No lining

Reducing the weight by 10 tonnes and utilizing the extra capacity to haul ore can be the most cost-efficient option when hauling low-abrasive ore, with the body lasting 25,000-35,000 hours. Advances in materials now make it possible to build truck bodies using wear-resistant materials with structural capabilities, such as Hardox^® 500 Tuf (approximately 500 Brinell). This innovation enables the option of running without a liner, even for medium-abrasive ore. The cost-effectiveness of this approach depends on weighing the expense of replacing an entire body against installing a new liner package, along with the benefits of hauling ore instead of 10 tonnes of steel. Typically, adding 5 mm of extra thickness to the floor structure is recommended to compensate for the absence of a liner. 

Conventional lining

This is the most common solution. It reduces the potential for carryback, discharges the fastest and has the lowest gravity point during discharge. 

Wear bars

Wear bars are a common solution primarily used to reduce the wear in the tail. In the weight calculation in the table below, the wear bars are installed on top a 20 mm liner plate. 

“Dead beds”

Reducing liner weight by cutting out rectangular holes is a proven method. This approach can be applied across the entire floor or specifically in the tail section. Dead beds aim to increase friction and trap ore within the pockets, significantly reducing weight compared to a solid plate. The figure below illustrates a dead bed and other tail solutions. 
The weight efficiency depends on the density of the ore that fills the holes. It is generally assumed that about 70% of the cut-out volume contributes to carryback. This trapped material can become highly compacted and take on a concrete-like consistency, with an estimated density of 80% of solid rock. 
For optimal performance, a dead bed lining requires a body with a well-maintained, flat floor structure. 

Waffle plates

Waffle plates are similar to dead beds, but with the advantage of generating less cut-off waste during production. However, designing waffle plates is more complex because the pieces must fit together like a puzzle. Another drawback is that the individual segments tend to be more slender, making it vital to incorporate radiused edges to minimize the risk of cracking. 

Grid structures

In copper mines, grid structures have been widely used. They can be easily manufactured by cutting 35-40 mm wide strips from a 15 mm Hardox^® 450 or Hardox^® 500 Tuf plate. The grid fills with ore, making it most effective for copper ore, which has a relatively low density.

Different solutions for reducing wear in the tail of a mining truck body.

The table presents the calculated weight per square meter for typical solutions, along with a summary of their benefits and drawbacks.

Benefits and drawbacks of using different solutions to combat wear in the tail of a mining truck body.