Safe in Workshop, Safe on Site: How AI and Data can Revolutionize Tire Health Monitoring 

It was a regular Tuesday morning at a Delta Air Lines tire maintenance facility near the Atlanta airport. Tire technicians were working on wheel components being disassembled for maintenance when a tire exploded, killing two workers and injuring one. This tragic event underscores why AI-powered tire health monitoring, especially in high-risk industries like mining, is essential for safety and operational efficiency.

A former airline mechanic, John Goglia, spoke to 11Alive, a local news channel, about two ways this tragedy could have happened. “Either the explosion may have been caused by procedural lapses or a weakened tire due to repeated landings” he said. This accident occurred in the aviation sector, which is known for its strict safety protocols — yet it underscores how even industries with high standards face risks. The same principles of AI-powered tire health monitoring in mining apply across high-risk sectors.

The same applies to the mining sector, where massive off-the-road (OTR) tires power haul trucks and loaders. Here, the role of AI-powered tire health monitoring in mining and predictive maintenance is becoming critical to prevent accidents, enhance safety, and improve operational efficiency.

Why Tire Health Matters in Mining

Tires rank among the top five operating costs for mining companies, making effective tire management crucial for safety, efficiency, and profitability. Keeping them in good shape not only ensures safe mining operations but also reduces downtime, extends tire life, and boosts profitability.

But the challenge isn’t just financial — it’s also environmental. According to Tyre Stewardship Australia’s 2023-24 Material Flow Analysis Report, the mining sector generated about 109,000 tons of used OTR tires. Of this, the vast majority — over 95,000 tons — were disposed of onsite through burial or stockpiling, while less than 5% entered recovery pathways such as reuse, recycling, or energy recovery. This highlights the persistent challenge of sustainable tire management in mining.

Safety through Regular OTR Tire Maintenance

Mining tires face some of the harshest conditions imaginable. With massive haul trucks and loaders navigating rough terrain, maintaining tire integrity is crucial for both safety and efficiency in mining operations.

The key aspects of tire health monitoring include:

• Regular inspections – Checking for cuts, punctures, cracks, and irregular wear to prevent failures.
• Proper inflation – Maintaining correct tire pressure to extend tire life, improve safety, and lower fuel consumption.
• Tire rotation – Ensuring even wear and preventing premature failures in heavy mining vehicles.
• Data-driven insights – Using predictive maintenance systems powered by AI and analytics to detect anomalies before they become costly breakdowns.

Innovations in Tire Health Monitoring

To address these challenges, the mining industry is adopting advanced solutions:

• AI-powered tire inspection – Thermal imaging and machine learning can detect weaknesses invisible to manual checks, revolutionizing tire safety in mining.
• Sustainable tire solutions – New compounds and recycling initiatives improve durability while supporting mining sustainability goals.
• Enhanced safety protocols – Comprehensive training and strict adherence to maintenance procedures reduce risks and strengthen workplace safety.

Proper tire maintenance is directly linked to the safety of employees working at such high-risk sites. The Mining Association of Canada in its report – The Mining Story 2024 – talks about safety being paramount in the sector. Canadian mining companies work hard to create a positive safety culture with employees, contractors and communities.

The results of this dedication to safety can be seen in the decline in rates of injury across the industry over the past decade. Between 2012 and 2021, the most recent year for which data is available, the rate of fatal injuries per 10,000 employees fell from 3.5 to 2.7, a decline of 23%. Non-fatal injuries, too, fell over the same period from 315 to 269 per 10,000 employees. 

Where SYMX.AI comes in

SYMX.AI is at the forefront of tire health management with its AI-powered predictive maintenance solutions. Our technology provides real-time updates on tire conditions by analyzing data from sensors and historical performance metrics. This predictive capability allows for proactive maintenance, enabling operators to address potential tire failures before they occur, leading to reduced downtime.

Building on this foundation, X.Tires, part of SYMX.AI’s product suite, delivers continuous monitoring of key tire health indicators. By tracking critical parameters in real time, X.Tires provides early alerts that help prevent blowouts, extend tire life, and keep equipment running at peak efficiency.

With predictive insights from X.Tires, mines can:

• Prevent accidents by identifying unsafe tire conditions before they escalate.
• Lower costs by maximizing tire usage and reducing downtime.
• Operate with confidence knowing their fleet is safeguarded by proactive monitoring.

X.Tires ensures that one of mining’s most expensive and high-risk components is managed with precision, enhancing both safety and performance on site.

As the mining industry evolves, maintaining effective tire management practices remains crucial. By integrating innovative AI solutions like X.Tires and upholding stringent safety standards, the industry can enhance safety, operational efficiency, and sustainability.

For more information on how SYMX.AI’s predictive maintenance solutions can transform your tire management practices, book a demo with us.