/ Reference library · Technical

The OTR reference library.

TRA service codes, tyre naming systems, mixing rules under AS4457, glossary, failure modes. The standards reference for off-the-road earthmover tyres.

Reference notice. Material on this page is general technical reference. Not engineering advice. Confirm against current manufacturer specifications, AS4457:2019, and qualified inspection before acting on specifics.

/ 01 – TRA SERVICE CODES

The TRA service code matrix

The Tire and Rim Association service code is the cross-manufacturer system for describing OTR tyre application. The letter is the machine category. The number is tread depth, intended use, and compound family. Where the same physical tyre appears in two manufacturer databooks, the TRA code is usually the only label that's consistent.

Service codes do not specify the tyre size, load capacity, or compound type. They sit alongside those things. A 26.5R25 L-5 from Bridgestone has the same TRA code as a 26.5R25 L-5 from BKT – the codes match the application, not the maker.

E – Earthmover (haul trucks and ADTs)

Code Name Description Typical fitment
E-1RibSmooth-shoulder ribbed tread for on-highway haul vehicles.Highway dump trucks, water carts
E-2TractionStandard traction tread for general earthmoving.ADTs, smaller haul trucks
E-3Rock RegularStandard tread depth, normal-duty rock applications.Mid-size haul trucks (90–150t)
E-4Rock DeepExtra-deep tread (~1.5× E-3), longer life, cut resistance.Tier-one Pilbara iron ore haul (CAT 793, Komatsu 830E, 930E)
E-5Rock Extra DeepMaximum tread depth, extreme applications. Uncommon.Severe rock conditions, niche fleet
E-7FlotationWide footprint, low ground pressure.Soft-ground earthmoving

L – Loader and dozer

CodeNameDescriptionTypical fitment
L-2TractionGeneral traction lug pattern.Light loader, smaller dozers
L-3Rock RegularStandard rock tread, general-purpose loader.CAT 966–972, Volvo L150
L-4Rock DeepDeeper tread, longer wear, mid-tier mining and quarry.CAT 980–988, Komatsu WA470–WA500
L-5Rock Extra DeepExtra-deep tread, high cut and heat resistance. The default for hard-rock and abrasive iron ore.CAT 988–994, Komatsu WA600–WA1200
L-5SSmooth Extra DeepSmooth tread, extra deep – underground loader applications.Underground LHDs, dozers in fine material

G – Grader

CodeNameDescriptionTypical fitment
G-1RibSmooth-shoulder ribbed pattern, on-haul road grading.Civil road graders, highway maintenance
G-2TractionGeneral-purpose traction pattern for grader applications.CAT 14M, 16M, 24M; Komatsu GD-series
G-3RockDeeper tread for off-road grading.Quarry graders, rough-ground civil

C – Compactor

CodeNameDescriptionTypical fitment
C-1SmoothSmooth tread for landfill and waste compactors.Landfill compactors, RTLT
C-2LugDeep lug pattern, traction-focused compaction.Waste compactor, soil compaction

IND – Industrial and specialty

CodeDescriptionTypical fitment
SLMSmooth multi-purpose for material handlers and port equipment.Container handlers, RTGs, reach stackers
SKSStandard pattern for skid-steer and small wheel loader applications.Skid-steer, mini-loader
SDTSolid drive tyre, port and industrial.Port handlers, ferry decks
/ Practical note

The TRA code is one input when matching a tyre to a machine. The other inputs that matter just as much: load index, speed symbol, TKPH rating (heat capacity), compound type (heat- or cut-resistant), and star rating. The right tyre passes all of these – not just the code.

/ 02 – TYRE NAMING SYSTEMS

How to read a tyre name

OTR tyres use two main naming systems: the older inch-based system (e.g. 33.00R51) and the metric / aspect-ratio system (e.g. 45/65R45). They look different but describe the same kind of thing: cross-section width, construction type, and rim diameter.

Inch-based – e.g. 33.00R51

ComponentMeans
33.00Section width: 33 inches at the widest point of the tyre at correct inflation.
RConstruction: R = radial. The alternative is bias (no letter, or "-" between numbers, e.g. 33.00-51).
51Rim diameter: 51 inches. The wheel rim this tyre fits.

