BHP and Rio Tinto collaborate on battery-electric haul truck trials in the Pilbara

Trial Details and Timeline

The collaboration will see two Caterpillar 793 battery-electric haul trucks trialled from the second half of 2024, followed by two Komatsu 930 haul trucks from 2026. Each manufacturer will supply one truck to both BHP and Rio Tinto, with BHP operating the Caterpillar models and Rio Tinto testing the Komatsu units. All trials will take place at mine sites in the Pilbara, Western Australia, a region known for its intense heat, dust and demanding operational conditions. The phased approach allows each company to gather data independently while sharing outcomes to accelerate learning.

Testing will cover not only the vehicles themselves but also battery performance, static charging systems and dynamic charging solutions. This holistic evaluation aims to understand how electric haul trucks function within existing mine planning, haulage networks and safety protocols. Both companies emphasise that replacing diesel requires more than just swapping fuel types — it demands a full operational ecosystem redesign, including changes to mine infrastructure, maintenance routines and worker training.

The trials build on work since 2021, during which BHP and Rio Tinto individually engaged with Caterpillar and Komatsu to develop and validate prototype battery-electric haul trucks. The vehicles now entering trial are based on those earlier prototypes, meaning the current phase focuses on real-world validation rather than initial design. By running parallel tests, the miners hope to compare performance across different technologies and operating conditions more quickly than if they proceeded separately.

Emissions Impact and Decarbonisation Goals

Diesel consumption remains a major contributor to operational emissions for both BHP and Rio Tinto. In FY2020, carbon emissions from diesel combustion accounted for approximately 40% of BHP’s Scope 1 and 2 greenhouse gas emissions. For Rio Tinto, diesel use in mining equipment and rail fleets represented 12% of its Scope 1 and 2 emissions in 2023. These figures highlight the potential scale of impact if battery-electric haul trucks can successfully replace diesel-powered models across large fleets.

Both companies have already made progress in reducing emissions through renewable electricity adoption. BHP noted a step-change reduction in Scope 1 and 2 emissions after switching some of its power supply to renewables. The battery-electric haul truck trials are seen as the next phase in building on that progress, targeting one of the most stubborn sources of mining emissions: mobile equipment. Success in the Pilbara could inform broader deployment strategies across other operations globally.

The initiative directly supports the net-zero ambitions of both firms. BHP and Rio Tinto have each pledged to reach net-zero operational greenhouse gas emissions by 2050. Achieving this will require eliminating emissions from sources like diesel haulage, which currently lack commercially viable alternatives at scale. By proving the feasibility of battery-electric technology in real mining conditions, the trials aim to de-risk future investment and speed up industry-wide adoption.

Industry Collaboration and Knowledge Sharing

A key aspect of the project is the agreement between BHP and Rio Tinto to share trial outcomes. Despite being commercial rivals, the two companies recognise that advancing zero-emissions haulage benefits the entire sector and requires collective effort. By pooling data on vehicle performance, charging efficiency and operational challenges, they aim to avoid duplication of effort and accelerate the learning curve for battery-electric technology in mining.

The collaboration also involves close work with the original equipment manufacturers. Caterpillar and Komatsu are not only supplying the trucks but also providing technical support throughout the testing phases. Their involvement ensures that feedback from the trials can be fed back into ongoing design improvements for battery, chassis and charging systems. This manufacturer-miner partnership model mirrors approaches seen in other industries developing electric heavy-duty vehicles.

Beyond the immediate participants, both BHP and Rio Tinto are active in industry bodies such as the International Council on Mining and Metals (ICMM) and CharIN, the global association for charging interface standards. Their engagement with these groups helps ensure that insights from the Pilbara trials contribute to broader efforts to standardise battery-electric haulage technology and develop supporting infrastructure, such as mine-site charging grids and battery recycling protocols.

Implications for Mining and Heavy Industry

The trials signal a shift in how major mining companies approach decarbonisation, moving beyond incremental improvements to test transformative technologies. While renewable electricity and energy efficiency have delivered early gains, tackling Scope 1 emissions from mobile equipment requires bolder steps. Battery-electric haul trucks, if proven viable, could eliminate a significant portion of diesel use in surface mining operations, particularly in open-pit mines where haulage distances are long and frequent.

Success in the Pilbara could also influence suppliers and service providers across the mining value chain. Companies specialising in mine planning, energy management and automation may see increased demand for solutions tailored to electric fleets. Similarly, firms involved in battery production, charging infrastructure and grid integration could find new opportunities as miners prepare for larger-scale transitions.

For business consumers and investors, the project underscores the growing importance of environmental, social and governance (ESG) factors in resource sector valuations. Demonstratable progress on emissions reduction can enhance corporate reputation, support access to green financing and help meet evolving regulatory expectations. The transparency of sharing trial results may also set a precedent for how competitors collaborate on pre-competitive climate challenges.

What this means

The BHP and Rio Tinto battery-electric haul truck trials in the Pilbara represent more than just a technology test — they embody a pragmatic approach to one of mining’s toughest decarbonisation challenges. By working together with rivals and manufacturers, the companies are creating a shared knowledge base that could hasten the arrival of zero-emissions haulage across the industry. While significant hurdles remain — including battery weight, charging times and infrastructure costs — the initiative shows that major players are willing to invest in collaborative innovation to meet long-term climate goals. For businesses monitoring the resources sector, the project offers a clear signal: the transition to electric mining equipment is moving from prototype to proving ground, with real-world data expected to shape future investment and operational decisions.