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equipmentworld.com | February 2017
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HOW SUBSTANCE ABUSE ENDANGERS WORKERS, HURTS RECRUITING AND THREATENS YOUR BOTTOM LINE. Part one of a two-part series.
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*Based on IHS Automotive, Polk TIPNet U.S. Class 8 Straight Truck Conventional, 10 liter and larger engines. Report period January 2014 through November 2015.
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Cover Story
Vol. 29 Number 2 |
table of contents | February 2017
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high Page
Equipment 15
20
In the first of our two-part series on drug use in construction, we look at how substance abuse endangers workers, hurts recruiting and threatens your bottom line.
Marketplace
32 Machine Matters
45 Maintenance
73 Road Technology
Komatsu PC650 excavator, Ditch Witch JT10 HDD, John Deere 844K wheel loader, Brokk 110 remote-controlled demo machine, Bolt OffVehicle Coupler, Enerpac Hydraulic Toolbox, TobrocoGiant USA E-Skid
Wheel loader features beyond Tier 4 Final engines.
CMMS implementation: A 14-point plan to bring your maintenance-management system into the digital age.
Contractors warm up to intelligent compaction as spec requirements increase.
EquipmentWorld.com | February 2017
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table of contents | continued
Features 53 DEF Contamination
Tips on how to prevent this engine killer.
58 Highway Contractor
Concrete Pavers: Control improvements and options, quick changes and flexibility boost contractor productivity.
69 Contractor of the Year Finalist
Jack Bailey, JBR Incorporated, Fredericksburg, Virginia
®
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81 Technology
Adapt or die: Kiewit looks at the past and the future of construction and why you must embrace technology to survive.
Departments 9 On Record A good year. 11 Reporter Tier 4 regs driving contractors to lower-tiered used equipment; Atlas Copco sells Dynapac to Bomag parent; ConExpo mobile app to give automatic updates; Beyond Traffic 2045 report; Holt Cat launches investment harm to back dealer-focused tech.
57 Quick Data Aerial lifts 65 Safety Watch Warming fire turns deadly. Attachments 86 Demolition A compilation of tools for multiple demolition functions, including crushing, breaking, cutting and grinding.
94 Pro Pickup
Texas shop remanufactures pickups in under 48 hours, sells them for half price.
98 Final Word ConExpo as a recruiting and retention tool. For subscription information/inquiries, please email equipmentworld@halldata.com. Equipment World (ISSN 1057-7262) is published monthly by Randall-Reilly Publishing Company, LLC, 3200 Rice Mine Road N.E., Tuscaloosa, AL 35406. Periodicals Postage-Paid at Tuscaloosa, Alabama, and at additional mailing offices. POSTMASTER: SEND ALL UAA TO CFS (SEE DMM 507.1.5.2). Non-postal and military facilities: send address corrections to Equipment World, P.O. Box 2187, Skokie, IL 60076-9921 or email at equipmentworld@halldata.com. Rates for non-qualified subscriptions (pre-paid US currency only): US & possessions, $48 1–year, $84 2–year; Canada/Mexico, $78 1–year, $147 2–year; Foreign, $86 1–year, $154 2–year. Single copies are available for $6 US, $9 Canada/Mexico and $12 foreign. The advertiser and/ or advertising agency will defend, indemnify and hold Randall-Reilly Publishing Company, LLC harmless from and against any loss, expenses or other liability resulting from any claims or suits for libel violations of right of privacy or publicity, plagiarisms, copyright or trademark infringement and any other claims or suits that July arise out of publication of such advertisement. Copyright ©2017 Randall-Reilly Publishing Company, LLC All rights reserved. Reproduction in whole or in part without written permission is prohibited. Equipment World is a trademark of Randall-Reilly Publishing Company, LLC Randall-Reilly Publishing Company, LLC neither endorses nor makes any representation or guarantee regarding the quality of goods and services advertised herein.
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February 2017 | EquipmentWorld.com
Chairman: Mike Reilly President and CEO: Brent Reilly Chief Operations Officer: Shane Elmore Chief Financial Officer: Russell McEwen Senior Vice President, Sales: Scott Miller Senior Vice President, Editorial and Research: Linda Longton Senior Vice President, Audience Data: Prescott Shibles Vice President, Events: Stacy McCants Vice President, Digital Services: Nick Reid Vice President, Marketing: Julie Arsenault Vice President, Business Analyst: Joe Donald Director of Media Sales: Scott Maldonado Vice President, Strategic Accounts: Michael Newman For change of address and other subscription inquiries, please contact: equipmentworld@halldata.com Editorial Awards: Eddie award for B-to-B Series of Articles, 2016 Highways 2.0, Folio: magazine Editorial Excellence, Original Research, Silver Award, 2016 American Society of Business Publication Editors Jesse H. Neal Award, Better Roads, 2011 American Business Media Robert F. Boger Award for Special Reports, 2006, 2007, 2008 Construction Writers Association Jesse H. Neal Award, Best Subject-Related Series of Articles, 2006 American Business Media Editorial Excellence Special Section Gold Award, 2006 Midwest-South Region, American Society of Business Publication Editors Editorial Excellence News Analysis Gold Award, 2006 Midwest-South Region, American Society of Business Publication Editors Editorial Excellence News Section Silver Award, 2005 Midwest-South Region, American Society of Business Publication Editors
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on record | by Marcia Gruver Doyle MGruver@randallreilly.com
A good year
I
made a mistake when I bought my iPhone a few years ago: I only got 16 GB of storage. Hence, I tend to see the dreaded “storage almost full” message on my phone … a lot. Time to delete. Since the usual culprit is photos, that’s where I go first. (Yes, I know there’s iCloud storage, but bear with me.) And so at the end of 2016, I once again got the message, and I once again started going through my photos. It was at this time when everyone was talking about how bad 2016 had been. Whatever your political persuasion, I’ve yet to find anyone who looks back on the election grind with any fondness. Then the music icons from our youth started dropping: Bowie, Prince, Frey and Haggard, compounded by sports legends Muhammad Ali and Arnold Palmer. And in December, the final blow: the Fisher-Reynolds double death that made hearts heavy across generations. There was no doubt about the consensus: 2016 sucked. But as I went through the forced culling of the photos that I had taken in the past year, it hit me: 2016 had been a very good year, and here was the proof. There were small moments and memorable trips. Seeing “Sing” in 3D with my granddaughter, visiting my
50th state in the 50th state, birthday dinners with friends, family gatherings. Moments that perhaps would have been forgotten if not for the instant convenience of a quick click. I overheard a conversation at the World of Concrete this past week that got me thinking about this year-end photographic look back. When someone asked the typical “how’s it going?” to a person they see infrequently, the half-joking reply was “grim determination, my friend, for the next four years.” While I understand some of his trepidation, I also think the coming year – and those that follow it – deserve more than grim determination. Whatever it brings, there will be moments in 2017 when you bring out the phone, snap a photo and preserve a memory. That photo may well be destined for the trash the next time you make a decision about what to save. But it may also serve as future evidence that this year wasn’t the dire time period that people will likely be complaining about come December. All it takes to gain some perspective is to click on your smartphone photo archive and take a look back. You have friends, families, co-workers and colleagues; you are surrounded and supported. When those things happen, it’s always a good year.
EquipmentWorld.com | February 2017 9
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reporter
| staff report
Beyond Traffic 2045: U.S. ill-equipped to keep up with transportation challenges
T
he final version of the U.S. Department of Transportation’s Beyond Traffic 2045 emphasizes that the nation’s current transportation system won’t be able to meet the demands in technology, population and climate. “The final report again shows that if we do not invest in our infrastructure, we will let conditions move us backwards,” says Anthony Foxx, outgoing U.S. transportation secretary. The report, first issued in draft form in February 2015, says: • America’s population is expected to grow by 70 million by 2045, and by 2050, three-quarters of Americans could live in eleven emerging megaregions, clusters that span multiple cities and communities. • Freight volume is expected to increase by more than 40 percent, partly driven by online shopping • Automation and robotics will affect all modes of transportation. • Federal gas tax revenues could decline further as fuel efficiency improves. The USDOT has designated 18 Beyond Traffic Innovation Centers in several universities to lead research on transportation challenges identified in the report. – Chris Hill
ConExpo mobile app automatically gives you show updates
A
vailable in both Apple and Android formats, the ConExpo mobile app gives you easy access to the following: • Easily find exhibitors, educational sessions and events via 3D maps and routing • Organize and save favorite educational sessions, exhibitors and special events on the fly.
• Track your Personal Development Hours upon completion of education sessions, and receive certificates of completion For more on what exhibitors have planned for ConExpo, be sure to check out the Show Planner polybagged with this issue of Equipment World.
Briefs Dozr, the Canadian contractor-to-contractor equipment rental service, has begun operations in both New Jersey and Florida. Terry Dolan has stepped down from his position at Ritchie Bros Auctioneers as president of the U.S. and Latin America operations. Ritchie Bros. also anticipates its IronPlanet purchase will close by the end of the second quarter. Terex has sold its United Kingdom-based compact equipment operation to Mecalac, a French manufacturer of compact loaders and excavators. In addition, the company completed the sale of its Material Handling and Port Solutions Business to Finnish manufacturer Konecranes. Volvo Construction Equipment says it will relocate its global headquarters from Brussels, Belgium to Gothenburg, Sweden, home of the Volvo Group. Northern Ireland-based Euro Auctions has purchased U.S.-based auctioneer Yoder & Frey. The Euro Auctions sales site in Atlanta will be re-branded Yoder & Frey, aimed at strengthening the company’s Ohio, Pennsylvania and Kissimmee, Florida auctions. EquipmentWorld.com | February 2017 11
reporter |
I
continued
Tier 4 regs driving contractors to buy lower-tiered used equipment
f you suspected that contractors are snapping up as much used Tier 3 equipment as they can get their hands on, now there’s evidence. A recent survey conducted by the Independent Equipment Dealers Association (IEDA) found that the Environmental Protection Agency’s Tier 4 emissions mandates for diesel powered off-road equipment are driving up demand for equipment with less complex and less costly exhaust emissions technology. IEDA members report seeing resale prices on the lower tiered equipment increase as much as 20 percent. And more than 50 percent of the survey respondents said that quality used equipment is getting harder to find. “Our members buy and sell used equipment globally, which makes them well aware of market trends,” says Drew Van Brunt, IEDA president and owner of Global Tractor in Colleyville, Texas. “As a group, we make it
a point to share trends we see in the market with each other, as well as with used equipment buyers and sellers. The current used equipment market is strong, but it will be affected by Tier 4 machines in the near future.” The survey also found that members are unsure how well Tier 4 machines will hold their value when these models hit the used equipment market. Thirty-seven percent think the Tier 4 machines will not retain their value as well as non-Tier 4 equipment. But others said that Tier 4 machines could have better resale value if more construction projects require the use of best available emissions technology. Currently there are few Tier 4 machines in the used equipment market. IEDA members say that this market is four to eight years away from becoming dominant, and at that point non-Tier 4 machines will be harder to find and pricing on Tier 4 equipment will level out. – Tom Jackson
Atlas Copco sells Dynapac to Bomag parent
A
tlas Copco has sold its Dynapac road construction equipment division to Fayat Group, parent company of Bomag. “We will continue to leverage the strengths of our existing organizations and Dynapc in parallel,” says Jean-Claude Fayat, president of the Fayat Group. “All customers will continue to be supported with their products.” Saying that Dynapac has “an excellent strategic place” in the company, Fayat says his firm would continue to grow and expand Dynapac’s presence and product offering. The Dynapac division manufactures pavers, planers and roller compactors for asphalt and soil applications. The division has sales and service operations in 37 countries, production units in five countries and employs 1,265 people. When Atlas Copco purchased the Malmo, Swedenbased Dynapac AB in 2007, it called the company “a very good fit with, and that the same time an extension of” other company businesses, allowing it to grow in the “expanding road construction market.”
12 February 2017 | EquipmentWorld.com
Briefs (continued) IronDirect has opened a Customer Experience Center in Asheville, North Carolina, which includes a 9,600-square-foot indoor product pavilion, deck, grandstand and staged worksites for indoor, outdoor and virtual product demonstrations. The U.S. Department of Transportation named Martin Klepper as the first executive director of its Build America Bureau, designed to streamline credit and grant opportunities. The organization will also provide technical assistance and encourage best practices in project planning, financing, delivery and monitoring. The bureau will be a single entity in charge of USDOT credit, large scale and intermodal project development, and infrastructure finance and development. Komatsu America has formed Komatsu Northeast, taking over the New Jersey territory formerly served by Binder Machinery. The move follows Komatsu’s earlier formation of Komatsu Southwest, created when the company purchased four branches – three in New Mexico and one in Texas – of Arizona-based dealer Road Machinery. J. J. Kane Auctioneers has named Proxibid as the exclusive provider of its timed auctions.
For more on each of these stories go to equipmentworld.com.
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R’S O T EDI ICK P
marketplace
| by Marcia Gruver Doyle |
MGruver@randallreilly.com
PRODUCTION LOAD 30- TO 40-TON TRUCKS Komatsu has updated its PC650 excavator with improvements to the machine’s cab design, fuel efficiency and serviceability. With operating weights between 140,456 and 145,284 pounds, the new PC650LC-11 is powered by a 436-horsepower Komatsu SAA6D140E-7 engine and is designed for production loading of 30- to 40-ton trucks. The engine employs a selective catalyst reduction system and diesel exhaust fluid (DEF) to meet Tier 4 Final emissions standards and features a variable geometry turbocharger and exhaust gas recirculation for more precise
temperature and air management control and longer component life. The excavator features an integrated hydraulic system design with center load sensing that works with three working modes to quickly match machine performance to the application at hand. The hydraulics also drive a reversible cooling fan that varies speed in response to coolant, hydraulic oil and ambient air temperatures. A large 16.4-gallon DEF tank is easy to reach inside a lockable compartment and the radiator and hydraulic oil coolers are mounted side by side for easier access.
