Why Haul Trucks Are Losing Ground to Conveyors in Aggregate Operations

Despite their limitations, haul trucks continue to be a staple on many job sites. However, more cost-conscious and efficiency-focused operators are switching to conveyors and stackers for stockpiling aggregate material. In today’s world, where environmental impact matters, product specifications are paramount, and optimized production is essential, conveyors are proving to be a practical and increasingly popular alternative to haul trucks.

The main advantage of haul trucks is their flexibility, which essentially means they’re easier to point in a different direction. Groundline conveyors, on the other hand, are fixed to the ground, which makes them less mobile. However, when it comes to cost, efficiency, and environmental impact, the drawbacks of haul trucks far outweigh their benefits.

Let’s take a closer look at 5 Reasons Why Haul Trucks Don’t Make the Grade in modern aggregate operations:

1. They Don’t Handle Grades Well

Haul trucks are designed to operate on level ground, with a maximum incline of about 6 degrees. Once hills are involved, safety and operating costs become major concerns. On steep terrain, trucks are more prone to accidents and require additional safety precautions, driving up operational costs.

2. Increased Downtime for Maintenance and Service

Haul trucks require frequent maintenance and downtime. Specialized technicians with specific tools and parts are often needed for repairs, which means waiting for both the service provider and any specialized parts – particularly difficult-to-find items like certain tire sizes. This extended downtime affects productivity and can be costly.

3. Higher Operating Costs

Haul trucks are labour-intensive and fuel-hungry. Each truck needs an operator, which adds labour costs, including wages, overtime, workers’ compensation, training, and other considerations. In addition to fuel costs, haul trucks also incur higher maintenance expenses. Compared to conveyors, where fewer operators and less fuel are required, haul trucks are a costly choice.

4. Environmental Concerns

Haul trucks contribute to environmental issues through fuel consumption, oil leaks, exhaust emissions, and potential groundwater contamination. Regulations around emissions and environmental impact are only becoming stricter, especially as more operations take place near residential areas. Choosing conveyors can significantly reduce an operation’s environmental footprint.

As regulations tighten and operational costs rise, more operators are recognizing the benefits of conveyors and stackers for material handling. While haul trucks still have their place, especially for short-term and flexible applications, conveyors are increasingly becoming the preferred choice for efficient, cost-effective, and environmentally conscious material transport.