Standard Operating Procedure Tyres, Wheels and Rims Management

Standard Operating Procedure Tyres, Wheels and Rims Management

Document Number: Document Owner: Approval Date: VULCAN MINE VUL-SOP-072a-Tyres, Wheels and Rims

Management Document Controller 08 / 09 / 2020

Vulcan Mine - Safety and Health Management System Standard Operating Procedure – Tyres, Wheels and Rims Management

Version Approval Date Review Date Print Date Page 2 of 26 02 14/07/2020 14/07/2023 8/9/2020 10:53 AM UNCONTROLLED DOCUMENT WHEN PRINTED

Contents

1. PURPOSE........................................................................................................................................................................................... 4 2. SCOPE ................................................................................................................................................................................................. 4 3. DEFINITIONS .................................................................................................................................................................................. 4 4. PROCEDURE .................................................................................................................................................................................... 5

Mandatory Requirements .............................................................................................................................................. 5 Hazards .................................................................................................................................................................................. 5 Technical Guidance ........................................................................................................................................................... 6

Selection and Procurement ...................................................................................................................................... 6 Exclusions ........................................................................................................................................................................ 6

Receipt and Storage of Tyres, Wheels and Rims .................................................................................................. 6 Transportation, Receipting, Loading, Handling and Unloading .............................................................. 6

Competent Personnel ...................................................................................................................................................... 8 Remove and Fit Wheel or Rim Assemblies; Demount and Mount Tyres and Tubes ...................... 8 Off the Road Tyre Fitting Verification of Competency ................................................................................. 8 Remove and Fit Light Vehicle Wheels and Tyres ........................................................................................... 8 Summary of On-Site Competency Requirements ........................................................................................... 9

Tyre Operation .................................................................................................................................................................... 9 Hazardous Tyres, Wheels and Rims ....................................................................................................................... 10 Maintenance and Inspections ................................................................................................................................... 10

Tyre Inspections ........................................................................................................................................................ 10 Scheduled Service Inspections ............................................................................................................................ 11 Tyre Size, Pressure and Torque Chart ............................................................................................................. 11 Tyre Pressure Checks .............................................................................................................................................. 11

Tyre Deflation ................................................................................................................................................................... 12 Tyre Handler ..................................................................................................................................................................... 12 Remove and Fit Wheel and Rim Assemblies ...................................................................................................... 13

Record Wheel, Rim and Tyre Changes........................................................................................................ 13 Plant Setup ......................................................................................................................................................................... 13 Remove and Fit Multi-Piece Wheel and Tyre Assembly ................................................................................ 14 Remove and Fit Multi-Piece Rim and Tyre Assembly .................................................................................... 14 Light Vehicles and Transportable Equipment ................................................................................................... 15 Remove and Fit Wheels – Split Rims ...................................................................................................................... 15 Torque Wheel and Rim Retaining Nuts/Bolts ................................................................................................... 16

Retaining Nut/Bolt Torque .............................................................................................................................. 16 Re-Torque Wheels ............................................................................................................................................... 16 Re-Torque Demountable Rims....................................................................................................................... 16

Demounting Tyre – Five-Piece Rim ........................................................................................................................ 17 Wheel and Rim Inspections and Repairs ............................................................................................................. 18



General Rim Inspections ................................................................................................................................... 18 Non-Destructive Testing Inspection of Wheels and Rims greater than 24 inches ................. 18 NDT Inspection or Replacement of Wheels and Rims up to 24 inches ........................................ 19

Wheel and Rim Repairs ................................................................................................................................................ 19 Tyre Inspections and Repairs.................................................................................................................................... 19

Tyre Inspections ................................................................................................................................................... 19 Tyre Repairs ........................................................................................................................................................... 19

Mount Tyre – Five-Piece Wheel or Rim ................................................................................................................ 20 Vertical Mounting Tyre to Wheel or Rim ............................................................................................................. 20 Demount and Mount Light and Medium Vehicle Tyres ................................................................................. 21

Medium Vehicle Multi-Piece Wheels or Rims ......................................................................................... 21 One-piece Wheels ................................................................................................................................................ 21

Tyre Inflating .................................................................................................................................................................... 21 Tooling ...................................................................................................................................................................... 21 Tyre Inflation Exclusion Zones ...................................................................................................................... 22 Vertical Wheel or Rim and Tyre Assembly ............................................................................................... 22 Horizontal Tyre and Rim Assembly ............................................................................................................. 22 Sealing Assembly and Seating Components ............................................................................................. 23 Final Inflation ........................................................................................................................................................ 23

Record Keeping................................................................................................................................................................ 24 5. ROLES AND RESPONSIBILITIES .......................................................................................................................................... 24 6. REFERENCES ............................................................................................................................................................................... 24 7. REVIEW .......................................................................................................................................................................................... 25 8. AUTHORISATION ....................................................................................................................................................................... 25 9. AMENDMENTS ............................................................................................................................................................................ 26 10. DOCUMENT REVIEW: ATTENDANCE RECORD ............................................................................................................ 26

Tables Table 1: Summary of On-Site Competency Requirements .......................................................................................... 9

Table 2: Tyre Recommended Pressures ........................................................................................................................... 24

Figures Figure 1: Dual Wheel Assembly. .......................................................................................................................................... 14

Figure 2: Rim and Tyre Assembly - Retained by Cleats, Wedges or Wedge Band ......................................... 15

Figure 3: Two Halves of a Split Rim ................................................................................................................................... 16

Figure 4: Five Piece Wheel/Rim Components ............................................................................................................... 17

Figure 5: Wheel Checking Points ......................................................................................................................................... 18

Figure 6: Tyre Inflation Exclusion Zone ........................................................................................................................... 22

Figure 7: Tyre inflation exclusion zone ............................................................................................................................ 23



1. PURPOSE

The purpose of this procedure is to describe the action to be taken and the management of hazards and risks associated with the fitting, removing, testing, maintaining and repairing of tyres, wheels and rims on fixed and mobile plant at the Vulcan Mine.

