### Surpac Road Design Tutorial: Step-by-Step Guide for Haul Road Design
This tutorial provides a detailed, step-by-step guide for designing a haul road in GEOVIA Surpac,
focusing on creating a safe and efficient path for transporting material from an open-pit mine to
a waste dump or processing facility. The process leverages Surpac’s **Road Design** module,
integrating with digital terrain models (DTMs), pit outlines, and waste dump surfaces. The
tutorial is based on standard Surpac workflows (e.g., Surpac 6/7 Road Design Tutorial) and
assumes familiarity with Surpac’s interface, geological databases, and block modeling. It
includes practical tips, example parameters, and references to visualization for a clear
understanding, tailored for users seeking a hands-on approach.
### **Prerequisites**
- **Software**: GEOVIA Surpac 6.x or 7.x installed, with a valid license.
- **Data**:
- DTM surface (e.g., `topo_ex3.dtm`) representing the terrain.
- Pit outline intersection with DTM (e.g., `intersect_topo_pit_v1.str`).
- Waste dump intersection with DTM (e.g., `intersect_topo_wd_v2w.str`).
- **Toolbars**: Enable **Edit**, **Display/Hide**, **Surface Design**, and **Road Design**
toolbars.
- **Parameters** (example values, adjust per project):
- Road width: 20m (two-lane for haul trucks).
- Maximum gradient: 8–10% (sustained).
- Minimum curve radius: 50m (horizontal).
- Superelevation: 4–8% (curve banking).
- Berm width: 2m; Ditch depth: 1m.
- Truck specs: Assume 200-ton haul trucks (e.g., CAT 793F, turning radius ~15m).
- **Units**: Meters for consistency.
- **Time Estimate**: 1–2 hours for a basic design.
### **Step-by-Step Tutorial for Haul Road Design in Surpac**
#### **Step 1: Load and Visualize Input Data**
1. **Open Surpac** and create a new project or load an existing one.
2. **Load DTM and Intersections**:
- Go to **File > Open > DTM File**; Select `topo_ex3.dtm`.
- Load pit and waste dump strings: **File > Open > String File**; Select
`intersect_topo_pit_v1.str` and `intersect_topo_wd_v2w.str`.
- Display in the graphics viewport using **Display > DTM File** and **Display > String**.
3. **Generate Contours for Reference**:
- Go to **Surface > Contouring > Contour DTM file**.
- In the dialog:
- **DTM**: Location = `topo_ex3`; Field = z; Object ID = 1; Trisolation ID = 1.
- **Contours**: Interval = 2m; Min = 70m; Max = 336m.
- **Output**: Location = `topo_ex3_cont.str`; Index contours = `topo_ex3_cont10.str` (Interval
= 10m).
- Apply and display contours using **Display > String**.
- **Purpose**: Contours visualize terrain elevation for alignment planning.
- **Visualization**: Grey contour lines (2m intervals) with bold index contours (10m) overlaid on
the DTM.
#### **Step 2: Digitize Initial Road Centerline**
1. **Create a New Layer**:
- Go to **Layers > New**; Name = `road_centerline_pit_wd`.
2. **Set Digitizing Attributes**:
- Click **Enter/Change digitizer point attributes** (toolbar icon).
- In “Digitiser string attributes”: String # = 102; Z = 0; Apply.
3. **Digitize Centerline**:
- In the graphics viewport, digitize a polyline from the pit rim (e.g., `intersect_topo_pit_v1`) to
the waste dump (e.g., `intersect_topo_wd_v2w`).
- Use **Snap to Grid** or **Snap to Points** to align with key features; Avoid steep slopes.
- Save as `road_centerline_pit_wd.str` via **File > Save > String File**.
- **Purpose**: Defines the initial 2D path for the haul road.
- **Visualization**: Blue polyline in plan view, overlaid on DTM contours and pit/dump outlines.
#### **Step 3: Design Horizontal Alignment**
1. **Access Horizontal Alignment Tool**:
- Go to **Road Design > Design horizontal alignment**.
2. **Configure Parameters**:
- **Input**: String # = 102 (`road_centerline_pit_wd.str`).
