{"id":2521,"date":"2026-06-28T17:24:22","date_gmt":"2026-06-28T15:24:22","guid":{"rendered":"https:\/\/duratray.com\/?p=2521"},"modified":"2026-06-28T17:25:53","modified_gmt":"2026-06-28T15:25:53","slug":"switch-from-outdated-steel-trays-why-duratrays-suspended-load-isolation-system-is-the-future-of-heavy-haulage","status":"publish","type":"post","link":"https:\/\/duratray.com\/es\/switch-from-outdated-steel-trays-why-duratrays-suspended-load-isolation-system-is-the-future-of-heavy-haulage\/","title":{"rendered":"Switch from Outdated Steel Trays: Why Duratray\u2019s Suspended Load Isolation System is the Future of Heavy Haulage"},"content":{"rendered":"
\"\"<\/figure>
\n

For decades, the mining sector has treated haul truck dump bodies as basic, heavy-duty steel boxes. When an outdated steel tray floor wears out or cracks under high-impact loading, the traditional response has been to weld on thicker, heavier steel wear plates. But adding more steel creates a compounding problem \u2014 it increases tare weight, limits payload capacity, and turns your truck body into a giant acoustic gong vibrating the entire chassis.<\/p>\n\n\n\n

Duratray’s Suspended Load Isolation System (SILS)<\/strong> throws this old-school engineering out of the window. Instead of brute-force mass, SILS relies on material elasticity and field data to optimise fleet performance.<\/p>\n<\/div><\/div>\n\n\n\n

<\/div>\n\n\n\n
\n
\n
THE TECHNOLOGY<\/h6>\n\n\n\n

The physics of elasticity vs brute force<\/h2>\n\n\n\n
<\/div>\n\n\n\n

Standard steel trays act like rigid springs, transmitting loading shockwaves directly through the truck’s frame, tyres, and cabin. Duratray’s SILS uses a Interfaz de Hist\u00e9resis Viscoel\u00e1stica<\/strong> \u2014 a three-component system that absorbs and dissipates kinetic energy rather than resisting it.<\/p>\n<\/div>\n<\/div>\n\n\n\n

\n
\n
Lightweight steel space skeleton<\/h5>\n\n\n\n

High-strength, reduced-weight steel frame that provides structural shape without unnecessary mass.<\/p>\n<\/div>\n\n\n\n

\n
High-performance elastomeric ropes<\/h5>\n\n\n\n

Synthetic, rubber-coated suspension cables anchored to the steel skeleton.<\/p>\n<\/div>\n\n\n\n

\n
Flexible rubber wear mat<\/h5>\n\n\n\n

A thick, impact-resistant rubber membrane suspended directly on the elastomeric ropes.<\/p>\n<\/div>\n<\/div>\n\n\n\n

When an excavator drops tens of tonnes of abrasive rock into the tray, the suspended mat sags, absorbing up to 50% of the kinetic energy<\/strong> and dissipating it as heat \u2014 dampening impact instead of transmitting a shockwave into the multi-million-dollar chassis.<\/p>\n\n\n\n

<\/div>\n\n\n\n
THE DATA<\/h6>\n\n\n\n

Fact-based architecture: the raw operational numbers<\/h2>\n\n\n\n

Engineers run operations on data, not promises. The benefits of switching from outdated steel trays are highly quantifiable across three critical areas.<\/p>\n\n\n\n

<\/div>\n\n\n\n
\n
\n

1. Eliminating the carryback tax<\/h3>\n\n\n\n

Sticky clay and frozen overburden cling to rigid steel corners. This leftover material \u2014 reinversi\u00f3n<\/strong> \u2014 acts as a permanent payload tax, burning diesel to haul useless dead weight. During dumping, the SILS mat sags and recoils, creating “Active Material Ejection” that dislodges cohesive soils.<\/p>\n\n\n\n

<\/div>\n\n\n\n
\n
\n
Field Proof<\/h5>\n\n\n\n

An Anglo American trial reduced sticky carryback from\u00a035% down to under 2%<\/strong>. At BHP’s Ekati Diamond Mine, SILS completely eliminated frozen granite carryback at temperatures as low as \u221250\u00b0C.<\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n

<\/div>\n\n\n\n
\n
\n

2. Shaving tare weight to boost payload<\/h3>\n\n\n\n

A truck’s gross vehicle weight is a fixed engineering limit. By eliminating heavy steel plate, SILS reduces dump body tare weight by up to 40%<\/strong>. Every kilogram removed is a kilogram of extra payload on every cycle.<\/p>\n\n\n\n

