Steep grades ahead. The mining truck market is as difficult a MINING TRUCKS

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1 Steep grades ahead Paul Moore looks again at the global mining truck market, including the role of consultants and as always news on the Chinese situation The mining truck market is as difficult a situation as any other sector in equipment supply due to the current low commodity price situation, not least continued drops in iron ore prices, in what is already a fairly small market globally relatively speaking not least for the largest mining trucks. In addition, rather than buying new fleets, mines are finding ways to keep their existing fleets running as long as they can; part of the trend of sweating assets that has been often referred to in recent years in IM. That said there are always some interesting trends. There are more trolley assist projects being advanced than there have been in many years from Kevitsa to Sentinel to expansion of trolley at Sishen as well as others. The current global trolley assist mines operating or in development include Sishen (iron ore, South Africa: Komatsu 730E, 860E, 960E); Sentinel (copper, Zambia: Komatsu 860E, 960E); Kansanshi (copper, Zambia: Hitachi EH3500AC); Exxaro Grootegeluk (coal, South Africa: Hitachi EH4500); Kisladag (gold, Turkey: Hitachi EH4000AC3); Husab (uranium, Namibia: Komatsu 960E); Kevitsa (gold, Finland: Caterpillar 795F AC); and Lumwana (copper, Zambia: Hitachi EH3500). This of course relates to rising diesel prices versus cheap power in certain parts of the world but also the emergence of mining companies willing to go forward with technologies and lacking the conservatism of others. Truck OEMs themselves are changing too. The Chinese players, notably the likes of NHL, XCMG, Liugong and XEMC; are all getting more established both within China and NHL continues to be one of the most successful mining truck companies in China, now also through its own NTE branded machines internationally; while there are other players with more uncertain futures but which nevertheless have managed to produce machines. The wait continues for the European Truck Factory (ETF) trucks to be commissioned. There have been delays due to the complex nature of the project and the fact that it is the first complete machine, but the first MT240 truck is now 95% complete (see photo) and will be shipped to the launch customer Vale in Brazil this year. Thereafter, the Maribor, Slovenia facility will be used to assemble the major components with final assembly at customer sites. As previously stated in IM, the trucks will ETF s MT t truck finally nearing completion in Maribor, to be delivered to Vale 00 International Mining MAY 2015

2 in future be offered as part of an integrated haulage contract by ETF. Hitachi and Liebherr are progressing with integration of more of their own components in their trucks, with Hitachi AC drives and Liebherr Litronic AC drives both now being used on their mining trucks. Caterpillar is pressing ahead on a number of fronts, both with autonomy, the new MT5300D AC drive truck and a trolley version of the 795F AC truck; in addition to developing authorised modification processes for used Cat Tier 4 Interim products that require modification for operation outside of Highly Regulated Countries (HRCs), where the products were originally manufactured to operate. Manufacturer updates While the market leaders are still Caterpillar and Komatsu by some distance in terms of the installed base, the other players continue to increase their influence. Hitachi continues to expand its presence in the mining truck market and maintains its range from either the HCM (Japan) or HTM (Canada) facilities, depending upon market demand moving forward. A notable success area has been in Turkey, where Tuprag s Kisladag gold mine now has ten trolley ready EH4000AC3 trucks running with a Hitachi EX5600 electric hydraulic excavator and two EX3600 diesel hydraulic excavators. A source at Tuprag in Turkey stated: The fuel economy of these EH4000AC3 trucks has far and away exceeded our expectations. More recently, the Celikler coal mine has purchased ten EH3500AC3 trucks with heated bodies. Greg Smith, General Manager, Mining Support Group at Hitachi told IM: Due to the introduction of various fleets of Hitachi AC Drive rigid dump trucks into extreme cold weather climates, there have been some upgrades to the Cold Weather Packages implemented by the Continuous Improvement Team. Those particular sites are experiencing temperatures down to - 50 C. Operator comfort is a very high priority in design targets and concepts. The new Hitachi truck ranges, both the ACII and AC3 models have been very successful. Over 350 units of the EH3500AC and EH4000AC trucks are now in operation in what has been a relatively short period of