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33 cu ft) I 27
= 83 lcy
62 lcy I hr
EXCAVATORS
General Information
Machines which make use of hydraulic pressure to develop bucket penetration into
mate1i.als are classified by the digging motion of the bucket. l11e hydraulically controlled boom
and stick, to which the bucket is attached, may be mounted on either a crawler or a \Vhc:el
tractor base. A downward arc unit is classified as a "hoe." It develops excavation breakout force
by pulling the bucket toward the machine and curling the bucket inward. An upward motion
unit is known as a "front shovel. 11 A shovel develops break out force by crowding mate1ial mvay
from the machine. The doVv'Jlward swing of a hoe dictates usage for excavating below the nmning.
gear. l11e boom of a shovel swings upward to load; therefore, the machine requires a material
face above the ru1111mg gear to work against.
Front Shovels
Front shovels are used predominately for hard digging above track level, and loading
haul units. The loading of shot rock would be a typical application. A shovel is capable of
developing a high breakout force. The material being excavated should be such that it will stand
with a faiTly ve1tical face. Crawler-mounted shovels have very slow travel speeds, less than 3
mph. Figure 8-1 illustrates a crawler-mounted shovel.
:i- ,
.. -~~?!',~~:> '''.
FIGURE 3.11
A hydraulic-operated front shovel loading material into a truck. (Caterpillar Inc.)
55
The size of a shovel is indicated by the size of the bucket. e\pressed in cubic yards
1l1ere are three different bucket rating standards, PCSA Standard No. 3. Society of Auto1110tive Engineers (SAE) Standard J-296, and the Committee on European Construction Equipment
(CECE) method. All the methods are based only on the physical dime11sions of the bucket and
do not address tbe "bucket loading motion" of a specific machine. For buckets greater
3-cu-yd capacity. ratings are on
1
/4
tll;111
btH.:kL~ts
m11s1
be conec,ted to average bucket payload based on the charac,te1istics of the mate1ial being handled.
Manufacturers usually suggest factors, commonly named "fill factors," for making such corrections. Fill factors are percentages which, when multiplied by a rated heaped capacity. adjust tlie
volume by accounting for how the specific material will load into the bucket
lt is always best to conduct field tests based on the weight of rnate1ial per bucket lucid
Material
Fill factor
(%)
100-110
Rock-earth mixture
105-115
Rock-poorly blasted
85-100
Rock-well blasted
100-110
85-100
The basic pa11s of a front shovel include the mounting, cab, boom, stick. and bucket.
With a shovel in the con-ect position, near the face of the mate1ial to be excavated, the
bucket is lowered to the floor of the pit, with the teeth pointing into the face. A crowding force
is applied by hydraulic pressure to the stick cylinder at the same time the bucket cylinder rotall's
the bucket through the face. lf the height of the face is just right, conside1ing the type of material
and the size of the bucket, the bucket will be filled when it reaches the top of the face If
the height of the face, refoned to as the "height of cut", is too shallow. it will not be possible
to fill the bucket completely without making a second pass at the face If the height of the face
is grea1er than required to fill the bucket, it will be 11ecessa1y to reduce the depth of' penet 1at in11
of the bucket into the fuce if the full fuce is to be excavated in one pass or to stai1 the excavation
above the floor of the pit. Material left near the floor of the pit will be excavated after the
upper po1tion of the face is removed.
FIGURE 3.12
Basic parts of a hydraulic front shovel
:ii.15) Selecting a Front Shovel
ln selecting a shovel, the user should consider the probable co11centnitio11 of Hork
10
be perfo1med. Two fundamental factors which should be taken into account are the cost per
cubic yard of mate1ial excavated and the job conditions under which the shovel will operate
In estimating the cost per cubic yard, one should consider the following factors
I.
The size of the job. as a larger job may justify the hjgher cost of a lart>:e shm el
2.
The cost of transpo1ting the machine (a large shovel will involve more cost than a s111all
one).
3.
The combined cost of drilling, blasting, and excavating. For a large shovel these co-;ts
may be less than for a small shovel as a large machine will handle more massive rocks
than a smalJ one. Large shovels may permit savings in d1illing and blasting costs.
