# Haul Truck Tyre Management: TKPH, Tyre Life and Cost per Hour

Source: https://honestdig.io/blog/haul-truck-tyre-management
Published: 2026-11-04

November 4, 2026Daniel Rowe

Learn how to calculate TKPH, extend haul truck tyre life, reduce premature failures, and measure tyre cost per hour and cost per tonne.

A mining truck tyre costing $48,000 is removed after 3,000 hours instead of an expected 4,000\. Its cost per operating hour rises from $12 to $16, excluding replacement downtime.

Across a fleet, premature tyre removals can increase haulage costs and disrupt production.

Effective **haul truck tyre management** requires three measures: TKPH (tonne-kilometres per hour), actual tyre service life, and cost per hour.

The challenge is matching tyre capacity to operating conditions without compromising production or safety.

## Key Takeaway

A higher TKPH rating does not automatically guarantee longer tyre life. Effective tyre management requires matching tyre capacity to actual loads, speeds, temperatures, and road conditions, then monitoring tyre cost per tonne alongside service hours.

## What Is TKPH and How Is It Calculated?

TKPH measures a mining tyre's thermal working capacity based on average load and operating speed.

As tyres carry heavy loads and flex during travel, they generate heat. Excessive thermal demand can damage internal components and contribute to premature failure.

Tyre manufacturers such as Michelin specify TKPH ratings based on tyre construction, compound, and operating conditions.

**Basic site TKPH = Average tyre load × Average speed**

Where:

* Average tyre load = (Loaded tyre load + Empty tyre load) ÷ 2
* Average speed = Total distance travelled ÷ Operating hours

Manufacturer calculation methods can require corrections for journey length and ambient temperature.

For example, Michelin's methodology applies correction factors for cycle length (K1) and temperature (K2).

**Corrected site TKPH = Basic site TKPH × K1 × K2**

The corrected site demand must be compared against the selected tyre's manufacturer-rated TKPH.

## TKPH Calculation: Worked Example

Consider a hypothetical operation using a 70-tonne-class haul truck with 24.00R35 tyres, comparable in class to a Caterpillar 775.

Assume the most heavily loaded tyre position has:

* Loaded tyre load: 18.5 tonnes
* Empty tyre load: 18.2 tonnes
* Round-trip distance: 4 km
* Completed cycles: 40
* Operating shift: 8 hours

**Average load = (18.5 + 18.2) ÷ 2 = 18.35 tonnes**

**Average speed = (4 × 40) ÷ 8 = 20 km/h**

**Basic site TKPH = 18.35 × 20 = 367**

For illustration, assume the applicable correction factors are both 1.0.

Against a hypothetical tyre rating of 450 TKPH, the operating demand is within capacity, with approximately 18% headroom.

Now consider a longer 6 km route, still completing 40 cycles in eight hours.

Average speed increases to 30 km/h.

**Basic site TKPH = 18.35 × 30 = 550.5**

Even before applying any additional correction factors, the demand exceeds the hypothetical 450 TKPH rating.

This demonstrates how changes in haul distance and operating speed can increase thermal demand.

Actual tyre selection must follow manufacturer correction tables and site measurements. Operating speeds must also remain within established mine safety limits.

Learn more about [haul truck cycle time calculations](https://honestdig.io/blog/how-to-calculate-haul-truck-cycle-time).

## What Reduces Haul Truck Tyre Life?

Several operating conditions affect tyre performance and replacement frequency.

| Factor              | Impact on Tyre Performance                 | Corrective Action                       |
| ------------------- | ------------------------------------------ | --------------------------------------- |
| Overloading         | Increases tyre stress and heat generation  | Monitor payload and axle loading        |
| Incorrect inflation | Causes excessive flexing or irregular wear | Maintain recommended inflation pressure |
| Poor haul roads     | Increases cuts, impacts, and casing damage | Improve grading and drainage            |
| Excessive speed     | Increases thermal demand                   | Monitor TKPH and operating speed        |

Under-inflation increases tyre flexing and heat generation. Excessive inflation can contribute to irregular wear and greater susceptibility to certain impact damage.

Tyre pressure and temperature monitoring systems help identify developing problems before they become serious failures.

Position-specific inspections and manufacturer-approved tyre rotation practices also support tyre life.

Because large mining tyre failures can create significant safety hazards, inspection and maintenance activities must follow established exclusion-zone and tyre-handling procedures.

