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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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ArcelorMittal cuts water use on haul roads by 75% with biological dust control

Written by Janet Reznicek on . Posted in Case study. No Comments on ArcelorMittal cuts water use on haul roads by 75% with biological dust control

Client:
ArcelorMittal Iron Ore Mine

Location:
Liberia

Challenge:
Water scarcity & dust control to protect nearby communities

Use-Case:
Dust Control on haul roads

The cost, labour, and environmental impact of this approach added up, and with the operation situated near a local community, the need to control dust without wasting water was a key priority.

After reviewing all their options, the mine trialled a biological dust control method. The results were striking: water usage fell by 75%, dust fallout was significantly reduced, and truck cycle time improved.

Problem: Dust control with traditional methods

ArcelorMittal’s Liberian site is a high-production iron ore operation with dump trucks and light vehicles cycling through every minute on 12m-wide haul roads.

Controlling dust is essential to protect nearby communities and maintain safe driving conditions. However, the traditional approach relied entirely on water, applied several times a day with a fleet of water trucks.

The daily water requirements for dust suppression were high – sometimes reaching up to 300,000 litres per day – and it still wasn’t enough to keep dust levels under control.

“Like so many mining operations that use only water to control dust, they were stuck in a cycle where they had to keep applying water, but that water would destabilise the road, forcing them to rework the surface more often,” explains JC Le Roux, Head of Business Development at Bind-X.

In addition to the strain on water resources, the repeated watering cycles caused road deterioration, increasing maintenance costs and reducing vehicle cycle times.

“The type of iron ore dust there is extremely fine and when it plumes you can’t see five metres in front of you,” says Le Roux. “Dust fallout significantly reduced visibility during material hauling, occasionally causing delays and lowering cycle times.”

A biological dust control approach

Biological dust control is sprayed on the road to create a rock hard layer by means of bio-cementation

Seeking a more sustainable and efficient way, the Operations Manager tested a biological dust control method developed by Bind-X. The product called Terrabind, uses biological technology to bind the upper wearing course layer with bio-cementation, forming a stable surface that reduces dust and makes the road more durable.

Unlike bitumen-based solutions, which are costly and pose environmental risks, biological dust control is a process that already occurs in nature, and is safe for waterways and ecosystems. The solid, cement-like layer that it forms reduces the need for water as dust particles in the soil are bound tight.

The mining services team were intrigued by the concept of using clean technology to control dust so they decided to trial it.

Dust control trial implementation

The team conducted a three-month trial on two sections of road: a primary haul road with heavy traffic and a secondary road with less frequent use. They applied the product in two ways: as an additive to the road surface during construction and as a surface treatment for existing roads.

Could a biological dust control approach deliver the same results as traditional methods?

“Once the trial began, the roads started holding up better almost immediately,” said Le Roux. “The product formed a hard, stable layer that didn’t require constant watering or reapplication.”

Results: 75% less water usage

The trial delivered dramatic improvements. Water usage dropped by 75%, a drop in daily consumption from 300,000 litres to just 75,000 litres. The dust-free roads improved air quality for workers and nearby communities.

In addition to water savings, the operation experienced other cascading benefits. The roads required far less maintenance, freeing up equipment and labour for other tasks. Truck cycle times improved as drivers encountered less dust plumes blocking vision, and smoother, more stable surfaces.

Mining service manager
ArcelorMittal iron ore mine, Liberia

“Reducing water trips from three or four times a day to just once every few days made a huge difference. We’re seeing better road durability, less equipment wear, and fewer operational interruptions.”

A new standard for sustainable mining

After the trial report was signed off, ArcelorMittal decided to fully adopt the biological dust control solution across its Liberian site. The move has not only helped conserve water but also improved the mine’s overall environmental footprint and they are now preparing to roll it out at other locations.

“This approach aligns perfectly with our sustainability goals,” said the Mining Services Manager. “It’s allowed us to cut water use dramatically while improving operational efficiency and reducing our impact on the community.”

The transition has also simplified logistics. Unlike traditional chemical suppressants, the biological product is easy to store, transport, and apply, further reducing costs and environmental risks.

“Our experience shows that you don’t have to choose between sustainability and performance,” said Le Roux. “With the right approach, you can achieve both.”

By embracing biological dust control, ArcelorMittal has set a new benchmark for responsible mining practices, demonstrating how modern technology can drive operational excellence while protecting vital resources.

