Case Study: VR Steel achieves 20% load-body mass reduction, 11% fuel savings and faster unloading with Altair EDEM

VR Steel reduced mass, maintained integrity, and increased performanc

VR Steel (Pty) Ltd, a designer and builder of fabricated mining equipment and truck load bodies, faced the challenge of reducing load body mass while maintaining structural integrity and improving unloading performance and operating costs. To streamline the design process and cut prototyping costs, VR Steel turned to Altair’s EDEM virtual prototyping tools to evaluate new, lighter load body concepts and prove performance for customers.

Using Altair EDEM, VR Steel imported 3D CAD models, created material models, and ran repeatable virtual loading and unloading tests to compare conventional and new designs, reducing the need for physical prototypes. Altair’s solution helped VR Steel cut body mass by 20%, reduce fuel consumption by 11% (about 70,000 L/yr per truck, ≈$55K), speed unloading, and gain a market advantage through faster, validated design iterations.

VR Steel

Bertus Haasbroek

Chief Design Engineer