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 2011 Coal Cost Guide

DEVELOPMENT SERIES
Number 6 October 2010

The Costs of Re-contouring

Scott Stebbins, P.E.
Aventurine Mine Cost Engineering, Inc.

Slope Angle Reduction
Re-contouring, as it pertains to mining projects, most
often refers to one of a number of variations of the task
of reducing the slope of a stockpile of waste,
overburden, or tailings. These materials are most often
placed in a way that leaves their side-slopes at an
associated angle of repose.
The preferred way to reduce the side-slope angle of
these stockpiles has a bulldozer excavating horizontal
cuts into the material and then casting it down the face
(figure 1). Specifically, the bulldozer begins on the
top of the stockpile at the surface expression of the
desired (post re-contoured) crest. It then angles
toward the existing crest, dozing a load of material
with it. The machine continues to the existing crest
and casts the material down the face of the slope. It
repeats this process until all of the material from the
initial cut has been excavated, transported, and cast.
Next, the expression of the final slope on the bench is
surveyed in and staked, and the machine begins again
with the next cut thereby eventually providing the
desired final slope in the new face of the stockpile.

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As is evident, after a point roughly half-way down the
vertical extent of the stockpile, all of the material
moved will consist of that previously excavated from
above and so re-handling of previously cast material
quickly becomes part of the re-contouring process
(figure 2). There are other ways to re-slope the face of
a stockpile, however each requires varying amounts of
In general terms, the volume of material re-handled is
roughly equivalent to the volume of material originally
excavated. In other words, because some of the cast
material must be re-excavated and re-cast (in some
cases multiple times), the volume of material that must
be moved to re-contour a slope is generally about
twice the amount excavated in the first place.
However, a straight-forward 2:1 relationship does not
suffice because the angle of the underlying slope also
impacts the calculations, as do the factors of swell and
compaction for the excavated material. These all play
into the amount of material that must be moved to
arrive at the desired face slope of the stockpile and
must be considered when estimating the costs of re-
contouring.
Near the lower extremities of the slope, the bench
widths may become too narrow to allow for effective
use of the bulldozer. At that point, the bulldozer may
work directly down the face to re-contour the final
base of the slope. Typically, after all of the benches
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re-handling. Of these methods, the one presented here
and used to estimate the following costs is the method
that minimizes both the total amount of material
moved and the average distance that the bulldozer
must transport it, which maximizes the efficiency of
the bulldozer.
have been excavated and the final slope angle is
obtained, the bulldozer travels up and down the slope
to smooth the re-contoured face, to compact the newly
placed material, and to cleat the surface to impede
erosion and to prepare the slope for planting.
In the following sets of tables, the costs of re-
sloping the face of a stockpile (of either waste, topsoil,
or tailings) from an assumed angle of repose (42°) to
a variety of face angles are presented. These final face
slopes include angles of (33°) (1.5:1 - horizontal:
vertical), (30°) (1.75:1), (26°) (2:1), and (19°) (3:1).
The process of estimating the following costs begins
with calculating the amount of material that must be
excavated and determining where (how far in from
face) that excavation must begin. After that
information has been derived, the work of estimating
costs consists of a series of cycle-time calculations and
then the assignment of the associated wages and
prices.
Copyright © 2010 InfoMine USA, Inc.
 In the first four tables, a 310 horsepower bulldozer
is used to re-contour the slope. Costs presented are for
each 100 feet (30 meters) of length along the slope
face at a point roughly half-way down the vertical
extent of the stockpile . In other words, if the crest
length of the stockpile is 800 feet, the applicable value
from the following tables must be multiplied by 8 to
arrive at the overall cost. The slopes of the underlying
surface, that is the slopes of the surface upon which
the stockpile was placed, are listed in the column
farthest to the left.

Table 1. 33 degree final slope

Stockpile Height (feet)
Underlying
Slope 80 120 160 200 240 280 320 360 400
(degrees) (24 meters) (37 meters) (49 meters) (61 meters) (73 meters) (86 meters) (98 meters) (110 meters) (122 meters)

2 $1,983 $3,112 $4,332 $5,642 $7,044 $8,899 $11,200 $13,890 $17,010

4 1,984 3,113 4,334 5,645 7,048 8,905 11,210 13,900 17,020
6 1,985 3,115 4,336 5,649 7,053 8,912 11,220 13,920 17,040
8 1,986 3,117 4,341 5,656 7,062 8,923 11,240 13,940 17,070
10 1,988 3,119 4,344 5,660 7,069 8,972 11,310 14,040 17,210
12 1,993 3,129 4,359 5,682 7,099 9,016 11,370 14,120 17,330
14 2,004 3,149 4,390 5,726 7,158 9,102 11,490 14,300 17,560
16 2,022 3,184 4,445 5,807 7,268 9,305 11,790 14,700 18,100

