QUARRY AND AGGREGATES

PRIMARY LOADING TOOL

Selection Guide
Selecting the Right Machine
There are several major application and owning/operating issues to consider when purchasing a primary
loading tool. While the needs of a project will quickly narrow the scope of machines to be considered, final
selection must be based on a thorough understanding of the application needs at specific job sites. Use this
guide to help in making an informed decision.
CONTENTS

Selection Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Product Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Site Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19
Selection Process
Quarry-specific needs and working face attributes are primary selection considerations. The overall goal is to maximize profit with a
loading system that meets targeted hourly production at the lowest cost per unit of material moved.

ON-SITE EVALUATION
• Face material Important considerations when selecting a loading unit:
• Material fragmentation • Life of the quarry operation
• Penetration characteristics • Primary loading
• Material angle of repose • Multiple loading faces
• Face height and angle • Secondary functions such as stockpiling, loading rail cars,
• Bench width feeding the primary crusher, cleanup, and maintaining a
• Maneuvering space surge pile.
• Multiple loading faces The wheel loader, hydraulic shovel, and hydraulic excavator fit
• Blending requirements into primary loading functions. The equipment that is best for the
• Floor conditions job depends on the characteristics of the job site.
• Job set-up
• Load area support equipment needs
• Blasting restrictions

4
Product Descriptions

WHEEL LOADERS KEY POINTS:

• 30- to 40-second cycle times
Large wheel loaders have grown in size over time to match
increasing off-highway truck payload capacities. They increase • Highly versatile and mobile
productivity with consistent high bucket fill factors and are used • Same level truck loading
effectively as primary loading tools where mobility is paramount.
In conditions common to crushed-stone applications, wheel • High bucket-fill factors (90% to 110% in well shot rock)
loaders keep loading floors clean, work between multiple • No cleanup support required
faces, and transport oversize material away from loading area.
Productivity remains high even when the machines encounter FAVORABLE SITE CONDITIONS:
face conditions such as free-flowing material or material with • Good loading materials
low angles of repose.
• Level, stable floor
These reasons, plus lower owning and operating costs compared
to other types of loading tools, have made wheel loaders very • Work multiple benches
popular in mines worldwide. • No bench height restrictions
Although wheel loaders articulate at a full 40 degrees, they still
UNFAVORABLE CONDITIONS:
need ample maneuvering room. Caution should be noted with
wheel loaders in tight box cuts. Due to the lack of room, the • Undulating and poorly drained floors
loader may grind tires and decrease their life. This occurs by • Tight loading quarters
not keeping the loader moving fore and aft while making tight
maneuvers and chewing the rubber from the tread. • Below-grade digging

5
Product Descriptions

HYDRAULIC EXCAVATORS KEY POINTS:

Hydraulic excavators provide high digging forces in a versatile
form with the ability to work in a variety of conditions. With
proper job set-up, a hydraulic excavator can be the centerpiece
of a productive crushed-stone loading system in the form of a
mass excavator.
• Multiple front linkages (Mass ex/general purpose)
• 90% to 110% bucket fill factor in well shot rock
• Fast truck loading/fast truck exchange
• 18- to 28-second cycle time

Mass excavators work best when positioned on an upper • Low mobility

bench with haulers at a lower level. Excavators with a general-
purpose linkage work best when same level loading is required.
The optimal bench height is no greater than the stick length to
provide adequate reach for loading and dumping. This typically
requires material with a high angle of repose.
Excavators require support equipment to minimize truck tire
hazards, prepare the working bench, and clean up and remove
oversize material. But the excavator’s ability to achieve fast cycle
times has made it a popular choice.
• Ability to load multiple truck sizes and types
• High digging forces
FAVORABLE SITE CONDITIONS:
• Bench loading from single loading face
• High production if set up properly
• Works well in tight quarters
• Trucks positioned below excavator
• Level floor to support track frame

UNFAVORABLE CONDITIONS:
• Requires cleanup and bench preparation support
equipment
• Working multiple benches
• High and extremely low benches
• Frequent traveling
• Digging and removing oversize material

