2012 national ready mixed concrete association fleet
TRANSCRIPT
Report of:
2012 National Ready Mixed Concrete Association Fleet
Benchmarking and Costs Survey
July, 2012
Mike Zagula, Metro Ready Mix
NRMCA OES Committee Chairman
Jeff Hinkle, Chandler Concrete
NRMCA OES Committee Vice Chairman
Bryce Mobley, Mobley Construction
NRMCA Operations Task Group Chairman
David Williams, Chaney Enterprises
NRMCA Operation Task Group Vice-Chair
Gary M. Mullings, NRMCA
Sr. Vice President of Operations and Compliance
2012 NRMCA Fleet Benchmarking and Costs Survey
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Introduction
The National Ready Mixed Concrete Association (NRMCA) Fleet Benchmarking and Costs Survey was
established to provide concrete producers with information to evaluate and benchmark ready mixed
concrete fleet maintenance and utilization. The survey was developed and responses analyzed by the
NRMCA Operations, Environmental and Safety (OES) Committee. For the ready mixed concrete industry,
those involved in the day to day management of a fleet of mixer trucks are confronted with an ever
changing array of business environments and thus a never ending array of decisions. The competitive nature
of the business and long construction seasons makes operating a fleet of mixer trucks very demanding.
What used to be a nine month business in most northern climates has become a 12 month a year
construction season. In the most recent years, the industry has witnessed a downturn in ready mixed
concrete production the likes of which have not been seen since the great depression and at the same time a
dramatic shift in management to one that includes expectations with no tolerance for unsatisfactory
performance, forcing ready mixed concrete fleet managers to reevaluate their fleet, park trucks, sell trucks,
reduce the work force and yet still maintain exceedingly high levels of reliability and cost efficiency day in
and day out. Most, if not all, successful ready mixed concrete producers have always measured themselves
in one way or another, relying primarily on financial accounting principles.
Fleet operating statistics are measured to quantify current performance and to plan and budget for future
improvements, whether it’s downsizing to meet current demand levels or buying to meet current and future
challenges. The real challenge is to know what to measure, when to measure and to know what constitutes
good performance. Benchmarking allows the fleet manager, accountant or ready mixed concrete
executive to identify and compare cost and other performance factors with industry averages as
obtained from this survey. Once the fleet’s management strategies and performance have been
successfully benchmarked, the fleet manager has a tool to identify the unsatisfactory as well as the
excellent performance areas of their fleet.
Benchmarking fleet statistics allows the ready mixed concrete industry to identify the areas that require
change and facilitates continuous improvement of fleet operations. Lacking a complete understanding of the
fleet’s cost components and a strategy for adequate fleet replacement schedules is a significant issue in fleet
management. Therefore the goal of this survey is to provide a useful tool for ready mixed concrete
producers to better manage their fleet operations and to consistently improve on fleet performance.
Confidentiality
The National Ready Mixed Concrete Association keeps all individual company and or divisional data
submitted for the survey strictly confidential. After verification of all data entry and calculations, the
Association destroys and or deletes the entry forms and all tabulation records that specifically
attribute data to a producer, division and plant. This policy was established to help elevate the level of
2012 NRMCA Fleet Benchmarking and Costs Survey
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participation and enhance the statistics through a strong sampling of the industry. NRMCA treats
confidentiality with the highest priority and under no circumstances will release any single company
results
2012 Fleet Benchmarking Survey
The 2012 Fleet Benchmarking Survey Form was sent
to NRMCA member company’s fleet managers,
financial officers and primary contacts in January
2012 through the NRMCA e-news weekly and was
also posted on NRMCA’s website, www.nrmca.org.
