MINING TYRES From new manufacturing capacity to fresh

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Burning
rubber
From new manufacturing
capacity to fresh
approaches to tyre
protection and haul road
management, Paul Moore
reviews the current
mining tyre market
ith the demand for mining tyres not
showing any signs of abating, the
majors are all gearing up to reap the
rewards having learnt from not investing in new
capacity prior to the last major mining tyre
shortage.
Bridgestone is increasing the production
capacity of its Kitakyushu plant in Japan for
large and ultralarge off-the-road radial tyres for
mining vehicles. The company states that the
increased production capacity, referred to as
phase 3, will help it to meet the growing global
mining tyre demand. The plan calls for
production capacity to be increased by
approximately 20 t per day, to approximately
165 t per day, in the first half of 2014, with work
starting in late 2012. In addition, the
Bridgestone Group has decided to increase
production capacity at its Saga plant for steel
cord used in large and ultralarge mining tyres.
Bridgestone is also to build a new plant in Aiken
County, South Carolina, to produce large and
ultra large mining tyres with production
scheduled to begin in the first half of 2014. Work
on this project began in 2011.
Moving forward, the group states that it will
build a production system “that can continually
respond rapidly to changes in market demand
trends and can supply customers with worldclass quality products on a timely basis.”
Structurally a change has also been made in
North America, with Bridgestone Americas Tire
Operations forming an integrated mining tyre
business unit. The new business unit,
Bridgestone Mining Solutions, combines all
mining tyre sales, service and sales engineering,
as well as a select group of US and Canadian
stores, into one integrated structure. Shawn
W
140 International Mining | SEPTEMBER 2012
Rasey will lead the new organisation as Vice
President of Bridgestone Mining Solutions.
Bridgestone says the new unit will employ
around 300 people.
In Asia, Bridgestone is building a new plant in
Amata City Industrial Estate, Rayong, Thailand
for the production of off-the-road radial tyres for
mining vehicles. Bridgestone is also set to start
production of steel cord used in these tyres at
its subsidiary for manufacturing steel cord in
Thailand. Production at the new tyre plant will
begin in the first half of 2015. Production
capacity at the new plant is expected to reach
approximately 85 t per day by the first half of
2019, when scheduled capacity increases are
completed. Until now, Bridgestone has
produced its mining tyres in Japan and the US
only. The new plant in Thailand will allow the
group to enhance global off-the-road tyre
capacity while responding with increased
flexibility to changes in the market. The facility
will also incorporate advanced environmental
technologies which will contribute to resource
conservation. The technologies will include a
system for processing wastewater while
manufacturing to maximise water reuse, and a
cogeneration system.
Michelin North America is also expanding its
radial mining tyre operations in South Carolina,
first through a new manufacturing plant in
Anderson County, but also by expanding its
existing facility in Lexington. The two projects
represent a $750 million investment and will
create up to 500 new jobs. This announcement
is in addition to Michelin's 2011 commitment to
add an estimated 270 jobs and invest $200
million in its existing Lexington passenger and
light truck tyre manufacturing facility. The
The Sideflex system from RUD-Erlau uses
platelets that shield the entire sidewall of the
mining tyre deflecting rock fragments
expanded operation at Lexington will begin
production in October 2012. "Michelin intends
to maintain and strengthen its leadership in all
its specialty businesses, especially earthmover
radial tyres," said Jean-Dominique Senard,
Managing General Partner of Michelin. "The
market for earthmover tyres grew by more than
20% between 2009 and 2011. This new facility
will help us meet sustained demand while also
attaining our growth objectives for 2015."
Michelin North America Chairman and
President Pete Selleck said: "Nearly every
earthmover tyre is sold before it is produced.
Michelin is one of very few companies in the
world that is able to produce these high
technology tyres." The new plant will be
Michelin's 19th manufacturing facility in North
America and its ninth in South Carolina. More
than 8,000 of Michelin North America's 22,300
employees are based in South Carolina. The new
earthmover tyre plant will be adjacent to
Michelin's existing rubber processing plant in
Starr. The company also operates a 2.5 million
ft2 rubber processing plant, the largest in the
world, in Sandy Springs. In addition to the
Lexington plant, Michelin currently produces
earthmover tyres in Waterville, Canada; Campo
Grande, Brazil; Le Puy and Montceau-les-Mines,
France; Vitoria, Spain and Zalau, Romania.
Finally, Goodyear Tire & Rubber Company has
also announced a major expansion in Japan. The
company has acquired 100% ownership of its
Nippon Giant Tire (NGT) subsidiary in Tatsuno.
Goodyear, the majority shareholder of NGT since
1985, has purchased the shares owned by its
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Michelin, Goodyear and Bridgestone
have all announced major capacity
increases for mining tyres to meet
current and future demand
joint venture partners, Toyo Tire & Rubber and
Mitsubishi Corporation. Additionally, Goodyear
is to invest $250 million to upgrade and expand
NGT’s tyre manufacturing facility to increase its
global supply of mining tyres for key customers.