Complete larger-diameter reams on smaller jobs The compact Ditch Witch JT10 horizontal directional drill is powered by a 66-horsepower Deutz diesel engine. With a combination of 10,000-pounds of pullback force and a standard 16-gpm mud pump, the unit allows operators to complete larger-diameter reams on smaller jobs, says the company. An onboard 40-gallon fluid tank provides additional fluid during short bores; the unit also has an onboard drill-pipe capacity of 324 feet. A traversing seat positions the operator in the center of the pipe rack for easy-to-reach pipe handling. Single joystick controls handle thrust and rotation and a monitor displays operational and engine performance diagnostics. EquipmentWorld.com | February 2017 15
marketplace
| continued
Load out 24 tons in just two passes John Deere has updated its 844K wheel loader with improvements to the hydraulic plumbing. The model’s Aggregate Handler configuration has a new enhanced performance bucket. Powered by a 13.5-liter Deere PowerTech engine, the 844KIII boasts 380 horsepower while the Agg Handler configuration has 401. A five-speed transmission with torque-converter lockup in gears two through five complements its Tier 4 Final engine, increasing acceleration, speeds and cycles while optimizing power and fuel efficiency during transport, roading and ramp climbing. The Aggregate Handler configuration of the 844K-III can load 24 short tons of non-heaping, lower-density processed matter in just two passes into on-road dump trucks, according to the company. Deere has improved the hydraulic plumbing on these machines, replacing 81 feet of hoses with more than three dozen steel tubes. The update improves service and uptime by minimizing hose rubs. Deere has also routed hydraulic hoses away from vital operating components to increase wear life and has enlarged the articulation-joint and linkage pins for greater productivity. 16 February 2017 | EquipmentWorld.com
Electrically powered demolition Boasting more efficient operation and more hitting power than its predecessor, Brokk has introduced its latest remote-controlled demolition machine, the Brokk 110. This electrically powered demolition machine has a 10-foot reach and weighs 2,183 pounds. At only 31 inches wide, the machine can fit through standard doors and inside passenger elevators. It packs 15 percent more power than the Brokk 100 it replaces and features the company’s new electrical system which incorporates hardened components and fewer moving parts than the previous system. This system can sense when a power supply is poor or faulty, making it suitable for generators or unreliable power supplies. The unit is compatible with the same range of attachments available for the Brokk 100, including breakers, crushers, grapples, rock drills and shears.
For every innovation in our CONEXPO booth, there are hundreds who said, “That’s impossible.”
Turns out impossible just depends on who you’re talking to. Come push boundaries with us. North Hall Booth N10036 or Gold Lot Booth 3894. volvoconexpo.com
marketplace
| continued
Deter trailer theft Bolt’s OffVehicle Coupler Lock secures a trailer when it’s not attached to a vehicle. The onekey lock technology permanently programs locks to the vehicle’s ignition key for single-key use no matter how many Bolt locks are being used. The lock works with 1 7/8-inch, 2-inch and 2 15/16-inch couplers to keep a variety of trailers secure. The visible theft deterrent has a plate tumbler sidebar to prevent picking and bumping.
Portable hydraulics Enerpac’s Hydraulic Toolbox is a portable tool set that includes the necessary hydraulic components to begin working on any application. The toolbox is a full hydraulic system, including a hydraulic cylinder, a lightweight hand pump with angled gauge adaptor assembly, couplers and hose. It’s available with several cylinder options. The box protects the tools from environmental contaminants. 18 February 2017 | EquipmentWorld.com
Fully battery-powered mini skid steer The Tobroco-Giant USA E-Skid is a fully battery-powered mini skid steer slated to debut in the second half of the year. The same size as the company’s diesel-powered SK25ID, the machine features a German Jungheinrich battery system and four Parker wheel-motors. Capable of being operated as both a ride-on and remote-controlled unit, the unit can be used in a variety of construction applications.
The KOHLER Diesel KDI engine is a Tier 4 final with common-rail fuel injection and no DPF. So you skip the DPF maintenance costs, get savings at the pump, and laugh all the way to the bank. ®
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hard cover story
| by Tom Jackson |
TJackson@randallreilly.com
hat
How substance abuse endangers workers, hurts recruiting and threatens your bottom line –
high
the first in a two-part series
20 February 2017 | EquipmentWorld.com
part 1: the scope of the problem
I
t’s a story that received national headnational average. That’s more than one out lines. On June 5, 2013, equipment of every eight of the workers around you – operator Sean Benschop maneuvered an the guy driving the truck past your crane, 18-ton excavator toward a four-story brick the guy on the excavator, the flagger on building slated for demolition in Philadelyour busy roadside construction site. phia, Pennsylvania. But in part because of Complicating the issue are the country’s Behschop’s failure to follow safe demolition contradictory laws concerning marijuana practices, an unsupported wall gave way use, which pose difficult personnel and and crashed down onto legal issues for employers. an adjacent one-story And the widely-reported Salvation Army Store. Six opioid abuse epidemic is people in the store died in part due to medications According to the and another 13 were prescribed for pain from Department of Labor, injured. job-related injuries that drug and alcohol Toxicology reports are all too common in abuse contribute to showed evidence of construction. marijuana and codeine 65 percent of on-thein Benschop’s blood. He A history of problems job accidents and already had a long rap Substance abuse has up to 50 percent of sheet, including 11 arrests dogged the construcworkers’ compensaon charges including tion industry for a long drugs, theft and weapons time. According to a 1988 tion claims. Substance possession. Benschop was National Institute on Drug abusers are absent arrested and eventually Abuse survey, 28 percent from work an average sentenced to 7 to 15 years of construction workers of five days a month, in prison for manslaughadmitted to using illegal ter. The construction drugs. This was the highare ten times more contractor, Griffin Campest percentage of drug use likely to steal from bell, directing Benschop’s found in any industry at the company or other work, was sentenced the time. employees, use three to 15 to 30 years. The The passage of the building inspector for that Drug-Free Workplace Act times the normal level area, Ronald Wagenhoffer, 25 years ago helped lower of employee health drug abuse rates in all incommitted suicide a week benefits and incur dustries. But the numbers after the incident. 300 percent higher are still cause for alarm This tragedy, and the given the dangerous nadrug use that contribmedical costs. ture and the high rate of uted to it, is no isolated accidents and fatalities in incident. The construction construction work. industry has a drug probIn the construction industry, it is not lem – a huge one. uncommon to find 25 to 35 percent of preemployment drug tests coming up positive, Second sickest industry according to the insurance and risk manageOf all the employment categories in the ment firm IMRI. Even when construction United States, construction has the second workers know they are going to be tested, 3 worst record when it comes to substance abuse. (Substance Abuse by Industry Catto 5 percent still test positive. egory chart on the following page). And drugs bring big problems. The DeSome 12 percent of construction workpartment of Labor says drug and alcohol ers use illegal drugs monthly, double the abuse contribute to up to 65 percent of onEquipmentWorld.com | February 2017 21
Hard Hat High
| continued
the-job accidents and up to 50 percent of workers’ compensation claims. Substance abusers are absent from work an average of five days a month, are ten times more likely to steal from the company or other employees, use three times the normal level of employee health benefits and incur 300 percent higher medical costs.
Drugged out nation Even if you do regular drug testing and only work with people you trust, the problem of drug abuse is all around you. Last year the Substance Abuse and Mental Health Services Administration (SAMHSA) found that “almost half of all Americans take prescription painkillers, tranquilizers, stimulants or sedatives.” Codeine, such as was found in Sean Behschop’s drug test, is one such drug.
Some 119-million people, 45 percent of the population over the age of 12, took prescription psychotherapeutic drugs. Of those, 19 percent didn’t have a prescription and 5 percent of those say they got the drugs from a dealer. All told, 16 percent of all prescription drug use is actually misuse. This widespread illegal substance use is a contributing factor to the construction industry’s high injury rate. The evidence comes from construction companies that have implemented drug testing. According to a 2001 Cornell University study, construction companies that instituted drug testing policies saw a 51 percent reduction in injuries within a two-year time span. Additionally, companies with a drug testing program show an 11 percent reduction in workers’ compensation claims.
substance abuse* by industry Past year substance use disorder among adults aged 18 to 64 employed full time, by industry category: combined 2008 to 2012 Accommodations and food services Construction Arts, entertainment, and recreation Mining Utilities Management Retail trade Agriculture, forestry, fishing, and hunting Wholesale trade Other services (except public administration) Real estate, rental, and leasing Information Finance and insurance Manufacturing Transportation and warehousing Professional, scientific, and technical services Public administration Health care and social assistance Educational services
Percent: 0
16.9 14.3 12.9 11.8 11.5 11.4 10.5 10.5 10.4 10.1 10.0 9.8 9.4 9.3 9.1 8.8 7.2 5.7 5.5 5
10
15
20
*Drug use includes marijuana, hashish, cocaine, crack, inhalants, hallucinogens, heroin and prescription drugs used non-medically. (Source: National Survey on Drug use and Health from the Substance Abuse and Mental Health Services Administration.) 22 February 2017 | EquipmentWorld.com
What construction workers on Reddit have to say about drug use Reddit is a popular and anonymous online forum, where anyone can discuss anything. Accordingly, you get some eye-opening honesty when it comes to things such as drug use. We searched the forums to see what people who work in construction had to say about their drug habits. We’ve preserved the typos, bad grammar and misspellings to give you the full flavor of the experience.
How can I be successful on meth Im a 22 yr old construction workers living on my own…I was bound to come across it eventually, being the drug of choice for us blue collared hard working types… Make it a game Keep a schedule of doses that are structured around your work and responsibility. Make it into a game, “I will get high and then I will do my job with extreme precision in a calm demeanor and never let on that I am not naturally this on point. Sleep at least half as much as recommended by doctors. So about 2 to 4 hours a night. Using Tramadol to boost physical endurance Hey. I’m currently a construction worker…Problem is that sometimes work can be overwhelming…So I’m thinking of taking Tramadol after I eat at 12:00 to keep me going on rough days. Is this a really bad idea?
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Hard Hat High
| continued
drugs that top the hit list ing statistics began to emerge. Marijuana, the often legal high The Rocky Mountain High IntenThe election of November 2016 sity Drug Trafficking Area, a federal brought legalized, recreational mariresearch organization, found that the juana to four new states: California, number of fatal crashes in Colorado Maine, Massachusetts and Nevada. in which one drivWhen you add er tested positive those to the states for marijuana rose and districts that alfrom 8.1 percent in lowed recreational There are now 2013 (the year the marijuana before 75 million people drug was legalized the election – in the state) to 12.4 Colorado, Oregon, living with legal percent. They also Washington, Alaska access to pot. found that marijuaand the District of That’s more than na was involved in Columbia – there 20 percent of traffic are now 75 million one-fifth of the fatalities compared people living with population of the to just 10 percent access to legal pot. United States. five years ago. That’s more than The AAA Founone-fifth of the dation for Safety population of the found similar United States. (See chart “Where marijuana is now legal” results in Washington state where the percentage of drivers involved below.) in fatal car crashes who had recently Just one year into Colorado’s smoked marijuana increased from 8 experiment with full legalization for recreational marijuana, some disturb- to 17 percent in 2014.
where marijuana is now legal Illegal
Medicinal use allowed
Recreational use allowed
Decriminalized
What construction workers on Reddit have to say about drug use (continued): F*%k Benzo withdrawal I’m at work, on a construction site, I’m sitting in the Porta potty for the fifth time in the past six hours. My head is pounding. I have almost s*%t in my pants on my ladder twice and I can’t stop shaking. No one here understands what I’m dealing with. Btw this is an intentional detox. I should have planned better. Taking Adderall while doing manual labor in the heat I’m working with my dad tomorrow on a house he’s building and it’s going to be upwards of 100 degrees. I’ll probably be doing some serious grunt work and I was wondering if it would be wise to take some Adderall. I really don’t do well in the heat.
Reply: As a person who does manual labor every day, I can say from experience that days on amphetamine are always bad. I always end up feeling like my chest is about to explode, I’ll pass out, or something of that sort. Even when I haven’t really exerted all that much energy. If you absolutely have to, maybe give it a shot. Not recommending it by any means, though. Another reply: I do it sometimes and work outside doing manual labor. It makes me sweat like crazy so be sure to drink a lot of water.
24 February 2017 | EquipmentWorld.com
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Hard Hat High
| continued
Opioids’ deadly track record Construction workers spend more on opioid prescriptions than any other occupational category, says Liz Griggs, chairman and CEO of Canterbury Health Care. Griggs also cites a survey from the insurance firm CNA Financial that reports the construction industry has the highest rate of opioid addiction in the country, five to 10 percent higher than the general population. The news is filled with stories about the nation’s new opioid epidemic. Part of the problem results from over-prescription of painkillers, but a more sinister development is the rise of cheap heroin. In his book Dreamland, Sam Quinones says the new dealers are low-profile young Mexicans who deliver nearly pure black tar heroin to whoever needs it, whenever they need it. Heroin has moved out of the ghetto and into middle class and working class life with a nearly
foolproof marketing and distribution plan. Dealers choose rural markets and places where they don’t have to battle with existing gangs, avoiding New York and Chicago and concentrating on places like Portsmouth, Ohio, and Boise, Idaho. (See chart “Opioid’s deadly geography” below.) Quinones also says that some 70 percent of these heroin addicts started out with prescription pain medications – the same kind of painkillers often prescribed to construction workers who are injured on the job. According to the Centers for Disease Control, the combination of over-prescription of pain meds, dirty doctors and their pill mills and easyto-obtain black tar Mexican heroin has resulted in some 100 overdose deaths a day in the United States. In 2016, heroin deaths surpassed gun homicides. And opioid-related deaths of all kinds have surpassed the number of vehicle deaths in the United States as well.
opioid's deadly geography Age-adjusted death rates (per 100,000) for overdose deaths from all opioid drugs 3
5
26 February 2017 | EquipmentWorld.com
10
15
20
36
(Source: Centers for Disease Control.)
What construction workers on Reddit have to say about drug use (continued): Cold water extraction Does anyone have any experience with this? I work in landscape construction and have some oxycodone a friend gave me for my back, but I don’t want to f*%k up my liver any more than I already have with booze. Any input would be appreciated.
Got rid of my bad habits and haven’t felt better I decided to clean up and try to turn my life around…I was smoking almost an eighth a day, popping 2x20mg Adderall XR every morning at 7 am and getting less than 3 hours sleep…and take a Xanax to get to sleep only to wake up at 7am the next morning and pop more Adderall…So now, one month later, everything has changed. It was a struggle at first, but I picked up a job doing manual labor to “teach myself a lesson.” On my third day I moved over a ton of concrete by hand and after that my sleep schedule went right back to normal. (It’s impossible to work manual labor and stay up late partying on weeknights.)
