10 - Hauling and Hoisting PDF

CHAPTER 10
HAULING & HOISTING

Dr. Teuku Andika R Putra
USM 2014
Excavators
Dr. Kadri Dagdelen Loading Equipment 2

Hydraulic Shovels Specifications

Excavator Specifications

Digging Envelopes
Front Shovels

Curl and Crowd Forces
Front Shovels

Digging Envelopes
Excavators

Excavators Bucket

Loaders

Breakout Force
Loaders

Breakout Force from
Rackback Loaders

Carry Position
Loaders

900 Series II – Dimensions
Loaders

900 Series II – Dimensions
Loaders

Specifications
Loaders

Specifications
Loaders

Travel Time – Loaded
Loaders

Travel Time – Empty
Loaders

Excavator Production
Calculations
A standard formula for cyclic excavators can be

employed:
O = B x BF x D x HS x J x A x 3,600
seconds
(1+S) C hour
Bucket Load Buckets/Period

Bucket Load
B x BF x D/(1 + S) < Recommended

Operating Capacity
– With wheel loaders:
50% of full turn static tipping load for
a specific bucket type
– With front shovels:
Maximum load

Bucket Load
• Bucket weight depends on size, duty and

ground engaging tools
• Bucket size depends on reach
• Bucket size (B) based on 2:1 heap
• Bucket fill (BF) decreases with increasing
material consolidation

Wheel Loader Bucket Fill Factors
(CAT)
Weight of Materials
Dr. Kadri Dagdelen Loading Equipment (CAT) 23

Bucket Load
• % Swell increases and load factor

decreases with degree of consolidation
• In place density (D) important and should
be a measured number
• Loose density (D/(1 + S)) important and
should be a measures number

Buckets/Period
• Average cycle time (C) based on standard

cycle time adjusted for:
– Material
– Material fragmentation
– Material size distribution
– Pile configuration

Buckets/Period
• Average cycle time (C) based on standard

cycle time adjusted for:
– Consistency of operation
– Swing angle (Shovels)
– Travel distance (Loaders)
– Operator ability

Wheel Loader Cycle Time
Average cycle time for truck loading

increases with machine size
Loader Size (cy) Cycle time (min)
1.7-4.5 .45-.50
5.0-7.5 .50-.55
7.5-11 .55-.60
15-21 .60-.70

Cycle Time
• Hours scheduled (HS) usually a given,

based on management preferences and
required output
• Longer shifts appear to be trend to
minimize start-up, shut-down impact

Cycle Time
• Job factor (J) depends on:

– Truck assignment
– Management issues
– Job layout (Blending, etc.)

Cycle Time
• Mechanical availability (A) depends on:

– Material
– Management/suppliers
– Age of machine
– Schedule

Loading Methods
• Loading method impacts cycle time and job

factor
• Wheel loaders
– Y pattern used with machine digging point left to right
– Truck spotting location important
– With a limited truck fleet and excess loader capacity,
staggered and chain loading can be utilized

Loading Methods

Loading Methods
(Mining Magazine)

Shovels:
Double Back-Up
Options include
• Double back-up
• Single back-up
• Drive-by
• Modified drive-by

Shovels:
Double Back-Up
• Trucks loaded on both sides

• Average swing angle reduces
• Clean-up allowed on one side while
loading continues
• Moves required as shovel penetrates bank

Shovels:
Double Back-Up

Shovels:
Double Back-Up
Requires
balance of
move time
versus
cycle time
(Oslund and Russell)

Shovels:
Single Back-Up
• Truck loaded on one side

• Larger swing angle
• Potential clean-up delays
• Potential spotting delays depending on
excavator first cycle

Shovels:
Single Back-Up

Shovels:
Drive-By
• Used with tractor trailers

• Large swing angles
• Minimal amount of shovel moves
• Blending problems

Shovels:
Drive-By

Shovels:
Modified Drive-By
• Truck backs in to reduce swing angle

• Minimal amount of shovel moves
• Blending problems
• Depth of cut effects cycle time and move
time

