Mining Job EfficiencyEquipment Management Training

LOADINGSection

Hauling Cycle Elements+ Exchange

Visual Inspection - Loading ZoneFloor Is SmoothWater Removal Is AdequateDebris Is Cleared AwayTrucks Dont Drive Over RocksTrucks Leave Under Full, Continuous AccelerationTrucks Return Without Making Tight, High-speed Turns

Floor Condition

Load Area Floor Condition

LoadEntry Into the Loading Area

Waiting TimeTruck BunchingDo we have too many trucks? Are we timing the spacing between the trucks (follow my leader)

Truck Exchange and Truck PositionGet Truck Into the Right PositionShortest Time Least manoeuvreLoader Spots

Exit From the Loading Area

Cycle Time - Loading ToolDigSwing / ManoeuvreDumpReturn / Manoeuvre

Find Information in Performance Handbook

SwingMax 90 Degrees

Minimize the Swing Time

Swing Right to Left Operator Has Visibility of truck

LoadFill the Body Properly

Load Needs to Be Full

Do Not Hit Dumper Body

543HOW TO LOAD21

ReturnSame as Swing Minimize Swing Angle

Minimize manoeuvre time

Exchange TimeFull Truck Leaves Load Area

Empty Truck Manoeuvres into Position

Excavator can Some Clean UpSpot Truck

Good First Bucket FillTruck Capacity = 4 Passes1 Load1 Load1 Load1 Load= 4 CyclesTruck Capacity = 4 Passes1/2 Load1 Load1 Load1 Load Load= 5 CyclesFirst Pass Must Be a Full Pass!

ExchangeAllow loaded machine to exit

Allow empty machine to get into position in least time

Effects of Payload Too little payloadLost productivity

Too much payloadExceed the safe operating weight of the machine BrakesSteeringReduce hauling speeds Impact component durability

ME Job Set-up

ME Job Set-up Over The Rail Loading Trucks on Bottom Level Bench Height Equals Stick Length Minimum Swing Set-up Provides Ample Dig and Reach Alternate Loading Positions

ME Set-up (Drive By)Thru The Gate LoadingTrucks on Bottom Level

Modified Drive-by MethodBest Where Trucks Limited90 Degree Swing

ME Set-up (Both over the Rail & Thru Gate)Wide Cut in easy Dig Bench Height Equals Stick LengthMinimum SwingOffers Less Shovel MovesAlternate Loading Positions

ME Set-up (Box Cut , Same Level)Thru the Gate LoadingTrucks & ME at Same Level

Single or Double LoadingMinimum Dig Depth60 Degree Swing

ME Set-up (Box Cut Same Level)Thru The Gate LoadingTrucks & ME at Same Level

Drive-by MethodBest Where Truck LimitedMaximum Dig Depth90 Degree Swing

Not a recommended practice

HAULINGSection

HaulingHaul Road Geometry Should Allow Smooth and Cost-efficient Operation of a Haul Truck Fleet at Designed Operating Speed and Target Payload

The Road Construction Quality Should be Maintained Throughout Normal Expected Mining Conditions

What Can Slow Us Down on Haul RoadsUneven Haul RoadBumps / Dips

Rolling Resistance

Passing Machines

Corners

Grades

Haul Road Width - Allow PassingOne Way - 3 Truck Widths (use largest truck)Two Way Straights - 3.5 Truck WidthsTwo Way Corners 3.5 to 4 Truck WidthsGIVE LOADED TRUCKS PRIORITY

CornersMost People Slow Down for Corners

Design Corners and Crests That Permit Sufficient Visibility at Normal Travel Speeds

Avoid Corners on Crests

Avoid Curves at Bottom of Downgrade

Intersections (Loaded Has Priority)

Super-elevation

GradeMaintain Smooth Grade

Maintain Consistent Percentage

Uneven GradeAEDCBFA Hit ramp slows down - down shiftsB Grade decreases speeds up - up shiftsC Grade increases slows down - down shiftsD Grade increases slows down - down shiftsE Grade decreases speeds up - up shiftsF Grade Increases slows down - downshifts

Visual Inspection - Main Haul RoadRoad Is Free of Puddles, Potholes, Ruts, GulliesPassing Room Is AdequateCorner Radius Allows Safe Operation at High SpeedSpillage Is Removed QuicklyNo Rubber Deposits on Tight, Rocky TurnsHigh Braking Forces Not Necessary on CornersExpected Road Speeds Are Achieved

Visual Inspection - Dumping ZoneFloor Is SmoothTrucks Enter at High Speed, Parallel to EdgeTrucks Brake in Straight Line, Then Turn and Stop to Reverse to DumpSafety Berms Are Regulation HeightIs Dump Stable Enough to Dump Over Safely or Should You Dump Short and Push off?

Remember.The Haul Road..Starts HereFinishes Here

Haul Road MaintenanceA Haul Road Requires Maintenance, Similar to the Equipment Operating on It

Like the Machines, Haul Road Maintenance Schedule Should Exist at Every Mine Site

Water ManagementWater Is the Enemy of Roads. Thus Roads Should NEVER Be Flat Unless It NEVER Rains on Your Site!

