D2 S7 Thompson

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Mine Machine Productivity 2006Mine Machine Productivity 2006

Employing best practice in designing,Employing best practice in designing,

constructing, monitoring andconstructing, monitoring and

maintaining haul roadsmaintaining haul roads

Alex T VisserAlex T Visser11

Roger J ThompsonRoger J Thompson22

11

Department of Civil & BioDepartment of Civil & Bio--systems Engineeringsystems Engineering22Department of Mining EngineeringDepartment of Mining Engineering

University of Pretoria, South AfricaUniversity of Pretoria, South Africa

Aim of PresentationAim of Presentation

What are the equipment, materials,What are the equipment, materials,

methods and procedures for roadmethods and procedures for road

construction based on life of road,construction based on life of road,usage and location?usage and location?


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How to ensuring proper maintenanceHow to ensuring proper maintenance

of haul roads to increase the life ofof haul roads to increase the life of

trucks and tyrestrucks and tyres

Evaluating road maintenance strategiesEvaluating road maintenance strategies Measuring road roughness as a basis forMeasuring road roughness as a basis for

road maintenance management decisionsroad maintenance management decisions


To show how designTo show how design solutionssolutionscan becan be

benchmarked and evaluated, in termsbenchmarked and evaluated, in terms

of;of; philosophy of provisionphilosophy of provision

management (minemanagement (mine-- or contractoror contractor--driven)driven)

level of servicelevel of service

road maintenance capabilitiesroad maintenance capabilities


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IntroductionIntroduction

UltraUltra--heavy mine haul trucks apply wheelheavy mine haul trucks apply wheel

loads in excess of 890kNloads in excess of 890kN albeit atalbeit at

relatively low traffic volumesrelatively low traffic volumes

Mine roads were empirically designed andMine roads were empirically designed andmanaged with little recognition of;managed with little recognition of;


Cost of inadequate design on cost perCost of inadequate design on cost per

ton hauledton hauled


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Poor wearing course material selectionPoor wearing course material selection

and deteriorationand deterioration




Poor wearing course material selectionPoor wearing course material selection

and deteriorationand deterioration

The role of road maintenance inThe role of road maintenance in

reducing total road user costsreducing total road user costs


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Primary measure of mine roadPrimary measure of mine road

performance is often based onperformance is often based on rollingrolling

resistanceresistance

ButBut.what is rolling resistance and.what is rolling resistance andhow is it generated?how is it generated?

Rolling ResistanceRolling Resistance

Rolling resistance is the extraRolling resistance is the extra

resistance to truck motion due to;resistance to truck motion due to;

Road deformation under theRoad deformation under the tyretyre

TyreTyre penetration into the road surfacepenetration into the road surface

TyreTyre deformation effects on roaddeformation effects on road

surfacesurface



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TyreTyre penetration intopenetration into

the road surfacethe road surface

TyreTyre deformationdeformationeffects on roadeffects on road

surfacesurface

RoadRoad

deformationdeformation

under theunder the tyretyre


What is the rolling resistance here?What is the rolling resistance here?

2%2%

3%3%

4%4%

5%??5%??


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And here?And here?

3%3%

4%4%

5%5%

6%??6%??

6%6%

3%3%

Benchmark maximum rolling resistance 2%


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Effect of rolling resistance on truck speed

1

2

3

4

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Percent REDUCTION in speed

P

ercentINCREASEinrolling

resistance

10 8 6 4 2 0 Grade of road (%)


Basic rolling resistance 2%, 220t capacity 376tGVM RDTBasic rolling resistance 2%, 220t capacity 376tGVM RDT

S

R

PracticalPractical

ApplicationApplication

RampsRamps -- 1%RR1%RR 1010--13%KPH13%KPH Surface roadsSurface roads-- 1%RR1%RR 1818--2626%KPH%KPHBasic rolling resistance 2%, 220t capacity 376tGVM RDTBasic rolling resistance 2%, 220t capacity 376tGVM RDT


9/35

PracticalPractical


Effect of rolling resistance on production and fuel

010

20

30

40

50

60

70

80

90

100

0 1 2 3 4

Percent INCREASE in roll ing resistance

PercentINCREASEinfuelcost

.

