The mining tyre sector has always occupied somewhat of a unique position, with the major players more focused on on-road truck tyres and passenger car tyres, with mining not always first priority. Today, mines have a much greater choice of manufacturers than they had ten years ago, but this also includes some potential risks with unknown and untested brands.
And the demand levels are not uniform, reflecting as would be expected, differing performance in mining itself across different commodities and regions. Peter Kearney, OTR mine analyst specialist, Titan Mining Services, a subsidiary of Titan International, told IM: “As our international presence continues to grow, we’ve seen mining tyre demand remain steady as a whole. But while certain areas of the mining sector have seen a bit of a dip in 2013 – such as the North American coal market – others have remained very strong. There’s still a demand for raw materials in developing countries such as China and India, which has kept mines in Chile, Peru, Indonesia, Australia, Russia and other areas running strong. We’re also seeing some new projects developing in Africa and expect some big operations to be underway in Zambia and DRC by 2014.”
The selection of the actual tyre type is not related to region and mine type, with the focus more on haul speed, distance, weight the tyre is hauling, temperatures and haul road conditions. Most tyre sizes are used consistently throughout the world, but tyre compounds – whether wear-resistant, heat-resistant or cutresistant – can differ greatly from one mine to the next. A coal mine hauling 1 km round trips on rocky, curvy haul roads would likely need a wear-resistant tyre compound, whereas another coal mine hauling 10 km round trips at higher speeds would be better off with a heat-resistant compound. Tyres in mining are mostly sitespecific, which is why the major suppliers recommend conducting regular TMPH/TKPH studies before purchase decisions are made.
In terms of Titan’s response to supply and demand, Kearney adds: “Titan took the steps necessary steps to address the shortage by doubling our mining tyre production capacity from 2011 to 2012. Now, supply has caught up to the demand, and most of the in-demand sizes are readily available. So, we believe that our production levels are appropriate for the market demand of existing products, but we’ve also put a lot of effort toward developing new tyre molds and technologies. For instance, we’re launching some new Low Sidewall (LSW) options for the CAT 994, including the Titan LDR150 58/80R63, which will significantly improve machine stability and reduce swaying during peak load by increasing wheel size and reducing the aspect ratio of the tyre. We’re currently the only company with an LSW offering, largely because we also manufacture wheels, so we have the ability to develop tyre and wheel assemblies that complement each other.”
As far as tyre purchasing agreements and allocations are concerns, a lot of mines are still building up their tyre inventory in the aftermath of the shortage. Interestingly this is less true of the larger mines running ultra-class radials which tend to have long term allocations locked in, but applies rather to medium sized operations running a lot of 33.00R51 and 45/65R45 radials, which are still forecasting tyre usage by quarter and building their inventory on-site. That said, a lot of the smaller mines with four to five machines are less concerned with tyre availability than they were a year ago, and are not stockpiling tyres from the spot market the way they were before.
Like the market for mining equipment, the market for mining tyres also has a strategic element when it comes to brand. The major mines prefer to run top-tier tyres from the major manufacturers, whether that be Michelin, Bridgestone, Titan, Goodyear, Yokohama, Eurotire or otherwise – due to their proven costs per hour that have been thoroughly tested in the field. But, many operators also like the option of also using second-tier tyres that they’ve tested and can run on a few of their machines, giving them bargaining power to some extent but also in the event of a supply issue, they have another brand they know they can turn to if necessary. This remains the primary use of Chinese tyres for many mines, though may only apply to rear tyre positions. That said, overall this adds up to large quantities, and these operations would not be using some of these Chinese brands if they were not good quality – and the influence of the likes of Techking, Qingdao Qizhou Rubber, Qingdao Hengda, Shandong Xingda and others is only likely to increase, as Chinese-owned and controlled mining operations in Africa, Australia, South America and elsewhere come on-stream.