Shovels:
Modified Drive-By

Modified Drive-By:
Optimum Width

Truck Selection
• Number and type of trucks selected should

be based on overall system economics
• Lowest cost fleet selected considering
operating and capital coats

Truck Selection
• Production requirement and operating

schedule
• Material characteristics
– Density in place and loose, swell
– General size distribution, particularly
maximum and minimum sizes and percentage
of total
– Hardness and texture
– Ease of handling

Truck Selection
• Physical and climatic conditions

– Effect of altitude on engine efficiency
– Effect of ambient temperature on engine
cooling, tire performance, and use of
lubricants
– Effect of rainfall, frost, snow, fog, etc. on road
conditions and travel
• Haul road characteristics
– Length, grade, and surface condition of
segment

Truck Selection
• Loading
• Space and ground conditions at loading point
• Type and size of loading equipment
• Total availability of loading equipment
• Dumping
• Dumping arrangements: rear dump into hopper, drive
over hopper, edge of spoil, windrow, etc.
• Space and ground condition at dump point
• Total availability of down stream equipment

Truck Selection:
Rear Dump
• High horsepower to weight ratio

• Deep pits, high grades, maneuverability required
high impact and rough in pit conditions.
• Can be used with any type of material ( e.g.,
blocky, free flowing, etc. )
• Used for dumping into hoppers or over bank or
fill
• Economic distance limited

Truck Selection:
Bottom Dump
• Low HP/weight ratio

• Free flowing material
• Dumping over hopper or in windrow
• Operational advantages: Dump on the
move, More favorable tire and axle
loading, high speed hauling on level hauls
• Moderate grade and long distance hauls

Production Calculations
• The prime mover delivers a force that

propels the haulage vehicle plus the load
• The force the drive wheels deliver to the
ground is referred to as rimpull
• This force is a function of: the torque
developed by the engine, the ratio of the
gears, and the size of the wheels

Production Calculations
• Maximum velocity is reached when rimpull

is equal to resisting forces of gravity,
rolling resistance. etc.
Horsepower x 375 x Efficiency
Available Rimpull =
Speed in MPH

Rimpull vs. Velocity

Rolling Resistance
• Measure of the force required to overcome

internal bearing friction and the retarding effect
between the tires and the ground (i.e., tire
penetration and tire flexing).
• Expressed in terms of lb/ton vehicle weight or %
vehicle weight
• Haul Road Resistance can be estimated by:
RR = 2%+1.5% per inch of tire penetration

Rolling Resistance
Factors
TYPICAL ROLLING RESISTANCE FACTORS
Various tire sizes and inflation pressures will greatly reduce or increase the rolling resistance. The
values in this table are approximate, particularly for the track and track+ tire machines. These values
can be used for estimating purposes when specific performance information on particular equipment
and given soil conditions is not available See Mining and Earthmoving Section for more detail:
ROLLING RESISTANCE, PERCENT`
Tires Track Track
UNDERFOOTING Bias Radial ** +Tires
A very hard, smooth roadway, concrete, cold asphalt
or dirt surface, no penetration or flexing 1.5%* 1.2% 0% 1.0%
A hard; smooth, stabilized surfaced roadway
without penetration under load; watered; maintained 2.0% 1.7% 0% 1.2%
A firm, smooth, rolling roadway with dirt or light
surfacing, flexing slightly under load or undulating,
maintained fairly regularly, watered 3.0% 2.5% 0% 1.8%
A dirt roadway, rutted or flexing under load; little
maintenance, no water, 25 mm (1”) tire penetration
or flexing 4.0% 4.0% 0% 2.4%
A dirt roadway; rutted or flexing under load; little
maintenance, no water, 50 mm (2”) tire penetration
or flexing 5.0% 5.0% 0% 3.0%
Rutted dirt roadway, soft under travel, no
maintenance, no stabilization 100 mm (4”) tire
penetration or flexing 8.0% 8.0% 0% 4.8%
Loose sand or gravel 10.0% 10:0% 2% 7.0%
Rutted dirt roadway, soft under travel, no
maintenance, no stabilization, 200 mm (8”) tire
penetration and flexing 14.0% 14.0% 5% 10:0%
Very soft, muddy, rutted roadway, 300 mm (12”)
tire penetration, no flexing 20.0% 20.0% 8% 15%
*Percent of combined machine weight.

