Mining operations are under constant pressure to deliver safe, consistent performance while balancing cost, productivity and reliability. Although tyres are often treated as consumables, their influence extends well beyond replacement cycles – affecting fleet availability, maintenance planning, safety outcomes and production continuity.
As mines grow in scale and complexity, the expectations placed on tyre performance are increasing. Larger fleets, more remote environments and tighter production targets are reshaping how operations approach tyre management. At the same time, the introduction of automation, connected systems and advanced analytics is changing how tyres are monitored and maintained.
Despite these technological advances, one fundamental truth remains: tyre management is still a hands-on discipline requiring strict safety protocols and consistent execution.
“The industry is moving toward a more integrated model, where human expertise, operational discipline and technology work together to improve consistency and performance,” says Miles Rigney, Senior Vice President, Kal Tire’s Mining Tire Group. “This shift is not about replacing traditional approaches. It is about strengthening them.”
Moving beyond reactive tyre management
Tyres represent one of the highest operating costs in surface mining after fuel, which means even marginal improvements can deliver meaningful financial and operational impact. Equally, poor tyre performance can have consequences that extend well beyond cost – disrupting maintenance schedules, reducing equipment availability and, most significantly, reducing production.
For this reason, leading operations are shifting away from reactive approaches to a broader, more integrated view of tyre management. This view considers the operating conditions, behaviours and planning decisions that influence tyre performance over time.
Access to better information is helping drive this transition. Data from inspections, condition monitoring systems and asset tracking tools provides greater visibility into tyre performance. It allows operations to detect patterns earlier, identify emerging risks and plan interventions more effectively.
However, data alone is not a solution. Its value depends on the quality of the data, and how it is interpreted and applied in real-world conditions. “In mining, you can have all the data and all the alerts, but it only provides value if you have experts on the other side taking action,” says Rigney.
This interplay between information and expertise is where modern tyre management is evolving. Technology enables visibility, but it is experienced professionals and planners who determine the right course of action within the operational context of the mine.
Aligning tyre management with mine performance
One of the more significant developments in recent years has been the integration of tyre management into broader mine planning and operational systems. What was once treated as a standalone service is now increasingly aligned with production targets, maintenance schedules and overall fleet strategy.
“Tyre planning teams have to be aligned with the production realities of the site and be accountable to the KPIs that go along with that,” says Rigney. “Aligning tyre strategy with overall mine strategy requires working in an integrated, strategic way from the outset.”
Practically, this means tyre service teams are no longer judged solely on their ability to complete individual tasks. They are expected to contribute to consistency, predictability and measurable outcomes across the operation.
When effectively integrated, this approach enables more proactive planning. Tyre work can be scheduled in alignment with vehicle maintenance, reducing unplanned downtime and allowing for more efficient use of resources.
Managing risk through disciplined execution
As tyre management becomes more closely aligned with mine planning and performance, it does not change the fundamental priority that tyre service work must be carried out safely, consistently and by highly trained technicians. Tyre service work is inherently high risk, involving large, pressurised assemblies, heavy equipment and dynamic operating conditions, often in remote locations.
Incidents rarely result from a single cause. More often, they stem from gaps in process discipline, training, supervision or execution. Factors such as fatigue, inconsistent practices and unclear accountability can compound risk.
“Tyre management is a high-risk activity, and mining tyre service is not a place for low-skill labour,” says Rigney. “It depends on adherence to quality safe work documentation, highly trained technicians, and consistent training, standardisation and processes to reduce the potential for incidents.”
The evolving role of the technician
As tyre management becomes more integrated and technology-enabled, the role of the tyre technician remains centred on the critical hands-on work that keeps fleets operating safely and efficiently. That includes tyre changes, pressure management, inspections, repairs and the safe execution of service procedures in demanding environments.
What is changing is the level of coordination required around that work. Technicians are increasingly supported by planners, supervisors, data specialists and operational teams who help interpret condition monitoring information, align tyre activity with maintenance schedules and connect tyre performance to broader site priorities. In this environment, effective tyre management depends on the right expertise being applied at the right time.
This shift reflects a broader recognition that tyre service teams are part of the operational infrastructure of the mine. Their work directly influences productivity, safety and cost control, making their expertise integral to overall site performance.
Turning data into action
The growing use of analytics and monitoring systems is transforming how tyre performance is understood. Technologies such as Kal Tire’s KalPRO™ TireSight and KalPRO HaulSight autonomous inspection systems are providing real-time visibility into potential issues related to the tyres on the vehicle and the road beneath it.
For example, TireSight uses thermal imaging cameras by Pitcrew AI to detect early indicators of potential issues such as heat-related events, tread damage and structural concerns. As haul trucks pass inspection points, multiple rotations of the tyres can be captured several times a day without the trucks needing to stop. By increasing the frequency and quality of inspections without disrupting production, TireSight helps teams detect emerging concerns earlier and plan maintenance before those issues develop into more significant failures.
At the same time, HaulSight uses Decoda sensors mounted on the front and rear of haul trucks to monitor haul road conditions during normal operation. As trucks move through the site, the system sends real-time alerts on hazards such as road undulations, spillage and non-compliant berm heights, giving teams earlier insight into conditions that can contribute to tyre damage and equipment strain. With clearer information on where road issues are occurring, mines can prioritise remediation work, support better tyre performance and improve the consistency of daily operations.
However, the value of these technologies is not only in the information they generate, but in how that information is used. Kal Tire’s 24/7 Condition Monitoring Analysts (CMA) play a critical role in turning inspection and monitoring data into practical action. The team reviews information from TireSight and HaulSight, validates alerts, identifies trends and helps determine which issues require immediate attention and which can be planned into upcoming maintenance work.
“Technology provides better visibility into potential issues, but the value comes from how that information is interpreted and acted on,” says Rigney. “It takes experienced analysts and site teams working together to turn data into practical actions and decisions that improve planning, manage risk and support overall fleet performance.”
A more integrated future
Tyre management is becoming more closely linked to overall mine performance. As fleets grow larger and automation continues to expand, the need for consistent, integrated systems will only increase. At the same time, the importance of fundamentals – skilled people, disciplined processes and strong safety protocols – will remain unchanged.
Ultimately, progress in tyre management is not driven by any single factor. It depends on the alignment of expertise, structured processes and technology delivering reliable information.
“The future of tyre management will be shaped by how well mines combine technology with practical expertise, expert insight and the structured processes required to carry out high-risk work safely and consistently,” says Rigney. “That combination is what will allow tyre management to contribute more meaningfully to safety, productivity and long-term fleet performance.”