This procedure has been developed to ensure compliance with the following section of the CMSHR:

• s72(a) ‘fitting, removing, testing, maintaining and repairing tyres and rims on fixed and mobile plant'.

2. SCOPE

This procedure is applicable to all persons at the Vulcan Mine including employees, contractors and visitors.

The controls within this procedure are mandatory.

3. DEFINITIONS

Authorised Person A person who has the required competencies and who has been appointed by the Site Senior Executive to carry out a designated scope of duties.

CMSHA Queensland Coal Mining Safety and Health Act (1999).

CMSHR Queensland Coal Mining Safety and Health Regulation (2017).

CMW Coal Mine Worker.

Competent Person A person who has, through a combination of training, education and experience, acquired knowledge and skills enabling that person to perform correctly a specified task.

HME Heavy Mining Equipment.

JHA Job Hazard Analysis.

kPa Kilopascal.

NATA National Association of Testing Authorities.

NDT Non-destructive Testing.

OEM Original Equipment Manufacturer.

OTR Off the Road.

psi Pounds per Square Inch.



SHMS Safety Health Management System.

SOP Standard Operating Procedure.

SSE Site Senior Executive.

Take 5 Personal Risk Assessment.

TKPH Tonne kilometres per hour.

VOC Verification of Competency.

WLL Working Load Limit.

4. PROCEDURE

Mandatory Requirements

The core mandatory requirements and expectations of Vulcan Mine are that all workers (including internal employees, contractors and visitors) will follow the SHMS as it applies when working. Should a system gap be identified, a Supervisor must be notified immediately, and a risk assessment conducted before the work can continue.

Further mandatory requirements identified include the following:

• all workers will comply with CMSHA s. 39 Obligations of persons generally; • all workers shall be trained, competent and authorised to be on site and to carry out those tasks

specific to their role; • all workers must present themselves in a state fit for duty and unaffected by drugs, alcohol, fatigue

and other physical or psychological impairment; • all workers will conduct a personal risk assessment (Take 5) prior to undertaking tasks and in the

event of a change to the conditions, process or environment; • there are risk assessments (JHAs) in place under which tasks are being carried out. These risk

assessments may indicate controls that go above and beyond the legislative or SHMS requirements and must be followed;

• workers will follow the direction of all signage as if given as an instruction by their Supervisor; • errant behaviours are prevented through compliance to the training scheme, and managed

appropriately through supervision and site discipline procedures; • at any stage should a worker feel unsafe or at risk when undertaking a task, they are to stop work,

make the area safe (if necessary and possible) and immediately report this to their Supervisor; and • if a worker sights another worker undertaking a task, which they feel is unsafe or at risk, that work

may be stopped, and a Supervisor immediately notified.

Hazards

Incidents resulting from the sudden, uncontrolled release of stored energies during tyre maintenance activities have resulted in serious personal injuries and fatalities.

Tyre maintenance activities are considered high-risk and a disciplined approach is required to ensure that personnel involved in these activities:



• hold the relevant competencies and authorisations for the task; • have the correct tools and equipment available to perform the task; and • have access to the relevant procedures and work instructions for the task.

Hazards associated with the operation and maintenance of tyres, wheels and rims may include:

• incorrect handling of wheel and rim components; • handling wet tyre, wheel and assemblies; • uncontrolled plant movement during tyre maintenance; • ejection or release of tooling or components; • rim or component failure; • tyre explosion; • tyre burst; • tyre fires; and • wheel nuts coming loose.

Technical Guidance

Selection and Procurement

Personnel who select tyres shall ensure the tyre is fit for purpose, i.e. capable of performing the task safely.

Information and guidance on tyre selection is available from the plant OEM, tyre specialists within the Vulcan Mine team and DNRME Recognised Standard 13.

Where any tyre is found not to have the appropriate specification for the given application, the tyre shall be replaced with a tyre of the appropriate capacity.

Vulcan Mine and contractor procurement must consider tyre and rim specifications to ensure they are appropriate for the intended application. Procurement officers shall seek guidance from tyre specialists within the Vulcan Mine team and OEMs.

Exclusions

Two-piece or multi-piece wheels are not to be used on light or medium vehicles where a one-piece option is available; SSE approval required.

Receipt and Storage of Tyres, Wheels and Rims

Transportation, Receipting, Loading, Handling and Unloading

When transporting assembled tyres, wheels and rims, the following shall occur:

• the inflation pressure shall be 25-35psi (175-240kPa) for haul truck tyres with 24 inch rim size or larger;

• in the absence of specifically designed vertical transportation trailers, the tyre, wheel or rim shall lay flat and be secured with tie down straps; and

• the plant hauling the tyres, wheels or rims shall have adequate signage and be escorted if the load is over-width for the route to be travelled.

https://www.dnrme.qld.gov.au/__data/assets/pdf_file/0004/986071/recognised-standard-13.pdf



Where tyres have been fitted off site, a fitment verification check must be conducted by a tyre fitter competent in the relevant competency according to the VUL-REG-18-09-Training Needs Analysis. Verify the competencies of the person who assembled the wheel or rim assembly.

When receipting tyres, wheels and rims, the following shall occur:

• check that tyres are at the site’s nominated pressure 25-35psi (175-240kPa)), prior to storage; • OTR tyres have been transported at the site accepted pressure of 25-35psi (175-240kPa), with the

residual pressure marked on the tyre; • tyre sidewall information and wheel or rim branding or stamping shall be visible and segregated

to avoid mismatching; • the wheels or rims are stamped or branded with serial numbers and, if relevant prior history of

tyres, wheels and rims are known; and • transportation with lock ring fitted.

The site tyre management and tracking process for tyres, wheels and rims shall contain:

• tyre, wheel and rim details (e.g. TKPH); • application (equipment and working environment); • pressures, tread history, damage, position, rotation history, hours and/or kilometres; • NDT history; and • maintenance records including repair history.

