Chapter-3 Construction Equipment Management

ADDIS ABABA UNIVERSITY
AAiT- SCHOOL OF CIVIL AND ENVIRONMENRAL

ENGINEERING
CENG5213: CONSTRUCTION EQUIPMENT
CHAPTER-3
CONSTRUCTION EQUIPMENT MANAGEMENT
CONTENTS
1. EQUIPMENT MANAGEMENT IN CONSTRUCTION PROJECTS
GENERAL
 EQUIPMENT PLANNING
 EXTENT OF MECHANIZATION
USE OF MACHINES V/S USE OF MANUAL LABOUR
FORECASTING EQUIPMENT REQUIREMENT
 SCIENTIFIC PLANNING
 SELECTION OF EQUIPMENT
 FORWARD PLANNING
 PURCHASE OF EQUIPMENT
WORKSHOP INSTALLATION
SPARE PARTS MANAGEMENT
MAINTENANCE MANAGEMENT
CONTENTS
DOWN-TIME AND AVAILABILITY
OPERATION AND UTILISATION
 MANAGEMENT TECHNIQUES
 REDUCTION OF CONSTRUCTION COST
 DECISION-MAKING
2. ECONOMICS OF CONSTRUCTION EQUIPMENT

GENERAL
OWNING COSTS
OPERATING COSTS
STANDARD COSTING
COST- ACCOUNTING
REPLACEMENT OF EQUIPMENTS
1.1 GENERAL
 The cost of equipment in a project varies from 10 to 30% of the total
cost of the project, depending upon the extent of mechanization.
 In modern fully mechanized projects the cost of equipment goes up to
30%.
 Proper planning, selection, procurement, installation, operation,
maintenance and equipment replacement policy plays an important
role in equipment management for the successful completion of the
project.
 Equipment manager‟s main task is to reduce downtime, achieve
optimum equipment utilization and increase production at
minimum cost.
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1.1 GENERAL
 Equipment engineer should coordinate with various wings of the
organization in discharging his job of:
 Equipment planning,
 Balancing,
 Selection of equipment and its utilization,
 Personnel selection and training,
 Financial planning,
 Preventive maintenance and
 General supervision.
 Thus equipment management integrates and continuously interacts
with human, technical, financial and production system in order to
achieve top efficiency and cost effectiveness.
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1.2 EQUIPMENT PLANNING
 Modern construction projects are complex in nature and success of a
project depends greatly on proper and scientific planning.
 Before starting every project its planning is done with great care, as
the efficiency of the whole project largely depends upon its planning.
 While planning a project we must very carefully decide about the
extent of use of construction equipments.
1.3 EXTENT OF MECHANIZATION
 Extent to which mechanization in a project should be planned
depends upon the following main factors:
1. Manpower: Type of manpower required by the project for its
execution, is first decided and whether this type of manual labour is
cheaply and sufficiently available round the year.
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2. Completion period: Completion period plays a deciding role about
the extent of mechanization, since less the completion period more
the mechanization.
3. Nature of work: Nature of work includes adverse weather, climatic
conditions, topography, toughness, handling of large quantities of
construction material for long distance.
4. Availability of money: Since cost of equipment is too high and to
be spent initially, it needs heavy investment in the beginning.
Therefore availability of money is a main factor in deciding the
extent of mechanization.
5. Availability of Indigenous Equipment: After sales service, repair
facilities are also considered where equipments manufactured in
our own country are not available.
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6. Social objects of the project: Sometimes projects are sanctioned
with the object of providing employment opportunities, to improve
the economic condition of the masses in addition to the
development in the area.
7. Labour Relations: In certain areas, past experience indicates labour
unrests, strikes, absenteeism, uncertainty, unavailability of labour
or seasonal fluctuations. In such circumstances machines are
preferred being more reliable to complete the project in time.
8. Overseas Projects: It is difficult and expensive to send large
number of man-power required in adopting the manual means in
these projects, therefore only alternative left is to execute the
project using construction equipments only.
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9. Quality and Performance: The work carried out by means of
construction equipments is of high standard of quality and
performance. The quality is consistent, execution is fast and work is
more durable.
10. Development of Industries: In countries like Ethiopia where
industries are in developing stage, it is the need of time to use
construction equipments for the development of manufacturing
industry and faster industrialization of the country.
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1.4 USE OF MACHINES V/S USE OF MANUAL LABOUR
 The advantages and disadvantages of using machines and manual
labour in construction projects are briefly described hereunder:
Points in favor of Machines Points in favor of Manual labour
1. It can handle tough works which cannot be 1. Initial heavy investments are not required to be
performed by manual labour. made.
2. It is cheaper when quantum of work is more and 2. Valuable foreign exchange is saved by employing
material is required to be transported for long exchange is saved by employing manual labour instead
distances. of using machines which are to be imported.
3. Machines when used in the project, it delivers 3. Small and short duration projects are sometimes
better quality of work. found to be economical with manual labour.
4. It is possible to adhere to schedules. 4. Direct advantage to considerably large number of