6
 Quarry and Aggregates Primary Loading Tool Selection Guide

FRONT SHOVELS KEY POINTS:

• Fast cycles (26 to 28 seconds)
Front shovels combine the benefits of high digging forces
with large capacity buckets. They can selectively dig deposits • 90% to 100% bucket fill factor in well shot rock
anywhere in the face, giving operators added flexibility. Shovels • Low mobility
are usually used at highly consolidated working faces (12 m/
40 ft plus) to penetrate tough material. • Same-level truck loading

Front shovels work well in extreme underfoot conditions (soft • High digging force
or jagged floors) and in tight quarters, where benches may be
FAVORABLE SITE CONDITIONS:
narrow. Truck positioning and proper truck match are critical to
maximum productivity. • Single loading face
A full range of hydraulic excavators and front shovel products • High production if set up properly
are available from Caterpillar, including models up to 1000 ton • Works well in tight quarters
operating weight and more than 90 ton payload.
• Level floor to support track frame
• Rock piles with steep angles of repose

UNFAVORABLE CONDITIONS:
• May require cleanup support to prevent truck tire cuts
• Working multiple benches
• Low benches
• Versatility required
• Excessive traveling
• Removing oversize material

7
Site Conditions
DIGGING RANGES

Wheel Loader

Hydraulic Excavator

Front Shovel

Similar to wheel loaders, front shovels are positioned in front of the working face. They can penetrate the face at any height and work
up through the face. Hydraulic excavators are positioned at the top of the face with a digging motion toward the machine.

8
 Quarry and Aggregates Primary Loading Tool Selection Guide

FLOOR CONDITIONS
Solid, flat floors are ideal for all loading systems, but changing floor conditions require careful choice of tires for wheel loaders, and
track shoes for hydraulic shovels and excavators, that are the best fit for the operation.

Tires
BIAS PLY TIRES
Best used in shot-rock, underground mining, and extremely soft sand applications
Advantages Disadvantages
• High sidewall durability • Rough ride
• Generally retreadable • Lower service life/durability – multiple carcass layers cause
• Lower initial cost heat buildup

• Good self-cleaning • Higher maintenance cost

• Side-to-side stability approximately 15% over radial

RADIAL TIRES
Typically used in load and carry applications
Advantages Disadvantages
• Long service life • Higher initial cost
• Good durability • Marginal self-cleaning
• Good traction in a variety of applications • More side-to-side movement
• Faster top speeds due to less heat buildup
• Long tread wear life
• Heat dissipation
• Smooth ride
• Low profile option for better side-to-side
stability/better rimpull

Tracks
In crushed stone applications, the narrowest single grouser All loading systems can work on pitched slopes, or pitched
shoes are generally the most durable choice. In soft, spongy seams, but wheel loaders typically are less effective than
conditions, a wider shoe provides better flotation. On jagged or shovels/excavators when grades are over 15 to 25 percent. If
rolling ground, hydraulic excavators and front shovels often will floor conditions are severe (wet) or change cannot be controlled,
“pad” a floor by adding fines to form a stable loading platform. wheel loader production may decrease, so track machines are
This can prevent the shovel or excavator from rocking on the better suited.
undercarriage during the loading cycle, as rocking significantly
reduces undercarriage life. Wheel loaders, which don’t suffer
from these undercarriage constraints, also do an excellent job
of adding fines and filling in low areas to construct a better
working surface.

Soft/Spongy Jagged/Rolling Pitched Wet

9
Site Conditions

GROUND PRESSURE
Nominal ground pressure and gross machine weight are In general, ground pressures increase as machine size
indicators of machine flotation in poor underfoot conditions. increases. Very large machines must have a solid sub-base
Hydraulic excavators and hydraulic shovels exert approximately to operate effectively. Also, wider tracks or tires will reduce
one-third of the ground pressure compared to similar-sized ground pressure.
wheel loaders. Changing floor conditions such as rainwater or the freeze/
thaw cycle must also be taken into account. Good mobility,
GROUND PRESSURES TIRE OR TRACK traction, and flotation must be considered during the entire
range of conditions. The operator has the ability to adapt the
Wheel Loaders
face and floor conditions for the loading tool to ensure
988-993 345-551 kPa (50-80 psi) continued productivity:
Front Shovels • Face height
• Muckpile conditions (fragmentation and looseness)
6030 FS 184-272 kPa (27-39 psi)
• Floor padding (adding rock fines to the floor)
Hydraulic Excavators • Additional support units
336 ME-6030 65-274 kPa (9.5-40 psi)

