Haul Road Maintenance

Prévia do material em texto

Getting More From Your
Cat Mining System
MineEIA Sensitivity Analysis- -Hauling
 Reduction in Cost Per Ton
5% Factor 0% 1% 2% 3% 4% 5% 6% 7%
Operator Eff iciency
Cycle Times
Payload
Fuel Consumption
Maintenance and Repair
Mechanical Availability
Utilization
Machine Capital
Machine Life
Operator Wages
Tires
Lubricants
Approximate range of f inal results, based on analyses to date.
Cost parameters, including fuel, may vary greatly by location and application
 A 5% Change in Each of the Listed Factors Cause the Following % Reduction in Cost Per Ton
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
777 785 789 793 797
S
q
.
 
I
n
c
h
e
s
91% 
107% 
269% 
44% 
Compaction Areas 
From Large Trucks 
Poor haul road Good haul road
Permanent plastic strain 
due to shear failure
Tire load
9
4
 
i
n
c
h
More severe
Current Technology
Haul Road Modeling
Haul Road Design 
Rolling Resistance
• Hard, well-maintained road . . . . . . . 1.5%
• Well-maintained road with flex . . . . . . 3%
• 25 mm/1 in tire penetration . . . . . . . . .4%
• 50 mm/2 in tire penetration . . . . . . . . .5%
• 100 mm/4 in tire penetration . . . . . . . .8%
• 200 mm/8 in tire penetration . . . . . . .14% 
Tire penetration
20 – 24” Tire Penetration = 30 – 35% Rolling Resistance 
Haul Road Economics 
Haul road conditions directly impact productivity 
levels and unit costs. 
Payload
Increase
Haul Road 
Resistance 
Increase
Haul Road 
Grade 
Increase
Wheel Gp/Diff
Life
Significant
Decrease
Significant
Increase
Very
Significant
Decrease
Very
Significant 
Increase
Very
Significant 
Decrease
Very
Significant 
Increase
Insignificant
Change
May or May
Not Be 
Significant
Slight 
Increase
Insignificant 
Change
Significant 
Decrease
Significant 
Decrease
No Change No Change No Change
Wheel Gp/Diff
Life
Wheel Gp/Diff
Cost/Hr
Engine
Life & Cost/Hr Production
Fuel
Efficiency
Summary-Application Impact
Comfortable with Tire Life? 
Over the life of the truck, you will spend the initial
purchase price of the truck in tire related cost. 
Tire Failure Mode 
Cut 45%
Impact 29%
Separation 11% 
Worn out 7%
Other 8%
100%
Tire Considerations 
Source:Actual data, world-class metal mine
Speed, Curve Radius and Supers Are Related
Tire Considerations (What To Watch For)
• Superelevation
– Tire side forces—casing life.
– Scuffing and tread wear.
– Consistent speeds—less braking—less 
torque, heat.
– Spillage—cut damage.
Haul Road Design
Corners
• Use maximum practical radius.
• Employ super elevation for 
higher speed operations.
• Use super elevation >10% 
with caution. 
Haul Road Design
Horizontal and Vertical Alignment
• Design corners and crests that allow 
excellent visibility at normal travel 
speeds.
• Use worst-case scenarios. 
10
1
Cross Slope:
Design of Surface Mine Haulage 
Roads
• Rapid removal of water.
• Recommended rate: 1/4 -1/2 in/ ft (2%-4%). 
Surface texture. Ice or mud.
• Single-lane - - governed by land features.
• Crown appropriate for multiple-lane 
construction. 
Ditching
Haul Road Design 
Drainage & Safety Berms
• Drainage system - sized to 
accommodate maximum rainfall.
• Berm size - at least one-half wheel 
height. 
Drainage
1/2 wheel height
Build and Maintain Consistent 
Linear Grades
Affects of Inconsistent Linear Grades
Truck Downshifts
Truck Upshifts
• Reduces number of truck transmission shifts
• Reduces fuel consumption
• Improves truck cycle times
• Reduces spillage
Haul Road Design
Road Width
• One way - 3 truck widths.
• Two-way straights - 3.5 truck widths.
• Two way corners - 4 truck widths. 
One-way (Straights/corners)
Two-way (In Straights)
Two-way (In Corners)
Haul Road Design 
Bench Width
• Truck must clear loader under full 
acceleration.
• Minimum width = machine swing 
diameter + truck width + width of safety 
berm. 
Bench Width
Haul Road Visual Inspection
Main Haul Road
• Road is free of puddles, potholes, ruts, gullies.
• Passing room is adequate.
• Corner radius allows safe operation at high 
speed.
• Spillage is removed quickly.
• No rubber deposits on tight, rocky turns.
• High braking forces not necessary on corners.
• Expected road speeds are achieved.
Haul Road Visual Inspection
Load Zone
• Floor is smooth.
• Water removal is 
adequate.
• Debris is cleared away.
• Trucks don’t drive over 
rocks.
• Trucks leave under full, 
continuous acceleration.
• Trucks return without 
making tight, high-speed 
turns.
• Observe location of 2nd
gear reweigh.
Loading Zone
Haul Road Visual Inspection
Dump Zone
• Floor is smooth.
• Trucks enter at high speed, parallel to edge.
• Trucks brake in straight line, then turn and 
stop to 
reverse to dump.
• Safety berms are regulation height.
• Is dump stable enough to 
dump over safely or 
should you dump short 
and push off.
Properly Train M.G Operators 
ƒArticulated Turns
ƒProper gear Selection
ƒDifferential Lock
ƒProper Coverage
ƒWheel Lean 
Full Coverage ?
Is operator 
taking full 
advantage of 
moldboard 
width to 
achieve best 
coverage and 
higher 
production.
Does Haul Road 
Allow 2 Way Traffic 
Points to Remember
• The best haul roads have crowned straight sections, 
superelevated curves, safety berms and drainage 
ditches on both sides.
• Because excessive water is a detriment to any road, 
the most important item (for many sites) in road 
maintenance is providing and maintaining a good 
drainage system.
Consult Caterpillar H-Series MG Application Guide, Videos
Points to Remember 
• Over-Watering Haul Roads:
– Softens and makes slippery
– Surface susceptible to damage
– Water often scarce
– Set up/adjust water trucks 
Haul Road Support ! 
What to look for?
Points to Remember
• The haul road begins at the loading face and 
ends at the dump point.
• Once a road deteriorates, it takes five times as 
long to repair it to good condition again. “Fix it 
once, fix it right!”
• If one can travel comfortably in a light truck at 
mph, then road surfaces are good.
• Good roads improve production, extend tire life 
and reduce overall operating costs.
Points to Remember
• Flagmen or other control measures at potentially 
dangerous points.
• Road signs for speed and gear selection.
Caterpillar Haul Road Guidelines—
• Fabric-like material is 
being incorporated in 
road building for areas 
with high rainfall and 
poor materials.
• Functions: 
reinforcement, 
separation, filtration. 
Current Technology 
Other Haul Road Technology—
Geotextile 
Smooth Haul Roads ? 
Current Technology
• Road 
Analysis 
Control (RAC)
Haul Road Maintenance 
Analysis Tools 
• Application Severity Analysis (ASA).
• Vital Information Management System 
(VIMS).
• Fleet Production and Cost (FPC).
• M.G Calculator
Questions / Comments ?
THANKS