time. The AC3 models are the result of the introduction of the Hitachi drive control system technologies that were able to be proven and incorporated into the base unit, in a relatively short period of time, as well as the availability of optional engines, with the customer able to now opt for Cummins or MTU. Smith adds: One of the great advantages of the AC drive technology and its implementation to the mining rigid dump truck market is the endless scope and opportunity to improve the product as technological advancements are invented, created, tested and proven. The performance gap over the mechanical drive truck will continue to grow; only getting bigger, year after year. One customer stated: Uphill loaded speed of the Hitachi trucks is extraordinary. The old mechanical trucks just do not compare On progress with the automation project at the Meandu mine, Smith comments: The progress is extremely positive and meeting the primary scheduled milestones for the critical functionality KPIs. Unfortunately, the AHS development is a highly proprietary initiative by Hitachi and it is not open for public. However, HCM is aware of the extremely high interest in the project and will be revealing an informative update media release regarding the AHS in the second half of Caterpillar continues to offer both mechanical and electric drive solutions in the large capacity mining truck world. John Ingle, Cat Mining Truck Marketing Manager commented to IM: "With the now complete and successful pilot program, Caterpillar has begun a worldwide controlled introduction of the MT5300D AC." Controlled means that the truck won't necessarily be available for a while in some regions but an announcement later in 2015 will be made when the truck is widely available. One roll out dealer is Hastings Deering in eastern Australia, where Managing Director, Dean Mehmet, said: Our MT5300 ultra-class mining truck has demonstrated a measured 7,000 h/yr production reliability. This is significantly above standard industry averages. The new truck has been developed in response to customer demand for 290 t payload haulage but comes packed with additional features. In response to progress on the 795F AC trolley assist program Ingle told IM that: "Caterpillar is working with specific customers to implement the trolley-capable 795F AC into a mine site." First Quantum has stated publicly that it is Hitachi has seen marked success with the EH3500AC and EH4000AC due to Hitachi drive performance working with Caterpillar on a trolley assist project at the Kevitsa operation in Finland but this is still at an early stage. Autonomy wise, the two trials at iron ore mining operations with BHP Billiton at Wheelarra 4 with six Caterpillar 793F trucks and at Jimblebar next door with another six 793F produced very positive results and the trucks continue to work at both sites, where it is possible to make close comparisons with the manned trucks that work alongside them. At FMG Solomon Hub, Caterpillar now has over F trucks operating of a final total that is planned at 45. FMG has stated in its 2014 annual report: The trial of autonomous trucks at Solomon has demonstrated that the technology is suitable for deployment across the Firetail and Kings Valley projects. Also in Australia, Rio Tinto currently has 57 autonomous Komatsu 930E-AT trucks operating across three iron ore mine sites at Yandicoogina (13), Nammuldi (28) and Hope Downs 4 (16). Michael Gollschewski, Managing Director Pilbara Mines told IM: Automated trucks and drills are able to operate for longer periods within each shift resulting in a higher effective utilisation. The major drivers include elimination of crib, breaks, absenteeism and shift change. This more than offsets the inherent requirements of automation, such as, longer daily inspections on technology hardware and potential downtime due to GPS signal issues, which are very infrequent. This higher effective utilisation results in a reduction in fleet size and lower capital requirement to sustain a site and meet plan. Automation in mining has seen a 13% decrease in load and haul costs and a 10% reduction in drilling cost. Rio Tinto said that it decides to invest in technology based on a combination of internal 00 International Mining JANUARY 2015

