Dump Crest Windrow & Setback Calculator
Work out a minimum windrow (safety bund) height for a waste-dump tip head from the largest tyre diameter of the vehicles using it, and record a crest setback distance. It is a guidance figure only — the actual tip-head design, windrow height and setback must follow the mine's dump management plan and a geotechnical assessment.
Enter Values
Before you rely on this: First-pass guide only. Verify safety-critical or regulated work against the relevant standards, your project requirements and a qualified professional.
How to use this calculator
- Enter the largest wheel or tyre diameter (in metres) of the vehicles that will use the dump — usually the haul trucks.
- Leave the windrow factor at 0.667 for haul trucks (about two-thirds of the tyre) or set it to 0.5 for light-vehicle areas.
- Optionally enter a crest setback distance to keep the tip-head windrow and working edge back from the dump crest.
How it works
The tool multiplies the largest tyre diameter by the windrow factor to give a minimum windrow height: windrow = tyre diameter × factor. Tying the bund height to tyre size gives a windrow that reaches an effective height relative to the vehicles operating there — commonly at least two-thirds of the tyre for haul trucks and about half for light vehicles. A windrow is an awareness and guidance feature to alert operators to the edge; it is not engineered to physically stop or retain a loaded truck.
Worked example
Worked example. For a haul truck with a 3.5 m tyre and a 0.667 factor, the minimum windrow height is 3.5 × 0.667 = 2.335 m. In a light-vehicle area with a 1.2 m tyre and a 0.5 factor, it is 1.2 × 0.5 = 0.6 m.
Common mistakes
- Treating the windrow as a physical barrier that can stop a runaway or over-tipping truck — it is a guidance feature, not a restraint.
- Sizing the windrow off a light-vehicle tyre when haul trucks also use the dump; always use the LARGEST tyre diameter present.
- Ignoring tip-head stability and edge condition — soft, cracked or over-tipped ground can fail regardless of windrow height, so the dump plan and geotech assessment govern.
Frequently asked questions
Why base the windrow on tyre diameter?
Linking the bund to the largest tyre gives a height that is meaningful relative to the machines using the dump, so operators get a consistent visual and physical cue at the edge. The two-thirds and one-half fractions are common industry guides, but your dump management plan sets the actual requirement.
Does the windrow replace a setback from the crest?
No. A windrow and a crest setback are complementary controls. Tip-heads are managed with setbacks, spotters or dump-assist systems, controlled tipping and monitoring of edge stability, all defined in the dump / tip-head management plan under MDG guidance.
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Tip: Enter any known values to calculate the remaining results.
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