people by way of employment which help in social and
economic betterment.
5. It is easy to predict the behavior of a machine as 5. No problem due to delay in procurement of spares
compared to that of man, hence planning is easy. for the repair of machines. The delay (lead time) is
substantially high in case of imported equipments.
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1.4 USE OF MACHINES V/S USE OF MANUAL LABOUR
Points in favor of Machines Points in favor of Manual labour
6. Being lesser number of persons, (operators only), it is easy 6. Project can be started immediately, which is not possible in case
to supervise and control. machines are used. Since importation, shipment, transportation
installation and commissioning of equipments require a
substantial time.
7. It helps in development of technical knowhow, skill and 7. Disposal of equipment and its balance spare parts poses a
industrial development of the country. problem after the project is completed.
8. Availability of Manpower and seasonal fluctuations will not

affect the project’s progress.
9. Effect of climate and topographic conditions is less when

machines are used as compared to that when manual labour is
used.
10. No problem for housing and transportation of persons and

also for the arrangement for supply of food, water, light and
medicines etc.
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1.5 FORECASTING EQUIPMENT REQUIREMENT
 Following are the main points planner has to decide in equipment
planning.
1. Working Shifts: By increasing the number of shifts we can reduce the
number of equipment required, as the same equipment can be used in
second and third shift.
2. Number and Size of Equipments: For deciding the number and size of
the equipments following factors should be considered.
 Quantum of work,
 Working days available for completion of project.
 Number of shifts planned.
3. Matching Units: The number and size of the matching equipments
should be planned for each activity, keeping in view that complete
matching set must be utilized at the maximum and combination must
be optimum.
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1.5 FORECASTING EQUIPMENT REQUIREMENT
4. Procurement Scheduling: Procurement scheduling is done
considering procurement time required and time when equipment is
required.
5. Workshop and Stores Planning: While planning for the purchase
of equipments, it is necessary to plan for the workshop and stores
for carrying out the repair and maintenance.
6. Man power planning: Planning for manpower in order to operate
the equipment and to carry out the repair and maintenance is also
necessarily be done sufficiently in advance.
7. Site Conditions: The type of equipment selected mainly depends
upon soil available, and valley conditions, surface and strata where
work is to be carried out.
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1.6 SCIENTIFIC PLANNING
 Modern construction projects are complex in nature and success of a
project depends greatly on proper and scientific planning.
 This means that the data or basis taken should be based on past
experiences gained in various projects and on work studies carried out
in various conditions at various places.
 While planning a project we must very carefully decide about the
extent of use of construction equipments.
1.6.1 Quantum of work
 The first stage of planning is to calculate the total quantity of work
involved in each operation.
 For correct planning it is very much essential to ascertain quantity of
work as accurate as possible.
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1.6.1 Quantum of work
 While calculating the quantity of work involved it is necessary to
take a note of various constraints, for example,
A. limitation of working space, which may affect the efficiency of
the machine, so as to assess the output rate of equipment to be
used,
B. location of quarries and amount of material available in each of
them.
1.6.2 Output and Capacity of Equipment
 Next phase of planning is to decide the equipment on the basis of its
output and capability.
 The equipment must be capable to handle the work efficiently on
which it is to be engaged.
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1.6.2 Output and Capacity of Equipment
 Output of the equipment varies with various conditions. Following
are some of them:
 Different type of soil needs different amount of effort.
 Reduction of horse power of engine due to altitude.
 Time spent on servicing and inspection varies with the working
conditions.
 Output of the equipment also depends upon the operator‟s
efficiency.
 Output of dumper etc. depends on the condition of haul road.
 Time spent on the unproductive works.
 Changing weather conditions are responsible for variation in output.
 Capacities of the matching machineries working in the same group.
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1.6.3 Utilization and Time-period
 It is always a good practice to utilize equipment to the limit of its
useful life on one particular project.
 For a project of nearly 4 years or more duration, it is possible to use
the equipment to its full economic life.
 Experience has shown that a yearly utilization for as equipment under
average working condition in most case is as follows:
 Single shift operation – 1500 hrs.
 Double shift operation – 2500 hrs.
 Triple shift operation – 3200 hrs.
 Two shift operation of equipment is economical and should be
employed whenever possible.
 Three shift working results in frequent breakdowns and low
availability, which means more standbys and increase in cost.
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1.6.4 Equipment Operation Planning
 Following are the main points which should be considered while
planning for equipment operation:
 Equipments must work in coordination, especially when they are
required to work in a team.
 Proper working and the maintenance of auxiliary equipments should
also be ensured.
 Poor maintenance of service roads may result in more cycle time of
trucks, dumpers etc. besides causing more downtime.
 In order to ensure proper operating of equipment and to eliminate
delays it is necessary to ensure scheduled maintenance in addition
to watch the working by the operator.
 Safety on the work is a must.
 Good workmen should be given proper incentives.
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1.6.5 Manpower Planning
 To achieve maximum production at lower cost and at desired quality,
right man at right place at right job and at right time must be put.
 This is what is called scientific assessment of manpower planning.
 Following are the essential requirements for a sound manpower
planning:
 It should be done sufficiently in advance.
 It should be reviewed periodically, so that modifications or
alternations if any can be incorporated.
 The planning should have top management support.
 It should be need based.
 It should be economic in nature.
 It should incorporate the elements of flexibility and elasticity.
 It should provide a suitable policy
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1.6.5 Manpower Planning
 To achieve maximum production at lower cost and at desired quality,
right man at right place at right job and at right time must be put.
 For an effective and efficient manpower planning following main
factors should be considered:
 Working Hours: Manpower requirement is directly related to the
total hours worked per day by the employee in a project.
 Number of shifts: It has been experienced that production falls in
the night shifts as compared with day shifts.
 Nature of work: Nature of work decides the output and capabilities
hence plays and important role in deciding manpower requirement.
 Operators Efficiency: Normally following standard is considered as
guidelines for measuring workers efficiency:
 Operators having one year of job experience = 85%
 Newly appointed operators after training = 60%
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1.7 SELECTION OF EQUIPMENT
 Proper selection of equipment for a construction project is of vital
importance for its speedy and economical completion.
 For proper selection of equipment, a considerable experience in the
operation and maintenance in the field is essential.
 Following are the main points which should be considered in the
process of equipment selection.
A. Suitability for Job Conditions: The equipment must meet the
requirement of the work, climate and working conditions.
B. Size of the Equipment: Size of equipment should be such that it
must be able to be used with other matching units.
C. Standardization: It is better to have same type and size of
equipments in the project.
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D. Availability of Equipment in the market: The equipment which is
easily available in the market should be purchased.
E. Availability of Spare Parts: While selecting a particular type or make
of equipment, it should be ensured that the spare parts will be available
at reasonable price throughout the working life of the equipment.
F. Multipurpose Equipments (Versatility): There are certain types of
equipments which are not utilized fully.
G. Availability of Know-how: The equipment selected should be
satisfactorily handled by available operators and mechanics.
H. Use in Future projects: When equipment completes only a part of
their useful life in a project, it should be kept in view that the
equipment can be used in future projects and may not become
obsolete.
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I. The Economical Aspects: While selecting the equipment, it should
be considered that the cost of unit production should be minimum.
J. Reliability of the Equipment: Equipment selected for the project
must be reliable one.
K. Service Support: Service support should be available in the area of
project where the equipment shall be used. Service after sales is a
major criteria for selection of equipment.
L. Operating Requirements: The equipment selected should be easy
to operate and maintain, acceptable to the operator and should have
lesser fuel consumption.
M. Past performance: If the equipment being purchased is of new
make and model, it is desirable to enquire about its performance
from other users, who are using this make and model.
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I. Reputation of the manufacturer.
J. Warranty or guarantee offered by the manufacturer.
K. Use of standard components in the equipment.
L. Adequacy of drive mechanism or power of the prime-mover.

