Dust-Free for 12 Weeks: How Dust Down™ Transformed Underground Road Maintenance at a Major Australian Copper Mine

Reducing dust by up to 90%, eliminating daily watering, and significantly reducing road maintenance requirements.

Underground mining environments present unique challenges when it comes to dust control. High vehicle traffic, confined spaces, and continuous operations can create significant dust exposure risks for workers while also increasing road maintenance requirements.

When the management team at one of Australia's largest copper mining operations approached DUSTAC looking for an alternative to traditional water-based dust suppression, the goal was clear: achieve long-term dust control while reducing the ongoing maintenance burden associated with watering and frequent grading.

The results exceeded expectations.

The Challenge

The mine's 4-kilometre underground decline was experiencing persistent dust problems despite significant efforts to control it.

Prior to treatment, the operation faced:

• High dust levels throughout the decline

• Road grading requirements of approximately three times per week

• Continuous reliance on overhead water sprays and water cart applications

• Ongoing maintenance costs and operational disruptions

• Potential health and safety concerns associated with airborne dust exposure

Despite the use of conventional suppression methods, dust levels remained difficult to manage effectively.

A Different Approach to Dust Control

Rather than increasing water usage, DUSTAC recommended the application of Dust

Down™ Granular, which is designed to bind fine particles within the road structure.

Unlike traditional methods that rely on constant watering, Dust Down™ works by:

• Binding gravel and clay particles together to prevent them from becoming airborne

• Retaining moisture within the road profile through its hygroscopic properties

• Improving road surface stability

• Reducing the need for frequent maintenance interventions

Initial Application Process

The treatment process was straightforward:

1. Apply Dust Down™ Granular using a Dustac spreader

2. Allow the product to establish within the road structure

3. Avoid watering the treated area after application

4. Conduct a maintenance application approximately every 12 weeks if required

A key component of the strategy was eliminating post-application watering. Once established, the product maintains moisture retention and dust control without ongoing water inputs.

Immediate Results

The impact of Dust Down™ was evident within days of application.

What was previously a dusty, high-maintenance decline quickly transformed into a stable road surface with significantly reduced airborne dust.

Within the first month:

• No additional water had been applied since treatment

• Overhead spray systems remained isolated

• No grading was required

• Dust levels were dramatically reduced

The road surface remained stable, and traffic continued without the maintenance interruptions previously experienced.

Sustained Performance Over Three Months

One of the most impressive aspects of the trial was the longevity of the treatment.

One Month After Application

The decline remained dust controlled with:

• Zero water applications

• No grading activities required

• Significant and visible reduction in airborne dust

Two Months After Application

Performance remained consistent:

• No watering

• No grading

• Continued dust suppression across the treated section

Three Months After Application

At the 12-week review point:

• Dust control performance remained strong

• Water sprays were still not required

• Road grading remained negligible

• Road integrity was maintained despite heavy operational use

This level of sustained performance represented a substantial operational improvement compared with the site's previous maintenance regime.

Managing Difficult Road Materials

An additional benefit observed during the project involved the road construction materials themselves.

Some of the sheeting material used on the decline exhibited hydrophobic characteristics, meaning it naturally repels water and can be challenging to manage using conventional dust suppression techniques.

Dust Down™ proved effective in binding these materials within the road matrix, contributing to improved surface stability and helping prevent the generation of airborne dust.

The Outcome

Following treatment of the 4-kilometre underground decline, the mine achieved:

✅ Up to 90% reduction in dust levels

✅ Elimination of daily watering requirements

✅ Significant reduction in road grading activities

✅ Improved Road stability

✅ Reduced maintenance costs and operational disruption

✅ Improved control of dust-related health and safety risks

By moving away from a water-dependent approach, the operation successfully achieved long-term, sustainable dust control while reducing resource consumption and maintenance demands.

Before Trial After Trial

Why Dust Control Matters

Dust exposure remains one of the key health and safety risks in mining operations. Effective dust management not only improves visibility and operational efficiency but also helps create a safer working environment for personnel working underground.

This project demonstrates that with the right technology, mines can achieve substantial dust reduction while lowering maintenance requirements and reducing water consumption.

Partner with DUSTAC

DUSTAC delivers practical dust management solutions across underground mining, haul roads, fixed plant operations, access roads, and environmental monitoring programs.

Whether you're looking to reduce water usage, improve road performance, or create a safer work environment, Dust Down™ offers a proven solution for long-term dust control.

Interested in learning how Dust Down™ can improve dust management at your operation? Contact DUSTAC to discuss a site-specific solution.