The Slope Needed to Carry Water off the Road Can Be Obtained From Either Crowning or Crossfall

A Crown Is the Centre of the Road Being Higher Than the Sides

A Constant Crossfall Is Keeping One Side or the Road Higher Than the Centre

DrainageAny Haul Road Design Is Only As Good As Its DrainageCompared to a Sealed Road:Drainage is important as material on site typically not greatSince there is no seal, traffic & water can damage road quickly

The Keys to Maintaining a Haul Road in Best Condition Are:Quickly shedding water through crown or crossfallQuickly draining water from the side of the road by use of drainsIntercepting water before it reaches the road

DrainageThe Simplest Way to Reduce Water Damage to a Haul Road

Elevate the Haul Road Above the Lay of the LandEdge BermRoadDrain

Haul Road MaintenanceWhen Major Repairs Are Required to a Section of Road, the Following Steps Need to Be Carried Out

Ripping of gravel surface (1st layer)Re-shaping of road to original designCompaction and watering of surface

Haul Road EconomicsGood Haul Road Planning and Maintenance Provide Substantial BenefitsSafer mine pit environmentIncreased tyre lifeMore uptime Increased operator efficiencyLower repair costs

Improved Production/Lower Costs

Haul Road MaintenanceGrading Is the Key Element to Haul Road Maintenance

It facilitates bringing material in from the sides or cutting down high sections and filling the low spots with surplus loose material

Maintenance grading should not penetrate past the first layer of a haul road

**Lets take a look at floor condition*Whats wrong with this picture?

Whatever the loading tool being used here, there is insufficient clean up support. If it is the wheel loader, the operator and supervisor is not being vigilant in using the loader to clean up potentially damaging rocks.

If the loading tool is a excavator, where are the support dozers? Keep an eye out for these conditions in your pits and direct your support equipment to clean rock up around the loading tool.**Over The Rail LoadingTrucks on Bottom Level

Bench Height Equals Stick LengthMinimum SwingSet-up Provides Ample Dig and ReachAlternate Loading Positions*Thru The Gate LoadingTrucks on Bottom Level

ModifiedDrive-by MethodBest Where Truck Limited90 Degree Swing*Trucks on bottom level

Wide Cut in easy Dig Bench Height Equals Stick LengthMinimum SwingOffers Less Shovel MovesAlternate Loading Positions*Thru the Gate LoadingTrucks & ME at Same Level

Single or Double LoadingMinimum Dig Depth60 Degree Swing*Thru The Gate LoadingTrucks & ME at Same Level

Drive-by MethodBest Where Truck LimitedMaximum Dig Depth90 Degree Swing

*The first geometry consideration is road width

The recommendation for fast, safe travel is shown here.

For one way traffic, we recommend a road that is three times wider than the largest truck on siteFor two way traffic on straight roads, we recommend a road that is three and a half times as wide as the largest truck.For two way traffic going around a bend, we recommend a road that is 4 times as wide as the largest truck on site.

Obviously, there may be nothing you can do about existing roads, but keep these recommendations in mind when involved in the planning of new roads*It may sound obvious, but you want to maintain a smooth, consistent grade as far as possible.

Smooth roads makes for a more comfortable ride for the operator.

Smooth roads also reduce unnecessary high-energy transmission shifts, which both accelerate transmission clutch wear, and introduce the chance of spillage from the body and subsequent tyre damage.

****A haul road, in many respects, is like a mining machine. It requires maintenance to keep it in safe and efficient operating condition.

A road maintenance schedule will depend on environmental and haul conditions on the site. Your maintenance schedule should take these factors into account and the schedule may vary from season to season, or due to the use of different hauls or dumps.

Caterpillar considers the haul road to start at the loading tool and end at the dump. Some of the best gains can be made on the pit floor and across the dump.*Water is the major enemy of roads. Poor water management will cause roads to deteriorate through soil erosion and effects the safe and workable operation of the road.

Erosive action on haulroads can cause ruts and washouts and can saturate the subgrades causing instability and structural failure. The proper use of drainage can alleviate these problems, resulting in safer and more efficient operations.

You can get the required slope to drain water via crowning or crossfall.

A crowned road has the centre higher than the edges, and constant crossfall is one side of the road higher than the other.*As we mentioned earlier, water is the major contributor to haul road degradation. The key to good haul road life is water management, and water management is determined by the drainage capabilities designed into the road system.

Two factors make drainage much more important in unsealed mine haul roads than on sealed highways.Firstly, the material used in haulroads is typically from the site, and is generally of lower quality that what you might use for a sealed highway for the simple reason it is cost-prohibitive to import better materialSecondly, since the road does not have a surface seal of bitumen, the combination of traffic and water is able to erode the road structure more readily than sealed roads.

There are three key areas that need attention:Water that falls onto the road surface must be shed from the surface as fast as possible by the use of crown or crossfallWater collected alongside the road must be drained away from the road as fast as possible by the use of drainsWater flows that approach a road from higher ground must be intercepted before it reaches the road by catch drains

The size and design of drains is beyond the scope of this presentation, but there is information in the references Ill talk about at the end and some information on your CD*The photo here shows a haulroad with basically no drainage. Pooled water on the surface cant escape.

If construction of complex drainage is not practical, the other option available on low-lying land is to elevate the roadway above the in-situ material*When road defects need to be repaired, the following three fundamental steps need to be carried out:Ripping of the surface layer to AT LEAST the bottom of the defect, be it a pothole, rut or corrugationBlending the material and reshaping the road profile with the motor graderWatering and compacting of the surface **Grading is the key maintenance element for keeping haul roads in safe and efficient condition.

Grading allows defects to be cut from the road, and material to be moved into low spots.

Grading should not penetrate through the first layer of surface material. Considering a grader like a 24H can easily cut 100mm passes, the surface layer needs to be thick enough to allow maintenance without affecting the subgrade levels of the road.

Finally, grading must be used to ensure the correct crossfall to ensure water drains from the surface.