032-00 DESIGN, CONSTRUCTION

AND MAINTENANCE OF MINE ROADS

Procedure No: QC-PQC032.00
Issue No: 0

Page: 1 of 10
10-January-2002

QC-PQC032-00 Design, Construction and Maintenance of Mine Roads

Table of Contents
1.

PURPOSE................................................................................................................................................................ 2

2.

SCOPE ..................................................................................................................................................................... 2

3.

REFERENCES........................................................................................................................................................ 2
3.1
3.2
3.3

4.

COMPLIANCE WITH COAL MINING SAFETY AND HEALTH REGULATION 2001 .................................................. 2
SUBSIDIARY DOCUMENTS ................................................................................................................................ 3
OTHER REFERENCES......................................................................................................................................... 3

DEFINITIONS ........................................................................................................................................................ 3
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8

5.

SHALL........................................................................................................................................................... 3
PRIMARY HAUL ROAD...................................................................................................................................... 3
SAFETY BERM .................................................................................................................................................. 3
ROAD WIDTH ................................................................................................................................................... 3
VEHICLE ........................................................................................................................................................... 3
LIGHT VEHICLES.............................................................................................................................................. 3
VEHICLE WIDTH ............................................................................................................................................... 4
LARGEST VEHICLE REGULARLY USING THE ROAD ............................................................................................. 4

ACTIONS ................................................................................................................................................................ 4
5.1
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.3
5.4

6.

TRAFFIC FLOW STANDARDS ............................................................................................................................. 4

DESIGN STANDARDS......................................................................................................................................... 4
Category 1 - Primary haulroad regularly used for two way traffic............................................................ 5
Category 2 - Ramps and in-pit roads used by light and heavy equipment ................................................. 6
Category 3 - Prestrip and overburden haulroads ...................................................................................... 7
Category 4 - Light vehicle access roads .................................................................................................... 7
Category 5 Temporary roads or tracks ................................................................................................... 7
CONSTRUCTION OF ROADS ............................................................................................................................... 7
MAINTENANCE AND DUST CONTROL OF ROADS ............................................................................................... 8

ROLES AND RESPONSIBILITIES ..................................................................................................................... 8

6.1
6.2

MINING MANAGER ........................................................................................................................................... 8

MINEWORKERS AND VISITORS ......................................................................................................................... 8

7.

PERFORMANCE INDICATORS......................................................................................................................... 8

8.

RECORDS ............................................................................................................................................................... 8

9.

ATTACHMENTS ................................................................................................................................................... 9
9.1

10.
10.1

CONSULTATION TASK FORCE BHP MINE ROAD DESIGN MANAUL ............................................................... 9

DEVELOPMENT AND REVIEW RECORD ............................................................................................... 10
DEVELOPMENT RECORDS ............................................................................................................................... 10

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032-00 DESIGN, CONSTRUCTION

AND MAINTENANCE OF MINE ROADS
Procedure No: QC-PQC032.00
Issue No: 0

1.

Page: 2 of 10
10-January-2002

PURPOSE
The purpose of this specification is to establish the road design, construction and maintenance
standards for the safe operation of vehicles and equipment at the mine site.

2.

SCOPE
This specification applies to all roads operated and under the control of the mine site. It
provides guidelines and procedures to follow in relation to:
Traffic flow standards
Design standards for width, grade, curve radii, intersections and safety berms
Requirements for barriers, guideposts and signage
Base and surfacing materials
Maintenance and watering methods.
The specification is intended to apply to the categories of roads defined in section 5.2. It is
not intended to apply to industrial and preparation plant areas; or mining faces and dumps.
These are still subject to vehicle movement procedures and should be set out with appropriate
consideration of the risks at the time.

3.

REFERENCES
3.1 Compliance with Coal Mining Safety and Health Regulation 2001
Specification for Roads: Section 128 of the regulation requires the mine Safety and
Health management System (SHMS) to provide a specification for design and
construction of mine roads. The specification must take into account the nature of the
mine vehicles, the method of operation, and the nature of the road construction
materials.
The regulation requires the specification to be developed through a formal risk
assessment process, and to cover the following requirements:
barriers
curvature
grade
guideposts
pavement shape
safety berms (mandated if the vertical drop off is more than 0.5 metres)
signs
surface materials
width (mandated as 3.5 times the vehicle width of the larges regularly used vehicle
for primary haulroads with two way traffic)

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032-00 DESIGN, CONSTRUCTION

AND MAINTENANCE OF MINE ROADS
Procedure No: QC-PQC032.00
Issue No: 0

Page: 3 of 10
10-January-2002

Road maintenance: Section 129 of the regulation requires the mine to have a standard
operating procedure covering maintenance and watering of roads. This requirement is
address by the Standard operating Procedure QC-PST030-00 Safe Operation and
Movement of Vehicles but relies in part on reference to this specification for design and
maintenance.
3.2 Subsidiary Documents
n/a
3.3 Other References
QC-PST030-00 Safe Operation and Movement of Vehicles
BHP Mine Road Design Manual, 1998
BHP Mine Road Design Guidelines, 1998
4.

