Kal Tire–Decoda haul road hazard detection: operational insights for mine engineers
Reviewed by Joe Ashwell

First reported on International Mining – News
30 Second Briefing
Kal Tire’s Mining Tire Group and Australian mining tech firm Decoda have formed a strategic alliance to deploy KalPRO HaulSight, an autonomous haul road hazard detection system aimed at boosting truck productivity, tyre life and fuel efficiency. Building on the existing KalPRO TireSight autonomous monitoring platform, HaulSight uses real-time data from haul trucks to identify surface defects and other road hazards that accelerate tyre wear or slow cycle times. The move signals growing integration of tyre condition analytics with haul road maintenance planning and fleet management systems in large open-pit operations.
Technical Brief
- KalPRO HaulSight ingests on-board haul truck telemetry to autonomously flag anomalous vibration and impact events.
- Hazard detection logic is derived from KalPRO TireSight tyre condition datasets, correlating road defects with tyre damage signatures.
- System outputs are designed to integrate with mine planning and dispatch platforms for targeted road maintenance scheduling.
- Decoda contributes edge-computing capability so detection runs on-vehicle, avoiding latency and connectivity dependence.
- Continuous monitoring reduces reliance on periodic manual haul road inspections, lowering worker exposure to active haul routes.
- Event severity thresholds can be tuned to site-specific tyre types, payloads and speed regimes.
- Data records provide an auditable trail of road condition versus truck speed limits, supporting compliance with site safety rules.
- Similar autonomous hazard detection layers could be extended to berm integrity, intersection geometry and dump edge approach control.
Our Take
Kal Tire’s Mining Tire Group appears only sporadically in our 590 Mining stories, so this Australia-focused KalPRO HaulSight roll-out signals a push to position the company more as a digital mining systems supplier than just a tyre service provider.
The related KalPRO HaulSight piece notes integration with TOMS (Tire & Operations Managing System), which means Australian sites already using Kal Tire’s tyre management platform can likely adopt hazard detection with minimal additional on-board hardware integration work.
Among the 1,166 safety-tagged pieces in our database, relatively few involve edge-computing and LiDAR-based systems at the haul road level, suggesting Decoda’s role gives Kal Tire a technical differentiator in the crowded mining safety product space in Australia.
Prepared by collating external sources, AI-assisted tools, and Geomechanics.io’s proprietary mining database, then reviewed for technical accuracy & edited by our geotechnical team.
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