Professional Documents
Culture Documents
Haul Trucks
Haul Trucks
Selection
When selecting haul truck bodies, there
are a number of factors to be considered
including: the characteristics of the
material to be hauled; truck payload/
design; the range of bodies available;
which loading tools the truck will be
matched with; haul road conditions, grade
and average haul distance; plus
environmental conditions at the site.
Before we begin a design, we conduct
an extensive review of the mine needs,
operations (loading tools), facilities and
production budget requirements, says
Rich Peters, sales manager for North
America at Westech. This includes
maintenance facilities and road conditions.
Once this is complete, we use the latest in
engineering technology to design, model
and measure the design. We use such
www.
.com
113
A DT HiLoad
body on its way
to Xstratas
Mount Owen
mine
Design
The most important factor affecting truck
body design is the material being hauled.
This will not only determine the capacity
and position of the body on the chassis
due to the stated materials angle of
repose (the stacking angle), but it will also
determine which accessories/wear parts
may be needed so that the body can
achieve its specified life.
For example, if the material being
hauled is very abrasive or the particles are
very large, it may be beneficial to add
liners to protect the truck body from
premature wear and/or localised denting.
If the material is very light, such as coal,
then it is unlikely that liners or heavy main
plates would be needed.
The loose density of the material
affects the volumetric design of a truck
body, and directly determines the payload
of the truck: the weight of the final truck
body design, plus the truck chassis
weight, subtracted from the gross vehicle
weight (GVW) will give the potential
payload. The lighter the body, the greater
the payload potential, and the heavier the
truck body the less payload potential
there is within the trucks GVW range.
In addition, allowances must be made
for environmental influences, such as the
weather, on the material; moist material
can have a tenancy to hang up (stick) in
The loose
density of
the material
affects the
volumetric
design of a
truck body,
and directly
determines
the payload
of the
truck
September 2012
113,115-117,119,121-122,124,127-128,130-132MM1209.indd 113
20/08/2012 11:52
RDO.indd 1
14/08/2012 15:36
Truck performance
An optimal body design will maximise
machine productivity and component life,
resulting in the lowest operating cost per
tonne for the customer. When designing a
body for a specific application, it is
www.
.com
115
Truck bodies
must be
designed to
accomodate the
loading tools
used. This photo
shows a VR Steel
body in use
Maintenance
All truck bodies will require some amount
of repair. However, the frequency will vary
greatly depending on the application and
the care taken by the customer. Knowing
customer expectations and having an
understanding of the application is the
best way to ensure that payload and
durability are balanced.
Some customers, those who want to
maximise production even at the expense
of some additional costs, prefer a
consumable lightweight body that will
operate for a certain amount of time
before being replaced, Mr Llano tells
MM. Customers at the other extreme
want a single body to last the life of the
chassis with no major rebuilds. There is a
middle ground too, where most customers
fall a body that can be refurbished or
rebuilt for a second or third life.
Regularly scheduled maintenance
inspections are critical to ensure maximum
life. Application severity plays a major role
as well; rock impact is the number one
cause of body damage. Applications with
large rocks and inexperienced loading
tool operators tend to have more impact
damage (denting or buckling of ribs).
Another consideration is the abrasiveness
of the material being hauled. Some ore
contains a high amount of silica and can
quickly erode the steel as it exits the
body, resulting in higher maintenance
frequency or reduced body life.
Steve Grant, vice-president of technical
and marketing support at Hitachi,
comments: A standard-type body with
When
designing a
body, it is
important
to make
sure it is
not only of
the correct
capacity,
but also
positioned
correctly on
the chassis
September 2012
113,115-117,119,121-122,124,127-128,130-132MM1209.indd 115
20/08/2012 11:53
The payload
must be
distributed
correctly on the
chassis to avoid
steering and
stability issues
Proper
loading
practices,
operations
management,
blasting
practices
and loading
tools all
play a role
in the life of
a body
Repair or replace?
The replacement of truck bodies varies
greatly with design and application. The
decision is usually decided based on the
expected chassis life of the truck.
Mr Frank tells MM: Mine Rite designs
its truck bodies to the customers needs
and works with them to match the
number of replacement bodies needed to
reach the customers life expectation of
the truck chassis.
