Por: DOUGLAS D. GRANSBERG, CALIN M. POPESCU, RICHARD C. RYANContents
Chapter 1
Evolution of Heavy Construction Equipment........................................................................1
1.1 Introduction .................................................................................................................1
1.2 Role of Heavy Construction Equipment......................................................................1
1.3 From Tools to Machines..............................................................................................2
1.4 Development of Earthmoving, Excavating, and Lifting Machines ..............................4
1.5 Heavy Construction Equipment Today .......................................................................8
1.6 Future of Heavy Construction Equipment ..................................................................8
References ............................................................................................................................16
Chapter 2
Cost of Owning and Operating Construction Equipment....................................................19
2.1 Introduction ...............................................................................................................19
2.2 Ownership Cost..........................................................................................................20
2.2.1 Initial Cost ......................................................................................................20
2.2.2 Depreciation ...................................................................................................20
2.2.3 Investment (or Interest) Cost..........................................................................23
2.2.4 Insurance Tax and Storage Costs ...................................................................24
2.3 Total Ownership Cost ................................................................................................24
2.4 Cost of Operating Construction Equipment ..............................................................25
2.4.1 Maintenance and Repair Cost ........................................................................25
2.4.2 Tire Cost .........................................................................................................27
2.4.3 Consumable Costs ..........................................................................................27
2.4.4 Mobilization and Demobilization Cost ..........................................................29
2.4.5 Equipment Operator Cost ..............................................................................29
2.4.6 Special Items Cost...........................................................................................29
2.5 Methods of Calculating Ownership and Operating Cost ...........................................29
2.5.1 Caterpillar Method .........................................................................................29
2.5.2 Corps of Engineers Method............................................................................30
2.5.3 Associated General Contractors of America (AGC) Method ........................32
2.5.4 Peurifoy/Schexnayder Method........................................................................35
2.5.5 Comparison of Costs Calculated by Different Methods.................................37
2.6 Summary ....................................................................................................................37
References ............................................................................................................................38
Chapter 3
Equipment Life and Replacement Procedures .....................................................................39
3.1 Introduction ...............................................................................................................39
3.2 Equipment Life ..........................................................................................................40
3.2.1 Physical Life....................................................................................................40
3.2.2 Profit Life .......................................................................................................41
3.2.3 Economic Life.................................................................................................41
3.3 Replacement Analysis ................................................................................................46
3.3.1 Theoretical Methods .......................................................................................46
3.3.2 Practical Methods ...........................................................................................52
3.3.3 Sensitivity Analysis on Theoretical Methods..................................................55
3.3.4 Comparison and Discussion of Sensitivity Analysis Results ..........................58
3.4 Replacement Equipment Selection .............................................................................60
3.4.1 Replacement Decision Making .......................................................................61
3.4.2 General Factors ..............................................................................................62
3.5 Summary ....................................................................................................................64
References ............................................................................................................................64
Chapter 4
Earthmoving, Excavating, and Lifting Equipment Selection ........................................................ 65
4.1 Introduction ...............................................................................................................65
4.2 Basic Considerations for Equipment Selection ..........................................................65
4.3 Earthmoving and Excavating Considerations............................................................67
4.3.1 Tracks and Tires .............................................................................................67
4.3.2 Buckets and Blades .........................................................................................70
4.3.3 Accessories and Attachments..........................................................................76
4.3.4 Earthmoving and Excavating Work ...............................................................76
4.4 Earthmoving Equipment Selection.............................................................................80
4.4.1 Bulldozers .......................................................................................................80
4.4.2 Front-End Loaders .........................................................................................84
4.4.3 Motor Graders................................................................................................86
4.4.4 Scrapers...........................................................................................................88
4.4.5 Trucks .............................................................................................................92
4.5 Excavating Equipment Selection................................................................................94
4.5.1 Excavators ......................................................................................................94
4.5.2 Backhoes.........................................................................................................98
4.5.3 Front Shovels................................................................................................100
4.6 Lifting Considerations..............................................................................................100
4.6.1 Placing a Load..............................................................................................100
4.6.2 The Operator ................................................................................................103
4.6.3 Mobilization and Setup ................................................................................103
4.6.4 Booms...........................................................................................................104
4.6.5 Forks.............................................................................................................104
4.6.6 Rigging..........................................................................................................107
4.6.7 Jibs ................................................................................................................110
4.6.8 Hoist Speed...................................................................................................111
4.7 Lifting Equipment Selection.....................................................................................111
4.7.1 Cranes ...........................................................................................................111
4.7.2 Forklifts ........................................................................................................118
4.7.3 Personnel Lifts ..............................................................................................118
References ..........................................................................................................................120
