{"id":3746,"date":"2025-12-26T22:27:18","date_gmt":"2025-12-26T22:27:18","guid":{"rendered":"https:\/\/fmminermag.com\/htdocs\/?post_type=issue-article&p=3746"},"modified":"2025-12-30T19:34:45","modified_gmt":"2025-12-30T19:34:45","slug":"bagdad-completes-autonomous-conversion","status":"publish","type":"issue-article","link":"https:\/\/fmminermag.com\/htdocs\/issue-article\/bagdad-completes-autonomous-conversion\/","title":{"rendered":"Bagdad Completes Autonomous Conversion"},"content":{"rendered":"

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VOL. 08\u00a0 |\u00a0 ISSUE 4\u00a0 |\u00a0 Winter 2025\/2026<\/p>\n

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Bagdad
Completes
Autonomous
Conversion<\/h1>\n<\/div>\n<\/div>\n

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The project advances Freeport\u2019s \u2018long history\u2019 of innovation<\/h2>\n

[\/et_pb_text][et_pb_text admin_label=”Body Text” _builder_version=”4.27.5″ _module_preset=”default” text_font=”Fira Sans Condensed|300|||||||” text_text_color=”#4d4d4f” text_font_size=”18px” text_line_height=”1.5em” header_3_font=”Fira Sans Condensed|600|||||||” header_3_text_color=”#4d4d4f” header_3_font_size=”18px” header_3_line_height=”1.5em” custom_padding=”||||false|false” custom_padding_tablet=”|125px|||false|false” custom_padding_phone=”|0px|||false|false” custom_padding_last_edited=”on|phone” global_colors_info=”{}”]<\/p>\n

When the general managers of mines across Freeport Americas met to discuss the potential of autonomous haulage, one question led the conversation: Which site was best positioned to test the technology and take it to full-scale implementation.<\/p>\n

Jeff Monteith, General Manager\u2013Bagdad, knew the answer.<\/p>\n

Bagdad struck the perfect balance \u2013 large enough to realize meaningful efficiencies yet streamlined enough to avoid the complexity that could stall a rollout. It was the ideal proving ground.<\/p>\n

Monteith had another reason for believing Bagdad was the best place for Freeport to switch to driverless haul trucks.<\/p>\n

\u201cBagdad has a very long history of innovation,\u201d Monteith said. \u201cThat\u2019s something that existed long before I got here. I was excited about the opportunity for Bagdad to actually take on that challenge. The team that we have here is devoted to innovation.\u201d<\/p>\n

Since the announcement in July 2023 that Bagdad would convert to fully autonomous haulage, that devotion to innovation has paid off.<\/p>\n

All 33 haul trucks that will operate autonomously were fully converted and have been in service since August. Seven staffed trucks will operate through the end of the year to help meet production goals. After those trucks cease operation, Bagdad will be the only major mine in the United States with fully autonomous haulage. The company also has lived up to its commitment that no haul truck drivers would lose their jobs because of the conversion.<\/p>\n

That success was achieved six months ahead of schedule.<\/p>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row column_structure=”1_2,1_2″ admin_label=”Row” _builder_version=”4.27.5″ _module_preset=”default” background_color=”#f6f5f3″ custom_margin=”||||false|false” custom_padding=”25px|25px|25px|25px|false|false” background_color_phone=”#FFFFFF” background_last_edited=”on|phone” background_enable_color_phone=”on” custom_css_main_element=”display: flex;||flex-wrap: wrap;” global_colors_info=”{}”][et_pb_column type=”1_2″ _builder_version=”4.27.4″ _module_preset=”default” background_color=”RGBA(255,255,255,0)” background_color_phone=”RGBA(255,255,255,0)” background_last_edited=”on|phone” background_enable_color_phone=”on” global_colors_info=”{}” custom_css_main_element_last_edited=”on|phone” custom_css_main_element_phone=”order: 2;||”][et_pb_text admin_label=”Body Text” _builder_version=”4.27.5″ _module_preset=”default” text_font=”Fira Sans Condensed|300|||||||” text_text_color=”#4d4d4f” text_font_size=”18px” text_line_height=”1.5em” header_3_font=”Fira Sans Condensed|600|||||||” header_3_text_color=”#4d4d4f” header_3_font_size=”18px” header_3_line_height=”1.5em” custom_padding=”||||false|false” custom_padding_tablet=”|125px|||false|false” custom_padding_phone=”|0px|||false|false” custom_padding_last_edited=”on|phone” global_colors_info=”{}”]<\/p>\n

