Industry: Mining
The Client
- Industry: Mining
- Location: Victoria
- Type of Facility: Active Mining Operation
A Victorian-based mining operation required a fully integrated traffic control system at the intersection of a public road and the haul road leading into the mine site.
The Operational Challenge
The intersection between the public road and the mine’s haul road carried a mix of public traffic and heavy mining vehicles, creating an ongoing safety risk that needed to be actively managed.
The client required a robust, automated solution capable of safely regulating vehicle movement through the intersection — ensuring right-of-way was clearly communicated to drivers and that physical entry to the haul road was controlled when traffic was not permitted.
The system needed to be reliable in a remote, mining-grade environment, simple for site personnel to interact with, and compliant with applicable Australian standards.
Objectives
The client required:
- A fully integrated traffic light and boom gate system at the intersection
- Automated, timed sequencing of right-of-way between the two roads
- Physical control of vehicle entry via boom gates synchronised to the lights
- Equipment rated for mining and remote-area conditions
- End-user-adjustable timing without requiring an automation callout
- Compliance with relevant Australian electrical and traffic standards
- A complete, factory-tested system ready for site installation by their nominated contractors
Our Solution
We designed, supplied, and factory-tested a complete traffic control system, ready for installation by the client’s nominated on-site contractors. Our scope covered system design, electrical schematics, control logic programming, supply of all equipment, and full off-site testing — along with detailed installation documentation and technical support to ensure the on-site team could complete the install efficiently and confidently.
System Components
The supplied system comprises:
- 4 x Two-aspect (red/green) 200mm LED traffic lights, IP55-rated, with hot-dipped galvanised VicRoads-approved 3.2m signal posts
- 4 x FAAC B614 4M electromechanical boom gates
- 1 x Siemens PLC-based control panel housed in a heavy-duty sloping-roof enclosure, with high-quality industrially rated components throughout
Description of Operation
The system operates in a fully automated, timed sequence:
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- The two traffic lights on the public road operate in tandem, as do the two lights on the haul road
- Traffic flow alternates between the two roads on a timed cycle: a 60-second green phase, followed by a 5-second flashing red phase to alert drivers of the upcoming change, then a 5-second solid red phase to ensure the intersection is fully clear before switching right-of-way
- Boom gates are lowered whenever the corresponding lights are red, physically preventing entry
- Each boom gate is fully raised before its corresponding light turns green, ensuring safe passage
- The 60-second green timer is easily adjusted by the end user via a simple up-down clicker installed in the control board — no automation callout required to change timing
Project Delivery & Installation Support
All major assembly, programming, and testing were completed off-site to streamline on-site works and reduce installation risk for the client’s contractors. We provided fully tested, pre-programmed components ready for immediate installation, along with detailed installation drawings, wiring schedules, and mounting instructions for every element of the system.
Remote technical support was made available throughout the on-site installation phase, with clear points of contact for any site queries or troubleshooting — ensuring the contractor scope of mechanical installation, field wiring, and final terminations could be completed smoothly under our guidance.
The Result
We delivered a complete, factory-tested traffic control system designed specifically for the client’s intersection — fully programmed, fully documented, and ready for site installation by their nominated contractors.
The combination of LED traffic lights, electromechanical boom gates, and a Siemens PLC-based control board provides a reliable, low-maintenance solution suited to the mining environment. The end-user-adjustable timing built into the control board gives site personnel the flexibility to tune cycle timing themselves without requiring callouts for routine adjustments.
Key Client Benefits
- Complete design, supply, and factory-test scope under a single point of responsibility
- Fully automated, synchronised traffic light and boom gate control logic
- Physical control of haul road entry, supporting site safety objectives
- Mining-grade, IP55-rated equipment suited to remote-area conditions
- Siemens PLC-based control system using high-quality industrial components
- End-user-adjustable timing — no automation callout required for routine changes
- Off-site factory testing reducing on-site complexity and risk for installing contractors
- Detailed installation documentation and remote technical support throughout install
