Suncor progresses Cat AHS at Mildred Lake & reports success with Mud Mode on Komatsu AHS trucks at Base Plant
Suncor has reached another important milestone in its autonomous haulage journey with the launch of its first Autonomous Operating Zone at Syncrude’s Mildred Lake – with the Syncrude operations being controlled by Suncor since late 2021 . It says this achievement builds on the successful implementation of AHS with a fleet of about 140 autonomous trucks at Base Plant in 2024 and shows what can be accomplished when technology, expertise and collaboration come together across its operations.
Today, 19 363 t class mechanical drive Caterpillar 797F trucks have been retrofitted for autonomous operation with Caterpillar’s Command for hauling at Mildred Lake, with plans to convert an additional 21 by the end of 2026. Suncor works with Caterpillar and its dealer Finning Canada on the installation of the system.
Suncor stated: “As we continue to focus on optimising mining performance, innovations like AHS are helping drive productivity, reliability and cost competitiveness across the business…this summer, the autonomous fuel module will be brought online and teams will continue expanding training and applying lessons learned to support the planned growth of the AHS fleet to 70 trucks. The Base Plant deployment showed what was possible. Syncrude proves it wasn’t a one-time success. That’s what going back-to-back looks like.”
Talking of Base Plant, which has a 363 t class diesel electric drive Komatsu 980E fleet and operates using Komatsu’s FrontRunner AHS, the term ‘Mud Mode’ recently came up on oil sands mining major Suncor’s Q2 2026 earnings call. So what is it? Suncor says Mud Mode started in an unexpected place: an observation by someone determined to solve a practical problem. For Michael Gartenburg, Director Operations – AHS Deployment, Base Plant, the spark came from a familiar source: the drive mode in his own vehicle.
He states: “Just like my vehicle has different settings to help it handle snow, mud or rough terrain, I knew there had to be a way to use the data in our AHS system to do something similar at a larger scale on our haul trucks.” At Base Plant, home to what Suncor says is the world’s largest ultra-class autonomous haul truck fleet at a single mining site, the concept had the potential to solve a real challenge. Soft ground and wet weather can affect traction, leading to truck stoppages and field interventions.
Mud Mode 2.0 has been rolled out on 90% of the Komatsu AHS fleet at Base Plant
Mud Mode helps AHS trucks better respond to those conditions. Suncor says using data already generated by AHS and truck drive systems, the technology allows haul trucks to maintain better traction and avoid unnecessary stops. The solution involved work from Suncor, Komatsu and Komatsu dealer SMS Equipment, and combines data, testing and real-world experience to keep trucks moving safely and efficiently. Implemented in spring 2025, Mud Mode 1.0 focused on slippage during forward travel. Suncor says the results were impressive. Slippage-related stoppages improved significantly and enabled the movement of approximately six million additional tonnes, generating an estimated C$25 million in value.
The team built on that early success through continued testing, learning and refinement, leading to the launch of Mud Mode 2.0 in Spring 2026. The enhanced version operates at higher speeds and in reverse, including when trucks are backing up to a shovel or dump, and gives trucks more time to regain traction before stopping in slippery conditions.
Suncor: “The timing couldn’t have been better. With snow and rainfall this spring reaching levels not seen in decades, Mud Mode 2.0 was put to the test – and delivered. Since testing began in early May, performance has improved by 40% over Mud Mode 1.0 across a range of weather conditions, demonstrating the benefit of continuous improvement. Mud Mode 2.0 has been rolled out in 90% of the fleet, with completion on track in the third quarter.”
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