M. Versatility of the equipment should be given due priority: This
means a machine which can be used for many jobs.
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1.8 FORWARD PLANNING
 The planning of a project should be made at least 6 to 9 months in
advance of commencement of work.
 This time lead is essential for the following main tasks to be
performed before the commencement of project:
A. Purchase of Equipment: This includes the formalities for calling
enquiries from manufacturers, selecting an equipment; time taken by
the supplier for supply of the equipment and transporting it to the
project site, installation and commissioning it.
B. Workshop Installation: A well equipped workshop should be
installed in the project, so as to fulfill the requirement of repair of
equipment.
C. Spare Parts Stock: Initial lot of spares should be purchased along
with the equipment.
D. Posting of Personnel: Selection of the right operator.
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1.9 PURCHASE OF EQUIPMENT
 Once the selection of the equipment is done the purchase order for the
selected model and type is issued considering lead time for the supply
of equipment, time required for its installation and commissioning,
and the time when equipment should be available for use.
 The process of selection of equipment is generally a part of
procurement, followed by equipment planning and helps in purchase
of equipment.
 The complete procurement action is divided in various activities like
calling enquiries, its technical and financial evaluation, ordering,
contract-making, transporting, assembling and installation and
commissioning.
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1.9.1 Purchasing v/s Hiring
 Contractors and other users of construction equipment are required to
take a decision as to whether to purchase an equipment or to acquire it
on hire.
 Following are the points which are in favor of purchasing an
equipment:
 When the equipment used for the most of the construction period and
likely to complete almost its full life, while working in the project.
 It remains available for use whenever it is needed.
 Purchased equipment means an own equipment, is generally kept in
better mechanical condition and is more reliable. This means
matching equipments will not be affected adversely due to frequent
breakdowns.
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1.9.1 Purchasing v/s Hiring
 Following are the points which are against owning the equipment:
 When the equipment cannot be used for its full life, then the owning
may be more expensive than hiring.
 The purchaser is required to do huge investment initially, which
otherwise he may need for other purposes.
 Contractor may have to face the danger of obsolescence of the
equipment.
1.9.2 Hiring with an option to purchase
 In this system user hire the equipment at the prevailing rate with a
provision that he may purchase it at a later date if he wishes to do so.
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1.10 WORKSHOP INSTALLATION
 A workshop should be installed in the project so as to enable to carry
out necessary repair and maintenance of the equipment. Workshop
should cater for the following facilities:
 Servicing, which includes cleaning, cooling, lubrication, and check-
ups.
 Field repairs.
 To carry out inspection at regular specified intervals to detect faults
which can be rectified in time to avoid breakdowns. It detects the
defects in operation, change in adjustments, wear and tear, cracks or
any other indication for likely breakdown in near future.
 Tire repair.
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1.11 SPARE PARTS MANAGEMENT
 Machines worth millions of Birr are idle for want of spares, on other
hand huge stock of spares are lying which perhaps may not be used.
 This emphasizes the need of paying more attention on the management
of spares.
 Improvement in the capacity utilization and cost reduction can be
achieved by better spare parts management.
 The objective of spare parts management is to provide right parts in
right quantity, in right place, at right time and at right cost.
 The parts must be properly codified and classified.
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1.12 MAINTENANCE MANAGEMENT
 Every machine is thoroughly tested and inspected by the
manufacturers before selling.
 When used it is subjected to wear and tear, hence proper attention
should be given to protect the machine and its components from undue
wear and thus protect them from failures.
 A proper attention means lubrication, cleaning, timely inspection and
systematic maintenance.
 Maintenance means efforts directed towards the up keep and the repair
of that machine.
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 Following are the types of maintenances:
A. Repair Maintenance can be followed for non-critical equipments,
and where failures are unpredicted.
B. Corrective Maintenance should be adopted for frequently falling
components.
C. Preventive Maintenance (planned or scheduled or systematic
maintenance). Periodic inspection or checking at the pre-decided
frequency helps to find out the reasons leading to breakdown and to
rectify them when they are in minor (or initial) stages.
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1.12.1 Functions of Preventive Maintenance
 Following are some of the important functions of the preventive
maintenance programme:
A. Inspection or checkups at carefully decided frequencies.
B. Lubrication. Mechanical components like gears, bearings, bushes
and other friction surfaces give good performance for long periods
C. Every preventive maintenance work should be preplanned.
D. Good record keeping is essential for good preventive maintenance.
E. Training of maintenance personnel.
F. Storage of maintenance spares.
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1.12.1 Functions of Preventive Maintenance
 Advantages of Preventive Maintenance
A. Less overtime work required as it is pre-planned.
B. Less repair costs
C. Less Production downtime.
D. Less stand-by equipments needed.
E. Increased life expectancy.
F. Better spare parts control leading to reduced inventory.
G. More reliability.
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1.12.2 Tyre Maintenance
 Correct tyre selection and proper tyre maintenance are therefore very
essential for ensuring economic operation.
 For proper maintenance of tyres following factors should be considered:
 Proper inflation.
 Proper Loading.
 Proper Speed.
 Keeping the tyre up to desired temperature.
 Proper driving habit.
 Avoiding vehicles‟ mechanical irregularities.
 Storing of tyres properly.
 Tyre rotation and Retreading at right time.
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1.13 DOWN-TIME AND AVAILABILITY
 The downtime is the duration from the time when equipment goes
under breakdown to the time when it is restored to service.
 Down time can be reduced by following ways:
 Speedy Fault Detection. Fault should be detected before it becomes
serious enough to affect performance.
 Speedy Fault Diagnosis. The time spent in fault diagnosis can be
reduced by following a logical method of fault diagnosis.
 Speedy repairs. Time for repairs include time required for fault
detection and diagnosis, removal of assembly, stripping, adjustments,
assembly and then final trial test.
 Reduction in Waiting Time. Waiting time for repair is considerably
higher than actual time taken for repairs due to the irregular (random)
arrival of repair jobs.
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1.14 OPERATION AND UTILISATION
 Since this is the task directly responsible for production, maximum
managerial care should be given to the „operation‟.
