Skip to main content

Tag: Dust control

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 Alex McHaffie, General Manager, Bind-X.

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

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

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

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

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

Soil testing and compatibility

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

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

30% less water truck trips

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

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

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

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.

Topic

Topic

Find out about biological dust control for your site

Enquire now

Continue reading

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

article



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

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

How does biocementation work?

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

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

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

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

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

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

How is it applied?

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

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

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

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

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

Where is it being used?

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

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

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

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

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

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

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

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

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

Future-proofing your haul roads

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

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

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

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

Topic

Topic

Find out about biological dust control for your site

Enquire now

Continue reading

Transforming dust management at Rosh Pinah Zinc Mine’s TSF

article



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 Alex McHaffie, General Manager 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 McHaffie. “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 McHaffie.

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,” McHaffie 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.

Alexander McHaffie
General Manager Bind-X South Africa

“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.

Topic

Topic

Find out about biological dust control for your site

Enquire now

Sign up to our 10x Mining Newsletter

Sign up and 10x your mining results with know how and new technologies.

[contact-form-7 id=”b2b0a25″ title=”Anmeldung Newsletter”]

Continue reading

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

article



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

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 

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

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

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 

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 binding 

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. 

Topic

Topic

Find out about biological dust control for your site

Enquire now

Continue reading

Is bitumen still a safe option for dust control?

article



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

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

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

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

The ugly side of bitumen emulsion

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

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

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

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

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

Less messy alternatives

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

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

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

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

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

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

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

Phasing out bitumen emulsions

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

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

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

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

Topic

Topic

Find out about biological dust control for your site

Enquire now

Continue reading

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

article



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

Why does rainfall matter for roads and dust control?

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

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

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

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

Dry Season

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

1. Use dust-binding agents

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

2. Optimise water usage

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

3. Focus on road surface maintenance

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

4. Adopt a biological approach

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

Wet Season

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

1. Ensure proper drainage

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

2. Plan for post-rain grading

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

3. Monitor road conditions

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

4. Use road stabilisation agents

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

Seasonal transitions

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

● Conduct pre-season inspections to identify vulnerabilities. 

● Test the soil and adjust dust control products and application schedules to match anticipated conditions.

 ● Train staff on seasonal best practices for road maintenance and dust suppression.

Develop a seasonal haul road dust management plan to streamline efforts and reduce expenses. This plan should include:

● An annual schedule for inspections, treatments, and maintenance activities. 

● Clear guidelines on when and how to apply dust-control agents. 

● Metrics to evaluate the effectiveness of dust control measures, such as water savings, reduced downtime, and maintenance costs.

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

Topic

Topic

Find out about biological dust control for your site

Enquire now

Continue reading

Eramet’s GCO reduces road water usage by 85% with biological dust control approach



Client:
Client
Grande Côte Opérations (GCO)

Location:
Location
Senegal

Challange:
Challenge
Water damages road infrastructure 

Use-Case:
use-case
haul road stabilisation and dust control

The mine is close to a local community, so there’s always pressure to do things better — reducing environmental impact and using less water are top priorities. 

 In 2022, the mining services team realised they were spraying over 242,000 litres of water per day on the roads just to keep road dust under control. They wanted to reduce water consumption, so the business proactively decided to test other options. One of the tests, a biological dust control method, reduced water usage by 85% and created a three-fold drop in dust fallout. Here’s how they did it. 

The pressure on water resources in WA mining

With a local community living nearby, the mine services team had to keep a close eye on air quality. And from a production point of view, any fines kicked-up from the road reduced visibility for the drivers and slowed down cycle time. 

At that time, the mining services team was using only ground water to control dust on very arid land. All of their water trucks were being run at maximum capacity, and they had even bought new trucks to expand the fleet and keep the dust down. 

As they increased the frequency of watering, they noticed another problem. 

“Once you apply water to a road, it evaporates and afterwards you’ve got no stability in that road infrastructure,” says Alex McHaffie, General Manager, Bind-X. 

