1

Mining Magazine
Centenary Mining Congress
(c) 2009 Duratray International
Stephen Hall
BEng, MAusIMM
Duratray International
steve.hall@duratray.com
Niagara; 08-09 Oct 2009
Duratray Suspended Dump Bodies
- What, How & Why -
Why the strange body?
Cat-793 Duratray; BHPB Ekati
Other view even stranger?
Riotinto Diavik
Komatsu 830E Duratrays
Its big, but will it work?
Caterpillar-797B Duratray;
SAE 2:1; 315 Yd =240m
Congress Presentation themes
Suspended Dump Bodies
Why do people buy them
(c) 2009 Duratray International
Why dont people buy them
Why and How does it work
Why consider SDBs
Let us consider
Mine Production & Maintenance
What are the drivers?
B th d ti & i t
(c) 2009 Duratray International
Both production & maintenance
What are the metrics?
How do they see a Dump Body?
How can it be improved?
Do Asset Management & Reliability
work only at the Truck entity level?
2
Firstly - Asset Management
The J ourney
Domain Attitude Rewards Activities Drivers Behaviour
1
Regressive Don't fix it
Short term
savings
Meet Budget Decaying
Acknowledgement; Ledet, W.J., Making the move towards a learning organization: A Classic Journey of Change.
2
Reactive
Fix after it
breaks
Overtime
heroes
Breakdowns Responding
3
Planned
Fix before it
breaks
No surprises
(we hope)
Predict, plan,
schedule
Avoid
Failures
Planning
4
Improved Precision
Don't just fix
- Improve it
Competitive
Advantage
Eliminate defects,
improve
precision,
redesign
Uptime
Organisational
Discipline
5
World Class Innovation Best in Class Differentiating Growth
Organisational
Learning
The Asset Management J ourney
Acknowledgement; Peter Townson, Reliability The Journey at Blackwater Mine; ICOMS Conference 2007
Could this apply to Dump Body Systems
Wear Mat
Optional FrontLiner
Optional Canopy Liner
A systemthat provides:
Impact attenuation
Details of what is a
Suspended Dump Body
SDBS
(c) 2007 Duratray International
UndermatandLPS
SuspensionRopes
Shock absorption
Vibration reduction
Noiseabatement
Increased Payloads
Carryback elimination
Less maintenance&risk
Components of a
Suspended Dump Body;
Installing New or Replacement Wear Mat
Wearmat held down
with Clamp Plates
^ Under-Mat, LPS & Ropes
. . .Note shear pins for Wearmat
Komatsu 930E4 Duratray
Anglo-American Los Bronces
The Finished Product; The History channel
Originally developed by Skega, the
Duratray SDB has provided the
mining industry with a unique &
innovative product for 30
+
years.
Suspended Dump Bodies (SDB)
The Duratray SDB was a world-first
in concept and design, created on
the principles of improving mining
operations output and efficiency.
SKEGA

