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Truck Cycle Time and Fleet Calculator

How long does one truck take to load, haul, dump, and return? How many trucks keep the excavator busy all day? Enter your haul distance, speeds, and loading time. The calculator shows cycle time, optimal fleet size, production rate, and excavator utilization in real time. Built for excavation foremen matching trucks to iron, not logistics software.

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The math, shown transparently

No black box. Here is exactly what the calculator computes on every input change. Every formula matches the Caterpillar Performance Handbook fleet matching method.

// Timing. All values in minutes.

haul_time = (distance / loaded_speed) x 60

return_time = (distance / empty_speed) x 60

cycle_time = load + haul + dump + return + spot

// Fleet sizing.

trucks_needed = ceil(cycle_time / load_time)

trucks_active = min(available, needed)

// Production.

loads_per_hour_per_truck = 60 / cycle_time

total_loads_per_hour = trucks_active x loads_per_hour

production_yd3_per_hour = total_loads x capacity

// Utilization and wait time.

utilization = (trucks_active / trucks_needed) x 100

excavator_wait = cycle_time - load_time x available (if understaffed)

truck_wait = (load_time x available - cycle_time) / available (if overstaffed)

Worked example

A 5-mile haul at 30 mph loaded / 40 mph empty, 5-minute loading, 3-minute dump, 1-minute spot, with 12 yd³ tandems:

haul_time = (5 / 30) x 60 = 10.0 min

return_time = (5 / 40) x 60 = 7.5 min

cycle_time = 5 + 10 + 3 + 7.5 + 1 = 26.5 min

trucks_needed = ceil(26.5 / 5) = 6 trucks

loads/hr/truck = 60 / 26.5 = 2.26

total loads/hr = 6 x 2.26 = 13.6

production = 13.6 x 12 = 163 yd³/hr

Every formula in the calculator is covered by a unit test that locks the expected output. The math cannot drift without breaking the build.

Understanding fleet matching

Fleet matching is the art of putting the right number of trucks in front of an excavator so that neither the iron nor the trucks sit idle. Three scenarios:

  • Understaffed (too few trucks). The excavator finishes loading a truck, swings back, and waits. That idle time is pure waste on your most expensive asset. Production drops in direct proportion to the shortfall.
  • Matched (optimal). A truck pulls up just as the excavator finishes the previous load. Zero wait on either side. This is the theoretical optimum. In practice, you will always have some variability.
  • Overstaffed (too many trucks). Trucks queue up waiting to be loaded. The excavator is fully utilized, but you are paying for trucks that are not moving dirt. Each extra truck adds cost without adding production.

The calculator shows all three scenarios and highlights which one applies to your inputs. It also shows the exact wait time per cycle so you can see how much idle time you are paying for.

Speed presets explained

The three speed presets cover the most common haul scenarios for excavation work. Speeds are conservative averages that account for acceleration, deceleration, turns, and stops.

  • Site roads (25/35 mph): Gravel or dirt roads on site. Slow going loaded, a bit faster empty. Typical for on-site spoil relocation.
  • Local highway (40/50 mph): Town roads and short highway stretches. Most common for hauling to a nearby dump or fill site.
  • Long haul (50/60 mph): Highway to a distant dump or borrow pit. The loaded speed is limited by weight and grade.

Frequently asked questions

How do I calculate truck cycle time?

Truck cycle time is the total time for one truck to complete a full loop: loading at the excavator, hauling to the dump site, dumping, returning empty, and spotting (positioning for the next load). The formula is cycle = load time + (distance / loaded speed) x 60 + dump time + (distance / empty speed) x 60 + spot time. All times are in minutes. The loaded speed is slower than the empty speed because the truck is heavier.

How many trucks do I need to keep the excavator busy?

Divide the total cycle time by the loading time. If a cycle takes 26.5 minutes and loading takes 5 minutes, you need ceil(26.5 / 5) = 6 trucks. With fewer trucks the excavator sits idle between loads. With more trucks, the extra trucks queue up waiting to be loaded. The sweet spot is when the last truck arrives just as the excavator finishes loading the previous one.

What is excavator utilization?

Excavator utilization is the percentage of time the excavator is actively loading trucks versus sitting idle waiting for the next truck. At 100% utilization the excavator never waits. If you have 3 trucks but need 6, utilization is 50% and the excavator is idle half the time. Low utilization means your most expensive piece of equipment is not earning its keep.

Should I add one more truck?

It depends on the marginal cost versus marginal production. The calculator compares your current fleet to current-plus-one. If adding a truck costs $85/hr but produces an extra 27 yd3/hr, the marginal cost is about $3.15 per extra cubic yard. If your cost per cubic yard is already $5, the extra truck pays for itself. If you are already at or above the optimal truck count, adding another produces zero extra output because the excavator is the bottleneck.

Why is the empty return speed higher than the loaded speed?

An empty dump truck weighs significantly less than a loaded one. It accelerates faster, climbs grades more easily, and can safely travel at higher speeds. On site roads the difference is about 10 mph (25 loaded vs 35 empty). On highways the gap narrows but still exists. The calculator uses separate speeds for each direction because using a single average speed underestimates cycle time.

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