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Designing a year-round dust control plan

Written by Janet Reznicek on . Posted in Article. No Comments on Designing a year-round dust control plan

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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

Stronger orads and less dust with Terrabind

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

Stronger orads and less dust with Terrabind

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. No Comments on One switch transformed dust control at a manganese operation

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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.”

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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Dust can risk your license to operate

Is dust control risking your license to operate?

Written by Janet Reznicek on . Posted in Article. No Comments on Is dust control risking your license to operate?

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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, CEO at 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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More water trucks won’t fix your dust problem

Written by Janet Reznicek on . Posted in Article. No Comments on More water trucks won’t fix your dust problem

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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 orads 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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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.

Martin Krehenbrink
General Manager at Bind-X Africa

“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 Martin.

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 Martin 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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Dangote Cement reduces water consumption by 70% with biological dust control

Written by Janet Reznicek on . Posted in Case study. No Comments on Dangote Cement reduces water consumption by 70% with biological dust control

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Client:
Dangote Cement

Location:
Senegal

Challenge:
Excessive dust and water usage 

Use-Case:
Dust control and road maintenance

One of Africa’s leading cement manufacturers, Dangote has not only reduced their water use for dust suppression by 70% but also dramatically decreased road maintenance costs — just by using a biological dust control approach.

The problem: High water usage and constant maintenance

Only one year earlier, Dangote was experiencing several operational challenges:

  • Excessive dust reduced visibility across the site, creating safety concerns
  • Water trucks were constantly running at maximum capacity
  • Significant resources were dedicated to road maintenance and grading
  • Vehicles and equipment required frequent cleaning and maintenance
  • Environmental impact was a growing concern

“That place was extremely dusty. Even outside the plant, there was a dust cloud hanging everywhere. Visibility was poor,” recalls JC Le Roux, Head of Business Development Africa, Bind-X, who visited the site.

While the plant management had previously explored bitumen-based dust control options, they found these solutions too expensive. This left them continuing to rely on water alone, despite its clear limitations and resource intensity.

Trialling biological dust control

The mine’s Operational Sustainability Manager at Dangote was looking for a better way to cut water usage and manage dust, while also keeping cost in mind. 

When he heard about a new and proven biological dust control product, and looked at the cost analysis, he was keen to run a trial on site. 

They began a trial of Terrabind Max on a stretch of road at the facility a few kilometers long. As a spray-on application, it was ideal for their well-established roads and didn’t need to be built in with a grader.

The implementation process was straightforward:

  1. The team received on-site technical assistance and training on product mixing and application
  2. An initial higher dose was applied to establish the road treatment over 2-3 days
  3. After the initial application, the team transitioned to a lower maintenance dose applied once daily

The result with biological dust control

The trial demonstrated immediate and substantial benefits — a 70% reduction in water usage for dust control — leading Dangote to continue using the method, and now expanding it across their operations.

The most significant outcomes included:

  • Dramatically improved visibility and safety across the site
  • Reduced frequency of road grading and maintenance
  • Lower fuel consumption for both water trucks and graders
  • Decreased wear on vehicles and equipment
  • Recognition from environmental authorities

“Suddenly, buses, trucks, and other vehicles could drive over the road without kicking up dust. That was a game-changer for the operation,” JC noted.

Perhaps most unexpectedly, the Ministry of Environmental Affairs witnessed the results during a site visit. “When they drove on that road, they were surprised at the lack of dust. They stopped and asked what was being used. They were impressed when they learned it was a biological dust suppression method, which is 100% environmentally safe, and they praised the initiative.”

Long-term impact

Based on the success of the initial results, Dangote now:

  • Continues to use biological dust control at their current site
  • Expanded the approach to additional roads within their operation
  • Implemented the same solution at another facility

“The two biggest benefits for Dangote were water savings and reduced road maintenance,” JC explained. “The team should be commended for their competence and excellent teamwork in executing the project.”

The combined benefits of water conservation, improved safety, reduced maintenance, and environmental recognition have made biological dust control an essential part of Dangote’s operational strategy going forward.

