The Power of Less: How Duratray’s Suspended Dump Body Reduces Diesel Use by up to 15% in Mining: Proven!

In mining, small changes can deliver big results — and Duratray’s Suspended Dump Body is a prime example. The Suspended Dump Body Diesel savings are significant. Proven in operations worldwide, it cuts diesel use by up to 15%, boosts payload capacity, eliminates most carry-back, and extends the working life of haul truck bodies. These aren’t just marketing claims — they’re supported by real-world data from some of the toughest mining environments on the planet.

Diesel remains one of the largest day-to-day costs for mines, as well as a significant source of CO₂ emissions. By rethinking the design and materials of something as fundamental as the dump body, Duratray has shown that fuel savings, productivity gains, and environmental benefits can go hand-in-hand.

Lighter Weight, Lower Fuel Use – Suspended Dump Body Diesel Savings in Action

The foundation of the Suspended Dump Body’s fuel efficiency is its much lower tare weight — the empty weight of the truck body itself. Traditional steel trays are strong, but also heavy, requiring significant fuel to move even without a load.

The Suspended Dump Body replaces large sections of steel with a suspended rubber floor, supported by high-strength cables and a lighter steel frame. This design typically makes the tray 10–20% lighter than a standard steel body, and in some cases up to 40% lighter.

A lighter body means less energy required to get moving, whether the truck is full or empty. Multiply the savings from each haul cycle across an entire fleet, and the result is a significant drop in diesel consumption. For a mine running thousands of cycles per month, this difference quickly translates into substantial operational savings and lower emissions.

More Payload, Fewer Trips – How Suspended Dump Body Diesel Savings Boost Productivity

When the truck body is lighter, more of the truck’s capacity can be used for actual ore or overburden, rather than its own structure. Mines using the Suspended Dump Body regularly report payload increases of 5–10% per cycle, with some achieving over 20%.

The Anglo Thermal Coal New Vaal mine is a prime example. Using the Suspended Dump Body, they recorded an average payload of 58.39 tonnes per load compared to 44.65 tonnes for a steel tray on the same truck — a remarkable 30% jump. At BHP’s Ekati Diamond Mine, switching to the Suspended Dump Body resulted in an 8% payload gain.

Fewer trips to move the same amount of material mean reduced engine hours, less fuel burned, lower maintenance costs, and a smaller carbon footprint — all while increasing daily production.

Tackling Carry-back for Greater Suspended Dump Body Diesel Savings

One of the most persistent efficiency losses in mining haulage is carry-back — material that remains stuck in the tray after dumping. This ‘dead weight’ not only reduces the next load’s payload, but also forces trucks to burn extra fuel hauling unwanted material back to the pit.

Steel trays, especially when carrying wet or sticky materials such as clay or coal, are particularly prone to carry-back. The Suspended Dump Body solves this problem through its flexible rubber floor and smooth internal surfaces. As the truck is loaded or tipped, the floor naturally flexes, helping to loosen and release stuck material. The curved sides and rounded edges prevent material from lodging in corners.

At New Vaal, steel trays retained 8–10% of their load as carry-back. After switching to the Suspended Dump Body, carry-back was virtually eliminated. With less dead weight, trucks consume less fuel on return trips, increasing overall haulage efficiency.

Smoother Hauling, Longer Life with Proven Suspended Dump Body Diesel Savings

The Suspended Dump Body not only moves more material with less fuel — it also cushions the impact of loading, reducing wear on the truck and its components.

In a traditional steel tray, dumped material hits with full force, creating vibrations that travel through the body, chassis, and suspension. This leads to cracks, weld fatigue, and increased maintenance requirements. The suspended rubber floor in the Suspended Dump Body absorbs much of this impact energy, protecting both the tray and the truck.

Operators benefit too. Reduced vibration and noise make for a smoother, more comfortable ride, which can help reduce fatigue and improve concentration over long shifts. Mines adopting the Suspended Dump Body report fewer unplanned maintenance stoppages, longer intervals between overhauls, and improved driver satisfaction.

Real-World Results – Mines Reporting Suspended Dump Body Diesel Savings up to 15%

Across different commodities and regions, the Suspended Dump Body consistently delivers measurable fuel savings. Average reductions of 10–15% are common, with some sites seeing even greater improvements.

