IJSTE - International Journal of Science Technology & Engineering | Volume 2 | Issue 11 | May 2016

ISSN (online): 2349-784X

Design of Surface Mine Haul Road

Pankaj Kumar Yadav Raj Bahadur Singh
B. Tech Student B. Tech Student
Department of Civil Engineering Department of Civil Engineering
IIMT college of engg, greater noida IIMT college of engg, greater noida

Rohit Kumar Rahul Kumar Singh

B. Tech Student B. Tech Student
Department of Civil Engineering Department of Civil Engineering
IIMT college of engg, greater noida IIMT college of engg, greater noida

Murad Ali
B. Tech Student
Department of Civil Engineering
IIMT college of engg, greater noida

Abstract
This Bureau for design of surface mine haul road covers such aspects of haul road design as road alignment (both vertical and
horizontal), construction materials, cross slope, and drainage provisions. Traffic control and design of proper lane widths to
promote safe vehicle movement are included, as are suggested criteria for road and vehicle maintenance and for runaway vehicle
safety provisions. The aim of this publication is to provide those involved with the surface mine haul road design with a complete
detail of recommended practices that, if implemented, will promote safer, more efficient haulage routes.
Keywords: cross-section, switchbacks, manoeuvring, haulageway, berms
________________________________________________________________________________________________________

I. INTRODUCTION

During the past 30 years, surface mine haulage equipment has developed from trucks capable of moving 20 tons of material to
vehicles that transport as much as 350 tons. Unfortunately, the design of roads this equipment must traverse has not advanced at
the same rate. In many areas, road-building technology appropriate to vehicles of three decades past is still being practiced today.
As a result, numerous unnecessary haulage road accidents occur every year. A number of these mishaps can be attributed to
operator error. However, far too many are caused by road conditions that are beyond the vehicle's ability to negotiate safely. With
this history of haulage related problems in mind, the Bureau of Mines undertook a project to produce a design manual that would
ultimately guide surface mine road planners toward safer, more efficient haulage systems. Design guidelines for each weight
category, including velocity stopping distance curves, vertical curve controls, haulage way widths, curve widening, and spacing
of runaway devices, drainage provision, are presented in this report.

II. FOUR BASIC LAYERS OF HAUL ROAD

- Sub-grade
- Sub-base
- Base course
- Surface course

Fig. 1: Typical haul road cross-section

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III. STOPPING DISTANCE

Specifications for brake performance provided by most truck manufacturers are generally limited to an illustration of the speed
that can be maintained on a downgrade by use of dynamic or hydraulic retardation through the drive components. Although this is
an efficient method of controlling descent speed, it does not replace effective service brakes. When the retardation system fail,
wheel brakes become the second line of defence to prevent vehicle runaway.
Recognising, the need for effective brake performance standards, the Society of Automotive Engineers (SAE) developed test
procedures and minimum stopping distance design criteria for different weight categories of large, off-highway trucks. It is
uncertain how brake performance may vary with changes in grade, road surface conditions, initial speed, or, indeed, with brake
system wear or contamination with dust, oil, water, etc.
To assess stopping distances for different grades and speeds, Kaufman and Ault (1977) developed an empirical formula based
on the SAE stopping distance limitations:
1 𝑔𝑡 sin 𝜃+𝑣0 2
SD = 𝑔𝑡 2 sin 𝜃 + 𝑉0 𝑡 + [ ]
2 2𝑔(𝑈𝑚𝑖𝑛 −sin 𝜃)
Where;
SD = Stopping distance (m)
g = gravitational acceleration (9.81 ms)
t = elapsed time between driver’s perception of the need to stop and the actual occurrence of frictional contact at the wheel
brakes (s)
𝜃 = angle of descent (degree)

IV. SIGHT DISTANCE AND VERTICAL CURVE

Sight distance is defined as "the extent of the peripheral area visible to the vehicle operator." It is imperative that sight distance be
sufficient to enable a vehicle travelling at a given speed to stop before reaching a hazard. The distance measured from the driver's
eye to the hazard ahead must always equal or exceed the required stopping distance
Vertical curves are used to provide smooth transitions from one grade to another. Their lengths should be adequate to drive
comfortably and provide ample sight distances at the design speed. Generally, vertical curve lengths greater than the minimum are
desirable, and result in longer sight distances however, excessive lengths can result in long, relatively flat sections, a feature that
discourages good drainage and frequently leads to "soft spots" and potholes
Vertical alignment in road design requires judicious selection of grades and vertical curves that permit adequate stopping and
sight distances on all segments of the haul road. The relationship between operator sight distance and vehicle stopping distance is
illustrated on Figure 2-1 for safe and unsafe conditions.

Fig. 2: Sight distance diagram for horizontal and vertical curves

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V. SUPER ELEVATION

Vehicles negotiating short radius curves are forced radially outward by centrifugal force. Counteracting forces are the friction
between the tires and the road surface, and the vehicle weight component due to the superelevation. The basic formula is:
𝑣2
𝑒+𝑓 =
15𝑅
Where,
e = superelevation rate (feet per foot)
f = side friction factor
v = vehicle speed (miles per hour)
R = curve radius (feet)

Fig. 3: Superelevation on curves

VI. HAULAGE WIDTH

The haulage road designer must be very concerned about the road width. Sufficient room for manoeuvring must be allowed at all
times to promote safety and maintain continuity in the haulage cycle. Width criteria for the travelled lane of a straight haul segment
should be based on the widest vehicle in use. Designing for anything less than this dimension will create a safety hazard due to
lack of proper clearance. In addition, narrow lanes often create an uncomfortable driving environment, resulting in slower traffic.

