BHP’s Western Australian Iron Ore (WAIO) operations are poised to generate tens of millions of dollars in additional annual revenue following the implementation of an engineering upgrade to its haul truck fleet, the company announced February 7, 2026.
The upgrade centers on newly designed hoist cylinders installed beneath the truck trays, enabling a higher tipping angle and more complete unloading of iron ore. Previously, limitations in tray heights prevented some trucks from fully emptying their loads, reducing efficiency. The new cylinders, developed in collaboration with Chinese supplier JC Cylinders and BHP’s South Flank operations and engineering teams, address this issue.
BHP anticipates the modification will increase iron ore movement by approximately 127,000 tonnes each month, equating to roughly 1.52 million tonnes annually. “These bespoke cylinder hoists have been a tipping point for haul truck productivity, resulting in a 54 per cent reduction in the number of times product is carried back in the truck,” said Rashpal Bhatti, BHP group procurement officer. “It’s a small solution with a big impact. We’re tipping the productivity uplift to unlock tens of millions of dollars in additional revenue every year.”
The company highlighted the strategic importance of its global procurement spend in driving innovation across its supply chain. According to BHP, this approach facilitates solutions that deliver cost reduction, productivity, resilience, and safety improvements. “By lifting tray performance on these trucks and tipping an extra 1.5 million tonnes a year, we’ve delivered a real productivity boost to help preserve WAIO moving at pace,” stated Tim Day, BHP WAIO asset president.
BHP’s WAIO operations are a significant component of the company’s overall iron ore production. The upgrade is expected to contribute to maintaining production levels and maximizing revenue generation in a competitive market.