**Assumes drag load has been subtracted. to give Drawbar Pull for good to moderate conditions.
Some resistance added for soft conditions. (CAT)

Grade Resistance
• Force required to overcome gravity when

moving vehicle uphill. Expressed in % vehicle
weight (adds power to vehicle downhill).
• Percent Grade = Vertical rise or drop (ft) x 100
Horizontal Distance (ft)
e.g., 60 ft rise in 1,000 ft, Grade = 60/ 1,000 x 100 =
6%
Horizontal Distance =
(Horizontal distance2 + vertical distance2)1/2
e.g., (1,0002 +602)1/2 = 1,001.8 ft

Weights and Traction
• Weights: determines the force required to
propel vehicle.
– Function of vehicle weight, rated capacity (CY),
and density of material hauled, number of passes
of excavator
• Traction: force deliverable can be limited by
traction conditions
– Usable rimpull is a function of road surface and
weight on the drive wheels
Usable Rimpull =
Coefficient of Traction x Weight on Drive
Wheels

Coefficient of Traction Factors
(CAT)

Altitude Deration
(CAT)

Speed Limits
• Speed Limits: limits on curves, in pit, and

on main haul roads
– Curves based on radius and super elevation
– In pit, ramp, and main haul roads, the speed
limit depends on haul road width and
conditions

Acceleration,
Deceleration, Operator
• Speeds obtained from performance curves

indicate maximum velocity under optimum
conditions on a given profile.
• These speeds must be corrected for
acceleration, deceleration, and operator
performance to yield reasonable haul and return
times.
– F=Ma Simulation utilized to account for acceleration
and deceleration
– Time studies indicate that simulated haul times are
less than actual haul times

Tires
• Limit capability of machine to perform by

limiting load and speed
• Ton-mile-per-hour ratings should not be
exceeded and depend on:
– Weight (Flex/revolution)
– Speed (Flexes/period)
– Ambient Temperature
– Road Surface Temperature

Tires
TMPH = Average Tire Load x Average Speed for Shift
Average Tire Load = Empty Tire Load + Loaded Tire Load

(tons) 2
Average Speed = Round Trip (mi) x Trips/Shift

Total Hours (hr)
Limits by tire type and limits may also include maximum

speed

Ton-MPH Data
(CAT)
Estimating Cycle Time
• Limiting factors are considered in developing an

estimate of the cycle time. The cycle time
consists of variable or travel time (haul and
return time) plus the fixed time (load, dump, and
spot times).
• Travel time (haul and return times) is a function
of payload, vehicle weight, HP/weight ratio, haul
road segment lengths, rolling and grade
resistance, speed limits, etc.

Estimating Cycle Time
• Loading time is a function bucket size, fill factor,

excavator cycle time, loose material density,
and truck capacity
• Other fixed times depend on loading method
and dump configuration
– Spot and maneuver in loading area (typically .6-.8
min)
– Dumping (typically 1-1.2 min)
• Unit production calculated considering truck
payload, truck cycle time, hours per shift, and
operating efficiency

Unit Production
• Unit Production (Tons/shift)

– Truck payload / Truck cycle time x Operating
efficiency x Hours/shift
– Units required are a function of total shift tonnage
requirements and unit production and mechanical
availability
• Units Required Operating
– Tons required/shift / Unit truck production/shift
(Usually rounded up)

Unit Production
• Units Required Purchased

– Units Required Operating (Not rounded) /
Mechanical availability

Match Factor and System
• Production of the excavator truck system

dependent on the number of trucks
assigned to the excavator

Match Factor and System
Allocations based on at least two

approaches:
• Number of trucks = Truck cycle time / Load time
(excluding first pass)
This calculation approach reduces excavator delays
• Number of trucks =
Truck cycle time
Load time (excluding first pass) + Truck exchange time

