Feasibility of constructing mine haul roads at the oil sands mines using concrete prepared from by-products and mine wastes of the oils sands industry (sulfur, fly ash, coke and tailing sand) is evaluated.

An extensive laboratory test program including unconfined compression, split tensile and freeze thaw durability tests were carried out to characterize the physical and mechanical properties of different mix designs of sulfur concrete. A study of the geochemical interaction of sulfur concrete with the near surface environment included: short term interaction of surface exposed sulfur concrete during the construction and operational life of the haul road and long term interaction of sulfur concrete with ground water following its burial with mine wastes in the mined-out pits.

Haul road test sections were designed based on critical strain and resilient modulus design method. Stress and strain distributions in the haul road cross section induced by the truck tires were calculated using finite element analysis. Required pavement layer thicknesses were then determined on the basis of the truck loads and the resilient modulus and strength of the sulfur concrete and sub-grade material using the critical strain and resilient modulus design method.