DEFINITIONS
4.1 Shall
The word shall is to be understood as mandatory and the word should as nonmandatory, advisory or recommended.
4.2 Primary Haul Road
This is a main haulage road constructed for access to a mining area over an extended
period, in excess of a single strip. It does not include in-pit roads or ramps, and is
restricted to sections capable of carrying mixed traffic at speeds in excess of 40 kph.
4.3 Safety Berm
A safety berm (or windrow or bund or rill) is a structure of earth, rock or other
competent material constructed along the edge of a road or adjacent to a drop-off, of
suitable and sufficient dimensions to significantly reduce the risk of a vehicle running
off the road or over the drop-off.
4.4 Road Width
Road width is measured as the width of useable running pavement on the road clear of
guideposts, grader rills and safety berms.
4.5 Vehicle
Vehicle shall, unless the context requires otherwise, mean any truck, mobile machine
and vehicle.
4.6 Light Vehicles
Light vehicles are generally classed as those that can freely be driven on a road (as
defined in the Traffic Act) as opposed to heavy vehicles or equipment used on the mine
site for earthmoving and like duties.

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032-00 DESIGN, CONSTRUCTION

AND MAINTENANCE OF MINE ROADS
Procedure No: QC-PQC032.00
Issue No: 0

Page: 4 of 10
10-January-2002

4.7 Vehicle Width

Vehicle width is measured across the widest part of the vehicle, but excludes collapsible
projecting parts such as lights and mirrors. Usually the widest part of a heavy vehicle is
across the tyres.
4.8 Largest vehicle regularly using the road
This is taken to mean the widest vehicle that travels on the road in normal operation,
and does not include vehicles subject to special arrangements to ensure safety of other
traffic.
5.

ACTIONS
5.1 Traffic Flow Standards
From an operational viewpoint, the traffic flow standards are outlined in detail in
procedure for the mine site, SOP030.00 Safe Operation and Movement of Vehicles.
From a design and construction viewpoint, the following parameters should be used as a
guide.
In general and where it is practicable, the operation of light and heavy vehicles
should be separated.
Primary haulroads should be designed to be as straight as possible with a minimum
number of intersections or roads entering.
Primary haulroads shall be designated such that all vehicles have right of way, with
the exception for emergency vehicles.
All intersections or roads entering should be at right angles with a clear view of at
least 150m in either direction.
5.2 Design Standards
The BHP standard for mine road construction (BHP Mine Road Design Manual, 1998,
and BHP Mine Road Design Guidelines, 1998) provides for a good general reference
grounded on risk review for traffic flow criteria and the construction of roads.
However, to provide a guideline for everyday road construction activities on site, this
procedure establishes criteria for different classes of roads.
For design and construction purposes, mine roads shall be categorised as:
Category 1 Primary haulroads
Category 2 Ramp and in-pit roads
Category 3 Prestrip and overburden haulroads
Category 4 Light vehicle access roads
Category 5 Temporary roads and/or tracks.
The basic design standards that shall be used for the various types of roads are outlined.