DUNLOP

CONYMET
3
The History - continued
In 2001, Conymet Chile acquired
Duratray International from Pacific
Dunlop, adding rubber SDB bodies to
their successful range of all-steel trays.
Today 1,000 Duratray SDBs are
operating successfully in Europe,
Australia, Asia, North & South America.
CONYMET
&
DURATRAY
Production, Maintenance & Safety
advantages are applicable
in any Hauling Environment
Large Mines
and
Quarries
(c) 2009 Duratray International
Quarries
or
On- Highway
1. Higher Payloads
Lighter deadweight than OEM steel bodies (20+%)
Increased volumetric Capacity
Reduced Carry-back
Reduced Spillage
CentralisedLoads less bias
Product Advantages
Duratray SDB
Centralised Loads less bias
2. Maximised Availability
Higher Go-Line Availability (+3% claimed)
Longer Wear Life (typically 2-3 times)
Shorter Maintenance cycles (shifts vs. weeks)
3. Improved HSE Profile
Improved Operator comfort & safety
Impact, Vibration, Noise reduction
Improved Performance
Higher Payload (Higher Volume)
Lihir Gold Ltd Papua New Guinea
Cat-785; 102m Duratray vs. OEM 78 m
Body weight 21 tonnes vs. 27.5t for MSD-II
Improved Performance
12.5%Higher Payloads
134.8 t 119.8 t
Higher Payloads
- No Carryback -
Flexible Duratray SDB
virtually Eliminates
Carry Back
10-30% Carry-Back in
Conventional
Steel Bodies
4
Low Maintenance - >
Maximised Go-Line Availability
Conventional Steel Bodies:
Overhaul 2-3-4 weeks
High demand for Resources
Increased Safety Risks
Typical cost US$80K per 2 years
Duratray SDB Body:
Overhaul 1-2 shifts
Low demand for Resources
Spare dump bodies not required
Typical cost US$40K per 4 years
Maintenance Ultra Class
Over12,000Hours
SteelBoxes=US$13.10/Hr
DuratraySDB=US$5.50/Hr
380 short ton
Trucks
Body
Weight
SAE
Capacity
Average
Payload
Long-Term
Maintenance
Improved Performance
In Deadweight, Capacity, Payload
and Long-term Maintenance
OEM Steel Body
with Liners
63
tonnes
196 m 340 metric $ 13.10 / Op Hour
Duratray SDB
44.8
tonnes
240 m 364 metric $ 5.50 / Op Hour
- 29% +22% +7.1% -58%
Notes;
Copper application with 4100XPB loading
Based-on 20 Duratrays in fleet of 132 units
Data shown covers 2 years 2006-2008
Notes;
OEM steel body repair cycle 12,000 Hrs
Quantity of steel replaced; 24-26 tonnes
Duration of Overhaul steel trays 30 Days
120%
KPI's380tonTruckBodies
Improved Performance
Higher Av Payloads; 364t vs 340t
0%
20%
40%
60%
80%
100%
Weight Production Maintenance
OEMSteelBody
DuratraySDB
Improved Performance
Payload & Maintenance 240t
Maintenance
Time
Type
Transport
Vibration
Stability
Loading
Shock
Noise
Risk Exposure
Zones and Durations
Rio Tinto IOC Barrick Veladero Escondida
(c) 2007 Duratray International
Whole Body Vibration ( WBV) Noise I nduced Hearing Loss ( NI HL)
Shock Burns Falls Heavy Lifting I nhalants
5
Loading and Transport
Risks
90% subject to
Loading Impact
35% subject to
Loading Impact
(c) 2007 Duratray International I mpact Zones
Sub-structure not
subject to Impact
Repetitive
exposure to
Shock and Vibration
Reduction
(c) 2007 Duratray International
exposure to
shock and
Whole Body
Vibration (WBV)
are significant
health issues for
truck operators.
With Duratrays the
I mpact is Absorbed
in Three Dimensions
Stretches in all 3
X- Y- Z Directions
Less Shock
Transmitted to the
Cab and Operator
Loading Shock
Reduction
Duratray SDBs
Most of shock taken
by mat and ropes
Transmitted to rope
attachments
(c) 2007 Duratray International
Banana Beams flex
and absorb more
of the shock
Less shock reaches
chassis pins
Slower, low- amplitude
suspension cycles
Approx. 40% reduction in vertical acceleration.
Steel
A
z
=2.52m/ s
2
0.26g
Duratray
A
z
=1.5m/ s
2
0.15g
Source; Mutual de Seguridad study, Collahuasi, 2005
Coping with Impact under large
shovels & in adverse climates
Cat 793 SDB BHPBilliton Ekati, Canada
20 Units
Loading Noise
Operator Exposure
90
90
Loading Noise Comparison
Conventi onal Steel Body vs. Suspended Rubber Body
Steel Body
Boliden Mine, Sweden
(c) 2007 Duratray International
Du mp Tr u c k Cab Ex c av at o r c ab
90
80
80
63
60
65
70
75
80
85
d
B
(
A
)
Op er at o r ' s Exp o su r e
y
Duratray Body
Loading Noise
Environmental Exposure
94
90
95
L
e
v
e
l
Steel Body
Duratray Body
Boliden Mine, Sweden
(c) 2007 Duratray International
at 25m at 50m at 100m
80
86
75
81
68
65
70
75
80
85
M
e
a
s
u
r
e
d