The expansion will also support growth in the
company’s Asia Pacific OTR business, primarily
in Australia. Goodyear states: “The plant
upgrades will significantly grow NGT’s
capabilities by utilising new manufacturing
technologies and processes. The expanded
facility is expected to be fully operational in
early 2014 and increase employment at the
operation to approximately 400 workers.”
Richard Kramer, Chairman and CEO
comments: “Goodyear’s OTR tyres are in high
demand globally. This expansion in Japan is
aligned to our Strategy Roadmap, as it will
enable us to use market-back innovation to
grow in one of our targeted market segments,
the global OTR business.” The investment will
enable NGT to manufacture a full line of 57 in
tyres, as well as 63 in tyres at a future date,
added Dan Smytka, President of Goodyear’s
Asia Pacific region. “The time is right for us to
increase our presence in OTR in Asia Pacific. We
are proud of our achievements and will continue
to build on the strong momentum accelerated
by this expansion.” Goodyear began production
of 63 in OTR tyres at its plant in Topeka, Kansas
in late 2010. The company also produces OTR
tyres at facilities in Brazil, Colombia, Germany,
Luxembourg, India, Indonesia, Thailand, South
Africa and Turkey.
142 International Mining | SEPTEMBER 2012
With the increasing influence of Chinese
mining tyre manufacturers such as Techking,
Qingdao Qizhou Rubber, Qingdao Hengda,
Shandong Xingda and many others, joint
ventures and tie-ups with Chinese groups are
continuing to be a focus for the main nonChinese players. Yokohama Rubber recently
announced that it signed an agreement with
Shandong Xingda Tyre, a Chinese mining tyre
manufacturer, whereby Yokohama Rubber will
provide Shandong Xingda Tyre with technical
support regarding radial mining tyres and that
Yokohama Rubber would off-take a fixed
quantity of mining tyres manufactured by
Shandong Xingda Tyre. Technical support is
planned to begin in 2012, and the off-take is
planned to begin in the latter half of 2013. Tyres
off-taken will be radial tyres 25 in or larger,
while details as to the quantities and time
period remain to be finalised. Yokohama Rubber
will be globally marketing all the off-taken tyres
under the Yokohama brand.
Yokohama stated: “While off the road tyres,
which are used for dump trucks and wheel loaders,
are in high demand amid the globally accelerating
resources development, only a limited number of
tire makers can manufacture high-quality, reliable
off the road tyres.” Yokohama is also in the process
of developing a 49 in radial tyre, a size which is in
high demand. The company states that the
partnership with Shandong Xingda Tyre will allow it
to increase supply in a short space of time without
the need for capital investment.
For Shandong Xingda Tyre, a manufacturer
founded in 2005 that is specialised in radial
mining tyres, the partnership with Yokohama
Rubber will contribute to quality improvement
and stable operation. The company possesses a
large-scale factory with the latest facilities in
Dongying, Shandong and produces and sells its
products mainly for export.
The new two
Large radial mining tyre suppliers Eurotire and
Titan International probably have the highest
profile in the industry after Michelin,
Bridgestone, Goodyear and Yokohama.
Eurotire is working towards eventual production of
the largest radial 63 in tyres at its Romania factory.
The largest tyres are used on ultraclass trucks such
as the Komatsu 960E and Liebherr T282 shown here
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Focusing on mining customers, Eurotire made
the strategic decision some years ago to apply
its OTR tyre expertise and create a radial mining
tyre product. A state of the art radial tyre design
and manufacturing facility has been constructed
in Drobeta, along the Danube River in Romania.
The company told IM that the factory is now in
full swing producing radial tyres for mining
customers. This 1,000,000 ft2 facility
incorporates modern, leading edge
manufacturing technology and sophisticated
process control techniques making it what
Eurotire believes to be one of the most
advanced radial tyre facilities of its kind in the
world. It is also equipped with one of the largest
dynamic tyre testing facilities in Europe. The
facility is staffed by a team of senior design
engineers, field engineers and plant operations
engineers.
Currently Drobeta is manufacturing quality
radial tyres from 25 in upwards and has already
achieved ISO9001 certification. The company is
moving toward the production of its first 57 in
radial tyres in the fourth quarter of 2012.
Beyond this, the capability to build 63 in tyres is
also programmed into the factory development
plan, which foresees 63 in tyres being in
production during 2015 and Eurotire states that
it is on track to achieve that. The company told
IM: “Our radial program is on track but R&D is
at the fore as equipment installations and new
144 International Mining | SEPTEMBER 2012
moulds are continuously being installed. This
takes time and requires a lot of validation before
taking the product to the commercial market.”
Eurotire also offers a wide range of large bias
ply mining tyres. These have been sold in large
quantities in many countries around the world
where it states they have been working very well
at mines in Mexico, Africa, India, Australia,
Russia, China and Central Asia. The company
told IM in terms of the bias market: “The focus
is to provide an acceptable price/performance
value to the customer that really validates the
bias tyre option. The choice and accurate
assessment of usage conditions is critical when
assessing whether bias tyres can work or not
and certainly not every application will be able
to use bias tyres successfully. Our bias tyres
have provided a particularly good value solution
in mines where there are high rates of
accidental damage or where the loads and
speeds are within limits or least can be well
controlled.”