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Hard Hat High
| continued
Methamphetamine: productivity’s best friend Among many blue collar workers, using methamphetamine is the way to get things done. The initial rush from ingesting meth brings increased energy and alertness, an elevated positive mood state and decreased appetite. Compared with other stimulants (e.g., cocaine) the high lasts much longer, ranging from eight to 12 hours. Users can get high in the morning, work like a fiend all day, come home, play with the kids, tune up the car and paint the house before the drug wears off. But what goes up, must come down. And with meth, the landing is brutal. Methamphetamine use has been linked to many psychiatric difficulties, such as depression, irritability, insomnia, paranoia and
bedded himself with a group of aggressive behaviors. meth users in Jefferson County, SAMHSA says that workers in the restaurant, construction, facMissouri, over the course of nearly tory, and mining industries, along a decade. In a 2013 interview with white-collar workers and truck in the New Republic, Pine said: drivers fall prey to the allure of boundless energy A study of meth users in rural Coloand alertness that rado found that use is particularly meth brings. Acprevalent among workers in construccording to a joint study compiled tion, agriculture, oil production and by Rural Center other occupations that demand long for AIDS/STD hours and/or tedious tasks. Prevention, a study of meth users in rural Colorado found that use is particularly “Many of the people I met began prevalent among workers in conmeth on the job – concrete work, struction, agriculture, oil production roofing, trucking, factory work. It’s a way to make the job easier, and other occupations that demand to work longer hours and make long hours and/or tedious tasks. more money.” Anthropologist Jason Pine em-
Colorado contractor: Legal pot and construction don’t mix
C
olorado, the first state to legalize recreational marijuana use, has become the unfortunate guinea pig for legalization’s effect on the construction industry. And while it may be legal, contractors around the state are united in their refusal to hire – and willingness to fire – anyone who tests positive for the drug. It doesn’t matter if workers toke up only on weekends. Zero tolerance means zero tolerance. “We are upfront that we will not accept an applicant if they are consuming drugs or alcohol,” says Dan Starr, president of the construction company GE Johnson. “That tends to weed out about 90 percent of them.” Starr says the zero tolerance attitude prevails across most companies in the state and that being up front about it has actually helped reduce the number of job applicants who fail the drug test. “The rejection rate is much higher for those companies that don’t make that clear,” he says. In addition to its pre-employment drug screening, GE Johnson also does random drug testing throughout the year. If an employee fails, they are fired immediately, but after 90 days they can reapply and come back to work if they pass the test.
28 February 2017 | EquipmentWorld.com
The problem is relatively rare. In the past five years the company has only had to fire one long-term employee who failed a drug test, says Starr. In an ingenious way, part of that success may be due to GE Johnson’s “stretch and flex” program, where the crews do a few minutes of warm up exercises every morning before work. The warm up is ostensibly to prevent muscular-skeletal injuries, but it also allows foremen to gauge the fitness of employees before they start work. If somebody is having trouble balancing, they may be sent home. If they show up ripped and red-eyed, their supervisor knows it immediately. And while the rest of Colorado may be celebrating the legalization of marijuana, Starr is firmly against it, to the point where his company will not build or work on any of the greenhouses and buildings being put up to grow and process the plant. In an interview with the Colorado Springs Gazette, he was blunt: “This is a very troublesome issue for our industry, but I do not see us bending or lowering our hiring standards,” Starr said. “Our workplaces are too dangerous and too dynamic to tolerate drug use. And marijuana? In many ways, this is worse than alcohol. I’m still in shock at how we (Colorado) voted. Everyone was asleep at the wheel.”
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Hard Hat High
| continued
Alcohol While the main focus of this series is illegal drug use (and marijuana even where it is legal), alcohol abuse creates many of the same problems. In February last year, New York City-based WABC television uncovered a group of construction workers from four different Manhattan
jobsites engaged in heavy lunchtime drinking (four and sometimes five drinks each) on three different occasions – including workers who were tasked with rigging crane loads and operating equipment. Reaction was swift. The contractor, Gilbane, fired several of the workers. And some in the city gov-
ernment have called for mandatory alcohol testing. The incident points to a much larger problem, uncovered in SAMHSA’s survey of heavy alcohol use by industry: mining and construction take the number one and two spots respectively. (See chart below).
heavy alcohol use by industry Mining Construction Accommodations and food services Arts, entertainment, and recreation Utilities Wholesale trade Management Manufacturing Agriculture, forestry, fishing, and hunting Retail trade Transportation and warehousing Other services (except public administration) Real estate, rental, and leasing Information Professional, scientific, and technical services Finance and insurance Public administration Educational services Health care and social assistance
Percent: 0
17.5 16.5 11.8 11.5 10.3 10.2 9.9 9.7 9.4 9.0 8.8 8.5 8.5 8.1 7.7 7.4 6.6 4.7 4.4 5
10
15
20
(Source: SAMHSA)
Next in the series: What’s to be done As discouraging as the statistics may seem, there is a lot you can do as a construction company owner or manager to push back against the corrosive effect of drugs in our society and mitigate the risks to your workers and your company. In Part 2 of this series we’ll bring you the latest on the
30 February 2017 | EquipmentWorld.com
legal battles being waged regarding legalized marijuana, a report on what construction associations are doing to strengthen the industry’s drug-free workplace programs, and a look at how the over-the-road trucking industry weeds out drug users.
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018
WHEEL LOADER machine matters
| by Richard Ries
FEATURES BEYOND TIER 4 FINAL ENGINES So what have wheel loader manufacturers been working on since Tier 4 engines and aftertreatment have been resolved?
We asked specifically about hydraulics, electronics and components. How have these areas been improved and how does that translate to value for the customer?
Controlled acceleration on the KCM 90Z7 Tier 4 Final loader precisely matches fuel delivery with acceleration objectives for improved fuel efficiency. Transmission shift points are varied to provide optimal balance between speed and rimpull.
32 February 2017 | EquipmentWorld.com
I
Hydraulics get efficient n the past, manufacturers used fixed-displacement pumps. These run the same flow and same pressure all the time regardless of demand. The only way to change their performance is to vary input speed by varying engine speed. More speed, more flow. Less speed, less flow. When flow exceeds demand, the excess dumps over a relief valve. Fixed-displacement pumps are inexpensive, simple and provided quick response when a control valve is opened. Most OEMs have now switched to variable-displacement pumps, which vary output based on demand. A fixed-displacement pump puts the same load on the engine whether the loader is running up a ramp with a full bucket or sitting idly by awaiting the next truck to get into position. A variable-displacement pump
puts little load on the engine until the pump is called upon to provide more output, at which time the load on the engine is increased in proportion to the demand placed on the pump. The result is that variabledisplacement pumps are much more fuel efficient. What about other factors? Because there’s no excess flow through a relief valve, the system runs much cooler. Initial cost is higher with variable-displacement pumps, but payback can come quickly depending on fuel cost and operating hours. Variable-displacement pumps are more complex than fixed-displacement pumps, but modern components give thousands of hours of service life before rebuild or replacement is required. Responsiveness has increased because pumps are inte-
grated with the machine’s electronics; there’s no more delay in pump response to an electric signal than there is a light bulb’s response to an electric switch. Variable-displacement pumps need input to know how much output to produce. The whole system is called load-sensing hydraulics. But while load-sensing hydraulics have become commonplace, they are not universal, says Eric Yeomans, product manager, Volvo Construction Equipment. “Customers should be aware that load-sensing hydraulics aren’t present in every manufacturer’s lineup.” There is at least one holdout to using variable-displacement pumps: SDLG. They’ve positioned themselves in North America as a lowcost leader by offering machines with fewer frills, and their hydraulics reflect this. “Our open-center, fixed-displacement gear pump
EquipmentWorld.com | February 2017 33
machine matters
| continued
A third valve for such attachments as a multi-purpose bucket comes standard on the Doosan DL450-5. Doosan offers two coupler styles for ease-of-use with a wide range of attachments. Flow is 70.3 gallons per minute; system pressures are 3,989 pounds per square inch working and 2,901 psi steering. does carry a fuel penalty of up to 20 percent,” says SDLG sales manager Nick Tullo. “But there’s also 30-percent less cost in a new machine and 30-percent less cost at replacement.” Tullo says while many loaders see 2,000 operating hours per year, SDLG customers’ machines average half that. Half the hours means it will take twice the time to pay back in fuel savings using a more expensive variable-displacement pump. “And if customers want a fully-featured machine, we walk them over to the Volvo line.” SDLG and Volvo have a distribution, sales and service agreement in the U.S. In the early days of electrohydraulics, operator feel was an issue. Once engineers figured out how to restore sensitivity to EH controls, they took their skills to new areas. The Eco Pedal on Hyundai loaders, for example, begins to resist pedal travel at 85 percent throttle. This encourages operators to work at more fuelefficient engine speeds. Controls for optional hydraulic features are typically integrated with standard controls. On Komatsu loaders with the optional third spool, for example, the operator uses the standard monolever to control the third spool by thumb. The third spool valve can be operated in either continuous or proportional flow mode.
Electronics make it easy Electronics maximize modern hydraulic systems, including the ways those systems can be tailored to fit the demands of specific applications and the preferences of specific operators. Power and work modes, return-to-carry and return-to-dig are among the features available thanks to electronics. At first these features were positioned as a way to enhance the performance of new operators, an especially compelling argument as the economy improved. Finding and keeping experienced operators became more challenging and contractors often had to hire less-skilled workers. But customers soon discovered that the benefits of electronic controls and features helped even seasoned operators increase their production and contractors with more advanced equipment were better able to attract and 34 February 2017 | EquipmentWorld.com
The Tier 4 Final Hyundai HL960 has a 222-horsepower Cummins QSB6.7 engine. The load-sensing hydraulic system uses a variable-displacement piston pump, providing up to 65 gallons per minute at up to 3,983 psi. Controls are either 2- or 3-spool (bucket and boom or bucket, boom and auxiliary).
Unloaded spool valves in the valve block of the JCB 437 allow arms to lower by gravity, not hydraulic force, to reduce fuel consumption. Full hydraulic dual-circuit braking and oil-immersed disks that turn at wheel speed reduce heat and drag and give the braking system a virtually maintenance-free lifespan.
New Holland C Series compact wheel loaders use an open-center, flow-compensated hydraulic system with a fixed gear pump. The W50 C is available with either Z-bar or parallel lift. The W80C (shown) is available with optional highflow hydraulics (34 gpm at 2,900 psi) and optional high-speed transmission yielding travel speeds up to 21.7 mph.
Ready. Set. slow.
Introducing the new I-Shift with Crawler Gears from Volvo Trucks. It allows drivers to travel at speeds as slow as 0.6 miles per hour and maintain a precise, controlled roll. It’s an ideal automated manual transmission for applications like pouring curbs or laying asphalt, where low speeds are crucial to doing the job right. See the new standard in powertrains: DoWork.VolvoTrucks.US
I-shift with crawler gears
Volvo Trucks. Driving Progress
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retain more advanced operators. As electronics grew, so did the challenge of presenting information to operators in a way that made it easy for them to manage all the options. Improvements to in-cab monitors have helped. Case, for example, offers an eight-inch LCD monitor that gives information on such items as fuel levels, temperatures and pressure readings, trip information, maintenance reminders and machine diagnostics. The monitor also serves as the display for the optional integrated rearview camera and provides fingertip selection of operating modes and features such as Auto Idle and Auto Shutdown. Functions not accessed through the monitor are easier to use, too. Case has an automotive-style steering console with familiar controls for lights, wipers, and turn signals. A membrane keypad replaces an array of rocker switches for other machine functions. Just as advanced hydraulics require careful control of fluid, advanced electronics require careful control of current flow. “We’ve incorporated a solid-state controller that provides software control over electrical power distribution and basic vehicle functions,” says Andrew Dargatz, brand marketing manager, Case Construction Equipment. “This design also eliminates fuses and relays and significantly lowers the amount of wiring throughout the machine.” Electronics make it easier for operators to do mundane tasks. Komatsu loaders have a remote boom and bucket positioner that will store three horizontal settings, allowing the operator to change attachments without resetting the bucket level. Automatic kickdown to first forward gear eliminates the need for the operator to manually downshift when entering the pile. “Making everyday tasks easier reduces fatigue and improves job satisfaction,” says Craig McGiniss, wheel loader product manager, Komatsu. “It’s as much a part of the improved operator environment as a quiet cab, high-capacity HVAC and comfortable seat.” Use of telematics remains spotty. One complaint is the drinking-from-a-firehose syndrome of way too much information, all the time. Yeomans says Volvo now offers both CareTrack reports and ActiveCare monitoring service. “ActiveCare was designed to cut through the noise and deliver only information that matters to the contractor along. ActiveCare will also provide specific recommendations for actions so customers know what actions will deliver benefits to their machine, their fleet and their business.”
Hard parts doing hard work In automotive parlance, hard parts are anything cast, machined, welded, etc. They include everything from pistons to door latches. Transmissions are quintessential hard parts, and transmissions have been updated to match advances in other areas. Lock-up torque converters provide more torque for demanding applications and improved fuel efficiency in all conditions, but optimal performance requires careful control. Matching engine output to lock-up is one of the tasks assigned to Komatsu SmartLoader Logic. SmartLoader Logic tailors engine torque to machine demands throughout operations and using this feature to optimize lock-up was a logical extension of technology. The K-II Series models of John Deere 524, 544, and 624 loaders 36 February 2017 | EquipmentWorld.com
An automotive-style console and control stalks make the cab of the Doosan DL350-5 familiar. F-NR controls on the joystick make direction changes easy. Pulling back on the joystick overrides the lift kickout, which sets a maximum lift height when working in enclosed areas or under obstructions.
Among the updates found in Cat Production Measurement (CPM) 2.0 is expanded system data memory, allowing storage of data for the last 3,500 payloads. The Advanced Productivity app gives owners remote access to historical payload data. Customers using the list management feature can track up to 250 each material and truck IDs and operators can now add or delete list entries on the fly on the touchscreen display.
Case GT Series loaders have three bucket and linkage options: Z-bar offers the best breakout force and is good for general purpose applications, XR for extended reach, and the parallel-lift XT for handling palletized and stacked materials. The 621G XT shown has 172 horsepower and can be matched with buckets of 2.5 to 4.5 cubic yards.
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machine matters have 5-speed transmissions as standard equipment; their predecessors had 4-speeds. Top speed is still 25 mph. The extra gear allows more flexibility in matching engine speed to the task at hand. Powershift transmissions with lock-up torque converters are available on models from the 544K-II to the 844K-III. While peak engine outputs remain the same, torque curves have been adjusted to further improve performance. The adaptive clutch cutoff was also changed on K-II loaders. On previous models, it could be set to Off or one
of three user-selectable positions. K-II machines make this decision automatically based on input from a wide range of sensors, including those for brake pedal pressure and throttle position. “Based on the data, the loader assumes an application,” says Matt Miller, 4WD loader product consultant at John Deere. “So, for example, it would give a later release when the machine is driving up a ramp to load a hopper than it would when the machine was operating on flat ground to load trucks.” Caterpillar departed from conventional thinking in
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7-11 Like the John Deere 524K-II andMARCH 624K-II, Las Vegas the 163-horsepower 544K-II is a Tier 4 Final machine approved for work even in non-attainment areas. Load-sensing, excavator-style hydraulics provide smooth combined functions and fast work cycles. Fuel efficiency is improved up to 10 percent over previous models.
Features of Volvo’s OptiShift technology include a lockup torque converter and Reverse By Braking (RBB). The latter senses the loader’s direction of travel and when the operator changes directions, RBB automatically reduces engine speed and applies the service brakes. The OptiShift system reduces fuel consumption, reduces components wear and improves operator comfort.