3 launched its Invertex 200T AC Electric Drive System for heavy-haul surface mining trucks. This system is designed for optimal weight and durability and provides a best-in-class mix of payload, on-grade, top end and retarding speeds for the 200 t mining truck class. The 200T drive system exemplifies our commitment to develop leading technology that delivers productivity for the mining industry. Its integrated system and advanced control takes wheel-motor performance to the next level and reduces life cycle cost for mine operators. Komatsu now has 57 autonomous trucks running in the Pilbara across three sites and external research and is looking to deliver real improvements in safety, reliability and efficiency. It makes for only very minor and less frequent deviations from plans and schedules; and allows people to focus on more strategic business decision while machines do the work. Technologies such as autonomous trucks, drills, train dumpers, stackers and reclaimers significantly reduce employee exposure to hazards and risks associated with operating heavy equipment, such as fatigue related incidents, particularly on night shift, and also sprains, strains and other soft tissue injuries. Drive systems IM spoke with General Manager of the General Electric Propulsion Systems Business, Gagan Sood on the latest GE offerings for mining truck drives. Field-proven AC and DC electric drive systems for surface-mining haul trucks have been supplied by GE s Mining business since 1963 and approximately 13,000 systems have been delivered worldwide, representing 700+ million hours of operation. GE s Mining business introduced AC motorised systems for mining trucks in 1996, and to date it has delivered more than 3,500 systems and 185 million operating hours of operation. GE s Mining business supplies complete electric drive systems and technologies for surface-mining haul trucks larger than 150 t applications. Sood comments: These proven drive systems are capable of withstanding the harshest conditions, such as in terms of high tractive effort, as well as environments, such as ambient temperature and altitude extremes. We service multiple OEMs across regions and segments. This includes both the established players like Komatsu but also the emerging players like XEMC. These rugged drive systems enable mines to improve operating cost per tonne by eliminating or reducing wearing components like torque Consulting creativity Paul Moore spoke to Chris Althausen, Director of converters, drive shafts, transmissions, differentials and bearings that demand higher maintenance intervals and costs; offering higher on-grade, top and retarding speeds to shorten cycle time; delivering fuel savings and productivity, and improving truck availability and life cycle costs. Working with its OEM partners, GE recently launched a series of aftermarket products to help customers increase Mean Time Between Overhauls (MTBO), reduce fuel consumption, and improve performance of existing mining trucks. Some of these products include Fuel Saver, which in certain instances has proven to reduce fuel consumption by 5%; Contactor Eliminator, which replaces mechanical contactor tips with solid state switching device improving reliability and reducing LCC; and J Grids, which improve performance and life cycle costs of retarder grids. As part of the Internet of Things GE is also better connecting machines, data and people so that they can perform better, faster, safer, and more reliably. GE calls this the Industrial Internet, and is leveraging its RM&D expertise, supported by its Industrial Internet, already evolved Sales & Marketing at Pioneer Solutions LLC, a leading specialist engineering consultancy specialising in mining trucks, about its scope of work. Generally speaking the company has three main offering areas in its business. The first of these is engineering services consultancy. This includes high level concept engineering for mining trucks as well as field issue resolution. Mining truck OEMs place new trucks in customer fleets or test mines for field following testing; and often there are teething problems in terms of componentry malfunction or failure. For the established mature market OEM, Pioneer tends to assist their already existing design team with some aspect of design troubleshooting, often where they do not have enough manpower for that particular project. An example of this would be re-engineering of the truck chassis due to the incorporation of Tier 4 engines. Another example would be helping the key suppliers of LNG solutions for mining trucks retrofit the LNG tank and other components onto an existing truck design and ensure the truck is able to through extensive Oil cooled brake design from attach and hold experience over 10 years in railroad operations on more Pioneer Solutions LLC them safely. However, for developing than 15,000 machines, to reduce life cycle costs and improve availability of mining assets. The Invertex II is a state-of-the-art control system that is now available for all GE drive systems. This control system has much greater processing capability for data transfer and high speed control. The open architecture of this system makes it very flexible and scalable for future enhancements and integrating third party upgrades. The system is able to achieve all of the above with fewer cards and components, making it best in class in terms of reliability. GE in 2012 world OEMs, where Pioneer has many customers in China, India and elsewhere, this consultancy work is often much broader incorporating a much greater area of Pioneer s mining truck product knowledge and experience. They may have built a complete mining truck based on work done by a national design institute or university. And while often the powertrain and drives are fairly standard as they are buying from established suppliers, but in areas such as the drive axle and differential planetary drives; the truck frame/chassis design; and understanding shear 00 International Mining MAY 2015

