Mining and Estimating Production Off-the-Job

Earthmoving ● Example Problem (English)

● Example Problem (Metric)

8. Check pusher-scraper combinations: 10. Estimate Compaction:

Pusher cycle time consists of load, boost, return and Compaction = S.F. × hourly fleet production
maneuver time. Where actual job data is not available, requirement = 0.85 × 1947 BCY/hr
the following may be used. = 1655 CCY/hr
Boost time = 0.10 minute Compaction capability (given the following):
Return time = 40% of load time Compacting width, 7.4 ft (W)
Maneuver time = 0.15 minute Average compacting speed, 6 mph (S)
Pusher cycle time = 140% of load time + 0.25 minute Compacted lift thickness, 7 in (L)
Pusher cycle time = 140% of 0.7 min + 0.25 minute No. of passes required, 3 (P)
= 0.98 + 0.25 = 1.23 minute 825G production =
Scraper cycle time divided by pusher cycle time indi- W × S × L × 16.3
cates the number of scrapers which can be handled by CCY/hr = (conversion constant)
each pusher. P
6.95 min 7.4 × 6 × 7 × 16.3
= 5.65 CCY/hr =
1.23 min 3
Each push tractor is capable of handling five plus CCY/hr = 1688 CCY/hr
scrapers. Therefore the two pushers can adequately Given the compaction requirement of 1655 CCY/hr,
serve the eleven scrapers. the 825G is an adequate compactor match-up for the
9. Estimate Production: rest of the fleet. However, any change to job layout
Cycles/hour = 60 min ÷ Total cycle time that would increase fleet production would upset this
= 60 min/hr ÷ 6.95 min/cycle balance.
= 8.6 cycles/hr
● ● ●
Estimated load = Heaped capacity × L.F.
= 31 LCY × 0.80
= 24.8 BCY Example problem (Metric)
Hourly unit = Est. load × cycles/hr
A contractor is planning to put the following spread on
production = 24.8 BCY × 8.6 cycles/hr
a dam job. What is the estimated production?
= 213 BCY/hr
Adjusted = Efficiency factor × hourly Equipment:
production production 11 — 631G Wheel Tractor-Scrapers
= 0.83 (50 min hour) × 213 BCY 2 — D9T Tractors with C-dozers
= 177 BCY/hr 2 — 12H Motor Graders
Hourly fleet = Unit production × No. of units 1 — 825G Tamping Foot Compactor
production = 177 BCY/hr × 11 Material:
= 1947 BCY/hr Description — Sandy clay; damp, natural bed
Bank Density — 1770 kg/BCM
Load Factor — 0.80
Shrinkage Factor — 0.85
Traction Factor — 0.50
Altitude — 2300 meters

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 Estimating Production Off-the-Job Mining and
● Example Problem (Metric) Earthmoving

Job Layout — Haul and Return: 0% Grade

rade
4% G
0% Grade 0% Grade Sec. D — Fill 150 m
30 0 m
— Haul RR = 100 kg/t
. C
Sec /t Eff. Grade = 10%
Sec. A — Cut 150 m Sec. B — Haul 450 m 40 kg
RR = 100 kg/t RR = 40 kg/t RR = rade = 8%
Eff. G
Eff. Grade = 10% Eff. Grade = 4%

Total Effective Grade = RR (%) ± GR (%) Rolling Resistance —

Sec. A: Total Effective Grade = 10% + 0% = 10% RR = RR Factor (kg/mton) × GMW (metric tons)
Sec. B: Total Effective Grade = 4% + 0% = 4% Sec. A: = 100 kg/metric ton × 80.48 metric tons
Sec. C: Total Effective Grade = 4% + 4% = 8% = 8048 kg
Sec. D: Total Effective Grade = 10% + 0% = 10% Sec. B: = 40 kg/metric ton × 80.48 metric tons
= 3219 kg
1. Estimate Payload: Sec. C: = 40 kg/metric ton × 80.48 metric tons
Est. load (LCM) × L.F. × Bank Density = payload = 3219 kg
24 LCM × 0.80 × 1770 kg/BCM = 34 000 kg payload Sec. D: = 100 kg/metric ton × 80.48 metric tons
2. Machine Weight: = 8048 kg
Empty Wt. — 46 475 kg or 46.48 metric tons Total Resistance —
Wt. of Load — 34 000 kg or 34 metric tons TR = RR + GR
Total (GMW) — 80 475 kg or 80.48 metric tons Sec. A: = 8048 kg + 0 = 8048 kg
3. Calculate Usable Pull (traction limitation): Sec. B: = 3219 kg + 0 = 3219 kg
Loaded: (weight on driving wheels = 54%) (GMW) Sec. C: = 3219 kg + 3219 kg = 6438 kg
Traction Factor × Wt. on driving wheels = Sec. D: = 8048 kg + 0 = 8048 kg
28
0.50 × 80 475 kg × 54% = 21 728 kg Check usable kilogram force against maximum
Empty: (weight on driving wheels = 69%) (GMW) kilogram force required to move the 631G.
Traction Factor × Wt. on driving wheels = Force usable … 21 728 kg loaded
0.50 × 46 475 kg × 69% = 16 034 kg Force required … 8048 kg maximum total resistance
4. Derate for Altitude: Estimate travel time for haul from 631G (loaded)
Check power available at 2300 m from altitude dera- travel time curve; read travel time from distance and
tion table in the Tables Section. effective grade.
631G — 100% 12H — 83% Travel time (from curves):
D9T — 100% 825G — 100% Sec. A: 0.60 min
Sec. B: 1.00
Then adjust if necessary:
Sec. C: 1.20
Load Time — controlled by D9T, at 100% power, no
Sec. D: 0.60
change.
Travel, Maneuver and Spread time — 631G, no change. 3.40 min
5. Compare Total Resistance to Tractive Effort on haul: NOTE: This is an estimate only; it does not account for all
Grade Resistance — the acceleration and deceleration time, therefore
GR = 10 kg/metric ton × tons × adverse grade it is not as accurate as the information obtained
in percent from a computer program.
Sec. C: = 10 kg/metric ton × 80.48 metric tons × 4% 6. Compare Total Resistance to Tractive Effort on return:
grade = 3219 kg Grade Assistance —
GA = 10 kg/mton × metric tons × negative grade
in percent
Sec. C: = 10 kg/metric ton × 46.48 metric tons
× 4% grade = 1859 kg