An electronic format file of the survey form was
distributed via email to the NRMCA membership as
well. A target email campaign was also initiated
where as all past survey applicants, the OES
committee members and selected NRMCA database
individuals were also sent electronic copies of the
survey to further participation from NRMCA
members. The deadline for all survey responses was
April 1, 2012 (extended until April 15). The survey
(attached in the appendix of this report) consisted of 69 fill-in-the-blank type questions. The form for 2012
was reviewed by the OES committee and Operations Task Group and approved for distribution. The survey
response represents data for calendar year 2011. The fleet managers and financial officers were instructed to
submit information to the extent available, if all questions could not be answered. The 69 survey questions
were placed in the following 10 sections:
Region
Mixer Fleet
Chassis Configuration
Fleet Performance
Fuel Consumption
Mixer Maintenance
Tire Information
Preventive Maintenance
Front-End-Loaders
Benchmarking
Survey Responses
Now in its fourteenth year, the annual survey is limited to NRMCA member companies only. NRMCA
received submissions from 86 companies or divisions (8% less than 2011). The usefulness of these fleet
performance statistics are enhanced by the level of participation in the survey. Some items were not
responded to by all participants. The percentage response is reported in each of the following sections and it
is suggested by the authors that a response less than about 30% may not be statistically significant. Results
of the survey are complied nationally. Responses came from eight geographical regions which are mapped
in the appendix of this report.
Table 1: Geographical Distribution of Survey Responses in Percent
US Region % of Total Reponses US Region % of Total Reponses
Southeastern 19% Rocky Mountain 5%
Eastern 24% North-Central 3%
Great Lakes/Mid-West 15% Pacific Northwest 1%
South-Central 16% Pacific Southwest 16%
2012 NRMCA Fleet Benchmarking and Costs Survey
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Mixer Fleets
A total of 12,602 concrete mixer trucks are represented in the 2012 survey. In 2011 the survey represented
15,504 truck mixers. Using yards delivered per truck annually, 4,050 (median from survey question #63)
and the estimated total US ready mixed concrete produced from the NRMCA website (approx.
263,000,000), one can estimate the number of ready mixed concrete trucks currently operating in the United
States to be approximately 65,000. This is compared to an estimated 80,000 just a few years ago. On a
national basis the severe recession in the ready mixed concrete industry started in the middle part of 2006
and the rate of decline in production peaked between the third and fourth quarters of 2009. Along with the
reduction in production, most companies have retired older mixers, sold off some of their fleet, and have
parked and removed tags on other trucks.
Based on data submitted, the average number of mixer trucks per company/division (represented by this
survey) is 147 (down about 10% from the 2011 report). This number continues to change every year due to
consolidation, mergers, recession and demographics of those who participate in this survey. The median
number (which may be more typical) for truck mixers in a fleet is 94. This means that about half of the
companies who responded to the survey have 94 truck mixers or less and the other half reported more than
94 truck mixers.
The average age of a fleet by company and average age of the individual trucks was higher as compared to
last year. The average fleet age for the 86 companies/divisions who responded to this question was 8.0
years, while the average age of individual truck was calculated to be 7.6 years as compared to 6.9 last year.
(Individual company number of trucks x fleet age / total number of trucks surveyed)
These numbers reflect industry’s practice of retiring and selling off older vehicles while at the same time
not replacing those vehicles with newer units. According to the Truck Mixer’s Manufacturer’s Bureau,
sales of new truck mixers were higher in 2011 than 2010 but still at very low levels when compared to just a
few years ago.
In terms of sheer numbers, rear discharge mixers still dominate the survey representing approximately 81%
of all mixers. Front discharge mixers make up the remaining 19% of the truck mixers. It is interesting to
note that 24% of all companies/divisions reporting do have mixed fleets with some front and some rear
discharge mixers. Considering previous trends with fleets that include at least one mixer truck with a
conveyor system attached, these data suggest that this frequency is about one in ten companies.
2012 NRMCA Fleet Benchmarking and Costs Survey
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Table 2: Mixer Fleet Statistics
Chassis Configurations
Over the last several decades many variations in axle configuration have been developed in response to
varying state weight laws. According to the 2012 Fleet Survey, three-axle and four-axle booster or pusher
configurations are most common. This accounts for about 68 percent of the operating mixer trucks. In order
to meet federal bridge weight restrictions and increase load carrying capacity, more ready mixed concrete
trucks are using four or more axles. In the four-axle category, tail axles out number pushers by nearly 2-to-
1. These data may be biased by the geographical distribution of responses and the pertinent state and local
weight restrictions.
