Kal Tire’s Mining Tire Group has partnered with Australian mining technology firm Decoda to deliver a real-time haul road hazard detection solution aimed at improving productivity, tyre life and fuel efficiency across mine sites.
The strategic alliance has resulted in the development of KalPRO™ HaulSight, an autonomous system that builds on the company’s existing KalPRO TireSight technology. While TireSight focuses on tyre inspection, HaulSight is designed to proactively identify and mitigate haul road hazards before they lead to damage or downtime.
Kal Tire Mining Tire Group technology services director Christian Erdelyi said the system represents a shift from reactive to preventative maintenance.
“HaulSight’s ability to detect road hazards as they arise means mines can prevent the tyre damage that TireSight detects,” Erdelyi said.
“We’re excited about how this collaboration with Decoda will further our achievements in the autonomous space to bring customers even greater improvements to tyre life, productivity and fuel efficiency.”
HaulSight uses LiDAR and camera sensors mounted to the front and rear of haul trucks, combined with edge computing to process data in real time. The system alerts operators and site teams to hazards such as spillage, road undulations and high G-force events that can impact truck performance and tyre wear.
The technology integrates with Kal Tire’s Tire & Operations Management System, enabling condition monitoring teams to assess issues and automatically generate priority-based work orders.
Decoda executive general manager George Spink said the platform delivers actionable insights that translate directly into operational gains.
“HaulSight gives mine sites unprecedented visibility across the entire haul circuit and turns that insight into action,” Spink said.
“By making critical data easy to visualise and act on, operations see measurable improvements, like faster circuits and reduced downtime, from day one.”
Beyond real-time alerts, HaulSight also offers long-range insights that help operators make informed maintenance and road upgrade decisions.
The system has already undergone 18 months of testing at Canadian mine sites, including in sub-zero conditions, delivering strong performance. Its adaptability allows it to account for varying road conditions both within and between sites, while also providing guidance to operators to avoid hazards during loading and dumping.
As mining operations continue to adopt autonomous and electrified fleets, Kal Tire and Decoda expect technologies such as HaulSight to play an increasingly critical role in optimising performance and reducing operating costs.
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