He explains that a truck chassis that has
achieved half the life of the customers
expectation and is ready for a replacement body may only need one more body
to reach the customers ultimate chassis
life goal. However, the customer may opt
for a lightweight replacement body and
increase the trucks payload potential by
accepting that it might have to replace
advertiser
113,115-117,119,121-122,124,127-128,130-132MM1209.indd 116
20/08/2012 11:53
117
Special designs
Certain applications present particular
challenges and opportunities, and a
number of manufacturers have designed
bodies to optimise the hauling of these
materials. Material characteristics such as
density, moisture content, abrasiveness or
stickiness are the key drivers for special
truck body designs. Material density is a
key determinant for capacity sizing, and
moisture content may dictate a design that
resists material sticking to the truck body.
Coal applications
Special coal bodies are necessary due to
the low material density. Many coal
operations see material densities in the
range of 0.75 to 1.25,explains Mr Miller.
In order to maximise the payload of
the trucks hauling this material, bodies are
required that are wider, longer and taller
than the standard designs, in order to
achieve the volumes necessary to haul at
the rated payload.
Westech introduced its first gate-free
coal body in 2001. Traditionally, coal was
hauled in large heavy gated bodies, but
the new design helped increase payloads
and reduce maintenance costs. Our new
Flow Control body is designed to make the
truck platform safer, by discharging the
coal in a metered fashion, making the
Some
operations
go with
disposable
truck bodies
... and more
often than
not, the
bodies
outlived
their
intended
lifespan
considerably
advertiser
113,115-117,119,121-122,124,127-128,130-132MM1209.indd 117
20/08/2012 11:53
T H E EVO LU T I O N O F M I N I N G
Its time to move on. The future belongs to the smarter. The smaller.
The ones that get the job done, but with less fuel, fewer parts and
fewer problems. The ones that will deliver higher availability, increased
productivity and better protability. Welcome to a new era of mining
solutions at scania.com/mining. Or see us at MineEx po, stand 17210,
Silver lot, Las Vegas Convent ion Center, 24-26 September 2012.
h_SCAN176_Ad_B_Mining_Magazine_275x200mm.indd 1
2012-07-13 15:03
119
Bodies
need to be
specific to
the purpose
and the
operation
are too big to fall through the bars, they exit the
tray with a tumbling motion during dumping,
rather than sliding along the floor; a tumbling
rock creates less wear than a sliding rock, and
SSAB says the wear rate can be reduced by
30-40% compared with a flat plate.
SSAB has launched WearCalc2.0, an
application that calculates the relative service life
of abrasion-resistant spare parts. Combined with
a comparison of material and production costs,
the application allows quick selection of optimum
wear materials. It predicts erosive and impact
wear as well as sliding wear for all types of
Hardox wear plate.
Hardox
www.
.com
NanoSteel
The NanoSteel Co has developed the NanoSteel
SHS 9700 Wear Plate, which it claims provides
400% more wear life than 500 Brinell steel plates
in mining applications.
The company provided a monolithic
NanoSteel SHS 9700 overlay wear plate for
testing to a hard rock mine in southwest US. The
mines 240t trucks were transporting ore from an
electric shovel to a primary crusher, and the 500
Brinell quench and tempered wear plates used to
line the truck beds were lasting an average 12
months due to severe sliding abrasion.
The NanoSteel wear plate remained in service
after 48 months and after hauling more than
10Mt of ore. An ultrasonic inspection of the plate
at 48 months showed 40% of the original 6mm
overlay thickness remaining.
Astralloy
AstraWear 400F is produced by Astralloy, a
subsidiary of Arcelor Mittal. It is a water-tempered martensitic steel, with typical hardness of
400 BHN. Its resistance, high hardness and high
yield strength make AstraWear 400F suitable for
use in applications that require resistance to wear
from scraping or moderate impact.
Astralloy says that AstraWear 400F is
especially suited for mining, quarrying and
construction applications, as it allows a significant
reduction in design thickness, and is up to three
times more resistant than standard steels.
September 2012
113,115-117,119,121-122,124,127-128,130-132MM1209.indd 119
20/08/2012 11:54
MINExpo 2012
in Las Vegas
Las Vegas Convention Center
Central Hall, Booth 7627
September 24-26
www.liebherr.com
The Group
121
Every mine
has its own
challenges
and needs a
truck body
that is
customised
for that
application
advertiser
sleipner.fi
sleipner@sleipner.fi
113,115-117,119,121-122,124,127-128,130-132MM1209.indd 121
20/08/2012 11:54
Komatsu
designs and
manufactures all
its truck body
parts in-house.