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machine matters developing their XE technology a few years ago. Engine power is split into two paths, one mechanical and one hydraulic. The two paths converge at a set of planetary gears where the mechanical path functions much like a direct-drive transmission. The hydraulic path, by means of a variable-displacement pump, works as a hydrostatic transmission to assist the mechanical drive. The amount of assist provided is continuously variable and the net effect is basically a continuously-variable transmission (CVT), which eliminates the torque converter. This feature is available on the 966M XE and 972M XE.
Liebherr calls their split approach to transmissions XPower. The XPower’s hydrostatic drive is best for charging the pile and traveling short distances while its mechanical drive is better for longer distances and when driving on gradients. Liebherr says XPower can reduce fuel consumption by up to 30 percent. The ratio of hydrostatic and mechanical drive varies continuously and automatically to match conditions. XPower is standard on Liebherr loaders. Limited-slip differentials also enhance drive performance. Sensors indicate which wheels have the most traction. Torque is allocated based on available traction to
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Whether rented, leased or purchased, the 357-horsepower Komatsu WA500-8 is covered by the Komatsu CARE program for the first 2,000 hours. Included are limited factoryscheduled maintenance, a 50-point inspection at each service, and two complimentary Komatsu Diesel Particulate Filter exchanges and two factory-recommended services of the Diesel Exhaust Fluid system during the first five years.
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The Tier 4 Final L 556 XPower loader from Liebherr has a 272-horsepower engine, an operating weight of 40,565 pounds, and a tipping load of 30,203 pounds. Shown is the “industrial” lift linkage; a Z-bar linkage is also available.
Engineering Innovation since 1921
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EquipmentWorld.com | February 2017 41 53194_7_Montabert_2017_EW_4-5x7-375_Feb.indd 1
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machine matters give superior tractive effort and maneuverability in tough terrain. Aaron Kleingartner, sales and marketing development manager, Doosan Construction Equipment, says limited-slip differentials are standard on Doosan wheel loaders. A hydraulic locking front differential is an option on most Doosan wheel loaders and comes standard on the DL550-5. It locks the front wheels together, providing superior traction for driving over loose, slippery terrain or pushing into big, heavy piles. Doosan wheel loader lift arms and bucket linkages have sensors so that operators can change their return-todig setting from inside the cab. “The cylinders and cutting edge return to the same position every time, enabling more efficient, consistent work,” says Kleingartner. Sensors and hydraulics also work together to provide ride control, which minimizes spillage when carrying a load and reduces operator fatigue. Perhaps the best example of the
| continued marriage of hydraulics, electronics and hard parts is on-board weighing systems. Numbers can be broken down by almost any subset, such as bucket, truck, shift and operator. The information is helpful to the operator and, in a connected worksite, to the truck driver. Production numbers are transmitted by telematics to an office along with other machine data. “Integrated operations tracking technology is a current trend,” says Juston Thompson, product training manager at Hyundai Construction Equipment Americas. “We expect to see continued development. Weight management is key to many operations and is one of the reasons it’s included as standard equipment on HL900 series loaders.” Thompson says the proprietary loading measurement system is accurate to within plus-or-minus 1 percent and has both automatic and manual settings for monitoring individual and cumulative bucket load weights. Data from the system is displayed on the in-cab monitor.
Thompson says the improved bucket design on Hyundai loaders features a wider opening, curved side plates and enhanced spill guard to maximize bucket capacity and minimize spillage during travel. Bucket durability is enhanced with Hardox 400 grade steel in key structural areas. Liebherr offers a Z-bar or what they call an “industrial” linkage for the L 550, L 556, L 566 and L580 XPower wheel loaders. While the industrial lift arm is best suited for heavy lifting, the Z-bar has been modified to provide 20 percent higher breakout force than previous models. Platforms around Cat’s wheel loaders are punched plates, providing a durable slip-resistant surface. Ladders are inclined at 15 degrees to make entry and exit more natural; an optional lighting kit enhances safety on the ladder. And M Series loaders include a windshield cleaning platform with a harness tie-off point on the left mirror to make it easy and safe to clean the windshield. “Caterpillar
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invests resources to improve how personnel move around on a machine and how they enter and exit the cab,” says Lucas Sardenberg, product marketing consultant, Caterpillar. “When it comes to safety, comfort and efficiency, it’s all about the details.”
Tier 4 Final lingers There is still some chatter about Tier 4 Final, even though it’s been in place since January 1, 2015 for engine sizes used in most wheel loaders. A lot of the discussion centers on control methods. KCM’s Tier 4 Final engines do not require diesel particulate filters. This is accomplished with advanced in-cylinder combustion control that virtually eliminates diesel particulates. With particulate matter under control without relying on a diesel particulate filter (DPF), oxides of nitrogen are managed with selective catalytic reduction and diesel exhaust fluid (DEF). Removing the DPF eliminates a significant maintenance item and eliminates the need for periodic DPF regeneration. DEF consumption varies but is typically between 4 and 6 percent of fuel consumption. There was some concern regarding the added cost of DEF, which runs about the same per-gallon cost as diesel fuel. To put customers’ minds at ease, Komatsu promotes their “fluid neutral or better” position, saying that the total consumption of fuel and DEF will be equal to or less than the fuelonly consumption of the machines its Tier 4 Final models replace. Komatsu says DEF use in their loaders is closer to 2 percent of fuel consumption. SDLG continues to offer Tier 4 Interim and even Tier 3 machines under the EPA’s Transition Program for Equipment Manufacturers (TPEM, or flex credits). But by the end of this year, SDLG’s full line will be Tier 4 Final compliant. Other OEMs have blunted the pain of the increased cost of Tier 4 Final machines by bundling in many of the features we’ve discussed here. SDLG, with their fewer-frills approach, doesn’t have this option and is instead focusing on minimizing Tier 4 Final costs.
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maintenance
| by Preston Ingalls
Collaboration, commitment and management buy-in are crucial for a successful CMMS implementation.
CMMS
IMPLEMENTATION You bought it. Now you have to make it work. Here’s a 14-point plan to bring your maintenancemanagement protocols into the digital age. STEP 1: DEVELOP GOALS AND OBJECTIVES It’s important to first develop the short and long term goals of what you hope to accomplish with the CMMS, such as inventory control, maintenance labor and material cost tracking, generating PMs, and planning and scheduling maintenance activities. It’s also vital to determine how the CMMS system will interface with your enterprise resource systems or
I
n January, we looked at how to evaluate and choose a computerized maintenance management system (CMMS). But that’s just half the battle. Implementing the system is equally as important. A weak effort here could bring disappointing returns on the investment, confusion in the ranks and egg on your face. By following the 14-step process below, you can have a successful implementation and reap the many rewards. But you don’t just flip a switch. A typical CMMS implementation for a construction or construction materials company takes six to 12 months.
accounting system. The integration of your CMMS and back office systems will necessitate answering the following questions: • How soon does that need to happen? • Did you intend to use tablets or smartphones and how soon does this need to happen? • Did you want your CMMS to generate and track purchase orders, and if so, how soon? EquipmentWorld.com | February 2017 45
maintenance
| continued
STEP 2: DETERMINE RESOURCE NEEDS Form an implementation team and appoint a project manager. The project manager must commit the majority of his or her time to the effort – you can’t just add it to their existing responsibilities. Make sure they are knowledgeable about maintenance processes, which can be a common failure point with many implementation projects. One of the first steps the team should take is to determine how much manpower you need to gather the information on the assets entered into the system. Are your assets currently identified and labeled with a unique identifier or asset number? If not, additional time will be needed to inventory and mark physical assets. Consider using an outside resource such as an implementation consultant who can reduce the learning curve and get this done sooner
mentation (and failures) as a pre-read before meeting with management. Some good sources for articles are reliabilityweb.com and maintenanceresources.com.
STEP 4: DEVELOP THE PLAN All CMMS software publishers have a project implementation template they use, often in the form of a Gantt Chart like the one below. The plan should be fairly detailed with start and stop dates and resources assigned, so it requires answers to the following questions: • Is there a critical path? • Are there key milestones that must be met? • What are the work order priorities, types and status codes that need to be identified?
STEP 3: INVOLVE MANAGEMENT Management should be educated as to the purpose, return on investment, benefits, costs and resources needed to successfully complete implementation. If they don’t understand the necessity of those resources, they will be frugal and overly selective. Be candid with the commitments you need for people, time and hardware. If you don’t ask for it, you won’t get it. Consider sending several articles on CMMS imple-
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You will need to delegate who will be responsible for each activity and create a suitable timeframe for completion. Follow up to ensure that those responsible for activities understand how to complete their tasks and have the resources to accomplish them. Share the plan with all team members. Make sure the work gets done – not just assigned. There are a few good quality project management software solutions available. For example, google the list PC Magazine published on January 5th, “The Best Project Management Software of 2017.”
STEP 5: DEVELOP STRUCTURES AND SCHEMES At this point, it is important to determine how things such as parts will be numbered and referred to in inventory control and bills of materials, and have a uniform way to refer to assets. This means selecting a numbering and naming convention. Will you use a company part numbering system over the vendor’s part numbering (highly recommended)? Will the numbers be intelligent or significant? This means the numbering scheme will provide information about the part itself. An example of an intelligent naming and numbering system would be to use something like RES100-2342, where RES stands for resistor, the first three numbers indicate the ohms and the last four are serial numbers. Al-
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though it takes time to set up an intelligent or significant numbering convention, it will save time and improve accuracy later. This is also the time to agree on problem-cause-remedy failure codes. PCR failure codes need to be agreed upon as IMPLEMENTATION most CMMS failure codes are too generic and not equipment or industry specific. This way, analysis of failures can be sorted more efficiently later.
CMMS
STEP 6: CONFIRM ASSETS You will be surprised how many asset lists are out-ofdate and inaccurate. A good step here is to do a physical inventory of all assets at all locations. This is best performed on weekends when work is least likely to disrupt the activity. Make sure every asset has a unique identifier or asset number, including trailers, light towers, portable compressors and other small equipment types. The physical inventory should result in “hands and eyes” on every piece of company equipment. Shop assets (like motors above a certain horsepower rating), pumps and compressors need to have an asset number assigned if they are repairable or recoverable. One of the values of a good CMMS is the ability to drill down for specific information, but you can only do that if you have enough detail.
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EquipmentWorld.com | February 2017 47 Untitled-37 1
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maintenance
| continued
STEP 7: USE THE MANAGEMENT OF CHANGE Implementing a CMMS will involve a change to the culture. You may be introducing computerized information management to folks who are computer illiterate or more comfortable with manual paperwork. Changes may be seen as threats by some. Our best advice: communicate, communicate, communicate. The more awareness people have about the what, why, and when, the less of a threat it appears. An effective format for educating and communicating change is called the management of change or the MOC 6-step communications format. The MOC 6-steps are: 1. Define the opportunity: Explain the rationale for the change. 2. Define the direction ahead: Explain in general terms what and why the change is occurring and what the end state looks like. 3. What is unchanged: Explain what remains the same. 4. What is changing: Explain what specifically will be changing or different. 5. Define commitments and next steps: Explain management’s backing and immediate next steps. 6. Contacts: Explain who to contact for additional information on the changes.
STEP 8: GATHER DATA One of the important tasks is transferring data from the old system. In some cases, the information may be so inaccurate that starting from scratch may be the best option. Another alternative is to transfer it via a spreadsheet formatted to accommodate the new system. Data migration is important and should be screened for inaccuracies prior to migration. This is called data scrubbing. Think of this as a quality control step. The equipment register will need to be populated with equipment specifics like: • Equipment model • Acquisition costs • Serial number • Horsepower • Warranty data
• PM procedures and frequencies • Parts and bill of material information • Functional locations
All your assets must be entered into the new CMMS. Consider hiring outside help to get this done quicker.
48 February 2017 | EquipmentWorld.com Untitled-89 1
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STEP 9: DATA MIGRATION Data entry is a tedious but important step. Who will do this job? It is not advisable that it be done by the project manager because of the time to perform it. Consider outside contractors, current employees or temporary hires. The good news is most of this is a one-time assignment. Next, you need to determine the best person to enter the necessary day-to-day information that the CMMS will manage. Will it be a planner/scheduler or an admin?
STEP 10: DEVELOP WORK FLOWS AND PDFS Many organizations make a mistake in automating inefficient and broken systems. Because their business processes never change, this approach simply automates existing difficulties and issues so that they occur faster than before. A recommended process is to redesign practices, processes and procedures. This is called re-engineering or business process re-engineering. Process mapping is done using process flow diagramming to study current process flows. These start out being ‘as-is’ maps that include the problems associated with them, and are then recast by mapping out an ideal or a ‘should be’ model. Once the new system is designed, an equipment build or CMMS process guide that includes coding and naming
conventions and other formats can be developed. This method would also involve a PM process guide. You would want a spares process guide that includes item naming conventions, abbreviations, how to deal with IMPLEMENTATION manufacturer’s part numbers. The MOC 6-step format can be used to inform people of the changes and training provided to show how to perform the new procedures.
CMMS
STEP 11: CREATE REPORTING PROCESS One of the key purposes of a good CMMS is the reporting capabilities. Otherwise, you can be “data rich and information poor.” Most decent CMMS programs come with a set of stock reports. Some should be generated automatically while others are upon request. The important point here is the reports should provide information to monitor progress and identify areas that need attention. Another feature is the ability to create custom or ad-hoc reports. Quality programs allow custom report generation with little effort. Some of the articles posted on reliabilityweb.com explain common reports, but the following questions should be answered at the start of the template generation process: • Who will receive regularly scheduled reports?
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EquipmentWorld.com | February 2017 49 Untitled-38 1
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maintenance • How often will you issue those reports? • Which reports are the most critical to your organization for decision making?
| continued Training is key to implementation. Make it hands on, at the computer.
Thinking about reports ahead of time will help ensure that the system is configured and used in a way that will get you the information you need. Decisions are made with reliable and prompt information
STEP 12: TRAINING Because of the complexities of the CMMS, training is required. This is one of the largest failure points leading to CMMS implementation disasters – underestimating training needs. All CMMS vendors provide training in many forms ranging from onsite to online.
50 February 2017 | EquipmentWorld.com Untitled-54 1
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Vendor training will allow more accuracy via their ability to answer questions and provide examples in real-time. Training is not an area where you can skimp. Consider how new employees will be trained and use the MOC 6-step format to help with education. Training needs to be hands-on at a computer.
STEP 13: AUDIT. AUDIT. AUDIT. Set-up a PM for monthly and quarterly data integrity reviews. You need to be vigilant in looking for weaknesses in CMMS data integrity. Otherwise the system will appear weak and inefficient. Remember “garbage in-garbage out.” Standard operating procedures lists or process guides need to be developed to ensure data consistency and integrity. Inspect what you expect. Routinely look for input errors, omissions, poor failure coding, inefficient naming conventions, improper structure and poorly generated PMs to prevent problems.
benchmark. To become the best, you study the best. Periodically conduct surveys to find out what is and isn’t working. Be open to critiques and respond to them. Practice intellectual curiosity by reading some IMPLEMENTATION of the resources mentioned here.