05

1015

2025

30

3540

4550

At 10% grade with 2% minimum rolling resistance

Percent

DECREASEinproduction

Fuel costs

Production

PracticalPractical


How can you quicklyHow can you quickly eyeballeyeball rollingrolling

resistance?resistance?

Evaluate critical rolling resistance roadEvaluate critical rolling resistance roaddefectsdefects according to;according to;

How bad they are (Degree 1How bad they are (Degree 1 5)5) How much road is effected (Extent 1How much road is effected (Extent 1 5)5)


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4949Total scoreTotal score

884422StonesStones -- fixedfixed

12124433Loose materialLoose material

15155533RuttingRutting

221122CorrugationsCorrugations

12123344PotholesPotholes

DegreeDegree

xx

ExtentExtent

ExtentExtent

(1(1--5)5)

DegreeDegree

(1(1--5)5)DefectDefect

PracticalPractical


1

2

3

4

5

6

7

8

9

10

11

5 25 45 65 85 105 125

Defect total score

Rollingresistance(%)

5km/h

10km/h

15km/h

20km/h

25km/h

30km/h

35km/h

40km/h

45km/h

49

4,5%

PracticalPractical



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Best Practice inBest Practice in

Haul Road DesignHaul Road Design

How do we ensure the best possibleHow do we ensure the best possible

road design which minimises rollingroad design which minimises rolling

resistance?resistance?

Road design exerts a significantRoad design exerts a significant

influence on rolling resistance;influence on rolling resistance;

Structural designStructural design -- deformation underdeformation under tyretyre

Functional designFunctional design -- penetration andpenetration and tyretyre

deformationdeformation

Maintenance designMaintenance design reduction of rollingreduction of rolling

resistanceresistance

Best Practice inBest Practice in

Haul Road DesignHaul Road Design


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Integrated Haul Road DesignIntegrated Haul Road Design

Functionaldesign

BASIC

DA

TA

Structuraldesign

MaintenanceManagement

System

Dust PalliativeManagement

Within limits no treatment required

Chemical

palliation

Water-based spraying

Modify wearing courseselection

Dust Model

PalliativePerformance

Model

Geometricdesign

Functionaldesign

BASIC

DA

TA

Structuraldesign

MaintenanceManagement

System

Dust PalliativeManagement

Within limits no treatment required

Chemicalpalliation

Water-based spraying

Modify wearing courseselection

Dust Model

PalliativePerformance

Model

Geometricdesign

Integrated Haul Road DesignIntegrated Haul Road Design


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Geometric DesignGeometric Design

Use a structured approach to geometricUse a structured approach to geometric

design;design;

Firstly, a set of mine geometric designFirstly, a set of mine geometric design

standardsstandards Secondly, the conceptual designSecondly, the conceptual design

Finally, the asFinally, the as--built designbuilt design

Conceptual roadverti calandhorizontal layout

ConceptualConceptualroadverticalroadvertical

andhorizontal layoutandhorizontal layout

Truckminimumbrakingdistances(unassisted)Trucktypicalspeedsup-and down-gradeTrucksightdistancerequirements


Layoutt heroadaccordingto 9-11%sustainedgradeAssumeinitialwidthofroad4,5xwidthof truck

includingbermsanddrainsHighlightlocationof

SwitchbacksCurves(horizontalandvertical)Intersections

Layoutthe roadaccordingto9-11%sustainedgradeAssumeinitial widthof road4,5xwidthof truck



Examineconceptualdesignfollowingvertical andhorizontalalignmentrequirements

ExamineconceptualExamineconceptual

designfollowingdesignfollowingvertical andhorizontalvertical andhorizontal

alignmentalignmentrequirementsrequirements

Locateswitch-backson sectionof roadwithnoverticalgrades

Locateswitch-backson sectionof roadwithnovertical grades

IntersectiondesignIntersection designIntersection design

DrainagedesignDrainagedesignDrainagedesign

Locateintersectionsonlevel withadequatesight,curvesandrun-out.