David Anckaert, General Manager, Global OTR Tires at The Goodyear Tire & Rubber Company told IM: “There has been a slowdown in mining, including the cancellation and postponement of some new large mining projects. However, demand for ultra-large tyres remains robust across the board due to the operational efficiencies that these products offer. We continue to optimise our products, performance and mix in order to meet the evolving needs of our customers, while upgrading and expanding our manufacturing capabilities, such as the $250 million investment in 57 in tyre production at our Nippon Giant Tire plant in Japan that we announced last year.”
Different applications call for different tyre designs and features, which Goodyear takes into consideration in product development. The RM (Rock Mining) OTR tyre line drives optimal performance in very difficult environments, such as those found in large haulage coal and hard rock mining applications. Available globally, the RM line’s unique features include a nondirectional tread pattern with high-angle grooves for improved traction; an optimised tread pattern for optimal wear/temperature balance; and Goodyear’s exclusive CycleMax tread compound for cool running. The company says it is currently working on next-generation RM products for haulage applications, as well as next-generation tyres for loader and grader applications.
In the wider area of tyre management, Anckaert stated: “Product performance has become a primary consideration, which continues to spur growth in demand for Tier One OTR tyres. At the same time, customers also continue to look for more than just tyres to help them lower their operating costs. We offer a wide range of services to help our customers achieve optimal returns on their tyre investment. These services include mine site audits; temperature studies; training (basic, advanced and service); and development engineering follow-up. We also provide support/advice on mine operating conditions to help customers get the most out of their tires. In addition, we have a mobile repair unit that performs on-site tyre repairs, as well as a mobile science unit for advanced engineering studies. And our field managers and regional managers provide application and after-sale support, which is vital.”
Eurotire Business Development Manager for Mexico/Central America, Courtland Acosta told IM: “Demand for OTR tyres has decreased due to the OEM companies not selling new equipment and several mining operations running at reduced operating schedules to lower commodity pricing. Supply currently exceeds demand and will most likely be this way through 2014.” On general market trends he states: “Coal due to the influx of natural gas and cleaner air standards in the industrialised countries is in decline. Newly proposed tax increases in Mexico on precious metal mine operators could deter future mine development and may cause mine closures if passed by the new administration. The increased availability of 57 in and 63 in radial tyres by the Tier One suppliers will be a major factor in the slowdown of the bias tyre market at the larger mine operations globally. Water and environmental restrictions are still a very serious issue in South America and in many cases has delayed new mine development and has created additional costs for those in production..”
In terms of securing supply long term for large mines, contracts for extended periods with price escalation clauses are now very common. This also means that the spot market is very competitive as fewer mine operators are purchasing outside of their supply agreements with the Tier One suppliers. With the current supply exceeding demand several of the larger companies are no longer looking at alternate suppliers for their current and future OTR tyre needs. This makes introducing a new product into these operations far more difficult.
Steve Bailey, Eurotire Regional Business Manager in South East Asia, offered some insight for that part of the world: “Currently there are no greenfield mines being opened due to the global low export thermal and coking coal prices. Presently it’s more of looking for low strip ratios with increased production to offset the low coal price and hence smaller profit margin. Adding to this is the new process law that Indonesia government is trying to bring in is causing more uncertainty within Indonesia. The Philippines is still going ahead with more construction and infrastructure projects rather than new greenfield mines, with Philippine major contractors purchasing more 100 t and 150 t haul trucks. The largest requirement SEA currently has in terms of tyre sizes is for 24.00R35 and 27.00R49. However the more established and larger projects do have 150 t and larger trucks. However, within Indonesia there is a large surplus and pressure from manufacturers to maintain market share of 60 and 100 t truck tyres causing spot contract pricing to fall sharply. There is a surplus of tyres currently within SEA this includes small and large tyres. However, everyone is experiencing very good prices at the moment on all sizes.” Some of these large miners are actually selling off some of their excess tyres to other contractors which is causing some supply companies to have excess stock and then they reduce spot tyre prices to their dealer network.
At Eurotire’s state of the art Romanian factory, the 57 in radial is still being developed with a limited amount of units running in areas close to the plant so the engineering group can get detailed performance data and make the needed changes in a more efficient manner. Other radial tyre sizes are being produced to meet the current market demand.