THE LOADING PROCESS

BLASTING MUCKPILE LOADING

$ COST
Rock strength Fragmentation Crowd/rimpull Repairs
Laminations Voids/swell (looseness) Breakout Tires and U/C
Drill pattern and angle Rock angularity Bucket shape Bucket/G.E.T.
Hole size Pile shape Penetration Labor
Explosives Fill factor
Powder factor Productivity

In many ways, loading is the central part of any earthmoving process. The entire system’s productivity is governed by the loader’s
productivity. There are strong links to the muckpile condition upstream and the truck fleet downstream of the loading tool. If the
loading process is productive and cost-effective, the entire rock moving process will be also.

10
 Quarry and Aggregates Primary Loading Tool Selection Guide

BLASTING AND FRAGMENTATION

It is generally acknowledged that explosives are the lowest-cost Improved fragmentation through blasting can have downsides
way to break rock. The benefits of breaking rock with explosive as well:
flow through the processing cost chain. These include: • Higher cost of drilling
• Improved bucket fill and reduced bucket load time result in • Increased cost of explosives
better loader productivity, longer loader life, and reduced cost
per ton of rock loaded. • More fines produced
• Improved primary loader productivity, as less time is spent Typically, the improvements in loader productivity more than
digging out and placing oversize rocks for secondary breakage offset the higher costs associated with drilling and blasting.
• Reduction of oversize rocks and associated secondary
breakage costs
• Reduced congestion in the load area, caused by storage of
oversize rocks, leading to improved truck exchange time.
• More stable truckloads
• Less tipping impact at hoppers and crushers
• Reduced crushing costs and improved crusher throughput,
lowering crushing cost per ton

SEGMENTS OF THE MUCKPILE

The overriding objective is to provide an earthmoving system
that moves material for the lowest cost per unit ($/bcm [bcy]
or $/tonnes [ton]). The degree of material fragmentation and
looseness has a direct influence on loading and hauling
productivity and cost. Poorly shot material can reduce
productivity significantly and increase wear and tear on the
loading tool.
Muckpiles are not uniform throughout. In fact, even well-shot
muckpiles have zones of oversize and toe rock that will slow
production and raise average cost per unit. These different
zones, or segments, have different load times and costs
associated with them. Each loading tool will see the same pile
somewhat differently. A balance is needed between loading tools
and costs.
Rock
Top

Optimum
Loading Oversize
up
rt-
Sta

Start-up
Well-shot
Poorly Shot
Cleanup
11
Site Conditions

COSTS
Drilling and blasting costs vary over the range of pile conditions.
Moving from poorly shot to well-shot may only take a few more
cents per bcm (bcy). Moving from well-shot to pulverized may
double or triple the drill and blast cost with little influence on
loader production cost.
Loading and hauling costs are fairly linear versus pile condition
for material that is pulverized to material considered to be
well-shot. However, as the average pile condition moves into
the poorly shot range with more and more oversize rock, costs
increase rapidly as productivity drops and wear-and-tear
increases. The drill-and-blast and load-and-haul curves oppose
each other. Drill-and-blast costs are high for a pulverized
muckpile. Conversely, load-and-haul costs are high for poorly
shot muckpiles. Therefore, the total cost curve (sum of drill-and-
blast and load-and-haul) is U-shaped.
Finding the minimum, or optimum cost, requires finding the right
combination of drill-and-blasting and loading-and-hauling for a
particular site. The key to providing cost-effective loading is to
shoot the rock just enough, but not too much.