The group opened a new tyre training centre
in Ukraine in 2011 for both customer and
employee training. Located in Dnepropetrovsk,
the Eurotire Training Center is an educational
facility offering training in technical, safety,
commercial and industry aspects of the mining
tyre market. The aim of the centre is to further
education in the mining industry regarding all
OTR related matters. Jack James, a long-time
OTR veteran and experienced OTR instructor, has
been named Director of the centre. In March
2011, the company successfully graduated the
first official Eurotire Certified personnel.
As part of the practical training program, mine
site visits are undertaken to large scale mining
operations located in the region and trainees are
given the chance to apply classroom instruction
on safety and technical matters to the real world
of mining. Additionally, attendees are given an
extensive factory tour of Eurotire’s Ukrainian
manufacturing facility.
Titan International entered the mining market
in February 2008 with the production of its first
giant radial off-the-road tyre. In 2010, Titan
introduced its second generation 007 MFT
mining tyre product line, offering enhanced
durability, a more aggressive tread pattern,
improved heat dissipation and the ability to
carry a larger payload.
The company recently has expanded its
global influence with its purchase of a majority
56% ownership interest in the Planet
Corporation group of companies. Planet
includes National Tyres, Acme Wheel, Resource
Tyre and Choice Tyres Wholesalers and is based
in Perth, Australia. Planet is an OTR tyre and
wheel specialist that manufactures, distributes
and services products to customers in the
mining, agriculture, construction and
earthmoving industries. Planet is now a
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The Titan ACT wheel reduces the use of heavy impact wrenches that were
required in the past to torque and retorque 50 to 60 wheel nuts when
removing a mining wheel and tyre assembly
subsidiary of Titan Mining Services, which was formed recently to build
Titan’s mining business globally.
Titan also recently announced a major deal in the OEM truck tyre market
with a multi-year supply contract with Caterpillar. Titan has agreed to
supply OTR tyres to Caterpillar under a three-year agreement starting in
2012. The value of the contract is expected to exceed a minimum of $100
million. Maurice Taylor, Titan International Chairman and CEO commented,
"Titan is honoured to work with Caterpillar and we look forward to
supplying tyres in support of Caterpillar equipment."
Tyre monitoring and protection
In July 2012, Rimex introduced TyreSense lite, a more affordable TPMS
offering for the mining and industrial market. Unlike any other system
available, Rimex says it is a modular approach to tyre monitoring,
personalised to meet site requirements and budgets. Users have the option
to start with the basic system, and add features or upgrade functionality
and/or add reporting capabilities as required. It is suitable for all
applications, from open pit and underground mining to forestry, quarries
and docks. Whether an operation has one or 200 trucks, TyreSense lite
adapts to fulfill their pressure maintenance requirements. TyreSense is the
original TPMS developed by Rimex in 2001.
TyreSense sensors are installed within the tyre chamber and they
constantly send packets of information to a receiver that is mounted within
the cab of the truck. These sensors relay real-time pressure and
temperature data through an in-cab display unit for monitoring. But
TyreSense data can also be displayed using Bluetooth technology on a
handheld field PC or remotely through cellular and wireless Ethernet
connectivity from anywhere in the world. In addition, the data is integrated
with many of the dispatch systems used in major mining operations
worldwide. Not only does the user have access to live pressures and
temperatures but each receiving unit in the cab is equipped with a GPS
module allowing the user to gather speed and travel information. Alerts
are sent in two levels: level one is a high warning alert indicating that the
user should take preventative action by changing the conditions of the unit
to bring the tire back to ideal operating levels; level two is a critical
warning alert indicating that immediate action should be taken because
the tyre is operating dangerously outside of its ideal manufacturing
parameters. All of the information gathered by the system can be charted
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in an easy to interpret data log and
relationships. AM Bromley said it
can be exported to Microsoft
wanted a company which
Excel for full reporting by
understood the ‘value added’
the day, month, and
nature of the TMS product.
year.
Leemasters have
Hutchinson offers
specialised in the
the Tire Shield which it
distribution of OTR tyres for
states provides
more than 20 years,
‘military tough’
recently expanding their
protection to the
activities to include tyre
highly stressed
maintenance solutions.
sidewalls of mining
Their Philippines operation,
tyres and ensures the
which focuses on clients in
continued operation of
the mining sector, is now
vehicles in difficult terrain. The
working with the TMS solution.