- **Output**: String # = 103; Name = `road_pit_wd_horizontal`.
- **Chainage**: Initial = 0m; Interval = 20m.
- **Vehicle Velocity**: 25 km/h (affects superelevation calculations).
- **Turn Radii**: Enter minimum radii for curves (e.g., Turn 1–6: 50m, 50m, 100m, 100m, 50m,
100m; based on truck turning radius ~15m).
3. **Calculate and Validate**:
- Click **Calculate**; Surpac generates spiral transitions and superelevation (e.g.,
\( \text{Superelevation} = \frac{\text{velocity}^2}{127 \times \text{radius}} \)).
- Check **Status** column for “Valid” (adjust radii if “Invalid” due to sharp turns).
- Save as `road_pit_wd_hz.str`.
- **Purpose**: Creates smooth curves for safe truck navigation.
- **Visualization**: Plan view with blue centerline, arcs for curves, and chainage labels (e.g.,
every 20m).
#### **Step 4: Drape Horizontal Alignment Over DTM**
1. **Load DTM**:
- Go to **Pit Design > Load a DTM surface**; Select `topo_ex3.dtm`; Apply.
2. **Drape the Alignment**:
- Go to **Road Design > Drape segment over DTM**.
- Select String # = 103 (`road_pit_wd_hz.str`) and DTM = `topo_ex3`.
- Save as `road_pit_wd_hz_draped.str`.
- **Purpose**: Projects the 2D alignment onto the 3D terrain, assigning elevation values.
- **Visualization**: 3D view of the centerline following terrain contours, with pit and dump
intersections visible.
#### **Step 5: Create Longitudinal Profile**
1. **Generate Profile**:
- Go to **Road Design > Create longitudinal profile**.
- In the dialog:
- **Input**: String # = 103 (`road_pit_wd_hz_draped.str`).
- **Output**: Layer = `road_pit_wd_long_prof`; String # = 105.
- **Vertical View Scale Factor**: 1.0 (or 5:1 for exaggeration).
- Enable **Digitizing Plane Mode** (splits viewport).
2. **View Output**:
- Top window: Plan view of the alignment.
- Bottom window: Profile view (distance vs. elevation).
- **Purpose**: Visualizes elevation changes along the road for vertical design.
- **Visualization**: Split-screen with plan view (top) and longitudinal profile (bottom, showing
draped elevation curve).
#### **Step 6: Design Vertical Alignment**
1. **Add Inflection Points**:
- In the profile view, go to **Road Design > Design vertical inflection points > Create new points
using the mouse**.
- Set **Snap mode** to chainage intervals (e.g., 20m).
- Click to add inflection points at grade changes (e.g., crests, sags).
- Set grades: Max +8% (uphill), -10% (downhill) per mining standards.
2. **Design Vertical Curves**:
- Go to **Road Design > Design vertical curves**.
- Select inflection points; Enter parameters:
- **K-value**: 100 (for vertical curvature, based on sight distance).
- **Curve Length**: Auto-calculated or manual (e.g., 50m).
- Click **Calculate**; Validate grades (<10%) and curve smoothness.
- Save as `road_pit_wd_vertical.str`.
- **Purpose**: Ensures safe, gradual elevation changes for trucks.
- **Visualization**: Longitudinal profile with blue parabolic curves connecting straight grade
segments, labeled with % grades (e.g., +8%).
#### **Step 7: Create Road Outline**
1. **Generate Outline**:
- Go to **Road Design > Create road outline**.
- In the dialog:
- **Input**: String # = 105 (`road_pit_wd_vertical.str`); DTM = `topo_ex3`.
- **Road Width**: 20m (10m each side for two-lane).
- **Berm Width**: 2m; **Ditch Depth**: 1m.
- **Superelevation**: Use values from horizontal design (e.g., 6% max).
- **Slopes**: Cut = 1:1.5; Fill = 1:2.
- Apply; Surpac generates left/right edge strings.
- Save as `road_pit_wd_final.str`.
- **Purpose**: Defines the full road geometry, including safety and drainage features.
