Mine loading and haulage operations account for 50% to 60% of total open-pit mining expenses, with Off-The-Road (OTR) tires representing the second-largest operational cost after fuel (Mamani et al., 2024). Unfortunately, between 30% and 90% of mining tires fail prematurely prior to reaching their full wear life due to severe mechanical damage and thermal degradation (Shakenov et al., 2022). Haul truck speed management offers a dual-benefit strategy that protects operator safety while significantly reducing fleet operating costs. Speed control prevents heat-induced tire explosions, minimizes severe impact cuts, and preserves valuable rubber assets.
Heavy haulage tires generate considerable internal heat through continuous flexure under heavy loads. Excessive travel speeds accelerate internal heat accumulation through increased hysteresis losses within the rubber compounds (Chalmers, 2022). When vehicles exceed their rated Tonne Kilometre Per Hour (TKPH) thresholds, internal temperatures surpass safe operational limits (Heuver, 2024). Extreme thermal build-up causes tread heat peeling, ply delamination, and inner liner pyrolysis (Glencore, 2020). Gas auto-ignition inside overheating tires can trigger catastrophic explosions and severe sidewall zipper failures (Shakenov et al., 2022). Seasonal speed restrictions, such as capping loaded haul trucks at 30 km/h during hot ambient conditions, keep internal temperatures within safe parameters and eliminate sudden tire destruction.
High speeds over unpaved haul roads multiply the impact forces transmitted to tires when striking potholes, ruts, or fallen rocks. Physical cuts and severe impacts on treads and sidewalls account for many premature tire scraps in open-pit operations (Badu, 2022; Mamani et al., 2024). Furthermore, high velocity directly increases stopping distances and reduces vehicle stability on steep downgrades or sharp curves (Bureau of Mines, 1981). Drivers who travel too fast risk brake fade and loss of control over rough haul routes (MSHA, 2021). Strict speed regulation near loading zones and degraded road segments mitigates deep tread cuts while protecting haul truck operators from rollover hazards.
Premature tire disposal imposes substantial financial losses on mining companies through wasted rubber and lost production hours. Speed awareness initiatives paired with bi-weekly tire maintenance routines can extend average tire lifespan by up to 27%, raising average service life from ~56,000 km to over 73,000 km (Hia & Singgih, 2025). Operational speed control also optimizes fuel consumption and reduces rolling resistance losses across haul routes (Shakenov et al., 2022). Reduced mechanical stress on truck suspensions and brake linings yields additional maintenance savings for fleet operations.
Speed management serves as a crucial operational discipline that bridges worker safety and cost efficiency. The regulation of haul truck speeds protects personnel from thermal tire explosions and runaway vehicle incidents while preserving costly OTR tire investments. Mine managers should deploy GPS telemetry to monitor real-time haul speeds, establish mandatory speed caps during hot weather, and enforce routine haul road surface grading. These integrated measures allow operations to maximize tire longevity without sacrificing daily production targets.
References
Badu, F. A. (2022). A Review of Haul Truck Tyre Life and Its Impacts on Mining Production and Cost – A Case Study. Unpublished Masters Thesis, University of Mines and Technology.
Bureau of Mines. (1981). Design of Surface Mine Haulage Roads – A Manual. U.S. Department of the Interior, Bureau of Mines Information Circular.
Chalmers University of Technology. (2022). Effects of External Tire Heating on Rolling Resistance Energy Consumption. Research Publications.
Glencore. (2020). Tyre and Rim Management Protocol (G-S-PTC-0014). Glencore SafeWork Health, Safety, Environment and Community Protocol.
Heuver. (2024). TKPH: Tonne Kilometre Per Hour. Heuver OTR Knowledge Base.
Hia, S. W., & Singgih, M. L. (2025). Improving Tire Lifespan Using the Six Sigma Approach: A Case Study in a Coal-Hauling Company. Management and Production Engineering Review, 15(1), 1–7.
Mamani, R., et al. (2024). Assessing Operational Damage Impact on Mining Tires (Case Study). Journal of Mining and Environment, 15(3), 1–15.
MSHA. (2021). Protecting Miners Powered Haulage Equipment Safety Guidance. Mine Safety and Health Administration.
Shakenov, A., Sadkowski, A., & Stolpovskikh, I. (2022). Haul road condition impact on tire life of mining dump truck. Scientific Visnyk of Natsionalnoho Hirnychoho Universitetu, 2022(6), 26–30.