Tire Shield consists of heavy
Designed for use in heavy
Hutchinson offers the Tire
duty reinforced rubber
industrial
sectors and capable of
Shield which consists of heavy
duty reinforced rubber carefully withstanding extreme
carefully selected to be
selected to be extremely
extremely resistant to tearing
operational conditions, the TMS
resistant to tearing and
and perforation. It creates a
system integrates tyre pressure
perforation
barrier in between the tyre
sensors (internal and external) in
sidewall and potentially damaging sharp edged
real-time with a data management system that
rocks or debris. Hutchinson also refers to the
means drivers and managers can access key tyre
lightweight and durable materials used in the
performance information via cab interfaces and
product, which can help in achieving savings in
PC programmes while vehicles are in service.
fuel consumption, the initial product cost and a
AM Bromley told IM: “The capital intensive
maintenance costs by prolonging the life of the
nature of mining means the reliability of large
tyre.
equipment is critical and the sector has long
Advantage PressurePro offers a number of
sought to harness leading edge technologies as
tyre pressure monitoring system (TPMS)
offered by the TMS system. Its benefits include
solutions to the mining industry. These include
improved fuel efficiency, reduced wear and tear
standalone monitoring options which utilise RF
and the ability to predict problems enabling the
technology to transmit real time tyre pressure
scheduling of appropriate tyre maintenance and
and temperature information from a monitor,
maintenance of operational efficiencies.”
which sits in-cab, along with sensors which fit to
Leemasters trialled and is now actively
user equipment’s valve stems. Partnering with
promoting the TMS system with its clients. The
leading telematics providers, PressurePro’s
company reports numerous benefits including
integrated options also allow fleets to utilise
“significant and immediate improvements to
PressurePro’s full TPMS capabilities without the
tyre maintenance regimes”, a reduction in onaddition of screens in-cab. Communicating over
site workloads, increased confidence among
the truck-line, or direct to a box or screen,
clients and high levels of support from the TMS
PressurePro is able to provide real time
technical team. Tyre monitoring equipment is
pressures, temperatures and alerts for drivers
not a standard implementation yet in the South
while eliminating driver distraction and cab
East Asia region but this is expected to change
clutter. Integrated options also provide fleets
rapidly with the ever increasing demand for
with the ability to monitor the performance of
other mining-related equipment.
every tyre in the mining fleet from a single
RUD-Erlau is well known as one of the global
control point.
leaders in mining tyre protection chains, for
Since its launch in 2005, the Tire Monitor
System (TMS) from AM Bromley has been well
received both in the UK and internationally with
thousands of units sold throughout North
America, South America, Europe and Australia,
according to the group. Recently, the company
states that it has experienced a surge in interest
from South East Asia and a distributor,
Leemasters International Systems, has been
appointed to offer strong local knowledge and
allow the technology to benefit from existing
The TMS system from AM Bromley is being
distributed in Asia by Leemasters International
146 International Mining | SEPTEMBER 2012
which the largest market remains wheel loaders.
Due to feedback from its engineers, RUD-Erlau
told IM that is has long been well-aware of the
vulnerability of mining truck tyres and asked its
R&D team to tackle the problem. With over 130
years of experience in the development and
manufacture of chain components, the first
instinct was to create a device based on steelalloy elements. However, the team ultimately
turned its attention to materials used in other
industries and developed Sideflex – what it
believes to be a “truly innovative addition” to its
range of asset protection products.
A sturdy set of replacement wheel nuts and
extensions support a simple steel ring to which
is attached a fanned array of over-lapping
platelets. These platelets shield the entire
sidewall of the truck tyre deflecting rock
fragments. While the mounting components are
made of steel, the Sideflex shield is
manufactured from an engineered polymer
which has found many applications in the
automotive and other industries. The robust
material has a memory capability that enables
the platelets to flex and deform upon impact
and then return to their original shape without
any loss of integrity. The entire Sideflex
assembly is lightweight and low-profile to the
point that RUD-Erlau believes that owners of
mining trucks for the first time have a costeffective means of protecting their tyres.
Extensive mining field trials have been
conducted and the groups states that Sideflex is
performing well.
Transense Technologies, a provider of sensor
systems for the transportation and industrial
markets, has announced that subsequent to
recent successful field trials, its trading division,
Translogik has received an initial order for its
iTrack tyre temperature and pressure monitoring
systems for mining and off the road vehicles
from Kumba Iron Ore. The first systems will be
installed on 29 haul trucks at the Sishen mine in
Northern Cape Province. Translogik now has a
technical staff member permanently based in
South Africa who will be responsible for training
Kumba's tyre service provider in the installation
process and ongoing support of the system. It is
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anticipated that the South African Translogik
team will expand as further mines sign up for
the iTrack system.
Graham Storey, CEO of Transense,
commented: "This order from Kumba represents
the first commercial success for Translogik's
iTrack system in South Africa. Kumba is a leader
in mine safety, committed to achieving a 'zero
harm' policy for all its staff. The ability to
monitor the tyre performance of all its vehicles
24/7 and receive instant notification of any
potential hazardous situations will allow it to
achieve greater levels of safety and efficiency
throughout its mines."