When handling tyres, wheels and rims, the following shall occur:

• fit for purpose equipment such as a task specific tyre handler shall be used; and • personnel who operate a tyre handler to remove or fit tyres, wheels and rims shall hold the current

nationally recognised competency.

For guidance on the safe use of a tyre handler refer to Section 4.10.

Tyre, wheel and rim assemblies being mounted to OTR plant shall be supported and secured by at least six equally spaced wheel retaining bolts/nuts before an operator can leave the cab of the tyre handler.

Tyres, wheels and rims shall be stored in a designated tyre storage area that is clear, level, and free of flammable materials, petrochemicals or corrosive compounds. The storage area shall have adequate area to enable the tyre handler to operate safely and efficiently.

Storage of tyres, wheels and rims shall be as per the following:

• new and reusable (run out) tyres shall be standing and leaning against stacked scrap tyres or fit for purpose support frames. Support shall be provided to ensure tyres cannot roll sidewards;

• OTR tyres fitted to wheels or rims shall be inflated to a pressure between 25-35psi (175-240kPa); and

• scrap tyres may be stacked on their side. Each stack should contain tyres of a similar diameter, be a maximum of three tyres high and have tyres that have suffered major side wall or impact failures placed on top.



Competent Personnel

Remove and Fit Wheel or Rim Assemblies; Demount and Mount Tyres and Tubes

All personnel who remove and fit wheel or rim assemblies, or demount and mount tyres and tubes, shall hold the relevant national competency and be authorised to perform the task, unless stated otherwise in this document.

For OTR earthmover tyres, wheels and rims with a diameter of 24 inches and above, personnel shall hold current competencies for:

• AURKTJ011 Remove, Inspect and Fit Earthmoving and Off the Road Tyres (or equivalent); • AURKTJ012 Remove, Inspect and Fit Off the Road Wheel Assemblies (or equivalent); and • AURHTJ006 Remove, Inspect, Repair and Refit Heavy Vehicle Tyres and Tubes (or equivalent).

Training for the above competencies shall be provided by training organisations who specialise in the maintenance of OTR earthmover tyres, wheels and rims with a diameter of 24 inches and above. Equivalent competencies shall meet or exceed the requirements of the applicable Australian National Competency Standards.

Personnel who hold the above competencies and are authorised, can perform these tasks on all site plant including light and medium vehicles.

Non-competent personnel who are assisting with the removal and fitting of wheel assemblies and demounting and mounting of tyres and tubes, shall work under the supervision of a competent person.

Maintenance personnel who supervise the maintenance and operation of OTR earthmover tyres, wheels and rims with a diameter of 24 inches and above, shall be trained in relevant competencies.

No tyres, wheels or rims are to be repaired on site.

Off the Road Tyre Fitting Verification of Competency

Personnel shall be verified as competent prior to performing OTR earthmover tyre, wheel or rim maintenance tasks on site. The VOC process shall be applicable to the competency and include theory and practical assessments. The practical assessment shall include:

• horizontal demount and mount an earthmover tyre; • vertical demount and mount an earthmover tyre; • remove and fit an earthmover and medium vehicle wheel and tyre assembly; and • remove and fit a rim and tyre assembly.

Personnel who have not performed any of the above tasks within the previous six months shall complete a practical refresher assessment prior to performing the task.

Remove and Fit Light Vehicle Wheels and Tyres

There is no formal competency requirement to remove and fit light vehicle, ancillary and transportable equipment one-piece wheel and tyre assemblies, however personnel shall:

• have a sound knowledge of the vehicle operation; and • read and understand the wheel changing section of the operating manual.



Summary of On-Site Competency Requirements

Table 1: Summary of On-Site Competency Requirements

Task Competency Requirement

Remove and fit tyre and wheel assembly - light vehicle (≤ 4.5T) with one-piece wheel

No formal competency required.

Read and understand the Wheel Changing section of the Operating Manual.

Remove and fit tyre and wheel assembly - light vehicle (≤ 4.5T) with multi-piece wheel

AURKTJ011 Remove, Inspect and Fit Earthmoving and Off the Road Tyres or equivalent.

Remove and fit tyre, wheel and rim assembly - all plant greater than 4.5T


AURKTJ012 Remove, Inspect and Fit Off the Road Wheel Assemblies or equivalent.

Fit and remove tyres to all wheels or rims


Fit and remove tyres to light vehicle wheels

AURLTJ2002 Remove, Inspect, Repair and Fit Tyres and Tubes (Light) or equivalent

Operate Tyre Handler RIIMPO208D Operate Support Equipment (Tyre Handler) or equivalent

Hazardous Tyre Inspection RIISAM211D Remove Repair and Refit Tyres and Tubes or equivalent

Earthmover Tyre Application Certificate or equivalent

OEM/ Tyre Specialist

Supervise tyre maintenance and operations

Earthmover Tyre Application Certificate or equivalent

Tyre Operation

Tyres should be operated within the tyre manufacturers design specifications and as per recommendations supplied by the tyre manufacturer and tyre specialists. Any tyres operated outside the tyre manufacturers design specifications shall have an approved risk assessment.

Tyres shall not be operated in a manner that is likely to increase the risk of premature failures that impose a risk to the safety and health of personnel using or nearby the plant or involved in the maintenance and operation of the tyres.



Hazardous Tyres, Wheels and Rims

Hazardous tyre, wheel or rim conditions present a real danger to personnel operating, maintaining or in the direct vicinity of HME. Hazardous tyre, wheel or rim situations can include:

• deep or long side wall cut; • belts exposed; • tread lug detachment; • hot tyre or tread detachment due to heat; • sidewall splits, bulges or deformation; • run flat or under inflated tyre; • tyre directly exposed to fire; • plant contact with a high or low voltage power source; and • plant struck by lightning.

Hazardous tyres, wheels and rims shall be inspected by a competent person.

The area around the direct vicinity of the plant shall be evacuated, a hazardous tyre exclusion zone established and the tyres allowed to stabilise for 24 hours if:

• plant has been struck by lightning or contacted a low or high voltage power source; • the tyre has been exposed to extreme heat or fire; • hot tyre is present; or • considered to be at risk of burst or exploding for any other reason.