 Following are the main factors which effect the operation:
i. Availability of Trained Personnel.
ii. Adequate repair and maintenance facilities in the projects.
iii. Availability of spares required for repair and maintenance.
iv. Working Conditions.
v. Haul roads should be well maintained
vi. Information Monitoring System
vii. Feedback should be extended to the manufacturers
viii.The output of each equipment should be compared with that of
pre-determined norms.
ix. Encourage operators and maintenance personnel for giving long
life of the equipment.
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1.15 MANAGEMENT TECHNIQUES
A. Network Techniques. Network techniques can be used to prepare
equipment schedules, organizing and executing the work of
assembling, installation and commissioning of plants, to organize and
execute major repair job of equipment.
B. Work Study. Work study is performed to determine:
i. A best way of doing a work so as to get maximum output without
affecting the equipment adversely.
ii. How much time a unit of work should take to perform or how much
work per hour should be performed by the equipment?
C. Operation Research Techniques. Operation research is a method of
analysis by which management receives aid for their decision. It
offers alternative plans for a problem for decision by adopting
analytical methods.
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C. Operation Research Techniques.
 The methods of operation research which can be applied to equipment
management are:
i. Waiting line models,
ii. equipment replacement models,
iii. simulation and
iv. transportation model.
D. Communication. Communication means transmission of ideas,
information, directions etc. The communication is a continuous
process and must move freely in both directions and can be either
oral or written, and flows either in upward or downward or horizontal
directions.
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E. Computerization in Equipment management. Computers are
sued effectively for various aspects related to the equipment
management like, availability of equipment, resource leveling,
maintenance of history cards and then using them for planning the
over hauling of assemblies/equipment as a whole.
F. Value Engineering. Value engineering is a tool of management to
determine the approaches for saving the cost from the point of
„value.‟
 The job of value engineers is to make a study of the design,
specifications, materials and methods of construction of the
project at a lesser cost without reducing the equality and
usefulness of project.
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1.16 REDUCTION OF CONSTRUCTION COST
 A cost reduction in construction can be achieved by adopting following
ways:
i. Proper planning
ii. Timely supply of funds, equipment, materials, and personnel.
iii. Proper equipment planning and selection.
iv. Proper equipment operation, maintenance and utilization.
v. Adopting proper inventory control.
vi. Engaging experienced operators
vii. Monitoring progress and adopting scientific methods.
viii. Ensuring continuous supervision.
ix. Adopting innovations and latest techniques suitable for the job
x. Eliminate unnecessary construction requirements.
xi. Use local materials when they are satisfactory.
xii. By applying value Engineering.
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1.17 DECISION-MAKING
 Decision-making is the most important task in equipment management
and we can say that good decision making ability is the key to success.
 Efficiency, loss or profit, and working atmosphere of a construction
firm are affected by these decisions.
 Management without decisions is like a man without backbone.
 The days of hit and mis methods in management are over and have
been replaced by new concepts and scientific techniques.
 In general, decisions are the output of the following inputs:
i. Knowledge and information,
ii. Ability and skill: Communications, analytical, or conceptual.
iii. Value system: Opinions, attitudes, habits, or belief
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 The job of equipment management involves a large number of
decisions e.g.
a) Which equipment should be used?
b) What work is to be done by equipment?
c) Whether to use equipment or to do it manually?
d) What make and model of the equipment is to be purchased?
e) Which of the matching equipment and of what size and in what
number to be deployed?
f) Which of the accessories to be purchased with the equipment?
g) Whether to purchase the equipment or take on hire.
h) When to purchase from own capital or take loan.
i) Whether to purchase a particular spare for store or purchase when
needed.
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Characteristics of a Good Decision:
a) It is the choice of the best course among various alternatives.
b) It is the end process preceded by the deliberations and reasoning
c) It is associated with commitment.
d) It is rational.
e) Evaluation process exists in every course of decision making.
Procedure for Decision-Making:
a) Recognizing and analyzing the problems.
b) Finding relevant facts.
c) Determining possible alternatives.
d) Evaluating the impact of alternatives.
e) Selecting the best solution.
f) Implementation of the decision.
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GENERAL
 Principles and techniques of engineering economics are utilized
while making equipment selection and planning of finances for the
purchase of construction equipments.
 Economics of construction equipment deals with the study of
working of the equipment and to compute the unit costs of
production.
 Unit cost of production is calculated after estimating the best of
production by calculating hourly ownership and operating cost of the
equipment and knowing hourly production of that equipment.
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2.1 OWNING COSTS
2.1.1 Investment Costs
 This is a kind of fixed cost and continues to be incurred whether the
equipment is used or not. Investment costs comprises of the
following:
 Interest on the money invested in the procurement of the
equipment.
 Various taxes on the equipment.
 Insurance expenses.
 Storage costs.
 If the money spent on the purchase of the equipment, was invested
in the bank or similar other agencies, it would have earned an
interest. Now this amount, equivalent to the interest, should be
recovered from this equipment.
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2.1 OWNING COSTS
2.1.1 Investment Costs
 Generally these investment costs are taken as about 10 to 15% of the
total cost of the equipment. This total cost comprises of the
following:
a) Price of the equipment with all attachments and accessories.
b) Insurance and freight charges.
c) Expenses on un-loading, clearance and custom duty.
d) Cost of transportation to the job site including loading and
unloading.
e) Erection and commissioning charges.
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2.1 OWNING COSTS
2.1.2 Depreciation
 Due to use and obsolescence every equipment loses its value. This
loss is accounted for by depreciating the equipment every year.
 Depreciation. Whenever any machine or equipment performs useful
work its wear and tear is bound to occur. This can be minimized up
to some extent by proper care and maintenance but can‟t be totally
prevented.
 Obsolescence. is the depreciation of existing machinery or asset due
to new and better invention, design of equipment of processes etc.
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2.1 OWNING COSTS
2.1.2 Depreciation
 depreciation can be classified as under:
Depreciation
Depreciation due to Depreciation due to