4 forces in steering these emerging market players need help to get it right. Pioneer has spent a lot of time ironing out serious flaws that would be safety issues if not addressed. In other cases, Pioneer may take on much more of the development work, and in one cases they did 85% of a 200 t mining truck design for a company. This was essentially a clean sheet development including much of the initial concept and layout as well as structural, axle and hydraulic work. The second major area of business for Pioneer is actual manufactured components; as the company has its own in-house oil cooled disc brakes that it has developed and makes. These are sold to Chinese OEMs as well who are worried about safety issues with braking of large capacity mining trucks. If you buy an electric drive system from Siemens or GE you will still need an oil cooled brake on the rear and the new OEMs without a supplier in place want one that is proven and safe. In addition these OEMs often lack the knowledge and experience to do the necessary baseline/benchmark testing to get it to global industry standards; so testing is the third major area of work for Pioneer, as it has people with testing engineering experience. This includes strain gauges, pressure transducers; ROPS/FOPS and mobile testing rigs as well as overall test program planning. It ensures for emerging market OEMs that they have designed their trucks correctly for the conditions the truck is to be used in; with factory testing before it actually goes out into the market. This can include new brake installs to ISO 3450 certification. ROPS/FOPS testing is governed by two ISO standards, once of which involves a physical destructive certification where a cab has to be destroyed to show its point of failure. This involves a lot of components to set up the test, not to mention a lot of time and expense. Pioneer has a good record of not only setting up the test but also predicting if the cab will pass first time, therefore saving the OEM a lot of investment. Another player in this market is Off-Highway Engineering Inc (OHE) which primarily provides mining truck engineering design services. Mark Viau, General Manager Mechanical Engineering told IM: There is an ocean of engineering consultancy firms in the surface mining industry but there are only a few that can design a complete mining truck. Currently the company is working on the re-design of a 190 t truck for an OEM. The first and critical part of the project is determining the interface points between the truck chassis and struts, linkages, rear axle and front wheel groups. The forces that a truck frame will see can be greatly reduced if care is taken when choosing where linkages attach and which geometry is used. In this industry there are several ways the chassis is suspended by the front wheels and rear axle. OHE is using a proprietary method to suspend the truck chassis that dramatically reduces frame loads. We have two different patents in the provisional patent stage that accomplish this. The result is a lighter truck and more importantly a truck than can carry more pay-load on the same tyres as a comparable truck in its class. Our project includes converting complicated weldments into castings and design of the ROPS support. Steering system design is another deliverable from OHE. Steering is designed to have near perfect Ackerman steering at full turn. The front end geometry is being optimised to minimise change in tyre toe-in and minimise tyre scrub during full strut travel. Tyre wear is always a concern. Force extractions are performed using the PTC Creo 2 Mechanism Dynamics Option. A mechanism model of the machine is supported on springs and dampers and subject to different load cases. PTC Creo 2 Simulate is used for FEA analysis. Smaller engineering jobs are also important part of our business. OHE designed the hydraulic and mechanical system for an articulating shop boom and other tools for the tyre shop at a large mine in the Powder River basin. The mining companies often need a professional engineer to assist with mechanical design as compliance with OSHA and MSHA is mandatory. Mines insist on Federal safety compliance and all parties want a safe work environment. Moving