N
o
i
s
e

L
d
B
(
A
)
Envi ronmental Exposure
Note: The human ear registers a reduction of 10 dB(A) as half the noise.
Loading Noise Reduction is
Popular, even in unexpected areas
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Positive Operator Involvement
- Snr Drivers prefer Duratrays
in mixed fleet environments -
For me, this Duratray
Body is the best mining
invention. Personally, I
wish all trucks carried
Duratray bodies!
(c) 2009 Duratray International
Duratray bodies!
They absorb the shock
of the loading impact,
not me or the truck...
I do not want a steel
box any more!
Bernard White, Operator Truck #55 ( CAT 793)
BHP Billiton Ekati
Transport Stability Steel Boxes
For an imbalanced
load, weight is
concentrated where
it is placed so
(c) 2007 Duratray International
The uneven leverage on the suspension
exaggerates the instability, increases tire loads
t s p aced so
center of gravity
shifts noticeably.
Transport Stability - Duratrays
Curved, flexible floor transfers more weight to center of body.
Forces are attenuated through rope attachment and beams.
(c) 2007 Duratray International
High, off- center loads do
not leverage suspension
as greatly because the
CoG stays closer to Spec.
Comparative Maintenance Requirements
Steel vs. Duratray SDBS
MAINMAINTENANCE ACTIVITIES STEEL BODY DURATRAY
TensionedSteel Plates Removal of tensionedsteel platesinFront Wall,
Floor, Sidewallsandcanopy.
VeryLimitedor nomaintenanceneeds
Welding/ VoltArc ExposuretoRisksassociatedwithwelding. VeryLimitedor nomaintenanceneeds
Taskperformedwithheatsources Requirementsof significant tasksthat involve
welding, torching, arc-air, oxy-cutting, etc
VeryLimitedor nomaintenanceneeds
Taskperformedinheights / or
elevations
TaskperformedintheFront Wall, Canopy,
Sidewallsrequireworkingat heights
Onlyonropeadjustment process, operatingonaman
lift withsafetyharness
(c) 2007 Duratray International
Exposuretonoiseemissions Noiseemissionsourcesfrom: Welding, oxycut,
torchingandgrinding
Limitedtonormal sourceof noisewhentensioning
ropeswithanair impact gun.
Emissionofincandescentparticles Thishappenswhenoperationsusingoxycut, arc-
air, welding, oxy-torch, etc.
VeryLimitedor nomaintenanceneeds
Tasks poweredbyelectricity Welding, grinding Limitedtoair compressor for impact gun
Liftequipmentrequirements For tasksthat involvetransportingsteel plates,
for installation, bendingandremoval
Onlyapplicablefor lessthan60minuteswhen
reachingupfor ropeadjustment, every1,000hours.
Exposuretogas emissions Steel heatingandoxycut VeryLimitedor nomaintenanceneeds
Exposuretometallic fumes Highexposuretometallicfumes VeryLimitedor nomaintenanceneeds
HighMaintenancecostand
involvement
20-40%MaintenanceCostandinvolvement,
thansteel bodies
Lower-Risk Maintenance
Operations
Less maintenance
Rope Adjustment on PM;
60 minutes per 1,000 hours
Rope replacement: Average 0-2
ropes per year, 1-2 hours/Rope
Wearmat replacement: 1-2 shifts
per 20,000 to 30,000 hours
Little or no welding
Primarily operational damage
Low maintenance risk
Low risk tasks
No intolerable risk
- Common Tools
- On Routine PM
I ntolerable
Sources of Maintenance Risk
- RPN and ALARP Analysis -
Certain
Probable
p
o
s
u
r
e
Incan-
Descent
Particles
Emission Tensioned
steel
plates
Metallic
Fumes
Noise
Emission
Welding
Volt Arc
Work in
Heights
Work w/
heat
sources
Different
Surface
Levels
Tools
Tools
W k /
(c) 2009 Duratray International
Tolerable
ALARP
Possible
I mprobable
Very Rare
P
r
o
b
a
b
i
l
i
t
y

