HEAVY EQUIPMENT
MANAGEMENT
Minimizing total cost of the Project
Optimum Fleet Selection
Optimum Availability
Optimum Operations
(Productivity & Efficiency)
SELECTION OF EQUIPMENT
• Type of Project (Details of the Project)
• Project Completion Time
• Work Schedule
• Worksite Conditions
• Materials Handled
SELECTION OF EQUIPMENT
• 1. Application
a. Selection according to type of operation
b. Selection according to Haul Distance
c. Selection according to the type of Soil
(Factors for Best Equipment Selection)
LOWEST TOTAL COST
• Highest Production . . . Cost per hour
• Lowest Operating Cost . . .
Maintenance,
FOL, Spare Parts
• Lowest Investment Cost . . . Low
Acquisition, transport, erection
STANDARDIZATION
• Uniformity of units for easier familiarity
in operating, maintenance, repair
procedure and parts
FOLLOW UP/After Sales
• Solutions to encountered problems
• After sales support of Dealer/Suppliers
Type of Operation & Suitable
Machine
• A. Clearing
– Bulldozer
– Rake dozer
– Hydraulic excavator
– Dozer Shovel
Note: Always consider whether the machines
selected for the main operation can be
used for other work as well
B. Excavating
• Bulldozer
• Hydraulic ripper
• Hydraulic excavator
• Dozer shovel
Note: If the same machine is used for the main work and
other work, check how much production will change and
whether this difference can be offset by the savings in
indirect project costs cost of mobilization and duration of
its operation.
C. Loading
• Wheel Loader
• Hydraulic Excavator
• Dozer Shovel
• Clamshell
• Dragline
• Note: In small scale projects, it is better to use the same machine from
the point of view of ease in arranging operations and processes.
D. Excavating and Loading
• Hydraulic Excavator
• Clamshell
• Dragline
• Dozer Shovel
• Wheel Loader
• Note: Machines are selected which can cover as far as possible all the
processes from the preparation stage to the completion of the Project
E. Excavating and Hauling
• Bulldozer
• Dozer shovel
• Wheel Loader
• Towed Scraper
• Motor Scraper
• Note: When using several machines, its an advantage to keep to the
same model because it simplifies parts control both for the wear parts
and parts supply for breakdowns.
F. Hauling
• Dozer Shovel
• Wheel Loader
• Dump Truck
• Belt Conveyor
• Note: In this situation, the best machine depends on the
haul distance, terrain and arrangement of the processes.
G. Spreading
• Bulldozer
• Motorgrader
• Note: Selection will depends on the materials, speed of
spreading and finishes needed on the processes.
H. Compacting
• Bulldozer
• Sheep Foot Roller
• Pneumatic Roller
• Roller Compactor
• Tamping Rammer
• Plate Compactor
I. Leveling
• Bulldozer
• Motorgrader
• Wheel Dozer
J. Ditching
• Hydraulic Excavator
• Trencher
K. Breaking
• Bulldozer with ripper
• Hydraulic ripper
• Backhoe with breaker attachment
• Compressor with breaker
• Crawler drill combined with dynamite
blasting
B. Selection according to Haul
Distance & Max. Grade
Machine Haul Distance Max. Grade
(Meters) % Slope
Bulldozer 20 - 60 35 - 40 %
Wheel Loader 20 - 120 -
Towed Scraper 90 - 490 15 - 25 %
Motor Scraper 210 - 2000 5-8%
Dump Truck 90 - indefinite 10 - 15 %
C. Selection by Trafficability
(Type of Soil)
Machine Cone Index (kg/cm2)
Dump Truck 15 must be over
Wheel Loader 12 minimum
Dozer Shovel 7 minimum
Motor Scraper 4 (twin engine), 9 (single engine)
Towed Scraper 4 min
Hydraulic Excavator 4 min
Bulldozer 4 min
Crawler Dump 1.8 min
Swamp Bulldozer 0.7 min
Man 2.0
Heavy Equipment
• PRODUCTIVITY and EFFICIENCY
• Productivity Calculation
• Gang Balancing
• Equipment Matching
Calculation of Production
• 1st Calculate the theoretical value
• 2nd Adjust theoretical value according
to figures obtained from past experience
in similar situations
• 3rd from these figures you can adjust
the working efficiency to obtain realistic
data that is neither over optimistic nor
wasteful
General Method in
Calculating Production
• Operating Capacity is usually expressed in
Production per hour
• The Basic Formula:
• Q = q x N x E = q x 60/Cm x E ; where
• Q - Hourly production (M3/Hr; m2/Hr.)