forward, OHE says it is looking to work with both OEMs and mining companies wanting to innovate and lower production costs. One of its ongoing R&D development projects is a 10 tyre, 600 t, twin engine, AC drive, tractor-trailer hauler. While still in development the initial numbers are promising. Using AC drives we can put power and dynamic braking to 8 of 10 tyres instead of 4 of 6 on a conventional truck. The result is 20% more traction on grade. Tractortrailer is not a new concept however AC drives make twin engines a more realistic concept. The machine has the same track as a Cat 797. Fuel saving solutions Blutip Power Technologies provides control solutions for saving fuel, improving operations, and reducing emissions of large diesel-powered engines. In December 2014, it announced a New 600 t concept truck from Off Highway Engineering contract for the supply of Blutip s Advanced Universal Controller (AUC) for Anglo American s haul trucks in use at their coal operations in Australia. This agreement was executed after achieving significant fuel savings with Blutip s AUCs on Caterpillar 797, 793, 789 and 785 series haul trucks at Anglo American s Dawson, Capcoal and Drayton mines during The Blutip AUCs provide engine remapping that reduces fuel consumption while at the same time maintaining the power output of the engine and other functionality of the original equipment provider s electronic control unit. The improvement in Anglo American s fuel efficiency through use of the AUC is allowing Anglo American to reduce its carbon footprint as well as reduce particulate matter emissions. Blutip s AUCs also provide data analytic tools that include engine loading time distributions, integrated Global Positioning System (GPS) data and the capability to evaluate other fuel saving initiatives. The Blutip AUCs provide engine remapping that reduces fuel consumption while at the same time maintaining the power output of the engine and other functionality of the original equipment provider s electronic control unit Blutip is very proud to work with a leading mining company like Anglo American and support them in achieving their fuel efficiency objectives, said Chuck Knott, President and CEO of Blutip. We are committed to assisting Anglo American maximize their efficiency by allowing them to reduce the fuel consumed per tonnehour across their fleets and by providing real time fuel management analytic tools. On the new contract moving into 2015 Peter 00 International Mining MAY 2015

5 Carter, Blutip Vice President, Global Sales & Marketing told IM: The Anglo American Metallurgical Coal contracted rollout of our fuel saving solution has been very successful and covers the entire Cat 797, 793 and 789 fleets across the Dawson, Capcoal and Callide mining operations. All three mining operations are saving cash from reduced fuel usage and the subsequent benefits on engine life. Headquartered near Toronto (Mississauga), Ontario, Blutip now has customer installations in Australia, South America and North America with major mining companies. Customers include four of the 12 largest mining companies in the world (six of 12 if JV owners are included) Blutip provides software-driven fuel optimisation and emissions control for large diesel engines. Blutip helps customers reduce fuel consumption by 4 to 10% and eliminate up to 70% of particulate emissions, depending on the engine type, application and utilization parameters. The AUC is a patent pending smart Engine Control Module (ECM) built to plug and play with a specific engine type. It seamlessly integrates with the existing ECM to shift engine characteristics such as timing, torque curve, compression and fuel ratios to increase fuel efficiency &reduce emissions. The BlutipHy-Trend software interface is an integrated engine data streaming and analysis unit which improves efficiency by providing equipment level fuel usage and operational data. It also enables remote monitoring and logging, remote control of operations, internet-based analysis and reporting. OEMs develop engines for numerous applications and environments but do not necessarily optimise them for specific mining applications. Blutip s AUC optimises engine maps for specific applications and effectively monitors and modifies specific signals to the engine control module improving fuel economy but it does not replace the engine control module. Blutip s AUC in conjunction with high precision fuel meters also provide customers with unique fuel data analytics capabilities. Chinese OEMs Getting information on Chinese players is never easy but it is clear that in numeric terms, NHL and XEMC are leading the market currently, with by far the most delivered mining trucks of larger capacities across key operations such as numerous Shenhua coal sites and Jiangxi Copper operations. XEMC has also had the