Better management practices
A significant change seen in recent years is the rapid adoption of technology such as TMS/TPMS systems, but also the continued increase in the level of sophistication in terms of tyre management practices, and this now applies not only to the largest mining customers, but also many of the smaller mines and aggregate producers. Kearney comments: “At the bare minimum, most mines are recognising that tyre pressure monitors are essential. Even small aggregate quarries with four to five machines have started adopting this technology. For the larger customers with a little more capital to invest, we’re seeing adoption of more sophisticated technologies such as VBOX and TyreSense that can measure everything from tyre running temperatures and pressures to vehicle speed, distance travelled, cycle times, acceleration, vehicle location, and haul road grades. A lot of the larger operations have fleet managers that are accessing this type of information remotely for mines throughout the world in order to better manage their fleet and limit tyre wear.”
In technology news, AM Bromley recently launched what it says is a “unique state-of-theart OTR tyre monitoring system” that utilises advanced telematics technology to provide substantial cost-saving benefits, improved safety, and increased tyre life. Developed in collaboration with ENAiKOON, a telematics communications technology provider, the new system combines AM Bromley’s TMS solution with ENAiKOON’s advanced tracking software to deliver “an integrated system that offers realtime, anytime reporting for large off-road vehicles.”
Utilising a software plugin, the ENAiKOON TMS enables integration into inViu Web, ENAiKOON’s advanced telematics portal, facilitating real-time reporting of pressure and temperature developments across a fleet of vehicles not only to the driver, but also to the asset manager. Instant notification enables managers to become quickly aware of potential tyre performance issues, and to take the necessary remedial action immediately. “As such, the ENAiKOON TMS helps them to achieve the cost benefits resulting from extended tyre life, reduced tyre maintenance expenditure, improved fuel efficiency, and reduced vehicle downtime.”
Alert thresholds can now be reconfigured remotely to allow for seasonal and environmental variations, and the plugin may be upgraded remotely when tyres are changed. The ENAiKOON TMS also facilitates the delivery of historical data, truck location, and driver behaviour. The statement said: “Created cost-efficiently by a partnership between the only developers and manufacturers selling an integrated software tyre monitor system directly to the customer, the ENAiKOON TMS is available at a relatively low cost, accessible to smaller firms as well as big corporations with substantial budgets. In contrast to many competing products, introduction of the ENAiKOON TMS does not usually require the costly installation of an alternative infrastructure as it runs on the popular GSM and GPRS networks.” Existing owners of an AM Bromley TMS system wishing to upgrade to the ENAiKOON TMS system need only purchase a single piece of hardware from ENAiKOON to facilitate the new product.
Since the launch, the ENAiKOON TMS has been installed on trucks at two large UK quarries. At Hanson Aggregates’ Shap Beck limestone quarry near Penrith in Cumbria, a CAT 775 haul truck was recently fitted with TMS external sensors and the ENAiKOON TMS. The new plug-in ENAiKOON TMS product allows quarry managers to see first-hand, data relating to both real and cold compensated tyre pressure. Managers are notified of any alerts such those indicating low pressure, and may then initiate action to carry out the necessary maintenance when the truck next comes to the workshop. The TMS inViu web portal also allows historical data to be viewed, together with other material, such as vehicle tracking and driving patterns. The ENAiKOON TMS installation in July 2013 follows that in August 2012 of AM Bromley’s TMS and operator interface cab display in another vehicle, which allows the driver to see real time tyre pressure and temperature data.
Of both systems, Chris Herbert, Hanson’s Assistant Quarry Manager at Shap Beck, said: “Allowing the drivers to see first-hand the tyre data is extremely useful, allowing them to make decisions whilst on shift. The first truck fitted has had less out-of-hours service this year compared to previous years and we are working with our tyre service and supply partner to quantify the financial savings made on fuel and tyres in the past 12 months.”