Table 3: Summary of Chassis Configurations
Item Description
Companies
Reporting
(Percent)
Total
Number
Average per
company
reporting
High Low Median
8 2-Axle 0
(0%) 0 0 0 0 0
9 3-Axle 35
(41%) 3,604 95 440 1 51
10 4-Axle/Booster 44
(51%) 3,266 74 405 1 55
11 4-Axle/Pusher 30
(35%) 1,851 62 377 2 27
12 5-Axle 41
(48%) 2,359 58 260 1 53
13 6-Axle 16
(19%) 1,151 72 296 1 43
14 7-Axle 3
(3%) 281 94 251 9 21
Item Description Companies
Reporting
(Percent)
Total
Number
Average per
company
reporting
High Low Median
1 # Trucks 86
(100%) 12,602 147 566 18 94
2 Age, Years 86
(100%) 8.0 14.0 4.0 8.0
3 Front Discharge 29
(34%) 2,249 78 330 10 46
4 Rear Discharge 74
(86%) 10,200 138 542 10 92
5 All Wheel Drive 21
(24%) 2,129 101 330 20 65
6 Conveyor
Equipped
10
(12%) 61 6 17 1 5
7 Trailer Mixers 4
(5%) 60 15 53 2 3
2012 NRMCA Fleet Benchmarking and Costs Survey
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Fleet Performance
The survey represents ready mixed concrete trucks that traveled more than 180 million miles. That’s equal
to more than 7,200 trips around the equator. The average annual mileage on a ready mixed concrete truck
was 14,295 miles last year. This statistic is considerably lower than the high number recorded in the last 10
years of 18,896 (2006 survey) and can be contributed to the reduction in ready mixed concrete production
on a national basis.. Another interesting benchmarking data point is miles per cubic yard. This is calculated
by dividing average truck miles by average total cubic yards delivered per truck. Nationally, that number
this year is 3.3 miles/cubic yard. Miles per cubic yard can give a company an idea of how well its operation
is able to acquire jobs close to the production facility. Naturally, large urban areas will have an advantage
over more rural areas.
The average haul distance a truck mixer must travel will vary depending on location, type of construction,
and commitment to customers. The average one-way haul distance for the 78 companies that reported data
was 14.28 miles, which is one of the highest reported in the last 13 years.
For this survey the average load size was 7.71 cubic yards and the average full load was 9.75 cubic yards.
Important to a ready mixed concrete producer is the “load size coefficient” which can be calculated by
dividing average load size by typical full load size and multiplying times 100 to convert to a percentage. In
general, the higher the load size coefficient, the lower the cost of trucking per cubic yard. Of the 80
companies reporting both numbers, the calculated average load size coefficient was 79%, with a high of
99% and a low of 47%.