most success internationally, having sold four 230 t SF33901 trucks to Rio Tinto s Mount Tom Price iron ore mine, and in November 2014 having signed a signed a long-term agreement with Rio Tinto for XEMC to supply and service heavy mobile equipment for its global operations. It was the The XDE170 truck from XCMG at work in Inner Mongolia first global agreement Rio Tinto has signed with a Chinese supplier and means that XEMC's mining trucks and other equipment will be used not only at the Tom Price mine but at other mines owned by Rio Tinto. XEMC s range runs up to the SF t model, which is still being tested in Inner Mongolia. NHL s position in the market is complex, as it still offers the Terex brand TR series based on component sourcing from Terex Trucks in Scotland, now part of Volvo CE. NHL s TR series includes the TR35A (32 t); TR50 (45 t); TR60 (55 t) and TR100 (91 t). Then there is the MT series, which developed out of a partnership with Unit Rig, which of course then successively became part of Terex, Bucyrus and now Caterpillar, with whom the nature of any future co-operation is still being worked out, though it has been somewhat complicated with Caterpillar s own relaunch of its own MT4400D AC and MT5300D AC models. So at present, the MT series mining trucks are manufactured both by NHL and Caterpillar but NHL is only offering its MT series in the Chinese market. NHL offers the MT3600AC (172 t) with GE drive; MT3700AC (186 t) with GE drive; MT4400AC (236 t) with GE drive; and MT5500AC (326 t) with PI drive. Then there is a third series of NHL s own branded NTE trucks the NTE150AC (136 t) with GE drive; NTE200AC (186 t) with GE drive; NTE240AC (236 t) with GE drive; NTE240DC (236 t) with GE drive; NTE260AC (236 t) with Siemens drive; and NTE330AC (300 t) with Siemens drive. XCMG, SANY and Liugong also have high quality offerings but have yet to develop the same installed base as they have started making larger models later. XCMGs offering range of mining trucks includes the XDE110, XDE170, XDE240, XDE300 and XDE400. So far one XDE110 and one XDE170 have been sold and both are working in Inner Mongolia and are performing well according to its customers. Liugong offers the SGE150 and SGR50C currently, with SANY HE offering trucks currently up to the SET230, with a 230 t payload and Cummins QSK60-C2500 engine. Other players seem to have only built one or a handful of trucks. These include the 220 t MCC400A and HMTK600B 363 t mining dump truck from MCC (Xiantang) Heavy Industrial Equipment; and the HT t and multi axle HT5220 (also often shown as the WTW 220E) from China Sanjiang Space Group (CSSG) through its subsidiary Wuhan Sanjiang Import & Export Company Limited (WSIEC). There is also the BZK mining truck range, and Guangzhou Electric s CSR-220 (220 t) and CSR-300 (300 t) models. ADT developments The latest, G-Series ADTs build on Volvo CE s technology to offer more to customers in the mining and quarry and aggregates industries. They offer excellent visibility through the front windscreen, side windows and rear door; a patented, simplified load/dump brake interface and an integrated retarder/brake function now combined into one pedal for simplified use. To keep the G-Series haulers stable in even the most difficult job site conditions, Automatic Traction Control (ATC) and unique differential locks are standard. The unique ATC manages drive modes automatically for the operator, optimising performance and fuel efficiency to suit operating conditions. ATC starts in 6x4 drive mode to give high traction, but reduced fuel consumption and tyre wear. If or when additional traction is needed, it seamlessly adjusts to 6x6 drive mode, maximising

6 To keep the G-Series haulers stable in even the most difficult job site conditions, Automatic Traction Control (ATC) and unique differential locks are standard. performance but keeping costs to a minimum. Volvo s patented Full Suspension (FS) option is available on the A35GFS and A40GFS models. Simply, this is a robust, active system that continuously adapts performance to dramatically reduce road input to the chassis. It significantly increases operator comfort and control for shorter cycle times on poor or long haul roads, for higher productivity. As whole body vibration (WBV) regulations come into force in some markets, this Full Suspension feature will become increasingly important. A Volvo designed On-Board Weighing System (OBW), available on both FS and standard hauler models, measures transported loads, providing customers with the ideal solution for monitoring machine productivity. Transported loads are logged in the machine and can be seen on the incab display, together with the number of cycles. This data can also be accessed remotely via Volvo s CareTrack telematics system. The OBW is fully automatic, so requires no