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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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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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Jubilee Metals: Clearing the air with responsible mining

Written by Janet Reznicek on . Posted in Case study. No Comments on Jubilee Metals: Clearing the air with responsible mining

Client:
Jubilee Metals

Location:
Zambia

Challange:
Excessive dust and potential disruption of local environment 

Use-Case:
Access road stabilisation and dust control

They took proactive steps to not only treat the road in a clean, non-toxic way but to also restore the school’s soccer pitch. An approach that went far beyond compliance to create lasting benefits for the community.

Here’s how their initiative came together and what we can learn from their commitment to responsible mining.

The problem

“Jubilee Metals were looking for a brand new way of controlling dust on the mine that would be cleaner for the environment,” says JC Le Roux, Head of Business Development – Africa at Bind-X. “The company likes sustainable approaches and they are genuinely committed to responsible mining practices.”

Their environmental stewardship and investment in community well-being has guided their approach to every project, including their latest initiative during the exploration stage of the greenfield Munkoyo Project in Zambia.

The project team knew they had to take particular care of this section of road to keep the dust down long term and stabilise the road year-round.

They also noticed that the school’s soccer pitch, a central space for the students’ recreation, was overgrown with weeds and thorns and nearly unusable.

Considering their options

Jubilee Metals had tried various dust control options before on their other mine sites but sought a better approach that aligned with their sustainable vision, while also keeping operational costs down.

“There’s some light vehicle traffic currently, but there’s going to be a steady stream of vehicles travelling past once the site is operational which could generate a lot of dust, so it wouldn’t be good near the local school,” says JC.

Plain water was not a good option as it would have yielded poor results. Dust suppression from water would only last temporarily, and need constant reapplication. Further, they knew that plain water sprayed on the road would reduce road stability and worsen the problem over time.

They had considered traditional dust control products like bitumen emulsion and polymers. While they would have kept dust down, neither were particularly clean for the environment, with the potential for run-off to local waterways.

Their next step was to consider new technologies that would be safe for people, plants and surrounding streams. They had already used Terrabind biological dust control by Bind-X at their operating mines and had seen great results, so realised it could be ideal for this new project.

Biological dust control

Jubilee Metals chose to use a 100% natural biological binder called Terrabind. It works using a natural biocementation process in the soil. Naturally occurring bacteria devour the nutrients in soil and convert it to a mineral.

“That mineral becomes a glue that binds soil particles together. You end up with solidified soil, which you’ll see in natural structures like termite mounds and coral,” explains JC.

The project team decided to apply this clean binding agent to the feed roads in front of the school to lock the soil particles together and prevent fugitive dust. By treating the 1 km stretch of road in front of the school with Terrabind, the company significantly reduced dust levels, ensuring cleaner air for the children and the surrounding community. 

The application process was easily integrated into their existing operations, using regular water trucks for weekly reapplications. As traffic increases with the project’s progression, the frequency of application will be adjusted to maintain air quality, potentially as often as once daily.

Going above and beyond

Beyond dust reduction, Jubilee Metals extended their efforts to improve the school’s soccer field. The team graded the field, removed weeds and thorns, and treated it with a lighter application of Terrabind to create a safe, even surface for play. Care was taken to ensure the field remained soft enough for sports activities.

When we heard about the school, “We thought, how about we do something as well?” says JC.

“Before there was more or less a soccer field, but I mean, it wasn’t great. So we decided to grade it to make it more of a formal soccer field, to formalise it a bit.”

“Now it’s neat and you can see where the soccer field actually is, where the lines should be. We just wanted the kids to have a neat field that they can run on and play soccer and other sports. We also gave them some sports equipment to play with,” says JC.

The impact?

Health and environment benefits

The use of biological dust control has significantly improved air quality by reducing dust along the road, creating a cleaner and safer environment for the school and its surrounding community.

Community well-being

The upgraded soccer field and provision of sports equipment have revitalized a key recreational space, promoting physical activity and community engagement.

Operational efficiency

Unlike plain water, Terrabind improves road stability, reducing long-term wear and ensures sustainable dust control.

Responsible mining

Jubilee Metal’s approach reflects their dedication to building strong relationships with local communities. When the company learned of the school’s challenges, they didn’t hesitate to act.

“It’s been really nice to hear the stories and it’s quite heartwarming. It was really great to see a small gesture like a soccer ball and what it does to that child and the smile on their face,” explains JC.

