In the demanding world of underground mining, productivity is everything. Crews operate around the clock, navigating confined spaces, sharp debris and high-risk conditions. In these environments, equipment reliability is not just a matter of efficiency—it is a matter of safety. One of the most common and disruptive challenges in underground mining is flat tyres. They bring operations to a grinding halt, jeopardise safety and inflate maintenance budgets. That is where Carlisle steps in with a proven solution to keep mining vehicles moving, day in and day out, with TyrFil flatproofing.

Mining is an industry where every minute counts. A single hour of unscheduled downtime for a piece of equipment like a load, haul, dump (LHD) loader or underground haul truck can cost thousands of dollars in lost productivity. Multiply that by several flat tyres a month and it is easy to see how these setbacks can eat into a mine’s bottom line.

Beyond the direct cost of idle machines, there are ripple effects: delayed project timelines, disrupted workflows, and the labor hours required for tyre repair or replacement. For underground operations that work on tight margins and schedules, the financial impact of tyre failures can be staggering.

Why Air-Filled Tyres Fall Short

Air-filled pneumatic tires, while offering flexibility and ride comfort, are simply not built for the punishing environment below ground. Sharp rock fragments, metal debris and uneven surfaces can easily puncture tyres. Even with proactive maintenance, the risk of sudden flats is ever-present.

Underground mines, with their narrow tunnels and limited maneuvering space, make emergency tyre changes a logistical nightmare. Replacing a flat can require transporting equipment out of the shaft, mobilising specialised repair crews, and halting nearby operations for safety — all of which further compounds downtime.

Moreover, maintaining consistent tyre pressure underground is difficult. Variations in pressure not only increase the likelihood of flats but also compromise handling and stability, creating additional safety concerns for operators.

TyrFil Flatproofing is the Smarter Alternative

TyrFil eliminates the risk of flats entirely by replacing the air in pneumatic tyres with a polyurethane liquid that cures into a resilient elastomer core. Once filled, the tyre becomes completely flatproof, able to withstand the most hostile environments without failure.

This proprietary flatproofing material has been trusted in underground mining applications for more than five decades. It absorbs impacts, resists punctures, and maintains consistent internal pressure without the need for ongoing inflation or monitoring. That means zero flats, fewer maintenance interruptions, and safer operations.

Safety and Operator Comfort

Underground mining is not only tough on machines, it is tough on people. Operators spend long hours navigating rough terrain in low-light conditions, often in hot and humid environments. Fatigue, musculoskeletal strain and injury risk are persistent concerns.

TyrFil contributes to operator well-being by reducing vehicle bounce and minimising jarring movement over rough terrain. This smoother ride helps reduce physical strain, decrease operator fatigue and, ultimately, improve jobsite safety. Equipment fitted with tyre-filled pneumatics also exhibits improved stability, making it easier to maneuver through tight spaces without compromising control.

In a setting where visibility is limited and hazards are high, greater control means greater safety for the entire crew.

Protecting Equipment Investment

Mining equipment represents a significant capital investment. From underground loaders to drill rigs, these machines are subjected to relentless wear and tear. One often-overlooked contributor to equipment degradation is repeated shock from tyre failures and rough ride conditions.

TyrFil helps cushion that impact, extending the life of not just the tyre but the entire vehicle. By absorbing energy and reducing vibration, it protects axles, suspensions and hydraulic components from premature wear. That translates to fewer repairs, longer service intervals and extended equipment life.

This layer of protection is especially critical in underground environments, where transporting equipment for repair is costly and time-consuming.

Switching to TyrFil is more than a preventative measure, it is a smart investment in operational efficiency. The return on investment begins with the immediate elimination of flat-related downtime and continues with long-term savings on maintenance and repairs.

Here is what mines can expect from the switch:

• Zero flats: Eliminate the recurring costs of patching or replacing damaged tyres.
• Lower maintenance costs: Reduce repair frequency and extend the life of critical components.
• Increased uptime: Keep equipment in service longer with fewer disruptions.
• Improved safety: Create a more stable, controlled work environment for operators.
• Predictable budgeting: Minimise emergency repair expenses and better forecast maintenance spending.

When a tyre filled with TyrFil encounters debris that would normally cause a flat, it keeps rolling, uninterrupted and uncompromised. Over time, these avoided disruptions add up to significant savings and a more efficient operation.

Proven Performance, Backed by Experience

Carlisle TyrFil is not a newcomer to the mining industry. For over 50 years, TyrFil flatproofing technology has been tested and trusted in the most demanding jobsite conditions around the world. From deep shaft coal mines to narrow vein gold operations, the technology has consistently delivered performance, reliability and safety.

With multiple durometer options available, TyrFil can be tailored to meet the specific needs of different equipment types and operating conditions. That means whether you are managing a fleet of underground utility vehicles or specialised drilling rigs, there is a TyrFil formulation designed for your environment.

Underground mining is one of the harshest operating environments on earth. Every decision, from the tyres to the tools, matters when lives and livelihoods are on the line. Flat tyres do not belong in these settings — and with TyrFil, they do not have to be.

By eliminating flats, enhancing safety, protecting equipment and improving operational efficiency, Carlisle TyrFil helps mines stay productive, profitable and prepared for whatever challenges lie ahead. Because below the surface, there is no room for downtime.

Keep moving forward. Keep mining strong. Keep rolling with TyrFil.

Learn more at https://carlisletyrfil.com/who-we-serve/mining-applications/.