• q - Production per cycle (M3, M2)
• N = No. of cycle per hour; N=60/Cm
• E = Job efficiency
• Cm = Cycle time
Earth Volume Conversion
Factors
• For Ordinary Soil
• Unexcavated volume of 1000 m3
• Use a factor of 1.25 to convert to
• Loose Volume = 1,250 m3
• Use a factor of 0.72 to convert to
• Compacted volume = 900 m3
JOB EFFICIENCY - E
Operating | Maintenance of Machine
Condition | Excellent Good Normal Rather Poor Poor
-----------------------------------------------------------------------
Excellent | 0.83 0.81 0.76 0.70 0.63
Good | 0.78 0.75 0.71 0.65 0.60
Normal | 0.72 0.69 0.65 0.60 0.54
Rather Poor | 0.63 0.61 0.57 0.52 0.45
Poor | 0.52 0.50 0.47 0.42 0.32
Bucket Factor - K
Loading Conditions Factor
Easy Loading Loading materials from stockpiles & can be heaped 1.0 to 0.80
in the bucket. Sand, sandy soil or sticky soil with
moderate moisture content
Average Loading Loading from loose stockpiles which is more difficult 0.8 to 0.6
to penetrate but which will make nearly fully heaped
bucket. Dry sand, sandy soil, clayey soil, unscreened
gravel.
Rather Difficult Loading of finely crushed stones or rocks, hard clay, 0.6 to 0.50
Loading gravely sand, sand soil, clay with high moisture
content, which had been stockpile by an excavator.
Difficult to fill the bucket at its heaped capacity
Difficult Loading Bulky, irregular shaped or rugged rocks with spaces 0.5 to 0.40
between themselves, blasted rocks, boulders etc
which cannot be scooped up into the bucket.
Example of Wheel Loader Productivity Calculation:
A Komatsu WA500 Wheel Loader with a 4.0m3 bucket is working, loading
a Dump Truck with following conditions:
WORKING CONDITIONS:
Operating method: Cross Loading
Haul distance: 10 mtrs
Type of Soil: Sandy Clay
Job efficiency: 83%
Bucket Factor: 0.90 (Easy Loading)
Travel Speed: F1 (0-7.3 kph); R1 (0-7.8 kph)
SOLUTIONS: Wheel Loader Productivity
Production per cycle: q = 4.0 m3 (Heaped) x 0.90
q = 3.6 m3
Cycle Time: Forward Speed = 7.3 x 0.8 = 5.84 kph or (97.3 M/min)
Reverse Speed = 7.8 x 0.8 = 6.24 kph or (104 M/min)
Fixed Time = 0.3
Cycle Time, Cm = 10 + 10 + 0.3 = 0.50 minutes
97.3 104
Job Efficiency = 0.83
Productivity considering the Earth volume conversion factor for Sandy Soil:
Loose Soil f = 1.00
Unexcavated Soil f = 0.80
Continuation of Wheel Loader Productivity
Productivity with Loose Soil:
Q = 3.6 x 60 x 0.83 x x 1.00
0.50
= 359 cu. M/Hr.
Productivity with unexcavated soil:
Q = 3.6 x 60 x 0.83 x 0.80
0.50
= 287 cu. M/Hr.
