Reducing Tire-Changing INCIDENTS: The Tire Tech Work Station Built for Mining’s Largest Haul Trucks

By B&D Manufacturing Ltd.
For Mobile Maintenance, Heavy Equipment, and Tire-Service Professionals in Mining & Construction

Tire service on today’s ultra-class haul trucks is one of the most hazardous and physically demanding jobs in mobile maintenance. Tires exceeding 13 feet tall and weighing over 5 tonnes demand a level of precision, ergonomics, and environmental control that traditional tooling and open-floor procedures simply can’t offer.

B&D Manufacturing’s Tire Tech Work Station was engineered specifically to reduce incidents and improve the flow of tire-changing tasks on the world’s largest haul trucks. Below, we break down how the station directly addresses the four critical hazard categories most frequently seen during tire maintenance.

Controlling Fall Hazards: Stable Access for a High-Risk Task

Working around a haul truck wheel assembly often requires stepping onto uneven surfaces, climbing over tool clutter, or improvising access positions—all of which significantly increase fall risk.

How the Tire Tech Work Station Reduces Fall Hazards

• Integrated access platforms keep technicians at a consistent, stable working height around the wheel.
• Anti-slip surfaces, guardrails, and defined walk zones eliminate the unpredictable footing common on shop floors.
• Tool docking and hose management keep objects off the ground and eliminate trip hazards.
• Controlled work envelope ensures technicians stay within a safe, engineered operating area—no more balancing on blocks or scrambling up the tire.

Result: A predictable, uniform workspace that dramatically lowers slips, trips, and falls.

Reducing Tool-Handling Fatigue: Smarter Layout, Safer Productivity

The physical strain on tire technicians is well known. Heavy impact guns, bead breakers, torque multipliers, and lifting attachments have traditionally been handled manually—leading to shoulder strain, back injuries, and repetitive motion fatigue.

Ergonomic Features Designed for Technician Longevity

• Boom-mounted or rail-mounted tool balancers support the weight of impact guns and hydraulic tools.
• Built-in tool trays and pneumatic racks minimize bending and reaching.
• 360° rotation and slide-track positioning allow tools to be maneuvered with fingertips instead of force.
• Optimized workflow zones ensure that every tool has a logical, reachable location.

Result: Less fatigue per shift, fewer musculoskeletal injuries, and more consistent tool handling.

Managing Heavy-Impact Energy: Protecting People and Components

High-torque impact tools and large-format wheel components introduce the risk of uncontrolled energy release—one of the leading causes of tire-change injuries.

Built-In Controls for Safer Impact Work

• Tool reaction-management systems reduce kickback from high-torque tools.
• Anchored tool stations keep equipment securely fixed during use.
• Integrated bead-breaker supports prevent tool drift and sudden movement.
• Component restraints hold wheel parts in position during removal and installation.

Result: More predictable tool performance and a major reduction in high-energy incident potential.

Ergonomic Tire Service: Designed Around the Technician, Not the Task

Ultra-class tire service has historically relied on technician strength and improvisation. The Tire Tech Work Station shifts the workload from the worker to engineered controls.

Ergonomic Enhancements That Change the Game

• Adjustable work-height platforms eliminate overhead and floor-level strains.
• Hands-free wheel-stud access points keep technicians in neutral positions.
• Integrated lighting and visibility zones reduce posture strain caused by low visibility.
• Cabin-level control consoles allow heavy tools to be activated without manual lifting.

Result: A repeatable, technician-friendly process that increases safety while reducing downtime.

Why the Tire Tech Work Station Matters for Mining Operations

Fewer incidents → More uptime

A safer tire-change workflow directly translates to fewer near-misses, fewer LTI events, and fewer unplanned maintenance delays.

Consistent procedure → Better cross-shift reliability

The standardized workspace means tasks are performed the same way regardless of technician or shift.

Technician retention → Lower long-term costs

Ergonomics and fatigue reduction help retain skilled tire specialists—critical in today’s labor market.

Built for ultra-class machinery

Engineered to support the tire sizes used on CAT 797F, Komatsu 930E, Liebherr T284, and other giants of surface mining.

Conclusion: Tire Maintenance Doesn’t Have to Be High-Risk

B&D Manufacturing’s Tire Tech Work Station is more than a tool—it’s a complete safety and efficiency solution built for the realities of mining and construction mobile maintenance. By addressing fall protection, fatigue, impact forces, and ergonomic risks, the station helps maintenance teams perform one of the industry’s toughest jobs with greater confidence and dramatically fewer incidents.