<\/div>\n\n\n\n
\n
\n
Field proof \u2014 Anglo American New Vaal Colliery<\/h5>\n\n\n\n

Identical trucks running side by side: traditional steel bodies averaged 44.65 toneladas<\/strong>; Duratray SILS averaged 58.39 toneladas<\/strong> \u2014 a 30% increase<\/strong> in productive capacity.<\/p>\n<\/div>\n<\/div>\n\n\n\n

\n
\n

30%<\/h2>\n\n\n\n

Payload increase (New Vaal Colliery)<\/p>\n<\/div>\n\n\n\n

\n

40%<\/h2>\n\n\n\n

Reduction in dump body tare weight<\/p>\n<\/div>\n\n\n\n

\n

<2%<\/h2>\n\n\n\n

Carryback rate (vs 35% for steel)<\/p>\n<\/div>\n\n\n\n

\n

15\u201318%<\/h2>\n\n\n\n

Direct fuel savings<\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n

<\/div>\n\n\n\n
\n
\n

3. Lower fuel consumption and longer service intervals<\/h3>\n\n\n\n

Hauling a lighter tray with zero carryback means the engine does less work. The rubber mat’s elasticity also means operations don’t stop for frequent weld repairs.<\/p>\n\n\n\n

<\/div>\n\n\n\n
\n
\n
Operational data<\/h5>\n\n\n\n

Eliminating carryback and reducing tare weight yields fuel savings of\u00a015\u201318%<\/strong>\u00a0(roughly 23 litres of diesel per hour). SILS runs for\u00a035\u201340 months<\/strong>\u00a0between major overhauls \u2014 vs 9\u201312 months for standard steel dump bodies.<\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n

<\/div>\n\n\n\n
ENVIRONMENT & OPERATOR<\/h6>\n\n\n\n

Solving noise and vibration complaints<\/h2>\n\n\n\n
<\/div>\n\n\n\n

Mining operations near communities face strict environmental noise limits. Outdated steel trays function like massive amplifiers during loading. SILS naturally dampens this acoustic energy.<\/p>\n\n\n\n

<\/div>\n\n\n\n
\n
\n

At Yancoal’s Moolarben Coal mine in New South Wales, Duratray co-created custom sound-attenuating bodies for the mine’s Komatsu fleet. Loading noise fell by up to 10 decibels<\/strong>.<\/p>\n\n\n\n

Instrumented testing on a Unit 650 haul truck confirmed operator-level improvements:<\/p>\n\n\n\n

<\/div>\n\n\n\n
\n
\n

~50%<\/h2>\n\n\n\n

Reduction in vertical impact g-forces (1.984 \u2192 1.082 m\/s\u00b2)<\/p>\n<\/div>\n\n\n\n

\n

64%<\/h2>\n\n\n\n

Reduction in perceived in-cab loudness (\u22125.5 dB)<\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n

<\/div>\n\n\n\n
WHAT’S NEXT<\/h6>\n\n\n\n

Next-generation integration and regional innovation<\/h2>\n\n\n\n
<\/div>\n\n\n\n

Duratray’s engineering evolution has paved the way for Bandeja Inteligente 4.0<\/strong>, which integrates real-time telemetry to monitor payload distribution and cycle times on active haul roads.<\/p>\n\n\n\n

This innovation is backed by a partnership with Deakin University<\/strong> on advanced R&D \u2014 including a carbon-fibre dump body program \u2014 supported by Australian research grants and state advisory bodies.<\/p>\n\n\n\n

To scale this architecture, Conymet Duratray invested A$15 million<\/strong> to build a 10,000 m\u00b2 manufacturing facility in Pakenham, Victoria. The site houses one of only two industrial autoclaves in the Southern Hemisphere, specifically designed to cure SILS rubber wear mats.<\/p>\n\n\n\n

<\/div>\n\n\n\n
\n
\n

The verdict<\/strong><\/h2>\n\n\n\n

Continuing to haul rigid, high-maintenance equipment is an expensive, old-school habit. Duratray’s SILS uses the physics of elasticity to resolve structural fatigue, reduce noise, eliminate carryback, and maximise payload. When field data shows a 30% payload boost<\/strong> and a 15% fuel reduction<\/strong>, the engineering decision becomes remarkably simple.<\/p>\n<\/div>\n<\/div>\n\n\n\n

<\/div>\n\n\n\n
Preguntas frecuentes<\/h6>\n\n\n\n

Frequently asked questions<\/h2>\n\n\n\n
<\/div>\n\n\n\n
\n
\n