Testing and inspection of large tyres requires
specialist equipment. Steinbichler Optotechnik
has developed the Intact 4300 EM/OTR tyre
shearography machine which is specifically
designed for giant OTR tyres with an inner
diameter of between 45 in and 63 in, a width of
550-1,550 mm and a maximum weight of 7,500
kg. A key benefit of the machine is that
inspections are carried out with the tyre in a
vertical position, meaning that there is no need
for tyre flipping and therefore no need to allow
the tyre to settle before the second side of the
tyre is scanned. The tyres can therefore be
easily loaded and unloaded with a common
forklift. The machine also offers a short test
cycle of approximately 20 minutes with three
cameras operating simultaneously. Once the
tyre is loaded, the measuring heads inside the
chamber take images simultaneously of each
sidewall and the tread, whilst the tyre is relaxed.
Afterwards, further images are acquired while
the tyre is under 50 millibars of vacuum. These
measurements are then compared and
displayed on a computer screen, allowing the
identification of various non-visible defects
including belt edge separations and bead turnup failures.
Rims and wheels
To complement Titan International’s giant tyre
line, Titan Wheel offers the Superduty Titan
Machine Taper (STMT 63) and Accelerated
Change Technology (ACT 63) wheel assemblies.
These assemblies weigh less than competitors
according to Titan, allowing more payload
capacity per haul truck. The ACT allows tyres to
be changed or rotated without the need to
dismount the wheels. This system can save
mining contractors nearly 50% of the time
previously spent changing tires.
Titan states that it is the only company with
the ability to design, test and produce both
wheels and tyres for the mining market.
Because of this unique ability, Titan has created
Titan Mining Services (TMS) to offer complete
tyre, wheel and track services to end users near
large mines. The company's first location is in
Fort Mackay in Alberta, Canada. Titan chose the
oil sands mining region to launch these services
because of the huge amount of large mining
equipment used in the area. Titan is partnering
with Saskatoon Wholesale Tire, which has been
in the area for a number of years and also
represents Titan as a dealer. As the company
grows, Titan will open other TMS locations
around the world.
In detail, ACT is an approach that allows a
service technician to change or rotate the rear
tyres on a mine haul truck in a fraction of the
time. The system also helps enhance safety,
reduces service technician fatigue and increases
profitability by reducing tyre maintenance
downtime. The ACT wheel is designed for use on
the outside rear wheel position on mining
trucks. Once installed, there’s no need to
remove nuts or clamps to rotate the tyres off
and on the haul truck. A service technician
simply slides the tyre and the component wheel
parts across the outside wheel. Featuring twopiece lock rings that can release the tire
assembly from the wheel, the ACT wheel allows
for easy removal. When an inside dual tyre
needs to be changed, it simply slips over the
outer dual wheel. Employing a double-lock
system that stops rotation of the side flange,
the ACT wheel prevents expulsion of the flange
and helps control tire slippage. The back and
bead incorporates a full 360° pry-bar pocket
TYRE
PROTECTION
CHAINS
Open Pit Mining
Underground Mining
Slag / Recycling
which aids service personnel in demounting the
tire from the wheel. A Sur-Loc rim component
inside the bead band prevents tire inflation if
the lock ring is misassembled.
The ACT wheel also enhances safety and
reduces service technician fatigue. Service
technicians no longer need to handle the heavy
outside wheel. In addition, the ACT wheel
reduces the use of heavy impact wrenches that
were required in the past to torque and retorque
50 to 60 wheel nuts when removing a wheel and
tyre assembly. ACT wheels are compatible with
every size and brand of mining tyres on the
market, and are available for every haul truck
make and model.
GKN Wheels will use MINExpo as the launch
platform for its Swift Wheel Technologies
offering, which it describes as a key
development in its mining wheel and hub
technologies. The company is also set to
formally sign a new five-year distribution
agreement with Australia’s Rimtec at the show a partnership covering GKN’s wheels
distribution in the Asia Pacific Rim regions.
The new Swift Wheel Technologies mining
range includes a new 63 in Swift Change Rim;
Swift ID – a wheel identification system; and a
large capacity hub and spindle range – bringing
the latest 50,000 lb load capacity design to the
harsher environment of mining. GKN Wheels
says it will also emphasise the scale and scope
of its capabilities at MINExpo, exhibiting its 33
in and 49 in wheels alongside the new product
launches. GKN also offers a complete range of
standard and customised rim solutions for large
mining applications. These are available in sizes
from 33 in up to 63 in diameter for mining trucks.
GKN states: “The time required for the
inspection, maintenance and replacement of
wheels on heavy mining equipment creates a
significant cost consideration for mining
operators. Changing tyres on large wheels also
requires considerable care to ensure personnel
safety.” The new 63 in Swift Change Rim has a
double gutter design which minimises the time
needed for tyre changes, leading to increased
North Hall Booth 1861
Erlau AG
Erlau 16
73431 Aalen/Germany
Phone +49 7361/595-3496
Fax. +49 7361/595-3214
[email protected]
www.erlau.com
A Member of the Group
SEPTEMBER 2012 | International Mining 147
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on-site productivity. The Swift
Change Rim also offers improved
safety for tyre maintenance
personnel.