Advantage PressurePro and Trimble have introduced the Trimble TirePulse TMS system to assist fleet managers in reducing maintenance costs, increasing overall fleet productivity and promoting site safety. Part of the Trimble Connected Site portfolio, the advanced machine monitoring solution wirelessly reports tyre temperature and pressure data from the jobsite to the VisionLink fleet, asset and site productivity management solution from Trimble. Automatic, real-time tyre pressure and high temperature alerts help fleet managers and site supervisors schedule cost-effective preventative tyre maintenance, extend the life of tyres, increase fuel efficiency and avoid dangerous blowouts.
Under-inflated tyres can reduce fuel economy, increase overheating, tread wear and blowouts that take a machine out of production. Together, these factors can significantly affect fleet productivity and operating costs. Trimble TirePulse can improve tyre life while also reducing the need for fleet managers to drive to the site and visually inspect inflation, tyre wear and temperature. Using a Trimble TP920 Industrial Tyre Sensor in the tyre valve stem and a Trimble SNM940 Connected Site Gateway for communications, the information is automatically relayed back to the office for analysis by the fleet manager. Accurate data is communicated through VisionLink, so the fleet manager can proactively manage tyre maintenance on more machines across different mining sites.
The Trimble TirePulse system also promotes increased jobsite safety by reducing the risk of tyre blowout and injury to workers. Properly inflated tyres improve the performance of vehicle braking systems and allow a faster response time in potentially dangerous conditions. The system is also safer and more accurate than manual visual inspection because it does not require personnel to be in close proximity to overheated tyres. VisionLink automatically alerts the fleet manager or site foreman when a tyre experiences a 20% drop in pressure and becomes a potential hazard. It can also provide a high temperature alert to indicate that jobsite conditions are likely to accelerate tire breakdown.
“Preventative maintenance is more cost effective than a machine going down suddenly with a blown tyre. But with equipment moving around so much from site to site, fleet managers struggle to stay ahead of the game,” said Julian Dann, Business Area Director for machine control at Trimble. “TirePulse is priced for installation across the entire fleet of on- and off-road machine tyres, regardless of make, model or manufacturer. Increased wear or breakdown can be reported and acted upon proactively. The system can often pay for itself by preventing just one blowout.” VisionLink version 2.8 and the new Trimble TirePulse TMS are currently available through the Trimble SITECH Technology Dealer Channel in North America.
Service and maintenance
Eurotire states that it recently achieved record levels of tyre quality and durability at the Orenburg Minerals chrysotile operation in Yasny, Russia. The Eurotire 27.00R49 tyres were manufactured at the state-of-the-art all steel radial plant in Romania, and achieved 86,216 km (53,454 miles) in tyre life. This distance translates to more than 7,000 h of heavy use at the Yasny mine, with the tyres maintained in accordance with the standards of the Eurotire EuroCare service program. “The Orenmin milestone is proof of what our EuroCare mining tyre maintenance program can accomplish,” said Helen Ratnikova, Eurotire Marketing and Training Manager. “Regular monitoring, routine inspections and close communication with our trained Eurotire technicians can ensure any one of our tyres will provide top OTR tyre performance.”
The EuroCare program tracks the entire life cycle of a tyre, following it from the moment it leaves the factory to ensure that it is maintained, serviced and used to its full potential. Tailored to reflect the key performance indicators of each mining operation, Eurotire states that EuroCare “provides customers with the tools, service, training and support necessary to use each tyre effectively.”
In the tyre handling and service market, the Hedweld Trilift TH15000 workshop tyre handler has been specifically designed to provide a maintenance tool for the safe removal and installation of wheel assemblies from a range of earthmoving and plant equipment. Hedweld states: “As the size of mining equipment grows, traditional methods for handling components have become more hazardous. With respect to tyres the size and weight have increased progressively with each new model.” For example the size and weight of a CAT 777 tyre (a 27.00R49) is 2,835 lb and the tyre measures 8.8 ft in diameter, by comparison to the large tyres used on a Komatsu 930E (50.00R57) that weighs more than 15,700 lb and measures 12.6 ft across. On the Komatsu 960E, the tyre (a 56.00R63) weighs 16,500 lb with a 12.7 ft diameter. There also are even bigger tyres for 363 t class trucks and some tyre diameters exceed 13 ft. Hedweld told IM: “Traditionally, these components are moved by equipment such as telehandlers, mobile cranes and forklifts. These items have limitations due to their physical size, manoeuvrability and safety. A number of incidents occur every year involving machines used in this manner.”