Estimating the number of Dump Trucks Required
The number of Dump Trucks needed in combination with a
Loader working at its maximum job efficiency can be
computed as follows:
M = Cycle time of Dump Truck = Cmt
Loading time n.Cms
where; n = number of cycles required for a Loader to fill a Dump
Truck
Cms = Cycle time of Loader (minutes)
Cmt = Cycle time of Dump Truck (minutes)
Estimating Production of Dump Trucks;
The total hourly Production P of several Dump Trucks where they
are doing the same job is computed as follows;
P = C x 60 x Et x M
Cmt
where P: Hourly Production (m3/hr)
C: Production per cycle; C = n x q1 x K
n: Number of cycles to fill a Dump Truck
q1: Bucket Capacity (heaped, m3)
K: Bucket Factor
Et: Job Efficiency of Dump Truck
Cmt: Cycle Time of Dump Truck (min)
M: Number of Dump Trucks in operation
Combined used of Dump Trucks and Loader;
When Dump Trucks and Loaders are used in combination, it
is most desirable that the operating capacity of the Dump
Trucks be equal to that of the Loader. This can be
estimated as follows:
(Dump Truck) (Loader)
c x 60 x Et x M = 60 x q1 x K x Es
Cmt Cms
where: Cms = Cycle Time of a Loader (min.)
Es = Job efficiency of the Loader
q1 = Bucket capacity (heaped, m3)
K = Bucket Factor
Bulldozer Productivity;
In estimating the Hourly Production of the Bulldozer, the formula is
as follows;
Q = q x 60 x E (m3/Hour)
Cm
Where; q = Production per cycle (m3)
Cm = Cycle time (minutes)
E = Job Efficiency
For Dozing Operation; blade capacity is computed as follows;
q = L x H2 x a
Where; L = Blade width
H = Blade Height
a = Blade Factor
BLADE FACTOR
Level of Dozing Operation Blade Factor
Full blade of soil can be dozed as | 1.1 - 0.9
Easy Dozing completely dozed soil, Low water
content, stockpile materials
Soil is loose but impossible to doze
Average Dozing full blade. Soil with gravel, sand, fine 0.9 - 0.7
crushed rock
Rather High water content and sticky clay,
Difficult Dozing sand with cobbles, hard dry clay and 0.7 - 0.6
natural ground
Difficult Blasted rocks, or large pieces of 0.6 - 0.4
Dozing rocks or boulders
Hourly Productivity of Bulldozer
What is the Hourly Productivity of a D155A-1 Straight Blade
when dozing with the following conditions:
Working conditions:
Earth Volume Loose Soil
Blade Factor = 1.0
Job Efficiency = 0.75
Haul Distance = 40 meters
Type of Soil Sandy Clay (good operating condition & maintenance)
F1 = 0 - 3.7 kph
R2 = 0 - 8.2 kph
Conversion factor; f (loose) = 1.0; unexcavated = 0.80
Bulldozer Productivity;
Production per cycle;
q = H2 x L x Blade Factor
= (1.59)2 x 4.13 x 0.80
= 8.5 cu. Mtrs
Cycle Time:
Forward Speed; F = 3.7 x 0.75 = 2.8 kph (46.7 M/min)
Reverse Speed; R = 8.2 x 0.85 = 7.0 kph (116.7 M/min)
Gear Shifting time; Z = 0.05 mins.
Cycle Time; Cm = 40 + 40 + 0.05
46.7 116.7
= 1.25 minutes
Bulldozer Productivity;
Computed Productivity;
Productivity with Loose Earth;
Q = 8.5 x 60 x 0.75 x 1.00
1.26
= 304 m3 per hour
Productivity with unexcavated earth;
Q = 8.5 x 60 x 0.75 x 0.80
1.26
= 243 m3 per hour
Gang Balancing Problem
• There was a generated stockpile of soil of about 17,300 cu. Meters
by two units D85A-21 Bulldozer after clearing a 32 Hectares land.
This piece of land is intended to be converted into a subdivision.
The company leased a WA300 Wheel Loader and 2 units Dump
truck with the following capacity and rental rate.
