Mining Tire Waste Management for US Operations: Western States and Beyond

By:     Kieran Donnelly

The United States has the world’s largest surface mining operations for coal, copper, gold, iron ore, and other commodities. The western states, Nevada, Wyoming, Montana, Arizona, and New Mexico, together with coal country in Appalachia and the iron range of Minnesota, generate an enormous aggregate volume of end-of-life OTR tires from haul trucks, loaders, scrapers, and support equipment. Managing those tires is a significant operational and regulatory challenge that most mining companies handle reactively rather than strategically.

Reactive tire management, accumulating tires on a back lot until the pile becomes a regulatory problem, then paying a specialist contractor to process and remove them at a premium, is the most expensive approach. Strategic tire management, processing tires consistently on site with appropriate equipment as they are retired from service, turns a waste cost into a manageable operational process and eliminates the periodic large-cost cleanup events.

OTR Tire Categories in Western US Mining

Surface coal mines in Wyoming’s Powder River Basin and Appalachia, copper mines in Arizona and Nevada, and gold mines in Nevada and Colorado use haul trucks in the 150-ton to 400-ton payload class. These machines run on the largest commercially produced tires in the world, in the 53-inch to 63-inch diameter range, weighing 8,000 to 12,000 pounds each. Retired haul truck tires from these operations represent the most technically challenging OTR tire processing problem.

Iron ore operations in Minnesota’s Iron Range, phosphate mines in Florida, and potash mines in New Mexico generate mid-size OTR categories from loaders and mid-size haul trucks in the 35-inch to 49-inch range. These are more manageable but still require OTR-specific processing equipment rather than standard truck tire machinery.

On-Site vs. Contract Processing for Mine Operators

The decision between on-site processing capability and contracting specialist processors depends on tire generation volume, site remoteness, available infrastructure, and the strategic value of operational control over the waste stream. Large surface mines generating 200 or more large OTR tires per year almost always find on-site processing equipment economically justified on gate fee savings alone. The break-even against specialist contractor fees is typically reached within 18 to 30 months for operations at this volume.

Remote mines in Nevada, Montana, and Wyoming face additional logistics cost when using external contractors: haul truck mobilization, site access, and remote location premiums add to contractor fees and strengthen the on-site case. A mine 60 miles from the nearest highway cannot expect the same contractor pricing as a mine adjacent to a major interstate, and that cost differential shifts the economics further toward on-site equipment investment.

“The mines that invest in on-site OTR processing almost universally report that it was the right decision in retrospect,” says Conor Murphy, Director of Gradeall International. “The control over your own waste stream, the elimination of contractor scheduling dependency, and the cost savings at scale all contribute. The equipment pays back faster than the initial model suggested, because contractor fees tend to increase over time while equipment operating costs are predictable.”

OTR Processing Equipment for US Mine Sites

The Gradeall OTR Tire Sidewall Cutter and Gradeall OTR Tire Splitter form the core processing line for large OTR tire size reduction. The sidewall cutter removes the bead and sidewall sections, and the splitter divides the tread and belt assembly into sections suitable for container loading and transport to downstream TDF or crumb rubber processors.

For mid-size OTR categories from loaders and mid-size haul trucks, the Gradeall OTR range includes equipment configured for the 35-inch to 49-inch size range that is more manageable than the largest haul truck formats but still beyond the capability of standard truck tire processing equipment.

State Regulatory Requirements for Mine Site Tire Waste

Mine sites in western states operate under state solid waste regulations that classify end-of-life OTR tires as solid waste. Nevada, Wyoming, Montana, and Arizona each have solid waste program requirements for tire storage and processing at mine sites. Storage limits, hard-standing requirements, and fire safety standards apply to tire accumulation areas. Environmental permits for mine sites may include conditions specific to waste tire management as part of the broader site reclamation bond requirements.

The full Gradeall OTR tire cutting equipment range covers the complete size spectrum from mid-size OTR through to the largest haul truck formats in US mining. Contact Gradeall to discuss the specific tire sizes in your mine’s equipment fleet and the processing line configuration appropriate for your site.

Frequently Asked Questions

Can OTR tire sections be transported on standard flatbed trucks?

Cut OTR tire sections from the sidewall cutter and splitter can be loaded onto standard flatbed trailers for transport. Whole large OTR tires in the 53-inch and above range require oversize load permits and specialized loading equipment for transport. Processing on site reduces the tires to sections that fit within standard load dimensions and weights, eliminating oversize load permit requirements and significantly reducing transport costs. This logistics simplification is one of the operational benefits of on-site OTR processing.

What downstream markets accept OTR tire sections from mine sites?

OTR tire sections are accepted by TDF buyers at cement kilns (high energy content per ton makes them attractive as supplemental fuel), by large industrial shredding operations as feedstock, and by steel scrap dealers for the significant steel wire and belt content of OTR tire carcasses. Specific market access depends on your location and the volume you can supply. A waste materials broker with experience in industrial tire material can identify buyers in your region and negotiate supply agreements.

How does mine site OTR tire processing affect reclamation bonding?

Mine reclamation bonds cover the cost of restoring the site after mining operations cease. Unprocessed OTR tire stockpiles at the time of closure add to the reclamation cost and therefore to the bond liability. Operations with on-going tire processing programs that prevent large tire stockpile accumulation reduce their reclamation bond exposure proportionally. This regulatory benefit is in addition to the operational cost savings from on-site processing and should be factored into the investment case for large mine sites.

What safety requirements apply to OTR tire processing on a mine site?

Mine Safety and Health Administration (MSHA) standards apply to all operations at US mine sites, including tire processing activities. MSHA regulations cover machine guarding, electrical safety, hazardous energy control (lockout/tagout), and personal protective equipment requirements. Site-specific risk assessments for OTR tire processing activities, including the handling of very heavy tire sections with mechanical equipment, are required. Gradeall provides safety documentation and operational guidance with all OTR processing equipment.

Is there a market for whole unprocessed large OTR tires?

Some large OTR tires in reusable condition are sold as used tires for retreading or for lower-severity applications. However, genuinely end-of-life tires from high-cycle mining applications have limited resale value for reuse. The OTR tire secondary market is primarily relevant for tires with significant remaining tread life from equipment changes rather than for tires retired due to wear or damage. For truly end-of-life tires, processing for TDF, crumb rubber, or steel recovery is the appropriate route.

← Back to news