Metric / aspect-ratio – e.g. 45/65R45

ComponentMeans
45Section width in inches (or sometimes a coded width – Bridgestone uses 45 for ~45" width).
65Aspect ratio (section height as percentage of section width). 65 means height = 65% of width.
RConstruction: R = radial.
45Rim diameter in inches.

Load index and speed symbol

On the sidewall, after the size, you'll typically see a load index number (e.g. 200) and a speed symbol (e.g. A2, A5, B). The load index converts to a maximum load via a lookup table. The speed symbol indicates the maximum speed at which the load index applies.

  • Load index 200 ≈ 14,000 kg per tyre. Higher indices carry more.
  • Speed symbol A2 = 10 km/h max. A5 = 25 km/h. B = 50 km/h.
  • Most OTR mining tyres run A2 or A5. ADTs and civil graders are typically A5 or B.

Star rating

The star rating (★, ★★, ★★★) indicates a reserve load capacity above the published load index. Five-star ratings exist but are rare. Each star adds a load capacity increment. A three-star tyre allows higher loads at the same speed – or the same load at higher speeds – than a one-star equivalent.

Pattern code

Pattern codes are manufacturer-specific. Bridgestone uses VRDP, VSDL+, VRPS, etc. Michelin uses XDR, XHA2, XLD D2. There's no cross-manufacturer standard for pattern code – only for the TRA service code that the pattern fits within.

/ 03 – MIXING RULES

What you can and can't mix

Tyre mixing on OTR machines sits in AS4457 territory – the Australian standard for OTR wheel and tyre maintenance and safety. Manufacturer guidance from Bridgestone, Michelin, Goodyear, Yokohama and Continental is consistent on the principles, though specific limits vary.

/ Safety first

Mixing rules exist because mis-matched tyres cause real failures. Heat separation. Bead damage. Uneven contact patch leading to handling loss. On a haul truck this is a fatal-incident risk. When in doubt, don't mix – replace the set.

The hard rules – must not mix

  • Construction type on the same axle. Radial and bias have different deflection characteristics. Mixing them on one axle creates uneven contact pressure and unpredictable handling. Universal manufacturer no.
  • Construction type on twin assemblies. The dual tyres on a single hub position must match – same construction, same size, same load index. Mixing on twins amplifies the deflection problem.
  • Tyres with significantly different worn diameters on twins. A new tyre paired with a half-worn tyre on the same hub forces the new tyre to carry disproportionate load. Heat failure follows.
  • Different load indices on the same axle. The lower-rated tyre is over-loaded; the higher-rated tyre is under-loaded.
  • Different speed symbols on the same axle. The lower-rated tyre's speed limit governs the axle.

The soft rules – discouraged but possible

  • Different brands on the same axle. Acceptable when construction type, size, load index, speed symbol, and TRA code match. Common in trader-sourced fleets. Wear may be slightly uneven but it's a working configuration.
  • Different patterns within the same TRA code. A Bridgestone L-5 alongside a Michelin L-5, same size and load, is acceptable. The tread looks different but the application is the same.
  • Heat-resistant compound with standard compound on the same machine. Common at axle level (e.g. heat-resistant fronts on a 992 doing tight cycles). Acceptable provided load and speed match.
  • Mixed bias and radial across different axles. Mechanically possible on some machines, OEM guidance varies, handling characteristic changes. Most operators standardise to one construction type per machine.

The clean rules – what to aim for

  • Same construction type on every position of a machine.
  • Same size, load index, and speed symbol on the same axle.
  • Same worn diameter (within manufacturer tolerance – typically 2–4% diameter difference) on twins.
  • Compatible TRA code family (all L-5 across a 992, all E-4 across a haul truck).
  • Compound matched to duty – heat-resistant where heat is the constraint, cut-resistant where cuts are the constraint, standard where neither dominates.
/ When supply forces a mixed fit

If you're forced into a mixed configuration because the right tyre is on a 14-week lead time and the machine has to run – document the decision, run the machine at a reduced operating envelope (lower speed, lower load), and replace to a consistent setup at the first opportunity. For sourcing the right tyre fast: Jewell Tyres – independent traders move tyres the OEM channel can't.

