Revolutionary wheel gains traction: A real-world solution to mining’s costly tyre problem

One of the toughest operational challenges for mining companies has long been the cost, safety risks, and environmental burden associated with off-the-road (OTR) rubber tyres.

Tyres, fuel, and payroll are the three largest expenses for mining companies. Tyres wear out quickly under punishing conditions, are prone to overheating, and create long-term disposal liabilities.

Global Air Cylinder Wheels® (GACW) believe that this problem demands more than incremental improvements. It requires a fundamental reinvention. That is why they developed the patented Air Suspension Wheel (ASW): a durable, sustainable, non-pneumatic wheel designed to meet the extreme demands of the mining industry.

The ASW is a mechanical wheel constructed primarily of steel, integrating in-wheel suspension and damping via nitrogen-filled air cylinders and dampers. Unlike traditional rubber tyres, the ASW eliminates the risk of blowouts or overheating and dramatically reduces the waste associated with tyre disposal. Think of it as the wheel of the future – available today. The advantages for the mining sector are extensive:

• Durability: Designed to last the lifespan of the vehicle.
• Safety: Eliminates the risk of overheating or explosion.
• Sustainability: 100% rebuildable and recyclable, with replaceable treads reducing waste.
• Adaptable: The mechanical wheel design can be adjusted to the payload, speed, sideload, size, weight, and other requirements.
• Cost Savings: Potential for up to 60% lower total cost of ownership than traditional tyres.
• Time Savings: Individual treads can be replaced without removing the wheel, a time-consuming process that takes up to eight hours with OTR rubber tires.
• Environmental Impact: Reduces microplastic pollution, landfill waste, and emissions.
• Fuel Saving: Due to the reduced rolling resistance, the ASW also saves on fuel.

GACW's technology is no longer just a vision – it is proving itself in the field. In May 2025, GACW successfully raised US$1.47 million through Dealmaker to fund the fabrication and delivery of ASWs for an ongoing trial with a major US-based iron ore mining company. Early results are encouraging, and the trial is expected to conclude later this year, marking a pivotal milestone as the company transitions from R&D to full commercialisation.

The industry response has also been strong – GACW has already received more than US$6 million in anticipated purchase orders from six mining companies in the US, Canada, and Australia. They have also generated approximately US$4 million in revenue from industry contracts and trials. To accelerate adoption, GACW recently launched its third equity crowdfunding campaign on StartEngine, aiming to raise US$3.2 million under Regulation CF. This campaign, the fifth Regulation CF raise overall, is part of a broader, board-approved plan to secure up to US$15 million over the next 18 months.

These funds will expand production capacity, strengthen the company's patent portfolio, and scale operations globally. They will also pursue a complementary Regulation A+ offering to support additional growth. At the same time, GACW is in advanced discussions with multiple investment groups regarding potential strategic investments, reflecting the strong confidence in their business model and technology.

GACW’s mission is to deliver a safer, more cost-effective, and environmentally sustainable wheel that meets the demands of modern mining operations. With over 75 issued patents and more than 120 pending worldwide, the company is building a defensible market position in a US$30 billion OTR tyre sector. For mining operators, the opportunity is clear. GACW estimates that initial fleet orders for a single large mine could reach in excess of US$70 million, reflecting both the economic and environmental benefits of adopting the ASW at scale.

As mining companies face mounting cost pressures, regulatory scrutiny, and ESG expectations, solutions like the ASW are not optional, they are essential. GACW is committed to working closely with mining operators to deliver tangible results of reducing costs, increasing safety, and dramatically cutting environmental harm.

With their funding strategy, growing pipeline of purchase orders, and ongoing trials, GACW is well-positioned to make the Air Suspension Wheel the new standard for mining and beyond. 

Read the article online at: https://www.globalminingreview.com/mining/04092025/revolutionary-wheel-gains-traction-a-real-world-solution-to-minings-costly-tyre-problem/