- **Visualization**: Cross-section view showing trapezoidal profile (20m road, 2m berms, 1m
ditches, cut/fill slopes).
#### **Step 8: Calculate Cut/Fill Volumes**
1. **Compute Volumes**:
- Go to **Surface > Volumes > Volume between surfaces**.
- Select road outline surface (`road_pit_wd_final.str`) and DTM (`topo_ex3.dtm`).
- Compute cut (below DTM) and fill (above DTM) volumes.
2. **Review Report**:
- Output includes total length, max grade, curve radii, and earthwork volumes.
- Save report as CSV or text for documentation.
- **Purpose**: Quantifies earthworks for cost estimation and planning.
- **Visualization**: 3D model with red (cut) and blue (fill) shading along the road.
#### **Step 9: Validate and Finalize**
1. **Cross-Section Validation**:
- Go to **Graphics > Section > Create section** at key chainages (e.g., every 50m).
- Verify road width, berm/ditch geometry, and slope stability.
2. **Iterate if Needed**:
- Edit alignment using **Edit > Move** or **String > Smooth** to optimize (e.g., reduce cut/fill).
- Recalculate volumes and profiles as needed.
3. **Integrate with Mine Plan**:
- Load road into pit design or MineSched for scheduling.
- Export to DXF for CAD or reporting.
- **Purpose**: Ensures the design meets safety and operational standards.
#### **Step 10: Generate Visual Outputs**
1. **3D Perspective View**:
- Display DTM, road outline, and pit/dump strings in the graphics viewport.
- Use **Orbit** to set an isometric view (e.g., 45° tilt).
- Color-code: Road = blue, DTM = green, cut = red, fill = blue.
- Save screenshot (**File > Save Graphics Image**).
2. **Plan View**:
- Display horizontal alignment and contours.
- Add chainage labels (**Road Design > Display chainage**).
- Export as screenshot or DXF.
3. **Longitudinal Profile**:
- Save profile view from Step 5 as a screenshot.
4. **Cross-Section**:
- Generate sections at key chainages; Export as screenshot or DXF.
5. **Combine Outputs**:
- Use external tools (e.g., Adobe Illustrator, PowerPoint) to create a multi-panel diagram (3D,
plan, profile, cross-section).
---
### **Beautiful Visual Diagram Description**
As requested, here’s a description of a **beautiful visual diagram** for the haul road design,
based on Surpac outputs:
#### **Layout**
- **Canvas**: A 4-panel figure (2x2 grid):
- Top Left: **3D Perspective View**.
- Top Right: **Plan View**.
- Bottom Left: **Longitudinal Profile**.
- Bottom Right: **Cross-Section View**.
- **Style**: Clean, professional aesthetic with a color scheme (blue road, green DTM, red/blue
cut/fill, grey contours). Use bold fonts (e.g., Arial) for labels and a legend.
- **Title**: “Haul Road Design in Surpac: Pit to Waste Dump”.
- **Annotations**: Include parameters (width = 20m, max gradient = 10%, min radius = 50m).
#### **Panel Details**
1. **3D Perspective View**:
- Shows the road draped over the DTM, with pit and waste dump intersections.
- Blue road surface, green semi-transparent DTM, red pit outline, purple dump outline.
- Cut (red) and fill (blue) shaded areas.
- Labels: “Pit Entry,” “Waste Dump,” elevation markers (e.g., 70m–336m).
- Isometric angle with soft shadows for depth.
2. **Plan View**:
- 2D top-down view of horizontal alignment (`road_pit_wd_hz.str`).
- Blue centerline with arcs (radii labeled, e.g., “R=50m”).
- Grey contours (2m intervals, bold at 10m).
- Chainage markers (every 20m) and superelevation notes (e.g., 6%).
- Scale bar (100m).
3. **Longitudinal Profile**:
- Graph: Chainage (x-axis, 0–end) vs. elevation (y-axis, 70–336m).
- Black line for draped elevation, blue line for vertical alignment with parabolic curves.
- Labels: Grades (e.g., “+8%”), curve lengths (e.g., “K=100”).
