MINING EQUIPMENT MANAGEMENT

APPLICATION
guide book

Dec 2015
Contents
Introduction...................................................3
Choosing The Right Equipment
for Your Application
Loading Tools..............................................4
Hauling Machines.......................................5
Support Equipment...................................6-7
Making Haul Roads an Asset
To Your Operation.........................................8
Impact of Slower Cycle Times.....................9
Haul Road Design and Maintenance..........9
Training: Ensuring Operators and
Supervisors are Productive......................10
Evaluating Operators To Look For
Inefficiencies and Opportunities.............11
Conclusion...................................................12
Introduction
Achieving the lowest overall costs for your operation Once the right fleet has been selected and put to work,
begins with selecting the right equipment to support how that equipment is being operated and the conditions
it. This decision is based on a number of factors, in which it is working will determine the overall cost
including the material to be mined, the mine plan and per ton your site achieves. Proper selection and
the mining application. Each of these factors has an implementation of your machines, combined with an
impact on the performance of the fleet that you select. adherence to mining best practices, will drive your
Choosing production equipment is a priority, but it is operation toward lower owning and operating costs..
equally important to understand the impact that support
equipment can have on your operation, from drilling
and blasting to enabling a safe, efficient and productive
loading and hauling fleet.

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CHOOSING THE RIGHT EQUIPMENT
FOR YOUR APPLICATION
Loading Tools
Electric Rope Shovels. In the right conditions, with the appropriate
face height and adequate infrastructure, the electric rope shovel
(ERS) can deliver the lowest cost per ton. The mine life must be
long enough to support the investment in a machine with a long life
and the option to rebuild. In addition, the loading process must be
supported by a right-sized, efficient hauling fleet.

Hydraulic Mining Shovels. In most applications, a hydraulic

mining shovel (HMS)can deliver the same costs as a large wheel
loader. This shovel is ideal for large faces and benches that do not
require much tramming, as they lack the mobility to get from face
to face throughout the day. Breakout forces are greater with the
hydraulic mining shovels, so they perform better in tougher digging
materials than either the rope shovel or wheel loader.

Large Wheel Loaders. The cost per ton delivered by large wheel
loaders is very similar to that of hydraulic mining shovels in the
correct applications. They are considered a mobile machine so if
flexibility in locations is important, a wheel loader may be the best
choice. In addition, wheel loaders are capable of loading ultra class
trucks, keeping production going while maintenance is performed on
the main production tools.

Draglines. Thanks to their size, draglines deliver the lowest cost per
ton, but only in very specific conditions. They are typically operated
around the clock, and are one of the most important tools in coal
mining applications. They require support from dozers and in some
cases wheel tractor-scrapers. In addition, a dragline installation
requires a great deal of upfront mine and maintenance planning.

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CHOOSING THE RIGHT EQUIPMENT
FOR YOUR APPLICATION

Hauling Machines
Large Mining and Off-Highway Trucks. The hauling fleet can
account for 45 percent of overall mining costs. At the same time,
selection of the correct type and size of hauler to match the loading
fleet can deliver some of the greatest value to your operation.
Once you have determined the target payload, it’s crucial that you
maintain that target to achieve the lowest possible cost per ton.
Supporting the fleet with properly designed and maintained haul
roads is also critical. Good haul road maintenance can be achieved
with motor graders or wheel dozers, and the proper application of
water when required.

5
CHOOSING THE RIGHT EQUIPMENT
FOR YOUR APPLICATION

Support Equipment
Motor Graders. Motor graders have a direct influence on mine-site
productivity and costs by taking care of haul roads. When roads are
kept in top condition, trucks run faster, cycle times improve and more
ore is produced. Good road conditions also reduce truck maintenance,
lower fuel costs and reduce tire damage.

Wheel Dozers. Wheel dozers combine the production capabilities

of track-type tractors with the mobility and versatility of wheel
loaders. Applications include loading area cleanup, dump area
maintenance, haul road construction and maintenance, blasting
area cleanup, reclamation and stock pile. A wheel dozer should be
assigned to each loading tool (ERS or HMS) to keep the loading area
free of spillage and to eliminate rough surfaces. They are also useful
where compaction is desired, such as coal piles.

Track-Type Tractors. In mining and production dozing applications

it takes both machine weight and horsepower to move large volumes
of material. Large dozers have high weight-to-horsepower ratios to
push large loads. They perform several valuable functions in open pit
surface mines, such as truck dump maintenance, ripping, stockpile
management, stripping overburden, dragline support, trapping and
road building.

Hydraulic Excavators. Excavators perform many valuable

functions in open pit surface mines, such as building haul roads,
maintaining haul road berms, drains and drainage sumps, breaking
rock, cleaning truck beds, and many other tasks.

Scrapers. Wheel tractor-scrapers are ideal for jobs that require

moving large amounts of dirt with little time — like clearing
greenfield coal mines, removing overburden, digging partings,
spreading stone and reclaiming mine sites. They are quick to load
and unload, spread evenly on the go and have an appetite for
a broad range of materials. They offer the lowest cost in
moving materials.