CMMS
Editor’s note: CMMS processes for asphalt and concrete plants often follow a similar path to what’s described above, but with additional provisions and complexity. If you would like to learn more about how to implement CMMS for plants, get in touch with Preston Ingalls. You’ll find his contact information below.
Preston Ingalls consults with construction industry fleets on equipment uptime and cost improvements and has led relability improvement efforts across 30 countries for companies such as Royal Dutch Shell, Exxon, Occidental Petroleum, Toyota and others. He can be reached at www.tbr-strategies.com.
STEP 14: CONTINUOUS IMPROVEMENT Protect and maximize your investment by constantly reviewing what works and what doesn’t. Use debriefing sessions to find out what needs to be improved. Don’t be afraid to visit a company your software vendor told you is optimizing its CMMS program. Use them as a
Preston Ingalls
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engines
| by Tom Jackson |
TJackson@randallreilly.com
DEF CONTAMINATION Tips on how to prevent this engine killer To prevent costly contamination, a closed system with approved DEF handling materials is your best bet for refills in the field.
W
required for the proper functioning of most modern diesel hen it comes to the new Tier 4 Final emissionscompliant engines, OEMs preach the need to engines with greater than 75 horsepower, including the maintain clean fluids. But when it comes to the engines on diesel pickup trucks. It is composed of 32.5 purity of your diesel exhaust fluid (DEF) used in these percent urea and 67.5 percent de-ionized water. DEF is engines, the cleanliness specs are off the charts. sprayed into the exhaust stream of the engine and run Take a 5,000-gallon tanker truck of DEF. All it takes through a catalyst to break down NOx emissions into to contaminate this tank is one-tenth of a teaspoon of a harmless nitrogen and water – a process known as selecmetal such as copper, zinc, chromium or nickel, says Luke tive catalytic reduction or SCR. (See illustration below.) Van Wyk, owner and sales manager of Thunder Creek Equipment. If you don’t Illustration of an SCR System know what a teaspoon looks like, those Selective Catalytic Reduction tiny salt packets you get in a fast food An emissions control in the exhaust restaurant hold about a teaspoon. Other stream of a diesel engine. contaminants such as iron, aluminum, • DEF is sprayed into the catalyst phosphorous, magnesium, calcium, • DEF is urea and water sodium and potassium can also ruin a • Catalyst is coated with rare metals tanker-full of DEF in amounts of two such as tungsten, vanadium or zeolith. teaspoons or less. • NH3 + NO1 + O2 = H2O + N2 DEF, if you haven’t heard, is a fluid Illustration: Thunder Creek
EquipmentWorld.com | February 2017 53
engines
| continued
DEF consumption typically runs from 2 percent to 5 percent of your diesel fuel burn. The reason such small amounts of trace metals cause problems is because these elements build up inside the exhaust catalyst that turns the DEF and diesel exhaust into water vapor and nitrogen, says Van Wyk. Compromising your SCR system with contaminated DEF could create a host of problems including: • Increased DEF consumption • More pollution in the exhaust • SCR system shutdowns, leading to engine shut downs • Damage to the catalyst, which could cost tens of thousands of dollars to replace • Voided manufacturer’s warranty The American Petroleum Institute developed a standard for the purity of the DEF used in vehicles and equipment. As long as you purchase and use API-certified DEF, the purity of the delivered product should be guaranteed. But once your DEF is pumped out of its certified source or container there are lots of ways it can become contaminated downstream.
as jugs with screw-off caps sold at retail, are not recommended for field use due the likelihood of dust and debris contamination in the air and around the fill portal, says Van Wyk. • Pay attention to the shelf life and storage conditions of your DEF stockAs the temperature rises, the piles. Store the fluid out number of months your DEF of direct sunlight and can maintain its purity falls, avoid extremes of heat from 36 months at 50-deand cold. DEF will freeze grees Fahrenheit to only 6 at 12 degrees Fahrenheit, months at 95 degrees. so allow for some expansion in your storage containers if subjected to low Chart: Thunder Creek Equipment temperatures. Freezing won’t contaminate the DEF, but you won’t be able to use it until it thaws out. • Monitor the shelf life. The shelf life of DEF is directly proportional to the temperature it’s stored in. In the cooler, middle and northern parts of the country you will typically get 18 to 36 months of shelf life. For southern states and warmer climates this may only be 12 to 18 months. (See chart above.) • Finally, Van Wyk recommends that you do not use additives in your DEF that claim to prevent freezing or say that they are DEF anti-freeze. There are products that purport to do this but they don’t have any official sanction from the API and could very well damage your SCR system.
How to keep your DEF supplies clean • Never handle DEF using anything other than DEF-safe containers and hardware. Most standard pump fittings and components contain zinc, nickel, chrome, brass or aluminum and can contaminate your DEF. The only acceptable metal component material is stainless steel. The containers for DEF are made from high-density, crosslinked polyethylene (XLPE). ISO standard 22241 covers these specs in more detail. • Avoid contaminating your DEF during transfer. Never use steel or galvanized transfer containers. Don’t use the funnel you use for oil fills, brake fluid, coolant or other fluids. Use only DEFapproved materials and keep the equipment, the area you are working in and the fill points spotless. Be especially vigilant about dust and dirt in the field. And never refill an opened container. • Whenever possible, use a closed system to dispense your DEF. These systems, designed specifically for DEF handling, are sealed much like a beer keg so that no external contamination can get into the fluid as it’s being transferred. They range from large trailer-mounted systems to simple sealed containers intended This cut-away of a DEF storage tank shows the heating element that will thaw for single use. Open systems, such frozen DEF in equipment in the field. 54 February 2017 | EquipmentWorld.com
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quick data
Aerial lifts
| by Marcia Gruver Doyle |
MGruver@randallreilly.com
A snapshot of new and used sales trends from Randall-Reilly’s Equipment Data Associates and TopBid auction price service.
Year-over-year change*
NEW: UP 9% USED: DOWN 16%
Auctions Boom lifts
Aerial lift auction prices, 2011-2016
Scissor lifts
$90,000
Boom lifts: Current
Current average auction prices for the top 10 models of boom lifts are now at $21,407, or 25 percent below the five-year average of $28,665. On the scissor side, current prices are now 16 percent below the five-year average of $10,571.
$85,000 $80,000 $75,000 $70,000 $65,000
Low: 19,434
High: 38,594
$
$
$55,000
Scissor lifts: May 2012
$50,000
High: $13,535
$45,000
21,407
$
Top three states for aerial lift buyers*
Scissor lifts: Current
Boom lifts: June 2016
Boom lifts: June 2012
$60,000
*Comparison of number of aerial lifts (including utility bucket trucks) financed Dec. 1, 2015 to Nov. 30, 2016, and Dec. 1, 2014 to Nov. 30, 2015. Source: EDA, edadata.com
8,852
$
Scissor lifts: June 2016
Low: $8,219
$40,000 $35,000 $30,000 $25,000 $20,000 $15,000
1
Texas: 355 buyers
2
Florida: 184 buyers
3
Georgia: 159 buyers
$10,000
2011
2012
2013
2014
2015
Dec.
Jun.
Apr.
Jan.
Oct.
Jul.
Apr.
Jan.
Oct.
Jul.
Apr.
Jan.
Oct.
Jul.
Apr.
Jan.
Oct.
Jun.
May
Jan.
Oct.
Jul.
Apr.
PRICE
Jan.
$5,000
2016
Trend prices for the top 10 models of boom and scissor lifts sold at auction, not seasonally adjusted. Source: topbid.com
190,000
$
Top financed new aerial lift*
Top auction price, paid for 2015 JLG 1350SJP boom lift with 6 hours at a Alex Lyon & Son sale on Feb. 1, 2016 in Kissimmee, Florida.
98,000
OTHER $ TOP BID:
2016 Haulotte HA130RTJ PRO, 14 hours, Ritchie Bros., Aug. 16.
5
$
1
00 0 , 0 9
AVERAGE
$
0 ,00
HIGH
Jan. 1 – Dec. 31, 2016; prices of boom and scissor lifts 5 years old and newer, U.S. sales only. Only includes bids $5,000 and above. $5,000 and above. Source: TopBid, topbid.com
LOW
Final bids unit count: 263
New
Personnel lifts new/used sales trends, 2006-2015* 6,000 5,500 5,000
Both new and used financed personnel lifts saw reflective peaks (both in 2104) and valleys (both in 2010) in the past 10 years.
3
$
52 5 , 8 Used
New high: 2014, 5,316 units
Other top selling new machine:
Skyjack SJIII-3219 121 units
Top financed used aerial lift:*
4,500
Used low: 2010, 2,210 units
4,000
Genie GS-1930 162 units
JLG 600S, 151 units
3,500 3,000 2,500
Used high: 2014, 4,814 units
2,000 1,500 1,000
UNITS
New low: 2010, 1,434 units 2006
2007
2008
2009
2010
2011
2012
*Financed equipment, 2006 - 2015, number of units sold by sale or lease. Source: EDA, edadata.com (Note: EDA personnel lift data includes utility bucket trucks.)
2013
2014
2015
*In terms of number of financed units sold Dec. 1, 2015 to Nov. 30, 2016. Source: EDA, edadata.com (Note: EDA reports are continually updated. EDA personnel lift data includes utility bucket trucks.) EquipmentWorld.com | February 2017 57
highway contractor
58 February 2017 | EquipmentWorld.com
| by Chris Hill |
ChrisHill@randallreilly.com
CONCRETE PAVERS: Control improvements and options, quick changes and flexibility boost contractor productivity
C
hanges in concrete pavers that benefit contractors have been led by two main factors: improvements in controls and the ability to make changes at a faster pace. Options for controls have scaled down in size, but have grown in capabilities. Control panels are smaller and sleeker compared to just a few years ago, but new advancements in sensors can now allow operators to control multiple functions that used to require workers on the ground assisting the operator up top.
“Everything can be set up on the operator’s platform,” says Frank Hansel, senior service technician for Power Pavers. “You don’t have to do it with tape measures, extensions or any of that any more. I can see what all my sensors are doing – they’re all electronic, not hydraulic.” Hansel describes the electronics as a “big deal” as they are much more sensitive. During the 2017 World of Concrete show in Las Vegas, Hansel provided an overview of the control features of the Power Paver SF-1700.
Wirtgen’s new SP 64i paver can switch between inset and offset paving applications, providing contractors with increased flexibility for multiple jobs. EquipmentWorld.com | February 2017 59
highway contractor
| continued crete or run short. Now you can shut just the sensors off. It goes to standby, which shuts all the sensors off, so the machine can’t pivot and it can’t go up and down. It freezes it and locks it in place. It also shuts off the propel, the vibrators and tamper bar. It kills everything.” When there is enough concrete loaded up, the operator can go from standby to pave and get back to paving. It starts at the same speed it was and at the same rpms. With the display screen on the control panel, an operator can see all the factors the sensors are monitoring. “If my sensors go up too high it stops the machine, so there’s no big bump. When you don’t have a big bump or dip. The machine is smarter, so it does a better job.”
Control panel for the Power Paver SF-1700. “You can turn your elevation and steering off at any time,” he says. “You can turn off your sensor if there is something in the way. The machine will freeze right there and you can get past the obstruction and bring the sensor back out and put it back online. It’s all in the computers and the innovations that have brought this capability to use. It’s just simpler for the operator and saves a crew time.” Hansel says when the SF-1700 is in pave mode all the sensors are live. “It used to be a big problem with the hydraulic sensors because you would run out of con-
Remote controls Guntert & Zimmerman is moving toward providing more options for operators to control their pavers, particularly the S 400 and S 600, from positions contractors prefer to be stationed. “We’re starting to go remote control on our operations console,” says Ben Hoover, Guntert & Zimmerman marketing manager. “That essentially makes it so the operator doesn’t have to be locked on to the top of the machine.” Particularly when pouring concrete, it’s beneficial to have unobstructed view of the pour, Hoover adds. “Some contractors like to go to one side at ground level and use the remote control belly pack. There they are able to
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operate the machine completely during the entire pour for more of a wide view, rather than being confined up in that small space.” Terex Bid-Well also is adding remote control options to its roller paver models. At the World of Concrete the company launched three remote control options designed to make setting adjustments to their 2450, 3600 and 4800 roller pavers from ground level while paving. “While paving, it is common for the operator to make minor adjustments to machine settings,” says Dean Johnson, Terex Bid-Well service manager. “Without our remote operation, he or she will either call down to a laborer on the ground to make the adjustment or will have to stop the paving operation to make the change. Our remote control units give the operator the flexibility to move away from the platform and have greater control over machine settings.” The system includes two tethered control boxes that can be attached in any position on the paver’s frame. And operator can change paver speed, engine throttle, power crown adjustment and paving width. Control options include an entry-level keypad control, a local control featuring a touch-screen display or a radio remote control panel that allows a worker to carry along machine controls and operate the paver from the ground level from every position around the machine. The initial display screens for the units include a login
Power Paver SF-1700 on display at the 2017 World of Concrete. page so only operators with authorization can control the unit. The screen also displays a daily maintenance prestart-up checklist for the carriage, power unit, legs, travel bogies and controllers. Operators can see a live status overview of critical machine operating data and have access to auxiliary screen settings after prestart-up. They can also access and adjust with the remote unit the frame width, crown points, leg elevation, machine travel and working lights. And techni-
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highway contractor
| continued
Terex Bid-Well’s new radio remote control operator unit for its roller pavers. cians can track and repair any issues during operation with the units imbedded diagnostics screen.