Suspected hot tyres shall be monitored and appropriate controls put in place. This may include monitoring tyre pressures, changing the tyre operation, parking the plant up to allow the tyre to stabilise or removing the tyre from service. Hot tyres and suspected hot tyres shall be managed by a competent and authorised person.

Rubber tyred plant that has contacted a low or high voltage power source or been struck by lightning shall be given a 300-metre exclusion zone and not approached for 24 hours.

Maintenance and Inspections

Tyre Inspections

Visual inspections carried out by operators and maintenance personnel may include:

• tyre inflation; • tyre leaks; • tyre wear; • cuts to side walls and tread area; • bulges or deformation; • stones or items imbedded in the tread; • exposed wire or carcase materials; • signs or smell of a hot tyre; • damaged/misplaced wheel or rim or components; • loose wheel or rim retaining bolts/nuts;



• rocks caught between dual wheels; and • damaged or bent rock ejectors.

Items considered to be unsafe or present a risk to machinery damage shall be reported to the Supervisor.

Scheduled Service Inspections

The maintenance personnel shall inspect tyres during the scheduled service inspections. The tyre inspection shall include:

• tyre inflation pressures; • tyre tread depths; and • tyre condition.

Tyre Size, Pressure and Torque Chart

An approved VUL-ATT-002-Tyre Size, Pressure and Torque Chart shall be displayed in prominent locations within the mobile plant maintenance area. The chart shall include:

• plant make and model; • tyre brand, size and ply; • rim size; • the OEM’s recommended cold inflation pressure of the tyre and carrying capacity; • the OEM’s recommended torque setting for retaining nuts; • storage and transport pressure limits; and • all tyres with a diameter less than 24 inches shall refer to OEM specifications.

All tyres operating under dispensations from the tyre manufacturer shall be clearly highlighted on the VUL-ATT-002-Tyre Size, Pressure and Torque Chart.

Tyre Pressure Checks

Gauges A tyre master gauge system shall be available and maintained on site.

The tyre master gauge shall be recalibrated annually and records kept. The date of the last recalibration shall be displayed on the tyre master gauge.

Field tyre pressure gauges should consist of a digital or analogue, preferably liquid filled, gauge with a length of hose that has an in-line filter.

Pencil type tyre pressure gauges shall not be used.

Prior to performing tyre pressure checks in the field, the field tyre pressure gauge should be checked for accuracy against the tyre master gauge. Field tyre pressure gauges found to be inaccurate (beyond +/- 2psi/13kPa) shall be recalibrated or disposed of.

Intervals Pressures on currently working plant tyres with a diameter of 24 inches and above should be checked at intervals no greater than seven days.

Pressures on currently working plant tyres that have a diameter less than 24 inches shall be checked when scheduled services are performed and more frequently if required.



Pressures Pressures shall be maintained at the tyre manufacturer’s recommended cold inflation pressure.

Tyres on plant observed operating with pressures that are greater than 80% and less than 100% of the recommended cold inflation pressure shall be adjusted to the recommended cold inflation pressure.

Tyres on plant observed operating with pressures 130% or greater of the recommended cold inflation pressure, shall be treated as a hot tyre in accordance with site procedures.

A tyre on plant that has been observed operating with a pressure that is less than 80% of the specified cold pressure shall be deflated and removed from service. The tyre, wheel and rim assembly shall be dismantled and inspected prior to reassembly.

Tyres subjected to a controlled deflation to zero psi can be re-inflated once the locking ring has been inspected.

Recording Pressures for tyres shall be checked and recorded weekly.

Tyre Deflation

Correct tooling shall be used to remove the valve core. Care shall be taken as the valve core can be ejected by the air pressure once it is unscrewed.

An air muffler should be utilised to reduce the noise of the escaping air and capture any foreign debris escaping from the valve stem.

Acceptable methods of determining that tyres are fully deflated include:

• inserting a piece of wire down through the valve stem to check for a clear opening with no blockages; or

• using compressed air, inflate the tyre for a few seconds, remove the air source and check that the amount of air inputted, is now exhausting out of the stem opening.

Hydraulic pressure shall not be used to clear blocked valving.

Tyre Handler

A pre-start inspection shall be performed prior to operating a tyre handler.

The tyre handler shall not be overloaded due to the total weight of the load being lifted. Refer to the OEM manual:

• WLL specifications for the tyre handler machine and attachment; and • weight specifications for the tyre, wheel and rim. Consideration should be given to tyres that may

contain water ballast.

Unless the tyre handler design negates the need, tyre handlers shall be fitted with:

• anti-fallback arrestors that are in serviceable condition and locked in place before allowing tyre fitters to enter the operating space of the gripper arms; and

• over-pressurisation alarm/relief system fitted to the hydraulic clamping action of tyre handlers.

Hose burst protection shall be fitted directly to the load sharing ends of hydraulic cylinders on mobile plant used to carry tyre handlers. Burst protection shall consist of either controlled lowering devices, pilot-operated check valves or counterbalance valves.



Personnel shall remain clear of the tyre handler operation until the tyre is safely positioned. A spotter shall guide the operator if required.

The operator of the tyre handler shall not leave the cab of a tyre handler whilst a tyre is clamped in a vertical position and not supported on the wheel or rim base.

Tyre, wheel and rim assemblies being mounted to OTR plant shall be supported by at least six equally spaced wheel retaining bolts/nuts before an operator can leave the operator’s position of the tyre handler.

The tyre handler may be used to manoeuvre the tyre on the wheel or rim during the initial tyre inflation process to help the tyre to seal. Once the seal has been made, the air supply shall be shut off and the tyre handler removed from the clamping position.

A tyre shall not be clamped by a tyre handler during the tyre inflation process.

Remove and Fit Wheel and Rim Assemblies

Before removing a wheel or rim assembly, a visual inspection of the tyre, wheel or rim shall be carried out. Suspect wheel or rim assemblies shall be deflated to zero psi before the removal process begins.

