wide. Typically, water trucks apply a minimum of 2 litres of water per square metre of road. This can be more than five times per day but again, let’s use a conservative application frequency of twice per day.

That equates to 2 million litres of water per day. 730 million litres every year (of course, depending on climatic seasonalities).

With more than 350 operating mines in Australia, it’s likely that more than 250 billion litres of water gets poured onto dirt roads every year. And that’s just roads. We’re not even accounting for stockpiles, tailings, and open areas.

What’s the alternative for water-spray dust control? 

Smart mine operators have begun to adapt to a changed environment. Many of them are now looking into less water-hungry alternatives for dust control. These include bitumen emulsions, polymers, salts and lignosulfonates, all of which have their own drawbacks and can still place heavy demands on your water allocation, not to mention your bottom line.  

There is a new approach which has proven to slash water usage without reliance on crude oil-based or chemical products. Biological dust control removes the need to constantly rewater your roads by using microbes that bind the dust together, turning it into solid rock. These mineral-based bonds hold the dust particles together to form a smooth, solid surface and prevent them from becoming airborne. Martin says mines using this biological method have seen a dramatic reduction in water usage. 

Most mines cut water consumption by more than 90% and significantly improve the road quality when they switch from plain water to biological dust control. It’s because you have a binding approach, not only a wettening approach, with a positive impact on the needed application frequency.  

Cutting back on spraying roads reduces immediate operational pressure and, in the long run, will ensure that you can use your water budget for the process plant and reduce your risk of being impacted by shortages.  

Reduce carbon emissions to break the cycle 

It’s not just water that these sites are saving. Less frequent watering means less trucks and less fuel burned. When your trucks are out on the road all day, spraying a scarce resource, their emissions are compounding the problem by contributing to the climate change that is driving water shortages in the first place.

Martin says biological dust suppression promises to end that vicious circle.

“Why do we have a water problem?” Martin says.

“Besides human behaviour and mismanagement it’s mainly due to CO2 in the atmosphere and global warming leading to climate changes and desertification. If by saving water you have an indirect impact on reducing CO2 emissions, it means in the long run that you are also reducing the pressure from water scarcity.”

Water scarcity is a serious threat to mining operations. Taking action today to cut back on water wasted means you are setting your site up for tomorrow — and maybe even helping ease restrictions that promise to make operations more and more costly.

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What is biocementation and how does it work on mine roads?

Written by Janet Reznicek on . Posted in Article. No Comments on What is biocementation and how does it work on mine roads?

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New technologies, rooted in natural biological processes have emerged. One of these soil stabilising products allows mine operations to tackle two significant challenges: conserving scarce water resources and improving the quality of haul roads. It’s a method that is both effective and sustainable.

This new category — biological dust control — uses a natural biocementation process to bind dust particles together into a solid wearing course layer. It uses 90 percent less water than spraying water alone, and gives bitumen emulsion a run for its money when it comes to stability, with none of the environmental downsides. In this article, we look at what it is and why this alternative to traditional dust suppression methods is sparking interest across the sector.

How does biocementation work?

“The basic technology behind biocementation is naturally occurring bacteria that devour the nutrients in soil and convert it to a mineral,” says Luitpold Fried, Chief Technology Officer of Bind-X.

“That mineral becomes a glue that binds soil particles together. You end up with solidified soil, which you’ll see in natural structures like the Pinnacles of Nambung National Park or the Thrombolites at Lake Clifton in Western Australia.”

Indeed, there is a strong West Australian connection to the technology, originally developed at Murdoch University. What Bind-X has done is further developed this research and this natural process to make it suitable for mines wanting to move away from environmentally unfriendly dust control methods.

“Normally, bacteria like to live in liquid. We were the first to be able to dry this biocementation bacteria and keep them alive so we can deliver our product as a powder,” explains Luitpold.

This powder base contains only a small amount of bacteria, but when mixed up on-site, they quickly come back to life and get to work.

“It’s like if you make pizza at home, you go to the grocery store and you buy the dried yeast, which you add to your dough. The client gets a big bag with our product in, they dissolve it in water, and the process gets started.”

How is biological dust control applied?

Biological dust control can be applied in two different methods — one is to grade the existing road, spray Terrabind into the loosened material, then mix and compact the road surface to build a stabilised 10-15 cm layer (build-in application), while the other is to spray it onto the surface of existing roads (spray-on) and create a stable crust on the top wearing course. Both methods use equipment you already have onsite.

“At the moment, 70 percent of our clients use a spray on application,” Luitpold says. “Bigger mines might also build the road from scratch, especially if it’s a heavy use road like those in Australia, where you’re getting trucks with loads of 500 to 800 tonnes.”

Luitpold says switching to biocementation is often a case of just switching to a new product, rather than a new process. Given the importance of stable roads for productivity, it’s important that biological dust control can match or exceed bitumen emulsion’s performance while being more sustainable.

“The performance is identical to bitumen emulsion, so you get high flexibility and very similar levels of stability.”

The surface created by the biocementation process is solid and flexible. It’s a good match for bitumen emulsion in terms of road durability, without any of the toxic, crude oil-based downsides. Those drawbacks — sticking to equipment, damaging water trucks, and the toxicity to people and the environment — are familiar to operations teams who maintain haul roads. By creating a smooth, low-friction layer it reduces damage to tyres and vehicles, reducing maintenance and enabling safer, faster cycle times.

Where is it being used?

Luitpold says that mines in more than 15 countries, including Australia, have adopted biological dust control for environmental, safety and productivity reasons.

It’s been adopted quickly across the mining sector because it’s reapplied far less often than plain water for dust control, with each new application strengthening the original surface by binding any cracks together. This matters in parts of the world where water is a scarce and increasingly expensive resource.

“We had a client in Senegal who had to spray water five to 10 times a day to keep the dust down,” Luitpold says.

“They were consuming a lot of water and spent too much time and money on the maintenance of the trucks, which were on the road all day.”

Overwatering of mine roads also causes erosion and destabilisation and tends to make the surface muddy and slippery. This makes the roads less safe and requires trucks to slow down and maintain larger braking distances. All of which has a big impact on cycle speeds and productivity.

Within three months of switching to biological dust control, the mine saw a dramatic drop in water usage and haulage costs. Water use was reduced by 85 %, diesel consumption also dropped by 85 % and CO₂ emissions linked to dust control were slashed by 94 %.

“Water is a scarce resource in Senegal, so they have to drill really deep to get the groundwater for their operations,” Luitpold says.

“Cutting back on water has a real benefit for them. And there are local communities close to the mine — farms and schools and families of mine employees — so it’s important that the site uses a dust control method that is natural, biodegradable and non-toxic for people, animals and water sources.”

Similarly strong results have been seen in other parts of the world, with Australian iron ore mines adopting the technology over the last few years. Indeed, the increasing scarcity of water and tightening environmental regulations in these arid regions will make plain water and older dust control methods like bitumen less and less attractive over the coming years.

Future-proofing your haul roads

There is another major change that will require mining operations to think again about the most effective means of dust control.

“If you have 250 kilometres of road networks and you’re running autonomous trucks, without a person at the wheel, then dust control is going to be really, really important to you,” Luitpold says.

“A person at the wheel will drive slowly through heavy dust, but an AI-driven truck will just stop dead.”

As times change, it makes sense to look at what else is out there if you don’t want to be left behind. Biocementation is a proven method of dust control that’s economical, simple to apply and makes your roads better. With zero environmental risks and much less water required, it’s an appealing option for operational and environmental teams.

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