Match Factor Approach
• Match factor approach reduces truck delays

compared to first method. For example:
L o a d e r c y c le tim e .5 m in
N o. of passes 7
E f f e c tiv e lo a d in g tim e ( 7 - 1 ) x .5 3 .0 0 m in
T ru c k s p o t tim e (e x c h a n g e tim e ) 1 .3 0 m in
H a u l, d u m p a n d re tu rn 12 .7 1 m in
T ru c k c y c le tim e 17 .0 1 m in
N o . T r u c k s ( 1 7 .0 1 /3 .0 0 ) 5 .6 7
N o . T r u c k s ( 1 7 .0 1 /( 3 .0 0 + 1 .3 0 ) ) 3 .9 6

Example with three trucks

Example with four trucks

System Production
• System production must consider number of

trucks, unit production and excavator availability.
• System production
– Number of truck/shift x Unit production
(Tons/shift) x Excavator availability
• Complexity of calculations and variability of
times leads to use of fleet production simulators
such as FPC and TALPAC

Wheel Loader Production
Calculations
• Example:
Calculate the output in tons/hr of a 990 Wheel
Loader with a 11cy bucket with .55 min. cycle
time and 95% bucket fill factor loading material
with 3100 lbs. per LCY.
Assume 85% mechanical availability and 83.3%
job factor.
Dr. Kadri Dagdelen Truck Selection and Production Calculations 2

Calculations (Cont.)
• Equation to estimate the production per hour:
O = BC*BF*D*MA*JF*3,600sec
(1+SF)*CT hour
Where,
O =Production, tons/hr
BC =Bucket Size, CY (Usually heaped at 2:1)
BF =Bucket Fill Factor, %
D =In Place Density, tons/CY
MA=Mechanical Availability, %
JF =Job Factor, %
SF =Material Swell, %100
CT =Average cycle time, seconds

• Solution:
O = 11*0.95*1.55*0.85*0.833*3,600sec
33sec
= 1252 tons/hr

Loader-Truck Production
Calculations
• Example:
CAT775 truck (65ton) is loaded with a 11.0CY 990
loader with 0.55min cycle time with 95% fill factor.
For truck cycle time, use the following table.
Determine the number of trucks needed for the
loader and the total production per hour.
Truck cycle time

Haul 3.8min
Dump 1.0min
Return 1.8min
Spot 0.6min

Tons / cycle = 11CY/cycle * 0.95*3100lb/cy / 2000lb

= 16.2T/cycle
# of cycles/truck = 65T / truck / 1 cycle/16.2T

= 4 cycles
Loading time = (4-1) cycles * 0.55min / cycle = 1.65 min

Cycle time
Load 1.7min
Haul 3.8min
Dump 1.0min
Return 1.8min
Spot 0.6min
Total Cycle time 8.9min

• Number of Trucks/ Loader
No. of Trucks = Truck cycle time / Load time

= 8.9 min / 1.65 min
= 5.4 trucks
(Assume 6 trucks)

• Total Production
Assume – 50 min / hour, and 85% availability
65T/cycle*1cycle/8.9min*50min/hr*0.85/unit = 312T/hr
Total Production = No. of trucks * tons/hr – unit

= 5.4 trucks * 312T/hr per truck
= 1685 tons/ hr

Calculations
• Example:
A quarry works with CAT769D flat floor trucks (Max
payload 41T, Engine+-450hp) that is loaded by 8cy
loader.
The material density is 2800lb/LCY and the quarry is
located at the sea level, sending material at 260tons/
hour to the crusher.
Calculate truck loading time, productivity, and number
or trucks required.