By implementing Bind-X’s biological dust control method, Dangote has addressed critical dust control challenges while significantly reducing their environmental footprint and operational costs.

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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?

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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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Transforming dust management at Rosh Pinah Zinc Mine’s TSF

Written by Janet Reznicek on . Posted in Case study. No Comments on Transforming dust management at Rosh Pinah Zinc Mine’s TSF

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Client:
Rosh Pinah Zinc mine

Location:
Namibia

Challenge:
Excessive dust and potential disruption of local environment 

Use-Case:
Erosion control on tailings storage facilities

Managing the environmental and community risk of dust emissions is a big priority for the mine owners, that’s why they explored innovative methods to reduce dust and be more sustainable.

Today, the mine demonstrates how new dust control technology can improve operations, reduce costs, and pave the way for long-term rehabilitation.

The problem: dust and durability

At Rosh Pinah, the TSF has two main sections—one active and one dormant. Over time, the dormant sections became a significant source of dust, particularly during the windy season. Prior to 2021, the mine controlled dust by spraying polymers mixed with water on the TSF surface, particularly on the flat “beach” areas and the sidewalls.

Polymers initially seemed effective—they reduced dust fallout to acceptable limits—their application came with challenges. “Using polymers required specialised equipment and frequent maintenance,” explains JC Le Roux, Head of Business Development Africa at Bind-X. “It was hard on the pumps and water carts, often clogging seals and damaging centrifugal pumps. They would see two or three pumps wear out in a single application cycle.”

 Additionally, the plastic film created by the polymer spray was a long-term environmental liability, particularly for future rehabilitation. Polymers prevent vegetation growth and complicate efforts to return the land to its natural state when rehabilitation takes place.

The solution: a biological approach

A solid crust is formed on the surface of a tailings dam by means of biological dust control

In 2021, Rosh Pinah began trialing Bind-X’s biological dust control approach, Terrabind, as part of its broader push for sustainable mining practices. Unlike polymers, biological dust control is non-toxic, inert, and water-soluble. The trial, conducted on a two-hectare section of the TSF, focused on erosion resistance and binding performance over a two-month period.

“The results spoke for themselves,” says Le Roux. “The biological product formed a solid crust 20-30 millimeters thick—thicker and more durable than the polymers they’d used before.”

And the best part? It was far easier to apply.

Unlike polymers, which require specialised pumps and extensive flushing to prevent sticky residues, biological dust control can be mixed easily with water and applied using standard equipment. “It’s an entirely new category of dust control and it’s a game-changer in terms of simplicity and cost-effectiveness,” adds Le Roux.

Environmental and operational benefits

Beyond performance, a biological approach offers clear environmental advantages. Unlike polymers, which form a plastic-like layer that hinders plant growth, the biological cap binds the soil together with a solid rock-like consistency, while remaining water-soluble. This allows the area to be rehabilitated without additional cleanup or disruption.

“One of the biggest advantages is how well the biological product integrates into rehabilitation efforts,” Le Roux explains. “It provides a solid buffer for dust control while buying time to manage rehabilitation costs and timelines.”

In the two years since adopting Terrabind, Rosh Pinah has reported 30-40% cost savings compared to polymers. These savings are due not only to the lower product cost but also to reduced equipment wear, faster application, and easier handling.

A sustainable future

With the new dust control approach, Rosh Pinah has successfully reduced dust levels, met environmental regulations, and enhanced sustainability efforts. Dust control applications now last 6-12 months per cycle, providing consistent performance without the drawbacks of polymers.

Jc Le Roux
Head of Business Development Africa at Bind-X

This wouldn’t have been possible a few years ago with older dust control technologies. They’re not just controlling dust, they’re actively setting the stage for rehabilitation and long-term environmental stewardship.

As mining operations face increased pressure to adopt sustainable practices, the Rosh Pinah Zinc mine offers a compelling example of how new and proven technologies now available can balance environmental responsibility with operational efficiency.

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

Written by Janet Reznicek on . Posted in Article. No Comments on 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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