How to Calculate the Cost per Hour of Mining and Earthmoving Tyres

The purchase price of a tyre is easy to compare. Its true operating cost is more difficult to see. A lower-priced tyre may require earlier replacement, suffer more damage or cause additional downtime. A tyre with a higher initial price can deliver a lower cost per hour when it remains productive for longer. Cost per hour gives fleet managers and procurement teams a more reliable way to evaluate tyre performance. It connects tyre expenditure to the operating hours achieved under actual site conditions. This supports decisions based on service life, reliability and operational continuity rather than purchase price alone. The calculation applies to different mining and earthmoving tyres, but the results only become meaningful when you compare tyres working on similar machines and in comparable applications.

Why Purchase Price Does Not Show the True Tyre Cost

The purchase price only represents the initial tyre investment. It does not show how long the tyre will remain in service or how effectively it will support the machine during that period.

Consider two tyres used in comparable applications:

• Tyre A cost €8,000 and delivers 4,000 operating hours
• Tyre B cost €6,500 and delivers 2,800 operating hours

Based on purchase price alone, tyre B appears to be the less expensive option. A basic cost-per-hour calculation produces a different result:

• Tyre A: €8,000 ÷ 4,000 hours – €2.00 per hour
• Tyre B: €6,500 ÷ 2,800 hours – €2,32 per hour

Tyre A requires a higher initial investment but produces a lower basic cost per operating hour.

This comparison is still incomplete. Tyre B may also require more repairs or cause additional downtime. Tyre A may retain a casing value after removal. Once these factors are included, the difference in lifecycle cost may become larger. This is why tyre decisions should be based on operational value instead of purchase price alone. The most suitable tyre is not necessarily the least expensive product or the tyre with the longest theoretical service life. It is the tyre that delivers suitable performance at a controlled total cost within the specific application.

How to Calculate Tyre Cost per Hour

The simples formula is:

Basic tyre cost per hour = tyre purchase price ÷ operating hours

The total lifecycle cost can include:

• Purchase price
• Freight and import-related costs
• Fitting & Removal
• Inspection & Maintenance
• Repairs
• Replacement components directly related to the tyre
• Downtime caused by tyre-related events
• Disposal costs
• Minus any remaining casing or resale value

The appropriate level of detail depends on the purpose of the calculation. A fleet-level overview may use broader cost categories. A detailed product trial should record costs and performance per tyre. Consistency is more important than creating the most complex possible formula. Every tyre in the comparison must be assessed using the same method, cost categories and operating-hour definition.

What to include in Total Tyre Lifecycle Cost

Begin with costs that can be measured reliably. Purchase price, fitting, repairs and removal are normally easier to record than indirect productivity losses.

Downtime can have a substantial effect on the outcome, but it must be calculated carefully. A tyre-related stop does not automatically mean that the complete machine cost should be assigned to the tyre. Record the actual duration of the stop and determine which costs were directly caused by the event.

A practical calculation could use:

Total lifecycle cost = purchase price + fitting + repairs + tyre-related downtime cost – remaining casing value 

For example:

• Purchase price: €9,000
• Fitting & Removal: €300
• Repairs: €450
• Tyre-related downtime: €500
• Remaining casing value: €250
• Productive operating hours: 4,000

The calculation becomes:

€9,000 + €300 + €450 + €00 – €250 = €10,000

€10,000 ÷ 4,000 hours = €2.50 per hour

Recording the calculation transparently allows purchasing , maintenance and operations teams to understand why the result differs from a simple purchase-price comparison.

Which Operating Hours Should You Use?

Use hours that reflect the tyre’s actual working life. In most cases, this means the machine hours recorded between tyre installation and removal. The start and end readings must be registered accurately. If a tyre is transferred to another machine, include the operating hours from both installations. If the machine hour meter is unreliable, use another consistent measurement such as verified shift records or distance travelled.

Planned idle time should not automatically be removed from the calculation if it forms part of normal machine operation. However, extended periods in which the machine is out of service for reasons unrelated to the tyre may distort the result. Establish the calculation rules before comparing products. Also record why the tyre was removed. A tyre that reaches its planned wear limit has a different performance history from a tyre removed early because of an impact, heat separation or sidewall damage. Both outcomes affect cost per hour, but they require different operational responses.

A Practical Tyre Cost-per-Hour Comparison

the following example compares three hypothetical tyres used in similar operating conditions.

Tyre B has the highest purchase price, but it produces the lowest lifecycle cost per hour. Its longer service life, lower repair costs, lower downtime cost and remaining casing value compensate for the initial investment.