Designdrainagesystem,especiallyroad-side,culvertlocation,switchbackandintersectiondrainage.

Designdrainagesystem,especiallyroad-side,culvertlocation,switchbackandi ntersectiondrainage.

Separateverticalandhorizontal curveswherepossible

Separateverticalandhorizontalcurveswherepossible

Conceptual roadverti calandhorizontal layout

ConceptualConceptualroadverticalroadvertical

andhorizontal layoutandhorizontal layout



Layoutt heroadaccordingto 9-11%sustainedgradeAssumeinitialwidthofroad4,5xwidthof truck



Layoutthe roadaccordingto9-11%sustainedgradeAssumeinitial widthof road4,5xwidthof truck



Examineconceptualdesignfollowingvertical andhorizontalalignmentrequirements

ExamineconceptualExamineconceptual

designfollowingdesignfollowingvertical andhorizontalvertical andhorizontal

alignmentalignmentrequirementsrequirements

Locateswitch-backson sectionof roadwithnoverticalgrades

Locateswitch-backson sectionof roadwithnovertical grades

IntersectiondesignIntersection designIntersection design

DrainagedesignDrainagedesignDrainagedesign



Designdrainagesystem,especiallyroad-side,culvertlocation,switchbackandintersectiondrainage.

Designdrainagesystem,especiallyroad-side,culvertlocation,switchbackandi ntersectiondrainage.

Separateverticalandhorizontal curveswherepossible

Separateverticalandhorizontalcurveswherepossible

Conceptual road verticaland horizontal layout

ConceptualConceptual road verticalroad vertical

and horizontal layoutand horizontal layout

Truck minimum braking distances (unassisted)Truck typical speeds up-and down-gradeTruck sight distance requirements

Truck minimum braking distances (unassisted)

Truck typical speeds up- and down-gradeTruck sight distance r equirements

Lay out the road according to 9-11% sustained gradeAssume initial width of road 4,5x width of truck

includingberms and drains

Highlight location ofSwitchbacksCurves (horizontal and vertical)Intersections

Lay out the road according to 9-11% sustained grade

Assume initial width of road 4,5x width of truckincludingberms and drains

Highlight location ofSwitchbacks

Curves (horizontal and vertical)Intersections

Examine conceptualdesign followingvertical and horizontalalignment

requirements

Examine conceptualExamine conceptual

design followingdesign following

vertical and horizontalvertical and horizontal

alignmentalignment

requirementsrequirements

Locate switch-backs on section of road with novertical grades

Locate switch-backs on section of road with no

vertical grades

Intersection designIntersection designIntersection design

Drainage designDrainage designDrainage design

Locate intersections on level with adequate sight,

curves and run-out.

Locate intersections on level with adequate sight,curves and run-out.

Design drainage system, especially road-side,culvert location, switchback and intersectiondrainage.

Design drainage system, especially road-side,culvert location, switchback and intersectiondrainage.

Separate vertical and horizontal curves wherepossible

Separate vertical and horizontal curves wherepossible


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Horizontal design andalignment

Horizontal design andHorizontal design and

alignmentalignment

Vertical design andalignment

Vertical design andVertical design and

alignmentalignmentEstablish minimum vertical curve lengths

based on change in grade (%) orheadlight distance for sag curves, forminimum stopping distance

Establish minimum vertical curve lengthsbased on change in grade (%) or

headlight distance for sag curves, forminimum stopping distance

Establish minimum horizontal curve lay-

back based on braking distance



Establish optimum grade 9-11%,.Establish optimum grade 9-11%,.

For every 1% increase inrolling resistance over 2%,

reduce optimum grade by 1%

For every 1% increase in

rolling resistance over 2%,reduce optimum grade by 1%

Establish cross-fall value or camber (2-

4%). Laden lane at uphill side of cross-fall.



Where pit geometry does notallow for minimum

requirements, apply speedlimit to each curve not

meeting requirements




Establish width of road according to;

Truck width

Traffic (1-2 lanes)

Safety berm at outslope and

centre of road


Truck width

Traffic (1-2 lanes)

Safety berm at outslope andcentre of road

Establish run-outs based on curve super-elevation, cross-fall and camber.


