Cost analysis for heavy equipment in earthfill work An optimization of heavy equipment fleet (Case study: Jabung ring dike project)

Cost analysis for heavy equipment in earthfill work An optimization of heavy equipment fleet (Case study: Jabung ring dike project) Muhammad Faizal Ardhiansyah Arifin Citation: AIP Conference Proceedings 1818, 020005 (2017); View online: https://doi.org/10.1063/1.4976869 View Table of Contents: http://aip.scitation.org/toc/apc/1818/1 Published by the American Institute of Physics Articles you may be interested in Preface: 5th International Conference on Education, Concept, and Application of Green Technology by Engineering International Committee AIP Conference Proceedings 1818, 010001 (2017); 10.1063/1.4976864 Application of woven tires waste as soft clay subgrade reinforcement for preventing highway structural failure AIP Conference Proceedings 1818, 020004 (2017); 10.1063/1.4976868 Thermal characteristics analysis of microwaves reactor for pyrolysis of used cooking oil AIP Conference Proceedings 1818, 020003 (2017); 10.1063/1.4976867 Factors on green service industry: Case study at AirAsia AIP Conference Proceedings 1818, 020001 (2017); 10.1063/1.4976865 Competitive adsorption of Pb 2+ and Zn 2+ ions from aqueous solutions by modified coal fly ash AIP Conference Proceedings 1818, 020007 (2017); 10.1063/1.4976871 A study on the static and impact structural behavior of concrete filled steel tubular members under Tsunami flotsam collision AIP Conference Proceedings 1818, 020011 (2017); 10.1063/1.4976875

Cost Analysis For Heavy Equipment in Earthfill Work An optimization of heavy equipment fleet (Case study : Jabung Ring Dike Project) Muhammad Faizal Ardhiansyah Arifin 1,a) 1 Civil Engineering Department, Engineering Faculty, Universitas Negeri Semarang, Indonesia a) Corresponding author:faizal.arifin.2008@gmail.com Abstract: Earth fill work with large volumes of soil deposits will involve a lot of heavy equipment with a variety of functions and with different objectives. Where each machine will have different productivity anyway. So that in this paper discusses the calculation of the cost required to do the compacted earthfill work for embankment in accordance with the volume of work, the target date for implementation, and the number of heavy equipment needs. As the cost calculations used heavy equipment rental price per hour. In the cost analysis calculations use heavy equipment here there are several factors that we included in the calculation, are: 1.)Hauling distance; 2.)Effective hour a day; 3.)Change factor of Soil Volume; 4.)Effective Speed; 5.)Equipment efficiency factor; 6.)Equipment coefficient; 7.)Cycle Time. INTRODUCTION In the work related to earthfill in large scale then we have to use heavy equipment to support the implementation process in this case commonly referred to as a mechanical earthmoving. It would require the implementation of the work plans are carefully and accurately to handle earthen embankment jobs on a large scale in order to avoid the occurrence of inefficiencies in the use of heavy equipment. It is expected to know the type of equipment and the number of equipment required then the work can be done efficiently so as to obtain the maximum benefit as well as the completion of the work in a timely manner in accordance with the plan target. And if possible even to do the job faster completion than the planned schedule. Mechanical earthmoving will be many uses of various types of heavy equipment that has the intent and purpose different but mutually supporting between one machine to the other heavy equipment. Where there is enormous dependency between one machine to the other heavy equipment, so there is no one type of heavy equipment that can work without the support than other heavy equipment to do various jobs there. Engineering International Conference (EIC) 2016 AIP Conf. Proc. 1818, 020005-1 020005-11; doi: 10.1063/1.4976869 Published by AIP Publishing. 978-0-7354-1486-0/$30.00 020005-1

