Load and Haul Fleet Selection

Based on Fixed Plant Production

Load and Haul Fleet Selection

Based on Fixed Plant Production

Ways to Estimate Productivity !!

The typical view is machine centred

What are we going to do ?

Review an approach which uses Crusher Output to
drive fleet selection.
Use a simple spreadsheet to manage this process
e.g. no bunching or cycle mismatch included.
Tie in the relevant concepts of earth and rock
moving into this process.
Seek to reinforces the outlook that
You cant Manage what you dont Measure !

Key Questions Addressed

What are the Production
Targets and Rates for Fixed Plant?
What Primary Load & Haul
Production is required?
What is the Load Area
Production Rate ?
What is the Match of Loading
Tool and Haulers ?
What does our Reality look like?

How much Time is Available?

How much of an Hour does the
Loading Tool spend Loading?
What are the Cycle Times for
Haulers and Loading Tool?
What is the Key Characteristic
of the Material?

Bunching and Cycle Mismatch

Quarry Contacts
Queensland and Northern Territory
Paul Soden

Hastings Deering,

Brisbane

Andrew Black

WesTrac,

Sydney

Ian Collins

William Adams,

Melbourne

Stuart Mc Donald

William Adams,

Launceston

Mark Taylor

Cavpower

Adelaide

Steve Sakich

WesTrac

Perth

New South Wales

Victoria

Tasmania

South Australia

Western Australia

Any Questions ?

The End

Concepts
Time Available

Work Days per year

Work Hours per Day
Job Efficiency Work Minutes per Work Hour
Load Area Activities

Material Density

Load Factor and Fragmentation

Fleet Match

Cycle Times
Bucket to Body Sizing Effective Pass Ratios

Bucket Fill Factor

Concepts
Time Available

Work Days per year

Work Hours per Day
Job Efficiency Work Minutes per Work Hour
Load Area Activities

Material Density

Load Factor and Fragmentation

Fleet Match

Cycle Times
Bucket to Body Sizing Effective Pass Ratios

Bucket Fill Factor

Work Hours Available per Year

Availability & Utilization
An Example
Job Efficiency Factors Machine Availability Loss
Off Time Loss
Utilization Loss
Mismatch
Unscheduled Downtime
Holidays
Ready, but unmanned
(90% On-Shift Availability)
Bunching
Weather
Shift Change
Operator Efficiency
(4.1% Off Time)
Lunch & Meetings
(85% Job Efficiency)
Scheduled Downtime &PM's
(87.5% Utilization)

PRODUCTIVE TIME
6615 HRS

Machine Operating Hours

(6615 HRS)
Machine Scheduled Hours
(7350 HRS)
Mine Scheduled Hours
(8400 HRS)
Total Annual Hours
(8760 HRS)

735
HRS

10 %

of

7350

1050
HRS

12.5%
of
8400

360
HRS

4.1 %
of
8760

Work Days per Year

Full Days
Partial Days
Partial Day Factor

220 days
48 days
0.50

Load & Haul Work Hours per Day

Load and Haul Scheduled Hours / Day 10 hours
less Non Operational Time
Mobilisation
Toolbox Talk - Inspect - Transit
Transit - Refuel - Shut Down
Breaks including Transit time
AM / PM Breaks
Lunch
Subtotal of Non Operational Time

20 minutes
20 minutes
20 minutes
45 minutes
1.75 hours

less Non Primary Load and Haul

Stock movement
Overburden
Subtotal Non-Primary Load and Haul

Work Hours per Day

0.75 hours
0 hours
0.75 hours

7.5 hours

Job Efficiency /
Work Minutes per Work Hour
Job Efficiency is one of the most complex elements of estimating
production since it is influenced by factors such as operator skill,
minor repairs and adjustments, personal delays and delays
caused by job layout. An approximation of efficiency, if no job
data is available, is given below.
Operation
Day
Night

Working Hour
50 minute hour
45 minute hour

Efficiency
Factor
0.83
0.75

These factors do not account for delays due to weather or machine

downtime for maintenance and repairs.You must account for such
factors based on experience and local conditions.

What about time lost for watering the load area ?

Analysis of Face Loader Activity

Load Area Activity of Wheel Loader
Preparing to Load
17 %

Non-Loading
Activities
30 %

Predig Pile
8%
Loading Truck
54 %

Remove Oversize
17 %

Maintain Floor
2%
Clean Floor
3%

Concepts
Time Available

Work Days per year

Work Hours per Day
Job Efficiency Work Minutes per Work Hour
Load Area Activities

Material Density

Load Factor and Fragmentation

Fleet Match

Cycle Times
Bucket to Body Sizing Effective Pass Ratios

Bucket Fill Factor

Density of Materials
Material
Gravel - pit run
Earth-dry
Earth- wet
Clay natural bed
Topsoil
Shale
Granite -broken
Limestone
Full Table in
PHB 42 P27-4

Bank
kg/m 3
2179
1900
2020
2020
1370
1660
2730
2610

Loose
kg/m 3
1930
1510
1600
1660
950
1250
1660
1540

Load
Factor
.89
.80
.79
.82
.70
.75
.61
.59

Concepts
Time Available

Work Days per year

Work Hours per Day
Job Efficiency Work Minutes per Work Hour
Load Area Activities

Material Density

Load Factor and Fragmentation

Fleet Match

Cycle Times
Bucket to Body Sizing Effective Pass Ratios

Bucket Fill Factor

Machine Production
CYCLE TIME

Operator Skill
LOAD
Fixed Time

RETURN
Variable Time

Delays
HAUL

DUMP

Variable Time

Fixed Time

Loading Tool / Hauler Pass Match

Target Truck Load Time
2 minutes
Target Exchange Time
0.7 minutes
Target Pass Match
Loader / Hauler = 3-5
Excavator / Hauler = 4-6

Concepts
Time Available

Work Days per year

Work Hours per Day
Job Efficiency Work Minutes per Work Hour
Load Area Activities

Material Density

Load Factor and Fragmentation

Fleet Match

Cycle Times
Bucket to Body Sizing Effective Pass Ratios

Bucket Fill Factor

Bucket Fill Factor (BFF)

Material

BFF as % of
Heaped Capacity

Moist Loam
Sand and Gravel Mix
Rock - Well Blasted
Rock - Poorly Blasted
12 20mm Aggregate

ABC-

100-120 %
95-110 %
80 - 95 %
50 - 75 %
85 - 90

A
C

BFF for Wheel Loader buckets tend to be

5 10 % higher than Excavator buckets due
to different angles of repose for SAE rating.
PHB 42
Pages 4-156, 9-161

Quarry Contacts
Queensland and Northern Territory
Paul Soden

Hastings Deering,

Brisbane

Andrew Black

WesTrac,

Sydney

Ian Collins

William Adams,

Melbourne

Stuart Mc Donald

William Adams,

Launceston

Mark Taylor

Cavpower

Adelaide

Steve Sakich

WesTrac

Perth

New South Wales

Victoria

Tasmania

South Australia

Western Australia

Any Questions ?

The End