Poor [haul road rolling resistance](https://honestdig.io/blog/haul-road-rolling-resistance) increases tyre stress and can slow haulage, making road maintenance an important part of tyre management.

## Tyre Cost per Hour vs Cost per Tonne

Purchase price alone does not determine tyre operating cost.

**Tyre cost per hour = Net tyre cost ÷ Actual service hours**

Consider a hypothetical tyre costing $48,000:

* At 4,000 operating hours: $12/hour
* At 3,000 operating hours: $16/hour

Across 20 tyres operating 4,000 hours annually, this difference represents approximately $320,000 in additional annualized tyre costs, assuming identical utilization and replacement economics.

However, cost per hour does not account for production volume.

**Tyre cost per tonne = Total tyre cost ÷ Tonnes hauled**

A tyre lasting longer under reduced payloads may still deliver a higher cost per tonne.

Tyre-related downtime also increases operating costs through maintenance labour, equipment unavailability, and lost production.

Learn more about [haul truck payload optimization and cost per tonne](https://honestdig.io/blog/haul-truck-payload-optimization-cost-per-tonne).

## How to Identify Premature Tyre Failure

Physical tyre inspections provide important evidence, but operational records help identify recurring patterns.

Common indicators include:

* **Cuts and impact damage:** Possible sharp rocks, road hazards, or contact damage.
* **Shoulder wear:** Potential inflation, loading, or alignment problems.
* **Heat-related separation:** Possible excessive speed, loading, or thermal duty-cycle demand.

Consistent tyre removal-reason coding is essential for comparing performance across equipment and routes.

For example, tyres operating on Route A may average 3,200 hours compared with 4,100 hours on similar routes.

Combining onboard payload data, GPS speed and distance records, and maintenance removal histories helps narrow the likely causes.

If payloads and inflation remain consistent while TKPH demand increases following a route change, thermal loading becomes an important area for investigation.

## Connecting Tyre Performance With Operational Intelligence

Consider a mining fleet experiencing premature tyre removals after haul routes are extended.

Maintenance records show shorter tyre life. GPS data identifies higher travel distance and average speed, while payload records indicate that loading conditions remain consistent.

Together, these observations suggest an increase in thermal duty-cycle demand.

This allows maintenance and production teams to investigate the operating conditions rather than assuming the tyres themselves are defective.

**AIM by HonestDig** focuses on connecting operational information to support equipment coordination, maintenance planning, and production visibility.

Its [Guaranteed Production Throughput](https://honestdig.io/solutions/guaranteed-production-throughput) solution supports a broader understanding of equipment performance and operational constraints.

The objective is not simply maximizing tyre service hours. It is matching tyre capacity to actual operating conditions while controlling cost per tonne and protecting production.

## Improve Mining Fleet Performance With HonestDig

Effective tyre management requires more than routine inspections and replacement schedules.

Mining teams need reliable operational information to understand how equipment loading, haulage conditions, and maintenance decisions affect production costs.

AIM by HonestDig helps connect fleet, equipment, and production intelligence to support better operational decisions.

[**Schedule a Demo**](https://api.leadconnectorhq.com/widget/form/zBSWx4QHILMqnRV0EBkl) or [**Contact HonestDig**](https://honestdig.io/#contact) to explore how connected operational intelligence can support your mining operation.

## Frequently Asked Questions

#### What is TKPH in mining tyres?

TKPH stands for tonne-kilometres per hour. It measures a tyre's thermal working capacity based on average tyre load and operating speed, with relevant corrections for site conditions.

#### How is haul truck tyre cost per hour calculated?

Divide the net tyre cost by its actual service hours. Maintenance, fitting, and other associated expenses can be included when calculating complete lifecycle costs.

#### What causes premature mining tyre failure?

Common causes include overloading, incorrect inflation pressure, excessive operating speed, poor haul road conditions, and unsuitable tyre specifications.

#### Does a higher TKPH rating mean longer tyre life?

Not necessarily. Higher TKPH indicates greater thermal working capacity, but actual tyre life also depends on wear resistance, road conditions, inflation, and operating practices.

#### How can mining companies improve tyre life?

Mining companies can improve tyre life by monitoring TKPH, maintaining correct inflation, controlling payload and speed, improving haul roads, and analyzing tyre inspection and removal records.

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