Haul Cycle Time Calculator

Enter Project Inputs

Unit system

Choose one system and keep it consistent.

Loaded haul distance

One-way loaded travel distance.

Empty return distance

One-way return distance.

Loaded travel speed

Average speed while loaded.

Empty travel speed

Average speed while empty.

Load time (min)

Time to load one truck.

Dump time (min)

Time to dump and clear.

Spot & maneuver (min)

Positioning at loader and dump.

Queue at load (min)

Waiting time before loading.

Queue at dump (min)

Waiting time before dumping.

Delay allowance (min)

Minor delays, checks, slowdowns.

Grade factor (loaded)

Multiply loaded travel time by this factor.

Grade factor (empty)

Multiply empty travel time by this factor.

Utilization (%)

Accounts for breaks and interruptions.

Truck count

Number of trucks in the fleet.

Payload per truck

Use consistent payload units below.

Payload unit

Used for production rate reporting.

Loader cycle per pass (min) (optional)

Set to 0 to ignore loader limiting.

Passes per truck (optional)

If known, this overrides bucket estimate.

Bucket capacity (m³) (optional)

Used only if passes are not provided.

Fill factor (optional)

Typical range: 0.8 to 1.0.

Reset

Example Data Table

Scenario	Loaded Dist.	Empty Dist.	Loaded Speed	Empty Speed	Load	Dump	Queues	Cycle Time
Short Haul	2 km	2 km	25 km/h	35 km/h	3.0 min	0.8 min	1.0 min	~15–18 min
Medium Haul	5 km	5 km	35 km/h	45 km/h	3.5 min	1.0 min	1.8 min	~20–25 min
Long Haul	10 km	10 km	40 km/h	55 km/h	4.0 min	1.2 min	2.5 min	~30–40 min

Example outputs vary with grade factors, utilization, and delays.

Formula Used

1) Loaded travel time (minutes)

T_loaded = (D_loaded / V_loaded) × 60 × F_loaded

2) Empty travel time (minutes)

T_empty = (D_empty / V_empty) × 60 × F_empty

3) Fixed time (minutes)

T_fixed = T_load + T_dump + T_spot + T_queue_load + T_queue_dump + T_delay

4) Cycle time (minutes)

T_cycle = T_loaded + T_empty + T_fixed

5) Effective cycle with utilization (minutes)

T_effective = T_cycle / U

6) Cycles per hour (per truck)

Cycles/hr = 60 / T_effective

7) Production (payload units per hour)

Fleet = TruckCount × Payload × Cycles/hr

D = distance, V = speed, F = grade factor, U = utilization fraction.

How to Use This Calculator

Choose a unit system and keep all distances and speeds consistent.
Enter loaded and empty distances, plus realistic average speeds.
Add load, dump, spotting, queues, and a small delay allowance.
Use grade factors to reflect uphill or rough haul roads.
Set utilization to account for breaks and interruptions.
Enter truck count and payload to estimate hourly production.
Optionally add loader cycle and passes to apply a loader limit.
Press Calculate to view results and download reports.

Haul cycle time as a planning baseline

Haul cycle time converts field observations into one repeatable number for scheduling. By entering loaded and empty distances, average speeds, and service times, you estimate minutes per round trip. Typical inputs come from GPS logs, spot checks, or dispatch data. Short cycles favor smaller fleets with higher turns; long cycles push you toward higher payload or more trucks. Test a best, expected, and worst case set.

Travel components and haul road realism

Travel minutes come from distance divided by speed, converted to minutes, then adjusted by grade factors. Use grade factors to reflect uphill segments, rolling resistance, and soft surfaces. A factor above 1.00 slows travel; below 1.00 reflects improved conditions or downhill return. Use conservative speeds that respect sight lines, curves, and weather restrictions.

Queueing, spotting, and fixed service time

Fixed time groups loading, dumping, maneuvering, and expected waiting. Even small queues add up across hundreds of cycles. Track average queue at the loader and at the dump separately, because constraints differ. Add a modest delay allowance for minor checks, traffic control, or windrow cleanup. If queues swing widely, plan with the upper quartile, not the average.

Utilization and effective production rates

Utilization converts theoretical cycle time into effective time by accounting for breaks, refueling, shift change, and interruptions. When utilization is 85%, the effective cycle increases by roughly 1/0.85. This adjustment reduces cycles per hour and produces a more defensible fleet output. Compare scenarios using the same utilization so changes reflect the road or operation, not accounting.

Balancing trucks and loader capacity

Fleet production equals payload per trip times cycles per hour times truck count. If the loader is the constraint, a loader-cycle limit can cap output. Enter loader cycle time and either passes per truck or bucket capacity with a fill factor. The net result highlights whether adding trucks will actually raise production. Use this output to right-size fleet, controlling overall cost per unit.

FAQs

1) What is a haul cycle time?

It is the total minutes for a truck to load, travel loaded, dump, return empty, and include typical queues and small delays.

2) Why use separate loaded and empty speeds?

Trucks usually travel slower when loaded and faster when empty. Using separate speeds improves realism and reduces overestimating production.

3) How do grade factors work?

Grade factors multiply travel time to reflect road resistance, slope, and surface conditions. Use values above 1.00 for slower travel and below 1.00 for easier segments.

4) What utilization value should I use?

Many projects use 70–90% depending on control, shift rules, and refueling needs. If unsure, start at 85% and test sensitivity around it.

5) When should I apply the loader limit?

Apply it when loading equipment is the bottleneck. Enter loader cycle time and passes per truck, or bucket capacity with fill factor, to cap fleet output.

6) How can I reduce cycle time on site?

Improve haul road condition, reduce congestion with traffic control, shorten spotting time with better dump layout, and align truck count to the loader’s practical service rate.