physical condition functional condition
Deferred
Inadequacy
Wear and Tear Physical decay Accidental Maintenance & Obsolescence
Neglect
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2.1 OWNING COSTS
2.1.2 Depreciation
 Methods of Calculation: The following are the methods for
calculating depreciation.
i. Straight line Methods
ii. Diminishing Balance Method
iii. Sinking fund Method
iv. Annuity Charging method
v. The Insurance policy method
vi. The Revaluation or Regular Valuation method
vii. Machine Hour Basis method
viii.The sum of the year‟s Digits method
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2.1 OWNING COSTS
2.1.2 Depreciation
Straight Line Method
 This method assumes that the loss of value of machine is directly
proportional to its age. It means one should deduct the scrap value
from the original value and divide the remaining value by the
number of years of useful life.
Let C be the Initial cost of a machine.
S be the scrap value.
N be the Number of years of life of machine. and
D be the depreciation amount per year.
CS
Then, D Birr
N
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2.1 OWNING COSTS
2.1.2 Depreciation
Example-1
(a) A machine was purchased for Birr 450,000 on 1st January, 1991,
the erection and installation work costs Birr 70,000. This was replaced
by a new one on 31st Dec, 2010. If the Scrap Value was estimated as
Birr 150,000 what should be the rate of depreciation and depreciation
fund on 15th June, 2000?
(b) If after 12 years of running, some assemblies are replaced and the
replacement cost is Birr 150,000 what will be the new rate of
depreciation?
52
2.1 OWNING COSTS
2.1.2 Depreciation
Solution
53
2.1 OWNING COSTS
2.1.2 Depreciation
Solution
54
2.1 OWNING COSTS
2.1.2 Depreciation
Solution
55
2.1 OWNING COSTS
2.1.2 Depreciation
Example-2
Consider an excavator purchased for 3.1 million birr having a useful
life of 5 yrs. Determine the depreciation and book value for each of
the 5 years using Straight Line method. Assume a salvage value of S
= 860,000 birr.
Solution
56
2.1 OWNING COSTS
2.1.2 Depreciation
Solution
57
2.1 OWNING COSTS
2.1.2 Depreciation
Diminishing Balance Method
 This is also called “Reducing Balance” Method. The diminishing
value of machine is greater in the early years. It depreciates rapidly
in the early and later-on slowly.
 So under this method, the book value of the machine goes on
decreasing as its existence continues.
 In this, let x be the fixed percentage taken to calculate the yearly
depreciation on the book value.
Where, C = initial cost, S = Scrap Value, N=No. of the years of life.