PASS MATCH
Caterpillar offers a world-class range of wheel loaders, hydraulic
excavators, front shovels, and quarry trucks designed to work
productively together. The loader must be matched to the truck,
with the right bucket size to optimize loading cycles.

TRUCK-LOADER PASS MATCH

725 730 735 740 770 772 773 775 777 785
986 – – – 4 4 5 6 – – –
988 – – – 3 3 4 5 6 – –
Wheel
990 – – – – – – 3 4 6 –
Loaders
992 – – – – – – – – 4 6-7
993 – – – – – – – – 3-4 5
Front
6030 FS – – – – – – – – 3-4 5
Shovels
336 ME 5 6 7 8 – – – – – –
349 4 5 6 7-8 – – – – – –
374 – – 4 4-5 4-5 – – – – –
Hydraulic
390 – – – 2-3 3-4 4-5 5-6 6 – –
Excavators
6015 – – – – – 3 4 5 6-7 –
6020 – – – – – – – 3 4-5 6-7
6030 – – – – – – – – 3-4 5

12
 Quarry and Aggregates Primary Loading Tool Selection Guide

PRODUCTIVITY TYPICAL CYCLE TIMES (IN SECONDS):

A good indicator of material loadability is the average time it Wheel Loaders 35

takes to load the bucket. Front Shovels 28
A proper loading tool productivity study measures the four-part Mass Excavators 22
loader cycle:
1. Dump • Loading time should take less than 15 seconds, regardless of
2. Travel empty or swing empty the loading tool.
3. Dig • Loading times longer than 10-15 seconds may be an indication
that the muckpile is not properly conditioned for the loading
4. Travel loaded or swing loaded tool. It could also be an indication of the operator’s skill level.
The total cycle time is the sum of segments 1 through 4. Note: Load times are averaged and will vary cycle to cycle as the
loading face changes. Handling oversize rocks or digging the toe
of a highwall will increase individual dig times.

PIT LOADING BENCH LOADING – END LOADING

• Truck transfer time is measured from the time that the truck • Dig over idlers
enters the load area and is in position to load, and should not • Spot with loaded bucket
exceed 42 seconds. • Minimize swing angle
• Wheel loader operator spots truck at 45° angle
• Position for fastest cycle times
• Wheel loader penetrates face at 90° angle BENCH LOADING – DRIVE-BY
• Keep rear tires off pile
• Minimize wait time • Truck spotted with rear wheel tucked into the side
of the bench
• Excavator loads through the rear of the machine and spreads
material using swing function
• Fast excavator cycles, quick truck exchange

Wheel Loader Operation Excavator Operation

13
Site Conditions

LOADING CONDITIONS
There is no one loader that will do all things on all jobs; each loading tool has a definite application range in which it is regularly used
and is suitable economically. This chart shows generally accepted guidelines for matching equipment to loading conditions.

Factor Condition Wheel Loader Front Shovel Excavator

Load area Single Open Bench
Multiple Benches
Confined area
Distant truck position
Rock Condition Good fragmentation
Blocky
Highly interlocked
Oversize rock common
Bank state earth and clay
Selective Digging
Bench Height High *
Low *
Angle of Repose Steep
Shallow
Floor - Shape Level and firm
Uneven or undulating
Floor - Surface Wet, Good traction
Wet, Low traction
Dry, Good traction
Bucket Performance Achieve rated capacity
Match multiple targets
Dig above grade
Dig below grade
Clean Up Blast clean up
Scaling face
Load area clean up
Levelling floor
Digging out toe
Travel Multiple loading sites
Sorting oversize
Evacuate for blasting
Load and carry
Secondary Tasks Blending
Ripping
Fit Quick Coupler

Yellow – Highly Recommended

Light Yellow – Recommended
Grey – Not Recommended
*Bench height needs to be sized for Excavator stick length.

