Open-pit haulage

Truck-Shovel Cycle Time Productivity Calculator

Calculate cycle time from load time, haul distance, speed, and wait time, then compare theoretical and actual productivity instantly.

Use fleet size sensitivity, operating rate comparisons, and bottleneck labels on the same screen.

Show cycle time and productivity together
Fleet size sensitivity
Operating rate comparison
Bottlenecks at a glance
How to read the result
Haulage in open-pit mining is hazardous. Results do not replace safety rules.
Cycle time

The loading, travel, and wait pieces are shown as one truck cycle.

Fleet balance

See whether the truck side or the shovel side is limiting, along with the recommended truck count.

Inputs are processed only in this browser and are never sent to a server.

Safety notice

  • Haulage in open-pit mining is hazardous. Results do not replace safety rules.
  • Grade, rolling resistance, payload limits, weather, and maintenance can change results a lot.
  • Use observed average wait time and operating rate from the site.
  • Always follow local law, dispatch rules, and safety procedures.

How to use

  1. Choose the unit system and payload unit.
  2. Choose simple or detailed travel mode, then enter load time, travel conditions, and wait time.
  3. Enter truck count, shovel count, and operating rate.
  4. Review cycle time, theoretical and actual productivity, bottlenecks, and fleet size sensitivity.

Sample

Metric basic case

Input

60 t payload, 3:00 load time, 4.0 km one-way haul, 25 km/h, 1:00 wait time, 6 trucks, 1 shovel, 85% operating rate

Output

cycle time about 23.2 min, theoretical about 973 t/h, actual about 791 t/h, truck-limited, recommended about 8 trucks/shovel

Imperial case

Input

80 st payload, 3:00 load time, 2.5 mi one-way haul, 18 mph, 1:30 wait time, 5 trucks, 1 shovel, 80% operating rate

Output

cycle time about 21.2 min, theoretical about 1,220 st/h, actual about 907 st/h, truck-limited

Detailed mode case

Input

60 t payload, loaded 4.0 km at 22 km/h, return 4.0 km at 32 km/h, 3:00 load time, 1:00 wait time, 8 trucks, 1 shovel, 90% operating rate

Output

cycle time about 22.4 min, theoretical about 1,200 t/h, actual about 1,080 t/h, shovel-limited

FAQ

Is haul distance one-way or round trip?

In simple mode, enter one-way distance and the tool doubles it internally. Detailed mode lets you enter loaded and return legs separately.

What is the difference between theoretical and actual productivity?

Theoretical productivity assumes no wait time and 100% operating rate. Actual productivity reflects wait time and operating rate.

What changes when I change the operating rate?

Actual productivity changes linearly. The comparison table shows the difference from 50% to 100%.

Is the fleet size analysis a queue simulation?

No. It is a static capacity comparison that keeps the entered average wait time fixed. It does not estimate queue growth automatically.

Can I switch between t and m³?

Yes. Choose the unit you actually use on site. The tool does not convert by density, so enter the basis unit directly.

Can multilingual teams use it?

Yes. The page is translated from English, and URL sharing reproduces the same state.

Glossary

Cycle time

Time for one truck to complete a full loading, haul, return, and wait cycle.

Payload

Average load carried per truck cycle.

Operating rate

Share of scheduled time actually used for production.

Bottleneck

The resource or step that most strongly limits output.

Match factor

Indicates the balance between truck-side and shovel-side capacity. Values near 1 are more balanced.

Wait time

Average waiting time including queue, dump, spotting, and short delays.

Formulas

  • map[Text:travelTimeSimple = 2 × haulDistance / haulSpeed × 60 text:travelTimeSimple = 2 × haulDistance / haulSpeed × 60]
  • map[Text:travelTimeDetailed = loadedHaulDistance / loadedHaulSpeed × 60 + returnHaulDistance / returnHaulSpeed × 60 text:travelTimeDetailed = loadedHaulDistance / loadedHaulSpeed × 60 + returnHaulDistance / returnHaulSpeed × 60]
  • map[Text:idealCycleTime = loadTime + travelTime text:idealCycleTime = loadTime + travelTime]
  • map[Text:actualCycleTime = idealCycleTime + waitTime text:actualCycleTime = idealCycleTime + waitTime]
  • map[Text:theoreticalTruckRate = payload / idealCycleTime × 60 text:theoreticalTruckRate = payload / idealCycleTime × 60]
  • map[Text:actualTruckRate = payload / actualCycleTime × 60 text:actualTruckRate = payload / actualCycleTime × 60]
  • map[Text:shovelRate = payload / loadTime × 60 text:shovelRate = payload / loadTime × 60]
  • map[Text:actualFleetRate = min(truckCount × actualTruckRate, shovelCount × shovelRate) × operatingRate text:actualFleetRate = min(truckCount × actualTruckRate, shovelCount × shovelRate) × operatingRate]
  • map[Text:recommendedTruckCount = ceil((shovelCount × shovelRate) / actualTruckRate) text:recommendedTruckCount = ceil((shovelCount × shovelRate) / actualTruckRate)]

Notes

  • This tool is a planning aid only. It is not a queue simulation.
  • Road grade and rolling resistance are not modeled automatically. Adjust speed and wait time to match site reality if needed.
  • Enter the payload unit used on site. The tool does not perform density conversion.
  • Fleet size sensitivity keeps the entered average wait time fixed.