 It will be more clear by the following solved example .
58
2.1 OWNING COSTS
2.1.2 Depreciation
Example - 3
A lathe is purchased for Birr 800,000 and the assumed life is 10 years
and scrap value Birr 200,000. If the depreciation is charged by
diminishing Balance method, calculate the percentage by which value
of the lathe is reduced every year and depreciation fund after 2 years.
Solution
59
2.1 OWNING COSTS
2.1.2 Depreciation
Solution
60
2.1 OWNING COSTS
2.1.2 Depreciation
Solution
61
2.1 OWNING COSTS
2.1.2 Depreciation
Solution
62
2.1 OWNING COSTS
2.1.3 Major Repair Cost
 While minor or field repairs are carried out during the day to day
working of the equipment the major repairs are carried out after the
substantial use of the equipment.
 Major repairs and over hauls are the replacement of major parts of
the equipment because of the excessive wear through a long period
of use.
 Since these repairs require a heavy amount of expenditure, they are
met from the major repair fund.
 Usual practice is to consider this major repair cost as a percentage of
straight line depreciation cost and is generally taken as 80 to 200%
of the cost of depreciation depending on the type of equipments.
63
2.2 OPERATING COSTS
2.2.1 Cost of Fuel
 The actual consumption of fuel or electricity in these construction
equipments depends upon:
i. Engine B.H.P
ii. The load factor, which means the extent to which the engine
will operate at full power. Load factor generally vary from
30% to 70%.
iii. The conditions of the engine
 Optimum fuel consumption in liters per hour may be calculated
using following formula:
Fuel consumption = 0.27 x load factor.
64
2.2 OPERATING COSTS
2.2.1 Cost of Fuel
 Recommended value of load factor
65
2.2 OPERATING COSTS
2.2.2 Cost of Lubricants
 Lubricants include the following:
 Engine oil
 Air filter oil
 Transmission oil
 Hydraulic oil
 Greases etc.
 The quantity of lubricating oil depends upon various factors. Some
of these factors are:
 Capacity of the crank case
 Condition of piston rings
 Number of hours between oil changes.
66
2.2 OPERATING COSTS
2.2.2 Cost of Lubricants
Lubricating Oil Consumed
 Requirement of lubricants including engine oil, air cleaner oil,
transmission oil, greases, and hydraulic oil, can be assessed on the
basis of information supplied by the equipment manufacturer.
 Following formula is used for estimating the quantity of oil required
per hour:
67
2.2 OPERATING COSTS
2.2.3 Servicing and Maintenance Cost
 Regular servicing and maintenance of each equipment is very
essential in order to have the equipment in reliable and perfect
condition of working. This cost includes:
 Change of lubricants
 Checking and servicing of fuel and lubricating systems, including
change of filter elements.
 Care of tyres and tubes
 Care of Battery and electrical system
 Cleaning of the equipment and other similar works.
68
2.2 OPERATING COSTS
2.2.4 Labour Cost
 Labour cost is an important element of operating cost and
contributing a major part of it.
 Labour cost element includes the salaries of operators, and helpers
engage on the equipment.
 Provision for leave reserve (may vary from 10 to 12%) is also made
under the bead of labour cost.
 A percentage of the wages of supervisory staff, depending upon the
attention required on that particular equipment, is also to be added.
69
2.2 OPERATING COSTS
2.2.5 Cost of Field Repairs
 This is the cost incurred on minor repairs which are carried out on
the site or in field workshops.
 These repairs include replacement of minor parts, such as fan belts,
filters, bearings, wire ropes etc. and other adjustments required to be
carried out during normal working of the equipment.
2.2.6 Overheads
 These are the charges which are incurred on complete fleet of the
equipment.
 These charges includes the pay on watchman, light and water
charges in the storage yards, uniform to the operating and
maintenance staff etc.
70
Determination of Owning and Operation Costs
 To determine the cost of owning and operating following procedure
is adopted.
71
72
73
2.3 EQUIPMENT RENTAL RATES ACCORDING TO ETHIOPIAN ROADS
AUTHORITY (ERA)
74
2.4 STANDARD COSTING
Standard Cost
 Standard cost is an estimated cost of a job or project prepared in
advance of execution.
 This is prepared considering normal cost of normal production with
in normal capacity and under normal conditions and efficiency.
Standard Costing V/S Budgetary Control
A. Common principles
 Establishing predetermined standards, target or yardstick of
performance.
 Measuring actual performance as compared to yardstick.
 Locating variances between actual and standard performances
 Disclosing reasons for such variances.
75
Standard Costing V/S Budgetary Control
B. Differences
76
Essential Requirements for Standard Costing
 Standard cost of a work requires following:
 Technical specifications of quality, type and quantity of direct material for
each item.
 Estimated prices of all materials required, based on current prices and
anticipated changes during the period.
 Estimates of direct labour time for each category of labour
 Standard hourly rates of each category of direct labour.
 Estimate overhead recovery rate
 Uses of Standard Costs
 Assisting the management in better planning, coordination and control.
 Facilitates in comparing with actual costs.
 Provides basis for measuring the productivity improvement.
 Provides basis for measuring the productivity improvement.
77
2.5 COST CONTROL AND COST REDUCTION
 Cost control is a method of comparing actual costs with
predetermined standards or targets.
 Whereas the cost-reduction is meant to take drastic actions,
sometimes by changing rigid boundaries laid down by the standards
or targets.
Steps for Cost Control and Cost Reduction
 Following essential steps are required to be taken for effective cost
control and cost-reduction.
i. Inculcating an all-round cost consciousness in the organization.
ii. While setting standards and norms, scope of cost reduction is to be explored.
iii. Decide priorities for attack to achieve quick results.
iv. Control on consumption as well as on block-up of capital is to be exercised.
v. Provide right climate to encourage creativity.
vi. Reporting and monitoring system should be strengthened.
78
Cost saving Areas
A. Reduction in Material Cost
 Ensure purchase of right quantities of right quality at right time
from right source and at right price.
 Avoid overstocking or inventory build-up
 Planning material procurement in advance, scientifically and from
practical consideration.
 Decision regarding whether to purchase aggregate etc. or to
manufacture.
 Minimum handling of material be ensured.
 Utilize scrap and waste material.
 Avoid wastage of material.
79
Cost saving Areas
B. Reduction in Labour Cost
 Judicious and rational distribution of workmen
 Labour rate should be decided considering actual norms of output.
 Suitable inspection and supervision methods be introduced.
 Decision for single shift, double shift, triple shift, or extended shift
(one shift of 10 to 12 hrs) be taken, considering overall economy.
 Operators should be trained from time to time to make them well
conversant with the latest technology to enable to achieve
maximum productivity.
80
Cost saving Areas
C. Reduction in Overheads
 Overhead expenditure should be maintained in a proper record