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032-00 DESIGN, CONSTRUCTION

AND MAINTENANCE OF MINE ROADS
Procedure No: QC-PQC032.00
Issue No: 0

Page: 5 of 10
10-January-2002

Prior to any road being constructed, a risk review should be conducted on the design or
proposed configuration of the road. This shall assess the suitability of the configuration
and materials used to ensure that the safety risk to vehicles using the road is of an
acceptable level.
The design should take the following aspects into consideration:
Lighting effects for roads in the vicinity of highly lit areas; including the needs for
permanent lights in critical areas and the hazard of background glare.
Presence of overhead structures and power lines
Drainage
Layout of and access to parking areas
Access from roads to adjacent dump areas
5.2.1 Category 1 - Primary haulroad regularly used for two way traffic
All primary haulroads are to be adequately designed in accordance with good
practice for heavy equipment roads and the following guidelines:
Road width - (as defined) of the road to be at least 3.5 times the width of the
largest vehicle regularly using the road.
Road grade - generally the grade should be less than 3% (1:30).
Road profile - the pavement shall be shaped so as to readily drain water and
to provide a safe surface to travel.
Curvature of bends - Refer to section 5 of BHP Mine Road Design Manual
for the sound engineering principles required). In general, bend radii should
be 400 metres or greater for main sections of road.
Intersections - all new intersections should be T intersections (angle of
approach of at least 70 degrees - refer to section 11 of BHP Mine Road
Design Manual). Where this is not possible, a risk assessment shall be
conducted on the alternative design to ensure that persons can use the
intersection with safety.
Safety berms or barriers shall be installed at any point where the drop off at
the side of the road is greater than half a metre (0.5 m), as detailed in the
following section. This drop off situation should be avoided wherever
possible by allowing a run-off slope at the side of the road battered at an angle
no steeper than 1:4. Design berm height is ideally half wheel height but a
minimum berm height of one (1.0) metres is recommended for haulroads
taking into account the need for visibility from light vehicles.
Guideposts are to be of such size, shape, robustness and visibility
(reflectorised) so as to adequately define the road boundaries in all conditions.
The spacing of the guideposts shall be a nominal 150 metres on the general
mine site and 100 metres on the haulroad. Section 13 of BHP Mine Road
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032-00 DESIGN, CONSTRUCTION

AND MAINTENANCE OF MINE ROADS
Procedure No: QC-PQC032.00
Issue No: 0

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Design Manual should be used as a guide. Culverts unprotected by barriers or

berms should be marked with pairs of guideposts as recommended in the
manual.
Signage - traffic control and direction signage shall be installed where
necessary. The signs shall comply with AS1742.(1...14): Manual of uniform
traffic control devices.
Surface material - haul roads should be sheeted with sufficient competent
material to provide an adequate degree of traction when wet, and to enable the
surface condition to be restored through normal road maintenance.
5.2.2 Category 2 - Ramps and in-pit roads used by light and heavy
equipment
These roads are generally of a temporary or semi permanent type:
Road width - to be adequate to allow margin for any vehicles to pass with
safety taking into account the type, speed and width of vehicles regularly
using the road, grade and bends; and considering the use of limited passing
sections in confined areas.
Road grade - the road grade should generally not exceed 10% (1:10) and
should be selected with consideration of the haul vehicle characteristics for
which it is designed, taking into account gearing, rimpull and retarding
capacity of the haul vehicle and the direction of normal travel of the loaded
vehicle.
Road profile - for in-pit roads where the cross-fall of the pit floor is
considered to be excessive for the safe operation of trucks or loading
equipment, the road or loading area should either be benched into the coal
or pit floor, or built up with waste material. Where possible, any corners
should be designed / constructed to have a positive super-elevation of at least
3% but no more than 10%.
Curvature of bends - the radii of bends should be at least 100 metres on
through travel sections of road, and effort should be made to shape the road as
the pit face progresses away from bends imposed by pit geometry.
Intersections and safety berms should generally be the same as 5.2.1 above.
Guideposts and signage Where the road is confined in ramps or pits, signs
and guideposts or reflectors should be used in areas where risk assessment
indicates they are required.
Surface material - ramps should be sheeted with suitable material to provide
safe traction for descending vehicles and to avoid wheel spin for ascending
vehicles. Pit roads should be constructed of best material available, and
sheeting with reject or other suitable material considered to provide adequate
traction and load carrying capacity.
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032-00 DESIGN, CONSTRUCTION

AND MAINTENANCE OF MINE ROADS
Procedure No: QC-PQC032.00
Issue No: 0

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10-January-2002

5.2.3 Category 3 - Prestrip and overburden haulroads

These roads are similar to in-pit roads and ramps and the same criteria should
apply, with the following special considerations:
Traffic flow should be restricted to limit access by vehicles other than haul
traffic, such that other traffic is required to notify and receive
acknowledgment from haul traffic before entering and using these roads.
The recommended minimum road width is 3.5 times the width of the largest
vehicle commonly using the road
No dedicated parking areas are to be included in the road design.
Pavement surface will frequently be contaminated by spillage, often with high
clay content, causing slippery conditions. Maintenance levels should be
adjusted to limit this hazard. Special measures such as application of sand to
the surface should be considered if available.
Roads will often cross pits or run adjacent to excavated faces and adequate
safety berms should be located to provide vehicle safety.
Combinations of vertical and horizontal curves often result from pit crossings
and road width and superelevation should be adjusted to provide for safe
operation.
5.2.4 Category 4 - Light vehicle access roads
These roads are those that are predominantly used by light vehicles and
occasionally by heavy vehicles.
Permanent and semi permanent access roads shall be designed and constructed to
at least 6 metres wide. Intersections, safety berms, guideposts and signage should
be similar to 5.2.1 above. Use of guard rails may be considered as an alternative
to safety berms for light vehicle traffic for culvert crossings and other areas
where appropriate.
5.2.5 Category 5 Temporary roads or tracks
Temporary roads are to be adequate for the safe operation of vehicles. Any such
road shall undergo a job safety analysis (JSA) or risk assessment, to ensure that
its design / construction does not pose an unacceptable level of risk.
Once any such road no longer has a purpose, it shall be closed off.
5.3 Construction of Roads
Primary haul roads shall be adequately formed and constructed with foundation
materials of suitable strength and compaction so as not to be readily prone to failure.
Base and top course materials are to be of adequate strength so as to not prematurely
break down and become slippery when wet.
The construction process commonly used at the mine site is:
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032-00 DESIGN, CONSTRUCTION