Berm designBermBerm designdesign

Design berms (median and outslope) withlargest truck and speed in mind.


Establish minimum horizontal curveradius based on speed of truck and super-elevation (5% max)

Establish minimum horizontal curve

radius based on speed of truck and super-elevation (5% max)







Where pit geometry does not

allow for minimumrequirements, apply speedlimit to each curve notmeeting requirements


requirements, apply speedlimit to each curve notmeeting requirements

Final geometricdesign

Final geometricFinal geometric

designdesign

Drainage re-evaluationDrainage reDrainage re--evaluationevaluation

Horizontal design andalignment

Horizontal design andHorizontal design and

alignmentalignment

Vertical design andalignment

Vertical design andVertical design and

alignmentalignmentEstablish minimum vertical curve lengths

based on change in grade (%) orheadlight distance for sag curves, forminimum stopping distance

Establish minimum vertical curve lengthsbased on change in grade (%) or

headlight distance for sag curves, forminimum stopping distance





Establish optimum grade 9-11%,.Establish optimum grade 9-11%,.

For every 1% increase inrolling resistance over 2%,

reduce optimum grade by 1%

For every 1% increase in

rolling resistance over 2%,reduce optimum grade by 1%












Truck width

Traffic (1-2 lanes)

Safety berm at outslope and

centre of road


Truck width

Traffic (1-2 lanes)

Safety berm at outslope andcentre of road



Berm designBermBerm designdesign



Establish minimum horizontal curveradius based on speed of truck and super-elevation (5% max)

Establish minimum horizontal curve

radius based on speed of truck and super-elevation (5% max)







Where pit geometry does not

allow for minimumrequirements, apply speedlimit to each curve notmeeting requirements


requirements, apply speedlimit to each curve notmeeting requirements

Final geometricdesign

Final geometricFinal geometric

designdesign

Drainage re-evaluationDrainage reDrainage re--evaluationevaluation


Well documentedWell documented but take specialbut take special

care with;care with;

RampsRamps grade breaks and max productivegrade breaks and max productive

total resistance (grade + rolling)total resistance (grade + rolling)


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Switchbacks and curvesSwitchbacks and curves large radius andlarge radius and

supersuper--elevatedelevated


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total resistance (grade + rolling)total resistance (grade + rolling) Switchbacks and curvesSwitchbacks and curves large radius andlarge radius and

supersuper--elevatedelevated


BermsBerms especially centreespecially centre bermsberms and atand at

switchbacksswitchbacks place a sand buffer on edgeplace a sand buffer on edgeto protectto protect tyrestyres


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BermsBerms especially centreespecially centre bermsberms and atand at

switchbacksswitchbacks place a sand buffer on edgeplace a sand buffer on edge

to protectto protect tyrestyres DrainageDrainagecrosscross--fall or camber andfall or camber and

roadside drainage ditchesroadside drainage ditches


Make sure that what you haveMake sure that what you have designeddesignedisis

built and maintained correctlybuilt and maintained correctly

Make use of signage to assist grader andMake use of signage to assist grader and

truck operators to make maximal use of thetruck operators to make maximal use of the

roadroad


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Structural DesignStructural Design

Load carrying capacity of the road. DesignLoad carrying capacity of the road. Design

for;for;

Better pavement response to applied loadsBetter pavement response to applied loads

Reduced deflection on surfaceReduced deflection on surface Eliminate deformation in subEliminate deformation in sub--grade or ingrade or in--situsitu


Mechanistic design approach usingMechanistic design approach using

pavement layer limiting vertical strain criteriapavement layer limiting vertical strain criteria

Limiting strain criteria tailored to trafficLimiting strain criteria tailored to traffic

volumes, type and life of mine road (ramp, pit orvolumes, type and life of mine road (ramp, pit or

main haul)main haul)


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Case StudyCase StudyStructural design comparisons

0250500

7501000125015001750

200022502500

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

Vertical (micro) strain in pavement

NewD

esignLayer

Depths(mm)