Before the removal process begins:

• tyre and wheel assemblies shall be deflated to 10psi (70 kPa); • dual mount tyre and wheel assemblies shall both be deflated to 10psi (70 kPa); • tyre and rim assemblies shall be deflated to zero; or • dual mount tyre and rim assemblies shall both be deflated to zero.

Before fitting a tyre, wheel or rim assembly, a competent person shall ensure:

• all mating surfaces are clean and free of paint, damage or burrs; • all wheel retaining studs/bolts are in place, clean and in good condition. Damaged studs/bolts are

to be replaced; and • retaining nut/bolt torqued as recommended by the OEM or nominated higher standard.

If a multi-piece wheel or rim and tyre assembly is dropped for any reason during general handling or the process of turning the assembly over, the tyre assembly shall be deflated to zero and the lock ring checked to ensure it is correctly positioned and seated. Tyres may be re-inflated in accordance with standard tyre inflation processes.

Record Wheel, Rim and Tyre Changes

Tyres, wheels or rims with a mounting diameter of 24 inches and above shall have individual identification numbers and all changes recorded in the VUL-REG-18-32-Tyres and Rims Register.

Plant Setup

Prior to changing tyres, wheels or rims, the plant setup shall be carried out in accordance with OEM and site procedures.

Jacks shall be inspected and be able to be safely positioned without the operator having to be under the plant.

Personnel shall not be under the plant when it is being raised or lowered.

Personnel shall not enter the area under a plant raised by a jack that is not supported by certified safety support stand or a jack with a mechanical locking mechanism engaged.



Personnel shall not be in the immediate vicinity of tyres when the weight of the plant is transferred onto the tyres.

Remove and Fit Multi-Piece Wheel and Tyre Assembly

Figure 1: Dual Wheel Assembly.

Wheels are manufactured with nave plates that are retained to the plant hub with bolts/studs/nuts. Refer Figure 1 above.

Tyres fitted on wheel assemblies shall be deflated to a maximum pressure of 10psi (70kPa) prior to any retaining nuts being loosened.

Before fitting the replacement tyre and wheel assembly, a competent person shall ensure the lock ring is correctly seated and other wheel or rim components are correctly positioned.

The tyre handler shall:

• have a firm grip of the tyre and wheel assembly prior to the removal of the wheel nuts; and • not release the tyre and wheel assembly from the tyre handler before the tyre and wheel assembly

is mounted to the hub, with at least six evenly spaced wheel nuts installed and firmly tightened.

Remove and Fit Multi-Piece Rim and Tyre Assembly

This section refers to multi-piece rim assemblies with lock rings.

Tyre and rim assemblies are retained by spacers, cleats, wedges or wedge bands which are clamped by bolts/studs/nuts.

The risks associated with the removal of cleat/wedge style rims is far greater than nave plate mounted wheels, due to the clamping force of the retaining nuts forming part of the structural integrity of the dual rim assembly as seen in Figure 2.



Figure 2: Rim and Tyre Assembly - Retained by Cleats, Wedges or Wedge Band

Tyres shall be deflated to zero psi prior to loosening any retaining nuts/wedges. Cleats and wedge bands shall be loosened prior to the removal of any retaining nuts. On dual rim applications both tyres shall be deflated to zero psi.

Before fitting the replacement tyre and rim assembly, the tyre shall be inflated to 10psi (70kPa). A competent person shall ensure the lock ring is correctly seated and other wheel or rim components are correctly positioned.

The tyre handler shall:

• have a firm grip of the tyre and rim assembly prior to the removal of the retaining nuts; and • not release the tyre and rim assembly before the tyre and rim assembly is mounted to the hub with

at least six evenly spaced retaining clamps installed and firmly tightened.

Light Vehicles and Transportable Equipment

Multi-piece wheels or rims shall not be used on light vehicles or transportable equipment where a one-piece option is available. Where no other option is available and multi-piece wheels must be used, SSE authorisation is required.

Light vehicle and transportable equipment wheel and tyre assemblies may be removed and fitted in accordance with the manufacturer’s recommended tyre inflation pressures.

Light vehicle and transportable equipment wheel and tyre assemblies shall be removed and installed in accordance with the plant operating manual.

Remove and Fit Wheels – Split Rims

A split or divided rim is made in two halves held together by a circle fitted of bolts. There are two sets of bolts:

• inner set - retains the wheel assembly to the machine; and • outer set - retains the two rim halves.

Plant with split rims shall have a warning system in place consisting of signage to indicate split rims are fitted and the bolts retaining the rim halves (the outer set) shall be clearly identifiable.

Split rims should be replaced with one-piece rims where a one-piece option is available. Where no other option is available and split rims must be used, SSE authorisation is required.



Tyres shall be deflated to zero psi prior to loosening any retaining nuts/bolts.

Figure 3: Two Halves of a Split Rim

Torque Wheel and Rim Retaining Nuts/Bolts

Retaining Nut/Bolt Torque

Wheel and rim retaining nuts/bolts shall be torqued to the manufacturer’s specification utilising a torque tool and attachments. A wheel and rim torque record should be completed by the person who performs the initial nut/bolt torque.

Light vehicle wheels changed in the field should be torqued to specifications as soon as practicable after wheel change.

On completion of a wheel or rim change, where re-torque is required, a Re-Torque Tag shall be displayed in a prominent location within the operator’s cab and only be removed by the person who performed the final re-torque.

Re-Torque Wheels

Wheel retaining nuts/bolts on wheels that have been removed or fitted (excluding inner wheels on dual wheel applications) shall be re-torqued after approximately one hour of operation.

Inner wheel retaining nuts/bolts shall be visually inspected to ensure they are all in place and secure with no signs of movement or fretting. If signs of movement or fretting are identified, the outer wheel shall be removed to inspect and re-torque the inner wheel retaining nuts/bolts.

