Professional Documents
Culture Documents
Co cepts
Concepts
Basic Load & Haul Equipment
9Earthmoving
g Cycle
y components
p
9Job Efficiency Factors
9M t i l Weights
9Material W i ht & Swell
S ll Factor
F t
9Vehicle Payloads
9Selection of Equipment
Factor 1
Earthmoving
g Cycle
y Components
p
z The productivity cycle may be separated into six (6) Components:
1. Haul or Push
2. Dump
3. Return
4. Spot
5. Delay
Delay Factors
Dump Factors Time spent waiting on loading unit or pusher
z Destination of material: Hopper, Over Bank, Stockpile, etc. Time spent waiting to dump at crusher
z Condition of dump area
z Type &maneuverability of hauling unit
z Type & condition of material
Factor 2
Job Efficiency
y Factors ((cont.))
An estimate must indicate sustained or average earthmoving
production over a long period of time.
z Night
Ni ht operating
ti
z Shovel moving
z Blasting
g
z Weather
z Traffic
z Shutdowns, or for factors such as management and supervision
efficiency, operator experience, proper balance of auxiliary
equipment such as pusher or spreader bulldozers
Maximum productivity of earthmovers:
Job Efficiency Favorable Average Unfavorable
Working Min.Per Hour 55 50 40
Per Cent 92 83 67
Factor 2
Job Efficiency
y Factors ((cont.))
z Favorable Job Conditions
1. Material being excavated & Hauled: Topsoil, Clay (low moister content), Tight earth (no rock)
2. Loading Area : Unrestricted in length or width, Dry & smooth (maintained by dozer or grader),
U it lload
Unit dddownhill
hill (f
(for scrapers))
3. Total Rolling Resistance is under 4%
4. Constant supervision at both loading & dumping areas
z Example :
1 cubic yard of 33% swell of shale is 1.33 cubic yards in the loose state
Shale weight 2800 lb per bank of cubic yard at the swell factor of 0.75(inverse of 1.33) the
weight of one loose cubic yard of shale is 2100 lb (2800 lb x 0.75=2100lb)
Factor 4
Vehicle Payloads
y
1. Payload capacity of the hauling unit in pounds & loose cubic yards
2 Rate
2. R t off production
d ti off the
th loading
l di unit
it
z Example: Find the load time of 55-ton hauler under an 8-yard shovel in
blasted rock which weighs 2800 pounds/LCY. Dipper factor is 0.65.
z Payload
P l d off Dipper
Di
lbs
Is result of multiplying the yardage Payload of Dipper = Yardage of Dipper x Dipper Factor x
capacity of the bucket by a dipper LCY
factor and multiplying by the Example : Assume : 4yd. shovel, 0.9 dipper factor, 3000 lbs/LCY
material weight per loose cubic yard 4 ydd 3000lbs
lb
Weight of material per Pass = 0.90 = 10,800lbs / pass
of material pass yd
HAULER PRODUCTION
Belt Loader and Hoppers
pp (cont.)
( )
Example:
p loading g rate of a loader with 60
Belt employing two 82-50 tractors is one
ton per second in average conditions.
Load time into a 55 ton hauler would be 55 seconds
Balance Between Size of Hauling and
Loading
g Equipment
q p
z To lower the cost per unit of earth moved, high production must
be obtained from the hauling fleet.
z Wh
When possible,
ibl lloading
di from
f overhead
h d hopper
h should
h ld be
b
considered because of the faster loading time obtained when this
arrangement is practical
z Generally, 3 to 6 passes of a shovel to fill a hauling unit represent
a good balance.
The size of the body is not too small in comparison to the shovel bucket,
resulting in excessive spillage and shock to the unit
Loading time is not so short that another hauler would not be available without
causing excessive shovel idle time
Turning, Dumping and Spotting Times
z Are dependent upon the unit being considered under the existing
operating conditions.
z Operation Conditions = accounts for all factors which can effect the
time for cycle component being estimated.