- Vertical exaggeration (5:1) with gridlines.
4. **Cross-Section View**:
- Trapezoidal profile at chainage 200m.
- Blue road (20m wide, 2% crown), grey berms (2m), dark grey ditches (1m deep).
- Red cut slope (1:1.5), blue fill slope (1:2), green DTM line.
- Labels: “20m Road,” “2m Berm,” “1m Ditch,” slope ratios.
#### **Creating the Diagram in Surpac**
- **Export Views**: Use **File > Save Graphics Image** for each view (3D, plan, profile, cross-
section).
- **Combine**: Import screenshots into Adobe Illustrator, PowerPoint, or Canva for a multi-panel
layout.
- **Enhance**: Add title, legend, and annotations for a polished look.
### **Optional: Python-Generated Diagram (Pending Confirmation)**
If you confirm, I can provide Python code using Matplotlib to create a simplified schematic of
the cross-section or longitudinal profile. Example output:
- **Cross-Section**: Trapezoidal road with berms, ditches, and cut/fill slopes, labeled with
dimensions.
- **Style**: Blue road, green DTM, red/blue cut/fill, with gridlines and annotations.
**Sample Code** (for cross-section, not executed unless confirmed):
```python
import matplotlib.pyplot as plt
import numpy as np
x = [-13, -11, -10, 0, 10, 11, 13] # Road width (20m), berms (2m), slopes
y = [1, 2, 0, 0, 0, 2, 1] # Ditch (1m), berm (2m), road surface
dtm_y = [1.5, 1.5, 1.5, 1.5, 1.5, 1.5, 1.5] # DTM baseline
cut_fill = np.minimum(y, dtm_y)
plt.figure(figsize=(8, 4))
plt.fill_between(x, y, dtm_y, where=(y <= dtm_y), color='red', alpha=0.3, label='Cut')
plt.fill_between(x, y, dtm_y, where=(y > dtm_y), color='blue', alpha=0.3, label='Fill')
plt.plot(x, y, 'b-', lw=2, label='Road Profile')
plt.plot(x, dtm_y, 'g--', lw=2, label='DTM')
plt.text(0, 0.2, '20m Road', ha='center')
plt.text(-11, 2.2, '2m Berm', ha='center')
plt.text(11, 2.2, '2m Berm', ha='center')
plt.text(-12, 1.5, '1m Ditch', ha='center')
plt.text(12, 1.5, '1m Ditch', ha='center')
plt.xlabel('Width (m)')
plt.ylabel('Height (m)')
plt.title('Haul Road Cross-Section in Surpac')
plt.grid(True)
plt.legend()
plt.tight_layout()
plt.show()
### **Practical Tips**
- **Data Validation**: Ensure DTM and intersection strings are accurate to avoid alignment
errors.
- **Geotechnical Input**: Use site-specific data (e.g., soil stability) for slopes and widths.
- **Standards**: Follow mining road guidelines (e.g., AASHTO, South African standards) for
gradients and radii.
- **Automation**: Use Surpac macros (TCL/SCL) for repetitive tasks (e.g., multiple road
segments).
- **Validation**: Cross-check cross-sections and volumes for feasibility.
### **Resources**
- **Surpac Documentation**: Check the “Road Design Tutorial” in Surpac 6/7 help files
(accessible via **Help > User Manual**).
- **Online Tutorials**: Search for “Surpac Road Design” on Udemy or YouTube for video guides
(e.g., Dassault Systèmes training videos).
- **Support**: Contact GEOVIA support or forums for troubleshooting.
### **Next Steps**
- **Image Generation**: Confirm if you want the Python code executed to generate a Matplotlib
diagram (e.g., cross-section or profile). I’ll provide the full script and output description.
- **Specific Needs**: If you need guidance on a particular Surpac tool, parameter tuning (e.g.,
optimizing radii), or additional visualizations, let me know!
- **Data**: If you have specific DTM or string files, share details for tailored steps.
This tutorial provides a complete workflow for haul road design in Surpac, with emphasis on
visualization for a professional output.