FIGURE 1.Site Plan of Study Area Object observed projects here are inundated project for flood control on the Solo River with locations in Tuban and Lamongan in East Java. This project has a scope of work largely in the form of jobs earthen embankment for water dike with a height varying between 3-5 m wide and 4-5 m above the dike. By using the selected material in core body embankment. Given the large volume of earthen embankment work that will be done then the source location embankment material using two locations within 5-6 km and 7-8 km from the project site. Therefore use two different location of the source material, the productivity of the machine will be different, especially Dump Truck productivity that used as a tool to mobilize the embankment material from the excavation site to the project site. Required careful and detailed planning to determine the configuration of the mechanically earthmoving. Configuration here one of which determine the various kinds of heavy equipment needed to perform the job earthen embankment. The heavy equipment will be used to do the job from the core embankment dike body includes : 1. Vibrator Roller 2. Water Tank Truck 3. Bulldozer 4. Dump Truk 8 Ton 5. Wheel Loader. Each machine that you mentioned above was needed according to the functions and demands the implementation of the work earthen embankment. Later after determining the configuration of a variety of heavy equipment such as those mentioned above, then we need to do the calculations required number of each machine in the fleet. Factors that should be considered in the calculation of the cost to determine the profit target from the the work of the land must be remembered that all five of its heavy equipment have different productivity. Base of calculation to determine the productivity of each all 5 heavy equipment varies depending from the shape of the dimensions, the workings and functions of each of these equipment. The following description of the factors that are used to make the calculation of productivity of each machine above : 1. Vibrator Roller : Avarage Speed, effective lenght of compaction, thick of carpet, a lot of trajectory, equipment efficiency factor. 2. Water Tank Truck : Basin capacity once load, equipment efficiency factor, avarege thread of water, avarege speed, empty avarage speed. 3. Bulldozer : Apart the mean operation, avarege speed, wide blade, thick of carpet, a lot of trajectory, equipment efficiency factor 4. Dump Truck : Basin capacity once load, equipment efficiency factor, avarage Speed, empty avarage speed 5. Wheel loader : bucket capacity, volume convercy factor, bucket factor, head speed, backward speed, distance. 020005-2

In the discussion in this paper on the project object we observed, we enter the Master Schedule earthen embankment work on the core body of the dike as a source Data to analyze the target volume earthen embankment work on the body s core dike. Then as consideration for the optimum benefit from the the operation of various kinds of heavy equipment that we also took a heavy equipment rental rates and unit price earthen embankment for the embankment core body as a source of data that we will though. Therefore these data will be outlining by the relationship productivity equipment with the target volume to be achieved in one day or at a certain time and do well with large costs for the operation of heavy equipment, so it can get the amount of each the ideal tool in the fleet of heavy equipment. FIGURE 2. Work Methode RESULT AND DISCUSSION Analysis Targeting Volume of Embankment Work As a basis for analyzing the target volume of work to be accomplished at a certain time so we took Data volume of work "Embankment of the Core Zone (hauling distance 5000-6000 m)" and work "Embankment of the Core Zone (hauling distance 7000-8000 m)" contained in the Master Schedule contract on the object which we observe. The quantity each volume of work that we observed is 205 520 Cu M and 616 540 Cu M. Where each volume of the work in accordance with the Master Schedule that there should be completed within a period of 12 months or less 368 days. Thus the target volume of each such work must be accomplished in one month 17.127 Cu M and 51.378 Cu M within one day should be reached 571 Cu M and 1713 Cu M. Based on the volume of the target data, the next step we will take into account the need for equipment to answer the targets that must be achieved so that the schedule for completion of the work can be completed on time or faster. Technique Analysis for Heavy Equipment Productivity In doing analysis we need to remember that we observe embankment material sourced from two locations that have different distances thereby affecting productivity values from the certain tools in machine configurations in a single fleet. 020005-3

