How to Plan Spoil Removal and Truck Loads
Quick answer
Convert the measured excavation from bank volume to loose volume, then check both truck volume and payload. The usable volume per trip is the smaller of bin capacity and payload divided by loose material density. Divide the loose spoil by that usable volume and round up for whole loads.
Separate what is dug from what is carted
Start with the excavation takeoff, then subtract material that will genuinely stay on the job. Keep topsoil, reusable fill and other material streams separate if their destinations or handling differ. Bulking changes the space occupied after digging; it does not create extra material mass.
Formulas
Loose spoil volume = bank volume × (1 + bulking percentage ÷ 100)
Check payload as well as bin size
Use the payload available for the actual vehicle, route and operating conditions, confirmed with the carrier. A volume estimate does not authorise a loading weight. Wet or dense material can reach the payload limit before the bin looks full.
Formulas
Payload-limited volume = available payload ÷ loose density
Usable volume per load = smaller of bin capacity and payload-limited volume
Loads = loose spoil volume ÷ usable volume per load, rounded up
Worked example: payload limits the load
Worked example
Measured spoil: 100 bank m³. Illustrative bulking allowance: 20%.
Loose volume = 100 × 1.2 = 120 m³.
Bin capacity 10 m³; assumed available payload 12 tonnes; loose density 1.5 t/m³.
Payload-limited volume = 12 ÷ 1.5 = 8 m³.
Use 8 m³ per trip: 120 ÷ 8 = 15 loads.
Check the truck cycle against the programme
Add loading, travel out, unloading, return travel and expected queue time. Use measured trips where available. Truck count and daily output depend on both the loading operation and the full cycle, so a faster digger alone may not improve cartage.
- —Confirm the receiving facility accepts the material before starting.
- —Check access, turnaround space and delivery windows with the carrier.
- —Plan for interruptions and record assumptions rather than treating every paid hour as productive.
- —Compare actual load counts and docket weights with the estimate during the job.
Build cartage assumptions into your earthworks estimate, alongside excavation, plant and disposal costs.
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