• Example (Cont.):
Loader data:
Capacity: 8cy
Fill factor: 80%
Cycle time: 0.5 min/pass
Mechanical availability: 88%

Truck cycle time data:
Spot time: 0.8 min
Dump time:1.5min
Truck mechanical availability: 85%

Road profile:
Segment Length (m) Speed limit Grade (%) Rolling

(km/hr) resistance (%)
1 122 45 0 4
2 762 20 8 2
3 152 45 0 4
Road condition: Firm

Tons / cycle = 8CY/cycle * 0.8*2800lb/cy / 2000lb

= 9T/cycle
# of cycles/truck = 41T / truck / 1 cycle / 9T

= 4.6 cycles (5 cycles)
Loading time = (5-1) cycles * 0.5min / cycle = 2.0 min

Haul Speed:
Segment1
Total Resistance = 4%
Max speed = 42km/h
< Speed limit (45km/hr)
42

Conversion of Max Speed to Average

Speed
Weights to HP ratio:
75050kg = 165456lb
165456lb / 450hp = 368lb/hp
Haul load length:
122m = 401ft
Conversion factor = 0.51
Avg speed = 42km/hr*0.51=21.4km/hr

Haul Speed :
Segment2

Max speed = 16km/h
Conversion factor = 1
Avg speed = 16km/hr
16

Haul Speed :
Segment3
Max speed = 42km/h
Conversion factor = 0.68

Avg speed
= 42km/hr*0.68=28.6km/hr
42

Haul Time:
Segment1:
0.122km / 21.4km/hr * 60min = 0.34 min
Segment2:
0.762km / 16km/hr * 60min = 2.86 min
Segment3:
0.152km / 28.6km/hr * 60min = 0.32 min
Total Haul Time:

0.34+2.86+0.32 = 3.52 min

Return Speed:
Segment1
Max speed = 73km/h
> Speed limit (45km/hr)
So, choose 45km/hr
Avg speed
= 45km/hr*0.68=30.6km/hr
73

Return Speed :
Segment2
Total Resistance = -8%+2% = -6%

Max speed = 69km/h
> Speed limit (20km/h)
6%
Choose 20km/hr
Avg speed = 20*0.95

= 19km/h
69

Return Speed :
Segment3
Max speed = 73km/h
> Speed limit (45km/hr)
So, choose 45km/hr
Avg speed
= 45km/hr*0.54=24.3km/hr
73

Return Time:
Segment1:
0.122km / 30.6km/hr * 60min = 0.24 min
Segment2:
0.762km / 19km/hr * 60min = 2.41 min
Segment3:
0.152km / 24.3km/hr * 60min = 0.38 min
Total Return Time:

0.24+2.41+0.38 = 3.02 min

Haul and Return Time Summary:

Haul
Length Total Resistance Speed Limit Avg. Speed
Segment (m) Grade(%) RR (%) (%) (km/hr) (km/hr) Conversion (km/hr) time (min)
1 122 0 4 4 42 45 0.51 21.42 0.34
2 762 8 2 10 16 20 1 16 2.86
3 152 0 4 4 42 45 0.68 28.56 0.32
Return
Length Total Resistance Speed Limit Avg. Speed
Segment (m) Grade(%) RR (%) (%) (km/hr) (km/hr) Conversion (km/hr) time (min)
1 122 0 4 4 73 45 0.68 30.6 0.24
2 762 -8 2 -6 69 20 0.95 19 2.41
3 152 0 4 4 73 45 0.54 24.3 0.38
Total time = 3.52min(haul)+3.02(return)=6.54 min

Truck cycle time (min)
Load 2.0 min

Haul 3.5min
Dump 1.5min
Return 3.0min
Spot 0.8min
Total 10.8min

• Slip condition check (Segment2):
Available Rimpull
=(Grade resistance + Rolling resistance)
* Gross Vehicle Weight
= (8% + 2%) * (34050kg + 41000kg)
= 10%*75050kg
= 7505kg

Usable Rimpull: Function of road surface and

weight on the drive wheels
Usable Rimpull
= Coefficient of Traction * Weight on Wheel

Typical Coefficient of Traction

Weight of Wheel:
769D: Rear 66.7%, Front 33.3% Distribution
(by CAT Performance Book)
Weight on Rear Tire is
75050kg * 0.667 = 50058kg
Then, Usable Rimpull is

0.6*50058kg*Cos(8%) = 29939kg

• CONDITION CHECK
Usable Rimpull > Available Rimpull
There is no slip condition.

