Schlam is reshaping the Hercules truck bed and Barracuda Bucket design from first load to end-of-life recovery.

Even something made from solid steel can be stretched.

As mines look for new ways to sweat their assets, Schlam is using data-driven strategies to stretch the life of their Hercules mining truck beds and Barracuda loading attachments while achieving targeted productivity and cost outcomes. The experience gained is now informing new services and product innovation.

The company’s executive general manager product lifecycle services (PLS) Amit Bareja told Australian Mining the solutions provide end-to-end support, from commissioning to decommissioning aligned with the requirements of mine asset management systems.

“We understand our load and haul products contribute to the delicate balance in managing costs, risk and performance, helping to maximise overall value for our customer,” Bareja said. “Through proactive lifecycle services, we can help asset managers improve the total cost of ownership for our equipment while also managing risk.”

Schlam products are customised in consultation with customers to fully consider each site’s application, operational conditions, planning and maintenance schedules. This includes understanding assumptions about estimated asset life, efficiency and performance metrics under the asset management system.

Schlam’s lifecycle services are planned based on these conditions to optimise operational hours while managing costs, ensuring every stage of equipment ownership delivers maximum value.

In a “capital constraints” environment, Bareja said, extending the life of a haulage truck bed or bucket through rebuilds can be a lower-cost option compared to a new asset, while still providing a safe and productive solution. 

Rebuilds are delivered through Schlam facilities in Western Australia and New South Wales, and contracted partners in Queensland.

“We manage the product in the field to help manage the output,” Bareja said.

“This includes being proactive about servicing and preventive maintenance to manage long term breakdown risk. We would rather solve a defect before they accumulate to the point where they can cause a breakdown.”

To achieve this, the PLS team integrates initial design data with operational performance monitoring. Planning for replacement parts, services and rebuilds is then informed by tracking wear, payload efficiency and using innovative modular components to minimise downtime and maintenance. 

Bareja said the performance data collated over the life of the asset then becomes an input into the design process for new or additional products acquired for the site, supporting continuous improvement and the evolution of the product.

“This is how our product design evolves,” he said.

“With some Hercules truck beds now reaching more than 10 years of operational service, there is a huge data set for what works and what doesn’t.

“The biggest benefit we can offer is the iterative improvement of our products based on real-world, operational experience and customer feedback.”

Bareja said customer expectation has also extended the range of services offered to include recycling for assets that have achieved their end-of-life.

For example, Schlam has recycled truck beds on behalf of a Pilbara iron ore customer since 2023. The end-of-life beds are collected on-site and transported to a metal recycling facility in Port Hedland, utilising the same freight that delivers new truck bed. The beds are then dismantled and processed into scrap steel, which is exported to Japan and used as input into new steel products.

More than 1125 tonnes of steel has been recycled in partnership with this iron ore customer.

“Managing scrap is not core business for the mines, so this is another way we can add value by reducing mine site waste, contributing to the circular economy and supporting a sustainable future,” Bareja said.

Schlam manufactures lightweight Hercules mining truck beds for haulage trucks ranging from 100 tonnes to more than 300 tonnes capacity, and Barracuda loading attachments for 100–600-tonne backhoes, excavators and loaders. There are now almost 3000 Hercules truck beds in operation on more than 100 sites around the world, mining commodities including iron ore, coal, copper, gold, silver, zinc, bauxite and lithium. 

Custom-engineered for performance, these large capacity, long life, weight optimised products boost productivity, reduce downtime, lower emissions, and streamline maintenance, supported by focused services designed to meet operational needs. 

This feature appeared in the February issue of Australian Mining magazine.