The functional need that the TH15000 fulfils is to minimise the space required to remove and replace a tyre. Traditionally, the customer would have to park a truck in the middle bay leaving a bay free either side so they can drive in a large mobile crane or 25 t forklift. The TH15000 has been designed with a narrow footprint to fit within one bay allowing for all bays to be utilised for other maintenance tasks. An independent trial undertaken at Komatsu in Western Australia demonstrated that the TH15000 is 60-75% more cost, time and labour efficient than traditional methods of tyre handling, according to Hedweld. During the trial, assessments were taken comparing the TH15000 to two other traditional methods of tyre handing – using a forklift and using a tyre basket. The data showed that the time to change four tyres with a basket was 180 min, with forklift 160 min but with the TH15000 100 min, with each approach requiring six, four and two workers respectively. Fewer people means freeing up skilled labour for other duties.
Ergonomically the TH15000 is driven using a remote control to give the user improved visibility when aligning the product with the component and removes any need for manual handling of the product. The TH15000 also has an optional jib arm to support the weight of the rattle gun that is required to remove the wheel nuts.
Hedweld manufactures its products to comply with Australian and ISO standards and says it is flexible enough in its production capabilities to be able to adhere to site specific needs which include additional signage, specific colours, alarms and lights.
Mark Gream, Hedweld Global Products Manager summarised: “The TH15000 is good value for money and allows the mine workshop staff to use one bay rather than three bays to perform the job of removing and replacing wheel assemblies. With truck availability being a major KPI within mine sites this is an invaluable product solution for our customers. Mines using the TH15000 will see that their equipment will be spending less time in the workshop and more time moving valuable cargo.”
Michelin states that it has certified 11 Michelin Professional Earthmover Dealers into the Michelin Earthmover Performance Repairs program since its inception in February 2013. These dealers have undergone the process of certifying their repair locations through a comprehensive audit. The program is designed to develop consistent, professional, and validated repair shops throughout the industry. This includes Tech International training, inventory control systems, traceability methods, and a proven quality repair process. Michelin believes that the program enables end users to get the most value out of their tyre investments. The Performance Repair Sites as of August 2013 included TCi Tire Centres in Mulberry, Florida; Saginaw, Michigan; Decatur, Alabama and San Antonio, Texas as well as Service Tire in York Pennsylvania, A&E Tire in Denver, Colorado; Meekoff Tire in Grand Rapids, Michigan; Purcell Tire sites in Potosi, Missouri, and Phoenix, Arizona; Multillantas y Servicios Grmialdi in Monterey, Mexico; and Ziegler Tire in Massillon, Ohio. “Our goal is to have complete North American coverage by 2014,” said Greg Williams, Earthmover Services Deployment Manager. “This value added program is for the benefit of the end users to help maintain and protect their Michelin Earthmover tyre assets.”
The new Stellar Industries TM20165 tyre manipulator was developed to accommodate the increased use of 63 in tyres in the mining market, and specifically the 59/80R63. Tim Davison, Product Manager, Bodies and Cranes at Stellar states: “Mines all over the world are increasing productivity by increasing haul truck sizes which means heavier utilisation of the 59/80R63 tyre and rim. But mines are facing the increasingly difficult task of changing these tyres should an “in the field” flat occur. Current truck mounted tyre manipulators could change these tyres at a close working radius, but have difficulties at extended reach. As a result, Stellar developed the TM20165 to extend the work radius of truck mounted manipulators and the TM20165 is now the world’s largest truck-mounted tyre manipulator.” Stellar believes that the market potential could be as many as 100 worldwide with that figure increasing annually as mines go over to the larger 63 in tyres and rims.
