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El. knyga: Mining Haul Roads: Theory and Practice

(Mineravia Consulting, Kalgoorlie, Australia), (Department of Civil Engineering, University of Pretoria, Hatfield, South Africa), (Federal University of Rio Grande do Sul, Porto Alegre, Brazil)
  • Formatas: 316 pages
  • Išleidimo metai: 15-Jan-2019
  • Leidėjas: CRC Press
  • Kalba: eng
  • ISBN-13: 9780429958007
Kitos knygos pagal šią temą:
Mining Haul Roads: Theory and PracticeDidesnis paveikslėlis
  • Formatas: 316 pages
  • Išleidimo metai: 15-Jan-2019
  • Leidėjas: CRC Press
  • Kalba: eng
  • ISBN-13: 9780429958007
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Mining operations may be classified into surface mining and underground operations where mining takes place in tunnels and galleries. In both situations roads play a key role as a typical mining operation consists of moving overburden and ore from wherethe material was formed or deposited to waste dumps or beneficiation plants. This book approaches the subject of how to design, build and operate mine haul roads from the perspectives of safety, economy and technical requirements over the life of a mine.Consideration is given to the geometrical, structural, functional and maintenance management aspects of design and construction, from both theoretical and practical viewpoints-- Mining haul roads are a critical component of surface mining infrastructure and the performance of these roads has a direct impact on operational efficiency, costs and safety. A significant proportion of a mine’s cost is associated with material haulage and well-designed and managed roads contribute directly to reductions in cycle times, fuel burn, tyre costs and overall cost per tonne hauled and critically, underpin a safe transport system.The first comprehensive treatise on mining haul road design, construction, operation and management, Mining Haul Roads – Theory and Practice presents an authoritative compendium of worldwide experience and state-of-the-art practices developed and applied over the last 25 years by the three authors, over three continents and many of the world’s leading surface mining operations. In this book, the authors:Introduce the four design components of an integrated design methodology for mining haul roads – geometric (including drainage), structural, functional and maintenance managementIllustrate how mine planning constraints inform road design requirementsDevelop the analytical framework for each of the design components from their theoretical basis, and using typical mine-site applications, illustrate how site-specific design guidelines are developed, together with their practical implementationSummarise the key road safety and geometric design considerations specific to mining haul roadsSpecify the mechanistic structural design approach unique to ultra-heavy wheel loading associated with OTR mine trucksDescribe the selection, application and management of the road wearing course material, together with its rehabilitation, including the use of palliativesDevelop road and operating cost models for estimating total road-user costs, based on road rolling resistance measurement and modelling techniquesIllustrate the approach of costing a mining road construction project based on the design methodologies previously introducedList and describe future trends in mine haulage system development, how mining haul road design will evolve to meet these new system challenges and how the increasing availability of data is used to manage road performance and ultimately provide 24x7 trafficability.Mining Haul Roads – Theory and Practice is a complete practical reference for mining operations, contractors and mine planners alike, as well as civil engineering practitioners and consulting engineers. It will also be invaluable in other fields of transportation infrastructure provision and for those seeking to learn and apply the state-of-the-art in mining haul roads.“This book is the most definitive treatise on mining haul roads ever written ( …) There has never been a text that addresses the many facets of mining haul roads on such a scope ( …)” From the Foreword by Jim Humphrey, Professional Engineer, Autonomous haulage systems developer and Distinguished Member of the Society of Mining, Metallurgy and Exploration.

Recenzijos

Up to the launch of the book, various aspects of this interesting field were covered in technical publications addressing specific topics. The book now combines all these into one publication that deals comprehensively with the design, operation and maintenance of haul roads in a very practical manner [ ] and is a must for the design engineer, contractor and mine operator.

Dr. Pierre van der Berg Pr Eng, CEO, Jones & Wagener, Civil Engineering, November 2019, p. 35

This is a very valuable, and long overdue, resource [ ] Across the globe, mining roads are being constructed without a sound technical, research-based, approach proposed by this book. The book could encourage uniformity and standardization of practices in various countries. It has a potential of becoming a valuable resource for improving cost-efficiency, productivity and safety on mining operations across the globe.

Damir Vagaja, Principal Consultant, RTSM Consulting, Australia

Mining Haul Roads, Theory and Practice is the most forthright, innovative, operational focused guide for haul road design and maintenance, since the advent of haul road design practices outlined by Kaufman and Ault in IC 8758 in 1977, and the guidelines review published by Tannant and Regensburg in 2001.

It is time to retire all former haul road design guidelines. There is now only one go to reference for haul road design. Thompson, Peroni and Visser have delivered what we have been waiting for.

This inspirational mechanistic haul road design work of Roger Thompson and Alex Visser of the past 20 years is now enhanced yet further with the addition of simple field evaluative function design and road management considerations; clearly illustrated through well thought out field case studies, that put for the first time a complete haul road ownership picture into context. In focus; chapters 3, 4 and 5 are essential reading, comprehension and application for any surface mining engineer worth their salt!

