Frequently Asked Questions

The Air Suspension Wheel (ASW) is a steel wheel with an integrated air-cylinder and damper suspension system. It replaces the conventional pneumatic OTR tyre and tyre-plus-rim assembly as a single bolt-on unit for validated configurations, using the OEM hub interface where compatibility has been confirmed. The suspension function is carried by engineered steel cylinders and dampers inside the wheel body. The ground interface is a bolt-on tread segment ring replaced individually without removing the wheel from the machine. See the full technical explanation on the ASW product page.

No machine modification is required. The ASW is designed to bolt on to the existing OEM hub interface — the same flange and stud pattern as the original pneumatic tyre and rim assembly. There is no re-engineering of the axle, suspension, or structural components required. This is a key advantage: the ASW is a wheel-level replacement, not a machine-level modification.

The ASW is available across a range of rim sizes from 20" through to 57" for ultra-class haul trucks. The specific rim size range for your machine class is confirmed through the fleet assessment process. Contact GACWheels with your machine OEM and model specifications to confirm compatibility. See the Applications & Fleets page for an overview by machine type.

For validated ASW configurations, the conventional pneumatic tyre TKPH limit is no longer the governing thermal constraint because the ASW does not rely on a rubber tyre carcass and large gas envelope to carry load. Overall fleet productivity remains subject to machine limits, haul road conditions, payload policy, duty cycle, operator practice, and site approvals.

Tread segments bolt to the outer ring of the ASW wheel body. They are replaced in-situ — the wheel does not need to be removed from the machine axle. Replacement requires standard hand tools and a trained maintenance technician; no specialised tyre-handling equipment (cage, inflation tools, bead breakers) is required. Individual worn segments can be replaced without changing the full tread ring, which significantly reduces the material cost per service event.

GACWheels has been issued 120+ patents across the ASW technology. This includes patents on the core wheel architecture, the air cylinder and damper system, the tread segment design and attachment system, and associated manufacturing processes. The breadth of the patent portfolio means the ASW system is protected across its key functional and structural elements.

The primary commercial model GACWheels offers is Wheels-as-a-Service (WaaS), a usage-aligned rate covering the wheel system, component supply, service support, and agreed maintenance scope. Alternative commercial structures may be considered for selected fleet configurations, subject to approval, service arrangements, and site-specific requirements.

The WaaS per-hour rate covers: ASW wheel system supply and installation, tread segment supply and replacement, air cylinder and damper servicing, fleet performance monitoring and reporting, component removal and return (zero disposal obligation on site), and technical support and maintenance team training. There are no additional costs for scheduled service events within the agreement scope. See the full breakdown on the Wheels-as-a-Service page.

WaaS agreements are structured to match the operational profile of the fleet. Contract duration is agreed as part of the commercial negotiation — GACWheels does not impose a fixed-term requirement. Typical commercial agreements run for 3–5 years, with provisions for fleet expansion and early termination. Trial agreements are structured separately, typically 6–12 months, before transitioning to a full commercial term.

Air cylinders in the ASW are smaller, sealed pressure components with defined inspection and service intervals. Their failure modes are assessed separately from a conventional large-volume pneumatic tyre blowout and are managed through engineering controls, maintenance procedures, and site-specific risk assessment.

GACWheels works with operations to establish compliance documentation appropriate to their regulatory jurisdiction. The ASW eliminates the pneumatic tyre exclusion zone requirement — one of the most significant safety management obligations associated with OTR tyre handling. Site-specific compliance assessment is conducted as part of the fleet assessment and trial onboarding process. See the Safety, ESG & Compliance page for the full safety position.

ASW component wear is gradual and detectable. Tread segment wear is visually observable and progresses predictably over operating hours. There is no sudden catastrophic failure mode equivalent to a pneumatic blowout. Under WaaS, GACWheels monitors operating hours and schedules segment replacement proactively — before segments reach critical wear. In the event of unexpected damage (e.g. sharp impact), the damaged segment can be replaced in-situ without removing the wheel from the machine.

Installation of ASW on a machine is coordinated with a planned maintenance shutdown window. The installation process is carried out by GACWheels technicians and is typically completed within the same timeframe as a conventional tyre change-out for that machine class. The exact duration depends on machine type, number of axles, and site access conditions. GACWheels will confirm the installation timeline as part of the trial programme planning.

Most operations move from initial enquiry to first wheel installed within 8–12 weeks. This covers: fleet assessment (1–2 weeks), trial agreement and component production lead time (4–6 weeks), and installation scheduling (aligned to next planned maintenance window). The timeline varies by fleet size, machine type, and site logistics. Contact GACWheels with your fleet details to get a specific timeline for your operation.

GACWheels provides maintenance team training as part of the WaaS onboarding process. Training covers: visual inspection of tread segments and cylinders, in-situ segment replacement procedure, cylinder service identification, and reporting to GACWheels' monitoring system. The training is straightforward — ASW maintenance requires standard hand tools and is less complex than conventional tyre change-out procedures. Training is included in the WaaS agreement.

Switching to ASW via WaaS eliminates the tyre disposal waste stream from your site — one of the most difficult solid waste streams to manage in surface mining. Under WaaS, worn components are returned to GACWheels; the operation has zero disposal obligation. This removes a reportable waste stream and eliminates landfill exposure. The reduction in unplanned downtime also improves overall vehicle utilisation, producing a secondary fuel efficiency and emissions benefit. GACWheels provides supporting data for ESG reporting under the service agreement.

GACWheels manages returned components within its supply chain — tread segments and cylinders are processed for remanufacture or recycling, depending on their condition. The specific recycling and remanufacture pathways are part of GACWheels' end-of-life component programme. For operations requiring detailed supply chain ESG disclosures, GACWheels can provide component lifecycle documentation under the service agreement.