“GCO has got some of the better road construction teams that I’ve seen across Africa, and they take a lot of pride in managing their roads the right way,” he explains. 

Losing fines from the road surface forced them to frequently re-lay the wearing course layer, trapping them in an endless maintenance cycle.  

Trialling bitumen emulsion and biological dust control

The team at GCO decided to trial different dust control options to conserve water and stabilise the roads.  

They had already tried bitumen-based emulsion products and were reasonably happy with the road stabilisation and dust control results. However, it’s expensive, especially to get the product into West Africa. And there were other challenges like shipping and handling bituminous liquids on site. From an environmental standpoint, there were concerns about the risk of water and soil contamination. 

Eramet had recently discovered a new, cleaner option — biological dust control — that had just won the Responsible Mining Innovation Challenge. This is a new method of dust control by Bind-X that binds the upper road layer, forming a stable cement-like structure in the soil. Made from a natural bio-based technology, it’s completely clean for the soil and waterways. Solidifying as hard as bitumen, it improves rolling resistance on the road surface, and dust fallout.  

They decided to trial the biological method on an extremely dusty 3 km section of primary haul road, and a smaller section of secondary road, over 3 months. The well-built road was laterite on top of a chert bed, built to handle heavy vehicles passing once every minute.   

They applied it two ways:

  •  Building it into the road surface
  • Spraying it on top of the existing road

The results

Three months later, the water trucks were no longer running at full capacity. The GCO team had reduced water use on the roads to just 36,000 litres on average per day — a 85% reduction.


“We drastically reduced water truck trips from three times a day to once every third day,” said Alex.


Also, onsite dust monitoring data showed a three-fold reduction in dust fallout.

18 months on, GCO now uses it routinely across the site.


“It had a huge impact on water usage,” says Alex. “Not to mention, they reduced chemical use on site, and reduced the ongoing cost to manage the roads.”


Because Bind-X’s biological product is a solid powder-based product, not a liquid, the operations team finds it easier to handle on site. And it eases logistics, too. Where they would ship two and a half containers, they now ship one container to treat a similar area on the mine.

Topic

Topic

Find out about biological dust control for your site

Enquire now

Sign up to our 10x Mining Newsletter

Sign up and 10x your mining results with know how and new technologies.

[contact-form-7 id=”b2b0a25″ title=”Anmeldung Newsletter”]

Continue reading

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

article



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

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

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

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

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

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

The need to act now to avoid future pain 

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

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

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

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

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

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

Billions of litres wasted on dust control

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

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

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

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

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

What’s the alternative? 

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

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

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

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

Reduce carbon emissions to break the cycle 

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

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

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

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

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

Topic

Topic

Find out about biological dust control for your site

Enquire now

Continue reading

70% of WA mines rely on plain water for dust control. Is it sustainable? 

article



Water scarcity is an escalating concern in Western Australia, particularly in arid mining regions. The mining industry in WA consumes approximately 1,000 GL of water annually. Across Australia, this number climbs to over 1,500 GL per year, a water footprint equivalent to 600 million Olympic-sized swimming pools.

Between dust suppression, drinking water, and dewatering, the volume of water removed from the ground is significant. Over 70 percent of WA mines still rely on plain water for dust control. This traditional approach, though widely used, is both inefficient and unsustainable in a state where water scarcity is more of an issue every year.

Operations manager
GCO Senegal

“We are reaping the rewards of implementing Bind-X on our mine. It’s reduced dust for the local community, is far less maintenance on our haul roads, and is cleaner for the environment.”

The pressure on water resources in WA mining

One of the biggest challenges facing the mining industry in WA’s Goldfields is water scarcity, according to an article by ABC News, where current shortages are described as a “key limitation on growth”. 

Similar issues exist in the Pilbara, where people have called for a more sustainable approach to groundwater management.