/ 04 – GLOSSARY

OTR tyre glossary

Forty common terms that come up in OTR tyre conversations. Definitions are practical, not academic – what the term means and when you'd actually hear it used.

Aspect ratio
Section height expressed as a percentage of section width. A 45/65R45 has aspect ratio 65 (height is 65% of width).
AS4457
The Australian Standard for off-the-road wheel and tyre maintenance and safety. Updated in 2019. Covers mixing rules, inspection, storage and handling.
Bead
The reinforced inner edge of the tyre that seats on the rim. Bead damage usually means scrap.
Bias
Construction type where ply cords cross diagonally at angles (typically 30–40° to the centreline). Older construction, stiffer sidewall, lower fuel efficiency. Largely replaced by radial in OTR.
Casing
The fabric and steel skeleton of the tyre under the tread and sidewall rubber. The casing is what holds the tyre's shape under load. Casing integrity determines whether a tyre can be retreaded.
Compound
The specific rubber recipe of the tread. Heat-resistant compounds run cooler under high TKPH duty. Cut-resistant compounds resist sharp-rock damage at the cost of heat performance.
Contact patch
The portion of the tyre tread actually touching the ground at any moment. Larger contact patch = lower ground pressure = better flotation but more rolling resistance.
Cut resistance
The compound and tread design properties that resist sharp-rock penetration. Important in iron ore, hard-rock quarrying, abrasive material handling.
Deflection
How much the tyre flattens under load. Higher deflection = more contact area but more heat generation. Manufacturers specify a deflection range for the load index.
Drive tyre
A tyre on a powered axle. On a haul truck the rear axle is the drive axle and typically carries the larger or higher-load-index tyre.
Earthmover
The general category of off-the-road machine that moves earth or material – haul trucks, wheel loaders, dozers, graders. Source of the "E" in TRA service codes.
End-of-mine
Inventory remaining when a mine closes or a contract ends. Often sold via independent traders as surplus dispersal.
Footprint
The contact patch, viewed from below. Wider footprint distributes load over more ground area.
Heat separation
A common OTR failure mode: tread separates from the casing because heat broke the bond between layers. Caused by overload, over-pressure, or running above the TKPH rating.
Inflation pressure
Air pressure inside the tyre. Set per the manufacturer's load–pressure chart for the actual axle load. Under- and over-inflation both cause heat issues.
Load index
A number from the international load index table that converts to a maximum load (kg or lb) at a specified speed. Load index 200 ≈ 14,000 kg.
OTR
Off-the-road. Tyres for machines that don't operate on public highways – mining, civil, ag, forestry, industrial.
Pattern
The tread design of a tyre. Each manufacturer names its own patterns – Bridgestone VRDP, Michelin XDR4, etc.
Ply rating
Historic measure of casing strength derived from the number of fabric layers. Largely replaced by load index, but still appears on older bias tyres.
Plug repair
A field repair where a hole in the tread is filled with rubber. Acceptable for small punctures only. Not suitable for sidewall damage.
Radial
Construction type where ply cords run radially (90° to the centreline). Standard modern OTR construction. Better heat dissipation and lower rolling resistance than bias.
Retread
A tyre whose worn tread has been replaced by bonding new tread onto the original casing. Cost-effective for tyres whose casings are sound. Mature technology for E-3 and E-4 sizes.
Rim
The metal wheel the tyre seats on. OTR rims are sized in inches (24", 25", 33", 49", 51", 57", 63"). The "R" in 26.5R25 says it's radial and fits a 25" rim.
Section repair
A factory-grade repair of more extensive damage than a plug. Patch from the inside, vulcanised. More expensive than plug, more durable.
Section width
The widest point of the inflated tyre, measured across the sidewall.
Sidewall
The outer surface of the tyre between the bead and the tread. Sidewall damage is generally not repairable.
Speed symbol
A letter (A1, A2, A5, B, etc.) indicating the maximum continuous speed at which the load index applies. OTR mining tyres typically A2 (10 km/h) or A5 (25 km/h).
Star rating
A symbol (★, ★★, ★★★) indicating reserve load capacity above the published load index. More stars = more capacity at the same speed.
Steer tyre
A tyre on a steering axle. Front of a haul truck, front of a wheel loader. Usually carries less load than the drive axle, often runs a less aggressive tread.
Tier 1
The established global premium manufacturers – Bridgestone, Michelin, Goodyear, Yokohama, Continental. Highest cost, highest residual, broadest fitment data.
Tier 2
Credible mid-tier manufacturers – BKT, Aeolus, Techking, Triangle, Double Coin and similar. 25–45% lower delivered cost; appropriate for many applications.
TKPH
Tonne Kilometre Per Hour. Heat-capacity rating for haul-truck tyres. Required TKPH = mean tyre load × average speed. Used to match tyre selection to haul cycle.
TMPH
Ton Mile Per Hour. The imperial-units equivalent of TKPH. Same purpose, different units.
TRA
Tire and Rim Association. Publishes the cross-manufacturer service code system and the Year Book reference for OTR tyre standards.
Tread
The portion of the tyre that contacts the ground. The pattern is moulded into the tread. The tread compound determines heat and cut behaviour.
Tread depth
The depth of the tread groove, typically measured in 32nds of an inch (US) or millimetres (metric). New OTR tyres run 80–110 mm depending on pattern.
Tube / tubeless
Tube tyres have an inner tube holding air; tubeless seal directly to the rim. Most modern OTR is tubeless. Tube fitment persists in some older machines and bias applications.
Twin assembly
Two tyres mounted on a single hub position, common on haul truck rear axles. Both tyres must match closely or the inner carries disproportionate load.
WCF
Work Capacity Factor. The equivalent of TKPH for loader and dozer tyres. Different math, same purpose – match tyre selection to operating duty.
Worn diameter
The outside diameter of a tyre after some wear. On twin assemblies, worn diameters between paired tyres must be within manufacturer tolerance (typically 2–4%).
/ 05 – COMMON FAILURE MODES