Chapter 5
Advanced Methods in Estimating and Optimizing Construction Equipment System
Productivity ........................................................................................................................121
5.1 Introduction .............................................................................................................121
5.2 Background..............................................................................................................121
5.3 Peurifoy’s Method of Optimizing Productivity ........................................................122
5.3.1 Rimpull .........................................................................................................122
5.3.2 Cycle Time and Optimum Number of Units ................................................124
5.4 Phelps’ Method ........................................................................................................125
5.4.1 Fixed Time....................................................................................................125
5.4.2 Variable Time ...............................................................................................125
5.4.3 Instantaneous and Sustained Cycle Times....................................................126
5.5 Optimizing the Hauling System Based on Loading Facility
Characteristics ..........................................................................................................127
5.5.1 Load Growth Curve Construction ...............................................................127
5.5.2 Belt Conveyor Load Growth Curve .............................................................129
5.5.3 Determining Optimum Number of Haul Units ............................................130
5.5.4 Rounding Based on Productivity..................................................................131
5.5.5 Rounding Based on Profit Differential.........................................................132
5.5.6 Optimizing with Cost Index Number ...........................................................133
5.5.7 Selecting Optimum Haul Unit Size...............................................................133
5.5.8 Optimizing the System with a Belt Conveyor ...............................................136
5.5.9 Selecting the Optimum Size-Loading Facility...............................................137
5.6 Comments on Optimizing Equipment Fleets ...........................................................138
References ..........................................................................................................................139
Chapter 6
Stochastic Methods for Estimating Productivity................................................................141
6.1 Introduction .............................................................................................................141
6.2 Background..............................................................................................................141
6.3 Developing Mathematical Models ...........................................................................142
6.3.1 Probability Theory........................................................................................142
6.3.2 Statistical Analysis ........................................................................................146
6.3.3 Historical Data .............................................................................................147
6.4 Simulations...............................................................................................................150
6.4.1 Monte Carlo Simulation Theory ..................................................................151
6.4.2 Other Simulations .........................................................................................154
6.5 Expected Production ................................................................................................157
6.5.1 Cost Estimating Factors ...............................................................................157
6.5.2 Production Management Factors ................................................................. 158
6.6 Validating Simulation Models..................................................................................158
6.6.1 Verifying Assumptions and Inputs ...............................................................159
6.6.2 Sensitivity Analysis .......................................................................................159
References ..........................................................................................................................161
Chapter 7
Scheduling Equipment-Intensive Horizontal Construction Projects ..................................163
7.1 Introduction .............................................................................................................163
7.2 Background..............................................................................................................164
7.3 Precedence Diagramming Method ...........................................................................165
7.3.1 Determining the Critical Path.......................................................................167
7.3.2 Critical Resource Identification ....................................................................169
7.3.3 Resource Loading the Schedule....................................................................170
7.3.4 Cost Loading the Schedule ...........................................................................171
7.4 Linear Scheduling Method.......................................................................................174
7.4.1 Identifying Production-Driven Activities......................................................176
7.4.2 Establishing Production Rates......................................................................177
7.4.3 Lines, Bars, and Blocks ................................................................................178
7.4.4 Converting to PDM......................................................................................182
7.5 Developing Equipment Resource Packages (Crews) ................................................189
7.5.1 Rules for Developing Crew Sizes..................................................................190
7.5.2 Developing Crew Costs.................................................................................190
7.6 Establishing Project Management Assessment Parameters......................................191
7.6.1 Minimum Required Daily Production..........................................................192
7.6.2 Expected Daily Production...........................................................................193
7.6.3 Allowable Cycle Time Variation...................................................................193
7.6.4 Cost and Unit Targets ..................................................................................194
7.7 Summary ..................................................................................................................195
References ..........................................................................................................................195
Chapter 8
Scheduling Lifting Equipment for Vertical Construction...................................................197
8.1 Introduction .............................................................................................................197
8.2 Lifting and Vertical Constructions...........................................................................197
8.3 Lifting Productivity..................................................................................................198
8.4 Scheduling Lifting for High-Rise Work...................................................................199
8.4.1 Lifting Strategy .............................................................................................199
8.4.2 Typical Lifting Activities for High-Rise Construction .................................201
8.5 Concrete-Placing Cranes ..........................................................................................202
8.5.1 Bucket Pouring .............................................................................................202
8.5.2 Pumping........................................................................................................206
8.5.3 Scheduling and Ordering Concrete ...............................................................208
8.6 Tower Crane Erection and Dismantling ..................................................................210
References ..........................................................................................................................224
Chapter 9
The Buy, Lease, or Rent Decision......................................................................................225
9.1 Introduction .............................................................................................................225
9.2 Acquiring Heavy Equipment....................................................................................225
9.3 Financing Methods ..................................................................................................226
9.3.1 Outright Cash Purchase................................................................................227