Jules Carter, Global Engineering
& Product Development Director at
GKN Wheels comments: “The new
range of larger mining wheels
complements and extends our
existing product lines and will
enable us to meet the needs of the
mining marketplace in China and
throughout Australasia. In
extending our offering to the
mining market, GKN Wheels has
taken a truly global approach, with
R&D activity focused in the US,
testing at the company’s dedicated Technical
Centres in the US and Italy, and production in
China. In addition, trial wheels have been
running on Caterpillar and Komatsu mining
trucks in the Asia Pacific region since 2009 and
are performing strongly, attracting some positive
customer feedback.”
Specifically on the development of its new
mining wheels range, he added: “The largest
open cast mining trucks carry loads of up to 400
short tons and the wheels for this machinery
must fulfil the toughest performance criteria,
demonstrating both strength and reliability. Of
course, it is also important to reduce weight
where possible to improve fuel efficiency. By
employing the latest engineering technologies
and computer-simulated modelling techniques,
we have been able to achieve all of these criteria.”
The Swift ID chip technology will allow
operators to access key information on the
wheel with a scanning device. Initially, the data
chips will allow access to manufacturing date,
operational hours and maintenance due dates.
This represents the first stage in a phased
programme that will progressively provide
operators with the ability to monitor a range of
information relating to aspects of wheel operation.
Exhibiting its high capacity solutions for the
first time, GKN Wheels can now supply fully
integrated wheel, hub and spindle designs that
have been manufactured and performanceverified using both engineering modelling and
live product testing. The ability to offer complete
high standard systems from a single source, and
in a comprehensive range of loads from 1,000 to
50,000 lb, allows GKN Wheels the flexibility
required to produce fully tested, reliable designs
more quickly.
Based in Australia, Rimtec is part of Downer
EDI Mining and is a leading provider of
replacement wheels, rims and mining wheel
solutions to mining customers for use on rigid
dump trucks and other large mining machinery.
The two companies have worked together since
148 International Mining | SEPTEMBER 2012
Getman’s RDG-1504 Roadbuilder is specifically
designed to clear mine roads underground
2009 and the new agreement builds on their
extensive experience of collaborating to serve
the aftersales market.
Shinagawa, Japan-based Topy Industries is to
establish a solely owned subsidiary company in
China for the manufacture and sales of its ultralarge wheel components, the Super Giant Off
the Road Rim (SGOR) product range, for mining
trucks. In the past, Topy has expanded
manufacturing capacity at its domestic
manufacturing site, the Ayase factory in
Kanagawa Prefecture to address increases in
demand but believes that the current market
requires this move. Chinese truck manufacturers
like XEMC and SANY are expected to grow
rapidly in the medium term.
The company states: “The market for dump
trucks used in mines is expected to grow as
resource development demand expands in Asia,
including China, and other Oceania regions.
Demand increase in the next three years is
expected to be around 30%.” Topy will also
modernise its steelmaking facilities at the
Toyohashi factory in Aichi Prefecture, where raw
materials for wheels are produced, with a target
to start operation in April 2015. Topy customers
are requesting a stable and long-term supply of
SGOR and in order to respond to these increases
in demand, it has become necessary to increase
its component manufacturing capacity. In view
of this, Topy opted to establish a subsidiary
company Tianjin Topy Machinery for the
manufacture of SGOR components. With the
operation of this component manufacturing
company, the capacity to assemble finished
products at the Ayase factory can be increased,
and by diversifying component procurement,
Topy believes it can mitigate procurement risk.
For further progression of the SGOR business,
Topy says it will formulate an “optimum global
manufacturing structure” centred around the
domestic manufacturing site.
In the wider wheels market,
Rimex is well known in the
industry for developing the
Machined Extreme Service
(MES) Series & Taper Secure
Radial (TSR) series of wheels
and rims. Having designed a
product that is machined for
true roundness and has over
100% more steel across the
rim in critical areas, Rimex
believes that it is the only
manufacturer to have
advanced wheel technology to
precisely match modern radial
tyre designs. The unique
design of the TSR series uses a taper concept to
secure all components in place. Absolute
stability of components and the tyre is achieved
as movement between parts is eliminated. When
the tyre is inflated, the rim parts lock into their
tapered landing areas. Rimex comments: “The
key benefit of the TSR design is absolute tyre
support. The flanges of the wheel do not move
on the base. The tyre is anchored with complete
stability and no air pressure is lost. As well as
extending tyre life, the life of rim components is
increased as there is no wearing or fatiguing of
the parts from component movement.”
Underground tyre life
Maintaining good roads in underground roads is
just as important as in surface mines and is a
key factor in extending underground tyre life.
Traditionally, many mines have improvised,
using LHD buckets to level off surfaces and
remove any blocks that may have fallen from
haulage trucks or conveyors. However, the use
of dedicated graders underground is increasing.
Poor roads underground can have a serious
impact on the overall operating cost of a mine’s
trackless fleet. Bad conditions slow productivity
and can result in damage to underground
equipment, which can drive up maintenance
costs and have an impact on safety.