AND MAINTENANCE OF MINE ROADS
Procedure No: QC-PQC032.00
Issue No: 0

Page: 8 of 10
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Remove the top and sub soil horizons to a suitable base material.
Backfill and compact with the most competent overburden material readily available.
Top course material and pavement should be competent material. During stripping
operations, suitable material (such as sandstone or gravels with low clay content)
should be stockpiled for road construction purposes if encountered.
Other semi permanent and temporary roads shall be formed and constructed out of
suitable local materials so as to form a safe running surface. Use of unweathered or
weathered sandstone will help form an all weather road if required.
5.4 Maintenance and Dust Control of Roads
All roads should be graded on a regular basis so as to maintain an adequate running
surface and drainage.
From time to time the primary haul road (in particular) may require structural
maintenance work that could include scarifying and re-compaction and/or resurfacing.
Ongoing work is required to ensure that the road boundary is clearly defined at all times
including the hours of darkness. This shall include cleaning of guideposts on a regular
basis and replacement of missing or damaged guideposts and signage.
Regular watering is required for dust control and maintenance of surface structure.
Refer to the standard operating procedure, SOP030.00 Safe Operation and Movement of
Vehicles, section 5.6.4 Watering Roads for details.
6.

ROLES AND RESPONSIBILITIES

6.1 Mining Manager
The Manager responsible for open cut mining operations is responsible to the Site
Senior Executive for implementation of this specification.
6.2 Mineworkers and Visitors
All persons authorised to operate mobile equipment and vehicles shall comply with the
requirements of the standard operating procedure, SOP030.00 Safe Operation and
Movement of Vehicles, and particularly section 5.4 Mine Traffic Rules relating to road
use.

7.

PERFORMANCE INDICATORS
n/a

8.

RECORDS
n/a

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032-00 DESIGN, CONSTRUCTION

AND MAINTENANCE OF MINE ROADS
Procedure No: QC-PQC032.00
Issue No: 0

9.

Page: 9 of 10
10-January-2002

ATTACHMENTS
9.1 Consultation Task Force BHP Mine Road Design Manual
This specification relies on the information contained in the BHP Mine Road Design
Manual, 1998. The original manual was first compiled and edited by Owen Williamson
in 1987. The BHP Minerals Vehicle Interaction Task Force identified the need for a
new and updated Mine Road Design Manual.
The Taskforce members were Bruce Grieve, Ray Southey, David Todd, Philip St.
Baker, Kevin Compton, Wayne Schiller, LeRoy Dugger, Wally Kowalczuk, Matt
Meyer, Scott Rosenthal and George Ray.

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032-00 DESIGN, CONSTRUCTION

AND MAINTENANCE OF MINE ROADS
Procedure No: QC-PQC032.00
Issue No: 0

Page: 10 of 10
10-January-2002

10. DEVELOPMENT AND REVIEW RECORD

10.1 Development Records

Date Reviewed

Tout 03/2001
15/03/01
22/03/01
28/03/01
13/12/01

Developed and Reviewed by:

Name
Mine Site

Cam Davidson
Geoff Caton
Terry Clarke
Ray Southey
John Davidson
C.R. Coffey
Derick Wilford
Cres Bulger
Des Flohr
Bruce Treasure
John Davidson
Eddy Haegel
Mark Anfruns
Ray Southey
Graham Schuler
Ross Ogden
Paul Stringer
Peter Walton
Cam Davidson

QCO
GN
PD
GN
BW
PD
SR
GC
SR
BW
BW
NP
PD
GR
GR
GR
GR
Iris RM
QCO

Position

Project Development Manager

Manager Operations Planning
Manager Technical Services
Mining Manager
Mining Manager
OCE, SSHR
Tech Services Manager
Senior Production Coordinator
Senior Stripping Foreman
Safety Manager
Stripping Superintendent
Mining Manager
Surveyor
Mining Manager
Senior Supervisor Mining
Prestrip Truck Driver, SSHR
Senior Supervisor Truck Shovel
Facilitator
Project Development Manager

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