In accordance with the factors we have mentioned above for calculating the production capability of the machine. then the following is an analysis of production for each of the heavy equipment that has been adapted to the distance of the source material referred earthen embankment. A. Earthen embankment for Dike Core Zone Distance 5 6 Km a. Vibro Roller Avarage Speed (v) = 3 Km/hour Effective Length of Compaction (b) = 3 Thick of Carpet (t) = 0,3 Ln m A lot of Trajectory (n) = 8 Equipment efficiency factor (Fa) = 0,85 Capacity production an hour determined as follow : Qa = [ (V x 1000) x b x Fa x t ] / n Then it was found that the value of Vibro Roller Production Capacity for each hour (Qa) is at 153 Cu M / hour. b. Water Tank Truck Avarage speed (v1) = 25 Km/hour Empty avarage speed (v2) = 40 Km/hour Basin capacity once load (V) = 5 Cu M Equipment efficiency factor (Fa) = 0,83 Avarage Thread of Water = 0,5 Km Cycle Time (TSL) by calculating time of the charge, without charge, load time, and more time is needed, then get the 4.11 minute. The production capacity an hour is determined as follows: Q2 = (V x Fa x 60) / Tsl So determined that the value of production capacity Water Tank Truck for each hour (Q2) is equal to 60.572 Cu M / Hour c. Bulldozer Avarage speed (s) = 5 Km/hour Apart the mean operation (d) = 50 Ln m Wide of Blade (W) = 3,2 Ln m Thick of Carpet (t) = 0,4 Ln m A lot of trajectory (n) = 2 trajectory Equipment efficiency factor (fl) = 0,85 Cycle Time (CT) by calculating time of digging and loading (C1) and the other time 0.02 hour (C2) 0.03 hour, then get CT = 0.05 hour. Production capacity an hour determined as follow : Q = (d x W x t x fl / 0,1) / (CT x n) So determined that the value of the Bulldozer production capacity for each hour (Q) is equal to 544 Cu M / hour. d. Dump Truck 8 Ton Avarage speed (v1) = 20 Km/hour Empty avarage speed (v2) = 35 Km/hour Basin capacity once load (V) = 3,75 Cu M Equipment efficiency factor (Fa) = 0,925 Cycle Time (TSL) to account for the time to charge (T1), without charge (T2), load time (T3), and more time is required (T4), then get minute 19.095. 020005-4

Production capacity an hour determined as follow : Q2 = (V x Fa x 60) / Tsl So determined that the value of the Dump Truck production capacity for each hour (Q2) is equal to 10.894 Cu M / Hour. e. Wheel Loader Bucket capacity (v1) = 1,5 Cu M Volume convercy factor (Ev) = 1 Work efficiency (Ea) = 0,83 Bucket factor (Eb) = 0,93 Head Speed (Vf) = 83,35 Backward speed (Vb) = 100,02 Distance (L) = 20 Ln m Cycle Time (CT) by calculating speed backward in a state of contents (t2), ahead speed in conditions of contents (t2), and other activities (turning, lifting, etc), then get CT = 0.59 minutes. Then by calculating Equipment efficiency factor (Fe) taking into account that Fe = Ev x Ea x Eb which found that Fe = 0.747. To cycle produce an hour (v) = v1 x Fe = 1.121. Production capacity an hour determined as follow : Q = (v x Fe x 60) / CT So determined that the value Wheel Loader of production capacity for each hour (Q) is equal to 85.133 Cu M / hour. B. Earthen embankment for Dike Core Zone Distance 7 8 Km a. Vibro Roller Avarage Speed (v) = 3 Km/hour Effective Length of Compaction (b) = 3 Thick of Carpet (t) = 0,3 Ln m A lot of Trajectory (n) = 8 Equipment efficiency factor (Fa) = 0,83 Capacity production an hour determined as follow : Qa = [ (V x 1000) x b x Fa x t ] / n Then it was found that the value of Vibro Roller Production Capacity for each hour (Qa) is equal to 149.4 Cu M / hour. b. Water Tank Truck Avarage speed (v1) = 25 Km/hour Empty avarage speed (v2) = 40 Km/hour Basin capacity once load (V) = 5 Cu M Equipment efficiency factor (Fa) = 0,83 Avarage Thread of Water = 0,5 Km Cycle Time (TSL) by calculating time of the charge, without charge, load time, and more time is needed, then get the 4.11 minute. Capacity production an hour determined as follow : Q2 = (V x Fa x 60) / Tsl So determined that the value of Water Tank Truck production capacity for each hour (Q2) is equal to 60.572 Cu M / Hour. c. Bulldozer Avarage speed (s) = 5 Km/hour 020005-5

