Haultrax Delivers The First Mining Fleet Management System Deployment for Prime Movers

Fleet Management Systems (FMS) have become standard tools for managing pit-based haulage fleets, delivering real-time visibility of production, utilisation, and delays. Yet across many mining operations, a critical segment of material movement has remained largely invisible: prime movers and road trains operating outside the traditional pit environment.

Most mining FMS platforms have been developed around the operating models of Tier 1 miners — focused on large off-highway haul truck fleets working within tightly defined pit cycles. However, prime movers are more typical of Tier 2 operations and contractors, and are also widely used in secondary and long-haul tasks within Tier 1 sites, particularly where rail infrastructure is not available.

Despite moving substantial volumes of material every day, prime movers have typically been excluded from mining FMS implementations.

Haultrax has challenged this convention, becoming the first mining Fleet Management System provider to successfully deploy FMS on prime movers and road trains within a mining environment — demonstrating that this critical segment can be fully integrated into modern mining fleet architecture.

Why Prime Movers Play a Critical Role

Compared to mining, prime movers are more fuel-efficient and cost-effective over extended haul lengths, and can operate across mine roads, shared infrastructure, and public roads without the need for dedicated off-highway routes.
Importantly, they also support seasonal operating models, allowing sites to demobilise fleets during wet seasons or shutdowns and rapidly remobilise when conditions improve.

Structural Challenges, Not Technological Ones

Prime movers operate over longer, less predictable routes, may service multiple dump locations in a single cycle, and frequently change trailer configurations. Vehicles may tow anywhere from two or more trailers with different axle counts and load limits, often adjusted dynamically in response to road conditions — particularly during wet weather.
Accurately capturing load, haul, and production data in this environment requires a fundamentally different approach.

Redefining the Prime Mover Cycle

Haultrax re-engineered its Fleet Management System cycle algorithm specifically for prime mover operations — ensuring these fleets receive the same level of operational visibility and production control traditionally available to haul trucks.
To properly service this segment, the system was redesigned to suit long-haul and multi-trailer workflows while maintaining mining-grade reporting standards. Automated cycle detection captures material movement from the mine to multiple destinations, with each dump recorded independently to ensure accurate load and haul accounting.
The architecture significantly reduces the manual input often required in alternative approaches, ensuring practicality in real-world operating conditions. Survey reconciliation is integrated to maintain accurate truck factor calculations, even as trailer configurations change dynamically throughout a shift.
The result is a prime mover solution that delivers the same structured reporting, accountability, and operational intelligence expected from mining haul truck fleets.

Solving the Trailer Configuration Challenge

Trailer configuration is one of the most complex challenges in prime mover haulage. To address this, Haultrax delivered two key system enhancements.
Machine Signals enable individual trailer IDs to be tracked per cycle. Operators can select exactly which trailers are loaded and tipped, allowing trailer capacities to be aggregated accurately and ensuring truck factors reflect actual operating conditions — even when only a subset of trailers is used due to weather or road constraints.

Prime Mover Algorithm is a purpose-built service developed specifically for road train operations. Unlike off-highway trucks, prime movers do not reverse to load and may dump at multiple locations across long distances. The new core combines tray-up signals from up to four trailers with vehicle speed, location, and loader proximity logic to reliably identify loading and dumping events without increasing operator workload.

Managing Seasonality with a Flexible Commercial Model

Prime mover haulage is often highly seasonal, particularly in regions affected by wet seasons. To align with this reality, Haultrax offers its Fleet Management solution under a Software-as-a-Service model (FMSaaS), bundling hardware, software, updates, and support into a single monthly fee per asset, with no minimum term.

This model removes upfront capital barriers and, critically, allows subscriptions to be “paused” during wet seasons or shutdowns — reducing costs while preserving the ability to remobilise quickly when conditions improve.

A New Chapter for Fleet Management

The successful deployment of Fleet Management on prime movers in Far North Queensland marks an important step forward for the mining industry. It demonstrates that fleet management can extend and deliver meaningful value across long-haul, road-based operations — even in highly seasonal environments.
For mining operations relying on road-based haulage, this represents a new opportunity: full visibility, accurate production data, and operational insight — without compromising flexibility or practicality.