Heavy equipment (construction)

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Heavy equipment refers to heavy-duty vehicles, specially designed for executing construction tasks, most frequently, ones involving earthwork operations. They are also known as, construction equipment, construction plant, earth movers, engineering vehicles, or just plain equipment. They usually comprise five equipment systems: implement, traction, structure, power train, control and information. Heavy equipment functions through the mechanical advantage of a simple machine, the ratio between input force applied and force exerted is multiplied Currently most equipment use hydraulics as a primary source of transferring power. The use of heavy equipment has a long history; the ancient Roman engineer Vitruvius (1st century BCE) gave detailed descriptions of heavy equipment and cranes in ancient Rome in his treatise De architectura.

Implements and Hydromechanical Work Tools

• auger
• backhoe
• bale spear
• broom
• bulldozer blade
• clam shell bucket
• cold plane
• demolition shears
• equipment bucket
• excavator bucket
• forks
• grapple
• hydraulic hammer, hoe ram
• hydraulics
• hydraulic tilting bucket (4-in-1)
• landscape tiller
• material handling arm
• mechanical pulverizer, crusher
• multi processor
• pavement removal bucket
• pile driver
• power take-off (PTO)
• quick coupler
• rake
• ripper
• rotating grab
• sheeps foot compactor
• skeleton bucket
• snow blower
• stump grinder
• stump shear
• thumb
• tiltrotator
• trencher
• vibratory plate compactor
• wheel saw

Facts & Figures

The forklift is a powered truck fitted with steel forks on its front end, used to lift and transport material. The two parallel steel forks slide beneath the material, often loaded onto a wooden pallet or skid, and then hoisted. Most are fitted with small wheels and are really only practical on finished or paved surfaces. Some forklifts carry their cargo on one side of the vehicle; these are called sideloaders. Though small by comparison to most heavy equipment vehicles, it has become indispensible for the warehousing and manufacturing sectors. Major manufacturers of forklifts (by market share) include Toyota, KION Group, Jungheinrich, NAACO Industries, Inc. (which includes Yale and Hyster brands), Komatsu, Manitou, Mitsubishi, Nissan, Caterpillar, Clark, and Crown Equipment, though many more brands are available among used forklifts. (Over the years, many other brands such as Allis-Chalmers have either gone out of business or been assumed into larger companies through acquisitions.)

Forklifts are organized by class. Forklifts range in size and capability from small, hand powered pallet jacks, designed only to give ground clearance and move the pallet from one area of floor, all the way to diesel-powered driver-operated models of enormous size, used for moving raw logs and capable of loads up to 50 tonnes. Most common are those in the middle, either electric-rechargeable or propane-powered models approximately 6-10 feet (2-3 meters) in length, with forks on a sliding hydraulic mast of cylinders or rails, and capable of loads between one and five tonnes.

Forklift operators must be well trained to operate the machine safely and effectively. Because most models steer from the rear, manouevering quickly can take some getting used to. Additionally, moving with a load held high upon the forks can upset the forklift's low center of gravity, and risk tipping. To keep the forklift balanced, some machines have a counterweight at the back, though in most cases it is the actual engine or battery that acts as the rear weight. Most forklifts have an overhead guard above the cab to protect the operator from falling debris. The exception would be those motorized pallet jacks upon which the operator stands.

Heavy Equipment Basic Unit Price Estimates

The price of the basic unit of heavy equipment consists of:
• Cost plan (initial cost or capital cost) ---> Owning Cost
• operation & maintenance costs (direct operational and maintenance costs) -----> Operational Cost

Would cost
Would cost (return on capital and interest) each year is calculated as follows:

Where:

G

=

cost per hour would

B

=

price of a local tool • If the procurement of equipment not through dealers, which are referred to the local price of the CIF price plus handling cost (entrance fees, rental fees incliring warehouse, freight etc) to the buyers warehouse • When buying local means through the dealer / agent is a price to the buyer's warehouse

C

=

The value of residual (salvage value) the value / price of the related equipment after its economic life  ends. Usually this value is taken 10% of the initial cost (cost of a local appliance)

D

=

factor installment / return on capital

A

=

economic life of equipment (Economic Life Years) in the year depending on length of usage levels and standards of the manufacturer

F

=

Insurance costs, taxes, etc. per year. The value is usually taken for two of the initial cost per mile or two per cent of the remaining value of equipment F = 0.002*B atau F = 0,02*C