What goes wrong and why

Off-the-road tyres fail in patterns. Understanding the patterns helps with the diagnosis after the fact and the prevention before. Eight common modes – what they look like, what causes them, what to do.

01 – Heat separation

What it looks like

Tread sections lifting away from the casing. Sometimes a visible bulge before the tread leaves. Often catastrophic on a haul truck – full tread strip departure.

What caused it

Heat exceeded the bond strength between tread and casing. Usually because the tyre ran above its TKPH rating – too much load, too much speed, too much ambient temperature, or all three.

What to do

Tyre is scrap. Reassess the haul cycle: recalculate required TKPH, upgrade the tyre rating, slow the cycle, or split the load. Repeats indicate a systemic mismatch.

02 – Impact break / cut to ply

What it looks like

A cut through the tread that exposes the underlying steel belt or fabric ply. Often from a hit by a large rock or sharp object. May be repairable depending on size and location.

What caused it

Single high-energy impact, typically from haul road rock or a poorly placed bench at the pit. May indicate haul road condition needs attention.

What to do

Small cuts (<25 mm, away from sidewall): section repair viable. Larger cuts, sidewall cuts, or cuts through to the bead: scrap. Investigate haul road condition.

03 – Shoulder separation

What it looks like

Tread separation at the edge where the tread meets the sidewall. Often visible as a bulge or split running circumferentially around the tyre.

What caused it

Shoulder area runs hotter than the centre of the tread under most loads. Persistent under-inflation accelerates this. Heavy side-loading (cornering) contributes.

What to do

Tyre is scrap. Audit inflation pressure management. If the machine corners hard, consider whether the tyre's load index includes adequate sidewall reserve.

04 – Bead damage

What it looks like

Visible damage to the bead – the reinforced inner edge that seats on the rim. Can be cuts, distortion, or visible wire from the bead bundle.

What caused it

Improper mounting (forcing the tyre over the rim), rim damage transferring to the bead, or extreme overload. Sometimes from running flat.

What to do

Tyre is scrap. Inspect the rim – a damaged rim will repeat the failure on the next tyre. Review mounting procedure with the fitter team.

05 – Rim damage

What it looks like

The wheel rim itself is bent, cracked, or has a damaged flange. Often visible only when the tyre comes off. May cause repeat bead damage on successive tyres.