o
f

E
x
p
Low Minor Moderate High Critical
Risk Level
Steel body
Duratray SDB
Work
w/Electricity
Gas
Exposure
Lift
Equipment
Noise
Emission
Work w/
heat
sources
Work in
Heights
Incan-
descent
Particles
Emission
Different
Surface
Levels
Work
w/
Electricity
Lift
Equipment
Gas
Exposure
Welding
Volt Arc
Metallic
Fumes
Tensioned
Steel
Plates
7
INTOLERABLE
3
Tensioned Steel Plates; Task performed in Heights; Task
performed with Heat Sources (Torch, Welding)
9
Standard Steel Body
Maintenance Risk Exposure
(c) 2007 Duratray International
TOLERABLE TOLERABLE
ALARP
(( As Low As As Low As
Reasonably Possible) Reasonably Possible)
0
General Endangerment Assessment
for standard steel dump bodies
analyzed the main sources of risk
when performing maintenance.
9
Different Surface Levels, Welding/ Volt Arc; Use
of Electricity, Metallic Fumes Exposure,
Heavy Duty Tools, Noise Emission,
Exposure To Gases, Heights,
Emission of Incandescent
particles
INTOLERABLE
0
8
Performed at different surface levels; Use of
electricity; Lift equipment requirement; ALARP
Duratray SDBs Maintenance
Risk Exposure
(c) 2007 Duratray International
TOLERABLE TOLERABLE
y; q p q ;
Exposure to gases; Tensioned steel plates;
Noise Emission, Heights and Heat Sources
(Torch, Welding)
4
Welding/ Volt Arc;
Metallic Fumes
exposure; emission
of incandescent
particles; Heavy
duty
tools
General Endangerment Assessment
for Duratray SDBS analyzed the main
sources of risk when performing
maintenance to dump bodies.
( As Low As ( As Low As
Reasonably Possible) Reasonably Possible)
HSE/OHS Summary
The Duratray Suspended Dump Body design reduces or
eliminates health and safety risks in three main categories:
Loading:
Reduced impact
(c) 2009 Duratray International
Reduced noise
Transport:
Reduced vibration
I mproved stability
Maintenance:
Lower risk operations
Less time exposed
DURATRAY EVOLUTION
Circa 2004 Two Products; 50%-50% Sales Split
By 2008-09 - Sales Split 90+% Duratray SDBs
. . . on similar volume of total units
Product Enhancement
1. Classic 4-Beam Duratray
2. XP-2 Duratray Lightweight
3. XP-3 Duratray further weight reduction
Rio Tinto sites
Site Trucks Quantity
Iron Ore of Canada Komatsu 830E 22
Komatsu 930E-4 3+2**
DuraRail 100T 1 DuraRail 100T 1
Diavik Komatsu 830E 12
Jacobs Ranch Komatsu 830E 2
Escondida (JV) Caterpillar 797B 10
Caterpillar 793D 1
Komatsu 930E4 10
Komatsu 960E1 2
Rio Tinto Alcan Cat-777F & Kom-HD985 5
** On-Order = 70
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Barrick Gold sites
Site Trucks Quantity
Veladero Cat-793C Classic SDB 15
Cat-793C Duratray XP 6
Cat-785C Duratray 1
Pascua-Lama ** Komatsu 930E-4 30
Cowal Cat-789C New-build SDB 2
Cat-789C Refurbished SDB 3
** On-Order = 57
BHPBilliton sites
Site Trucks Quantity
Ekati Caterpillar 793C 10
Caterpillar 789C 3
Caterpillar 777D 12
Escondida Caterpillar 797B 10
Caterpillar 793D 1
Komatsu 930E4 10
Komatsu 960E1 2
Spence Copper Caterpillar 793D 3
Gemco Groote Eylandt Komatsu HD785 6
Caterpillar 777F-LH 8
Worsley (BBM) Komatsu HD985-5 13
Caterpillar 785C-XQ ** 10
BMA Norwich Park Caterpillar 785C 8
BMA Goonyel la Komatsu 930E3 4
** On-Order =100
AngloAmerican sites
Site Trucks Quantity
Los Bronces Komatsu 930E 25
Komatsu 830E 7
Mantos Blancos Caterpillar 789B&C 22
Collahuasi JV Komatsu 830E 9
Komatsu 930E-4 2
Komatsu 960E-1 2
Caterpillar 793C 1
Anglo Platinum Komatsu 930E-4 ** 2
Lomas de Nquel Komatsu HD465 5
** On-Order =75
2009 New Deliveries
Cat-793C Newcrest Cadia, NSW
3 Units;
160 m
SAE capacity
38.5 tonnes deadweight g
12-14 tonne weight saving
2009 New Deliveries
Terex-MT4400AC Gibraltar Mines (148m
3
)
Komatsu 960E-1 Xstrata Anglo
Collahuasi Copper (235m
3
)
2009 New Deliveries
Two similar
960E units at
Escondida
9
2009 New Deliveries
Komatsu 940E-4; IOC Labrador
Conclusions
From the above slides we would assert;
Duratrays do provide positive HSE,
Production & Maintenance benefits
h l i h h i d ' They comply with the I mprove it, don't
j ust Repair it philosophy
However mine sites still do not keep
good statistics at the Dump Body level
they typically work to the Truck level
But . . . .
Conclusions
The sceptics are still out there and
they remain difficult to convince.
Acknowledgement; Dr. Melinda Hodkiewicz ; Engineering Asset Management and Risk, University of WA 2009.
Conclusions
Reasons for not adopting Duratrays;
Package purchases incl finance by OEMs
OEM Strategic Global Alliances
Lack of awareness of SDBs still high
Lack of a Champion for change
Our own failure to convince end-users
Conclusions
Reasons for adopting Duratrays;
The unique solution for;
Severe Abrasion
High Carryback
Noise & Impact problems
Reduced Maintenance workload & camp
requirements for large fleets in remote locations
And for everything in-between
Thank You & Questions?
Southern Copper, Per
9x Komatsu 930E Duratrays, Toquepala.