0250500

7501000125015001750

200022502500

Old Des ign New Design

OldDesignLayerDepths(mm)

W/course

Fill layer

Layer 3

In-situ

Selected

blasted waste

Layer 3

In-situ

W/course

Wearing course

Base

In-situ (soft)

Wearing course

Base

In-situ (soft)

Wearing course

Base

In-situ (soft)

Wearing course

Base

In-situ (soft)

Wearing course

Base

In-situ (soft)

Wearing course

Base

In-situ (soft)

PracticalPractical


To apply the mechanistic design approachTo apply the mechanistic design approach

some basic data is required;some basic data is required;

InIn--situ material strength below roadsitu material strength below road

Truck wheel load and traffic volume (kt/day)Truck wheel load and traffic volume (kt/day)

Life of road (main haul, ramp, bench, etc.)Life of road (main haul, ramp, bench, etc.)


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PracticalPractical


From this data, a design catalogue can beFrom this data, a design catalogue can be

developed by the mine for each type anddeveloped by the mine for each type and

generic location of road to be builtgeneric location of road to be built

The selection of wearing course materialsThe selection of wearing course materials

Reduced rolling resistanceReduced rolling resistance

improved costimproved cost

per ton hauledper ton hauled

To provide a safe, economic and vehicleTo provide a safe, economic and vehicle

friendly ridefriendly ride

Functional DesignFunctional Design


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Correct functional design will;Correct functional design will;

Reduce road rolling resistanceReduce road rolling resistance throughthrough

reduced wearing course defectsreduced wearing course defects

Reduce road deterioration rates andReduce road deterioration rates andmaintenance frequencymaintenance frequency


Wearing Course Selection

0

50

100

150

200

250

300

350

400

0 5 10 15 20 25 30 35 40 45 50

Grading Coefficient

ShrinkageProduct

Recommended (1) Recommended (2)

Dustiness Slippery when wet

Loose material

Loose stones

Tyre damage Corrugates


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0

50

100

150

200

250

300

350

400

450

500

550

0 10 20 30 40 50

Grading coefficient

Shrinkageproduct

.

Dust inessWet sk id res is tance

Loose s ton iness

Corrugat ions

Loose mater ia l

Dry sk id res is tance

1

2

PracticalPractical


0

50

100150

200

250

300

350

400

450

500

550

0 10 20 30 40 50

Grading coefficient

Shrin

kageproduct

.

Dust iness

Loose s ton iness

Dry sk id res is tance

1

PracticalPractical



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PracticalPractical


Maintenance interval comparison with rolling

resistance

1.0

1.3

1.5

1.8

2.0

2.3

2.5

2.8

3.0

0 1 2 3 4 5 6 7 8 9 10Road maintenance interval (days)

Rollingresistance(%)

Exist ing road wearing course'Rehabilitated' wearing course'New' wearing course

PracticalPractical


Functional Performance Model

020

40

60

80

100

120

140

160

0 1 2 3 4 5 6 7 8 9 10

Road maintenance interval (days)

AverageDefectScor

Existing road wearing course'Rehabilitated' wearing course'New' wearing course


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To apply the functional design approachTo apply the functional design approach

some basic data is required;some basic data is required;

Materials available for wearing courseMaterials available for wearing course

Road indicator test dataRoad indicator test dataWhether a new or rehabilitated road is requiredWhether a new or rehabilitated road is required

PracticalPractical


PracticalPractical


From this data, a design catalogue can beFrom this data, a design catalogue can be

developed by the mine for each type of roaddeveloped by the mine for each type of road


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MaintenanceMaintenance

ManagementManagement

Various road maintenance systems areVarious road maintenance systems are

applied on mines, including;applied on mines, including;

Routine road maintenanceRoutine road maintenance

ResurfacingResurfacing Rehabilitation / bettermentRehabilitation / betterment

MaintenanceMaintenanceManagementManagement

Routine haul road maintenance can beRoutine haul road maintenance can be

carried out by;carried out by;