14
 Quarry and Aggregates Primary Loading Tool Selection Guide
Applications
WORKING THE FACE
Excavating and loading operations account for a significant
portion of total material movement costs, so it is prudent to
search for the most cost-effective approach.
There are several types of excavating faces:
• Free Flowing – favors the wheel loader, but an excavator
could be placed on top of the pile for high production
applications with proper support equipment. This type of
material produces high fill factors and fast cycle times,
resulting in high productivity.
• Selective Digging – shovel domain. The narrow bucket and
ability to load anywhere in the face makes it a good selective
loader for extracting specific material without disturbing
or handling unwanted material. Hydraulic excavators can
also be used successfully in selectively digging some
consolidated material.
• Consolidated/Poorly shot – An excavator or shovel may
work in this situation. Other site needs may drive the
selection process.
Free Flowing
Selective Digging
Tight Shot Face
All the loading tools can work these types of faces, but each
one has its best fit. For instance, a loading tool with high digging
forces applied at an easy loading face would be a waste of
capability, raising the cost per unit. Or a wheel loader digging in
consolidated excavation might result in low productivity and high
component wear (G.E.T.), driving up unit cost.
Breakout forces and digging range play a part in each machine’s
digging ability.
• Front shovels/excavators have the ability to dig tougher
materials, partly due to the higher breakout force per length
of cutting edge. These higher cutting forces provide better
loading, particularly for material that is fragmented and keyed
together, or material that does not flow well into a bucket.
• Wheel loaders have adequate breakout force for all but the
toughest materials.
Consolidated
Well Fragmented
15
Applications

RIP AND LOAD

Generally speaking, the lowest cost per ton is achieved by
RIP AND LOAD OPERATION PRODUCTION BEST PRACTICE
reducing rock size at the face with blasting. In mines with
blasting restrictions, rip and load techniques can be an effective Ripping 30%
alternative if the material is conducive:
Tool Change 3%
Rippable Rock Characteristics
Loading 35%
• High degree of stratification
• Absence of massive formations Preparing 25%
• Frequent planes of weaknesses – fractures, faults, laminations Waiting 7%
• Weathering
– Damaged strata from weathering When compared to more traditional blasting and loading, a rip
– Moisture permeated formations and load operation generates lower production levels, but cost
• Low compressive and tensile strength rocks per ton can be managed effectively:
• Low field seismic velocity • Drilling and blasting costs are eliminated
A hydraulic excavator equipped with the appropriate quick • Same machine rips and loads so less equipment may
coupler, ripper, and rock bucket may be the right system to meet be needed
specific requirements.

16
 Quarry and Aggregates Primary Loading Tool Selection Guide

MOBILITY AND MULTIPLE USES

Wheel Loader
MAXIMUM TRAVEL SPEEDS (FORWARD)
Wheel loaders have a tremendous advantage over shovels and
excavators due to their ability to quickly move from face-to- Large Wheel Loader
face. This provides a degree of flexibility not available with track 21.7-38.6 km/hr (13.5-24 mph)
machines. Tires provide wheel loaders the flexibility to save time: Hydraulic Excavator/Front Shovel
• Moving out for a blast 2.0-4.8 km/hr (2.5-3 mph)
• Moving to a new face
• Moving to a stockpile for a blending operation
• Hopper and crusher loading
• Moving back to the service shop for maintenance
Mobility is a key attribute that allows the
wheel loader to do multiple tasks at the site.

Hydraulic Excavators Front Shovels

Due to slower travel speed and resulting costs from excessive The mobility of shovels is similar to excavators. The main
tramming, the excavator’s mobility is more limited. However, with difference is the design of the front linkage. As a result, shovels
the ability to work in various materials and faces, the excavator have less ability to be used in other applications.
is able to perform several secondary functions on the site
including stripping and secondary breakage. Due to the ability to
sit and swing, the excavator is also able to work in tighter areas.