Table 4: Summary of Fleet Performance
Item Description
Companies
Reporting
(Percent)
Average per
company
reporting
High Low Median
15 Mixers per Mechanic 86
(100%) 14.3 32 7 13
16 Annual Miles/Truck 82
(95%) 14,295 32,000 4,370 14,065
17 Annual Engine Hours 73
(85%) 1,463 2,700 500 1,416
18 Avg. One-Way Haul
Distance, miles 78
(91%) 14.3 31.6 5.6 14.0
19 Avg. Load Size, cu. yd. 81
(94%) 7.7 9.2 4.9 7.8
20 Typical Full Load Size,
cu. yd. 86
(100%) 9.8 11.0 8.0 10.0
2012 NRMCA Fleet Benchmarking and Costs Survey
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Fuel Consumption
One of the major costs in operating
a ready mixed concrete fleet is fuel
consumption. In the last few years
our industry has seen
unprecedented price swings for
diesel and gasoline. Unfortunately
it appears that by all accounts that
trend will continue for at least the
near future. Fuel consumption
factors can be measured in many
different ways. Typical “miles per
gallon” (mpg) is used as a measure
by many “long haul” trucking
companies. In the ready mixed
concrete industry, although most
companies track mpg data, it does
not provide a true picture of fuel
usage considering that a mixer
truck spends varying amount of
time at idle, mixing concrete or off-
road travel. The price paid per
gallon of fuel can also be
calculated from data reported by
companies on the basis of both “Gallon per Cubic Yard” and “Fuel Costs per Cubic Yard”:
Price per Gallon = Fuel Cost per yd3 / Gallons per yd
3
In 2011, fuel costs for the ready mixed concrete industry reached all time highs. The median fuel cost
according to this survey skyrocketed to $3.36 per gallon; an increase of $0.68 or almost 25% from the
average fuel cost of the previous year. Fuel costs per cubic yard are also way up from $3.05 per yard in
2010 to $3.91 per yard in 2011, about a 28% increase. Important to this industry is the percentage of fuel
usage for power-take-off (PTO) energy use. This information, however, cannot be determined from the
reported data. In 2006 NRMCA with cooperation of its member companies conducted a national study on
PTO fuel usage. The data and final report was made available to the Federal Internal Revenue Service for
consideration to rebate ready mixed concrete producers for excise taxes paid on this portion of fuel use.
The study estimated PTO fuel use to be approximately 20 to 25% of total fuel consumption.
Table 5: Summary of Fuel Usage
Item Description
Companies
Reporting
(Percent)
Average per
Company
Reporting
High Low Median
21 Miles Per Gallon 79
(92%) 3.22 5.1 2.4 3.3
22 Fuel, gal./hr. 64
(74%) 2.94 8.38 0.33 3.00
23 Fuel, gal./yd3
78
(91%) 1.16 4.30 0.60 1.04
24 Fuel, $/yd3 81
(94%) $3.91 $6.63 $1.80 $3.88
2012 NRMCA Fleet Benchmarking and Costs Survey
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Fleet Maintenance Expenses
Maintenance costs associated with fleet operations represent a major expense to the ready mixed concrete
producer. In past years, data reveal that cost of fleet maintenance is directly related to the average age of the
fleet. In general, a younger fleet will have lower maintenance costs. Although, with technology ever
advancing, new equipment and devices are being placed on mixers, most require at least some additional
maintenance. The total maintenance cost is calculated by the sum of cost of parts, outside repair services,
shop expenses, cost of tires, and cost for mobile communication.
Table 6: Summary of Fleet Maintenance Costs
Item Description
Companies
Reporting
(Percent)
Average per
Company
Reporting
High Low Median
25 Mixer Parts:
$/ yd3
77
(90%) $ 0.60 $ 4.07 $ 0.06 $ 0.40
25B Eng Parts: $/ yd3
73
(85%) $ 0.78 $ 2.88 $ 0.11 $ 0.67
26 Shop: $/ yd3
77
(90%) $ 1.51 $ 8.29 $ 0.06 $ 1.47
27 Outside Repairs:
$/ yd3
69
(80%) $ 0.35 $ 1.51 $ 0.01 $ 0.25
28 Tires & Tubes:
$/ yd3
83
(97%) $ 0.42 $ 1.05 $ 0.03 $ 0.41
29 TOTAL
(25-28) 84
(98%) $ 3.30 $ 10.32 $ 1.11 $ 3.10
30A Wrecker Costs:
$/ yd3
58
(67%) $ 0.04 $ 0.29 $ .001 $ 0.03
30B Wrecker Costs:
$/eng hr 11
(13%) $ 0.09 $ 0.62 $ 0.03 $ 0.04
31A Accident Repair
Cost: $/ yd3
39
(45%) $ 0.04 $ 0.27 $ 0.002 $ 0.02
31B Accident Repair
Cost: $/eng hr 9
(10%) $ 0.13 $ 0.40 $ 0.004 $ 0.09
32A Truck Wash:
$/yd3
62
(72%) $ 0.12 $ 0.42 $ 0.02 $ 0.11
32B Truck Wash:
$/truck/year
23
(27%) $ 408.25 $ 839.83 $ 98.28 $ 380.12
2012 NRMCA Fleet Benchmarking and Costs Survey
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Tires
Tires are an essential factor in
determining costs associated with
ready mixed concrete fleets. Of the
86 companies who reported, 5%
allow recaps on the steer axle tires.