It is no longer acceptable for any surface mining operation owning haul trucks to merely consider life cycle cost analysis of hauler assets, without taking heed to and including the vital knowledge presented here by Thompson, Peroni and Visser.

As an active mining engineering consultant, this milestone work now provides a firm foundation for any work that I would be remiss to ignore, in haul road design, operation and maintenance moving forward. This is truly the state-of-the-art do-it-yourself knowledge that mining operations will be expected to adhere to moving forward. The standard of application and the bar for mining operations has been raised to a level beyond expectation.

Dr. Tim Joseph, P.Eng., FCIM

Principal and President, JPI mine equipment & engineering consultants; Professor, Mining Engineering and Associate Dean, Faculty of Engineering, University of Alberta; Vice-President, Association of Professional Engineers and Geoscientists of Alberta (APEGA); and Ambassador, Canadian Institute of Mining, Metallurgy & Petroleum.

Dr. Joseph is a recognized global mining operational engineering expert and professional development trainer in ground equipment interactions, specializing in truck shovel systems Up to the launch of the book, various aspects of this interesting field were covered in technical publications addressing specific topics. The book now combines all these into one publication that deals comprehensively with the design, operation and maintenance of haul roads in a very practical manner [ ] and is a must for the design engineer, contractor and mine operator.

Dr. Pierre van der Berg Pr Eng, CEO, Jones & Wagener, Civil Engineering, November 2019, p. 35

This is a very valuable, and long overdue, resource [ ] Across the globe, mining roads are being constructed without a sound technical, research-based, approach proposed by this book. The book could encourage uniformity and standardization of practices in various countries. It has a potential of becoming a valuable resource for improving cost-efficiency, productivity and safety on mining operations across the globe.

Damir Vagaja, Principal Consultant, RTSM Consulting, Australia

Mining Haul Roads, Theory and Practice is the most forthright, innovative, operational focused guide for haul road design and maintenance, since the advent of haul road design practices outlined by Kaufman and Ault in IC 8758 in 1977, and the guidelines review published by Tannant and Regensburg in 2001.

It is time to retire all former haul road design guidelines. There is now only one go to reference for haul road design. Thompson, Peroni and Visser have delivered what we have been waiting for.

This inspirational mechanistic haul road design work of Roger Thompson and Alex Visser of the past 20 years is now enhanced yet further with the addition of simple field evaluative function design and road management considerations; clearly illustrated through well thought out field case studies, that put for the first time a complete haul road ownership picture into context. In focus; chapters 3, 4 and 5 are essential reading, comprehension and application for any surface mining engineer worth their salt!

It is no longer acceptable for any surface mining operation owning haul trucks to merely consider life cycle cost analysis of hauler assets, without taking heed to and including the vital knowledge presented here by Thompson, Peroni and Visser.

As an active mining engineering consultant, this milestone work now provides a firm foundation for any work that I would be remiss to ignore, in haul road design, operation and maintenance moving forward. This is truly the state-of-the-art do-it-yourself knowledge that mining operations will be expected to adhere to moving forward. The standard of application and the bar for mining operations has been raised to a level beyond expectation.

Dr. Tim Joseph, P.Eng., FCIM

Principal and President, JPI mine equipment & engineering consultants; Professor, Mining Engineering and Associate Dean, Faculty of Engineering, University of Alberta; Vice-President, Association of Professional Engineers and Geoscientists of Alberta (APEGA); and Ambassador, Canadian Institute of Mining, Metallurgy & Petroleum.

Dr. Joseph is a recognized global mining operational engineering expert and professional development trainer in ground equipment interactions, specializing in truck shovel systems