z The Favorable is a judgment made on base of personal experience and
familiarizing with the job
Turning &Dumping Times Spotting Time at Loading Machine
z The number of units required for given job depends on the production
requirements. The Number of required units can be found:
Job Efficiency
Application
pp cat o
Load and Haul Management
Terminology for earth moving operations
solid rock 1.3 cu-yds = 1.0 bank m3
shotrock in muckpile 1.25 - 1.35 (% swell )
shotrock on truck 2.1 cy-yds = 1.6 loose m3
compacted rockfill day 1.76 cu-yds = 1.35 dam m3
Loading front
New floor
Load and Haul Management
Optimum shotrock profiles for bulk loading operations
100 ft
200 ft
2
12
50 ft
8
150 ft
SB = 7.4 X 6.5 = 2.25 x 2 m
Rows = 3
4
0 ft
200
0 ft
100 ft 16
0
0 10 20 30 40 50 60 m
12 50 ft 150 ft 200 ft
0 ft 100 ft
150 ft
50 ft
0 ft
12 0
0 10 20 30 40 50 60 m
8
50
Surveyed 3- ANFO
0 ft
0
0 10 20 30 40 50 m
shotrock profiles
0 ft 50 ft 100 ft 150 ft 200 ft
Load and Haul Management
Loading capacities
Good
ding capacitty (bm3/h)
loading
conditions
1000 Hydraulic
Excavators
800 Difficult
loading
conditions
600
Gross load
400
1000
Good loading
800 Wheel conditions
Gross loading cap
loaders 20
Difficult loading
600 conditions Wheel
16 loaders
400
Buck
Hydraulic
Loader weight (tonnes) excavators
Con:
z Slow tramming speed between
active faces with the pit.
z Poor flexibility, requires cleanup
support.
Excavators:
Pro:
z Less sensitive to poor fragmentation
in the muck pile.
z Good kinematics for muck pile
penetration
t ti and d breakout
b k t force.
f
z Can serve a wider range of truck sizes
for a given class size.
z Impervious to floor conditions for
mucking.
ki
z Best stand-off from the working face.
z Can reach out to clean up the crest of
a bench with greater safety.
Con:
z Slow tramming speed between active
faces with the pit.
z Poor flexibility, requires cleanup
support.
z Must reach further when working off
the muck pile to load out.
Wheel Loaders:
Pro:
z Great speed and flexibility
z Can clean up and prform
primary loading functions.
Con:
z Unit size/bucket size to truck
size matching is very
important.
z Energy consumption per ton
of loaded rock is lower than
with excavators and shovels.
z Tires are susceptable to wear
and abrasion with poor floor
conditions and inexperienced
operators.
t
L/H Unit Operations
Fleet Sizing:
z Annual tonnage required?
900
Approach
Load/Haul
Load/Haul
Load/Haul
Load/Haul
Load/Haul
Load/Haul
Load/Haul
Load/Haul
Load/Haul
Load/Haul
Load/Haul
No Wasted Moves
1.5 Tire Revolutions
Minimum Travel Distance
High Idle
1st Gear
Boom Kick-Outs Set
Load/Haul
Ideal loadout
geometry.
900
Approach
300 to 450
Load/Haul
Ideal loadout
geometry.
3 to 4 pases
per truck to
obtain full
load is ideal.
Load/Haul
Bucket Flat,
Flat
1st gear
high engine RPM
Load/Haul
Bucket Flat,
Flat Hoist forks just
1st gear before wheels slip,
high engine RPM pushing hard into
the muck pile.
Do not curl
the bucket at
this point!
Load/Haul Full loads in the power band zone
Power
Band
Bucket Flat,
Flat Hoist forks just Apply the neutralizer
1st gear before wheels slip, pedal, tilt the bucket
high engine RPM pushing hard into full up while
the muck pile. advancing into the
muck pile.
pile
Load/Haul
Load and Haul Management
Load & Carry case study Loader
Bucket volume
CAT 988
8 lm3
Bucket filling ~ 85%
( buck et fill % versus roadway cleanu
Performance Degradation
And
Cost Escallation:
z 3 to 4 passes per load move out to 5 to 7
7.
z Truck spotting takes 2 to 3 times as long as it should.
z Sub-par
p technique
q increases stress on the loader frame and engine.
g
z Tires get chewed up faster.
z Overloaded loaders and trucks cost money and shorten service life.
z Non-standard cycle times compound loss of production.
z Discontunious feed to the plant can create sub-par crusher performance.
Load/Haul
Correction and
p
improvement:
z Improve muck fragmentation control, muckpile shape, and
consistent floor elevation with better blasting controls.
z Keep the road system level, clean, and dry where possible.
Loading
g and Hauling
g
Alternatives
te at es
Variations On Tradition:
In-Pit Crushing:
Truck out
Variations On Tradition:
In-Pit Crushing:
Conveyor out
Track Mounted
C h
Crusher
In-Pit
Conveyor Link
Co c us o
Conclusion
Load/Haul