The direct w1it cost per cubic yard for the excavation (less for a large shovel than J()r
a small one).
The following job conditions should be considered in selecting the size of a shovel:
I.
If the mate1ial to be excavated is hard and tough, the bucket of the large shovel.
which exe1ts higher digging pressures, will handle the material more easily
If blasted rock is to be excavated, the large-size bucket will handle bigger indi\ idual
pieces.
3.
lf the time allotted for the completion of a project requires a high hourly production.
either multiple small shovels or a large shovel must be used.
57
4.
n1e size of available hauling w1its should be considered in select in,?- the size of' a slim d.
If small hauling units must be used, the size of the shovel should be small_ whereas if
large hauling units are available, a large shovel should be used.
Manufacrw-ers' specifications should always be consulted for the exact values
or nrncliine
clearances. The maximum bucket dumping height is especially irnponant when the shovel is loading
haul units.
I.
Load bucket
2.
3.
Dump load
4.
Return swing
lt should be noted that a shovel does not travel during the digging and loading cycle
Travel is li.rnjted to moving into or along the face as the excavation prngresses
Typical cycle element times under average conditions, for 3-to "- cu yd SI/.e
sli1)\
el-;.
will be:
I.
Load bucket
7-9 sec
2.
4-6 sec
Dump load
2-4 sec
Return swing
4-5 sec
4.
1.
Class of material
2.
Height of cut
3.
Angle of swing
4.
5.
Operator skill
6.
011
order to obtain the bank-measure volume of a bucket of material, the average loose \ olu111e
should be divided by I plus the swell, expressed as a fraction. For example, if a 2-cu-yd bucket,
excavating mate1ial whose swell is 25%, vvill handle an average loose volume of 2.25 cu yd,
the bank-measure volume will be 2.25/I .25
per min, which includes no allowance for lost time, the output will be 2.5 , 1.8 = 4.5 bey
per min, or 270 bey per hour. TI1is is an ideal production, which will seldom_ if e\'er. be
ex'}Je1ienced on a project. Ideal production is based on digging at optimum height with a LJ0
swing and no delays.
58
The actual production of a shovel vviJI be significantly lower than the ideal because
operators do not operate continuously at peak efficiency, nor do they operate a full ()0 minutes
every hour. Machines require minor repairs, haul units tend to bunch together and other 111inor
delays always affect production.
Ideal production assumes no intenuption of the loading cycle. Transp01tation Research
Board (TRB) studies have sh0Vv11 that actual production times for slim els used in higll\\ ay
construction excavation operations are 50- 75% of the available \>..orki11g tillle Tlie1efo1 e. p1 oduction efficiency is only 30-45 min per hour. The factors causing tlii:-. loss of productio11
I.
2.
3.
4.
Haul-unit exchange
5.
6..
Operator breaks
;i1
In the field the machine vvill require time to move into the digging. position as the !i1ce
is advanced. One study found this type of motion to be required after about 20 bucket lnads.
and on the average it required 36 sec. When handling shot rock. carefltlly evaluate the amount
of oversize mate1ial to be moved .. A machine vvith a bucket whose bite width and pocket arc
satisfactory for the average size pieces may spend too much time handling individual O\ersize
pieces A larger bucket_ or a larger machine, or changing the blasting pattern should be
con-
If the height of the face from which a shovel is excavating. lll<lle1ial is too shallu\\. it
will be difficult or impossible to fill the bucket in one pass up the foce. rhe operator will l1ave
a choice of making more than one pass to fill the bucket, which will increase the time per cycle.
or with each cycle be may cany a pa11ly filled bucket to the hauling unit. In either case the
effect will be to reduce the production of the shovel.
If the height of the face is greater than the minimum required tu Jill the bucket with
favorable crowding and hoisting forces, the operator may do one of three things. He may reduce
the depth of the bucket penetration into the face in order to fill the bucket in one full stroke
ll1is vviJl increase the time for a cycle. He may start digging above the base of the face_ and
then remove the lower po1tion of the face later. Or he may mn the bucket up the full height
of the face and let the excess eaith spill down to the bottom of the face, to be picked up
later. ll1e choice of any one of the procedures will result in lost time, based on the time rcqttiiccl
to fill the bucket when it is digging at optimum height.