Table 2. 30 degree final slope

Stockpile Height (feet)
Underlying
Slope 80 120 160 200 240 280 320 360 400
(degrees) (24 meters) (37 meters) (49 meters) (61 meters) (73 meters) (86 meters) (98 meters) (110 meters) (122 meters)

2 $2,274 $3,671 $5,242 $7,171 $10,050 $13,660 $18,120 $23,540 $30,030

4 2,275 3,674 5,247 7,184 10,070 13,690 18,160 23,600 30,110
6 2,277 3,678 5,253 7,216 10,120 13,770 18,280 23,770 30,340
8 2,283 3,688 5,270 7,240 10,160 13,830 18,370 23,880 30,490
10 2,291 3,703 5,294 7,305 10,270 14,000 18,610 24,230 30,950
12 2,308 3,736 5,348 7,417 10,450 14,280 19,020 24,800 31,730
14 2,338 3,797 5,447 7,664 10,860 14,910 19,950 26,090 33,480
16 2,406 3,927 5,660 8,106 11,590 16,040 21,590 28,390 36,590

Table 3. 26 degree final slope

Stockpile Height (feet)
Underlying
Slope 80 120 160 200 240 280 320 360 400
(degrees) (24 meters) (37 meters) (49 meters) (61 meters) (73 meters) (86 meters) (98 meters) (110 meters) (122 meters)

2 $2,600 $4,356 $7,354 $11,720 $17,690 $25,540 $35,590 $48,100 $63,400

4 2,605 4,365 7,396 11,800 17,830 25,730 35,910 48,560 64,010
6 2,613 4,380 7,448 11,890 17,970 25,990 36,240 49,020 64,640
8 2,624 4,402 7,539 12,060 18,260 26,430 36,890 49,940 65,890
10 2,645 4,452 7,703 12,370 18,780 27,240 38,070 51,600 68,150
12 2,688 4,594 8,018 12,970 19,780 28,790 40,360 54,820 72,520
14 2,783 4,837 8,555 13,970 21,453 31,400 44,190 60,200 79,830
16 2,974 5,319 9,622 15,960 24,800 36,600 51,820 70,930 94,390

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 Table 4. 19 degree final slope
Stockpile Height (feet)
Underlying
Slope 80 120 160 200 240 280 320 360 400
(degrees) (24 meters) (37 meters) (49 meters) (61 meters) (73 meters) (86 meters) (98 meters) (110 meters) (122 meters)

2 $3,442 $8,043 $15,910 $28,040 $45,460 $69,160 $100,20 $139,40 $188,00

4 3,513 8,249 16,360 28,900 46,890 71,400 103,400 144,100 194,400
6 3,593 8,486 16,890 29,890 48,570 74,010 107,300 149,600 201,800
8 3,738 8,926 17,880 31,770 51,760 79,020 114,700 160,000 216,100
10 4,024 9,812 19,890 35,610 58,280 89,250 129,800 181,400 245,300
12 4,581 11,550 23,860 43,180 71,160 100,950 159,800 223,700 303,000
14 5,715 15,120 32,010 58,750 97,670 151,100 221,400 311,000 422,100
16 8,104 22,680 49,350 91,910 154,200 240,000 353,100 497,300 676,500

In the next four tables, the costs associated with re-contouring are listed for a series of scenarios in which a 580
horsepower bulldozer tractor is used to re-slope the stockpile. Costs presented are for each 100 feet (30 meters) of
length along the slope face at a point roughly half-way down the vertical extent of the stockpile.

Table 5. 33 degree final slope

Stockpile Height (feet)
Underlying
Slope 80 120 160 200 240 280 320 360 400
(degrees) (24 meters) (37 meters) (49 meters) (61 meters) (73 meters) (86 meters) (98 meters) (110 meters) (122 meters)

2 $1,496 $2,320 $3,195 $4,121 $5,097 $6,328 $7,808 $9,505 $11,440

4 1,497 2,321 3,197 4,123 5,100 6,332 7,814 9,512 11,450
6 1,498 2,323 3,199 4,125 5,104 6,336 7,820 9,520 11,460
8 1,499 2,325 3,202 4,128 5,109 6,344 7,829 9,534 11,480
10 1,500 2,328 3,204 4,133 5,114 6,372 7,870 9,584 11,560
12 1,503 2,332 3,213 4,146 5,131 6,397 7,906 9,640 11,620
14 1,509 2,343 3,230 4,171 5,166 6,447 7,977 9,737 11,750
16 1,519 2,363 3,262 4,217 5,227 6,561 8,142 9,965 12,060