Regions like Kalgoorlie-Boulder and the Pilbara illustrate the urgency of sustainable water use. In Kalgoorlie, the city council recently began reviewing its water contracts with local mines, reflecting rising concerns over equitable water distribution. 

In an interview with the Australian Water Association, GHD Technical Director Bob Kinnell says it’s important to start looking at the impact of the industry’s water use on the catchments in the Pilbara, but also to consider how mining operations manage water in the future.

“The region gets the odd cyclone, but otherwise the aquifers do not get any significant recharge. The volume of water removed is much bigger than the volume of water coming in. Some of the consequences of this movement will last for a long time,” he explains. 

Dust suppression—an important aspect of mining operations—accounts for a significant portion of water use. In fact, plain water applied to roads, stockpiles, and processing areas is often the largest single use of water in many operations. This approach not only wastes an irreplaceable resource but also fails to address the broader environmental and regulatory challenges. 

Traditional dust control methods are unsustainable

Plain water might seem like a simple solution, but it’s far from efficient. In dry conditions, much of the water evaporates almost immediately, needing frequent reapplication. This continuous cycle leads to significant water wasted while offering only temporary relief from dust. It poses serious environmental risks, including groundwater depletion and the disruption of local ecosystems.  “It’s not going to be replenished. That water you use will eventually be gone and you need to prioritise what to use it for,” explains Krehenbrink.  “Most of the water used in mining for dust suppression comes from sources that are not sustainable. When you’re pumping millions of liters of water a day, it’s a huge environmental cost.”  And while the amount of water sprayed on mining operations depends on soil and local conditions, on average, a one kilometre road will consume hundreds of thousands of litres of water a day exclusively for dust control.

Krehenbrink says a slew of economic and environmental implications result, including the expense to keep trucks running and a hefty carbon footprint. Allocating water towards dust control limits the availability of water for vital operations at the mine – to extract and process minerals.   

He refers to examples globally where mining industry water consumption during severe droughts has caused major problems. 

 “In the last few years in Chile, we have seen access to water preventing mines from operating, because there is just not enough water. There are caps on how much water they are allowed to use.”   

He hypothesises that persisting with outdated dust suppression methods will see a future where mining in certain regions is rendered impossible.   

“The access to water will be regulated or just not available,” says Krehenbrink.   

Dust control is an essential task for mines to ensure road visibility and decrease the chance of workers and the community inhaling airborne particles. However, it is a task that can be completed with greater care for the planet and people by relying on new and proven biotechnology methods.  

New technology: Biological dust control

New dust control technology like biological dust control offers a far better alternative to traditional methods. Developed at Murdoch University in WA, Bind-X’s new and proven technology uses natural, biodegradable, and non-toxic compounds to bind dust particles, significantly reducing the need for water.  Micro-organisms react with dust and dirt and cause sand particles to fuse and create a solid cement-like layer. Mines already applying the product use 90% less water, making it one of the easiest and most impactful steps toward meeting water reduction targets. Additionally, this approach is safer for the environment, as it avoids the use of crude-oil or industrial waste products that can harm ecosystems.  Grand Cote Operations in Senegal trialled Bind-X on their haul roads and now use 85% less water and 60,000 less litres of diesel. 

Broader ESG benefits

The switch to advanced dust control methods extends beyond water conservation.
 Krehenbrink emphasises, “When mines adopt modern approaches like biological dust control, the benefits cascade across the operation—from water savings to reduced emissions. It’s not just about compliance; it’s about leading the way in sustainable mining.”  For environmental managers, the path forward is clear. Addressing water scarcity is no longer optional, it’s a necessity for environmental approvals, to meet regulatory standards, and keep operations running smoothly. Dust control is an area where immediate and significant improvements can be made. 
 

WA’s mines can reduce their water dependency, protect precious aquifers, and set an example for sustainable mining practices worldwide. As the challenges of water scarcity intensify, the question remains: Is relying on plain water enough? The evidence suggests it’s time for a smarter solution. 

Topic

Topic

Find out about biological dust control for your site

Enquire now

Continue reading