Tyre A provides a middle result. Tyre C has the lowest purchase price, but early removal and higher secondary costs make it the most expensive option per operating hour.

The example also shows why cost per hour should be combined with operational context. If the tyres were used on different machines, routes or axle positions, the comparison would not be reliable. A front tyre on a wheel loader may experience different loads and wear patterns from a rear tyre on the same machine.

The application must therefore remain comparable. The article about earthmoving machines and their tyre requirements explains why machine type, load, speed, surface and operating cycle must be considered together.

What Increases Mining and Earthmoving Tyre Costs?

Poor tyre performance is not always caused by the tyre specification. Operating conditions and maintenance practices can increase costs even when the selected tyre is technically suitable. Underinflation increases tyre deflection and heat generation. It can also affect stability, fuel use and casing durability. Overinflation reduces the tyre’s ability to absorb impacts and can increase the risk of cuts or impact damage. Inflation pressure should be based on the tyre specification, actual load and operating conditions. Overloading places additional stress on the casing and increases heat build-up. Repeated overloads may shorten tyre life even when the machine remains within its nominal payload on average. Load distribution also matters because one tyre position may carry more weight than expected.

Speed and cycle distance influence heat generation. Long loaded hauls at sustained speed create different demands from short loading cycles with frequent turning. TKPH calculations help determine whether the tyre’s work capacity is suitable for repeated haul cycles. TKPH is an important technical selection value, while cost per hour evaluates the financial result after the tyre enters service.

Road and surface conditions can create further costs. Potholes, sharp rocks, spillage, poor drainage, steep gradients and narrow roads can increase impacts, cuts, wheel spin and sidewall damage. These conditions also influence speed, heat generation and operator behaviour. Read more about how haul road conditions affect mining tyre life. 

Wheel loaders introduce another set of operating demands. Stockpile loading, load-and-carry work and quarry-face operations do not place the same demands on the tyre. Tread depth, traction, heat resistance and casing protection must reflect the actual application. Our guide to wheel loader tyres by application explains these differences in more detail.

Other factors that can increase tyre cost per hour include:

• Incorrect tyre or TRA code selection
• Poorly maintained haul roads or working areas
• Aggressive acceleration, braking or cornering
• Excessive wheel spin
• Incorrect matching of tyres on the same axle
• Delayed rotation or position changes
• Insufficient tyre inspections
• Unrecorded pressure loss
• Poorly maintained rims or valves
• Continuing to operate a damaged tyre

These causes should be investigated before concluding that a different product is required.

How to Reduce Tyre Cost per Hour

Start with accurate application data. Record the machine, tyre position, load, speed, cycle distance, surface conditions and common damage risks. This helps you select tyres based on actual operating conditions. Maintain the correct inflation pressure and inspect each tyre regularly. Check the tread, sidewalls, valves and rims for damage or irregular wear. Assign every tyre a unique identification number and record:

• Installation and removal dates
• Machine hours and tyre position
• Inflation pressure and tread depth
• Repairs and inspection findings
• Damage and reason for removal
• Route and application data

Use these records to identify recurring problems. Repeated shoulder damage may point to narrow roads, poor edge conditions or cornering behaviour. Heat-related removals may require a review of payload, speed, cycle distance, inflation pressure or TKPH. Operator behaviour also affects tyre life. Heavy braking, rapid cornering, impacts and wheel spin can increase wear and damage. Compare multiple tyres in similar applications over a meaningful period to create a reliable basis for purchasing decisions. Correct application matching supports a lower tyre cost per hour. The Magna M-TERRAIN, Magna M-RIGID and Magna MA08 show how articulated dump trucks, rigid dump trucks and wheel loaders require different technical solutions. Confirm the machine, load, speed, cycle and site conditions before selecting a tyre.

Turning Tyre Data into Better Purchasing Decisions

Use cost per hour as part of a consistent decision-making process. Start by calculating the current cost per hour for each machine, tyre position and application. Record why tyres are removed and identify avoidable costs such as damage, downtime or incorrect pressure.When testing another tyre, use comparable machines, loads, routes and operating periods. Review cost per hour together with:

• Hours in service
• Tread wear rate
• Repair frequency
• Tyre-related downtime
• Removal reason and casing condition
• Tonnes moved or production output

For haulage operations, cost per tonne can add useful context. A tyre may achieve a low cost per hour while supporting lower production. Combining both figures provides a clearer view of operational value.The objective is to balance service life, productivity, safety, uptime and total operating cost. Magna Tyres supports fleets in selecting Mining & Earthmoving tyres for their machines and applications. Reliable data and technical selection help you improve tyre performance and gain better control over lifecycle costs.