Articulated Trucks. Articulated trucks are extremely

versatile — moving a wide variety of material in dozens of
applications and underfoot conditions. They are simple to operate,
with easy controls and automotive-style comfort. A tighter turning
radius makes articulated trucks more maneuverable than rigid trucks
in confined spaces, and their wider frame and lower center of gravity
make them ideal for extreme conditions, such as inclines and soft,
muddy, frozen or uneven ground. Options include standard dump or
on-the-go ejector options for faster cycle times.

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CHOOSING THE RIGHT EQUIPMENT
FOR YOUR APPLICATION

Support Equipment (Continued)

Water Trucks. Dust is a concern on many mine sites. Not only is

it a safety hazard because it reduces visibility, but dust also can
stress machines by clogging filters, brakes and other components.
A water truck is an essential piece of support equipment to
counter these problems by controlling the amount of dust in the air.
Caterpillar offers an off-highway truck bare chassis designed for
special machines, including water trucks. In addition, the Cat Water
Delivering & Control System (WDS) is an optional attachment that
controls spray patterns and allows for a consistent spray width
regardless of engine rpm. The WDS includes factory-installed
controls in the cab, a hydraulic pump and motor, a water pump
and spray heads.

Production Dozing. Track-type tractors are the most common

tool for production dozing, especially when the job requires a long
push distance. Maximizing the productivity of the tractor, having
the blade fully burdened during every pass, is key to production
dozing. This technique is critical for applications such as stripping,
stockpiling and reclamation. Ensuring the tractor is properly
equipped for the application it is being used in is imperative for
the highest possible level of productivity. DozSim is a simulation
application that allows the user to input specific information on
various machine characteristics, job specifications, and other
factors that might affect dozer productivity. This allows users to
perform “what if” calculations to see what affect changes in job
specifications, material, slope, operator skill, and other factors
have on anticipated machine productivity. Caterpillar also offers a
number of attachments and technologies that help operators with
minimal experience be successful in these applications.

Drilling & Blasting. Rock fragmentation is provided by the

complementary work of drilling and blasting. This starts the
entire process for mining and quarrying yet is critically dependet
on precision in planning and execution. This impacts owning and
operating cost from dig ability, haulage factors to thru put at the
plant. Model and drilling method selection are driven by application
requirements of bench height, hole diameter and rock hardness.
Drilling is conducted by the complimentary functions of high
pressure compressed air, rotation torque and speed with hydraulic
pull down force on the rock bit. Automation and autonomy are a
growing customer requirement which integrates this to
Cat® Terrain in Cat® MineStarTM.

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MAKING HAUL ROADS AN ASSET
TO YOUR OPERATION
Haul roads are the lifeline of the production system. They have working environment and improve visibility. In addition, good
a direct impact on productivity and profitability and can be a haul roads ensure better access for emergency vehicles in the
mining operation’s greatest asset — or its greatest liability. They event of an accident.
have a major effect on operating and maintenance costs as well
Haul roads are the operating domain of a site’s trucks, and
as machine downtime. Haul road conditions dictate speed, fuel
their design and maintenance should be approached with truck
burn, tire life, safety, machine and component life, and annual
performance in mind. Haul roads have the largest influence on
tonnage moved.
both the immediate and long-term performance and cost of truck
Smooth, constant grades extend the life of tires and components fleet, as well as the cost per ton they deliver. Poor haul roads
and reduce the chance of machine damage due to road hazards. have an adverse effect on cycle times, which will ultimately lead
Productivity gains can be realized as well. Shift change times to higher operation and maintenance costs.
are optimized when employees can reach their working areas
as quickly as possible, and cycle times are improved when
operators are not constantly reducing speed to avoid potholes
or other road hazards. Smooth, clean road surfaces also deliver
safety benefits. They suppress dust to provide a healthier

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MAKING HAUL ROADS AN ASSET
TO YOUR OPERATION

Impact of Slower Cycle Times

Just adding one minute to cycle time can have a significant
impact on productivity and cost per ton in a short-haul coal
mine. Let’s assume a mine is operating 785-size trucks, hauling
150 tons of overburden. Reducing the cycle time from 9 minutes
down to 8 can increase the number of cycles per hour by 0.8
cycles per hour. This is a difference of 120 tons per hour.

This doesn’t seem like much when looking at a short period of

time, however over the course of a year this slight reduction
in cycle time can reflect in a difference in revenue upwards of
$2.38 million. Minor changes can have a major impact on the
bottom line of an operation.

The minimal expenditure required to maintain good haul roads

will pay for itself many times over when compared to the extra
costs and lost productivity to be incurred when roads are in
poor condition.

Haul Road Design and

Maintenance Tools
Caterpillar can help mines improve their haul roads with the fol-
lowing tools:
• Fleet Production and Cost (FPC) Estimate cycle times,
fuel consumption and fleet productivity.
• Road Analysis Control (RAC) Monitor haul road
conditions by activating on several trucks.
• Mine Equipment Investment Analysis (MineEIA)
Compare the economics of two or more mining systems
in an application
• Value Estimating Tool (VET) Translate Cat features and
benefits into tangible value for customers.
• Performance Handbook Review machine performance
and overall owning and operating costs.
• Training Define training opportunities that will improve
site conditions and productivity.