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 Mining and Estimating Production Off-the-Job
Earthmoving ● Example Problem (Metric)

Rolling Resistance — Each push tractor is capable of handling five plus

RR = RR Factor × Empty Wt. scrapers. Therefore the two pushers can adequately
Sec. D: = 100 kg/metric ton × 46.48 metric tons serve the eleven scrapers.
= 4648 kg 9. Estimate Production:
Sec. C: = 40 kg/metric ton × 46.48 metric tons Cycles/hour = 60 min ÷ Total cycle time
= 1859 kg = 60 min/hr ÷ 6.95 min/cycle
Sec. B: = 40 kg/metric ton × 46.48 metric tons
= 8.6 cycles/hr
= 1859 kg
Sec. A: = 100 kg/metric ton × 46.48 metric tons Estimated load = Heaped capacity × L.F.
= 4648 kg = 24 LCM × 0.80
= 19.2 BCM
Total Resistance — Hourly unit = Est. load × cycles/hr
TR = RR – GA production = 19.2 BCM × 8.6 cycles/hr
Sec. D: = 4648 kg – 0 = 4648 kg = 165 BCM
Sec. C: = 1859 kg – 1859 kg = 0 Adjusted = Efficiency factor × hourly
Sec. B: = 1859 kg – 0 = 1859 kg production production
Sec. A: = 4648 kg – 0 = 4648 kg = 0.83 (50 min hour) × 165 BCM
Check usable kilogram force against maximum force = 137 BCM/hour
required to move the 631G. Hourly fleet = Unit production × No. of units
Kilogram force usable … 16 034 kg empty production = 137 BCM/hr × 11 units
Kilogram force required … 4645 kg = 1507 BCM/hr
Estimate travel time for return from 631G empty 10. Estimate Compaction:
travel time curve. Compaction = S.F. × hourly fleet production
Travel time (from curves): requirement = 0.85 × 1507 BCM/hr
Sec. A: 0.40 min = 1280 CCM/hr
Sec. B: 0.55 Compaction capability (given the following):
Sec. C: 0.80 Compacting width, 2.26 m (W)
Sec. D: 0.40 Average compacting speed, 9.6 km/h (S)
2.15 min Compacted lift thickness, 18 cm (L)
7. Estimate Cycle Time: No. of passes required, 3 (P)
Total Travel Time (Haul plus Return) = 5.55 min 825G production =
Adjusted for altitude: 100% × 5.55 min = 5.55 min W × S × L × 10
Load Time 0.7 min CCY/hr = (conversion factor)
P
Maneuver and Spread Time 0.7 min
2.26 × 9.6 × 18 × 10
Total Cycle Time 6.95 min CCY/hr =
3
8. Check pusher-scraper combinations:
Pusher cycle time consists of load, boost, return and CCY/hr = 1302
maneuver time. Where actual job data is not available, Given the compaction requirement of 1280 CCM/h,
the following may be used. the 825G is an adequate compactor match-up for the
Boost time = 0.10 minute rest of the fleet. However, any change to job layout
Return time = 40% of load time that would increase fleet production would upset this
Maneuver time = 0.15 minute balance.
Pusher cycle time= 140% of load time + 0.25 minute ● ● ●
Pusher cycle time= 140% of 0.7 min + 0.25 minute
= 0.98 + 0.25 = 1.23 minute
Scraper cycle time divided by pusher cycle time
indicates the number of scrapers which can be handled
by each pusher.
6.95 min
= 5.65
1.23 min

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 Estimating Production Off-the-Job Mining and
Systems Earthmoving
● Economic Haul Distances

SYSTEMS Haul System Selection: In selecting a hauling system

for a project, there may seem to be more than one
Caterpillar offers a variety of machines for different
“right” choice. Many systems may meet the distance,
applications and jobs. Many of these separate machines
ground conditions, grade, material type, and produc-
function together in mining and earthmoving systems.
tion rate requirements. After considering all of the
● Bulldozing with track-type tractors different factors, one hauling system usually provides
● Load-and-Carry with wheel loaders better performance. This makes it critical for the dealer
● Scrapers self-loading, elevator, auger, or push-pull and customer to work together to get accurate infor-
configurations, or push-loaded by track-type tractors mation for their operation or project. Caterpillar is com-
● Articulated trucks loaded by excavators, track load- mitted to providing the correct earthmoving system to
ers or wheel loaders match the customer’s specific needs.
● Off-highway trucks loaded by shovels, excavators or
● ● ●
wheel loaders

GENERAL LOADED HAUL DISTANCES FOR MOBILE SYSTEMS

Track-Type Tractor

Wheel Loader

Wheel Tractor-Scraper
28
Articulated Truck

Rear Dump Truck

10 m 100 m 1000 m 10 000 m
33 ft 328 ft 3280 ft 32,800 ft

LOADED HAUL DISTANCE

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