| Dust Control for Mining Road |
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Introduction
A mining customer had a three-mile access road that was constructed with compacted native soil, rocks, and clays. They had used different products to try to control their dust issues, to no avail.Road Conditions and Use
Mile 1
- Little grade with very gradual turns
- Approximately 200 personal/employee vehicles each day
- 40 - 70 vendor delivery trucks per day
Miles 2 - 3
- 10% grade with multiple turns and switchbacks
- 40 - 70 trucks per day
- Occasional small fleet of mining equipment (950 sized wheel loaders and fleet of light haul trucks - 40-ton articulated)
The customer had been testing environmentally benign dust control products.
The Challenge
- The customer needed a dust palliative that was cost effective and able to handle the site use rigor; they also needed something that would hold up to frequent rains.
- Corporate policy, air quality, and water permits mandate the use of a palliative to control dust while minimizing water usage
No salts, such as magnesium chloride or calcium chlorides were permitted
Pre-treatment Conditions
- In the past, the customer used various forms of lignite sulfates for dust control. When first applied, these products control dust and maintain a uniform surface, however, these products are not non-water soluble and during rain events, these products wash away.
- In their effort to extend the water used, the customer tried surfactant additives on these roads but found the solutions are not cost effective.
The Solution
The Test Area
The test area selected was on the steepest road grade and included ‘the switchback’ which is appropriately named because it has the sharpest turning areas and cornering.
Per the customer’s request, the selected road areas were treated with IntegraSeal as well as a “synthetic organic fluid” based dust suppressant. The “synthetic organic fluid” is nearly three times the cost of T.O.P. over a 9-month time period. Benefit - Environmental Stewardship
- The customer has proven their standing as a good neighbor to residents of a small community, a national forest and their guests, neighboring mines, and a major tourist highway in Arizona.
- The TOP significantly reduced particulate matter (PM) emissions and fugitive dust from traffic areas. The customer has maintained compliance with US Forest Service Mandates, ADEQ environmental regulations, and their Corporate Policies.
Benefit - Cost
- T.O.P. is applied at a 20-30% cost savings over the other resin based dust palliatives.
- On the 1-mile test area, the client reduced water usage by 5,000 gallons per day plus the water truck driver labor, and water truck wear and tear expenses
Project Size:
- 4/10th of a mile X approximately 30 ft (64,000 sq ft).
On this test site, due to the excessive amounts of mud/dirt track-on from the non-treated areas, IntegraSeal had an effective dust control life of 3-4 weeks. Maintenance coats were applied accordingly. In addition to the dust control, IntegraSeal stabilized the road surface against potholing and wash boarding due to the rain and water trucks.
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