Re-Torque Demountable Rims

Rim retaining nuts shall be re-torqued on all rims that have been removed or refitted to ensure the retaining system of cleats, wedges, spacers and bands are fully seated. This may require several re-torques which shall include:

• Re-torque 1: performed after one load in a controlled environment or no greater than one hour of operation; and



• additional re-torques: these are required after loads three and seven, until there is no movement of any of the nuts/bolts.

Removed re-torque tags and completed wheel and rim torque record should be given to the Maintenance Supervisor.

Demounting Tyre – Five-Piece Rim

The tyre and wheel/rim assembly shall be deflated to zero before commencing work on the tyre.

A soft hammer shall be used during both assembly and disassembly to ensure rim components are not damaged, especially on the leading edge of the bead seat band.

Figure 4: Five Piece Wheel/Rim Components

Keep fingers or hands free from pinch points when handling lock rings or components. Appropriate tooling to break beads, tyre levers and lifting equipment shall be used.

Personnel shall remain outside of the line of fire when using bead breaker tooling.



Wheel and Rim Inspections and Repairs

General Rim Inspections

Figure 5: Wheel Checking Points

Only wheel and rim and components that are permanently and clearly marked with the size, brand and style or part number/product code, that can be referenced, shall be used. These should be visible when the wheel or rim is fully assembled with a tyre.

Wheel and rim assemblies shall have clear manufacturer’s markings and be size and style compatible.

The lock ring, bead seat band, side rings and rim base on any one wheel or rim assembly shall all be the same size and style before being reused.

During the life cycle of a wheel or rim assembly, the gutter and/or back section welded components may be replaced by an authorised repairer. All replacement components must be size and style compatible.

All contact surface areas of rim components, including the O-ring groove, shall be cleaned without removing any parent material. High speed wire rotating brushes or buffing pads may be required.

All rim components shall be visually inspected for deformities, cracks and excessive corrosion pitting after cleaning. Any damage to the bead seat band, especially in the lock-ring area, shall be repaired in accordance with the OEM’s guidelines. Any component found to exhibit damage beyond the OEM’s limitations shall be scrapped.

One-piece lock ring ends shall overlap when in their free state (not fitted to the rim base) or be scrapped. The ends of the lock ring shall not touch when it is fitted to the rim base.

Non-Destructive Testing Inspection of Wheels and Rims greater than 24 inches

Wheels and rims with a diameter greater than 24 inches shall be removed for NDT inspections, wheel and rim refurbishment or replacement at the following frequencies and tolerances:

• new off-the-road wheels and rims - first NDT inspection at 15,000 hours or three years whichever comes first;

• thereafter every 15,000 hours or three years, whichever comes first; • used off-the-road wheels and rims with known NDT inspection history – subsequent NDT

inspections at 15,000-hour intervals or three years, whichever comes first;



• use off-the-road wheels and rims without known NDT inspection history – NDT inspection required before the wheels and rims are put into service; or

• Vulcan Mine approved wheel and rim refurbishment – Subsequent NDT inspections at 15,000-hour intervals or three years, whichever comes first; and

• a tolerance of 10% is allowable for NDT inspections.

NDT Inspection or Replacement of Wheels and Rims up to 24 inches

Multi-piece wheels or rims shall have NDT inspections at intervals no greater than five years, or as recommended by the rim manufacturer. NDT inspection dates shall be stamped on the wheel or rim.

Evidence of the age of each wheel or rim is required before the plant shall be put into service.

Rim history shall be recorded in the IMS.

One-piece wheels or rims shall be replaced on condition.

Wheel and Rim Repairs

Hot work shall not be performed on any wheel or rim component on site. An explosion can occur when welding or heating a wheel or rim, which is fitted with an inflated or deflated tyre.

Wheel and rim inspection and repairs shall be performed by the rim manufacturer or an authorised wheel and rim repairer. A NATA certified (or SSE approved equivalent) NDT inspection report and certificate of conformance shall be supplied with the rim when it is returned to site.

Remedial repairs to mechanical damage on bead seat bands and side rings can be carried out to the extent that it is permitted by the OEM manual.

Re-rolling or attempting to bend lock rings back into a conforming shape on site is not permitted under any circumstances.

Tyre Inspections and Repairs

Tyre Inspections

When fitting used tyres, an inspection shall be carried out prior to fitting. Tyres showing signs of bubbles, deformation or separation of the inner liner shall not be fitted unless an inspection has been carried out by a competent and authorised person.

Tyre Repairs

Repair of OTR tyres shall be performed by an authorised tyre repairer.

The repairer shall mark repaired tyres with ‘X’, ‘XX’ or ‘XXX’ to indicate the extent of the repair and recommendation for the future operation of a tyre. The identification marks shall be adjacent to the serial number on both sidewalls of the repaired tyre and should be at least 25 millimetres high. The repairer’s brand mark shall precede the ‘X’ markings.

‘X’ - A tyre that has a minor repair and is suitable for fitment on plant in any position with no restrictions.

‘XX’ - A tyre that has an intermediate repair and the extent of the damage did not completely penetrate the tyre. The repaired tyre is not for front wheel position with the exception of motor graders and wheel dozers. The end user may exercise the option of facing the repair to the chassis.



‘XXX’ - A tyre that has a major repair and the extent of the damage resulting from a full penetration of tyre casing. An internal reinforcing patch will be evident at the site of the damage. The repaired tyre is not suited to front wheel position with the exception of motor graders and wheel dozers, and the end user may position the repair facing the chassis. An additional ‘XXX’ or other identification shall be marked on the shoulder of the tyre adjacent to the repair.

Mount Tyre – Five-Piece Wheel or Rim

Any wheel or rim assemblies shall be size and style compatible. The lock ring, bead seat band, side rings and rim base on any one wheel or rim assembly shall all be the same size and style before being reused.

Tyres shall be assembled with tyre assembly lubricant as recommended by the tyres and/or rim manufacturers. Petroleum greases shall not be used to lubricate tyres.