On the other hand, 93% of all
reporting companies allow the use
of recaps on the drive or trailer axle tires. The maximum number of recaps allowed on a casing ranged from
one to six with an average of just over two.
The survey also provides an estimate of the cost to the producer for a breakdown due to a tire failure. After
removing outliers, this average cost was $149.91 in 2011. Another interesting number derived from the
data is road-calls per truck per year. On average, a ready mixed concrete company makes approximately 5
road calls related to tire failures per month for every 100 trucks in their fleet.
Table 7: Summary of Tire Information
Item Description
Companies
Reporting
(Percent)
Average per
Company
Reporting
High Low Median
33
Recaps for steer tires
=YES 86
(100%)
4
(5%)
=NO 82
(95%)
34 If yes to 33, max # of recaps per tire 6
7%) 1.8 4 1 1
35
Recaps for drive tires & lift axles
= YES 86
(100%)
79
(93%)
= NO 6
(7%)
36 If yes to 35, max # of recaps per tire 80
(93%) 2.33 6 1 2
37
Capitalize cost of tires/new mixers?
=YES 83
(97%)
43
(52%)
=NO 40
(51%)
38 Avg # road calls/month 72
(84%) 5.1 32 0.1 3.0
39 Avg lost hours./road call 82
(87%) 2.01 15.0 0.5 2.0
40 Avg cost/tire-related breakdown 64
(80%) $149.91 $375 $40 $149
41
Tire pressure checked Intervals
=DAILY 25(29%)
=WEEKLY 35(41%)
=BIWEEKLY 9(10%)
=MONTHLY 16(19%)
42
Tire check done by:
=DRIVER 57(66%)
=MECHANIC 11(13%)
=TIRE SERVICE 16(19%)
2012 NRMCA Fleet Benchmarking and Costs Survey
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Preventive Maintenance
In order to maintain an efficient ready mixed
concrete truck fleet all producers recognize the
need for Preventive Maintenance (PM). The
concept of PM is to carefully service and inspect
each truck in the fleet at regular intervals to
minimize the number of breakdowns. A good PM
program predicts breakdown frequency and
necessary repairs. This allows servicing to be
scheduled at optimum times before the breakdown
occurs. Typical PM drain intervals are calculated in
terms of hours of engine running time. Historically,
manufacturers have recommended PM drain
services at a frequency of about 300 hrs. Our
survey results for calendar year 2011 reveals that
about 86% producers base drain intervals on engine
hours and surprisingly, none base their drain
intervals on oil analysis.
Table 8: Summary of Preventive Maintenance Statistics
Item Description
Companies
Reporting
(Percent)
Average per
company
reporting
High Low Median
43
Basis forPM Drain
Interval, 83
(97%)
=MILAGE 4
(5%)
=ENGINE HOURS 71
(86%)
=CALENDAR DAYS 5
(6%)
=FUEL
CONSUMPTION 3
(4%)
=OIL ANALYSIS 0
(0%)
2012 NRMCA Fleet Benchmarking and Costs Survey
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Mixer Drums
Since 2006 the survey has included a section concerning drum chipping operations. Historically, drum
chipping has been performed by drivers during slow or off-peak times. In today’s fast-paced industry, an
increasing number of producers have elected to contract drum chipping to outside vendors. The survey
allows us to estimate about how many producers are using an outside service for drum chipping. That
number turns out to be about 84%.
New technology has come to our industry, within the past few years, that now enables a ready mixed
concrete producer to use a non-entry-system for drum cleaning. This system uses high pressure water to
clean hardened concrete from the drum while the operator remains safely outside. Also in this year’s survey
are addition questions which include costs of drum chipping.