AdAd--hochoc bladingblading

Scheduled (fixed)Scheduled (fixed) bladingblading

Maintenance management systems approachMaintenance management systems approach

RealReal--time management approachtime management approach


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Process

Opportunity

tominimisetotalroad-usercosts

Ad-hoc blading

Scheduledblading

MMS

RT-MMS

Mana

gementandsystemc

omplexity

Low complexity Low management input Un-optimised total road user costs

Low complexity Some management input Un-optimised total road user costs

Intermediate complexity Some management input Optimised total road user costs

High complexity existing system Low management input Optimised real-time total road

user costs

MaintenanceMaintenanceManagementManagement

Only the;Only the;

Maintenance management systems approachMaintenance management systems approach

RealReal--time management approachtime management approach

can minimise total roadcan minimise total road--user costsuser costs


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Maintenance frequency

Rolling resistance

Max

Min

Minimum total

cost solution

Max

Min

Costs

Maintenance ManagementMaintenance Management RoadRoad--useruserCost Variation ExampleCost Variation Example

Percentage increase in total road-user costs with

maintenance interval

0

5

10

15

20

25

30

35

40

0 1 2 3 4 5 6 7 8 9 10

Days between maintenance

Percentchange

B02 B03 B04

B05 S Ramp


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PracticalPractical

ApplicationsApplications

ID theID the KPSKPS KKeyey PPerformanceerformance SSegments onegments on

your road network;your road network;RampsRamps 1%RR1%RR 10%KPH10%KPH

Switchbacks, etc.Switchbacks, etc. Long term, high speed high tonnage roadsLong term, high speed high tonnage roads

Prioritize maintenance on these segmentsPrioritize maintenance on these segments

PracticalPractical


Visual inspectionsVisual inspections mark roads where maintenancemark roads where maintenance

should be done with red, yellow or green conesshould be done with red, yellow or green cones

prioritize.prioritize. Record maintenance intervention (what done) andRecord maintenance intervention (what done) and

frequencies (how often) per segmentfrequencies (how often) per segment establish aestablish a

rehabilitation schedulerehabilitation schedule prioritize BUTprioritize BUT..


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PracticalPractical


Why is the segment maintenance intensive?Why is the segment maintenance intensive?Poor design and / or build specs;Poor design and / or build specs;

GeometricsGeometrics

Structure (layer works and materials)Structure (layer works and materials)

Functional (wearing courseFunctional (wearing course surfacingsurfacing

materials)materials)

PracticalPractical


Investigate the rootInvestigate the root--cause of the undercause of the under--

performanceperformance beforebeforedeciding on a remediationdeciding on a remediation

strategystrategy


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Most large surface mines already use;Most large surface mines already use; OEM truck monitoring, data communication andOEM truck monitoring, data communication and

asset location systemsasset location systems

RealReal--time maintenance management systemtime maintenance management systemutilises existing data collation andutilises existing data collation and

communication protocolscommunication protocols

RealReal--time Road Maintenancetime Road Maintenance


Gradersentreal-time to

maintain road attriggerlocation

Event triggerand truck

location to D ispatch control

Haultruckdiagnostic data

GPS truck location

Implement and monitorC TMmanagement system module,integrating truck vital signs, hub

and dispatch protocols withroad

defect signature recognitionalgorithms

Management and controlofdefecttrigger levels and

maintenance transactions

Event triggering

Develop haulroaddefecteve nt signaturerecording, analysis and

event recognition

systems

Developmentofsystemarchitecture and communication

protocols between truck andModularMininghub

PHASE II

PHASE III

PHASE IV

KEY

Developmental phases forsystem

protocols, signatures and triggers

Operating system linksGradersentreal-time to

maintain road attriggerlocation

Event triggerand truck

location to D ispatch control

Haultruckdiagnostic data

GPS truck location

Implement and monitorC TMmanagement system module,integrating truck vital signs, hub

and dispatch protocols withroad

defect signature recognitionalgorithms

Management and controlofdefecttrigger levels and

maintenance transactions

Event triggering

Develop haulroaddefecteve nt signaturerecording, analysis and

event recognition

systems

Developmentofsystemarchitecture and communication

protocols between truck andModularMininghub

PHASE II

PHASE III

PHASE IV

KEY

Developmental phases forsystem

protocols, signatures and triggers

Operating system links

RealReal--time Haul Roadtime Haul Road


RealReal--time Haul Roadtime Haul RoadMaintenanceMaintenance

317t GVM haul truck instrumented with317t GVM haul truck instrumented with

piezoelectric acceleration recorder and GPS;piezoelectric acceleration recorder and GPS;RoadRoad defect signaturesdefect signatures initially recognisedinitially recognised

qualitatively (in terms ofqualitatively (in terms of high Ghigh G events)events)


