The mine relies on a network of unpaved internal haul roads to transport ore from the pit to the primary crusher. These roads are trafficked by haul trucks (Komatsu 830EAC), with gross vehicle weights exceeding 400 tons and operating frequencies ranging between 650 and 800 cycles per day under normal production conditions. Given the scale of operations, haul road reliability directly influences crusher feed continuity, equipment utilization, and daily production targets. 3.2 Performance Challenges Prior to Reinforcement Before implementation of the reinforced solution, the haul roads were constructed using conventional mine practices based on locally sourced materials placed in thick granular layers without controlled compaction. A typical section consisted of: • 1.0 m of coarse rock fragments forming the working platform • 0.7 m of itabirite-based sub-base material • 0.3 m of crushed aggregate used as a wearing surface These roads were particularly vulnerable during the rainy season (October–May), when monthly precipitation could exceed 200 mm, leading to rapid degradation of the running surface, deep rutting, and traffic instability. Operational monitoring indicated that rainfall events significantly affected haulage efficiency, reducing the average velocity of trips and impacting production continuity. Figure 4 – Average speed vs rainfall. The recurring need for classification and material replacement resulted in: • Increased equipment allocation to maintenance • Temporary access interruptions • Higher consumption of quarried rock materials • Escalating operational costs
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