Apart the mean operation (d) = 50 Ln m Wide of Blade (W) = 3,2 Ln m Thick of Carpet (t) = 0,4 Ln m A lot of trajectory (n) = 2 trajectory Equipment efficiency factor (fl) = 0,85 Cycle Time (CT) by calculating time of digging and loading (C1) and the other time 0.02 hour (C2) 0.03 hour, then get CT = 0.05 hour. Capacity production an hour determined as follow : Q = (d x W x t x fl / 0,1) / (CT x n) So determined that the value o f the Bulldozer production capacity for each hour (Q) is equal to 544 Cu M / hour. d. Dump Truck 8 Ton Avarage speed (v1) = 20 Km/hour Empty avarage speed (v2) = 35 Km/hour Basin capacity once load (V) = 3,75 Cu M Equipment efficiency factor (Fa) = 0,85 Cycle Time (TSL) to account for the time to charge (T1), without charge (T2), load time (T3), and more time is required (T4), then get minute 23.583. Capacity production an hour determined as follow : Q2 = (V x Fa x 60) / Tsl So determined that the value of the Dump Truck production capacity for each hour (Q2) is equal to 8.110 Cu M / Hour. e. Wheel Loader Bucket capacity (v1) = 1,5 Cu M Volume convercy factor (Ev) = 1 Work efficiency (Ea) = 0,83 Bucket factor (Eb) = 0,93 Head Speed (Vf) = 83,35 Backward speed (Vb) = 100,02 Distance (L) = 20 Ln m Cycle Time (CT) by calculating speed backward in a state of contents (t2), ahead speed in conditions of contents (t2), and other activities (turning, lifting, etc), then get CT = 1.03 minutes. Then by calculating Equipment efficiency factor (Fe) taking into account that Fe = Ev x Ea x Eb which found that Fe = 0.747. To cycle produce an hour (v) = v1 x Fe = 1.121. Capacity production an hour determined as follow : Q = (v x Fe x 60) / CT So determined that the value of Wheel Loader production capacity for each hour (Q) is equal to 48.766 Cu M / hour. From the analysis of the productivity of of heavy equipment for each heavy equipment above we can do further calculations required number of each machine according to the production target volume to be done every day by comparing the volume target every day and production capacity of each tool each day. As assumption hours of work every day for each of the heavy equipment is in normal time is 8 hours for 1 day. Here are the results of calculations in accordance with the needs of heavy equipment and the production capacity of the target volume of work in one day. 020005-6

Works Embankment of the Core Zone (hauling distance 5000-6000 m) with a target volume of 571 m3 per day. TABLE 1.Productivity Equipment for Hauling Distance 5000-6000 m Equipment Type Productivity unit Equipment Number Vibrator Roller 153 M3/hour 1 unit WT. Truck 60,57 M3/hour 2 unit Bulldozer 544 M3/hour 1 unit Dump Truck 10,89 M3/hour 7 unit Wheel Load 85,13 M3/hour 1 unit Works Embankment of the Core Zone (hauling distance 7000-8000 m) with a target volume of 1713 m3 per day. TABLE 2.Productivity Equipment for Hauling Distance 7000-8000 m Equipment Type Productivity unit Equipment Number Vibrator Roller 149,4 M3/hour 2 unit WT. Truck 60,57 M3/hour 4 unit Bulldozer 544 M3/hour 1 unit Dump Truck 8,10 M3/hour 27 unit Wheel Load 48,76 M3/hour 5 unit The combination of the two work Embankment of the Core Zone (hauling distance 5000-6000 m) with a target volume of 571 m3 per day and Embankment of the Core Zone (hauling distance 7000-8000 m) with a target volume of 1713 m3 per day in getting appropriate equipment needs with the table below. TABLE 3.Equipment Needed Equipment Type Equipment Needed Vibrator Roller WT. Truck Bulldozer Dump Truck Wheel Load 2 unit 5 unit 1 unit 33 unit 6 unit 020005-7

