Project overview
Mining haul cars operating at the open-pit mine are subjected to significant impact during every working cycle. When the excavator dumps rock and overburden into the car body, the floor directly receives high impact loads. When the car is tilted to discharge material, the side walls are subjected to friction against the material stream. The car body also experiences dynamic loads, vibration and deformation while travelling over uneven mine roads.
According to the technical proposal, the existing structure uses 16 mm-thick steel for the floor and 10 mm-thick steel for the side walls. After a period of operation, the car body showed wear, thinning and deformation, requiring frequent repairs during the working cycle. In severe cases, this could lead to floor damage and material spillage.
Based on the working conditions of each area, GAC proposed dividing the car body into different material zones instead of using a single steel grade throughout the entire structure. Hardox 500 TUF was specified for the floor, where direct abrasion and impact occur, while Perform 700 was used for the side walls, where the main requirements are structural load-bearing capacity, vibration resistance and deformation control.
Customer challenges
Car floor subjected to severe impact
Rock and overburden from the excavator bucket directly impact the car floor, generating high structural loads
Floor wear during unloading
Sharp-edged rock slides over the surface during unloading, continuously causing abrasive wear on the car floor
Car side walls subjected to dynamic loads
The side walls are exposed to dynamic loads from rock, vibration and deformation while the vehicle travels over uneven mine roads
Increased repair time
When the floor and side walls become damaged, welding repairs are required, increasing maintenance time during operation
CURRENT CONDITION OF THE WORN AND DEFORMED CAR FLOOR
The car floor was damaged due to continuous impact and friction from rock during transportation
PROJECT OBJECTIVES
IMPROVE ABRASION AND IMPACT RESISTANCE
Select suitable materials for the car floor to withstand simultaneous abrasive wear and heavy impact from rock and overburden
IMPROVE THE DURABILITY OF THE CAR SIDE WALLS
Use high-strength steel for the side walls to withstand dynamic loads and deformation under mining operating conditions
REDUCE HAUL CAR REPAIRS
Extend the service cycle of the car body components, thereby reducing vehicle downtime for repairs
Construction process
Analyze each working zone
GAC separated the car floor and side walls according to their respective load mechanisms, abrasion conditions and impact levels
Select Hardox 500 TUF
Hardox 500 TUF was proposed for the car floor, which is directly exposed to abrasive wear and impact from rock
Select Perform 700
Perform 700 was specified for the car side walls to meet dynamic load-bearing and structural requirements
Optimize material thickness
The proposed solution uses 15 mm-thick Hardox 500 TUF for the car floor and 8 mm-thick Perform 700 for the side walls
Arrange a comparative test
The proposed materials and the existing materials were arranged in separate test zones on HD785 mining haul cars for comparison under actual mining conditions
Project results
COMPLETED 5,927 TEST HAUL CYCLES
CAT 777E haul truck No. 937 completed 5,927 haul cycles over 7 months, with a total transported load of 1,939,607 ton-km
HARDOX 500 TUF WEAR LOSS: 3.2 MM
From an initial thickness of 16 mm, the Hardox 500 TUF plate retained approximately 12.8 mm after the test period
SURFACE REMAINED FLAT AND FREE FROM DEFORMATION
After 7 months, the Hardox 500 TUF section was recorded with a smooth, even surface, without warping or deformation
“We highly appreciate Gia Anh’s professional expertise and implementation capabilities. The construction process was carried out in accordance with the required procedures and technical standards, helping Kalenborn monitor and evaluate the installation quality.”
Ms. Tran Truong Phuong
Project Management Board - Deo Nai – Coc Sau Coal
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