CASE STUDY: SLOPE STABILISATION IN MINING ENVIRONMENTS

Anchoring Rope & Rigging (AR&R) | HULK Earth Anchors
Project Focus: Mining site slope stabilisation ensuring safety, efficiency, environmental sustainability
Core Products: HULK H and HG percussion earth anchors with CTB threaded bars.

Project Overview

Steep, high-risk terrain in active mine sites across eastern Australia demanded immediate and robust slope stabilisation solutions. Anchoring Rope & Rigging, partnering with HULK Earth Anchors, engineered and implemented large‑scale anchoring systems to prevent slope failures and minimise environmental impact. Two high profile deployments took place:

Project #1: Rookwood Weir Temporary anchoring

Embankment Stabilisation – Gogango QLD

Project #2: Onslow Haul Road Onslow

A cyclone prone Haul road embankment near Onslow – Pilbara (WA).

These projects underscored HULK’s “earth anchor concept” installing anchors with minimal disturbance and immediate proof-testing achieving long-term performance under harsh geotechnical conditions.

Challenges & Objectives

Mining Sector Challenges:

1. Steep Slope Profile: Benches between 30–70°, up to 45 m in height, high risk of collapse.
2. Confined Terrain: Areas adjacent to access roads and groundwater paths constrained excavation and staging.
3. Erosion & Soil Loss: Exposure to heavy rain and stormwater drainage threatened bank integrity and local habitats.
4. Scheduled Mined Areas: Minimising operational delays and refilling excavation time was critical.
5. Remote Locations: Constructability is a key consideration when operating remotely

Project Objectives:

• Instantly stabilise slopes to prevent landslip without excavation or bulky earthworks.
• Achieve certified holding capacities per geotechnical design.
• Ensure installations were labour efficient and environmentally benign.
• Provide long-term structural integrity and planning flexibility for future mine phases.

The HULK Earth Anchor Solution

AR&R introduced HULK H and HG‑series percussion-driven earth anchors, particularly the H50,H80, H110,HG100 and HG180 models, paired with CTB threaded bar tendons for high-capacity slope anchorage:

Why HULK H and HG-series?

• High holding capacity: capable of 45kN up to 180 kN loads.
• Hard Armour coating: 3 X corrosion resistance over galvanised anchors.
• Variable drive depth & quick setting and testing: thanks to optimal scoop and surface designs on the anchor head and tail.
• Minimal disturbance: driven via smasher rods without excavation, ideal for live slopes.

Installation Equipment:

• Excavator-mounted breakers with power smasher rods for most slope materials.
• PT150 proof-test jack to lock anchors and certify holding capacity instantly.

Project #1: Rookwood Weir Temporary anchoring

Site & Conditions

• Location: Gogango, QLD.
• Geology: A fill and cut Batter approximately 300m long and 60 metres high.
• Remote location

Solution Deployment

• Selected HULK H110 anchors for 45 kN design capacity.
• Installed anchors at 2 m centres in a staggered grid, reaching depths of 4–5 m.
• Used excavator-mounted breaker and 2.5 m smasher rods.

Proof-Testing & Load Certification

• PT100 jacks at each anchor made it possible to load test to 45 kN capacity.
• Immediate certification enabled reconnection of slope mesh within hours.

Outcomes Achieved

• No slope instabilities or safety incidents for duration of project post-installation.
• Scheduling disruptions avoided; re-installation or rebattering was unnecessary.
• No erosion

Project #2: Onslow Haul Road Onslow

Site & Conditions

• Location: Onslow WA
• Condition: 700m long 13 m high, 40° embankments to bridge approach required to be covered with flexible concrete mating at risk of uplift during the cyclone season
• Remote constraints and fill materials led to limited choice of anchors

Solution Deployment

• A total of 770 off H80 anchors with CTB threaded bar tendons arranged at 1.0 m spacing.
• Enabled by handheld jack hammer equipped with a smasher rod

Proof Testing & Verification

• All anchors engaged PT100 testers to confirm 35 kN capacities; certs recorded digitally.
• Installation completed over a six-week period; camp remained in operation throughout.

Outcomes Achieved

• Zero movement detected to date.
• No excavation reduced sediment runoff into adjacent streams.

Key HULK Product Specifications

Both models adhere to AS1831, AS4680, AS1666, AS2076 standards and achieve triple corrosion resistance versus HDG systems.

Installation Insights & Lessons Learned

Advanced Geotechnical Planning:

• Soil investigations and site conditions defined anchor spacing and depth.

Optimised Execution & Equipment Use:

• Handheld breakers for rapid drive in tough soils.
• PT100 tester guaranteed per-anchor load capacity.

Environmental and Efficiency Benefits:

• Anchors driven with zero excavation – preserving integrity of matt, reducing erosion.
• Instant readiness meant no curing delays or concrete spoil.
• Local manufacturing and processing of anchors supported sustainability.

Comparative Advantage Over Alternatives

AR&R Commitment to Sustainability & Efficiency

Anchoring Rope & Rigging stands firm in driving sustainable, efficient anchoring technologies that save time, money, and protect the environment. Their integrated service from geotechnical design to Australian-made HULK anchors, to onsite installation and proof-testing, reflects AR&R’s ethos:

• ISO 14001 certification for environmental management.
• Instant anchors with no spoil and reduced carbon footprint.
• Local job creation and materials sourcing.
• Real-time proof testing ensures safe, durable, cost effective stabilisation.

The result? Safer mining terrain, minimal ecological impact, faster delivery. All backed by documented performance and proven on steep, complex slopes.

Conclusion & Strategic Value

This case study demonstrates how AR&R and HULK Earth Anchors empower mining clients to deploy rapid, reliable, and sustainable slope stabilisation:

• Unmatched anchor performance with holding capacity up to 180 kN per anchor.
• Swift implementation – from site to load-tested completion in days.
• Environmental integrity – no excavation, no spoil, reduced erosion risk.
• Cost efficiency – Significant savings over traditional methods.
• Regulatory compliance – proof-tested anchors supporting engineering sign-off.

By choosing AR&R’s fully integrated solution & front-end design, local anchor manufacture, adaptable gear, and onsite proof testing, mining operators confidently manage slope risks while demonstrating environmental responsibility. It’s a win for site safety, schedule, budgets, and the living landscape.

Discover how AR&R and HULK Earth Anchors can transform your slope stabilisation program.

Contact AR&R at 1300 692 626 or info@arandr.com.au, or explore their full services and technical details online.

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