1. The document discusses the engineering challenges of constructing haul roads that can support ultra-heavy 600-ton dump trucks at a mining site in Australia. 2. It involves upgrading existing haul roads made of unsuitable overburden and constructing 12km of new roads to accommodate 12 new 600-ton dump trucks and 800-ton excavators. 3. Extensive testing of on-site sandstone materials was conducted to identify suitable sources for road construction, as the sandstone showed variability in quality, and recommendations were provided to optimize road design and construction based on the suitable materials.

1. 1
An Engineering Challenge
Building Hauls Roads for These Ultra Class Dump Trucks
with GVW 600t
Location : Bowen Basin Queensland, Australia
August2015

2. 2
TheChallenge
Liebherr weighs the same as A380 Jumbo

3. 3
TheChallenge
Purpose of Presentation is “Information Sharing Only” and opinions
shared are of the author only

4. 4
TheChallenge Liebherr T282B
Gross Vehicle Weight (GVW): 600 ton
Payload Class: 363 ton
Empty Vehicle Weight (EVW): 237 ton

5. 5
TheChallenge What does the project involve
Mine Upgrade 2012 involves the introduction of additional fleets:
 2 x Liebherr R9800 excavators (800t)
 12 x Liebherr T282B dump trucks
Construction of 12km of new hauls for T282B fleet

6. 6
TheChallenge What does the project involve ?
Mine Upgrade 2012 involves the introduction of additional fleets:
 2 x Liebherr R9800 excavators (800t)
 12 x Liebherr T282B dump trucks
Construction of 12km of new hauls for T282B fleet

7. 7
TheChallenge
Existing hauls roads
constructed from
overburden,
 not weather proof
 Roads will not
sustain T282 loads

8. 8
ProjectOverview Process for tackling this Project July 2012 start
 Principal & Main Contractor Sign New Mining Operations Contract
 Scope of Works for Construction of New Hauls Completed
 Appointment of Specialised Consultants (Pells Sullivan Meynink
Geotechnical Engineers)
 Source Rock Assessment (On-Site Sandstone)
 Source Rock Assessment (External Quarry Sites)
 Review Past Learning from other Mining Projects in QLD and NSW
 Review Technical Papers by Robert Thompson and others

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ProjectOverview

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ProjectOverview
T282B vehicle Dimensions Width = 9.69m
Haul Road Width = 40m

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MineSiteOverview
 Pad set up with sandstone that hs been used to build 800t excavator and withstood heavy
loading
Mechanical Team on were going to get site assessed by
Geotechnical as a 250T crawler crane was going to
operate on this hardstand for plant build of Liebherr
R9800 800t excavator and T282B dump truck builds

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MineSiteOverview PMS site investigation confirmed a large variability in sandstone rock geotechnical properties
 Thorough and carefully material selection would be very important

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MineSiteOverview
Potential sandstone source for suitable material for mobile crushing plant n site
however large mudstone deposit also present within source

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MineSiteOverview Challenge on site was to work on Change Management and work with
Mining Team to : build and assign correct resources and equipment to
construct haul route with appropriate material rather overburden
which is unsatisfactory in wet weather

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PMSSiteInspection Site Sandstone Rock
Variability
Red = Stop: Siltstone / Mudstone
(not suitable for road construction
Amber = Caution: Sandstone with
excessive quantity of siltstone
Green = Go : Sandstone with
suitable properties CBR 30 - 45

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PreliminaryInvestigation
Adrian Smith’s from PSM Site inspection :
 Some potential to utilise some sound sandstone material on site
 Carefully mining will need to take place to only utilise certain sandstone
sources for feed to on site crushing and screen plant
 Multiple samples take as per Thiess request for Laboratory Testing
 Thiess and PMS to work together on optimising the pavement design based on
sandstone material on site
Dave Tulloch from Road Safety Training Services completed assessment
on site on Mine Road Friction Resistance
 Challenge was for Mining Management Team to incorporate these
initiatives and recommendations

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MineSiteOverview Dave Tulloch from Road Safety Training Services completed assessment on
site on Friction Evaluation and Operational Protocol
 Challenge was for Mining Management Team to incorporate these
recommendation
 Construction of new haul roads would include recommendation from
report
 Challenge for site teams to “change mindset” and learn to use Vericom
system and adopt system of measuring and friction testing on haul
routes rather than using Open Cut Examiners judgement on safety of
haul roads post wet weather

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ResultsofSiteInvestigation
Site Sandstone Rock Variability
 Sandstone with suitable
properties CBR 30 – 45
 However variability was
evident in test results
 PMS report provided guidance
on variability

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Questions thank you for your time