This photo shows
a 960E model in
action
OEMs
KOMATSU
There are
obvious
benefits to
purchasing
a Komatsu
haul truck
equipped
with an
OEMdesigned
body
A Cat 789C
with gateless
coal body
CATERPILLAR
Caterpillar offers a selection of bodies for
its trucks. We have a specific configuration for every mine site using our bodies,
says Mr Llano. We have lightweight,
payload-focused bodies,
heavier, more
September 2012
113,115-117,119,121-122,124,127-128,130-132MM1209.indd 122
www.
.com
20/08/2012 11:54
A Cat 793F
dumps 250t of
rock waste
We see
customers
moving
away from
heavy-duty
bodies
toward a
lightweight,
payloadfocused
solution
Hitachi truck
bodies are
customised for
each customers
needs
Hitachi
Hitachi offers a range of body designs for
its trucks, including: lightweight, standard
bodies with liners, and approved
third-party designs from DT HiLoad,
Westec and Sebba. Nearly all Hitachi
bodies are custom designed for
customer-specific applications.
The companys own bodies are
designed in-house and built at Hitachi
factories or by fabricators close to their
point of sale. Most are built using 400 to
450 BHN steel.
Some of Hitachis primary markets for
truck sales include: Australia, Colombia,
Indonesia, South Africa, the US and
Zambia. Trucks can be purchased with or
without bodies, or can be fitted with
third-party-designed bodies on request.
Hitachi recently supplied trucks with
DT-Hiload bodies to the BHP-Anglo American- Xstrata Cerrejon coal mine in
Independents
September 2012
113,115-117,119,121-122,124,127-128,130-132MM1209.indd 124
www.
.com
20/08/2012 11:54
M
bo INE Co
ot xp me
h o a
#4 In nd
06 ter se
3, na e u
Ce tio s a
nt na t
ra l 2
lH 0
al 12
l!
SSAB Americas
Pittsburgh, PA - USA
T + 1 4 12 26 9 3 231
contactusa@ssab.com
Montral, QC - Canada
T +1 514 364 1752
Vancouver, B C - C anada
T +1 604 526 3700
contactcanada@ssab.com
Monterrey, Mex ico
T +52 81 8192 9130
contactmexico@ssab.com
Lima, Peru
T +51 1 242 1700
contactperu@ssab.com
Santiago, Chile
T + 56 2 9633580
contactchile@ssab.com
So Paulo, B razil
T +55 11 3 303 0800
contactbrazil@ssab.com
www.hardox.com
SSAB_Miningmagazine_8-13-2012.indd 1
8/13/2012 4:36:34 PM
www.ruukki.com/specialsteels
EVOLUTION
IS MORE
THAN
JUST
A THEORY.
Are you ready for the next product generation?
Do you believe in ultimate endurance? We do. Everything
can be evolved. For example, by switching to Raex steel with
superior wear resistance you could reach longer lifetime than
ever.
Together lets turn your evolution from theory into practice.
ABRASION
RESISTANT
STEEL
ESCO
ESCO currently offers three truck body
designs for the coal market: Dirt Boss,
Coal Boss and Combination. These can be
designed to fit any off-highway truck from
54t to 363t.
ESCOs truck bodies are differentiated
from standard OEM options in that they
are consistently about 1t lighter, and
address a customers specific production
problem, says Mr Raynor. For example,
ESCOs truck bodies are designed with a
curved sidewall and floor interface using
mine-specific material and productivity
data to minimise carry-back. The bodies
are also designed to function correctly
with on-site loading tools and optimise
the full capacity of the truck.
ESCOs bodies are built from
high-quality quenched and tempered
steel. AR500 steel plates are used for
internal surfaces, and ASTM A514 steel is
used for all structural components; ESCO
says its customers usually defer to its
experts to determine the type of steel
used. The company also provides a
warranty to bolster its material selection.
ESCO truck bodies are created by
ESCO engineers and by an outside
engineering firm with ESCO oversight. Mr
Raynor adds: The bodies are fabricated
utilising both internal and external
www.
.com
127
DT HiLoad truck
bodies being
assembled
before being
delivered to
customers
Mine Rite
Mine Rite has a variety of truck bodies for
applications including: overburden, ore,
coal, fly ash, oil sand, sand and gravel. Its
patented Tube-box truck body design
features steel tubing for all of the external
structure, rather than forming and
bending plate steel.