A good PM program is necessary to
ensure long mixer-drum life. In this
survey, the average service life of a mixer-
drum was determined to be 7.4 years,
while delivering just over 39,000 yards of
concrete. Both numbers are the highest
recorded by this survey. The life of a
drum is dependent on a number of factors
including the hardness of the aggregate
used in concrete. An aggregate made of
very hard granite might wear out a steel
drum with only 15,000 yards of concrete delivered, while, on the other hand, using a soft marine limestone
might allow the same drum to deliver about 70,000 cubic yards.
Table 9: Summary of Mixer Drums Statistics
Item Description
Companies
Reporting
(Percent)
Average per
company
reporting
High Low Median
44 Drum Chipping by:
Driver 10
(12%)
Maint. 3
(3%)
Outside
Service 72
(84%)
45 Drum Chipping
Frequency (months)
86
(100%) 7.1 36 1.8 6
46 Cost per Cleaning 67
(78%) $241.07 $2500 $7.39 $188
46B Chipping Cost
(per truck per year)
44
(51%) $345.40 $863 $72 $300
47
Capitalize Drum Cost?
= YES 37
(48%)
= NO 40
(52%)
48 Avg Drum Life/years. 80
(93%) 7.4 12.0 4.2 7.0
48B Avg Drum Life/yd3
80
(93%) 39,040 65,000 17,353 38,000
2012 NRMCA Fleet Benchmarking and Costs Survey
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Front End Loaders
Essential to a ready mixed concrete production facility is its front-end loader fleet. This piece of equipment
is vital to both production rate and product quality. Keeping the loader in good working condition is
mandatory for a successful operation. This survey, representing more than 1,700 loaders from 85
companies/divisions, reveals the average age of a loader is 11.3years. The data also shows that a company,
on average, operates 1 loader for every 7.1 truck mixers.
Table 10: Summary of Front End Loader Statistics
Item Description
Companies
Reporting
(Percent)
Average per
company
reporting
High Low Median
49 # Loaders 85
(99%) 20.8 113 1 13
50 Avg. age, years. 84
(98%) 11.3 23.5 1.5 10.1
51
Capitalize Loader Engine
Rebuilds?
= YES 76
(84%)
37
(49%)
= NO 39
(51%)
52A Loader parts: $/yd3
56
(65%) $0.14 $0.62 $0.01 $0.11
52B Loader parts: $/eng hr. 31
(36%) $3.49 $13.82 $0.10 $3.47
53A Loader shop exp.: $/yd3.
41
(48%) $0.25 $3.50 $0.01 $0.13
53B Loader. shop exp: $/eng. hr. 27
(31%) $3.10 $15.83 $0.03 $2.90
54A Loader outside repair: $/yd3
41
(48%) $0.12 $0.47 $0.01 $0.04
54B Loader outside repair:
$/eng.hr. 25
(29%) $2.88 $9.66 $0.05 $2.00
55A Tire/Tube: $/yd3
51
(59%) $0.07 $0.44 $0.01 $0.04
55B Tire/Tube: $/eng. hr. 28
(33%) $2.13 $12.86 $0.02 $1.20
56A TOTAL: $/yd
3
(from 53-56) 61
(71%) $0.44 $3.50 $0.02 $0.34
56B TOTAL $/eng. hr.