2 Equipment Configuration as Master Schedule 6 5 1 1 2 33 Information : 1. Vibrator Roller 4. Dump Truck 2. WT. Truck 5. Wheel Load 3. Bulldozer FIGURE 3. Equipment Configuration as Master Schedule Analysis Cost Production and Revenues In analyzing the production costs we need a heavy equipment rental pricing data every hour every type of the heavy equipment is needed according to the analysis of the production capacity we have done. Obtained data from sources note that the rental price of each heavy equipment is as follows: a. Vibrator Roller = Rp. 222.500 / hour b. Water Tank Truck = Rp. 171.400 / hour c. Bulldozer = Rp. 307.900 / hour d. Dump Truck 8 Ton = Rp. 179.800 / hour e. Wheel Loader = Rp. 239.500 / hour From needs analysis equipment where the combination work between the Embankment of the Core Zone (hauling distance 5000-6000 m) and Embankment of the Core Zone (hauling distance 7000-8000 m) then get that production costs there are as per the table below. TABLE 4.Equipment Cost a Day as Master Schedule Equipment Type Cost a Day (Rp) Vibrator Roller 3.560.000 WT. Truck 6.856.000 Bulldozer 2.463.200 Dump Truck 47.467.200 Wheel Load 11.496.000 Jumlah 71.842.400 With a daily production target of as much as 571 m3 for the work of "Embankment of the Core Zone (hauling distance 5000-6000 m) and 1713 m3 for Embankment of the Core Zone (hauling distance 7000-8000 m), the average production cost for per-m3 is equal to Rp.31.461,00. Unit price used herein is Rp. 51.175 / m3 for "Embankment of the Core Zone (hauling distance 5000-6000 m) and Rp. 59.686 / m3 for Embankment of the Core Zone (hauling distance 7000-8000 m). The target of 020005-8

volume then the work of embankment can be obtained revenue per day for Rp.131.434.145, - per day with a profit of Rp. 59,591,745 or profit per m3 of Rp. 26 096. As a note profit analysis calculations do not take into charge carriers, fuel and maintenance cost of the tool so the profit rate is still a rough idea only. Optimization Analysis The data will be used to perform optimization analysis starts from the heavy equipment needs of the target volume of the combined work "Embankment of the Core Zone (hauling distance 5000-6000 m) and 1713 m3 for Embankment of the Core Zone (hauling distance 7000-8000 m) amounted to 2284 m3. Then from the amount of the target volume of the work is done the analysis of productivity that can be obtained by each of its heavy equipment in order to obtain production capabilities one equipment in one day to serve two items of the work. The results from the the calculation data production capability of one equipment in one day can be seen in the analysis below, where there is inequality of productivity as in the table below. TABLE 5.Equipment Productivity a Day Equipment Type Productivity A Day Unit Vibrator Roller 1202,272 M3 WT. Truck 484,579 M3 Bulldozer 4352,000 M3 Dump Truck 69,306 M3 Wheel Load 436,777 M3 From the table it can be seen that the productivity Bulldozzer almost 9 times the productivity of Water Tank Truck, or even nearly 63-fold when compared with the productivity of Dump Truck. So as to optimize the production volume of these earthen embankment work productivity capabilities from the Bulldozer should be maximized, which means all the other heavy equipment minimized the inequality productivity by increasing the number of each equipment except the Bulldozer in the one fleet. From the analysis optimizations performed by adjusting the amount heavy equipment with the Bulldozer productivity capabilities then showed the number of heavy equipment configurations as follows. TABLE 6.Equipment Needed After Optimization Equipment Type Equipment Needed After Optimization Vibrator Roller WT. Truck Bulldozer Dump Truck Wheel Load 4 unit 9 unit 1 unit 63 unit 10 unit 020005-9

