CHALLENGES

During the expansion of a gold mining operation in Far North Queensland, mining activities moved closer to nearby residential areas, increasing scrutiny on environmental impacts—particularly operational noise. One major source of concern was the excessive noise generated when loading hard, primary ore into dump truck trays.

The mine required a fast and effective noise-reduction solution that could be implemented without disrupting production schedules. However, long lead times associated with fully engineered OEM liner packages were not feasible.

Key challenges included:
• Reducing truck loading noise to address community concerns.
• Managing heavy impact from sharp, hard primary ore.
• Providing durable wear protection under extreme operating conditions.
• Delivering a rapid solution without waiting for custom-moulded liner packages.
• Working without detailed OEM drawings of the truck tray.

SOLUTION

To overcome these challenges, steel-backed PP Rubber Wear Liners manufactured by Forech were supplied through our trusted channel partner Reglin Rubber (Australia).

Without access to detailed tray drawings, the mine’s contractor performed a laser scan to capture the dump truck tray geometry. Using this data, a custom-cut liner package was quickly designed and fabricated from stock materials, allowing for fast turnaround and rapid installation.

The liner package featured:
• 100 mm thick liners across most of the tray floor.
• 125 mm thick liners in the central loading impact zone.
• Premium SAR 60 rubber vulcanised to a heavy-duty steel backing.

This combination delivered effective impact absorption, abrasion resistance, and significant noise reduction during truck loading operations.

OUTCOME

Following installation, the mine achieved the following outcomes:
• Noticeable reduction in dump truck loading noise, helping address community concerns.
• Effective absorption of heavy impact from sharp, hard primary ore.
• Extended service life of the dump truck tray through improved wear protection.
• Rapid implementation without long lead times or production delays.
• A practical, trial-ready solution suitable for ongoing fleet operations.

CONCLUSION

By adopting French-manufactured steel-backed PP Rubber Wear Liners, supplied via Reglin Rubber (Australia), the gold mine successfully implemented a fast, reliable solution for noise reduction and wear protection in its dump truck fleet. This case study demonstrates how engineered rubber liner solutions can support both production efficiency and community relations in demanding mining environments.