and compared with estimates or standards from time to time.
 To keep control on indirect labour.
 To have versatile machines with different accessories to have
optimum utilization.
 Reduction in avoidable unproductive expenditure to the
maximum.
 Construction of colonies, office etc. be made by utilizing the
local material for economy and location be decided after careful
considerations.
81
2.6 Cost- Accounting
 In the current days of competition, it is necessary that the concern
should have utmost efficiency and minimum possible wastage and
losses.
Financial or Accounting Ratio Analysis
 Financial or accounting ratio may be defined as relating one
accounting figure to another to provide better comparison. Different
financial ratio are:
82
83
84
Uses of Financial Ratio Analysis
 Financial rations provide useful indications to appraise financial
health of a concern and overall efficiency of the project.
 Computation of rations often leads to a further enquiry into various
aspects of project, and which enables to bring out some important
facts, which ultimately helps in:
a) Planning: short, medium, and long range.
b) Diagnosis of financial ills or industrial sickness.
c) Decision marking of all types
d) Keeping a continuous watch on the financial trends and taking
corrective actions well in advance
85
Bidding by the Construction Agencies
 The value of the profit is decided after considering several factors,
some of them are:
 Competition in the market
 Size of the project.
 Facilities available like, mobilization advances, interval at which
payments will be made to the contractor.
 price escalation
 Risk involved
 Chances for utilizing the equipment after completion of the project.
 Availability of raw material from open market or on control and its
lead time.
 Maintenance period after completion of the project.
86
2.7 REPLACEMENT OF EQUIPMENTS
 The main reasons for the replacement of the equipment are:
A. Deterioration. It becomes necessary to replace the machine when