SUPPORT EQUIPMENT AND BENCH PREPARATION

Both the front shovel and hydraulic excavator are limited in
cleanup ability, as they can sweep only what they can reach.
Type of face material and operator skill level regulates the
cleanup need, and more frequent cleanup is needed in a stone
application than a sand and gravel operation.
A wheel dozer or wheel loader is usually used as cleanup
support by pushing loose rocks back into the face, most often in
the loading area where the trucks are staging, but in some cases
for the shovel and excavator working area. The wheel loader is
very mobile and has a wide sweeping bucket. It is therefore well
suited to handle its own cleanup chores. With a wheel loader, or
any loading system, “good housekeeping” habits are necessary
in the load area to avoid tire failures due to running over loose
rocks on the floor.
In shot rock (crushed stone) applications, the excavator is
normally supported by a dozer to prepare the loading bench. In
some cases the excavator will prepare its own bench, but is not
available to load trucks while preparing the bench. The cost for
this support equipment or bench prep time should be considered
when comparing an excavator with a wheel loader.

17
Buckets
BUCKET OPTIONS
Caterpillar offers a wide range of purpose-built, high Choosing the correct bucket can:
performance buckets, each designed to function as an integral • reduce cycle and loading times
part of the wheel loader, hydraulic excavator, or hydraulic shovel.
• lower operating costs by 10 to 20 percent or more
The combination of the right bucket with the right machine will
provide the best possible performance in a particular application. • eliminate unnecessary stress and fatigue for the machine,
bucket, and operator
All Cat® buckets are designed and built to meet the
specifications of various applications. High-strength, tempered
steel provides additional durability without requiring thicker,
heavier plates, resulting in longer life and larger payloads.

Extended center section to stop

spillage for linkage protection
Double sidebar
Slots in top guard for protectors
visibility to material available for
sidebar protection
Box section with
internal gussets for Wear plate
structural life and options on HD Rock,
stress distribution High Abrasion and
Heavy Duty Granite
Buckets
Wings/rock deflectors
Cat Advansys Tips and Adapters
• Improved productivity and
performance
• Enhanced reliability
Segments available • Simple, hammerless installation
for edge protection

Cat® ID plate

Bottom plate
extends across
entire bottom for
Raised heel plate for added structural
reduced wear and drag support

Shell and Tine Bottom wear

Construction plate protection
(Box Sections) to
strengthen floor

18
 Quarry and Aggregates Primary Loading Tool Selection Guide

CAT GROUND ENGAGING TOOLS (G.E.T.)

Engineered especially for Cat machines, G.E.T. can increase machine productivity
and protect expensive structural components of buckets.
• Reliable tip retention from better retainer locks
• Faster tip change-out due to a convenient twist-on design
• Increased tip life of 10 to 15 percent with sharper, better penetrating tips

Hinge

Hinge plates pass

through torque tube for Identification plate provides
better load distribution bucket information
and durability
Sidebar
Gussets for
maximum rigidity Sideplate

Angled sidebars
facilitate material
handling when Side wear plate
working with a
bucket thumb High-strength wear plates
for extra protection

Adjusted group
to easily correct
Cat K Series™ for slack without
Base edge removing the bucket

Sidebar Sideplate

Sidebars pre-drilled for

optional sidecutters and/or
sidebar protectors
Wrapper
Cat K Series adapters
are cast from DH-3™
material that maintains
hardness for longer wear
life in tough digging
applications when higher
temperatures
are generated
2-strap
adapters
Horizontal bottom wear plates Dual radius wrapper
Note: 6015B, 6020B, and 6030/6030FS use larger Cat G.E.T.
reinforce bucket for greater for increased heel
systems and different wear material. The specifications can be strength and rigidity as well clearance and improved
found in the Mining Bucket Reference Guide (GEJQ92328-02) as ease of replacement wear characteristics 19
CATERPILLAR LOADING SOLUTIONS
The success or failure of your operation has a lot to do with
selecting the proper loading machine. The goal is to achieve
the best results at the lowest cost. First-hand knowledge and
experience in analyzing field data and site conditions can greatly
increase efficiency and improve production.
Deciding on one machine over another is a complicated process.
Cat wheel loaders, hydraulic excavators, and front shovels offer
an established reputation for quality with the exceptionally low
owning and operating costs in the industry.

For more information, visit cat.com.

CAT, CATERPILLAR, their respective logos, “Caterpillar AEXC0631-03

Yellow” and the “Power Edge” trade dress, as well as
©2017 Caterpillar
corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission. All rights reserved.