For Jubilee Metals, responsible mining is about operational excellence combined with leaving a positive, lasting legacy. By prioritising the health and well-being of the communities they operate in, the company has demonstrated how clean technologies can have a positive impact on the environment, and the surrounding community.

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African iron ore mine achieves 30% less water truck trips on haul roads

Written by Janet Reznicek on . Posted in Case study. No Comments on African iron ore mine achieves 30% less water truck trips on haul roads

Client:
An Iron ore mine

Location:
South Africa

Challenge:
Water scarcity 

Use-Case:
Haul road stabilisation and dust control

Each day, this inefficient method strained the mine’s water resources, increased equipment wear, and put pressure on production costs.
The regulatory environment intensified the need to look for alternative options as the site faced warnings from South Africa’s Department of Mineral Resources and Energy (DMRE) due to excessive dust levels.

They knew that if they continued exceeding dust fallout limits, the DMRE could halt operations entirely. Faced with these challenges, the Mining Manager began to look into a more sustainable, cost-effective alternative that could control dust and reduce water use.

Researching alternative dust control methods

The mine operates in an arid region and access to water is limited. Anything that could reduce the amount of water on the roads was something the Iron Ore mine seriously considered.

“It’s a very water-scarce area. They’ve got a set amount of potable water that they can utilise across the whole mine. So anything that can reduce the amount that’s being sprayed onto the roads is worth considering because that’s put to better use in the process plant,” says JC Le Roux, Head of Business Development Africa, Bind-X.

Initially, the mine considered continuing with their existing options: lignosulfonates and bitumen blends. While these methods offered decent performance, they brought several limitations. Bitumen emulsions stained the water trucks, added wear and tear to equipment, and became cumbersome to apply.

Costs also posed a challenge: bitumen, being a crude-oil-based product, is deeply connected to the oil price which continued to rise, adding budget strain to an already cost-sensitive operation.

Although lignosulfonates helped stabilise roads, they required frequent reapplication and high volumes of water, both of which clashed with the mine’s commitment to conserving water in their community.

The Mining Manager explored newer technologies and found a biological dust control method by Bind-X which addressed each of these challenges. With Terrabind, the mine site could reduce daily dust suppression applications by 30%, conserving water and lowering labor costs.

The product’s application also proved simpler, required less frequent attention, and left no staining or residue on vehicles. And from an environmental perspective, it was clean for plants, animals, and waterways.

Soil testing and compatibility

First, Bind-X conducted soil sample tests to confirm compatibility with the mine’s iron ore haul roads. With positive results, they chose to move forward, providing training on the product’s application methods. As JC explains, “They initially queried whether less water and fewer applications would mean reduced effectiveness, but they were thrilled when we achieved the opposite: better dust results with less water.”

A biological approach also aligned with the mine’s strict budget and commitment to environmental safety. Instead of multiple daily sprays with high water volumes, the team could now apply a concentrated solution at less frequent intervals. This adjustment helped the operation reduce water and labour costs, optimise haul road durability, and prevent vehicle staining and equipment wear.

30% less water truck trips

With the new dust control method in place, the mine experienced substantial and immediate improvements. By reducing dust suppression applications by 30%, they cut water usage significantly, which allowed the operation to redirect water to essential mining processes. As a result, the haul roads required less maintenance, improving cycle times and production targets.

Moreover, they began to consistently meet the DMRE’s strict dust fallout regulations, ensuring the mine operated without regulatory interruptions. “Since switching to Bind-X, we haven’t faced any DMRE warnings in over 20 months,” reported the Mining Manager.

He also noted that vehicle maintenance had declined as the new dust control solution left no residue.

Mining manager
A South African iron ore mine

“It allowed us to achieve outcomes that meet or even surpass those from previous products. The application aligns perfectly with our environmental safety goals and also safeguards our equipment. We’re seeing superior dust control at lower costs, with the added benefit of reducing our carbon footprint. Each regulatory visit confirms our full compliance, and we’ve set a new benchmark for dust control on site.” 

By implementing a biological dust control method, the mine addressed critical water and dust control challenges head-on, and made their operation more environmentally responsible at the same time.  The mine’s success exemplifies how strategic, sustainable choices can drive operational excellence, allowing the mine to set a new standard in water efficiency, regulatory compliance, and long-term productivity.

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