Kal Tire’s Mining Tire Group and Australian mining technology company Decoda have announced a strategic alliance to deliver real-time, autonomous haul road hazard detection for mining operations.
The collaboration aims to enhance truck productivity, tyre life, and fuel efficiency across global mining fleets through the launch of KalPRO HaulSight, a new system developed from the success of KalPRO TireSight.
HaulSight represents the next evolution in autonomous monitoring solutions for mines.
Continuous scanning of haul roads and processing live feedback provides early detection of road conditions that can cause costly tyre and truck damage.
According to Kal Tire, this innovation closes the loop between identifying tyre damage and preventing it before it occurs.
“HaulSight’s ability to detect road hazards as they arise means mines can prevent the tyre damage that TireSight detects,” said Christian Erdelyi, technology services director, Kal Tire’s Mining Tire Group.
“We’re excited about how this collaboration with Decoda will further our achievements in the autonomous space to bring customers even greater improvements to tyre life, productivity and fuel efficiency.”
At the core of HaulSight’s technology are Decoda’s LiDAR and camera sensors mounted to both the front and rear of haul trucks.
These sensors feed live visual data into an edge computer, which processes it in real time to alert fleet teams of hazards such as spillage, uneven road surfaces, or high G-force events.
These alerts allow maintenance teams to act immediately, protecting assets and minimising delays.
HaulSight is designed to integrate directly with Kal Tire’s Tire & Operations Management System (TOMS).
This connection allows condition monitoring experts to assess flagged issues quickly and automatically generate priority-based work orders.
The system transforms road condition data into actionable insights for both daily operations and long-term maintenance planning.
“HaulSight gives mine sites unprecedented visibility across the entire haul circuit and turns that insight into action,” said executive general manager at Decoda executive general manager George Spink.
“By making critical data easy to visualise and act on, operations see measurable improvements, like faster circuits and reduced downtime, from day one.
“Leveraging Kal Tire’s longstanding relationships means we have the chance to bring these benefits to more mines, so we’re pleased to be a part of such a valuable partnership.”
HaulSight’s predictive analytics also help road crews optimise operating conditions for consistent cycle speeds and better fuel economy.
In addition to short-term hazard alerts, the system assesses the long-term economic impact of road quality, comparing the costs of tyre wear and reduced productivity against the potential benefits of road improvements.
“The responsiveness of the system means mine sites benefit right away with trucks spending more time hauling, but HaulSight also offers long-range planning insights that enable confident decision-making around tyre maintenance and road upgrade investments,” added Erdelyi.
After 18 months of testing at Canadian mine sites, HaulSight has demonstrated resilience in sub-zero climates and adaptability across varied mine conditions.
Its real-time guidance can even help truck operators avoid hazards when loading or dumping.
As autonomous and electric haul trucks become more prevalent, Kal Tire and Decoda expect HaulSight’s role to grow significantly in supporting both productivity and safety.
