Model a basic route or build detailed haul segments. The calculator estimates cycle time, output, fleet size, matching, and costs. Results remain planning estimates, so verify field conditions before final decisions.
Formula used
Detailed mode adjusts speed for grade, surface, rolling resistance, restrictions, performance, and congestion. Delay allowances then increase the expected cycle. Availability and efficiency reduce theoretical production.
How to use this calculator
- Select a basic route or detailed segments.
- Enter truck, material, loader, and payload data.
- Add fixed cycle times and operating delays.
- Set shift schedules, targets, and operating costs.
- Compare improvement scenarios before choosing a fleet.
- Calculate, review warnings, and export your results.
Worked example
A six-truck fleet moves loose material through three haul segments. Each truck carries about thirty-two metric tonnes. Loader data estimates loading time from six bucket passes.
The route includes a pit ramp, main road, and dump approach. Grade and surface factors reduce effective speeds. Queue and random delays increase the expected cycle.
The result compares operating output against hourly and shift targets. It also estimates loader matching and costs. Field observations should replace assumed delays during final planning.
| Example input | Value | Purpose |
|---|---|---|
| Operating trucks | 6 | Defines fleet output and cost. |
| Average payload | 32 t | Converts trips into production. |
| Loader cycle | 32 seconds | Estimates loading service time. |
| Shift length | 10 hours | Calculates shift production. |
| Traffic allowance | 5% | Adds expected route variability. |
| Hourly target | 900 t | Estimates required trucks. |
Assumptions and limitations
- Average speeds represent safe operating conditions.
- Grade adjustments are planning approximations, not OEM curves.
- Queue estimates use average values, not stochastic simulation.
- Material density and swell should match field conditions.
- Costs exclude taxes unless entered within hourly costs.
- Safety rules always override productivity calculations.
Frequently asked questions
What is haul cycle time?
Haul cycle time is the complete time for one truck trip. It includes loading, travel, dumping, return, and delays. Lower cycle time usually increases production.
Why use separate loaded and empty speeds?
Loaded trucks often accelerate slower and climb differently. Empty trucks may return faster on suitable roads. Separate speeds make the estimate more realistic.
How does grade affect travel time?
Positive grade usually lowers effective travel speed. Negative grade may raise speed within safe limits. Actual truck performance curves provide better final estimates.
What does the match factor mean?
The match factor compares truck loading demand with loader capacity. Values near one indicate a balanced fleet. Higher values suggest loader congestion.
How are required trucks rounded?
The calculator first shows an exact fractional requirement. It then rounds upward to whole operating trucks. Spare allowance is added separately.
Can the calculator estimate volume production?
Yes, density and swell connect weight with loose volume. The cost section reports cubic meters and cubic yards. Accurate density remains essential.
Why is adjusted production below theoretical production?
Availability, mechanical condition, operator efficiency, and dispatch reduce output. Real fleets rarely complete every theoretical cycle. Adjusted production is better for planning.
Should queue time be fixed or percentage-based?
Use fixed minutes when observations are available. Percentage delays work for uncertain route variability. Avoid counting the same delay twice.
Does this replace a haul simulation?
No, this tool provides deterministic planning estimates. Complex fleets may need dispatch or simulation software. Validate outputs against timed field cycles.
How can hauling cost be reduced?
Improve road conditions, loader matching, payload control, and dispatch. Reduce queues without compromising safety. Compare scenarios before changing equipment.