• WA300 Loader - 3.0 cu. M Capacity @P1,200 per hour
• 10 Wheeler Dump Truck with 15.0 cu. M capacity. @P950 per hour
• It had been observed that the Loader needs 10.0 minutes to fill one
Dump Truck
• The Dump Trucks disposes the soil in 30 minutes cycle time.
Assuming the roads are kept in good condition
• The company wants to finished the hauling in one months time at
48 hours a week working conditions.
• Analyze the present system and suggest alternatives solution.
ANALYSIS OF THE PRESENT CONDITION
• The capacity of the Loading Equipment is 90.0 cu meters per hour
• At this capacity the Loader can and capable to finish the job in less than a
month
• The capacity of the Dump Trucks is 60 cu meters per hour and it seems not
capable to finish the job on time
• As a supervisor, how can you improve or possibly speed up the hauling to
meet the condition by the company and how much savings or additional
cost you need as compared to the first condition.
• HINT: Balance the capacity of the Loading equipment and the hauling
equipment
COSTING FOR THE PRESENT METHOD
The Dump Trucks can haul 60 cu meter per hour and with it the capability of
the Loader will be dependent on the hauling equipment.
An experienced Earthwork engineer/personnel will noticed on the field that the
Loader will be waiting for the Dump truck after loading the first truck.
Present condition
Hauling time of 2 DT = 17,300 cu meters
60 cu m/hour
= 288.33 hrs @ Php 547,827
Loader will be rented for the same hours costing the company Php 345,996.00
Total cost would be Php893,823
Unit cost of Php51.66 per cu. Meter
ONE ALTERNATIVE SOLUTION
From our equation it would be observed that since the Loader is waiting for the arrival of
the Dump trucks it would be advisable and highly recommendable to add another
Dump truck to increase the capacity of the hauling equipment.
By adding another Dump truck/s, the capacity of the hauling unit would increase and
speed up the time to finish the job.
With 3 Dump trucks added, capacity increased to 90 cu meters.
Time to Haul soil using 3 Dump trucks;
= 17,300 cu meters
90 cu mtrs/hour
= 192.22 hours @Php547,827
The Loader will be used for the same duration @Php230,666.67
Total cost of Php =Php778,493.67
Unit cost of Php45.00 per cu meter.
This also meet the requirement of the company to finished the hauling in a month time.
SUMMARY
Present Set Up One Alternative Savings
• COST OF RENTAL Php893,823.00 Php547,827.00 Php345,996.00
• UNIT COST per cu. meter Php51.67 Php45.00 Php6.67
• DURATION OF THE PROJ. 288.33 hrs 192.22 hrs 96.11 hrs
• (6 weeks) (4 weeks) (2 weeks)
Advantages of Mechanization
1. Larger scale operations possible
2. Reduced work time
3. Uniformity and improvements
4. Reduced Operating unit
5. Reduced Manpower
6. Relief from heavy manual work
7. Improved operating safety
Disadvantages of Mechanization
1. Large capital needed for obtaining and maintaining
machines
2. Increased management work involved in owning
machines
3. Problems with training and keeping operators
4. Effort needed to keep up with the latest
mechanization
5. Effort needed to learn the most efficient use of the
machines.
AVAILABILITY OF EQUIPMENT
Effective Utilization
Effective Utilization = Working Hours x 100%
Working hrs + Repair hrs + Standby hrs
Effective utilization is affected by the following situations:
1. Stoppages due to rain or other climatic conditions
2. Lay-off of surplus machines
3. Stoppages due to uneven availability of matched machines
4. Stoppages while waiting for preparations to be completed
EQUIPMENT AVAILABILITY
• Mechanical Availability is the indicator of time lost due to
mechanical reasons
• Mech. Availability = Working Hours x 100%
Working Hours + Repair Hours
• Physical Availabiliy is the indicator of the total operational
availability, it includes time lost for any reasons.
• Physical Avail. = Working Hours x Standby Hours x 100%
Total Hours