At New Vaal, diesel use dropped from 125 litres per hour to 102 litres per hour after adopting the Suspended Dump Body — a saving of 23 litres every operating hour, per truck. For a fleet of 30 trucks running 20 hours a day, that’s nearly 14,000 litres saved daily. Over a year, the mine saved more than 5 million litres of diesel, along with the associated emissions.

These results are particularly significant in large-scale operations where fuel accounts for a major portion of operating costs. Over time, the fuel savings alone can offset the capital cost of the Suspended Dump Body, making it a financially and operationally sound investment.

A Step Towards Greener Mining

Reducing diesel use is not only good for the bottom line — it’s essential for environmental responsibility. Every 10–15% reduction in fuel consumption from the Suspended Dump Body directly reduces CO₂ emissions.

With growing pressure on mining companies to meet Environmental, Social, and Governance (ESG) commitments, the Suspended Dump Body offers a practical, proven method for lowering carbon output without sacrificing productivity. Mines adopting this technology demonstrate leadership in sustainable operations, strengthening their social licence to operate and improving their standing with investors and regulators.

The Suspended Dump Body and Future Mining Technologies

The Suspended Dump Body also complements emerging mining technologies such as hybrid and electric haul trucks. Lighter trays reduce energy demand, extending battery range or reducing fuel consumption in hybrid systems.

The durability of the Suspended Dump Body also aligns with predictive maintenance and automation strategies. Fewer repairs mean less unplanned downtime, enabling more consistent fleet scheduling. The smoother ride and reduced vibration also improve conditions for autonomous haulage systems, where equipment longevity and sensor stability are critical.

Built to Last in Harsh Conditions

Durability is a hallmark of the Suspended Dump Body. The suspended rubber floor absorbs the majority of wear and tear, protecting the steel frame beneath. Mines in extreme conditions — from the frozen diamond fields of Ekati to the tropical manganese pits of Groote Eylandt — have reported that Suspended Dump Body trays often last years without replacement, while steel trays in similar environments require major rebuilds within months.

This longevity reduces the need for frequent tray replacements, lowering both capital expenditure and the environmental impact of manufacturing and transporting new trays.

Continuous Innovation in the Suspended Dump Body Design

Duratray’s design team continues to refine the Suspended Dump Body, exploring ways to enhance performance, reduce weight further, and lower its manufacturing footprint. Future developments may include integrated wear sensors for real-time condition monitoring and advanced material blends tailored to specific ore types.

Even without these enhancements, the current generation of Suspended Dump Body technology has transformed haulage efficiency in multiple mining sectors, proving that rethinking a basic component can deliver industry-changing results.

In Summary: Smarter, Cleaner, More Efficient Mining

The Suspended Dump Body addresses key mining challenges — reducing diesel use, increasing payload, eliminating carry-back, and extending equipment life. These benefits have been proven at scale in diverse operations, making the SDB one of the most effective single upgrades a mine can implement.

By cutting fuel consumption and emissions while boosting productivity, the Suspended Dump Body embodies the principle that less can truly be more. For mines looking to improve efficiency, lower costs, and meet sustainability targets, it’s a solution that delivers both immediate and long-term value.

Frequently Asked Questions (FAQ)

Q1: What is a Suspended Dump Body in mining?
A Suspended Dump Body is a haul truck body that uses a high-strength steel frame with a suspended rubber floor, reducing weight, absorbing impact, and improving efficiency compared to conventional steel trays.

Q2: How does the Suspended Dump Body reduce diesel consumption?
By reducing tare weight, the Suspended Dump Body allows trucks to carry more material with less effort, lowering fuel burn by up to 15% across operations.

Q3: Which mining companies use the Suspended Dump Body?
The Suspended Dump Body is in use at sites worldwide, including Anglo Thermal Coal’s New Vaal mine, BHP’s Ekati Diamond Mine, and numerous iron ore, copper, and coal operations.

Q4: Does the Suspended Dump Body require special maintenance?
No. Maintenance is simplified with modular rubber liner sections that can be replaced or patched on-site without heavy welding.

Q5: How long does the Suspended Dump Body last?
In many sites, the Suspended Dump Body lasts two to three times longer than traditional steel trays, depending on conditions and maintenance practices.

Q6: Does the Suspended Dump Body help with carry-back?
Yes. The flexible rubber floor and smooth interior of the Suspended Dump Body minimise carry-back, preventing wasted fuel on return trips.