9.3.2 Conventional Financing Purchase ................................................................227
9.3.3 Leasing..........................................................................................................228
9.3.4 Renting .........................................................................................................230
9.3.5 Rent-to-Own (Rental Purchase) ...................................................................232
9.4 Equipment Financing Comparison ..........................................................................232
9.4.1 Acquisition Comparison ...............................................................................232
9.5 Rental and Lease Contract Considerations..............................................................233
9.6 The Buy, Lease, or Rent Decision ...........................................................................235
References ..........................................................................................................................236
Chapter 10
Construction Equipment Maintenance ..............................................................................237
10.1 Introduction ...........................................................................................................237
10.2 Need for a Maintenance Program..........................................................................237
10.2.1 Types of Maintenance Programs ...............................................................238
10.3 Designing the Maintenance Program .....................................................................238
10.3.1 Define Objectives and Goals .....................................................................239
10.3.2 Establish Responsibility and Authority.....................................................239
10.3.3 Actions and Controls ................................................................................241
10.4 Preventive and Predictive Maintenance Management............................................242
10.4.1 Preventive Maintenance.............................................................................242
10.4.2 Availability and Reliability........................................................................244
10.4.3 Oil Sample Analysis...................................................................................250
10.4.4 Preventive Maintenance Reporting Systems..............................................250
10.5 Maintenance Performance Control ........................................................................251
10.5.1 Maintenance Labor Productivity Control .................................................252
10.6 Preventive Maintenance Programs .........................................................................252
10.6.1 Operator Training .....................................................................................252
10.6.2 Maintenance Guidelines ............................................................................253
10.6.3 Maintenance Cost Control Metrics ...........................................................253
10.7 Field Maintenance..................................................................................................254
10.7.1 Field Maintenance Personnel and Support Facilities ................................254
10.7.2 Design Features for Field Maintenance Facilities .....................................256
10.7.3 Specialized Maintenance Tools ................................................................. 256
References ..........................................................................................................................256
Chapter 11
Construction Equipment Site Safety ..................................................................................259
11.1 Introduction ...........................................................................................................259
11.2 Safety as a Profit Center ........................................................................................259
11.3 The Job Safety Plan ...............................................................................................260
11.4 Heavy Construction Equipment Site Safety Considerations ..................................262
11.5 A Job Safety Analysis for Earthmoving................................................................. 265
11.6 Lifting Safety..........................................................................................................269
11.6.1 Safety Considerations ................................................................................269
11.6.2 Prelift Meetings .........................................................................................270
11.7 OSHA Accident Reporting and Record Keeping .................................................. 272
11.7.1 Reporting...................................................................................................272
11.7.2 Record Keeping.........................................................................................273
11.8 Safety Requirements for Construction Equipment ................................................274
References ..........................................................................................................................274
Chapter 12
Construction Equipment Security ......................................................................................275
12.1 Introduction ...........................................................................................................275
12.2 Security Issues ........................................................................................................275
12.3 Theft and Vandalism..............................................................................................276
12.4 Security Programs ..................................................................................................279
12.4.1 Security Planning.......................................................................................279
12.4.2 Security Inventories and Markings............................................................281
12.4.3 Job-Site Security ........................................................................................283
12.4.4 Heavy Equipment Protection ....................................................................285
12.5 Insurance ................................................................................................................286
12.5.1 Policy Information ....................................................................................286
12.5.2 Types of Policies........................................................................................288
12.5.3 Rates and Deductibles ...............................................................................289
12.6 Summary ................................................................................................................290
References ..........................................................................................................................290
Chapter 13
Inventory Procedures and Practices ...................................................................................293
13.1 Introduction ...........................................................................................................293
13.2 Objectives of Inventory Control.............................................................................293
13.3 Equipment and Parts Identification .......................................................................294
13.3.1 Equipment Identification...........................................................................294
13.3.2 Parts Identification ....................................................................................296
13.4 Inventory Record Keeping and Management Systems ..........................................297
13.4.1 Paper-Based Record Keeping....................................................................297
13.4.2 Electronic Record Keeping........................................................................298
13.5 Equipment Location and Utilization .....................................................................299
13.5.1 Geographic Information System Applications ..........................................299
13.5.2 Global Positioning System Equipment Fleet Management Systems .........300
13.5.3 Comparing GPS Systems...........................................................................301
13.6 Summary ................................................................................................................304
References ..........................................................................................................................304
Appendix A
Corp of Engineers Construction Equipment Ownership
and Operating Expense Schedule .......................................................................................305
Appendix B
Heavy Equipment Product Guides.....................................................................................537
Index..................................................................................................................................545
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