The mining and aggregate space is known for extreme working environments and unique challenges that evolve as sites develop and move forward. To ensure businesses in this segment remain productive and thrive, it is paramount that equipment manufacturers continue to innovate and improve upon their products.
For tyre manufacturers, material science and advanced engineering have been a source of innovation, opening up new avenues for heightened performance that can be tailored to the specific needs of each site.
Mining operations are not one-size-fits-all, and neither are the tyres that support them. From fractured rocks to high temperatures and everything in between, each site poses its own unique set of challenges for tyre requirements. Fortunately, tyre manufacturers have a strategic lever they can pull to influence tyre life and functionality at every job site: tread compound formulation.
More than just mixing rubber
Tread compound formulation is both an art and a science. Through tremendous amounts of testing and advancements, tyre manufacturers can now produce a variety of specialised rubber compounds, each designed to tackle specific operational challenges. From heat generated by long hauls to cutting from rocks and challenging underfoot conditions, manufacturers can engineer tread compounds that deliver optimal performance across a wide range of demanding environments.
The process of creating the perfect tread compound is more than combining various ingredients. This field of science is still evolving, but most tyres produced today will utilise a wide variety of ingredients, all of which impact the rubber’s physical properties. Some of the most common ingredients are natural rubber, synthetic rubber, silica, carbon black, and various other rubber chemicals. It starts with selecting the right polymers for the desired performance, which form the foundation of the tyre’s rubber. Natural rubber offers high tensile strength and fatigue resistance, two desirable characteristics for cut-resistant compounds. Synthetic rubber, such as butadiene, is a man-made polymer often used to help enhance durability and combat excessive heat buildup. Silica is used as a reinforcing agent that helps reduce heat generation and improve traction in wet conditions. Lastly, carbon black is used to enhance abrasion resistance and tread strength.
The chosen polymers are blended in internal mixers at carefully controlled temperatures and pressures. Modern mining tyre manufacturing facilities incorporate advanced technologies at every stage of the production process to optimise tyre performance and durability. Advanced mixing systems precisely blend natural and synthetic rubber with reinforcing agents, oils, and other additives to create the tread compounds needed to meet the specific demands of the end user. Computer-controlled curing presses then apply targeted temperatures and pressures to mold the tyre. This process chemically bonds the raw materials, giving the tyre its strength, rigidity, and tread pattern. By tailoring compounds to address challenges such as heat, cuts, or mixed conditions, manufacturers can significantly extend service life, reduce total cost of ownership, and help to improve safety in mining operations.