W

=

Number of hours of work tools in a single year • For heavy duty equipment (possible to work continuously throughout the year) is considered 8 hours / day and 250 days / year, then: W = 8 * 250 * 1 = 2000 hours / year • For equipment that is being considered on duty eight hours / days and 200 days / year, then: W = 8 * 200 * 1 = 16 000 hours / year For light duty equipment is considered 8 hours / day and 150 days / year, then: W = 8 * 150 * 1 = 1200 hours / year

Operation and Maintenance Costs
Operating and maintenance costs are theoretically
The amount of operating and maintenance costs of each unit of equipment that is used is calculated as follows:
The cost of fuel and maintenance costs

Fuel costs (H)
Supplies of fuel per hour taken from the relevant equipment manual. Fuel requirement is a requirement of fuel for the propulsion machinery following fuel used for the production process (eg AMP include fuel for heating and drying aggregate),.

Lubricants (I)
Lubricant material which includes engine oil material, the hydraulic oil, transmission oil, power steering lubricants, grease and so forth. Needs lubricant per hour can be calculated based on the needs of oil divided by how many hours required will need to replace oil (oil type and conformed to the manual of the relevant equipment)

Cost of care / workshop (J)
Maintenance costs include the cost of replacing oil filter, filter / filters, and others.

The cost of repairs / spare parts (K)
• Cost of replacement tires
• The cost of replacing worn parts (not spare parts) such as conveyor belts, sieve for crushed stone aggregate / AMP, etc.
Reimbursement • battery / battery
• Improved tools

Operator (M)
Wages in the operating costs are usually divided between wages for operators / drivers and maid service wages. The amount of wages for operators / drivers and helpers are calculated according to the "large wage calculation" in which wages accounted for operators and assistants per hour wage an effective hours of work.

Operation and maintenance costs approach
Given the many variety of equipment from various brands that will be used, the estimator will have difficulty if the calculation of operating and maintenance costs using the manual of each instrument in question. To simplify the calculation of operating costs and maintenance of the equipment can be used in formulas that apply the approach to the whole range of equipment.
Because this formula approach to nature, so if the formula is applied to calculate the cost of operation and maintenance of one kind peraltan results will be less accurate. But if the equipment is used to calculate all the results are still within the bounds of reasonableness.
Calculation formulas approach the operation and maintenance costs are as follows:

Fuel costs (H)
The amount of fuel used for the engine is hung from the large machines used kapasitass measured by HP (horse power).
H = (05.12 s / d 17.05)% * HP
Where:
H   = amount of fuel used in one hour (liters)
HP = horse power
For light duty tool multiplier is used 12.5%, while for heavy duty equipment used in the multiplier 17.5%.

Lubricant Cost (I)
The amount of lubricant (the use of lubricants including grease) used for the equipment concerned is calculated based on engine capacity, as measured by HP.
I = (1 s / d 2)% * HP
Where:
I     = the amount of lubricant consumption in the first hour (liters)
HP = horse power
For the simple equipment used in the multiplier 1%, whereas for a fairly complex equipment used in the multiplier 2%.

The cost of repairs and maintenance (K)
For calculating the cost of spare parts, tires, batteries and repair equipment, etc. associated with less improvement in the per-use approach to working hours as follows:
K = (05.12 s / d 17.05)% * B / W
Where:
B  = cost of equipment
W = number of working hours within one year
        For light duty tool multiplier is used 12.5%, while for heavy duty equipment used in the multiplier 17.5%.

Equipment rental costs
Equipment rental fee per hour is the sum would cost + operating and maintenance costs.

Problem:
Calculate the cost of certain and maintenance costs + operating costs Excavator with 80 HP power and capacity of 0.5 m3. Other data as follows:
• The economic life             : 5 years
• Working hours in a year   : 2000 hours
• The price of the appliance: Rp. 2,000,000,000, -
• Interest rate                     : 20% per year
• Wage operators               : Rp. 12 500, - per hour
• Wage assistant operator   : Rp. 7500, - per hour
• diesel fuel                         : Rp. 4500, - per liter
• Lubricating Oil                  : USD. 29 000, - per liter

Various kinds of heavy equipment

                                                                        1. Front Shovel

 

Function: This heavy equipment used to excavate soil and rock.

2. Motor Grader

 

      Function: can be used to flatten the ground and form a ground surface. Motor graders can also be used for mixing the soil and spread a mixture of soil and asphalt. In general, motor graders are used in projects and maintenance of roads and with the ability to brgerak, motor graders are often used in projects airfield.

3. Dragline

 Function: used to excavate soil and rock.

 

4. Truck Mixer

        Function: To stirring mixture of concrete and has the advantage because it can deliver concrete results to the location diiingkan stirring. This tool is also used as an agitator truck carrying the mortar from the mixing plant to the project.