59
n1e PCSA bas published findings on the optimum height of cut based on data from studies
of cable-operated shovels (see Table 3-8). In the table the percent of optimum height of' cut
is obtained by dividing the actual height of cut by the optimum height for the given mate1ial and
bucket then multiplying the result by !00. Thus, if the actual height of cut is 6 ft and the opti1nurn
height is 10 ft. the percent of optimum height of cut is ( 6/10) I 00 --, 60%.
TABLE 3-8
Factors for height of cut and angle of swing effett on shovel produrtion
45
60
Angle of swing
(degrees)
75
90
I 20
0 CJ3
0.89
0.85
0.80
0 72
0.96
0.91
0.81
1.04
0.98
0.73
- - - - - 0.86
077
Percent of
optimum depth
40
--
60
- - - - - - - -
80
--
1.10
1.03
- - - - -- 1.22
1.12
- -
- -
--------
180
150
0 5q
0.65
- -
0.66
- - -
06lJ
100
1.26
1.16
1.07
l.00
088
07CJ
071
120
I 20
l 11
1.03
0 q7
() 8(l
0 77
() 7()
l.+0
I 12
10-i
0 97
0.91
081
073
160
l.03
0 96
0.90
0.85
0.75
0 67
Much of the PCSA work concerned smaller size machines. less than 3 cu vd. In 11ll1st
cases those small shovels have been replaced by other t)1)eS of e....:ca\ at ors. track or rubber
tire loaders Hut some general guidelines can still be g.kaned from the siudies.
The optimum height of cut ranges from 30 to
50~o
the lower percentage being representative of easy to load mate1ials. such as loam. sand, or grm el.
Hard to load materials, sticky clay or blasted rock, necessitate a greater optimum height, iu the
range of 50% of the maximum digging height value. Common ea1th would require-slightly less
than 40% of the maximum digging height.
(3
rue angle of swing of a shovel is the horizontal angle, expressed in degrees, between
the position of the bucket when it is excavating and the position when it is discharging the load.
ll1e total time in a cycle includes digging, swing to the dumping position. dumping, and returning
to the digging position. lf the angle of swing is increased, the time for a cycle will be increased.
whereas if the angle of swing is decreased, the time for cycle will be decreased. The ideal
production of a shovel is based on operating at a 90 swing and the optimum height of cut.
The efiect of the angle of swing on the production of a shovel is illustrated in Table 3.8. The
ideal production should be multiplied by the proper conversion factor in order to conect the
production for any given height and swing angle. For example, if a shovel which is digging at
optimum depth has the angle of swing reduced from 90 to 60, the production will be increased
by 16%.
60
Ex:11nple 3.5 : A 5-cu yd shovel having a maximum digging height of 34 ft is being u~ed to
load poorly blasted rock. The face being worked is 12 ft high and the haul units can be
positioned so that the swing angle is only 60. What is the adjusted ideal production if the ideal
cycle time is 2 I sec.
Optimum height for this machine and material (poorly blasted rock):
0.50
34 ft (max. height)= 17 ft
5 cu yd
0.9
77 l Icy/hr
12 ft = 0.71
17 ft
Although the infonnation given in Tables 3. 7 and 3.8 is based on extensive field studies.
the reader is cautioned against using it too literally without adjusting for conditions which will
probably exist on a pa11icular project.
( 3. N) Production
Efficiency Factor
As eve1y constructor knows, no two projects are alike. ll1ere are ceitain conditions at
every job over which the constrnctor has no control. These conditions must be considered
111
61
I.
Maintenance of equipment
2.
3.
Project housekeeping
4.
Haul-road condition
5.
6.
7.
which to adjust peak production. To select the precisely coITect efficiency factor eve1y time is
very difficult. Expe1ience and good judgment are essential to selecting the approp1iate efficiency
factor. Sometimes it will be found that actual job production is below the estimated production:
in such cases the selected factor should be reconsidered to guide titture estimating, but the.: job
conditions should also be carefully examined.
