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One switch transformed dust control at a manganese operation

Dust was under control, but road maintenance was turning into a constant firefight. When the manganese mine realised its bitumen-based dust control solution was causing equipment issues, costly delays, and admin-heavy workarounds, they made a bold switch. One year later, the difference is clear.

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.”

Bitumen emulsion in a water bowswr that is clogged

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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