it wears out and does not function properly.
B. Obsolescence. Whenever new equipment comes in the market,
which is capable of producing more products of good quality with
less labour and has more efficiency, the existing machine is to be
replaced with this machine although it was functioning well.
C. Inadequacy. With the change of product design to meet the
customers demand or quantity to be manufactured, old machinery
becomes inadequate and, therefore, calls for different
manufacturing equipment.
87
Equipment Replacement Policy
 Equipment replacement decision plays an important role in the
economic running of any concern. A firm has to face three types of
replacement decisions.
i. The replacement of capital equipment, as it wears out.
ii. The capital equipment required for expansion.
iii. The replacement of old technology by the new
(replacement of obsolete equipment)
88
Equipment Replacement Policy
 Large numbers of factors are responsible to replace the equipment
before the expiry of the estimated life, namely:
 To reduce production cost.
 To reduce fatigue.
 To raise quality
 To increase output
 To secure greater convenience, safety and reliability.
89
Guidelines in Replacement Analysis
 There are certain rules which may be used as guidelines for replacement
analysis.
A. For equipment in use
Do consider:
 Operating cost
 Repairs and maintenance cost.
 Down time cost.
 Salvage value
 Rebuilding cost
Do not consider:
 Original cost.
 Money already spent on repairs and maintenance
 Unrealistic book value
90
Guidelines in Replacement Analysis
B. For new equipment
Do consider:
 Initial cost
 Interest on capital investment.
 Salvage value at the end of useful life
 Cost advantage of improved product
 Labour savings.
Do not consider:
 Any savings not clearly assessable.
 Overhead charges
91
THANK YOU!
92

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ADDIS ABABA UNIVERSITY

AAiT- SCHOOL OF CIVIL AND ENVIRONMENRAL

CENG5213: CONSTRUCTION EQUIPMENT

USE OF MACHINES V/S USE OF MANUAL LABOUR

FORECASTING EQUIPMENT REQUIREMENT

SPARE PARTS MANAGEMENT

 REDUCTION OF CONSTRUCTION COST

2. ECONOMICS OF CONSTRUCTION EQUIPMENT

4. It is possible to adhere to schedules. 4. Direct advantage to considerably large number of

8. Availability of Manpower and seasonal fluctuations will not

9. Effect of climate and topographic conditions is less when

10. No problem for housing and transportation of persons and

L. Adequacy of drive mechanism or power of the prime-mover.

Depreciation due to Depreciation due to

Where, C = initial cost, S = Scrap Value, N=No. of the years of life.

 Overhead expenditure should be maintained in a proper record

A. Deterioration. It becomes necessary to replace the machine when

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