The company says that this offers a
number of advantages, such as not being
ESCOs
truck bodies
are differentiated from
standard
OEM options
in that they
are about 1t
lighter, and
address a
customers
specific
production
problem
An ESCO truck
body hauling
coal. Coal bodies
are usually wider,
longer and taller
than standard
designs
September 2012
113,115-117,119,121-122,124,127-128,130-132MM1209.indd 127
20/08/2012 11:55
Trinitys TMAX
body on a
Komatsu 930E
haul truck
Trinity Mining
Trinity Mining designs and fabricates
bodies for haul truck chassis of 90-363t
payload ratings. All TMAX bodies are
Above:
carry-back
before
applying
MRA
Right: after
applying
MRA carryback is
eliminated
VR Steel
VR Steel designs each truck body
according to the requirements of its
customers. We optimise the payload
keeping in mind the load body weight, life
expectancy, and materials transported,
says Mr van Reenen. We are the only
company in the world offering a minimum
15,000h maintenance warranty. We use
different steels to get to the maximum
payload, but have not used any coatings,
and our design does not require any wear
attachments. Our unique design and
advanced manufacturing techniques are
the rason we can offer long periods
between maintenance intervals.
September 2012
113,115-117,119,121-122,124,127-128,130-132MM1209.indd 128
www.
.com
20/08/2012 11:55
Visit us at MINExpo
p 2012
Unveiling our
NEMISYS lip
system at
MINExpo 2012!
EXPERIENCE INNOVATION
Join us at MINExpo as we unveil our latest products and services. From material
extraction to hauling and processing, ESCO offers a field-proven range of blades,
crusher wear parts, lip systems, ground engaging tools, attachments, truck bodies,
underground mining wear parts, and wear management services. Visit booth C4209
and see why ESCO is trusted at safe and productive mines worldwide.
www.escocorp.com
ESCO.indd 1
19/07/2012 15:04
Left: VR Steel
offers a 15,000h
guarantee for its
haul truck bodies
Right: PHILs new
body lifting
system. Inset:
hydrophobic
steel can be
added to PHIL
bodies to cut
carry-back
PHILIPPI-HAGENBUCH
PHIL began producing lightweight coal
bodies in the 1970s and has since
expanded its product range to include
gated and gateless bodies for hauling oil
sands, iron ore, gold, copper, coal, scrap
steel and radioactive materials.
Mr Swank says: PHIL has applied for
13 patents since MINExpo 2008, with an
additional eight patents having been
issued. Milestones in the past four years
include the introduction of an oil sands
body and our hard-rock body.
The company has also introduced a new
Body Lifting System that is supplied
advertiser
SEE A BRAKE AT
Central Hall Booth 5433
113,115-117,119,121-122,124,127-128,130-132MM1209.indd 130
20/08/2012 11:55
131
Duratray
Duratray manufactures Suspended Dump
Bodies (SDB) of 30-380t capacity with
flexible rubber components for mining
trucks. The rubber offers benefits in
carry-back reduction and increased wear
resistance, and reduces the load shock to
operators, as well as environmental noise.
The SDB comes in a number of
configurations with optional liner packages
on the side and front walls, and canopy/
headboard liners are offered in addition to
steel side liners. The company says that the
most common configuration selected by
clients is the optional front rubber liner.
Bodies are designed in-house and can
be delivered as modules, halves or whole.
The location of manufacture depends on
the mines location, logistics and the
delivery model selected by the client.
Duratray has appointed several steel
component fabricators worldwide, but
always sources rubber parts from its
factories in Melbourne, Perth and
Antofagasta. Assembly can be undertaken
in several ways according to the tray
capacity, location and transport restrictions.
Duratray can also work with OEMs to
supply SDBs for new trucks, customising
the body according to mine conditions,
truck fittings and clients requests.
The company says new bodies are
advertiser
113,115-117,119,121-122,124,127-128,130-132MM1209.indd 131
Duratrays
Suspended
Dump Body
design
20/08/2012 11:55
Westechs record-breaking
T282C Flow Control Body, the
worlds largest truck body
advertiser
113,115-117,119,121-122,124,127-128,130-132MM1209.indd 132
20/08/2012 11:56