Verified results from active sites

Challenge

A heavy-haul coal mine in Inner Mongolia faced excessive rolling resistance and fuel burn on its 10 km haul-road network, plus rapid surface degradation under continuous truck traffic.

Solution

Following a successful 2013 demo road, an additional 10 km of haul road was built using ROAD//STABILIZR® clay-soil stabilization, replacing aggregate inputs and producing a denser, lower-rolling-resistance running surface.

Measured Results

• 17.4% reduction in fuel consumption across the haul fleet
• ≈1 million gallons of diesel saved per year
• ≈$3.6 million USD per year in fuel savings (at $3.60/gal)

Challenge

SMB hauls 80,000 t of bauxite per day with up to 5,000 vehicles (60-90 t each) per day on the 41 km mine-to-port road. Conventional dust control required watering up to 10 times daily with 80+ water trucks and 300 drivers; clay roads degraded heavily under 3,000 mm/yr rainfall.

Solution

ROAD//STABILIZR® was applied to stabilize the clay-based haul-road network for both wet- and dry-season durability and to slash the watering fleet required for dust suppression.

Measured Results

• 41 km mine-to-port haul road stabilized
• 80,000 t/day ore throughput, up to 5,000 vehicles/day sustained
• Operations resilient through Guinea's 3,000 mm/yr rainfall

Challenge

Antucoya runs entirely on seawater, so any freshwater used for dust suppression is a real cost. Dust reduced visibility on the haul road and threatened operational safety.

Solution

DUST/BLOKR® (Municipal Blend) was applied to the haul road to suppress particulate emissions without increasing water consumption.

Measured Results

• ≈80% dust reduction on the treated haul road
• Improved visibility and a safer working environment for haul-truck operators
• Site context: 72,200 t of fine copper produced in 2018, 1,900+ workers

Challenge

Mary River — one of the world's northernmost active mines and one of the richest iron-ore deposits — runs a 100 km tote road from pit to Milne Port. The 2019 NIRB review put environmental and social-impact mitigation, including dust, at the top of operational priorities.

Solution

DUST/BLOKR® was applied along the 100 km tote-road corridor as part of the Cypher Green Roads™ programme.

Measured Results

• 100 km tote road treated — pit to Milne Port
• 38 totes of DUST/BLOKR® delivered with no shipping cost to the community
• Aligned with NIRB environmental-impact recommendations

Challenge

A Colombian coal mine producing ~2 Mt/yr and moving ~15 Mm³/yr of overburden needed haul roads strong enough for CAT 793 (380 t capacity) and CAT 777 (140 t) trucks running essentially continuously, with one CAT 793 passing every 5 minutes.

Solution

ROAD//STABILIZR® was used to build the haul roads for double truck lanes carrying 32 t gross-weight traffic at high frequency, replacing dependency on imported aggregate.

Measured Results

• Sustained CAT 793 (380 t) and CAT 777 (140 t) traffic
• 22 hours/day operation, ~one 380 t truck every 5 minutes
• Supports 2 Mt/yr coal output and 15 Mm³/yr material movement

Challenge

400-700 t loaded haul trucks in the Athabasca Oil Sands and clay-rich roads in Ecuador needed an alternative to expensive aggregate-import roadbuilding.

Solution

ROAD//STABILIZR® — a concentrated blend of organic catalysts, electrolytes and surfactants — was used to stabilize clay-rich soils in place, delivering haul-road strengths comparable to conventional aggregate roads.

Measured Results

• CBR (California Bearing Ratio) gains of 51% to 353% on treated clay soils
• 170% reduction in swell measured in Ecuador
• Product is >90% biodegradable within 28 days while soil-property gains remain long-lasting
• Validated against 400-700 t haul-truck loaded weights

Challenge

A coal mine in the Gobi Desert (one of the world's largest, 1,295,000 km²) faced extreme wind, aridity and heavy 100 t coal-truck loads on its haul roads.

Solution

ROAD//STABILIZR® was used for haul-road stabilization and DUST/BLOKR® for dust suppression in the high-wind regime characteristic of the Gobi.

Measured Results

• Road carried sustained loads above 100 t from coal-haul trucks
• DUST/BLOKR®-treated area was unaffected by the region's high winds

Challenge

Mining operations need durable, cost-effective unpaved haul roads. Conventional stabilization methods rely on expensive aggregate or chemical binders.

Solution

Two years of joint research with a postdoctoral researcher from Norwegian University of Science and Technology tested ROAD//STABILIZR® on Penner clay (medium plasticity) using CBR, semi-confined compression, and DCP testing protocols.