(from 43-56) 32
(37%) $10.14 $30.23 $0.04 $8.33
57 Loader Fuel: gal/eng. hr. 50
(58%)) 3.69 25.68 0.29 3.10
58 Loader Fuel: gal/ yd3
54
(63%) 0.13 0.75 0.01 0.07
59 Loader Fuel: $/yd3
67
(78%) $0.28 $1.17 $0.02 $0.24
2012 NRMCA Fleet Benchmarking and Costs Survey
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Benchmarking
Of utmost importance to a ready mixed concrete
production facility is its ability to measure and monitor
key ratios used to quantify productivity. Parked trucks due
to low driver availability can be very costly. Driver
availability rates are generally calculated daily for each
plant and averaged on a monthly or yearly basis. The
ready mixed concrete industry measures fleet statistics to
track the efficiency and effectiveness of equipment PM
and repair programs. Factors that affect the Fleet
Availability ratios are PM programs, average age of the
fleet, parts availability, competency of mechanics and
warranties. Fleet Utilization is another key ratio that matches the number of available drivers with available
trucks with a goal of 100% utilization. This can be quite difficult in markets that experience driver
shortages. Dispatch efficiency is determined as the (driver hours worked – driver standby hours)/driver
hours worked.
The OES committee also asked producers for backing accidents and roll-over incidents. The data reveal
those who reported at least one rollover (31 companies) the rollover rate per 100 trucks is 1.24 and for those
companies reporting at least one backing accident (57 companies) the rate is 6.6 backing accidents per 100
trucks. The benchmarking data in this section are not included in Table 12, “Trend Analysis”, of this report.
Table 11: Summary of Benchmarking Statistics
Item Description
Companies
Reporting
(Percent)
Total #
Average per
Company
Reporting
High Low Median
60 Driver Availability
Annually, % 68
(79%) 92% 100% 76% 92%
61 Fleet Availability
Annually, % 73
(85%) 91% 100% 5% 94%
62 Fleet Utilization
Annually, % 66
(77%) 81% 100% 46% 81%
63 Concrete delivered per
truck annually, yd3
81
(94%) 4,331 9,360 1,969 4,050
64 Dispatch Efficiency
Annually 51
(59%) 79% 97% 47% 80%
65 Rollovers in 2011 82
(95%) 52 0.63 6 0 0
66 Backing Accidents in
2011 68
(79%) 448 6.6 24 0 5
67 Volumetric Mixers
= YES 0
(0%)
= NO 84
(96%)
68 Number of Volumetric
Mixers?
0
(0%)
69 Concrete delivered by
volumetric mixers, yd3
0
(0%)
2012 NRMCA Fleet Benchmarking and Costs Survey
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Yearly Comparison
Table 12: Trend Analysis
Data for Year 2011 2010 2009 2008 2007 2006 2005 2004 2003 2002 2001 2000 1999
Companies Participating 86 94 87 90 82 99 56 46 41 80 75 67 68
Number of Trucks 12,606 15504 13,839 14,588 14,609 17,080 11,591 7,114 6,211 10,120 12,116 7035 6,987
Average Fleet Age, years 8.0 7.6 7.3 7.4 6.1 6.8 6.5 7.0 8.1 7.4 6.8 7.4 8.9
Average Truck Age, years 7.6 6.9 6.2 - - 6.2 6.2 6.7 6.7 6.7 6.4 6.8 7.6
Front Discharge, Percent 18% 24.6% 17.2% 17.0% 19.0% 15.7% 23% 16% 26% 29% 18% 18% 14%
Rear Discharge, Percent 81% 74.2% 82.8% 83.0% 81.0% 82.3% 77% 84% 74% 71% 82% 83% 86%