<\/span>Origins of autonomous<\/span><\/h2>\n

Many factors drove Freeport to adopt autonomous haulage.<\/p>\n

In the aftermath of the COVID-19 pandemic, Freeport\u2019s U.S. sites struggled to return to historical efficiencies. Staffing shortages were a problem, particularly at Bagdad, a remote site with limited housing.<\/p>\n

At the same time, company leaders were exploring how best to prepare for future technologies such as electrification of haulage fleets that require precision that is difficult to achieve with staffed vehicles.<\/p>\n

Bagdad was particularly well suited to implement autonomous haulage for reasons beyond its size and history of embracing innovation. The planned Bagdad 2X project will add a second mill and double the site\u2019s output capacity. One limiting factor is finding enough workers to fully staff the upscaled operation.<\/p>\n

Monteith said he knew there would be challenges in making driverless haulage work, and there have been . But he also knew from the start the historic importance of the work that would be done at Bagdad, and that overcoming the challenges would put his site and the rest of the company in a strong position far into the future.<\/p>\n

\u201cPersonally, I felt that it was a tremendous opportunity to do something that hadn’t been done before, certainly within the organization, but also within the United States,\u201d Monteith said. \u201cProfessionally, it’s always a bit of a risk taking on these large projects. There’s rarely a guarantee that everything is going to be successful. But Freeport as an organization does an extremely good job of supporting these large-scale initiatives, of which I’ve been a part of many. And all of them, through the cooperation of the company, have been successful.\u201d<\/p>\n

Bringing the project to fruition puts Bagdad in a good position to embrace new mining techniques and technology in line with the company\u2019s Reinvent Mining initiative, said Randall Yubeta, Chief Engineering Specialist at Freeport.<\/p>\n

\u201cWe view autonomous haulage and autonomy in general as an enabler for the future,\u201d Yubeta said. \u201cThere are a lot of unknowns on what that future is going to look like. But we definitely have a feeling that automation in our operations is going to be a key piece in enabling what comes.\u201d[\/et_pb_text][\/et_pb_column][et_pb_column type=”1_2″ _builder_version=”4.27.4″ _module_preset=”default” background_color=”RGBA(255,255,255,0)” background_color_phone=”RGBA(255,255,255,0)” background_last_edited=”on|phone” background_enable_color_phone=”on” global_colors_info=”{}” custom_css_main_element_last_edited=”on|phone” custom_css_main_element_phone=”order: 2;||”][et_pb_image src=”https:\/\/fmminermag.com\/htdocs\/wp-content\/uploads\/2025\/12\/haul-truck-232b.jpg” title_text=”haul-truck-232b” _builder_version=”4.27.5″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_image][et_pb_text admin_label=”SIDEBAR” _builder_version=”4.27.5″ _module_preset=”default” text_font=”Fira Sans Condensed|300|||||||” text_text_color=”#4d4d4f” text_font_size=”18px” text_line_height=”1.5em” header_2_font=”Fira Sans Condensed|500|||||||” header_2_text_color=”#3d485e” header_2_font_size=”30px” header_3_font=”Fira Sans Condensed|300|||||||” header_3_text_color=”#a36f58″ header_3_font_size=”30px” header_3_line_height=”1.2em” header_4_font=”Fira Sans Condensed||||||||” header_4_text_color=”#a36f58″ header_4_font_size=”14px” background_color=”#2e3645″ custom_margin=”0px||25px||false|false” custom_padding=”25px|25px|25px|25px|false|false” border_width_left=”16px” border_color_left=”#a36f58″ global_colors_info=”{}”]<\/p>\n

\u201cWe view autonomous haulage and autonomy in general as an enabler for the future.\u201d<\/h3>\n