operator intervention. OBW is a standard feature for FS models sold in Europe, Africa, Middle East and the Americas. Machine operation is constantly monitored and Volvo s MATRIS system collects this information, helping to optimise performance and fuel efficiency by tracking activity and identifying areas for improvement. In the cab, the Contronics system continuously monitors fluid levels and relays diagnostic information to the operator s screen, providing warning messages and early alerts to any potential problems, reducing downtime and promoting operator safety. G-Series haulers are also designed for safe and easy maintenance, with a front grille that swings down and functions as a service platform, with anti-slip steps. The engine compartment has a 90-degree tilting hood for easy access to filters and service points. The hydraulic tank, aftertreatment system, muffler, fuel tank and refuelling pipe have all been relocated to more intuitive locations, allowing for easier maintenance. The new Caterpillar 735C, 740C EJ, and 745C articulated trucks build on the proven performance, reliability and durability of their B Series predecessors with significant new features. These include engines that meet US EPA Tier 4 Final/EU Stage IV emission standards, new transmissions with expanded electronic control, automatic traction control, automatic retarder control, hill assist and waiting brake systems, and an optional payload weighing system, all aimed at delivering lower costs per tonne by reducing cycle times, saving fuel, and easing the operator's work load. Rated payload capacities for the new models are 32.7, 38, and 41 t, respectively, with all models replacing their B Series predecessors. The new 745C's 1.5 t capacity increase (compared with the 740B's capacity) combines with its faster cycle times for significant production gains. The new 740C EJ ejector model, which combines the 745C's tractor with a horizontaldischarge body, provides added versatility and safety in certain operations. The 740C EJ can unload material to uniform depths while traveling at speed, potentially reducing the need for onsite spreading equipment, and can discharge the load with added stability in soft underfoot conditions, on side slopes and grades, and in environments where overhead obstructions are present. Duratray truck bodies update For the largest gold mine in Western Australia, Duratray has recently supplied a new lightweight steel dump body to complement two suspended dump bodies at the same mine. Designed for 230 t payloads in abrasive hard-rock conditions, the new-generation FX-series body was manufactured in WA in conjunction with Schlam Engineering. The new dump body is light weight for optimum payload yet has design features to reduce impact damage and increase reliability. The body has several design and wear-pack configuration options including anti-collision features, reducing the potential for injury in the event of a vehicle-to-vehicle interaction. While new to the WA market, more than 400 Duratray lightweight steel bodies have been built the majority for ultraclass trucks operating in the copper industry of South America; these are used to maximise payload when the specialised characteristics of the traditional Duratray suspended dump bodies are not required. Duratray FX bodies for 220 t payloads have also been delivered to coal mines in the Bowen Basin, Queensland. Gahcho Kué diamond mine is the largest new mine under development near the region of Yellowknife in Canada. Considered one of the most important projects in the country this mine part of DeBeers group, has purchased Duratray Suspended Dump Bodies for its fleet of Komatsu 830E-1 haul trucks. Negotiated over an 18-month period, the purchase extends a successful tenyear Duratray relationship with large open pit diamond mines in the area around Yellowknife and brings to 50 units the fleet of SDBs in Canadian diamond mines. SDBs that are no longer required by customers due to their mines closing, going underground or buying new trucks but which are still in good condition often continue in service after refurb. Duratray has performed more than ten refurbishments in recent years, obtaining good results in mines across Australia Canada and South Africa. The latest cases are Boddington and Karara operations where second hand trays were acquired by Duratray from other mines, following a rigorous evaluation of the steel frame and rubber kits. Duratray s field service team and local workshops performed a comprehensive refurbishment of three second-hand Suspended Dump Bodies by replacing the rubber mat, suspension ropes and associated spare parts. The trays were re-painted and transported across the country by road from the original users, and finally delivered on site as per customer requirements. IM MAY 2015 International Mining 00