Heavy Plant
Plant Remapping for Quarry and Mining Operations
Quarry and mining operations run the plant hardest and longest — ADTs on continuous haul routes, excavators in the face all shift, loaders feeding the crusher. ECU remapping delivers the fuel savings and machine performance that makes the biggest difference at scale.
10–14%
ADT fuel savings
Fleet
Pricing — multiple machines
All major
Quarry plant covered
On-site
Quarry attendance
Quarries and mining operations are the highest-return environment for plant ECU remapping. The combination of continuous high-utilisation operation, long haul routes with significant gradient, and large fleets means that fuel savings from remapping have the greatest absolute financial impact of any application.
An ADT fleet running continuous loaded hauls on a quarry gradient is exactly the duty cycle where remapping has the most impact — more torque on grade, better fuel economy on the flat, measurably faster loaded cycle times. A quarry running 8 Bell B30Es saving 12% on fuel saves over £50,000 per year.
We are experienced at working within quarry site safety requirements and co-ordinate with the quarry manager to schedule visits around production cycles.
What's Included
- On-site quarry attendance across the UK
- Full diagnostic assessment on every machine
- Custom ECU calibration per machine
- Adblue and DPF solutions at the same visit
Benefits
Why Choose This Service
ADT Haul Route Fuel Savings
Articulated dump trucks on loaded haul routes with gradient are the highest-return remapping application in any quarry. More torque on grade, better fuel economy on the flat, faster loaded cycle times. On a fleet of 6–10 ADTs, the annual fuel saving is measured in tens of thousands of pounds.
Excavator Face Performance
Quarry excavators working in hard rock, blasted material, or dense gravel benefit significantly from increased digging torque and faster cycle times. More material moved per shift from the same machine is a direct productivity gain.
Wheel Loader Throughput
Loaders feeding the primary crusher operate on continuous loading cycles. More breakout force, faster loading response, and better fuel economy on the loading cycle — meaningful across a 3-shift crushing operation.
Dozer and Grader Efficiency
Quarry dozers pushing overburden and stockpile material, and graders maintaining haul road surfaces, benefit from more blade torque and better fuel economy on long continuous cycles.
Plant We Cover
Common Questions
Can you attend working quarry sites safely?
Yes — we are experienced at working within quarry site safety requirements including pre-site induction, PPE requirements, and the traffic management plans that apply to active quarry sites. We co-ordinate with the quarry manager before any visit.
What is the typical annual fuel saving for a quarry ADT fleet?
On a 30-tonne ADT burning 20 litres per hour, a 12% saving is £2.64 per hour. On a fleet of 8 machines running 2,500 hours per year, that is approximately £52,800 per year in fuel saved. Larger ADTs and higher fuel prices increase this figure proportionally.
Can you remap both the ADT fleet and the face excavators in the same visit?
Yes — a quarry fleet visit can cover all machine types on site. We work through the fleet systematically, typically starting at the end of a production shift to minimise disruption. The sequence is planned with the quarry manager in advance.
Do you cover Terex, Bell, and Volvo ADTs as well as Cat?
Yes — all major ADT brands are within our capability. Bell B-series (Mercedes-Benz engines), Volvo A-series (Volvo Penta engines), Cat 730–745 (ACERT engines), Terex TA-series (Scania engines), and Doosan Moxy ADTs are all covered.
How do we measure the fuel saving after the remap on our haul routes?
Your existing fuel monitoring system — whether on-board telematics or fuel card data — provides the before and after comparison. We recommend recording fuel consumption data for 2–4 weeks before the remap as a baseline, then comparing over the same period after.
Plant Remapping for Quarry and Mining Operations - on site, anywhere in the UK
Free to enquire. Fast response. Honest advice before any work starts.
Free quote · No obligation
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Plant Remapping for Quarry and Mining Operations
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