1, 4 EQUIPMENT CONFIGURATION AFTER OPTIMIZATION 5, 10 4, 63 2, 9 3, 1 1 2 Information : 1. Vibrator Roller 4. Dump Truck 2. WT. Truck 5. Wheel Load 3. Bulldozer FIGURE 4. Equipment Configuration After Optimization Along with the increasing number of heavy equipment, the productivity work per day also increased from the original in accordance with the Master Schedule is 2284 m3 per day to 4352 m3 per day to adjust the production capacity of Bulldozer. Thus, there is an increased cost of production per day as follows TABLE 7.Equipment Cost a Day After Optimization Equipment Type Cost a Day (Rp) Vibrator Roller 7.120.000 WT. Truck 12.340.800 Bulldozer 2.463.200 Dump Truck 90.619.200 Wheel Load 19.160.000 Jumlah 131.703.200 Despite the increased cost of production per day from the Rp. 71.8424 million to Rp. 131 703 200, but also a revenue increase from the previous Rp.131.434.145, - to Rp. 250 493 678, -. Thus the per-day gains obtained after the change in the number heavy equipment with optimization becomes Rp.118.790.078, - or perm3 Rp.27.925, -. Aside from the cost and revenue optimization also occurs optimization time, which speeds the completion of work from the 368 days to 215 days. 020005-10

Comparative Income After Optimization Rp250,4 93,278.7 1 Rp131,7 03,200. 00 1 2 Information : 1. Income a day before optimization 2. Income a day after optimization FIGURE 5. Cost and Profit/Loss After Optimization REFERENCES 1. Armstrong, Scott J., 2002. Principles of Forecasting. New York: Kluwer Academic Publisher. 2. Arif, J. 2014. Analisa Earned Value Analysis Jabung Ring Dyke Project. Penelitian Tugas Akhir Sarjana Teknik Sipil UNDIP. 3. Biro Administrasi PT Hutama Karya. 2006. Sosialisasi Manual Akuntansi PT. Hutama Karya. KPTS No.2189/KPTS/68/2006 Tanggal 26 Juni 2006 4. Ervianto, Wulfram I., 2005. Manajemen Proyek Konstruksi. Yogyakarta : Andi. 5. Ghozali, I. dan A. Chariri. 2007. Teori Akuntansi. Semarang: Badan Penerbit Universitas Diponegoro 6. Heizer, Jay & Render, Barry. 2006. Book 1 Operations Management. Jakarta: Salemba Empat. 7. Ikatan Akuntan Indonesia. 2007. Standar Akuntansi Keuangan. PSAK. No 34: Akuntansi Kontrak Konstruksi. Jakarta: Salemba Empat 8. Iman Soeharto. 1999. Manajemen Proyek. Jakarta: Erlanga. 9. Joni. 2005. Evaluasi Penerapan Saat Pengakuan Pendapatan Terhadap Kelayakan Laba Secara Periodik (Studi Kasus pada Perusahaan Konstruksi). Jurnal Ilmiah Akuntansi. Vol. 5, No. 1, h.71-93 10. Partono, Windu. 2007. Evaluasi Kelayakan Pendanaan Proyek dengan Teknik Pemrograman Linier. Jurnal Teknik Sipil Vol. 28 hal 1-8. Semarang 11. Pranoto, Sumbogo. Priyono, E.Y. & Dwiyanto. 2001. Buku Ajar Pemindahan Tanah Mekanis Teknik Sipil UNDIP. Semarang. 12. Preseiden Republik Indonesia, Peraturan Presiden Pengadaan Barang dan Jasa Pemerintah No. 54 Tahun 2010, 2010 13. Subianto, Agus. 2005. Penerapan Pemrograman Linier pada Produksi Beton Ready Mix. Master Tesis Teknik Sipil Institut Teknologi Bandung. 14. Tenriajeng, Andi. 2003. Pemindahan Tanah Mekanis. Jakarta: Penerbit Gunadarma 020005-11