Foreword xiii
Abbreviations and notation xv
Symbols xvii
1 Introduction to mine haul roads
1(18)
1.1 Importance of mine haul roads
1(6)
1.2 Characteristics of mine haul roads
7(2)
1.3 The provision of mine haul roads
9(2)
1.4 The quality of mine haul roads
11(8)
2 Concepts for geometrical design
19(54)
2.1 Geometric design and safer haul roads
19(4)
2.1.1 Integrating design methodology with safety audit systems
20(1)
2.1.2 Analysis of mine haul road and haulage incidents
21(2)
2.2 Integrating design methodology with mining plan
23(7)
2.2.1 Including haul roads in the ultimate pit design
25(1)
2.2.2 Integrating roads through the mine schedule
26(4)
2.3 Geometric design process
30(15)
2.3.1 Stopping and sight distances considerations
32(3)
2.3.2 Measurement of friction supply on mine haul roads
35(4)
2.3.3 Sight distances
39(4)
2.3.4 Truck cab blind spots
43(2)
2.4 Vertical alignment issues -- gradeability and brake performance
45(3)
2.5 Horizontal (longitudinal) alignment issues
48(13)
2.5.1 Width of road
48(4)
2.5.2 Turning circle of large haul trucks
52(1)
2.5.3 Curvature and switchbacks
53(2)
2.5.4 Curve super-elevation (banking)
55(2)
2.5.5 Road camber -- cross-fall or crown
57(2)
2.5.6 Development of super-elevation
59(1)
2.5.7 Combined alignment
60(1)
2.6 Safety berms
61(3)
2.7 Ditches and drainage
64(4)
2.8 Intersection design
68(5)
3 Structural design of haul roads
73(48)
3.1 Background and orientation
73(3)
3.2 The CBR structural design method
76(10)
3.2.1 Origin and background
76(1)
3.2.2 CBR thickness design method
77(2)
3.2.3 Example of application
79(4)
3.2.4 Material characterisation and laboratory tests
83(3)
3.2.5 Limitations of the CBR method
86(1)
3.3 Mechanistic-empirical design method
86(24)
3.3.1 Origin of method -- Boussinesq theory
86(1)
3.3.2 Critical parameters for analysis and input measurements
87(12)
3.3.3 Analytical methodology
99(3)
3.3.4 Example applications
102(5)
3.3.5 Comparison of design methodologies
107(3)
3.4 General construction notes -- layerworks
110(7)
3.4.1 Preparation of in-situ road bed materials
110(3)
3.4.2 Placing and compaction of material above road-bed
113(4)
3.5 Large tracked and platform-type equipment
117(4)
4 Functional design
121(66)
4.1 Introduction and requirements for functional acceptability
121(1)
4.2 Functional characterisation
122(17)
4.2.1 Material properties
122(3)
4.2.2 Laboratory characterisation of wearing course
125(9)
4.2.3 Field testing of wearing course
134(1)
4.2.4 Combination of materials to achieve desired wearing course properties
135(4)
4.3 Benchmarking and monitoring functional performance
139(15)
4.3.1 Qualitative assessment of road functionality
142(6)
4.3.2 Quantitative assessment of road functionality
148(6)
4.4 Benchmarking and monitoring rolling resistance
154(3)
4.4.1 Qualitative assessment of rolling resistance
154(3)
4.4.2 Quantitative assessment of rolling resistance
157(1)
4.5 General construction notes -- wearing course
157(5)
4.5.1 Material selection, crushing, blending and QAQC -- wearing course
160(2)
4.6 Stabilisation and dust palliation
162(25)
4.6.1 Products available for stabilisation and palliation
162(2)
4.6.2 The use of water for palliation
164(4)
4.6.3 Water-spray systems performance modelling
168(6)
4.6.4 Palliative selection
174(4)
4.6.5 Economic evaluation of palliation strategies
178(5)
4.6.6 Practical evaluation of additives
183(4)
5 Road management and maintenance
187(46)
5.1 Background and orientation
187(1)
5.2 Introduction to road management
187(17)
5.2.1 Root cause analysis in road maintenance
188(1)
5.2.2 Road maintenance activities
188(4)
5.2.3 Routine haul road maintenance -- untreated wearing courses
192(6)
5.2.4 Routine haul road maintenance -- treated (palliated) wearing courses
198(2)
5.2.5 Grader selection and road maintenance productivity
200(2)
5.2.6 Maintenance management systems (MMS)
202(2)
5.3 Minimising total costs across a network of roads
204(22)
5.3.1 Haul truck speed and cycle time estimation
206(1)
5.3.1.1 Speed rimpull gradeability curves
206(3)
5.3.1.2 Coopers speed estimation models
209(4)
5.3.1.3 Spline estimation techniques
213(3)
5.3.2 Vehicle operating cost models
216(1)
5.3.3 Road maintenance cost models
217(1)
5.3.4 Tyre cost models
218(1)
5.3.5 Vehicle maintenance, parts and labour cost models
218(2)
5.3.6 Optimising management of mine roads
220(2)
5.3.7 Example of MMS application
222(4)
5.4 Real-time road maintenance
226(7)
6 Equipment performance and costing road construction
233(28)
6.1 Introduction to accounting analysis
233(1)
6.2 Economic analysis
233(3)
6.2.1 Background
233(1)
6.2.2 Project evaluation
234(2)
6.2.3 Discussion of project analyses
236(1)
6.3 Equipment performance and costing for road construction
236(3)
6.4 Earthworks equipment and typical operations
239(8)
6.4.1 Typical excavator/loader applications
240(1)
6.4.2 Typical truck applications
240(1)
6.4.3 Typical tractor/dozer applications
241(2)
6.4.4 Typical motor grader applications
243(1)
6.4.4.1 Site preparation
243(1)
6.4.4.2 Heavy blading
244(1)
6.4.4.3 Finish grading
244(1)
6.4.4.4 Ripping/Scarifying
244(1)
6.4.5 Typical water truck applications
244(1)
6.4.6 Typical compactor applications
245(2)
6.5 Earthworks equipment capital and operational costs
247(3)
6.5.1 Estimating cost of operation
247(1)
6.5.1.1 Fuel or power costs
248(1)
6.5.1.2 Lubrication and filter costs
248(1)
6.5.1.3 Tyres or crawler and undercarriage
249(1)
6.5.1.4 Repair parts and overhauls
249(1)
6.5.1.5 Wear parts
250(1)
6.5.2 Estimating cost of ownership
250(1)
6.6 Cost comparison of road design options
250(11)
6.6.1 Cost estimation example
251(1)
6.6.1.1 Excavator hours
252(1)
6.6.1.2 Truck hours
253(1)
6.6.1.3 Dozer hours
254(1)
6.6.1.4 Motor grader hours
255(1)
6.6.1.5 Compactor hours
256(1)
6.6.1.6 Water truck hours
256(1)
6.6.2 Evaluation of design options costs and benefits
256(5)
7 New technology and haulage equipment developments
261(24)
7.1 Background and orientation
261(2)
7.2 Autonomous haulage
263(10)
7.2.1 Autonomy technologies in mine haulage
264(4)
7.2.2 Road design challenges for autonomous haulage and mining
268(2)
7.2.3 Roadmap for AHS haul road design and management
270(2)
7.2.4 Premium or long-life pavements
272(1)
7.3 Drone-based condition monitoring of haul roads
273(4)
7.4 Haul road geometrical diagnostics -- an example
277(4)
7.5 Fleet management systems
281(4)
References 285(6)
Subject index 291
Roger Thompson has over 25 years industry and academic experience in the field of surface mine haul road design, construction and management. He is Professor of Mining Engineering at the WA School of Mines, Kalgoorlie, Australia. Roger has undertaken numerous contract research and consulting assignments, centred on surface mining transportation and the provision, rehabilitation or improved design and management of mine haul roads for many of the worlds leading surface mining operations. He is the co-author of numerous peer reviewed publications in the field of mine haul road design and also runs Australian and International professional development and accredited training courses in mine road design, construction and management. He is the author of the 2011 Society of Mining, Metallurgy and Exploration (SME) Mining Engineering Handbook contribution on road design, construction and management for mines. Roger graduated from Camborne School of Mines in 1984 and 1990 with Bachelors and Masters degrees in mining and gained his Doctorate through the Department of Civil Engineering at the University of Pretoria. Roger has worked in gold- and coal-mining production, qualifying as a mine manager, as an academic at the University of Pretoria and as guest researcher at the National Institute for Occupational Safety and Health Spokane Research Laboratory (USA) and at Colorado School of Mines, as a Fulbright Scholar.