5. Crawel Crane

          Function: as a means of transportation that can move 360 º in the project site while doing a job.

6. Scraper

         Function: heavy equipment that serves to dredge, transport, and sow the dredging of a layered soil. Scaper can also be used as a means of transportation for a relatively long distance (± 2000 m) on flat ground with a tire-wheel drive equipment.

7. Truck crane

     Function: a transporter normally used in construction projects. By way of lifting materials to be moved, move horizontally, then lowered in place of the desired material.

 

Heavy equipment for construction

Heavy equipment for construction

 (a) Dragline. Singapore and Malaysia generally use dragline. The operations consist of bringing to site a track-mounted crane. With the crane are many 0.1 × 0.3 × 4.0 to 5.0 m planks which are self-laid by the crane for its own base. As work progresses, the planks are self-shifted by the crane so that it is resting at all times on a series of platform planks preventing it from bogging down in mud.

This particular equipment is particularly good for dike construction, canal digging and deepening (Fig. 6.9). Hence, it is suited for excavating shrimp trapping ponds in order to have deeper water. However, it is not practical for large-scale within-compartment-levelling because of its being too slow and unwieldy. Its use is also limited where mass hauling of earth in some areas for dike building is involved. It is by design, an equipment for in-place working. There is now in the market a crane mounted on LGP (low ground pressure) tracks. This makes the crane more maneuverable in swampy areas and cuts its non-productive plank-transferring time by half. This crane can be equipped with clam shell buckets.


Fig. 6.9 Range diagram and limits of work of drag line as defined for the construction of the perimeter dike
(After Hechanava and Tiensongrusmee, 1980)

The cost of using draglines vary with the kind of soil material and its size. The effective working range depends on the length of boom

(b) Dozer-crawlers (Fig. 6.10). This particular equipment is good for levelling provided the load-bearing capacity of the soil can support the equipment weight. Recent designs of these equipment are provided with mechanisms which improves speed and maneuverability, thus cutting down construction time. The effective working range of most dozers in dry soil conditions vary from 20 to 40 m.

Fig. 6.10 Some heavy equipment for fish farm construction
(After Tarnchalanukit, 1982)

Most crawler manufacturers have now incorporated LGP tracks to their line of crawlers to enable it to work on wet soils. On LGP, the ground pressure usually is around 0.28 kg/cm2. The LGP crawlers come in a variety of sizes, ranging from 20 to 200 BHp. One has therefore a good choice to suit the area to be developed or the transport situation to the work area. In some instances, small LGP dozers are chosen over a large one for convenience in transporting the equipment to the job site by raft or passing on bridges which have limited load capacity.

(c) Hydraulic excavators, backhoe, shovels, cranes, pay loaders (Fig. 6.10). These are equipment that can also be used to advantage in fishpond projects. One advantage the hydraulic equipment have over cable cranes are their fast action and flexibility to adapt to a variety of situations. These can also be adapted with clam shells and grapplers and can be used for uprooting small tree stumps.

(d) Scrapers, dump trucks, wheel-type loaders (Fig. 6.10). These may also be used effectively where soil conditions permit.

(e) Suggestions on mechanization. Much waste has been observed in the use of mechanized equipment. In order to be able to adopt this method with success, one must know the following: (i) capacity; (ii) limitations; (iii) limit of maximum operating range; (iv) ground pressure; (v) working conditions; (vi) amount of work to be done; (vii) type of work required; and (viii) cost per unit of work accomplished.

There are equipment now especially fabricated for reclamation and swamp work. These types can be used in mangroves effectively. However, one should be conversant with the different types of equipment and be able to judge critically the type of equipment needed after seeing the project area. There are some large equipment which can be taken apart into several components and reassembled at job-site. Some cranes and hydraulic lifters are also designed to be barge-mounted with their tracks on while on the shore.

In addition, the economical or effective range of the equipment should also be known. At what distance should one consider a loader and a dump truck combination over a crawler? It would be uneconomical beyond about 35 m due to its track wear and long cycle time. Beyond 35 m on volume of soil movement, one might want to employ combination pay loaders with several dump trucks. The economics of this operation should be worked out. Scrapers (self-loading and crawler-assisted) are ideal for large projects. Dredges can be used effectively too. Under special situations, jetting pumps can effectively facilitate uprooting of stumps. All of the above require a thorough knowledge of the project site peculiarities as well as the different equipment available, their specifications, capacities and limitations. An expert's advise in this field is usually necessary.