Versatility Width adjustments have plagued concrete paving operations for years, as it took a series of steps involving bolt and section removals, adjusting and then reassembling side units. “Typically it would be about a two-day job at least,”
62 February 2017 | EquipmentWorld.com Rubbertrax_EW0117_PG.indd 1
Guntert & Zimmerman S 600 on display at the 2017 World of Concrete. says Ron Guntert, president and CEO of Guntert & Zimmerman. “In 2009 we came up with a telescopic end section that allows the operator to hydraulically expand the ends. There is a hydraulic cylinder in the expansion tubes on the side that pushes them out and then you add spacers. They hang on hooks on the assembly on the front and back and a pin goes in the bottom. You have a three-piece system that an operator can handle. These surfaces are all machined so when this all comes back together everything is flat, the bottom and everything is flat and square. So a man or two can get this done in a
12/7/16 8:36 AM
manner of less than two hours.” “And we have some customers that do two, even three changes in a day, which in the past meant if you had to do more than one pour in a day you’d have to have another paver available.” Guntert says a contractor approached the company about solving his problem of switching between job types frequently, such as paving a parking lot one day and working a highway job the next. “He said to use he didn’t want to sacrifice the function of the side forms, but he wanted it to be telescopic. So we can now do this with 3 feet, or 1 meter. We also have another one that allows us you to do up to 4 feet telescopically, and we just did one for an Australian customer that did 7 feet or 2 meters, because they were constantly going between 8.1 meters and 10.1 meters.” Wirtgen’s new SP 60i line, including the SP 61i, SP62i and SP 64i, is boosting concrete paving versatility with both inset and offset applications. The line is a combination of the company’s SP 500 and the larger SP 90i series. As with the SP 94i and SP92i pavers, the SP 60i line offers multiple slipform systems for inset paving. The SP 62i and the SP 64i can pave up to 25 feet wide at thickness up to 18 inches. Where the versatility comes into play is the offset paving capabilities. The SP 60i series can accept trimmers and multiple conveyor belts or augers, making it an option for contractors needing to switch applications. The SP 61i, for example, can slipform pave medium to large profiles on either the left or right side of the machine, including roadway edging, concrete safety barriers, water gullies and paths up to 12 feet wide. This, combined with a higher lifting capacity from the columns, gives operators more flexibility in tight spots, such as a concrete safety barrier. Enhancements for the operator include a walkway that for the first time extends across the entire width of the machine, and a standardized operating and control concept similar to the SP 90 series. This is made up of a central control system and four
local control systems that are standard. Additional options include plug-and-play connection for remote controls that can be connected to each of the crawler tracks to accelerate slipform paving setup by positioning and zeroing the crawler tracks and swivel arms. Wirtgen displayed the SP 64i, the largest in the new line, at the World of Concrete. It features four crawlers on swivel arms as well as the new hydraulic concept included on the entire line. This change gives the series the capability of adding the offset forms.
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35th Management Conference & Annual Meeting March 4-6, 2017 Las Vegas, NV
Leadership: Beyond Management You are probably a great manager, but leadership demands more.
• CEOs, CFOs • Anyone who impacts your fleet intensive company
For complete conference schedule and hotel info – go to: www.aemp.org/annual
• New Technologies that Improve Safety and Reduce Your Costs • The Impact of the 2016 Election Cycle on Your Fleet • How Tier 4 Final is Changing the Game, and What’s Coming Next • The Equipment Triangle: More Important Now than Ever • How to Make a Case for Telematics Adoption in the C-suite • Leveraging AEMP University to Train Your Staff • How to Prepare Fleet Organization for the Next Recession • Contractor to Contractor Rentals: What to Watch For
HOTEL
• Equipment Managers and their fleet management team
SESSION HIGHLIGHTS
WHO
Applying effective management strategies to your fleet operations is necessary to stay in business, but you need more to be the market leader you want to be. The dynamic nature of this industry includes telematics, Tier IV regulations, safety considerations, and many other topics separating the leaders from followers at an ever increasing rate. Becoming a leader in the equipment management profession will help you and your company realize your full potential. Connect with other industry leaders at this conference – the networking alone is worth the cost of registration!
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safety watch
| by Tom Jackson |
TJackson@randallreilly.com
I
Illustration by Don Lomax
Warming fire turns deadly
t was cold, rainy, winter morning in the woods of Oregon, when the company mechanic arrived at the crack of dawn to perform field maintenance on the equipment. The 37-year-old mechanic was known as a safe and conscientious worker. He had been trained in basic safety procedures, hazard communication and Oregon-OSHA compliance. His company was one of the state’s largest logging and construction firms. As the mechanic began prepping for his work, a coworker started a warming fire using a mixture of diesel fuel and chainsaw gasoline. The coworker walked away from the fire for about 15 minutes to make a cell phone call. Accident investigators believe the mechanic, in an attempt to boost the fire in the coworker’s absence, poured straight gasoline from a 5-gallon container onto the smoldering fire. Heat from the fire vaporized the gasoline causing an explosion that engulfed the mechanic in flames. Date of safety talk: Attending:
When the coworker returned to the scene he found the mechanic on the ground a short distance away, still on fire. The 5-gallon plastic gasoline container was also found nearby, burning as well. The mechanic died at the scene as a result of his injuries.
How this accident could have been prevented: Never pour gasoline on an open flame or smoldering fire or use gasoline near an open flame. In addition to the likelihood of an explosion, the flames can travel up the stream of gasoline to the container and cause a massive explosion. Use appropriate materials to start and stoke a fire. The only approved method for using liquid fuel to start or stoke a fire involves the use of a drip torch with a diesel-gasoline mixture ratio of 3 to 1 or 4 to 1. Gasoline by itself is too volatile to start or stoke fires. There are also materials you can use that are designed
Leader:
specifically for starting fires in the woods. These can be mixtures of sawdust and wax or solid fuel gels that will not suddenly accelerate combustion. Employers should train workers on safe procedures for starting and stoking fires. These include: • Clear adequate firebreaks around warming fires or use burn barrels • Never use gasoline to stoke a fire. • Keep fires small. • Keep fire extinguishers and fire suppression tools nearby. • Keep chainsaws and saw fuel at least 10 feet away from open flames. • Do not engage in horseplay around a fire. • If your clothing catches on fire, remember to stop, drop and roll; and cover your face with your hands. For more information on this investigation and related fire-safety links go to: www.cdc.gov/niosh/face/ pdfs/06or001.pdf
_____________________ EquipmentWorld.com | February 2017 65
alerta de seguridad
| por Tom Jackson |
TJackson@randallreilly.com
Una fogata abrigadora se vuelve mortal
Cómo pudo haberse prevenido este accidente: Nunca vierta gasolina sobre llamas o fuego ardiendo ni utilice gasolina cerca de un fuego ardiente. Además de la posibilidad de una explosión, las llamas pueden recorrer el chorro de gasolina de regreso al contenedor y causar una explosión masiva. Use materiales apropiados para iniciar y atizar el fuego. El único método aprobado de usar líquido combustible para iniciar o atizar el fuego involucra la Fecha de la charla de seguridad: Asistentes: 66 February 2017 | EquipmentWorld.com
Líder:
Illustration por Don Lomax
E
ra una mañana de invierno fría y lluviosa en los bosques de Oregón, cuando el mecánico de la compañía llegó al quiebre del amanecer para realizar tareas de mantenimiento en la maquinaria. El mecánico de 37 años era conocido por ser un trabajador precavido y consciente. Había sido entrenado en procedimientos básicos de seguridad, comunicaciones de riesgo y en el cumplimiento de las normas de OSHA de Oregón. Su compañía era una de las más grandes firmas madereras y de la construcción del estado. Mientras el mecánico empezaba a alistarse a trabajar, un colega empezó una fogata para darse calor usando una mezcla de combustible diesel y gasolina de la motosierra. El colega se apartó del fuego por cerca de 15 minutos para hacer una llamada en el celular. Los investigadores creen que el mecánico, en un intento por acelerar el fuego, derramó la mezcla de gasolina directamente de un contenedor de cinco galones sobre el fuego ardiente. El calor del fuego evaporó la gasolina causando una explosión que envolvió al mecánico en llamas. Cuando el colega regresó a la escena encontró al mecánico sobre la tierra, todavía ardiendo, a una corta distancia. El contenedor plástico de cinco galones de gasolina también fue encontrado cerca, igualmente ardiendo. El mecánico murió en el lugar debido a sus heridas.
utilización de una antorcha de goteo con una mezcla proporcional de diesel-gasolina de 3 por 1 ó de 4 por 1. Existen también materiales para iniciar fogatas compuestos de aserrín y cera y combustibles sólidos en gel que no acelerarán la combustión de forma repentina. Los empleadores deberían capacitar a los trabajadores en los procedimientos seguros para iniciar y atizar fogatas. Entre estos se incluyen: • Despeje áreas apaga fuegos en torno a las fogatas calentadoras o utilice barriles de quemar. • Nunca utilice gasolina para atizar una fogata. • Mantenga las fogatas de tamaño pequeño. • Mantenga cerca un extinguidor de incendios y herramientas supresoras de fuego. • Mantenga el combustible de las motosierras y cortadoras al menos a 10 pies (3 metros) de distancia de las llamas ardiendo. • No se ponga a juguetear cerca de una fogata. • Si sus ropas empiezan a arder recuerde detenerse, acostarse y rodar –detener movimientos que podrían atizar el fuego, acostarse sobre la tierra y rodar para quitarle oxígeno al fuego–, y cúbrase la cara con las manos. Para mayor información sobre esta investigación y hallar enlaces relacionados con la seguridad contra el fuego visite: www.cdc.gov/niosh/face/pdfs/06or001.pdf
Looking for safety resources? ..............................................
Equipment World’s Safety Watch articles are now available for download on our website. Designed for use in training and in toolbox talks, the articles cover a range of important safety topics such as falls, trenching, welding, back-over accidents and more.
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Each Safety Watch features an actual construction accident, and outlines ways to prevent similar accidents from occurring on your jobsite. AVAILABLE IN ENGLISH and SPANISH
Visit equipmentworld.com/safetywatch
CONGRATULATIONS
to the 2016 Contractor of the Year winner and finalists IN
R
E
N
W
Gregory & Dawn Tatro G. W. Tatro Jeffersonville, Vermont
Garry Boyce
David and Eric Covington
Terry Michael Brock
Boyce Excavating Slate Hill, New York
DECCO Contractors-Paving Rogers, Arkansas
Brock’s Grading and Land Clearing Hartsville, South Carolina
Tina Dieudonne
Joseph Porchetta
Dieudonne Enterprises Harahan, Louisiana
GMP Contracting South Plainfield, New Jersey
Jeff Hansen
Jack Bailey
Hansen Bros. Enterprises Grass Valley, California
JBR Incorporated Fredericksburg, Virginia
Michael Brown B & P Excavating Sedalia, Missouri
Roger, Roger Jr., Kevin and Damon Brown R. Brown Construction Willow Creek, California
Sponsored by:
Alfred Gorick Gorick Construction Binghampton, New York
James MacKay MacKay Construction Services Wilmington, Massachusetts
contractor of the year
| by Wayne Grayson |
WayneGrayson@randallreilly.com
Born to build, Jack Bailey combined stick time with business smarts to create a legacy
Jack Bailey, owner of JBR Incorporated, says his business places the concerns of his customers as its top priority. “Whatever we do is a pie,” he says. “Everyone deserves a slice.”
W
hen Jack Bailey was a boy, his father took him to a piece of property he had bought and sold, tripling his money in only 90 days. “He said, ‘Son get out of construction. Development is where the money is at,’” as Bailey recalls. The boy listened, but the man has been unable to pull himself away. Put on a bulldozer for the first time when he was 9 years old and mentored by a father and grandfather who provided for their families the same way, Bailey says he just has too much dirt in his blood. “When I tell people ‘I’ve been around this business all my life, there’s the proof,” Bailey says, pointing to a black and white photograph taken in March of 1959
where a 3-year-old Jack Bailey, his father and grandfather are all present. After dropping out of college due to what he calls “impatience,” Jack started a small grading company with a partner who eventually bought him out. He then went to work for a development firm in Virginia Beach where he was placed in charge of construction. In the early 1980s he bought that company’s Fredericksburg-based division and built Bailey Hassell and Associates, a construction firm 120 employees strong. However, “the stress almost killed me,” Jack recalls. “I remember the first time we hit $3 million in sales and I looked at the margin and thought ‘That’s pretty sporty,’”
Jack Bailey, JBR Incorporated City, State: Fredericksburg, Virginia Year Started: 2003 Number of Between 30 and 40 employees: Annual revenue: $-8 -10 million Markets served: Excavation, pipe, total site packages
he says. “Then I hit $10 million in sales and the margin was the same frickin’ number.” In early 2001 he liquidated that business. “We had some clients go broke on us and we took a hit for almost $5 million,” he says. “What I learned from that experience though was that when you get to a certain size, you stop building projEquipmentWorld.com | February 2017 69
contractor of the year |
continued
The JBR offices in Fredericksburg, Virginia
Bailey (left) talks with employees inside the JBR shop.
ects and start building files. I hated it. Years later, I had a conversation with the Lord one day in a Denver hotel room that if the opportunity ever comes up to get back into that business, I said I’m going to do it differently and I’m going to do more with less.” After working a couple of years 70 February 2017 | EquipmentWorld.com
traveling the country as a consultant for an international bank, he got a call from a client asking if he’d be interested in partnering, buying some equipment and starting a business. In 2003, JBR was formed. “Anybody that’s in this business – and some people work
their entire life in a cubicle and never have anything to show for it – deep down inside that’s what drives us,” Bailey explains. “We leave something behind for the betterment of mankind. It sure as hell ain’t the money and the risk. Many times, the risk is far greater than the reward.”
Consulting gives JBR an edge The company steadily grew, incorporating the consulting skills Jack polished up, and continued to make money through the recession. Today JBR employs between 40 and 50 employees and pulls in revenues between $8 million and $10 million. “If you look at our logo it says ‘construction/consulting.’ What we do today is we rely on the hundreds of years of collective experience my lead team has. While certain jobs are always different, it’s just dirt, pipe and roads. So everything I see today is a similar situation to what I saw somewhere else,” Bailey says. However, though the company does account for consulting revenue, that element of the business only brought in between $12,000 and $15,000 in 2015. But Bailey says that’s because the company has become fairly adept at converting consulting calls into winning bids. “If you pay for the construction, you get the consulting for free. Once we get a customer we never lose them,” he says, explaining how much intangible value his consulting experience brings to the business. “If someone needs help getting their plans pushed through, I’m awfully good at that. If someone needs to sit down with their engineer and bring some suggestions to the table as to how to cost benefit the owner, this gray hair is worth something there,” he says, pointing to his head. “And Young Jack is now part of that because he’s seen some things. And we’ve built a reputation for being fair and looking out for the customer.” “Young Jack” is Bailey’s son. Though a passion for stock car racing led him on a path to driving in NASCAR’s Craftsman Truck Series (now known as the Camping World Truck Series), in 2010 he returned to the family business and is now the vice president of JBR. Bailey says he plans to exit the business within the next 10 years and let Jack Jr. buy him out.
Bailey points to a photograph in his office from 1959 where he, at 3 years old is present on a jobsite with his father and grandfather.
People first Beyond the edge that consulting provides, Bailey says the thing that differentiates his company from others is that he puts the concerns of his customers first. “I walked into a competitor’s office one day and saw a picture of a boat and on the back of it, it said ‘Change Order.’ And that’s the mindset of most contractors,” Bailey says. “Our approach is that whatever we do is a pie. Everyone deserves a slice. Everyone deserves to make something for what they do, but let’s not gouge the customer.” Bailey says another top prior-
ity is sharing the wealth with his employees. “The guys here, if you tell them to suck it up, they know you’re not BS’ing them,” he says. “Because the flip side of that is in good years when we do make money I share it with them. I’ve lived in the same house for 32 years. I don’t have a boat or an airplane. We had a great year last year and I shared it with our employees. We do more with less. I pay them well, give them the proper tools to work with and then don’t want to hear about the labor pains, just show me the baby.”
Bailey has a 10 year plan to transition the business to his son, Jack Bailey IV.
