Haul Road Construction and Maintenance

Haul roads are the temporary traffic routes used by construction plant and vehicles to move materials around the site.
A well-constructed haul road prevents vehicle bogging, reduces dust, controls drainage, and maintains safe driving conditions.
The road surface must be suitable for the heaviest vehicles using it — typically compacted granular material on a prepared formation.
Road width must allow two-way traffic with passing places, or a one-way system must be established with clear signage.
Gradients must not exceed safe limits for loaded vehicles — typically 1 in 10 for dumpers and 1 in 6 for tracked plant.
Speed limits appropriate to the road surface, gradient, and visibility must be set, signed, and enforced.
Drainage must be provided to prevent water accumulating on the road surface, softening the formation, and creating ruts.
Regular maintenance including grading, filling potholes, and adding material is essential to maintain a safe running surface.
Dust suppression using water bowsers is required during dry periods to maintain visibility and reduce community nuisance.
Haul road design must separate pedestrian routes from vehicle routes using physical barriers wherever possible.

Vehicle stability	A poorly maintained haul road with ruts, potholes, and soft spots causes vehicles to overturn, particularly loaded dumpers on gradients.
Dust hazard	Unsuppressed haul road dust reduces visibility, contaminates neighbouring properties, and creates respiratory hazards for site workers.
Pedestrian safety	Haul roads without separated pedestrian routes create the struck-by hazards that cause fatal injuries on construction sites.

Do

Don't

Construct haul roads with compacted granular material suitable for the heaviest vehicles.
Provide adequate road width for two-way traffic or establish a one-way system with signage.
Limit gradients to safe values for the vehicles and loads using the road.
Set speed limits appropriate to the road surface and conditions, and enforce them.
Install drainage to prevent water softening the road formation and creating ruts.
Maintain the road surface regularly — grade, fill potholes, and add material as needed.
Suppress dust with water bowsers during dry weather to maintain visibility.
Separate pedestrian routes from the haul road using physical barriers.
Inspect the haul road daily and after heavy rain for damage and soft spots.
Brief all drivers on speed limits, passing places, and the traffic management plan.

DON'T allow vehicles onto haul roads that cannot support their weight.
DON'T create narrow roads without passing places or a one-way traffic system.
DON'T allow gradients that exceed safe limits for the vehicles using the route.
DON'T operate without speed limits — uncontrolled speed on haul roads causes overturns.
DON'T let water accumulate on the road surface — it softens the formation rapidly.
DON'T leave potholes, ruts, and soft spots unrepaired on the haul road surface.
DON'T let dust build up in dry weather — suppress it with water regularly.
DON'T allow pedestrians to walk on haul roads used by heavy plant and vehicles.
DON'T use haul roads after heavy rain without inspecting for damage and instability.
DON'T assume drivers know the route — brief them on site-specific traffic arrangements.

See also: Site Speed Limits and Route Planning | Plant and Pedestrian Segregation

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