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Cross-erosion area 1

-3.0

0.0

3.0

0.0 2.0 4.0

Time (sec)

Acceleratio

n(G's)

Wasboard area 1

-3.0

0.0

3.0

0.0 2.0 4.0Time (s)

Acceleration(G's)

Hump line 2-5

-3.0

0.0

3.0

0.0 2.0 4.0

Time(s)

Acceleration(G's)

Fixed stone 8-10

-3.0

0.0

3.0

0.0 2.0 4.0Time(s)

Acceleration(G's)

Ditch line 2-3

-3.0

0.0

3.0

0.0 2.0 4.0Time(sec)

Acceleration(G's)

Tinaja Hills Test Track, Tucson, ArizonaTinaja Hills Test Track, Tucson, Arizona

Prepared haul road with 15 GPS surveyedPrepared haul road with 15 GPS surveyed

defect locations over 18 000mdefect locations over 18 000m22;; TailorTailor--made defects typical of existing mine roadmade defects typical of existing mine road

functional defectsfunctional defects

Defect degree, extent, dimensions and locationDefect degree, extent, dimensions and location

recordedrecorded

RealReal--time Haul Roadtime Haul RoadMaintenanceMaintenance


32/35

Kumba Resources Grootegeluk Mine, South AfricaKumba Resources Grootegeluk Mine, South Africa

Defect geometry reconstruction fromDefect geometry reconstruction from

truck measured responsetruck measured response

Road defect recognition

-0.1

-0.05

0

0.05

0.1

0.15

0.2

0 0.5 1 1.5 2 2.5 3 3.5 4

Arbitrary time (s)

Roadsurface

elevation(m)

Actual road defect

Reconstructed road defect from truck response


33/35

RealReal--time Haul Roadtime Haul Road

MaintenanceMaintenance --Practical ApplicationsPractical Applications

Leverage existing communication and onLeverage existing communication and on--

board systems to assist in defining poor roadboard systems to assist in defining poor road

performance;performance;

Average segment speeds cw benchmark speedsAverage segment speeds cw benchmark speedsStrut pressure differentials (RACS, etc.)Strut pressure differentials (RACS, etc.)

PracticalPractical


Why is the segment maintenance intensive?Why is the segment maintenance intensive?Poor design and / or build specs;Poor design and / or build specs;

GeometricsGeometricsStructure (layer works and materials)Structure (layer works and materials)

Functional (wearing courseFunctional (wearing course surfacingsurfacing

materials)materials)


34/35

PracticalPractical


Investigate the rootInvestigate the root--cause of the undercause of the under--

performanceperformance beforebeforedeciding on a remediationdeciding on a remediation

strategystrategy

PracticalPractical



35/35

AcknowledgementsAcknowledgements

Aspects of this work were made possible through the support of oAspects of this work were made possible through the support of our industryur industry

partners and clients in South Africa and internationaly. In parpartners and clients in South Africa and internationaly. In particular, Angloticular, Anglo

Coal SA, Kumba Resources, the Technology and Human Resources forCoal SA, Kumba Resources, the Technology and Human Resources for

Industry Programme and the Mine Health and Safety Council of SouIndustry Programme and the Mine Health and Safety Council of South Africa.th Africa.

Further acknowledgement is also given to the Fulbright CommissioFurther acknowledgement is also given to the Fulbright Commission andn and

CDCCDC--NIOSH for assistance with aspects of the realNIOSH for assistance with aspects of the real--time maintenance systemtime maintenance system

development initiatives.development initiatives.

D2 S7 Thompson

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