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The dump body of the off-highway dump truck is the large, prime structure, used to carry overburden and coal in mines. The body structure is subject to severe vibration, impact load, and oscillation events due to rough terrain conditions in the mines and the loading of rocks from a certain height from the shovel. Presently, the body mounting design is chassis pivot pin mounted, rubber rail seated, and has guide plates to lock transverse movements. Despite all these mounting arrangements, the body structure oscillates (or rattles) due to multiple field factors. The most effective solution to the problem is to provide an additional oscillation-arresting structure so that body stability is achieved and undesirable body-frame impact is avoided.

Fuel tank is considered as safety component in the vehicle, and it has to be tested to meet the safety requirements as per AIS 095. Earlier, fuel tanks were manufactured by using Hot dipped cold rolled steel material and the weld zones are applied with Anti-corrosive coating. Few fuel tanks were reported with Corrosion problems. The root cause analysis was carried out considering the raw material, manufacturing process, transpiration, storage and usage. As an improvement, the new fuel tank is designed to eliminate the limitations of the existing fuel tank. 3D modeling was done to check space and mounting requirement in the layout and used for volume calculations. FE analysis was performed to check structural stability. Emphasis given on Interchange-ability to cater the new fuel tanks in place of old as spares requirement. The fuel tank has developed with Alumina steel material.

Motor grader is self-propelled, versatile machine widely used for road construction and maintenance in mining and construction applications. It required working in rugged terrain with uneven and slippery surfaces. Probability of rollover in motor grader is more due to the vehicle profile and high centre of gravity. In light of the above, Roll over Protective Structure (ROPS) is essential to safe guard the operator from any fatal injuries / life during the operation of the equipment at different terrain conditions. Considering DGMS (Directorate of General Mines and safety) requirements, a rugged two post Rollover Protective Structure (ROPS) was designed as per ISO 3471 criteria for ROPS and Falling object Protection Structure (FOPS) as per ISO 3449 Material selection for ROPS and FOPS is one of significant factor in design process by meeting the design criteria. It should have dual characteristic, firstly, it is expected to tough enough to withstand sudden impact forces.