Getman Corporation offers a low-profile
underground road builder, originally developed
in the 1980s for use in low seam coal mines. The
Getman RDG-1504 Roadbuilder is specifically
designed to clear mine roads underground and
built exclusively to perform in harsh
underground conditions with “both safety and
efficiency in mind”, says the company. The
RDG-1504 produces more than 15,700 lb of
tractive effort, while applying more than 14,500
lb of working effort into the 12 ft mouldboard
blade, all smoothly transmitted to the ground
using a four-wheel drive bogie axle. According to
the conditions underground, the Getman
Roadbuilder can be fitted with an optional
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scarifier, carbite bits, float valve and/or ripper.
The company told IM: “Manufacturing an
underground grader requires a subtle mix
factors: it needs to be heavy and powerful to be
able to move compact dirt, it needs to be wide
enough to assure a single pass, but it also
needs to fit underground and be easily
manoeuverable through tight drifts. The Getman
grader can fit into a 4 m drift, and is operated
using a simple to use two-joystick
configuration.” Getman argues that rather than
improvising with existing equipment, a better
alternative is to utilise purpose-built equipment
specifically designed and adapted for
underground use.
Veekmas in Finland is the Nordic countries'
only motor grader manufacturer and a pioneer in
motor grader technology. In addition to motor
graders for traditional construction tasks and
snow removal, Veekmas offers another lowprofile motor grader solution for road
maintenance in underground hard rock mines.
Veekmas says that its UG motor graders have
been manufactured with attention to high
performance and low operating costs. The
company told IM: “When underground roads are
in good condition, it improves efficiency, enables
flowing traffic and lowers the maintenance costs
of other vehicles. But the conditions in
underground mines are different than on the
surface. That is why it is not easy to use a
traditional motor grader in restricted
underground working conditions as
underground tunnels are narrow, walls are close
to each other and the turns are sharply curved.”
Veekmas states that its UG motor graders are
ideal for operating in small dimensional and
sharply curved mine galleries. The frame
articulating joint is situated under the fore of
the canopy/cabin and the external dimensions
are smaller which eases turning and reduces
outer turning radius. Veekmas UG motor graders
have small turning
radiuses even when
pushing loads due to an
effective four-wheel drive
system. As the smaller
Veekmas UG motor
grader models have a
two-axis rear axle, the
rear axle does not try to
crank even in sharply
curved turns and the rear
wheels will not wear out
quickly.
The front wheel drive
of the Veekmas FG 7 C,
Veekmas FG 5 C and
Veekmas FG 3 C graders
is standard. The road material can be
transferred effectively by the middle blade even
in sharply curved turns by using the frame
articulation at the same time. If a motor grader
has a bogie axle or it has no front wheel drive
system, the motor grader will not turn in sharply
curved turns when the frame articulation is
activated. In these cases, the front wheels are
located at almost 90° position to the direction of
the rear axle causing the wheels to slip
Veekmas adds: “Road material can be moved
back to its correct locations and the road can be
shaped to a correct shape by the middle blade
of a motor grader. Correct road inclinations and
water ditches can also be made by means of a
motor grader. Loose stones can be pushed to
one side of the road by a front blade. A motor
grader not only pushes the road material but it
gives the road the correct shape and
inclinations.”
Retreads, training and technology
Rösler Tyre Innovators, a Germany-based OTR
retread specialist, has announced plans to
develop its network of turnkey retreading plants
Veekmas states that its UG motor graders are
ideal for operating in small dimensional and
sharply curved mine galleries
on a global basis. The company plans to achieve
between 20 and 30 plants over the next 5-10
years licensed to use the Schelkmann retreading
process, each with a capacity of some 1,500
tyres per year. The company's aim is to directly
target mining companies who have the need for
a high number of tyres annually. Rösler currently
has plants in Germany, Kazakhstan, Uzbekistan,
Indonesia and Australia as well as a newly
established plant set up in New Brunswick,
Canada. The company currently has no ongoing
projects in Africa but is actively looking at
opportunities and is establishing a
representative office. Other focus areas include
northern Chile, eastern Australia, the Kuzbass
region in Russia and Colombia.