EquipmentWorld.com | February 2017 71
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road technology
| by Chris Hill |
ChrisHill@randallreilly.com
Contractors warm up to intelligent compaction as spec requirements increase
A Hamm roller fitted with the company’s intelligent compaction system on a California Department of Transportation pilot project on State Route 25 near Tres Pinos.
I
ntelligent compaction (IC) has been the most-touted development in roller technology the past few years. It is quickly becoming a necessity as transportation agencies gradually integrate the requirement for it into their specifications.
For example, by 2018 the Minnesota Department of Transportation will require any project bigger than 5 lane miles to have 100 percent IC compaction. Currently, 21 states and the District of Columbia have some form of specifications in place for the use of IC with asphalt. (see
sidebar “Intelligent compaction resources” on page 78.) Requirements such as these have nudged contractors into implementing the technology. “We really don’t have a choice in Minnesota to not have IC if you want to bid on the big roads,” EquipmentWorld.com | February 2017 73
road technology
says Kirk Langum, director of support services for Hardrives Incorporated. The Rogers, Minnesota-based contractor added IC into their operation for the 2016 season, primarily due to the IC spec requirement on three jobs. These three jobs, according to Langum, were around the 35,000to 36,000-ton range and presented crews with some challenges in getting used to the Cat Compaction Control system on their Cat CW34 rubber-tire and two CB66B tandem-drum rollers. It took some getting used to, admits Langum. Crews achieved 33 and 36 percent potential density on their first two jobs using the compaction systemequipped rollers, but then shot up to 77 percent potential density on the third job. “Familiarity of the system, along with a little bit different mix, helped us improve 74 February 2017 | EquipmentWorld.com
| continued
on that last project,” he says. He adds that having Matt Krier, IC field superintendent, out on the project helped as well. “With Matt being out there full time and everything daily working like it should, we were able to really monitor rolling patterns and get the coverage we needed to get to get our density,” Langum says.
Top benefits Much of the focus on IC hones in on stiffness and density, and while these attributes are improved with the use of IC, contractors are beginning to realize that pass mapping and temperature readings are the top benefits, according to Tim Kowalski, applications support manager for Hamm. “Pass count and temperature are the two things that I try to show people that they need to be monitoring,” he says. “There is too
IC displays provide operators with color-coded renderings that provide pass counts, coverage and mat temperature.
much concentration on stiffness. And a lot of people are under the misconception that stiffness is going to give you density. It doesn’t give you density because stiffness in hot mix is related to temperature and time.” He says the top factor for compaction is consistency, which is what IC technology is best at monitoring. “The same speed, same amplitude, same frequency, same impact spacing, number of passes and the same temperature range are what we’re looking for. Consistency is what is going to drive the better compaction.” Krier says the temperature sensors on their rollers gave Hardrives’ operators an advantage
WITH YOU FROM THE GROUND UP The work may be under your feet, but you’re looking ahead—to the next challenge and the next deadline. We’re right there with you. You can count on our equipment to handle every task on your site, on our dealers to keep it running efficiently, and on our real-world training to help you master the latest techniques and technologies. Get the tools to tackle whatever challenges come your way. Visit our online resource center for mobile apps, calculators, application guides and more. Resources supporting you from the ground up—that’s what we’re built to deliver. Unlock the resource center at cat.com/AsphaltContractorResources
© 2016 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, BUILT FOR IT, their respective logos, “Caterpillar Yellow”, the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.
››
road technology
in time. “It helped with having temperature sensors on the front and back so the roller operators knew the optimum moment that they could get on that mat,” he says. Temperature readings are crucial in balancing stiffness and density, says Kowalski. But having tunnel vision solely on stiffness won’t necessarily provide a quality compaction. “I can pave a mat down and not touch it and it will actually get stiff without rolling it,” he says “But that doesn’t mean I’m going to get compaction.” Stiffness can provide a lot of hindsight information, Kowalski explains. First, it will indicate if there is a temperature change. 76 February 2017 | EquipmentWorld.com
| continued
Second, it will signify a mix change. Finally, it will show if there’s a change in subgrade. “Stiffness is not going to tell you density, but it will tell you if something has changed,” he adds. “Now if you get consistent stiffness numbers you know you should get consistent readings, you have a consistent material you’re laying over the top of and a consistent material you are placing.”
Pass mapping Krier says Hardrives’ operators improved their pass coverage under the Cat IC system because they were able to see where the roller traveled. “Every roller operator admitted that being able to
Hardrives Incorporated began using Cat Compaction Control on two CB66B rollers, such as the one seen here, and one CW34 rubber tire finish roller during the 2016 season.
see their patterns was great, but not all of them will admit they were actually missing anything,” he jokes. “We could see it on the charts their coverage was actually a lot better than when they weren’t using it when we wouldn’t let them see it,” Langum says. “It just really increased their coverage, which really helps us because we never know where a core sample is going to be taken.”
road technology
| continued
“After we used IC for some time I talked to one of the finish roller operators,” Langum adds. “He said that before he was rolling a lot more than he thought he had to, so he had a little extra time to be more efficient with the time he had. It’s less fuel for us with less use of the rollers.” However, reaction to adding IC at Hardrives wasn’t necessarily positive in the beginning, says Krier. “We had a few operators who were not happy about having more technology that they were supposed to rely on added to their machines,” he says, “Some thought we were trying to monitor them and their performance. When they realized that wasn’t the case, that it was just to put forth a better product, they really came around to it. We found a lot of them that would really take the time to learn how to use the display screen and go through the separate screens and look at their temperature and their pass count and their coverage. By the end of the season they really enjoyed using it.” Much like Hardrives’ operators initial thoughts, Kowalski admits that not all contractors have been enthusiastic about adding IC to their operations. Some have viewed it as a “finger-pointing tool” for state departments of transportation to identify breakdowns in pavement quality. “Some of the bigger contractors that have been using it early on have found that there has been a benefit to them for what they’re trying to do for consistency,” he says. “I think a lot of it has to do with how the states actually put it into their specs to present it the contractors in how it can be a useful tool for them. “Manufacturers are constantly upgrading the system and there are more states that are going to 78 February 2017 | EquipmentWorld.com
a VRS system, or virtual reference station,” Kowalski continues. “States will have their own stations around, and then we can tie into that instead trying to have a separate base or doing something different on our own. So the states are looking to make it easier for the contractors to want to use the system.”
IC as a training tool One side benefit to the capabilities of IC and all that it can measure is the potential for improving operator skill. “I see that contractors who have been using it on a regular basis have realized that it is a great tool for training,” Kowalski says. “That is especially the case if you have younger operators that are looking to improve how they are rolling, and looking at pass counts making sure they get the number of passes they need. They also can make sure that their cross over areas on their stop and start are thoroughly vibed through, and not just static, so they can improve the compaction in crossover areas.” Kowalski says the City of Los Angeles is one of the prime spots for working with an agency on IC integration. “They’re looking at it for training purposes to start with,” he says. “We went out there and did a project with them just to show them how they did things, and they were amazed at how much time they were wasting and over-rolling a lot of the projects, and actually destroying the mat.” Now he says the city is looking at IC not only as a tool to reduce the number of passes, but a way of saving money on fuel, getting better compaction and longer lasting materials. “They see it as a huge advantage,” he adds. Langum agrees that the training
potential for IC would be beneficial to Hardrives. “We’re bringing in new and younger people now and moving people to different roles. So I see in the mapping that it’s going to do nothing but help them understand what a rolling pattern is, and what 100 percent coverage looks like. I could see it being a good training tool in the future for new employees as well as our existing employees.” “I believe as we become more familiar with it, intelligent compaction will help us overall on any job that it is required on, and some that it’s not required on when we choose to use it to achieve a higher density potential for incentives,” says Krier. “When we become more familiar with it, our operators saw that they were getting 100 percent coverage with all their passes and that there was no failed core. We’ll see those density numbers keep on rising.”
Intelligent compaction resources Transtec Group’s intelligentcompaction.com offers a series of resources for the IC community, including a list of links to state specifications. In addition to states, the list includes the District of Columbia, as well as the Federal Highway Administration (FHWA), the Association of State Highway Transportation Officials and federal lands. The site also provides materials for on-site IC training for roller operators and quality control technicians, as well as results from IC projects funded by FHWA.
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technology
| by Tom Jackson |
TJackson@randallreilly.com
ADAPT OR DIE Kiewit looks at the past and the future of construction and why you must embrace technology to survive
Technology will be one of the key attributes to insure the success of construction companies in the next 50 years.
K
iewit is known as one of the country’s top construction firms. What is less well known is that they’ve diversified into software development. InEight is the company’s wholly owned subsidiary and offers HD Suite a group of software programs covering the gamut of back office and field solutions for all sizes of companies in the building, infrastructure, mining, oil and gas, and utility industries. (For more on this, see subhead “By contractors for contractors” on page 82). So why would a $9-billion, global construction company diversify from dirt and diesel into digits? “We did an internal study and looked at the top 500 construction companies from 1965 and compared that list to the top 500 companies in 2015,” says Chris Dill,
vice president of Kiewit Technology Group. “What we found was startling – 450 of 500 who were on the list in 1965 were gone in 2015,” Dill says. “Not off the list…gone.” Dill made his remarks as the closing keynote speaker at this year’s Trimble Dimensions conference, and in a follow up interview with Equipment World. Kiewit dug into the details and found three primary causes for the demise of 90 percent of the country’s top construction companies. • Change. They failed to recognize what was going on around them quickly enough to address it and mitigate the challenge. • Innovation. They failed to adopt and use technology. • Risk. They took on projects that went drastically over budget.
But Kiewit is also keeping its eye on the challenges of the future, Dill says, including: • A global population of 10 billion by 2050. The construction market needed to serve this population will grow to $15 trillion a year – a great opportunity, but only for those companies with the systems, efficiency and technology to support exponential growth. • Construction’s lack of productivity growth. “Construction is disjointed and geographically dispersed,” Dill says. “Communication and connectivity across the construction supply chain is a real challenge – and it’s only becoming more complex for our industry.” • Public-Private-Partnerships (P3s) and the changing relationship with project owners. In the past, construction compaEquipmentWorld.com | February 2017 81
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nies built the project, cashed the check and moved on. Financing, engineering, operations and maintenance were done by somebody else. Today, those lines are increasingly blurred, especially with P3s, where the contractor may finance or partially finance the project, design and engineer the structure, and then perform the maintenance and upkeep for up to five decades.
Pushing out paper Well before the creation of its software subsidiary InEight, Kiewit was an industry leader in the adoption of technology. In the past few years the company moved aggressively to eliminate as much paper as possible from their processes. “In 2010, we did over two-million visual equipment inspections on paper and processed one-million time cards,” Dill says. “We had trailers full of people processing that paper.” Kiewit realized its business could not evolve with the market as long as it relied on inefficient paper systems. In 2011, the company launched a massive initiative to modernize its processes and eliminate paper. “Now what you see on our jobsites is a lot of supervisors and foremen walking around with iPads in their hands,” says Dill. Communication between the office and the field becomes instantaneous and actionable at any level, helping everybody make good decisions without delays. A single source of truth Kiewit had also been an early adopter of third-party process management and back office software. “We had great solutions that did an excellent job,” says Dill. “The problem was they were largely single point solutions. They were used within a discipline, and those disciplines got value from them; but that information was not used in any larger context where we could paint 82 February 2017 | EquipmentWorld.com
a broader, more complete picture of what’s going on across a complete job or the entire portfolio.” Looking for a more holistic approach to information, Kiewit began building its own software solutions to create what Dill calls “a single source of truth” that would link the all the office functions to all the field functions. And with multiple subcontractors to coordinate, the company also shared the software with its partners. Out of this endeavor, the InEight subsidiary was born.
By contractors for contractors Originally created for internal use, the software developed into a suite of products to cover the full scope of Kiewit’s operations. And rather than keep it to themselves, Kiewit created InEight to sell this same software to the construction market at large, billing it as construction software built
By moving to paperless systems, Kiewit was able to give field personnel actionable, up-to-date information in real time. by a construction company. “Everything InEight produces is field tested by Kiewit,” says Dill. “It is cloud based and completely separate from Kiewit in every way.” The InEight project portfolio gives you the systems you need to run a capital intensive project from inception to decommission, says Dill. Everything from forecasting, estimating and budgeting to vendor and subcontractor coordination, equipment management, project management and turnover on the back end. It works with mobile devices for daily work planning and time capture. And it can be configured to integrate with your existing ERP and back office programs. The newest component
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of the InEight project portfolio is a model data manager that enables you to integrate 3D BIM models with project schedules, procurement, cost and other data. The expandable portfolio is geared to support the sophisticated needs of large companies, but the role-based subscription pricing is aimed at the local contractor, Dill says. “On the small-to-medium end of the market we see consumption of individual solutions. On the large end we see more consumption of the entire portfolio,” he says. Pricing depends on the number modules you choose and the number of users you license. For more information on the software go to www.ineight.com. 84 February 2017 | EquipmentWorld.com
The future is visual Not content to rest on its laurels, Kiewit is pushing into the realm of “information visualization.” In particular, Dill mentions Trimble’s joint venture with Microsoft HoloLens, where Trimble SketchUp drawing models can be viewed at any scale, any angle or perspective using the HoloLens virtual reality goggles. You can design a model of a building in SketchUp and then put on the HoloLens goggles and fly over the structure for a bird’seye view or virtually walk inside the design to see how the building looks from the interior. The SketchUp/HoloLens technology is not only a useful design technology, it’s a great presenta-
Visual information systems, like the Trimble SketchUp-HoloLens-created plans, are reshaping how contractors will design and build projects in the future. tion tool to show clients how their building or project will look when it’s finished. “If you thought the HoloLens presentation (at the Trimble Dimensions conference) was science fiction, or years down the road, I’m telling you, it’s here right now – and here to stay.” Dill says. “As an an early adopter of this type of technology, Kiewit is working hard to stay ahead of the curve and help not just one company stay ahead of the curve, but the entire industry,” Dill says.
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DEMO DUTY attachments
| by Marcia Gruver Doyle |
MGruver@randallreilly.com
From precision cutting to brute force demolition, use these attachments to get the job done.
Reused energy improves efficiency
JCB Hammermaster breakers combine hydraulic force and recovered energy in the hydraulic system by using an efficient internal control valve. Energy not absorbed by the material being broken is reused in the following blow, placing less demand on the carrier. The reused energy requires no additional hydraulic flow from the pump, improving efficiency. The hammers are available with either a moil or chisel tool as standard.