What caused it

Impact (kerb strike, rock hit, ramp drop), heat from a flat run, or fatigue cracking. Sometimes from misuse during demount.

What to do

Don't fit a new tyre to a damaged rim. Inspect, refurbish or replace the rim. AS4457 specifies rim inspection cycles for high-cost OTR rims.

06 – Sidewall flex failure

What it looks like

A bulge or weakness in the sidewall, often with internal fibre damage visible after demount. May progress to a sudden blowout.

What caused it

Sustained under-inflation flexing the sidewall beyond its design envelope, generating heat. Sometimes from running on a kerb or against fixed objects.

What to do

Tyre is scrap. Audit the inflation management programme – daily or per-shift pressure checks are standard practice on tier-one mining contracts.

07 – Ply failure

What it looks like

Internal layers (ply) breaking down, often invisible from outside until a bulge appears or air leaks through the casing. Sometimes evident only post-failure when the tyre is dissected.

What caused it

Sustained overload, age, water ingress through unrepaired cuts, or manufacturing defect.

What to do

Tyre is scrap. If a pattern emerges across multiple tyres of the same age and brand, raise with the supplier – could be a batch quality issue.

08 – Tread chunking

What it looks like

Chunks of tread rubber breaking away from the surface. Distinct from cuts – this is the rubber itself fragmenting, not being sliced.

What caused it

Compound mis-match – cut-resistant compound used in heavy heat-stress duty, or vice versa. Sometimes from rapid wear at the end of a tyre's life.

What to do

If early in tyre life: review compound selection. If late: normal end-of-life behaviour – plan replacement.

/ Pattern recognition

One tyre failing is an incident. Three tyres failing the same way in the same fleet position is a systemic problem. Track failures by mode, position, brand, batch and operator. Patterns will appear before catastrophic events do.

/ 06 – AS4457 SUMMARY

AS4457 – what it covers

AS4457:2019 – full title Earth-moving machinery – Off-the-road wheels and tyres – Maintenance and safety – is the Australian Standard that governs OTR tyre handling on Australian mine and civil sites. Tier-one mining contracts require compliance. Insurance, work-health-and-safety regulators, and procurement teams all reference it.

This is a summary in plain language. The actual standard is the authoritative document – purchase from SAI Global or Standards Australia if you need the formal text.

What AS4457 covers

  • Tyre selection criteria – load capacity, TRA service code, speed symbol, compound matching to duty.
  • Mounting and demounting practice – equipment requirements, safety procedures, exclusion zones.
  • Inflation pressure management – initial inflation, ongoing checks, derating for under-inflation.
  • Mixing rules – what can and can't be mixed across positions and axles (see Section 03 above).
  • In-service inspection – frequency, what to look for, when to remove from service.
  • Repair criteria – what's repairable (small cuts away from sidewall), what isn't (sidewall damage, bead damage, heat separation).
  • Storage – environmental conditions, ageing limits, rotation procedures for held stock.
  • Disposal – end-of-life tyre handling, retread eligibility, scrap pathways.
  • Wheel and rim inspection – cycle requirements, NDT (non-destructive testing) frequency for high-cost OTR rims.
  • Operator training – competency requirements for fitters working with OTR equipment.

How it affects buying and selling

  • A tyre destined for a tier-one mining contract should have documented provenance, fitment history, and current condition assessment. Independent trader sales typically include this documentation.
  • A used tyre's residual value depends on its AS4457-compliant condition: tyres with sidewall damage, bead damage, or heat separation are scrap regardless of remaining tread depth.
  • Storage age and conditions affect saleability. AS4457 has guidance on this.
  • Mixing constraints affect inventory liquidity – a single tyre that doesn't match the rest of a customer's fleet may be hard to sell into the contract market and is better placed in secondary fleet or trader stock.
/ Jewell Tyres and AS4457

Jewell Tyres trades within AS4457 compliance: tyres sold include documented condition assessment, age, and provenance where known. Tyres that don't meet AS4457 standards aren't sold – they're scrapped through compliant disposal channels. More on the Jewell Tyres safety position →