Austin Engineering innovates large mining trucks with Hardox 500 Tuf

Austin Engineering breaks the mold on every project, bringing one-of-a-kind mining truck equipment and solutions to forward-thinking operations. So, it’s no surprise they develop tough, long-lasting mining haul truck bodies using Hardox^® wear plate.

Nearly half a century ago, some of the largest mining trucks rumbled along as mega heavyweights in their class, hauling a mere 91 tonnes (100 tons) and often fashioned from 690 MPa (100ksi) yield strength steel. Any kind of redesign project to lighten up these inefficient haulers got sidelined by conventional thinking, and not many attempts could be made to challenge payload capacities without drastically tipping the scales.

The sheer weight from bulky steels required to handle loads safely contributed to the girth of these dump trucks for mining. Then, to extend service life, engineers had to add a hefty helping of abrasion resistant (AR) steel liners fitted to cradle gritty mining media like slurries of granite, quartz and sand or just boulders, rocks and stone. Plus, using conventional AR steel plate meant long days in the workshop dealing with brittleness, cracking and inconsistencies along with poor forming and welding properties.

These factors restricted meaningful truck configuration innovations until the 1980’s. That’s when WESTECH, now known as Austin Engineering, designed and built their first Hardox 400 steel plates into a liner application.

First to market, first to lead in mining truck and equipment advances

Initially, Austin noticed the ease of working with Hardox wear plate in the workshop when compared to what they had specified over the years. This inspired the company’s Global Engineering Manager, Rick Reynolds, to take a bold step and design the body’s main plates with Hardox 400, thereby eliminating the original 690 MPa (100 ksi) material. This allowed Austin to dramatically reduce truck body weight and immediately increase payload.

“That move was a huge success and really accelerated the migration from very heavy, inefficient equipment to lighter weight, more efficient equipment,” Reynolds explains. “Austin was the first in the industry to make that move. And as pioneers in designing mining trucks and equipment, we chose to partner with SSAB to drive innovation together.”

Extreme hardness and guaranteed toughness for large mining trucks

Hardox 500 Tuf features excellent weldability, formability and impact toughness, delivering high strength, extreme hardness and guaranteed toughness in a single wear plate – a perfect fit for the rigorous mining industry.

Today, Austin uses Hardox 500 Tuf in a variety of large mining trucks and applications and is able to reduce the weight of components by as much as 25% without sacrificing the wear life of the components. In other cases, Austin can offer extended life as much as 25% without increasing the weight.

“We currently have bodies made with Hardox 500 Tuf in three strategic areas of North America in applications ranging from the coldest environments to those withstanding relentless and severe impacts. We are also introducing designs utilizing Hardox 500 Tuf into Australia and South America,” Reynolds says. “To date, we have seen nothing but success in these applications. With SSAB’s help, we will continue to drive the industry forward and work together to develop tomorrow’s innovative solutions.”

Custom projects equal custom processes

While mine operators enjoy the benefits of custom equipment manufacturing, ensuring the material flow can be tricky at times with the challenge to keep production moving at break-neck speeds. Testing new steels may seem like a daunting task when the outcome could mean stalled material transports and costly downtime, especially when it involves a newly designed mining truck or other piece of equipment.

“Each mine site has unique materials and conditions requiring equally unique equipment designs. It’s truly a pleasure to deliver a one-of-a-kind vehicle to a customer that meets their exact needs,” explains Austin’s Johnny Greer, Supply Chain Manager, Americas. “At Austin, we don’t wait to see what the steel industry may come up with. So, our design concepts became reality when SSAB responded to our request to develop a tougher grade of AR500 material. Working with SSAB affords us the opportunity to continuously provide innovative designs that deliver improved performance and consistent quality and that were previously thought to be impossible.”

Austin entered Guinness World Records in 2012 with its Westech T282C Flow Control Body as the largest mining truck body by volume of 470.4 cubic meters at a coal density of .86 tons/m³. It was presented and measured at the North Antelope Rochelle Mine, Wyoming on June 14, 2011.

Mining truck equipment constantly evolving

Austin Engineering globally manufactures customized dump truck bodies, buckets, water tanks, tire handlers and other ancillary products used in the worldwide mining industry. The company also provides on- and off-site repair and maintenance to its customers. According to Austin, the evolution will continue. Mines all over the world can rely on more efficient production thanks in part to project customization and avant-garde engineers like Reynolds.

“As long as there are new materials featuring benefits that improve performance, efficiency and even safety, we’ll continue to test them in new projects,” Reynolds says. “We’re focused on solving the challenges that our mine operators bring to the table using every aspect of the project to deliver success. For example, our Flow Control Body^™ with its unique, patented floor design and material usage demonstrates how we’ve repeatedly delivered customized equipment that continue to be the industry standard. We expect that Hardox 500 Tuf will help keep us out front, which is where we always want to be.”

Get an upgrading consultation

Find out what upgrading to Hardox 500 Tuf can do for your mining equipment and your mine operations. We’ll be happy to meet you and find out about your specific wear environment and needs to find the best and most cost-effective solution for your business.

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