• Unit Production
Assuming 50min / hour
Productivity:
41T/cycle*1cycle/10.8min*50min/hr*0.85 = 161T/hr

• Number of Trucks/ Loader
For maximum productivity: 10.8min / 2.0min = 5.4
(6trucks)
To achieve 260T/hr: 260 / 161 = 1.61 (2 trucks)

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CHAPTER 10

HAULING & HOISTING

Dr. Kadri Dagdelen Loading Equipment 2

Dr. Kadri Dagdelen Loading Equipment 3

Dr. Kadri Dagdelen Loading Equipment 4

Dr. Kadri Dagdelen Loading Equipment 5

Dr. Kadri Dagdelen Loading Equipment 6

Dr. Kadri Dagdelen Loading Equipment 7

Dr. Kadri Dagdelen Loading Equipment 8

Dr. Kadri Dagdelen Loading Equipment 9

Dr. Kadri Dagdelen Loading Equipment 10

Dr. Kadri Dagdelen Loading Equipment 11

Dr. Kadri Dagdelen Loading Equipment 12

Dr. Kadri Dagdelen Loading Equipment 13

Dr. Kadri Dagdelen Loading Equipment 14

Dr. Kadri Dagdelen Loading Equipment 15

Dr. Kadri Dagdelen Loading Equipment 16

Dr. Kadri Dagdelen Loading Equipment 17

Dr. Kadri Dagdelen Loading Equipment 18

A standard formula for cyclic excavators can be

Dr. Kadri Dagdelen Loading Equipment 19

B x BF x D/(1 + S) < Recommended

Dr. Kadri Dagdelen Loading Equipment 20

• Bucket weight depends on size, duty and

Dr. Kadri Dagdelen Loading Equipment 21

Dr. Kadri Dagdelen Loading Equipment (CAT) 23

• % Swell increases and load factor

Dr. Kadri Dagdelen Loading Equipment 24

• Average cycle time (C) based on standard

Dr. Kadri Dagdelen Loading Equipment 25

• Average cycle time (C) based on standard

Dr. Kadri Dagdelen Loading Equipment 26

Average cycle time for truck loading

Dr. Kadri Dagdelen Loading Equipment 27

• Hours scheduled (HS) usually a given,

Dr. Kadri Dagdelen Loading Equipment 28

• Job factor (J) depends on:

Dr. Kadri Dagdelen Loading Equipment 29

• Mechanical availability (A) depends on:

Dr. Kadri Dagdelen Loading Equipment 30

• Loading method impacts cycle time and job

Dr. Kadri Dagdelen Loading Equipment 31

Dr. Kadri Dagdelen Loading Equipment 32

Dr. Kadri Dagdelen Loading Equipment 33

Dr. Kadri Dagdelen Loading Equipment 34

• Trucks loaded on both sides

Dr. Kadri Dagdelen Loading Equipment 35

Dr. Kadri Dagdelen Loading Equipment 36

(Oslund and Russell)

Dr. Kadri Dagdelen Loading Equipment 37

• Truck loaded on one side

Dr. Kadri Dagdelen Loading Equipment 38

Dr. Kadri Dagdelen Loading Equipment 39

• Used with tractor trailers

Dr. Kadri Dagdelen Loading Equipment 40

Dr. Kadri Dagdelen Loading Equipment 41

• Truck backs in to reduce swing angle

Dr. Kadri Dagdelen Loading Equipment 42

Dr. Kadri Dagdelen Loading Equipment 43

Dr. Kadri Dagdelen Loading Equipment 44

• Number and type of trucks selected should

Dr. Kadri Dagdelen Loading Equipment 45

• Production requirement and operating