South Africa’s mining sector is a key economic pillar in the country, annually contributing around R442 billion ($26 billion) to nominal gross domestic product.

It is therefore crucial that haul roads for transporting minerals are structurally-sound and well-maintained to prevent downtime, higher operating costs and safety risks.

Unfortunately, this is often not the case.

High traffic volumes of heavy-haul trucks with huge axle loads frequently damage road infrastructure and contribute to air pollution and other negative externalities.

In addition, many South African mines operate on weak, variable soils that fail to withstand the extreme loading levels required by the sector.

In response, the industry has been exploring ways to reinforce these critical routes.

Geocells, particularly Neoloy Tough-Cells, supplied by PRS Geo-Technologies, have subsequently emerged as a proven engineering solution.

Why Haul Roads in South African Mines Deteriorate Rapidly

Exceptionally high loads on South Africa’s haul roads often exceed public road standards, to the point that rolling resistance and maintenance costs increase exponentially.

However, often there is little choice for mining companies other than to use these roads as problems with South Africa’s port and rail infrastructure persist.

Haul roads are among the largest ongoing operational cost-drivers in open-pit mining, with substandard surfaces directly impacting fuel consumption, tyre wear and cycle times.

At the same time, because many mines are located on clayey, weathered or moisture-sensitive soils, routes on these sites take a battering from carrier trucks.

Weak subgrades deform under repeated heavy loads, resulting in rutting and shear failure, high traffic volumes cause unreinforced aggregate to spread laterally, and water ingress reduces bearing capacity and accelerates failure.

Engineering Objectives for High-Performance Mining Haul Roads

It is important to note that haul roads are engineered assets, not temporary tracks. 

Their performance directly affects operational efficiency and the cost per tonne of what is mined.

Given the role these routes play in mining profitability and, by extension, the South African economy, engineers need to be precise in ensuring that haul roads meet the highest possible standards.

These professionals need to be able to increase the load-bearing capacity of the road structure, reduce deformation and rutting under heavy, repetitive traffic, and extend maintenance intervals, all the while ensuring safety targets are met.

How Geocells Improve Haul Road Performance Under Heavy Loads

Geocell road stabilisation in South Africa is gaining traction among the country’s road engineers.

The three-dimensional, honeycomb-like Neoloy which are made from polymer materials, confining and strengthening the soil or aggregate within their cells, essentially creating a complete structure for soil stabilization.

By confining soil or aggregate within individual cells, lateral displacement under load is prevented. Stresses are also distributed over a wider area of the subgrade.

Within the geocells South Africa context, they are deemed an effective, cost-effective solution for improving haul roads for various reasons.

For one, they reduce rutting under ultra-heavy haul trucks. For another, implementation results in improved road stiffness and shape retention.

Thirdly, geocell soil stabilisation for weak subgrades delivers better performance on roads subjected to frequent braking, turning and acceleration.

Why Neoloy Tough-Cells Are Well Suited to Mining Haul Roads

Neoloy Tough-Cells stand out among geocells for their polymeric alloy geocell designed for heavy-duty applications.

Neoloy cells enable engineers to construct mechanically stabilized haul roads capable of withstanding the extreme loading conditions typical of South Africa’s mining operations.

Neoloy enables the lowest deformation with the highest confinement efficiency under sustained loads’ hallmarks of this technology, driven by its unique confinement mechanism and proven engineering design methodologies. 

Designed to perform over long service lives in demanding environments, Neoloy cells significantly Improved structural stability under extreme axle loads.

Neoloy also reduced thickness of imported high-quality aggregate where design allows, as well as increased durability under continuous trafficking and harsh site conditions. 

Practical Application on Mining Haul Roads in South Africa

Neoloy Tough-Cells are effective across the road spectrum, from open-pit mining haul roads and access roads between pit, plant, and waste dumps, to permanent and semi-permanent mining infrastructure.

They serve as a unique yet proven confinement layer in road structures that typically also include prepared subgrade, crushed stone or mine-approved granular infill, and wearing surface.

Importantly, implementation of these systems always aligns with the project priorities of safety, cost control and productivity.

Strengthening Mining Haul Roads with Geocell Reinforcement

In South Africa, haul road performance is critical to mining efficiency and safety and geocell reinforcement offers a practical, engineering-led solution.

Neoloy Tough-Cells provide long-term haul road performance by extending service life, minimizing maintenance, and ensuring operational reliability in the country’s mining sector.