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TRAINING: ENSURING OPERATORS AND
SUPERVISORS ARE PRODUCTIVE AND EFFICIENT
A decade ago, it would have take a new hire at a mine several Caterpillar can also assist with more advanced training that
years to become proficient at operating a single machine or teaches workers how to look at efficiencies across the mine in
gaining a total understanding of how a mine site operates. This the areas of loading, hauling, dumping and returning to the load
lengthy training period worked because senior operators were area. Training can also be broken down into training on individual
there to do what needed to be done. Today, a mine’s foremen or machine families.
supervisors may have just two years of mining experience. Most
Another approach to training that can be more economical, safer,
mines are so busy training new operators on individual tasks
and easier on equipment, is the use of simulators. Caterpillar has
that they do not have enough time to do advanced follow-up
a variety of its own basic simulators as well as an alliance with
with their quickly-promoted foremen or supervisors. These same
Immersive Technologies to provide cutting-edge, realistic training
individuals, with limited time and experience, are then responsible
opportunities.
for helping to educate newer operators. This scenario leads to
miscommunication and frustration for the management team.
Mining operations have a lot to lose when they don’t go beyond
the basic training new operators receive. These operators often
learn on the job, developing both good and bad habits. They focus
on the task at hand with little to no understanding of how what
they are doing can affect the mine’s cost per ton.
At the same time, today’s mine sites face a lack of skilled people
on site due to the retirement of many senior level employees and
the lack of people interested in working in the mining sector. The
result is lost knowledge that is difficult to replace.
Training courses
A key to overcoming this lack of skills and knowledge is providing
comprehensive training. While this may not be a core competency
of the mining organization, it is a key component of Caterpillar’s
beyond-the-iron offerings. Caterpillar offers:
• Instructor-led classroom sessions
• Instructor-led in-the-iron training sessions
• Online e-learning classes
• Self-learning CDs
• Simulators
Basic operator training can be provided at Caterpillar’s Tinaja Hills
training center near Tucson, Arizona.
Caterpillar can also assist with more advanced training that
teaches workers how to look at efficiencies across the mine in
the areas of loading, hauling, dumping and returning to the load
area. Training can also be broken down into training on individual

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EVALUATING OPERATIONS TO LOOK FOR
INEFFICIENCIES AND OPPORTUNITIES
The more productively, efficiently and cost-effectively a mine Site Assessment
can operate, the more profitable it will become. Continuous
The application in which a machine operates will have a
improvement is a must. By evaluating operations, equipment,
significant impact on its performance. It’s important to evaluate
maintenance practices and operator performance, mines can
site conditions and review all aspects of an operation beyond
identify inefficiencies and find opportunities for improvements
the equipment itself to identify areas of opportunity. Once these
that will have an impact on the overall cost per ton. Application
opportunities are identified a course of action can be determined
inefficiencies add up by the minute and can adversely affect
and the results measured over time. Improvement opportunities
overall production significantly. Even the slightest improvements
can be found in a number of areas, including:
can reap great benefits
• Operator Inefficiencies
Payload Management/Scale Study
• Haul Road Design
Managing payload and measuring productivity are essential to
helping mines improve the efficiency of operations and get more • Haul Road Maintenance
from their equipment investment. Production and volumetric • Payload Management
studies, which can be conducted in partnership with Caterpillar
Global Mining, can focus on a number of variables and analyses, • Fleet Optimization
such as:
• Vehicle and fleet productivity
• Loading/hauling system analysis
• Loading tool sizing/matching analysis
• Equipment operational reviews
• Payload weighing
• Productivity analysis
Haul trucks are designed to operate at a manufacturer-designed
payload. Exceeding that payload negatively affects fuel
consumption, the life of tires, frames and components, overall
cycle times and safety. More is not always better and has the
potential not only to reduce production and availability but also
to increase maintenance costs.
An important tool in the management of payload is the
scale truck, which is used in a scale study to weigh payload.
Scale studies are needed to monitor the fleet’s adherence to
Caterpillar’s 10/10/20 payload management guidelines. Scale
studies help mine sites:
• Ensure adherence to payload guidelines
• Improve load placement
• Establish a correct target payload
• Ensure TPMS accuracy for future payload management
The scope of any prospective study needs to be clearly
understood and agreed to up front. Such studies will typically
take three to five days on site, and another three to five days of
office work and report writing.
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CONCLUSION
Mine sites measure productivity by cost per ton – the lower that
number, the greater their profitability. A successful equipment
management program is essential in making this happen. While
there are significant benefits to simply selecting the appropriate
equipment fleet for your application, it is equally important to
ensure that best practices are being followed in maintaining and
operating the fleet.
Small changes at a site can have a major impact on the bottom line.
A noticeable reduction in cost per ton is recognized with a minimal
5% change in hourly efficiency, payload, operator efficiency and
cycle times –all by increasing machine availability and utilization.
For more information on all things application related,
please visit https://dealer.cat.com/en/ps/industry/
mining/c/application.html

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