Measured Results

• 356% strength gain between 1-day and 7-day cure on treated Penner clay
• +14.2% CBR (bearing strength) on treated clay vs untreated
• +124% strength gain when compaction energy increased from 10 to 40 proctor blows
• 19.4% slower moisture absorption in treated clay slabs
• All field-stabilized roads in the Brandon, MB study yielded CBR > 50

Challenge

Any dust-control product used on or near runways must prove non-corrosivity to airframes and engines. Aviation operators were demanding hard certification, not anecdotes.

Solution

DUST/BLOKR® passed the Boeing BSS7432 non-corrosivity standard, opening application at full-scale aviation sites including Olam Farms airstrip in Nigeria (1.2 km × 40 m on a 100,000-acre rice farm) and Bangalore Airport (32.3M passengers/year in 2018).

Measured Results

• Boeing BSS7432 conformity achieved
• Substantially lower cost than other Boeing-conformant dust-control products
• Field-deployed at Olam Farms airstrip (1.2 km × 40 m), Nigeria
• Field-deployed at Bangalore Airport, India (then India's fastest-growing airport)

Challenge

Aéroports de Montréal needed a long-lasting, non-corrosive dust-control solution for an unpaved service road only 500 ft (the legal minimum) from a major runway.

Solution

DUST/BLOKR® was applied to Route 500 at YUL in 2014 and renewed in 2015, with the airport authority documenting 'long-lasting capabilities'.

Measured Results

• Applied two consecutive seasons (2014, 2015) at a major international airport
• Operates at the legal minimum distance (500 ft) from an active runway
• Endorsed by Aéroports de Montréal

Challenge

Rural gravel roads in southwestern Manitoba (and across Canada) deteriorated rapidly under traffic, requiring expensive ongoing maintenance and aggregate top-ups.

Solution

A one-mile test section was reconstructed with 32% reactive clay and ¾" aggregate, treated with ROAD//STABILIZR®. Performance was measured with dynamic cone penetrometer, nuclear densometer, Atterberg-limit and Proctor analysis before and after.

Measured Results

• 77.3% reduction in dust
• +51.47% bearing strength after 20 days of traffic
• Compaction exceeded 100% maximum dry density and continued rising over 21 days
• Single superficial grading was the only maintenance needed in ~120 days

Challenge

Quito needed durable, low-maintenance unpaved-road technology for its municipal network, with measurable improvements in road quality and lifecycle cost.

Solution

Following the noticeable improvements in road quality and lifecycle cost from the initial ROAD//STABILIZR® applications, the city of Quito scheduled an additional 80 applications for the following year.

Measured Results

• Visible improvement in road quality acknowledged by city authorities
• Maintenance-cost savings reported
• 80 additional applications scheduled by the municipality for the following year

Challenge

The Rural Municipality of Cornwallis needed durable, low-maintenance unpaved roads under sustained heavy-truck traffic. The County commissioned independent academic validation through Brandon University.

Solution

Cypher Environmental and Brandon University partnered to construct and study 3 miles of road built with ROAD//STABILIZR®, with 2 miles built directly using the technology and one additional mile evaluated.

Measured Results

• Academic-grade independent validation of ROAD//STABILIZR® performance
• 5 km (3 miles) of rural road studied under sustained heavy-truck traffic
• Method published in collaboration with Brandon University

Challenge

Colombia has an estimated 150,000+ km of secondary unpaved roads on predominantly clay-based soils, repeatedly damaged by heavy rainfall. The Colombian government required environmentally friendly stabilization technologies to be evaluated nationally.

Solution

A 1 km demonstration road was built near Valencia, Córdoba in a joint project between Cypher Environmental, Roadcorp, the University of Antioquia and the Colombian Ministry of Transportation. INVIAS (the National Roads Institute) was the principal stakeholder. The University of Antioquia ran field and lab analysis of how ROAD//STABILIZR® and DUST/BLOKR® affect engineering properties of road materials.

Measured Results

• 1 km demonstration road built and instrumented
• Independent assessment by University of Antioquia for INVIAS
• Reviewed for country-wide approval covering ~150,000 km of unpaved roads

Challenge

B2Gold relocated the village of Fadougou in 2019 to enable development of the Fekola gold mine. The new community received water, lighting and a market, but ongoing dust from mine operations remained a community-impact issue.

Solution

DUST/BLOKR® was deployed under the Cypher Green Roads™ ESG/CSR programme — the first such initiative outside Canada — and remains B2Gold's dust-control product of choice in Mali two years later.

Measured Results

• First Cypher Green Roads™ deployment outside Canada
• Ongoing 2+ year use as B2Gold's primary dust-control product at Fekola
• Direct community-impact reduction at the relocated Fadougou village