Fig. 4: Typical haulage way section

VII. SHARP CURVE DESIGN

Switchbacks or other areas of haulage ways requiring sharp curves must be designed to take into consideration the minimum
turning path capability of the vehicles. The radii shown in the accompanying table are the minimum negotiable by all vehicles in
each classification. Responsible design dictates that these minimums be exceeded in all except the most severe and restricting
conditions. Widths required by vehicles in each weight category vary with the degree of curve.

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Fig. 5: Sharp curves diagram

VIII. SURFACE MATERIALS

Asphaltic concrete, crushed stone or gravel, and stabilized earth are the most practical construction materials for developing a
haulage road surface that will insure maximum safety and operational efficiency. Because each of these materials has merits that
are applicable to specific haulage situations, they are discussed separately in the following points.

Asphaltic Concrete:
From a safety standpoint, asphaltic concrete appears the most desirable road surface material. It offers a high coefficient of road
adhesion and creates a surface that reduces dust problems. In addition, the characteristic stability of this material creates a smooth
haulage surface that can be travelled with little fear of encountering deep ruts of potholes that would impede vehicular
controllability. If potholes or ruts do appear, they can be readily corrected by patching.

Compacted Gravel and crushed stones:

A great number of surface mining operations throughout the country are presently utilizing gravel and crushed stone surface
haulage roads. When constructed and maintained properly, both materials offer a stable roadway that resists deformation and
provides a relatively high coefficient of road adhesion with low rolling resistance. The greatest advantage of gravel and stone
surfaces is that safe and efficient roadway can be constructed rapidly at a relatively low cost.

Stabilized Earth:
Stabilized earth is defined as any soil that, through special procedures or additives, has been transformed from a natural
unconsolidated state to a degree of stability that will accommodate the weight of haulage vehicles. Achieving this level of
stabilization involves incorporating soil binders, such as cement, asphalt, calcium chloride, lignosulfates, or hydrated lime.

IX. CROSS SLOPE

Cross slope is defined as the difference in elevation between the road edges which must be given consideration during haulage
road design and construction. From the standpoint of reducing a driver's steering effort, a level surface would be most beneficial.
The recommended rate of cross slope for surfaces normally constructed on mine haulage roads is a 1/4 inch to 1/2 inch drop for
each foot of width. Cross slopes of one quarter inch per foot are applicable to relatively smooth road surfaces that can rapidly
dissipate surface water.

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Table – 1
Road gradient for max and min crossfall
Road Gradient Minimum crossfall- low rainfall or smooth surface Maximum crossfall- high rainfall or rough surface
0-3% 2% 5%
4-6% 2% 3%
6-10% 1% 1.5%

X. RULES OF THUMB FOR SAFETY BERM CONSTRUCTION

Recommended Height:
- Minimum of half the wheel height for conventional berms.
- Equal to tire height for boulder-faced berms.

Recommended Placement:
- Along the edge of the dump area
- Along all haul road edges with gaps for drainage
- Check your local mining regulations

XI. DRAINAGE PROVISIONS

Soil erosion by water is a common problem that can plague the operation of safe and workable haulage roads. Erosive action on
haulage roads can cause ruts and washouts, and can saturate the soil, causing instability. The proper use of drainage facilities can
alleviate this problem, resulting in safer, more efficient haulage roads.

Fig. 6: Drainage problem on road

XII. DITCH CONFIGURATION

Many factors influence final ditch configuration, including soil type, depth of road base, storm design frequency local restrictions,
percent of grade, and predicted runoff from contributing land areas. However, general recommendations may be made to provide
the operator with basic design concepts. V ditches are recommended for nearly all applications, owing to the relative ease of design,
construction, and maintenance
The ditch cross slope adjacent to the haulageway should be 4:1 or flatter except in extreme restrictive conditions. In no case
should it exceed a 2:1 slope. The ditch should be located in undisturbed earth or rock.

XIII. DUST CONTROL

- Watering removes dust hazard and maintains compaction.

- Use “checkerboard” or “spot” intermittent pattern on slopes to reduce slippage risk during braking grades.
- “Spot” watering works well for areas with limited water supply.

XIV. DUST SUPPRESSANTS

- Emulsified asphalt
- Calcium chloride
- Calcium lignosulfonate
- Surfactants

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XV. MEASURES TO REDUCE HAUL ROAD DETERIORATION

- Keep ditches and culverts clear of obstructions to minimize potential erosion factors.
- Use different areas of the haulage lane to avoid rutting
- Load vehicles within limits to prevent spillage
- Minimize dust problems with water trucks or sprinklers
- Employ support equipment (Motor Graders, Wheel Dozers, etc) to maintain cross slopes, remove spills, and fill and smooth
surface depressions.

XVI. CONCLUSIONS

Surface mining, regardless of mineral commodity being sought through its inception, is a highly competitive business and, like
any other business, a beneficial cost to profit ratio must be maintained. It is important to insure that cost efficiency does not impinge
upon the intangible aspects of mining such as operator safety and proper equipment utilization. From the sites selected as being
representative of typical mining operations, it became apparent that in many instances haulage road construction is not considerate
of operator safety; not as a result of disregard, but rather a lack of awareness of correct design principles. The most obvious
disparity between existing haulage road construction practices and criteria recommended for safety lies in the areas of alignment
and drainage.

REFERENCES
[1] Thompson, R.J. 1996. The design and maintenance of surface mine haul roads.
[2] Thompson, R.J. and Visser A.T. 1996. Towards the mechanistic structural design method for Surface Mine Haul Roads.
[3] USBM. 1977. The design of Surface Mine Haul Roads-A Manual. USDOI Bureau of Mines IC 8758.
[4] USBM, 1981. A Study of Mine Haulage Roadway Surface Safety Hazards.

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