Stellar designs and manufactures a full line of service trucks for OTR tyre service industries. Most bodies feature extruded aluminum floors for greater strength and longevity, including stainless steel hinges with stainless steel automotive style slam latches and direct-drive hydraulic driven air compressor systems. The crane and compressor are mounted on a unique common base, with articulating (knuckleboom) cranes having fully proportional radio remote control, fully enclosed extension boom cylinder, integral mounted pump and PTO and load holding counterbalance valves.
Iowa Mold Tooling (IMT) introduced a revamped line-up of TireHand tyre manipulators at MINExpo in 2012. John Field, Product Manager for Material Handling at IMT comments: “The enhanced TireHand offerings were driven by customer input and our desire to provide a product that met or exceeded our customers’ expectations. Our goal for revamping our existing TireHand lineup was to provide our customers with a tyre manipulator that increased their productivity while improving operator safety. By adding two new models — the TH20K167 and TH36K164 — we were also able to offer our customers a greater spectrum of capacity options, which enables them to choose the capacity that is right for their application while minimising the size and cost of their loader or forklift.” Available in loader or forklift truckmounted options,
IMT TireHand models and their capacities include:
H5K115: 2,495 kg
TH10K135: 4,536 kg
TH15K160: 6,804 kg
TH20K167: 9,072 kg
TH25K164: 11,340 kg
TH36K164: 16,329 kg
Field adds: “The two new TireHand models were developed in response to customer demand and helped fill niches in our TireHand lineup. The TH36K164 TireHand model is one of the highest capacity tyre manipulators available in the industry. It was designed to handle wheel loader tyres equipped with chains. Our TH20K167 TireHand model was designed to offer customers a tyre manipulator that provided more lifting capacity while minimising the size and cost of their loader or forklift. We have received positive feedback from international customers about our revamped TireHand lineup. Customers have been pleased with features including the new hydraulically controlled fallback protection, optimised pad design and minimised arm profile.” Integrated fallback protection arms are hydraulically controlled, making them easier to use and operate than their mechanical predecessors while providing an additional layer of operator safety. The hydraulically activated fallback protection system allows operators to position the fallback arms from the control station in the cab. This enables the operator to remain in the cab, which makes the work more efficient, improves overall productivity and increases safety. With a redesigned grip pattern and new tapering on the pad, TireHand tyre manipulators maintain their grip on the tyre without damage and handle rim flange hardware with ease. And the TireHand arms were narrowed to minimise interference with chassis components during tyre-handling operations.
IMT has also partnered with the forklift truck manufacturer Hyster to offer integrated TireHand tyre manipulator packages. “Seamless integration of the forklift and TireHand tyre manipulator minimises downtime associated with mating a carrier and tyre-handling attachment. With TireHand tyre manipulator units developed by IMT and Hyster, customers have mounting options to meet their specific needs, whether an integral mount providing a dedicated tool for tyre handling or a quick detach mount for forklift application flexibility.”
In addition to TireHand tyre manipulators, IMT also offers mining customers a lineup of Commander tyre trucks that provide all-around service units for mine tyre service applications. These trucks typically incorporate a crane, a TireHand tyre manipulator, an IMT air compressor and storage for tools and parts in a single package. They are available with various specifications to ensure a precise fit to specific tyre handling needs, increasing vehicle utilisation and reducing operating costs. This includes the Commander IV tyre truck that can handle giant 63 in tyres. On an engineer-to-order basis, the capacity of the Commander IV model can be increased to 7,711 kg, enabling customers to efficiently and safely handle the largest tyres in the industry.
For trucks and loaders, Manitou Group developed its own handling solution to maintain tyres. Emmanuel Amandjules, Mining Activities Manager, states: “Our attachment combined with our machine offer provides the best visibility on the market. Furthermore the operation is safer and more efficient than with other equipment.” For instance, wheel loaders or forklifts can suffer from a lack of visibility and no forward reach. Other disadvantages, according to Manitou are a higher purchase cost, high fuel consumption and unsuitability for rough terrain applications. Manitou telehandlers are backed by safety load charts and offer “great visibility” as well as being “generally more fuel efficient and versatile.”