Well known mining tyre management
consultancy Otraco International officially
opened a new tyre training centre in
Maddington, Perth in April 2012. The training
centre, which comprises a 2,000 m3 tyre pad and
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1,500 m3 of training rooms, offices, workshop
and a hard stand, will train tyre fitters for
Otraco’s operations on mine sites throughout
Australia and also elsewhere. Otraco’s decision
to establish the centre was based primarily on
two key factors – safety considerations and the
nationwide shortage of qualified OTR tyre
fitters. Otraco serves around 40 mine sites in
Australia, New Zealand, southern Africa and
South America. With its OTRACOM software and
rims and ancillaries business it also serves
additional mining clients globally. Major mining
clients include Rio Tinto, BHP Billiton, Minara
Resources, CITIC Pacific, Newmont, Codelco,
Newcrest, Minmetals, Barrick and Anglo
Platinum. The group is owned by Downer EDI so
also manages tyres for Downer EDI Mining at a
number of its contract mining sites. Otraco
General Manager Alistair Swanson said: “A key
component of the training offered by Otraco is
that it involves simulating the mine
environment, and trainees are able to work on
real mining equipment just 30 minutes from
Perth’s CBD. One of the most important
advantages of this approach is that it enables
the trainees to undergo their training in a very
safe, controlled environment. It also enables
them to decide whether they like the life, as
training and trainees will be required to work a
full mine roster, work nights, undergo mock
client audits and even eat in a crib room. After
completing the six-week course at the centre,
the trainees continue their training on mine
sites. Previously trainees would have received
all their training on site; now they start their job
equipped with key skills, and the role of a
trainer on site becomes more that of a mentor.”
Thanks to the support of the mining industry
and local businesses, the centre is equipped
with both open-pit and underground mining
equipment, including a Caterpillar 789B haul
truck donated by BHP Billiton, and an
Elphinstone R2900 LHD and tyre handler from
Downer EDI Mining.
Initially the centre will be offering courses on
an as-required basis to meet Otraco’s need for
tyre fitters. Each intake will comprise six to eight
trainees, who will ultimately graduate with a
Certificate II in Automotive Mechanical – Tyre
Fitting Heavy – which has been customised to
incorporate OTR. In addition to supplying
trained tyre fitters to the mines, the training
centre will be offering commercial courses to
mining equipment companies and local tyre
suppliers.
Goodyear Tire & Rubber recently announced a
development that could help consumers and the
environment by reducing the amount of
petroleum-based oil used in mining and other
tyres, while at the same time extending tread
life. Goodyear researchers at the company’s
innovation centre have found in tests that using
soybean oil in tyres can potentially increase
tread life by 10% and reduce the tyre maker’s
use of petroleum-based oil by up to 7 Mgal each
year. In addition, testing at Goodyear’s tyre
plant in Lawton, Oklahoma showed improved
mixing capabilities in the manufacturing
process. The company found that rubber
compounds made with soybean oil blend more
easily with the silica used in building tyres. This
can improve plant efficiency and reduce
energy consumption and greenhouse gas
emissions. Prototype tyres built in Lawton will
be tested at Goodyear’s proving grounds in
San Angelo, Texas. If indicators remain
positive, Goodyear expects consumers will be
able to purchase tyres made with soybean oil
as early as 2015.
The use of soybean oil is one of several
initiatives Goodyear is currently undertaking to
increase its use of renewable raw materials.
Goodyear and DuPont Industrial Biosciences
continue to work together to develop
BioIsoprene, a revolutionary bio-based
alternative for petroleum-derived isoprene.
BioIsoprene can be used for the production of
synthetic rubber—which in turn is an alternative
for natural rubber—and other elastomers. The
development of BioIsoprene may help further
reduce the tyre and rubber industry’s
dependence on petroleum-derived products.
Another effort underway in Goodyear to save
non-renewable fossil fuel is Goodyear’s Air
visit us at booth #7599
to see examples of our innovative
industry-leading designs
150 International Mining | SEPTEMBER 2012
Maintenance Technology (AMT). AMT will help
enable tyres to remain inflated at the optimum
pressure without the need for any external
pumps or electronics. All components of the
AMT system will be fully contained within the
tyre. The potential benefits of such a system
include improved fuel economy, reduced
emissions, longer tire life, enhanced safety and
performance.
In 2011, Denmark-based recycling equipment
manufacturer Eldan Recycling was approached
for a new solution to process mining tyres. The
company has come up with a solution that
combines a heavy duty demolition shear, the
Eldan Heavy Duty Super Chopper, a powerful
overband magnet and a granulation and
separation plant – to deal with large mining
tyres. The company performed a test run of the
system in 2011, which it says successfully
demonstrating the plant's ability to process
mining tyres of 3-4 m in diameter and weighing
up to 6 t. The mining tyres are first handled and
pre-cut by a heavy duty demolition shear into
pieces which fit the in-feed of the Eldan Heavy
Duty Super Chopper. This machine is specially
designed to process voluminous and tough
waste. In the Heavy Duty Super Chopper, larger
pieces of mining tyre are processed into tyre
shreds, and free steel wire is liberated and
removed from the shreds by the magnet. The
tyre shreds are further processed in the
granulation and separation plant. As the mining
tyre recycling system is combined with standard
tyre recycling systems, the output can be
decided according to the customer's specific
needs of output granulate size and quality. The
typical rubber granulate purity in the standard
systems is up to 99.9% free of liberated steel
and textile. However, by adding a quality
upgrading system, Eldan states that it is
possible to produce rubber powder up to
99.99% free of liberated steel and textile, and
100% free of metals, glass and stones. In
addition, the company states that it is possible
for the liberated steel wire to be further cleaned
into a steel fraction which is 99% free from
foreign materials. IM