Mining haul roads are unpaved or lightly paved access routes used for heavy transport within open-cast and underground mining sites. Repeated loading from dump trucks, wheel loaders, and mining equipment causes rapid rutting and surface deterioration on weak or variable subgrades. Secugrid® geogrids and Combigrid® geocomposites stabilise the base course, distribute loads and extend service life.
Application: Stabilisation of unpaved haul roads and access routes in open-cast and underground mining under repeated heavy axle loads.
Products: Secugrid®, Combigrid®, Secutex®
Subgrade: CBR < 3%, cohesive, variable or saturated subsoil typical in mining environments
Standards: BS 8006-1, Giroud & Han, BRE 470, AASHTO 93, EBGEO
Typical Projects: Open-cast mines, haul roads, log yard haul roads, run-of-mine stockpile access, rehabilitation of failed roads
Secugrid® and Combigrid® are proven on every haul road type across the mining sector, from primary haulage routes to secondary access tracks on challenging ground.
Heavy-duty mine roads on weak or variable ground.
Stable haul roads for logging operations on soft or boggy ground with limited site access.
Stable reinforcement for steep slopes and embankments on variable mine terrain.
Mining haul roads face some of the most demanding load conditions in civil construction. Dump trucks with gross vehicle weights exceeding 100 tonnes, repeated axle passes, and variable subgrade conditions demand geosynthetics engineered for toughness. Secugrid® geogrids and Combigrid® geocomposites are designed to withstand installation stresses from compaction equipment and aggregate placement. Their monolithic structure and welded junctions maintain integrity under load during and after construction.
Practical Advantages:
In many mining haul road projects, long-term performance depends not only on initial bearing capacity but on preventing subgrade fines from contaminating the aggregate base course. On saturated or cohesive subgrades, fines migrate upward under repeated loading, gradually reducing drainage and bearing capacity.
Key principle: Reinforcement improves bearing capacity. Separation and filtration protect the base course over the long term.
Product selection depends on subgrade conditions, load class, and whether separation and filtration are required. The table below provides a structured decision framework for project engineers.
| Subgrade Condition | Load Class | Filtration Required? | Recommended Product |
|---|---|---|---|
| CBR > 3%, granular, dry | Medium (haul trucks up to 60 t) | No | Secugrid® (single layer) |
| CBR 1–3%, cohesive or variable | Heavy (haul trucks 60–100 t) | No | Secugrid® (single or multi-layer) |
| CBR < 1%, saturated or plastic | Very heavy (>100 t GVW) | Yes | Combigrid® (single layer) or Secugrid® + Secutex® |
| Any, with fines migration risk | Any | Yes | Combigrid® (reinforcement + filtration in one product) |
| Very soft, CBR < 0.5% | Heavy to very heavy | Yes | Secugrid® (multi-layer) + Secutex® or Combigrid® (multi-layer) |
Less rutting, greater serviceability
Improved load distribution within the base course reduces surface deformation. Haul roads remain serviceable for longer between maintenance interventions, reducing operational downtime on site.
Increase bearing capacity on soft subgrade
The composite action of geogrid and base course mobilises horizontal forces and increases system bearing capacity.
Avoid aggregate replacement — reduce cost and programme
Stabilisation and reinforcement frequently eliminate the need for expensive and time-consuming subgrade replacement or deep excavation. Base course thickness can be reduced, saving material and transport cost.
Protect the base course long-term
With Combigrid® or Secutex® providing separation and filtration, fines migration from the subgrade is prevented. This sustains drainage and bearing capacity throughout the design life of the haul road.
Single-product installation efficiency
Combigrid® combines geogrid and geotextile in one product, simplifying installation in remote locations with limited specialist resources. 4.75 m wide rolls minimise joints and speed up construction.
Mining haul roads are unpaved or lightly surfaced access routes for heavy mining equipment, including dump trucks with gross vehicle weights exceeding 100 tonnes. Repeated axle loading on weak or variable subgrades causes progressive rutting and base course failure. Geogrid reinforcement using Secugrid® or Combigrid® improves load distribution, increases bearing capacity and extends the service life of these critical routes.
Secugrid® is the primary choice when the subgrade is stable enough to resist fines migration and only reinforcement is required. Combigrid® is recommended when the subgrade is cohesive, saturated or susceptible to fines migration, as it combines Secugrid® reinforcement with Secutex® separation and filtration in a single product layer, simplifying installation on site.
Design of geogrid-reinforced unpaved roads is typically carried out to Giroud & Han (2004), BRE 470, BS 8006-1 or manufacturer-specific design charts based on CBR and applied axle load. In Germany, EBGEO Chapter 6 applies. Naue's technical team and the SecuCalc design tool support project-specific dimensioning to these standards.
Geogrid reinforcement can reduce the required base course aggregate thickness, yielding direct savings in material procurement, transport and installation. In remote mining locations where aggregate must be hauled over long distances, reductions in fill volume deliver substantial cost savings.
The subgrade is graded to a level surface. The geogrid or geocomposite is unrolled directly onto the prepared subgrade. Combigrid®'s 4.75 m wide rolls match typical haul road widths, minimising cutting and overlap. Aggregate base course is then spread and compacted over the geosynthetic in the specified layer thickness. No specialist equipment is required for installation.
By reducing the volume of aggregate required, Secugrid® and Combigrid® systems reduce the amount of aggregate that must be extracted, processed and hauled to site. Locally available fill materials can often be used in place of imported crushed stone. Reduced maintenance interventions further decrease plant movements and fuel consumption over the design life of the road.
Yes. Secugrid® and Combigrid® have been specified on haul road and ground stabilisation projects across the mining sector on multiple continents, including open-cast mines, log yards, and run-of-mine stockpile access roads.
Secugrid® and Combigrid® are tested for creep resistance under sustained loading: the creep reduction factor for Secugrid® PET (polyester) is ≤ 1.40 at 120 years (EBGEO/BBA), confirming long-term tensile strength retention. The welded junction construction maintains load distribution under cyclic axle loading without degradation. Separation and filtration by the Secutex® nonwoven in Combigrid® prevents fines migration that would otherwise reduce bearing capacity over time.
Yes. For haul roads wider than the 4.75 m standard Combigrid® roll width, panels are overlapped or butted according to Naue installation guidelines. Overlap width is determined by subgrade CBR and design axle load. For wider roads, Secugrid® is available in wider rolls and can be combined with separate Secutex® geotextile panels for flexibility. The technical engineering team provide project-specific layout and overlap guidance for all road widths and configurations.
The dimensioning of geogrid systems for mining haul roads is carried out to recognised international standards. Naue supports project engineers in determining the optimal system for their project conditions, quickly, transparently and in accordance with applicable standards.
Naue Secugrid® geogrid stabilises and reinforces roads, embankments, working platforms, slopes and walls.
Naue Combigrid® is a geogrid with integrated nonwoven geotextile that combines stabilisation, reinforcement, separation and filtration in a single installation step.
Naue Secutex® is a mechanically bonded nonwoven geotextile for separation, filtration and protection in roads, railways and hydraulic engineering projects.