As a direct solution to change tyres, the Manitou handling solution can be fitted with the TH63+, already widely sold in Chile, which is a new type of tyre clamp. Totally adapted with heavy load telehandlers such as the MHT 10225, this tyre clamp designed by Manitou is capable of handling a 12 t, 63 in tyre. The design of the clamp has been enhanced, providing greater visibility when tyres are changed on a truck or loader thanks to its parallelogram design.
The tyre clamps cover the full range of standard wheels (from 23-63 in) for open pits and underground with a capacity of 1-12 t. They make it possible to pick up and position tyres with great precision when they are being changed. These operations can be performed using a remote control unit so that the tyres can be handled safely. These clamps are also very suitable for moving tyres in storage areas.
“This new attachment, which is ideally suited to safety and profitability requirements, in combination with the capacity and manoeuvrability of our machinery is proof of the know-how and ever increasing expertise of the Manitou Group New Business department and Product Unit teams in the mining and quarries sector,” said Amandjules. There is also a tyre handler for low profile tyres – a solution for limited accessibility, suitable for dual axles and medium dump trucks and for all MT/MLT/MRT models:
TH K1000 1,000 kg: 560 to 2,060 mm
TH K2000 2,000 kg: 560 to 2,190 mm
TH 49 2,500 kg: 1,150 to 3,140 mm
TH 51 3,500 kg: 1,130 to 3,410 mm
TH 57 6,000 kg: 1,220 to 3,830 mm
TH 63 9,300 kg: 1,580 to 4,170 mm
TH 63+ 12,000 kg: 600 to 4,200 mm
Capacity and product news
In April 2013, Bridgestone held a foundation stone laying ceremony at the site of its new plant in Thailand that will produce OTR radial tyres for mining and construction. In the past, Bridgestone has produced these tyres exclusively in Japan and the US. By constructing this new plant in Thailand, Bridgestone believes it will have established an optimal mining tyre production system that will enable it to respond better to growing tyre demand, and also to any future changes that might occur in the operating environment. The new plant is scheduled to begin production in the first half of 2015, and total daily production capacity is expected to reach approximately 85 t by the first half of 2019.
In product news, Bridgestone has introduced the new V-Steel Super Deep Rock Premium Radial tyre, which is available in two sizes to support mining operations. The V-Steel Super Deep Rock (VSDR) premium radial tyre features an improved tread design and more tread volume for long life, and comes in a 20.5R25 1* rating and in a 2* rating for loaders and dozers.
“Customer feedback guides and drives us to create better, smarter tyres that meet end-user needs and the new VSDR premium radial tyre is a result,” said Bert Jones, Manager, Product Marketing, TBR, Retread and OTR, Bridgestone Commercial Solutions. “We took the popular VSteel D-Lug (VSDL) off-the-road radial tyre and improved tread wear capability. When compared to the VSDL, the tread wear of the new VSDR improves up to 6%, depending upon application.”
Engineered to withstand various mining terrains, the 1* rating is designed for use on rock surfaces found in open pits and quarries, as well as paved surfaces for the demands of waste applications. The 2* rating is designed for use in underground operations. Additional tyre features include multi-ply steel belts and a unique shape to help protect tread and sidewall from cuts, as well as an extra-deep tread that helps resist cuts and impacts for long life.
Two new sizes are also available for the Michelin XADN+ tyre, which is used in smaller mines that run fleets of ADTs, where the focus is on providing constant mobility, despite changing conditions and difficult terrain. To meet this dual requirement for versatility and mobility, ADTs require tyres that are suited to their needs. That was the purpose of the development of the XADN+ tyre, launched in 2012 in the 29.5R25 size. This year the line-up has been extended to the sizes 23.5R25 and 26.5R25. With the new sizes, Michelin’s offer covers all types of ADT models. Michelin states that the XADN+ offers up to 15% greater longevity compared to the previous-generation Michelin XADN tyre.