Example 3.6 : A 3 cu yd shoveL having a maximum digging height of 30 ft, will be used on
a highway project to excavate well-blasted rock. The average face height is expected
22 ft. Most of the cut will require a 140 swing of the shovel in order
10
10
he.:
Swing loaded
4 sec
Dump
Swing empty
4 sec
21 sec or ,35
lTI1ll
Ideal production:
3 cu yd x l 0
30 ft
= 5 I 4 lcy/hr
15 ft
= 14 7%
Height ClUd swing factor: from table 3.8, for 147% and 140, by interpolation, 0.73
Adjusted production:
514 Icy x 0. 73
Well-blasted rock
375 Icy/hr
16
375 Icy/hr
= 60%
=
234 bey/hr
lf the TRB information is used, the efficiency would be 30-45 working minutes per hour
234 bey/Jn ' 45 = 175 bey/hr
60
The best estimating method is to develop specific histo1ical data by type of machine and
project factors. But infonnation such as the TRB study, which presents data from thousands of
shovel cycles, provides a good bench mark for selecting an efficiency factor.
FIGURE 3.13
Crawler-mounted hydraulic hoe loading a truck.
FIGURE 3.14
Crawler-mounted hydraulic hoe handling 72-in reinforced concrete pipe
63
(3.?0)Hoes
Hoes are used p1inmily to excavate below the irntural sudace of the grouud
011
\\hicl1
the machine rests. A hoe is sometimes refened to by other names. such as backhoe or hack
shovel. Hoes are adapted to excavating trenches and pits for basements, and the smaller machines
can handle general grading work. Because of their positive control, they are supe1ior to draglines in operating on close--range work and loading into haul units (see Fig 3.13). In stonn drain
and utility work the hoe can pe1fonn the trench excavation and handle the pipe, eliminating. a
second machine.
TABLE 3.9
Representative dimensions, loading clearance, and lifting capacity for hydraulic crawler hoes
I
I
Sit<
buC~\'I
(CU ~di
'
I
I!
\laximum
reach
'II
:--1irh
lt'll;'.ill
lf!J
Lifting capacity
15 fl
----
lnel
(fl I
depth
\la\imum
loading
height
(ft)
(ft)
ground
(o
\la\imum
digging
Shor! Mick
Fron I
(lb)
Side
(lb)
Long stirk
Front
Side
(lb)
(lh)
)-
19-22
12-15
14-16
2.900
2,600
2.900
2,600
'
11
I/
U>-1 S
17-19
7. JOO
5.:lOO
7.200
.~. \()()
I~
f,..
- .. J.j
2427
26-33
27-35
29-38
J~-27
19-24
21.400
14.500
21.600
~~
7-111
32-40
20-29
20-26
32,600
21,400
31.500
10-1 I
38-42
25-30
24-26
S I 2
.\6- .J
23-27
21-22
32.900'
:n.200
24.600'
21.900'
30.700'
32.400'
26.200
>!
44
29
47.900'
33.500'
-111--1(,
~h- ~2
27
:5-2()
34.100
27.)(){I'
.11.Wll
27.li(J()
'
Liftin~
~- I'
I'
II
'
,,
1..ip;u..11~
2r
'Lif11n~t..Jp.11.11;.
11
~.;'.1
1:
16-2.<
17-25
12.800
9.000
9.300
'J.:'00
17-21
18-23
17.100
10.100
17.700
I I. I00
14.200
24.400
22.000'
64
FIGURE 3.15
Basic parts and operating ranges of a hydraulic hoe. A, dumping height B, diggrng reach~ C, max. digging
depth.
1.i z1.;_i.:r
I
l I I:'\ I Ji' I~
.. ~
FIGURE 3.16
Arrangement of a hoe's hydraulic cylinders to develop digging forces.
65
CaJ1
tip radius to .the resistance of the material, one can take full advantage of the hoe's potential.