Table 6. 30 degree final slope

Stockpile Height (feet)
Underlying
Slope 80 120 160 200 240 280 320 360 400
(degrees) (24 meters) (37 meters) (49 meters) (61 meters) (73 meters) (86 meters) (98 meters) (110 meters) (122 meters)

2 $1,704 $2,712 $3,824 $5,150 $7,046 $9,384 $12,230 $15,650 $19,720

4 1,706 2,714 3,828 5,159 7,060 9,404 12,260 15,690 19,770
6 1,708 2,718 3,833 5,171 7,093 9,446 12,330 15,770 19,910
8 1,711 2,725 3,843 5,196 7,118 9,492 12,390 15,870 20,000
10 1,717 2,735 3,859 5,237 7,186 9,596 12,540 16,070 20,280
12 1,727 2,755 3,893 5,307 7,298 9,768 12,790 16,420 20,750
14 1,747 2,793 3,954 5,456 7,546 10,150 13,340 17,200 21,800
16 1,788 2,872 4,083 5,722 7,990 10,830 14,330 18,590 23,670

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 Table 7. 26 degree final slope
Stockpile Height (feet)
Underlying
Slope 80 120 160 200 240 280 320 360 400
(degrees) (24 meters) (37 meters) (49 meters) (61 meters) (73 meters) (86 meters) (98 meters) (110 meters) (122 meters)

2 $1,906 $3,130 $5,100 $7,885 $11,620 $16,490 $22,670 $30,310 $39,620

4 1,910 3,139 5,127 7,934 11,700 16,620 22,860 30,580 39,980
6 1,916 3,150 5,160 7,993 11,800 16,770 23,080 30,870 40,370
8 1,924 3,164 5,238 8,099 11,980 17,040 23,460 32,430 41,120
10 1,938 3,195 5,319 8,286 12,290 17,520 24,170 33,430 42,480
12 1,965 3,283 5,509 8,644 12,890 18,460 25,540 34,350 45,100
14 2,023 3,430 5,833 9,247 13,900 20,020 27,830 37,570 49,460
16 2,139 3,722 6,473 10,440 15,900 23,130 32,400 43,980 58,160

Table 8. 19 degree final slope

Stockpile Height (feet)
Underlying
Slope 80 120 160 200 240 280 320 360 400
(degrees) (24 meters) (37 meters) (49 meters) (61 meters) (73 meters) (86 meters) (98 meters) (110 meters) (122 meters)

2 $2,428 $5,362 $10,250 $17,680 $28,260 $42,580 $61,260 $85,880 $114,00

4 2,478 5,497 10,530 18,200 29,130 43,940 63,250 87,680 117,900
6 2,532 5,647 10,860 18,810 30,150 45,530 65,590 90,980 122,300
8 2,626 5,921 11,460 19,950 32,080 48,540 70,020 97,230 130,900
10 2,803 6,461 12,680 22,260 35,990 54,660 79,080 110,000 148,300
12 3,143 7,511 15,070 26,800 43,690 66,760 96,970 135,300 182,800
14 3,828 9,653 19,950 36,110 59,540 91,630 133,800 187,400 253,900
16 5,266 14,180 30,310 55,920 93,280 144,700 212,400 298,600 405,600

In the final four tables, the costs associated with re-contouring are listed for a series of scenarios in which an 850
horespower bulldozer tractor is used for the work. Costs presented are for each 100 feet (30 meters) of length along
the slope face at a point roughly half-way down the vertical extent of the stockpile.

Table 9. 33 degree final slope

Stockpile Height (feet)
Underlying
Slope 80 120 160 200 240 280 320 360 400
(degrees) (24 meters) (37 meters) (49 meters) (61 meters) (73 meters) (86 meters) (98 meters) (110 meters) (122 meters)

2 $1,236 $1,912 $2,626 $3,381 $4,173 $5,154 $6,325 $7,660 $9,178

4 1,237 1,913 2,628 3,383 4,175 5,159 6,329 7,665 9,185
6 1,238 1,914 2,630 3,385 4,178 5,162 6,335 7,673 9,194
8 1,239 1,916 2,632 3,388 4,182 5,168 6,343 7,683 9,207
10 1,240 1,918 2,635 3,391 4,188 5,190 6,375 7,727 9,267
12 1,242 1,922 2,641 3,401 4,200 5,210 6,403 7,765 9,316
14 1,247 1,931 2,655 3,420 4,226 5,247 6,456 7,840 9,416
16 1,255 1,946 2,679 3,455 4,273 5,334 6,580 8,011 9,647