 <\/p>\n

RANDALL YUBETA<\/strong> | CHIEF ENGINEERING SPECIALIST<\/h4>\n

[\/et_pb_text][et_pb_image src=”https:\/\/fmminermag.com\/htdocs\/wp-content\/uploads\/2025\/12\/haul-truck-232.jpg” title_text=”haul-truck-232″ _builder_version=”4.27.5″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_image][\/et_pb_column][\/et_pb_row][et_pb_row column_structure=”1_2,1_2″ admin_label=”Row” _builder_version=”4.27.5″ _module_preset=”default” background_color=”RGBA(255,255,255,0)” custom_margin=”75px||||false|false” custom_padding=”0px|0px|0px|0px|false|false” background_color_phone=”#FFFFFF” background_last_edited=”on|phone” background_enable_color_phone=”on” custom_css_main_element=”display: flex;||flex-wrap: wrap;” global_colors_info=”{}”][et_pb_column type=”1_2″ _builder_version=”4.27.4″ _module_preset=”default” background_color=”RGBA(255,255,255,0)” background_color_phone=”RGBA(255,255,255,0)” background_last_edited=”on|phone” background_enable_color_phone=”on” global_colors_info=”{}” custom_css_main_element_last_edited=”on|phone” custom_css_main_element_phone=”order: 2;||”][et_pb_image src=”https:\/\/fmminermag.com\/htdocs\/wp-content\/uploads\/2025\/12\/autonomous1.jpg” title_text=”autonomous1″ _builder_version=”4.27.5″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_image][et_pb_text admin_label=”Body Text” _builder_version=”4.27.5″ _module_preset=”default” text_font=”Fira Sans Condensed|300|||||||” text_text_color=”#4d4d4f” text_font_size=”18px” text_line_height=”1.5em” header_3_font=”Fira Sans Condensed|600|||||||” header_3_text_color=”#4d4d4f” header_3_font_size=”18px” header_3_line_height=”1.5em” custom_padding=”||||false|false” custom_padding_tablet=”|125px|||false|false” custom_padding_phone=”|0px|||false|false” custom_padding_last_edited=”on|phone” global_colors_info=”{}”]<\/p>\n

<\/span>Upgrading the system<\/span><\/h2>\n

Preparing for autonomous was a two-year process that involved retrofitting the trucks and the entire mine site with an array of sensors, communications systems and other high-tech gadgetry that allow the trucks to operate on their own.<\/p>\n

All the trucks underwent a two-stage conversion giving them new steering and braking systems, front wheel assemblies, and a variety of sensors and computer controls that allow them to operate without drivers.<\/p>\n

Beyond retrofitting the haul trucks themselves, extensive site improvements were required to make the autonomous system function. A new command center was built to monitor and control the trucks, communications and data transmission networks were upgraded, roads were widened, and an isolated autonomous operating zone was created to minimize human interactions with the driverless vehicles.<\/p>\n

October 1 was the official close-out date for the implementation phase of the project, said Mark Elliott, Project Manager. Now, the focus is on continuous improvement.[\/et_pb_text][\/et_pb_column][et_pb_column type=”1_2″ _builder_version=”4.27.4″ _module_preset=”default” background_color=”RGBA(255,255,255,0)” background_color_phone=”RGBA(255,255,255,0)” background_last_edited=”on|phone” background_enable_color_phone=”on” global_colors_info=”{}” custom_css_main_element_last_edited=”on|phone” custom_css_main_element_phone=”order: 2;||”][et_pb_image src=”https:\/\/fmminermag.com\/htdocs\/wp-content\/uploads\/2025\/12\/autonomous2.jpg” title_text=”autonomous2″ _builder_version=”4.27.5″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_image][et_pb_text admin_label=”Body Text” _builder_version=”4.27.5″ _module_preset=”default” text_font=”Fira Sans Condensed|300|||||||” text_text_color=”#4d4d4f” text_font_size=”18px” text_line_height=”1.5em” header_3_font=”Fira Sans Condensed|600|||||||” header_3_text_color=”#4d4d4f” header_3_font_size=”18px” header_3_line_height=”1.5em” custom_padding=”||||false|false” custom_padding_tablet=”|125px|||false|false” custom_padding_phone=”|0px|||false|false” custom_padding_last_edited=”on|phone” global_colors_info=”{}”]<\/p>\n

<\/span>Continuing to learn<\/span><\/h2>\n

The learning continues as everyone at Bagdad strives to maximize efficiency and hit production expectations, Elliott said.<\/p>\n

The predictability of the autonomous system has exposed shortcomings in other areas that in the past might have been glossed over through human intervention. <\/p>\n

As site operators gain experience with the autonomous system efficiency, production gains will follow, Elliott said. Asset efficiency and tons moved per day showed improvement in November.<\/p>\n

\u201cIt’s very much a learning curve,\u201d Elliott said. \u201cThe team here, including myself, continues to learn new things about how to efficiently operate. And I think those learnings are going to continue for the next year, at least, on how to efficiently operate and learn all the nuances within the autonomous system.\u201d[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row admin_label=”Row” _builder_version=”4.27.5″ _module_preset=”default” background_color=”RGBA(255,255,255,0)” custom_margin=”75px||||false|false” custom_padding=”0px|0px|0px|0px|false|false” background_color_phone=”#FFFFFF” background_last_edited=”on|phone” background_enable_color_phone=”on” custom_css_main_element=”display: flex;||flex-wrap: wrap;” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” background_color=”RGBA(255,255,255,0)” background_color_phone=”RGBA(255,255,255,0)” background_last_edited=”on|phone” background_enable_color_phone=”on” global_colors_info=”{}” custom_css_main_element_last_edited=”on|phone” custom_css_main_element_phone=”order: 2;||”][et_pb_code _builder_version=”4.27.5″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n