For easily excavated mate1ials wide buckets should be utilized. When excavating rocky mate1ial
or blasted rock, a nanow bucket with a short tip radius is best. In utility work the width of
the required trench may be the critical consideration. Fill factors hydraulic hoe buckets are
presented in Table 3.10.
Hoe Operating Efficiency and Production
The same elements which affect shovel production are applicable to hoe excavation
operations. 111e optimum depth of cut will depend on the type of material being excavated and
bucket selection. As a rule, the optimum depth of cut for a hoe is usually in the range of 3060% of the machine's maximum digging depth. Table 3.11 presents cycle times for hydraulic track
hoes based on bucket size and average conditions.
Example 3.7 : A 311 cu yd crawler hoe is being considered for use on a project to excavate
very hard clay from a bonow pit. 111e clay will be loaded into trucks having a loading height
of 9 ft 9 in. Soil-b01ing information indicates that below 8 ft the mate1ial changes to an unacceptable silt material. What is the estimated production of the hoe in cubic yards bank measure,
if the efficiency factor is equal to a 50 min hour ?
Fill factor: From table 3. l 0, hard clay 80-90%, use 80%
x 3Y2 cu
yd
0.8
454 Icy/hr
From table I. I.
50 nun hr
60 mm hr
= 280 bey/hr
Check : optimum depth, 30-60% maximum digging depth from Table 3. 9, 23-27 ft
8/23
8/27
30%
30% okay
< 21 okay
66
Table 3.10
Fill factors for hydraulic hoe buckets
Fill factor
Mate1ial
(%)
100-110
95-110
40-50
Rock-well blasted
60-75
80-90
Table 3.11
Excavation cycle times for hydraulic crawler hoes under average conditions
Bucket
size
(cu yd)
I
<
J
I 12
2 21 2
Load
bucket
(sec)
loaded
(sec)
Dump
bucket
(sec)
Swing
Swing
empty
(sec)
,.,
.)
,.,
Total
cycle
(sec)
14
.)
15
.)
17
,.,
.)
20
31::
22
22
.:;
24
Hoe cycle times are usually of greater duration than those for shovels, because, alter
making the cut, the hoe bucket must be raised above the g:roWld level in order to load a haul
unit or to get above a spoil pile. lf in Example 3.7 the trncks can be spotted
011
the floor of
the pit the bucket will be above the truck when the cut is completed. Then it would not be
necessary to raise the bucket any higher before swinging and dumping. 1l1e spotting of haul units
below the level of the hoe will increase production.
Factors to be carefully considered in selecting a hoe and planning its utilization are:
I
2.
3.
4.
5.
6.
7.
Hoisting capability
In trenching operations the prirruuy concern is to match the hoe's ability to excavate linear
feet of trench per unit of time with the pipe laying production. Usually, the volume of mate1ial
moved is not the question.
67
011
either
crawler tracks or wheels. The unit is designed as a versatile machine for both excavation and
cation.
FIGURE 3.17
Grad;:dl shaping the side slopes of a ditch.
The bucket of a gradall can be rotated (that is, the gradall's arm can rotate) 90 or
more, allowing it to be effective in reaching restricted working areas and where special shaping
of slopes is required. Note its use in Fig 3.17. The three-pait telescoping boom can be hydraulically extended or retracted to vary digging or shaping reach. It can exert breakout force
both above and below ground level
When used in a hope application to excavate below the mnning gear, its production rate
\Viii be less than a hoe equipped with an equal size bucket. Similarly, it can perfonn draglinetype tasks, but it does have limited reach compared to a dragline. Because the macillne pro-
vides the operator with positive hydraulic control of the bucket it can be used as a finishing
tool frn fine-grading slopes and confined areas, tasks which would normally be motor grader
work if there were no space constraints.
3.?3) Loaders
General Information
Loaders are used e\.1:ensively in construction work to handle and transport bulk rnate1ial
such as ea1th and rock, to load trucks, to excavate earth, and to charge aggregate bins at asphalt
and concrete plants.
68
FIGl;RE 3.18
Tr::ick-tvpe loader
FIGURE 3.19
Wheel-tractor loader