Wheel or rim assemblies that are 49-inch, EV style shall be fitted with a sure-lock ring, or where currently not fitted, replaced at the next tyre change with a sure-lock ring. If there are no serviceable sure-lock rings available on site at the time of assembly, a documented inspection must be completed.

Tyres with a diameter of 24 inches and above shall have the manufacturers recommended volume of tyre inhibitor added prior to fitting. Radiator coolants shall not be used as tyre inhibitor.

Soft faced hammers shall be used to tap lock rings into place during inflation due to the risk of damage to rim components and fragmenting steel particles.

During inflation, the leading edge of bead seat band shall clearly pass the lock ring. The bead seat band shall only contact the lock ring on the angled seating area.

Vertical Mounting Tyre to Wheel or Rim

Vertical mounting is the de-mounting and mounting of a tyre while the wheel or rim is attached to the plant.

Vertical mounts of tyres greater than 49 inches shall not be performed without fit for purpose tooling and equipment. Tooling and equipment may include lifting tools or component mounting stands.

Cutting and re-joining O-rings to allow the replacement of an O-ring on an inner position dual tyre while the outer dual tyre remains, is not permitted.

When inflating a vertical mount:

• lock ring and bead seat components shall be checked to ensure they are correctly positioned; • an inflation tool shall have adequate length of hose to allow remote inflation and pressure checks

outside the tyre inflation exclusion zone; • the tyre handler shall be parked in front of the tyre to restrict access and exits to the tyre handler; • personnel shall never stand in front of the tyre. They shall always stand to the side, at a maximum

distance allowable to the air supply pressure check point; • barricades or signage shall be used to ensure the safety of others outside of the established tyre

inflation exclusion zone; and • when performing a vertical mount on the outside position of a dual wheel/rim assembly, the inside

position can be deflated to a maximum of 10psi (70kPa).



Demount and Mount Light and Medium Vehicle Tyres

Medium Vehicle Multi-Piece Wheels or Rims

The tyre shall be deflated to zero before demounting and mounting tyres. Fit for purpose tools must be used.

Carry out inspection of wheel or rim, flange and lock ring, checking for defects, cracks, corrosion, etc. The lock ring shall be the correct profile to suit the wheel or rim groove and snap into position.

Any defects shall be reported to the Maintenance Supervisor.

Wheels or rims shall be replaced if they are older than five years or an NDT inspection has not been completed within the last five years.

Place the wheel or rim tyre assembly in a safety cage and inflate to approximately 5psi (35kPa). Ensure lock ring is secured in its groove. Tap into position with a soft hammer if required.

All repaired or second-hand medium vehicle tyres shall be inflated in a safety cage to 120% of the recommended cold inflation pressure and held for 20 minutes to test the integrity of the casing. The pressure shall be then reduced to the recommended pressure before mounting to the vehicle.

One-piece Wheels

Fit for purpose tyre changing equipment shall be used to break beads on one-piece wheels to reduce the damage to bead seat and flange areas, or wheel should be sent to an off-site supplier who can change these tyres safely and efficiently.

Tyre Inflating

Wheel or rim components that are damaged, incorrectly seated or incompatible, increase the risk for sudden and catastrophic release of stored energy during the tyre inflation process which can result in serious personal injury or fatality.

Barricades and signage shall be erected to ensure the tyre inflation exclusion zone is not accessible during inflation. A competent person may remain in this area for initial seating of the assembly but shall remain out of the extreme danger zone while air is being delivered into the tyre.

Tooling

Signs of wear or damage shall be repaired or tagged Out of Service.

The inflation tool shall have an adequate length of hose to allow remote inflation and pressure checks outside of the tyre inflation exclusion zone.

A safety cage shall be available on site for the inflation and seating of light or medium vehicle tyres fitted to multi-piece wheels or rims.

Soft faced hammers shall be used to seat lock rings or align other wheel or rim components during inflation.

Pressure gauges used during inflation shall be checked for accuracy against the tyre master gauge.

Screw-on super large bore inflation tools shall have a single piece chuck and shaft component as the chuck engages and retains the super large bore valve core housing when it is removed. Tools that do not meet this standard shall be replaced immediately with a conforming device.

Inflation tools which screw onto a valve extension shall be checked to ensure they have been securely attached prior to commencing inflation.



Tyre Inflation Exclusion Zones

Exclusion zones shall be established for tyres fitted to multi-piece wheels or rims that cannot practicably be inflated in a safety cage.

A tyre inflation exclusion zone shall be clearly defined with barricading and signage. A competent person may remain in this area for initial seating of the assembly but shall remain out of the extreme danger zone while air is being delivered into the tyre.

Vertical Wheel or Rim and Tyre Assembly

A tyre inflation exclusion zone for a vertical wheel or rim and tyre assembly shall cover an area at least 1.5 times the overall diameter of the tyre on either side of the centre point and extend at least six metres outwards from the inner facing side of the tyre being inflated.

Figure 6: Tyre Inflation Exclusion Zone

The tyre handler shall be placed as close as practicable in front of the tyre and rim assembly being inflated with access for a competent person during the initial seating of wheel or rim components.

Horizontal Tyre and Rim Assembly

A tyre inflation exclusion zone for horizontal tyre and rim assembly shall extend to a minimum distance of at least 1.5 times the diameter of the tyre around a horizontally positioned tyre and rim assembly.

The tyre handler arms shall be placed over the tyre and rim assembly being inflated with access for a competent person during the initial seating of wheel or rim components.



Figure 7: Tyre inflation exclusion zone

Sealing Assembly and Seating Components

The tyre handler may be used to manoeuvre the tyre on the rim during the initial tyre inflation process to help the tyre to seal. The tyre handler shall be released from the tyre and rim assembly once it has sealed. Inflation shall not continue while the tyre handler is clamping or holding the tyre due to the risk of damage to the tyre handler and uncontrolled release of the tyre.