Rodrigo Peroni is a Mining Engineer, graduated in 1994, finished his Master“s in Resources and Reserves Assessment in 1998, finished his PhD in Mine Planning in 2002 and his Pos-Doctoral in Remote Sensing in 2016. Rodrigo has over 20 years of Mining Experience, worked with aggregates, industrial minerals and gold during his professional life until 2006 when left the industry as a Chief Engineer of the Mine Planning and Geology Department of Rio Paracatu Mineraēćo (Kinross Gold Corporation) to join the Federal University of Rio Grande do Sul at the Mining Engineering Department as a professor. During his academic history Rodrigo is author and co-author of a number of peer reviewed papers, attended and presented several papers in conferences worldwide and supervised several master“s and PhD students. Currently Rodrigo“s research areas are mainly related to mine planning and design, reserves assessment, equipment and fleet sizing, haul road design and UAV applications to mining. He is member of professional associations worldwide (AusIMM, SAIMM, CBRR).

Alex Visser retired as the SA Roads Board Professor in Transportation Engineering in the Department of Civil Engineering at the University of Pretoria in 2009 after a career in research (20 years) and 21 years in academia. His fields of research interest are low volume road design and maintenance and at the other extreme roads for ultra-heavy applications such as mine dump trucks at surface mines and Reachstackers at container terminals, interlocking block paving as well as cast in-situ patented block paving, and road asset management systems. He has published more than 160 peer-reviewed papers and 5 keynote addresses and lectures internationally on these topics. Besides publishing he also serves as reviewer for a number of international journals. He continues guiding graduate students at the University of Pretoria and has a part-time appointment, as well as part-time Adjunct Professor appointments at Changan University, Xian, and Fuzhou University, China since 2017. Since retiring he has also provided advice on projects around the world, including developing procedures for truckless mining, also known as in-pit crushing and conveying. He is a Fellow and Past-President of the South African Institution of Civil Engineering (SAICE) and a Fellow of the South African Academy of Engineering.
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