Crush materials onsite
Atlas Copco’s next generation of bucket crusher attachments, the BC 2500 and the BC 3700, can process about 80 percent more material due to their hydraulic drive system, says the company. The BC 2500 fits 24-to-33-ton carriers and the BC 3700 (pictured) fits 30-to-42 ton carriers. The buckets are designed to provide a alternative to mobile jaw crushers on cramped worksites, and are capable of processing a wide range of materials, including aggregate, asphalt and concrete. The units’ drive system generates the high torque needed for powering the crushing jaw, allowing operators to crush as much as 110 tons of material per hour. A reverse function removes any blockages. 86 February 2017 | EquipmentWorld.com
Energy recovery system increases strike power Doosan hydraulic breakers are available in impact energy classes from 2,000 to 8,000 foot pounds and are designed for use with seven models of excavators and one wheeled excavator. The breakers feature an energy recovery system that increases strike power. The nitrogen-powered breakers have an upper/lower suspension system that isolates the power unit from the housing.
Maintain consistent performance
The Bobcat breaker attachment matches the hydraulic capacity of the carrier, allowing consistent machine-tobreaker performance. Auto Power automatically regulates pressures, ensuring breaker operation regardless of changes in outdoor temperature, and limits excessive pressure at the time of start-up. The hammer’s energy chamber keeps the nitrogen pressure constant, maintaining attachment performance. The cradle’s cylindrical design improves access to jobs in confined areas.
Cut hard-to-reach steel with ease
Brokk’s MC200 Multi Cutter is designed for steel-cutting applications, offering a high power-to-weight radio and a compact design. The 40-inch-long attachment can be used on machines weighing 2,650 to 6,170 pounds, including the Brokk 100, 120 D and 160 models. The unit has a 360-degree rotary drive for exact positioning and an 8-inch-wide jaw opening, capable of handling a variety of metals. Weighing 265 pounds, the attachment uses a hydraulic booster to exert 50 tons of cutting force at 3,900 psi. Combined with the smaller Brokk machines’ remote capabilities, the tool allows contractors to cut beams, cable, supply lines and steel pipes in hard-to-reach areas.
Customize teeth to job specs
The GDT Razer demolition tool from Genesis Attachments is optimized to fit on both standard and high-reach demolition machines. A short, flat-top head with bolt-on bracket makes installation simple, shortens the center of gravity and makes it easier to switch the tool between excavators. The number of crushing teeth and their locations can be configured to meet project needs, and the teeth can be interchanged and reversed front to back for longer life. Metal cutting blades on the back of jaw are four-way indexable and feature an apex design that draws material deeper into the jaw for more efficient cutting. EquipmentWorld.com | February 2017 87
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Better gripping force for multiple jobs The 5-model Indeco IMG Series of Multi Grabs uses the same hydraulic system as the host excavator and offers 360-dgree rotation. A high pressure hydraulic cylinder ensures better gripping force and demolition performance, and interchangeable and synchronized jaws handle multiple applications. The frame and jaws are made of Hardox wearresistant steel.
Multi-Ply Your Money!
Higher impact performance The Rhino RH1826EX hammer, with an impact range from 400 to 500 bpm, can perform underwater and requires less hydraulic output from the carrier, while maintaining maximum impact performance, says the company. Because of this, the hammers can be used with smaller carriers, reducing investment costs. The 3,319 foot-pound-impact-energy-class hammer has an operational weight of 3,836 pounds and a required oil/flow range of 34 to 40 gallons per minute.
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Grinding for a variety of applications Antraquip’s rock and concrete grinders are suitable for trenching, controlled demolition, scaling, soil remediation, tunneling, underwater cutting and general rock excavation. The models can fit on excavators ranging from 2 to 110 tons and a choice of cutter heads fits several different applications. The AQ line has a high-torque, low-speed hydraulic motor with rugged gearing and symmetrically aligned cutter bit patterns.
Fits on compact track loaders Kubota’s hammer breaker attachment fits on the company’s compact track loaders. It is available on Kubota’s SVL75-2, SVL90-2 and SVL95-2s models, ranging from 74.3 to 96 horsepower.
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Accomplish most demo jobs with one unit No auxiliary hydraulics required
TRK’s Mechanical Concrete Pulverizers do not require auxiliary hydraulics and feature AR500 alloy welded teeth that are easy to cut out and replace. The attachment can be mounted three different ways: either on a quick coupler, by directly pining it on the carrier machine or by using a universal mount that allows either option. The front piercing tooth is designed for cracking and unit has offset teeth for crushing. The unit can be rigged with a rebar shear.
Caterpillar’s MP300 multi-processor is equipped with a wide selection of interchangeable jaws, including concrete cutter, demolition, pulverizer, shear, universal and tank shear. Most demolition jobs can be accomplished using one common housing and selected job-specific jaws. The jaws can be changed in 10 minutes with basic tools. The unit’s SpeedBooster combines a speed valve and new smaller cylinder to speed up jaw open/close cycle times. Because the closing force has increased up to 6 percent, Cat says the unit is capable of generating 10 to 50 percent more production than previous models.
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Cylinder and tool holder in one piece Chicago Pneumatic’s RX12 hydraulic breaker has a service weight of 1,380 pounds, designed for a wide range of applications including demolition, building renovation, road construction, rock excavation and quarrying. With an impact rate of 950 blows per minute, the unit is specified for carriers with a capacity of 19,800 to 33,000 pounds. The RX12 has a two-in-one design, with the cylinder and tool holder in a onepiece body, eliminating the strain and risk of seizures. A one-piece floating wear bushing can be easily replaced in the field.
Faster speeds, higher impact energy
The 14-model Okada America ORV Series breakers range in energy classes from 150 to 12,000 foot pounds, fitting most types of construction equipment. The internal control valve system provides faster speeds and higher impact energy while steel allowing the breaker to operate at cooler temperatures, says the company. A large capacity accumulator reduces shock load in the system. A central grease port with internal grease passage adapts the breaker to most auto-lube systems. The durable breaker bracket includes a heavy duty bottom plate that protects the powercell and reduces noise and vibration.
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Quickly reduce and fragment material Breaker Technology’s MCP-IT Pulverizer reduces and fragments demolished material, making disposal and recycling easier by separating the reinforced iron from concrete. The attachment’s mouth is designed to enable users to easily replace worm parts and restore the unit to its original profile and performance
Drill holes up to 72 feet deep Compact drop hammer
The CPA 295 rock drill attachment by Montabert allows contractors to drill holes from 2 ½ to 4 inches in diameter up to 72 feet deep. Capable of being mounted on any excavator weighing more than 25 tons, the unit does not require major modifications to the machine, using the excavator’s quick coupler, standard auxiliary plumbing and a 24VDC power supply. The CPA 295 uses Montabert’s HC95 hydraulic drifter, and has a radio remote control, making it easy to operate the drill attachment from anywhere.
Universal Impact Technologies HD3700 3,700-footpount impact energy blow Hurricane drop hammer attachment has a bolt-on bottom-end with a dampening cushion system. The lightweight compact design allows the attachment to be easily transported, and the broad face of the striking surface gives additional area coverage and production. A shock-free ground engagement platform system keeps the unit grounded and dissipates the shock while working. The Hurrican requires a minimum hydraulic pressure of 2,200 psi.
Change tooling with ease With 11 rotating sizes ranging from 800 to 52,000 pounds, the Allied-Gator MT Series Multi-Tool fits on most carrier machines, from skid steers to mass excavators. Users can use the attachment to swap out several tools, including the Quick-Change Shear, Cracker/Crusher and Densifier Jaw Sets. The Cracker/Crusher Jaw Set processes reinforced concrete, heavy cast and rail materials. Interchangeable bolt-on tooth segments can be changed in under five minutes. 92 February 2017 | EquipmentWorld.com
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equipmentworld.com | February 2017
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64 43 47 HOW SUBSTANCE ABUSE 49 ENDANGERS WORKERS, HURTS RECRUITING AND THREATENS51 YOUR BOTTOM LINE. 95 Part one of a two-part series. 97 P. 89 BC 75 97 38 80 55 91 37 10 8 27 79 63, 91 23 39 IBC 79 COVER 29 19 31 25 72 88 13 14 97 2-3 88 41 96 90 56 52 62 4 48 96 7 42 44 79 50 46 17 35 77 61 40
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pro pickup | by Tom Quimby
Texas shop remanufactures pickups in under 48 hours, sells them for half price
Before and after:
Vehicle Reman’s intake vehicles can come in with more than a few dings and scratches (left). Forty-eight hours later, they’re ready for a new owner
W
ant a pickup that comes with a 3-year/75,000-mile warranty that goes for half price of a new vehicle? Then Vehicle Reman, out of Tyler, Texas, thinks it’s got the truck for you. The company has made a specialty out of rebuilding fleet vehicles, including trucks and vans, in a short amount of time. Using an assembly-line approach inside a spacious 60,000-square-foot facility, Vehicle Reman can rebuild an F-150 in about 42 hours. A rebuilt engine, transmission, drivetrain, interior and body breathe new life in a vehicle that otherwise may have been traded in or headed for the scrap heap. It’s not only good for the environment, says the company, it also offers a second tax break opportunity on vehicle de-
94 February 2017 | EquipmentWorld.com
preciation. Customer specs dictate the level of remanufacturing, and thus the cost. “The guy or gal who owns a new fleet is going to save half the cost of a new vehicle and run it for twice as long,” says Steve Belden, Vehicle Reman marketing director. Belden and Vehicle Reman cofounder Greig Latham both have strong backgrounds in the auto industry. Belden started with IBM and went on to own a couple of vehicle tech companies before concentrating his efforts on auto remanufacturing. Latham, an engineer with a background in industrial automation, worked for the federal government for several years remanufacturing various vehicles, including 5-ton transport trucks for the Red River Army Depot.
“The U.S. military has been doing this for decades for their own assets,” Belden explained. Seeing an opportunity in the private sector, Belden and Latham teamed up to open Vehicle Reman. “It really started with Greig’s personal Suburban,” said Belden, noting that Latham ran into challenges rebuilding the SUV. “That’s when he realized that it was a pain to rebuild a truck from scratch, because he realized he had to go to so many stops: get a motor, get a transmission, get a transaxle, get body work, get the interior…he thought it was crazy.” Borrowing on the successful military model, Vehicle Reman performs its rebuilds under one roof – including body work – and has plenty of room for expansion.
“We’re tooled up to run four vehicles per 8-hour shift through here,” Belden says. “It requires 21 mechanics to get those four completed, so we’re not there yet. “The only thing that we don’t do right now under roof is remanufacture motors and do the interior,” Belden continues. “We’ve got a local interior shop that is literally a stone’s throw away, but we have the space in the building to do both. We’ve set aside an engine shop and we’ve set aside an interior shop, so with increased volume we will bring in both of those profit centers under the roof.” Remanufactured engines come from ATK North America, the largest engine remanufacturer in the nation. Turns out, they’ve got a satellite location on the east side of Tyler, not too far
from Vehicle Reman. “We married up with ATK pretty quickly – [they have] high quality with a solid warranty behind their manufactured motors,” Belden said. “Until we get the volume, we’re using them for motors.” Vehicle Reman will also buy vehicles to rebuild and put up for sale. Of particular interest are Ford pickups with a 7.3-liter PowerStroke diesel engine. For those curious about the process, Vehicle Reman also conducts plant tours twice a week. “Anytime we conduct tours, the receptivity is at a 100 percent for those who show up and walk through the place,” Belden explained. “Their first response is, ‘I’ve never heard of it.’ And once they arrive they look at it and they’ve been impressed.”
Vehicle Reman says it’s tooled up to run four vehicles a day in an 8-hour shift.
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2017-01-10 9:04 AM 1/17/17 2:34 PM
final word | by Tom Jackson
TJackson@randallreilly.com
ConExpo as a recruiting and retention tool
B
ack when dinosaurs roamed the earth and I had a full-time job in construction, a paycheck was about all you could expect from a construction company – maybe a six pack of beer if you won a bet with the boss or beat a hot deadline. Back then there were lots of people like me working in construction. There was no labor shortage and hence no sense among employers that they had to do anything to keep you on. If you didn’t like it, shove off; there was always somebody in line to replace you – until there wasn’t. Now we’re in a 20-year, generational labor drought, and I can’t help but wonder if this wasn’t caused, at least in part, by the cavalier attitudes of bosses and companies back in the 70s and 80s. Unlike construction, my next two jobs, in the military and then publishing, offered plenty of training opportunities from the get-go. You were expected to grow your skills, become more valuable to your employer and move up the ranks. The military and the corporate world paid for the training and made sure you were given sufficient time. And it was a nice break to be able to step away from the day-to-day routines once or twice a year and sharpen the saw. That’s the kind of thing that builds loyal employees – and people who can contribute more to the bottom line. This year you have the big mac-daddy of them all when it comes to training and perks for your employees. I’m talking about ConExpo/ConAgg in Las Vegas, March 7 to 11, conexpoconagg.com. In addition to seeing all the latest equipment and technology, there are a boatload of educational sessions on asphalt, aggregates, concrete, cranes and lift equipment, earthmoving, equipment maintenance and management, safety,
98 February 2017 | EquipmentWorld.com
technology and workforce development. The contractors I know who bring their people to this show usually roll one of two ways. Some companies hand out assignments and ask their people to track down information on specific machines or trucks the company is interested in. Others just bring people along as a perk, with no assignments, knowing their sharpest people are going to use the education and floor time to acquire skills and knowledge to get better at their jobs. In addition to skill building and knowledge, shows like ConExpo are also a good way for bosses to show junior employees how you conduct business. A lot of your guys may be great craftsman, but they may not have yet learned the social aspects of business, how to develop relationships with vendors, how to sidestep BS and get information without being rude, and if you’ll pardon the cliché, how to win friends and influence people. If you’re grooming younger workers to be vice presidents someday, the floor of a big trade show is a great place to start. You don’t have much time though. You can register at the door, but with attendance expected to top 130,000, hotel rooms and flights are going to be hard to find. And if equipment maintenance and management is your thing, the Association of Equipment Management Professionals will have their annual meeting March 5 and 6, the weekend prior to ConExpo’s opening. AEMP also has a big slate of education sessions geared to everybody from the up-and-coming technician to senior fleet managers from many the largest construction companies in the world. Look for more information at AEMP.org. See you there, I hope, with your people.
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Discover an edge you didn’t expect. Visit us at ConExpo, booth N11603 in the North Hall.
TAKE YOUR PICK $5,000 RENTAL GIVEAWAY
What if you could add a machine to your job and cut costs at the same time? With the Cat Take Your Pick Sweepstakes, you can do both. Enter to win $5,000 in rental credit—then work with your Cat® dealer to choose the equipment, work tools and technologies that will boost your productivity and your bottom line. Enter now at catallday.com/takeyourpick8 catallday.com/takeyourpick8. Five winners will be announced March 7-11 during CONEXPO-CON/AGG 2017, plus 10 more winners in April. For eligible models and full terms & conditions, visit www.cat.com/en_US/campaigns/awareness/ heavy-rental/heavy-rent-terms-conditions.html. © 2016 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, BUILT FOR IT, their respective logos, “Caterpillar Yellow”, the “Power Edge” trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.