A tyre shall not be inflated beyond 5psi (35kPa) without tapping the lock ring into its correctly seated position in the lock ring groove. The air supply shall be shut off when lock rings are tapped in. The lock ring may need to be tapped again during the inflation process to ensure correct seating. Manufacturer’s tolerances associated with the seating of the lock ring on multi-piece rims shall be confirmed prior to commencing full inflation. These tolerances may include the gap between the lock ring and rim gutter and, where available, the gap between the ends of the lock ring. Further inflation shall not proceed if tolerances are not achieved and the lock ring is not seated correctly after 10psi (70kPa).

The seating of the lock ring on multi-piece rims shall conform to manufacturer's tolerances. The tapping of lock rings shall not be performed when the pressure inside the tyre exceeds 10psi (70kPa).

Personnel shall not enter the extreme danger zone when inflation is underway or after tyre inflation has exceeded 10psi (70kPa).

All flanges and tyre beads shall be in position and seated correctly. If any of these components are not seated properly after a maximum of 30psi (210kPa), the tyre shall be deflated to zero psi and checked prior to re-inflation commencing.

Final Inflation

Once the tyre has been inflated to 30psi (210kPa), all personnel shall be clear of the tyre inflation exclusion zone and remain clear during the ongoing inflation process.

Personnel shall be positioned outside the established tyre inflation exclusion zone when pressure inside the tyre exceeds 30psi (210kPa) during tyre inflation.

Wheel or rim valve hardware shall, where practicable, include a fusible link.

Tyre pressures relating to various situations are presented in Table 2.



Table 2: Tyre Recommended Pressures

OTR Tyre Fitted to a Wheel or Rim Recommended Pressure

At the time of fitting onto mobile plant Greater than 10psi (70kPa) and less than 30psi (210kPa)

In a storage area Greater than 25psi (175kPa) and less than 35psi (240kPa)

(Pressure shall be indicated on the tyre)

For transportation Greater than 25psi (175kPa) and less than 35psi (240kPa)

(Pressure shall be indicated on the tyre)

In operation on mobile plant Cold pressure as recommended by the tyre manufacturer or supplier

Record Keeping

The IMS shall be used to manage the maintenance and inspection history of all OTR tyres, and wheel or rims with a diameter of 24 inches and above.

5. ROLES AND RESPONSIBILITIES

SSE Shall review and approve this procedure. SHET Superintendent Shall ensure that all provisions of this procedure are implemented, and

that compliance is achieved. Superintendents Shall be responsible for their area of operations and the

implementation and application of this procedure; Provide adequate training, information, structure and supervision to ensure that this procedure is implemented; Carry-out a periodic review of activities to ensure the appropriate application and understanding of this procedure; and Ensure immediate and appropriate steps are taken to investigate and rectify any risks to health and safety arising from these activities.

Supervisors Ensure all CMWs are familiar with, have access to and comply with the requirements set out in this procedure.

All CMWs (including visitors and contactor)

Shall comply with the requirements of this procedure.

6. REFERENCES

AS 1271-2003 (R2016) Safety valves, other valves, liquid level gauges, and other fittings for boilers and unfired pressure vessels

AS 1973-1993 Pneumatic tyres - Passenger car, light truck, and truck/bus - Re-treading and repair processes

AS 4457.1-2007 Earth-moving machinery - Off-the-road wheels, rims & tyres - Maintenance & repair - Wheel assemblies & rim assemblies

AS 4457.2-2008 Earth-moving machinery - Off-the-road wheels, rims & tyres - Maintenance & repair - Tyres



AS/NZS 1680.0:2009 Interior lighting – Safe movement

AS/NZS 2538:2004 Vehicle support stands

AS/NZS 2693:2007 (R2017) Vehicle jacks

AS/NZS 3788:2006 (R2017) Pressure equipment - In-service inspection

Coal Mining Safety and Health Act 1999 (Qld)

Coal Mining Safety and Health Regulation 2017 (Qld)

DNRME Recognised Standard 13 Tyre, wheel and rim management

DNRME Guidance Note 31 Tyre, wheel & rim management

DNRME Safety Bulletin 118 Working safely with tyres: highway-style trailer haulage

DNRME Safety Bulletin 47 Tyre fires, pyrolysis and explosions

DNRME Safety Bulletin 77 Earthmover tyre and rim safety

Safe Work Australia – Guide for split rims (December 2015)

VUL-ATT-002-Tyre Size, Pressure and Torque Chart

VUL-MOP-082-Training Scheme

VUL-REG-XXX-Tyres and Rims Register

VUL-SOP-072e-Lifting Operations

7. REVIEW

This document shall be reviewed as follows:

• when there is a change of method and/or technology and/or legal or other requirement that may affect the accuracy of this document;

• when operational changes occur that effect the currency of the document; • when there has been a significant event to which this document was relevant; and • as a result of relevant audit findings.

8. AUTHORISATION

I, Michael Cavanagh as Site Senior Executive for Vulcan Mine approve this Standard Operating Procedure for use.

Signature: __________________________________________

https://www.dnrme.qld.gov.au/__data/assets/pdf_file/0004/986071/recognised-standard-13.pdf

https://www.dnrme.qld.gov.au/__data/assets/pdf_file/0005/1407785/qld-guidance-note-31.pdf

https://www.dnrme.qld.gov.au/business/mining/safety-and-health/alerts-and-bulletins/mines-safety/working-safely-with-tyres

https://www.dnrme.qld.gov.au/business/mining/safety-and-health/alerts-and-bulletins/mines-safety/tyre-fires,-pyrolysis-and-explosions

https://www.dnrme.qld.gov.au/business/mining/safety-and-health/alerts-and-bulletins/mines-safety/earthmover-tyre-and-rim-safety2

https://www.safeworkaustralia.gov.au/system/files/documents/1703/split-rims-guide.pdf



9. AMENDMENTS

Version Date Description Document Controller 01 02/06/2020 Initial draft Rachael Dacker 02 14/07/2020 Risk Workshop Shane Johnson

10. DOCUMENT REVIEW: ATTENDANCE RECORD

Date post:	05-Dec-2021
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Standard Operating Procedure Tyres, Wheels and Rims Management

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