For the underground mining market, the Michelin XTXL tyre is now available in a 25 in size. The XTXL range is specifically designed for underground mines faced with productivity requirements in a work environment where confinement, heat and debris represent constraining factors. The XTXL tyre range was first available in a 33 in, but the company has adding two new sizes: the 26.5R25 and 29.5R25. This means that a wider variety of underground mining machines can now be fitted with the XTXL tyre. Michelin states: “With increases of 10% in longevity, 20% in puncture resistance, and 30% in load capacity, the gains obtained by the new Michelin XTXL compared with the priorgeneration tyres effectively support companies operating in underground mines.”
Yokohama recently highlighted new mining tyres for the underground coal industry in September at the Bluefield Coal Show in West Virginia. The new tyres include the Y20, a 36-ply heavy-duty Y20 39 x 15 x 20 tyre, described as ideal for scoops and coal haulers needing heavy weight carrying capacity in a 39 in tall tyre. It also allows for the replacement of a 15 in rim with a heavy-duty 20 in rim for better durability and extra room around the hub. This promotes cooler running brakes, and better access and torque on the lug bolts. The rugged Y20 was also developed to take large shuttle cars down to lower levels, enabling access to deeper coal seams while still offering great carrying capacity. The 36 ply tough-tread Y67 44 x 15 x 20 is engineered for large shuttle cars, providing greater carrying capacity without having to change rims, and its wide footprint delivers an improved ride and longer tyre life.
Magna Tyres Group has launched the MAG NA MA06+ tyre, which is intended for fitting on rigid mining trucks and is designed for use on rocky, gravel or packed surfaces. Magna states that the MA06+ “offers excellent traction and outstanding stability due to its improved pattern.” Operating costs are minimised through lowered rolling resistance and cooler operating temperatures. The MAG NA MA06+ is available in four rubber compounds: standard, cutresistant, heatresistant and ultraheat-resistant. The ‘+’ in MA06+ indicates the new improved tread pattern compared to the MA06. The additional cooling vents contribute to optimised heat dissipation across the tyre. In combination with the innovative newly developed rubber compound, the average TKPH-value is increased by 8%, according to Magna. The MA06+ is available in tyre sizes 40.00R57, 46/90R57, 50/80R57 and 53/80R63.
Tyre chains
The design and operation of haul roads is crucial to the profitability of a mine’s operation. The shortest route from A to B is not always the best if gradients and cambers place avoidable stress on man and machine. It follows that the designer’s remit must be optimise fuel consumption, minimise vehicle maintenance costs and maximise operator safety. Daily housekeeping to keep paths clear of debris and measures to enhance visibility through dust suppression are as essential as is operator training and traffic management systems that monitor the position of each mobile item and keep haulers and utility vehicles at safe distances from each other. Working steep inclines asks a lot of truck tyres whether riding wet-clayey or iced-up surfaces. Tyre chains supplier RUD-Erlau argues that no matter how user-friendly the driving controls and how compatible the tyre treads, the driver may still find themselves struggling to keep their payload headed in the right direction as the tyres grip the gradient and flex against an adverse camber, making haul cycles longer and productivity much reduced.
RUD-Erlau states: “It is not surprising that owners of high altitude, ice-bound mines such as Codelco and Barrick choose to fit traction chains such as Erlau’s Terraplus. When the snow sets in, the light weight, steel-alloy, low energy, toothed Terraplus provides powerful surface grip without loss of performance. When site conditions improve, the chains are quickly and safely removed thanks to Erlau’s Easylock. Locked and unlocked by a simple 90 degree turn of a hex key, Easylock takes the time, inconvenience and risk out of traction chain installation. Used in haul road construction and maintenance, Terraplus is also used to enhance traction for wheeled dozer and grader tyres.”
The group also states that underground coal miners can also overcome clay and flint with the all-round protection of its TORO X19 chains, designed to provide traction and all-round protection and safety for low-profile loaders and haulers in underground galleries. Designed to fit within tight wheel arches, the reduced weight, TORO X19 cuts fuel consumption by as much as 30%, according to RUD-Erlau. The chains are also widely used in underground hard rock mines. IM