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 Table 10. 30 degree final slope
Stockpile Height (feet)
Underlying
Slope 80 120 160 200 240 280 320 360 400
(degrees) (24 meters) (37 meters) (49 meters) (61 meters) (73 meters) (86 meters) (98 meters) (110 meters) (122 meters)

2 $1,443 $2,297 $3,237 $4,357 $5,949 $7,913 $10,300 $13,170 $16,580

4 1,445 2,299 3,242 4,366 5,962 7,931 10,330 13,200 16,620
6 1,448 2,303 3,248 4,386 5,994 7,967 10,390 13,260 16,710
8 1,452 2,310 3,257 4,400 6,015 8,007 10,440 13,360 16,830
10 1,456 2,319 3,272 4,435 6,072 8,095 10,560 13,530 17,070
12 1,466 2,337 3,330 4,494 6,168 8,243 10,770 13,830 17,460
14 1,481 2,368 3,352 4,619 6,375 8,560 11,240 14,480 18,340
16 1,517 2,436 3,461 4,844 6,745 9,130 12,070 15,640 19,910

Table 11. 26 degree final slope

Stockpile Height (feet)
Underlying
Slope 80 120 160 200 240 280 320 360 400
(degrees) (24 meters) (37 meters) (49 meters) (61 meters) (73 meters) (86 meters) (98 meters) (110 meters) (122 meters)

2 $1,621 $2,658 $4,310 $6,645 $9,777 $13,850 $19,010 $25,410 $33,200

4 1,625 2,665 4,337 6,689 9,844 13,970 19,160 25,630 33,510
6 1,631 2,676 4,368 6,743 9,931 14,090 19,350 25,890 33,840
8 1,639 2,691 4,417 6,833 10,080 14,320 19,690 26,360 34,470
10 1,652 2,719 4,503 6,993 10,350 14,720 20,290 27,200 35,610
12 1,675 2,793 4,663 7,292 10,850 15,510 21,440 28,810 37,800
14 1,726 2,917 4,934 7,797 11,690 16,810 23,350 31,500 41,500
16 1,820 3,159 5,466 8,792 13,360 19,400 27,160 36,850 48,700

Table 12. 19 degree final slope

Stockpile Height (feet)
Underlying
Slope 80 120 160 200 240 280 320 360 400
(degrees) (24 meters) (37 meters) (49 meters) (61 meters) (73 meters) (86 meters) (98 meters) (110 meters) (122 meters)

2 $2,074 $4,545 $8,639 $14,860 $23,730 $35,730 $51,370 $71,150 $95,590

4 2,120 4,664 8,891 15,320 24,480 36,880 53,060 73,530 98,810
6 2,175 4,802 9,178 15,850 25,350 38,240 55,050 76,320 102,600
8 2,261 5,038 9,699 16,810 26,980 40,780 58,780 81,590 109,800
10 2,414 5,500 10,721 18,750 30,270 45,920 66,380 92,320 124,400
12 2,702 6,383 12,723 22,560 36,730 56,050 81,370 113,500 153,300
14 3,276 8,173 16,806 30,350 49,980 76,860 112,200 157,100 212,800
16 4,474 11,950 25,455 46,900 78,190 121,200 177,900 250,200 339,900

The above costs include those associated with owning,
maintaining, repairing, and operating the bulldozer as
well as the wages of the dozer operator. Also included
are those costs associated with surveying and staking
the slope during the process of re-contouring, and for
onsite supervision. Not included are costs for
mobilization, project management, contractor profit, or
engineering.
All costs were derived through the use of in-house,
spreadsheet-based cost models. These models work
with the project parameters (volumes moved over
specific distances and gradients, blade and traction
efficiencies, etc.) to calculate machine cycle times
which are used, in turn, to determine equipment and
labor needs. These are then combined with price and
wage data from Mining Cost Service to provide the
estimated costs. Itemized costs for the labor and
supplies used in the models are as follows:

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Unit Costs * Maintenance and repair parts, ground engaging
Labor components, and ownership costs are specific to
Foreman $ 27.54/hour each machine and based upon manufacturer
Surveyor $ 26.60/hour recommendations.
Equipment Operator $ 23.33/hour
Mechanic $ 22.66/hour Almost all of the costs of re-contouring are attributable
Laborer $ 20.60/hour to either labor or to the expenses of owning and
Burden Rate 36.1% of wages operating the equipment. Few supplies are consumed
except those associated with staking the slope as it is
Equipment Operation surveyed, and with the equipment-based consumables.
Diesel Fuel $ 2.645/gallon $ 0.699/liter Average cost distributions are listed in the following
Lubricants $ 8.09/gallon $ 2.137/liter tables:
Repair & Overhaul Parts*
Ground Engaging Components*
Equipment Ownership*

Selected Labor Cost Distribution (percent of total cost)

Final Slope
Bulldozer 19° 26° 30° 33°
310 horsepower 28.5% to 61.6% 34.0% to 71.9% 46.7% to 78.8% 70.3% to 88.5%
580 horsepower 19.2% to 61.2% 27.3% to 72.2% 42.3% to 78.8% 68.1% to 88.4%
850 horsepower 13.0% to 56.9% 21.7% to 68.9% 37.0% to 75.8% 65.5% to 87.2%

Average Fuel Cost Distribution (percent of total cost)

Final Slope
Bulldozer 19° 26° 30° 33°
310 horsepower 28.5% to 61.6% 34.0% to 71.9% 46.7% to 78.8% 70.3% to 88.5%
580 horsepower 19.2% to 61.2% 27.3% to 72.2% 42.3% to 78.8% 68.1% to 88.4%
850 horsepower 13.0% to 56.9% 21.7% to 68.9% 37.0% to 75.8% 310 horsepower

Average Equipment Operating and Ownership Cost Distribution (percent of total cost)
Final Slope
Bulldozer 19° 26° 30° 33°
310 horsepower 51.9% to 27.9% 47.9% to 20.4% 36.0% to 14.3% 11.4% to 4.4%
580 horsepower 53.3% to 27.5% 51.5% to 19.7% 38.4% to 14.1% 11.8% to 4.3%
850 horsepower 64.7% to 32.0% 58.2% to 23.1% 44.7% to 7.1% 14.5% to 5.4%

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 In the three preceding tables, the numbers to the
left of each range are typical of the 400-foot-high
stockpile, and the numbers to the right are those for the
80-foot-high stockpile.
Volumes excavated of course vary from one
model to the next and are based upon the size and
configuration of the stockpile, the slope angle of the
underlying surface as well as the cut and repose
angles, and the density, swell, and compaction
characteristics of the material. In addition to the size
of the stockpile and the steepness of the final slope,
costs are heavily influenced by the efficiency of the
dozer’s blade (which in this case is a function of the
thickness of the cut and the width of the bench) and by
the dozer’s ability to gain and maintain traction (which
is a function of the nature of the stockpiled material
and the weight of the machine). Some of the
parameter values used in the models include:

Site Work Evaluation Parameters (English units)

Bulldozer
Evaluation Parameter 310 horsepower 580 horsepower 850 horsepower
In-Place Density (pounds/cubic yard) 3,220 3,220 3,220
Loose Density (pounds/cubic yard) 2,875 2,875 2,875
Compacted Density (pounds/cubic yard) 3,220 3,220 3,220
Blade Capacity (cubic yards) 11.4 24.2 45
Blade Efficiency (percent) 60 to 90 50 to 90 40 to 90
Traction Efficiency (percent) 65 70 75
Excavated Cut Thickness (feet) 4 5 6

Site Work Evaluation Parameters (Metric units)

Bulldozer
Evaluation Parameter 310 horsepower 580 horsepower 850 horsepower
In-Place Density (kilograms/cubic meter) 1,910 1,910 1,910
Loose Density (kilograms/cubic meter) 1,705 1,705 1,705
Compacted Density (kilograms/cubic meter) 1,910 1,910 1,910
Blade Capacity (cubic meters) 8.7 18.5 34.4
Blade Efficiency (percent) 60 to 90 50 to 90 40 to 90
Traction Efficiency (percent) 65 70 75
Excavated Cut Thickness (meters) 1.22 1.52 1.83

Acknowledgment
The author wishes to thank Jeff Gabardi, Mining Engineer for the USDA Forest Service, Region 4, for his insights
into the tasks associated with re-contouring.

References
Campbell, D.B., Resloping Waste Rock Dumps, in International Mine Waste Management News, Volume 2, Number
2, April 1992.

Leinart, J.B. (Ed.), 2009, “Mining Cost Service,” InfoMine USA. Inc.

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