Avg. Annual Mileage per Truck, 14,295 13,860 13,801 15,062 17,755 17,976 18,896 16,895 16,952 18,437 16,954 16,987 19,760
Avg Haul, One Way, miles 14.3 13.8 14.4 14.2 14.1 14.6 12.1 14.3 13.0 12.1 13.4 12.2 12.0
Average Load Size, yd3 7.7 7.8 7.7 7.8 8.1 8.1 8.2 7.9 8.0 7.7 7.9 8.00 7.57
Average " Full Load" size, yd3 9.8 9.8 9.8 9.7 9.8 9.6 9.8 9.8 10 9.7 9.6 9.7 9.47
Fuel Usage: miles per gallon 3.22 3.32 3.38 3.38 3.40 3.60 3.60 3.79 3.6 3.87 3.93 3.83 4.03
Fuel Usage: gallons per yd3 1.08 1.14 1.10 1.07 1.06 1.16 0.99 0.85 1.0 0.95 0.94 1.07 1.21
Fuel Usage: $ per yd3 $3.91 $3.02 $2.81 $3.67 $2.80 $2.55 $2.15 $1.72 $1.36 $1.22 $1.37 $ 1.35 $ 1.32
Parts (mixer + truck): $ per yd3 $1.38 $0.99 $0.96 $1.14 $1.07 $1.12 $0.98 $0.93 $1.06 $1.05 $0.98 $ 1.06 $ 1.18
Shop expense: $ per yd3 $1.51 $1.64 $1.44 $1.53 $1.55 $1.46 $1.26 $1.33 $1.29 $1.50 $1.05 $ 1.29 $ 1.27
Tires & Tubes: $ per yd3 $0.42 $0.35 $0.35 $0.31 $0.31 $0.33 $0.31 $0.33 $0.30 $0.29 $0.34 $ 0.31 $ 0.40
Maintenance Cost: $ per yd3 $3.30 $3.18 $3.40 $3.58 $3.52 $3.21 $2.70 $2.87 $2.79 $3.03 $2.59 $ 3.22 $ 3.31
Recaps for Steer Tires? 5% 3% 3% 7% 7% 8% 0% 7% 5% 9% 16% 16% 20%
Recaps for Drive Tires? 93% 100% - - 93% 95% 96% 93% 95% 96% 96% 92% 96%
Avg$ per road call (Tire Related) $149.91 $199.95 $146.79 175.15 $139.39 $175.57 $162.15 $147.34 $135.62 $135.11 $127.51 $126.11 $118.60
PM Drain Interval, Eng. Hr. 86% 82% 82% 78% 71% 424 447 449 419 387 375 328 303
PM Drain Interval, Days 6% 7% 5% 7% 18% 112 90 94 87 148 128 102.6 95
PM Drain Interval, miles 5% 5% 9% 12% 7% 6,636 6,250 4,722 4,556 5,205 5,125 4,667 4,836
Mixer to Mechanics Ratio 14.3 14.8 13.9 13.3 13.5 13.6 13.4 13.2 13.4 12.2 12.7 11.1 12.6
Avg Drum Service Life, years 7.4 7.2 7.1 6.8 5.7 5.5 5.6 5.7 5.9 6.0 5.7 5.9 6.3
Avg Drum Service Life yd3 39,040 38,279 38,645 36,232 39,052 32,850 36,840 31,178 36,757 32,078 33,869 31,048 34,226
Number of Front-end Loaders 1,765 2,136 1,708 1,758 1,537 1495 1033 758 634 1030 1281 637 999
Average Loader age, years 11.3 11.0 10.8 9.9 9.0 9.0 10.0 10.4 12 10.6 9.0 13.0 11.0
Avg. Loader Maintenance: $/ yd3 $0.44 $0.48 $0.59 $0.54 $0.51 $0.43 $0.48 $0.24 $0.19 $0.24 $0.24 $ 0.24 $ 0.37
Avg. Loader Maintenance:
$/engine hour
$10.14 $9.40 $5.02 $12.93 $12.69 $11.26 $9.09 $6.38 $4.19 $6.61 $6.47 $ 5.35 $ 3.61
2012 NRMCA Fleet Benchmarking and Cost Survey
15
Acknowledgements The authors would like to thank all the companies and individuals who spent the time to voluntarily
participate in the survey. It is due to their efforts that these data can be used by the entire industry to
benchmark valuable industry specific fleet information. While the participation level has grown, the
reliability of these industry benchmarks can improve by increasing the sample size. Readers of this report
are encouraged to submit responses for the 2013 Survey. Forms will be available on or about January 1,
2013 at www.nrmca.org.
Table 13: Participating Companies
Company Reported By: Company Reported By:
Anderson Concrete Michael Anderson Harrison Construction Company Doug Brown
Advance Ready Mix Concrete Inc Jerry Wild IMI Tennessee, Inc. Robert Majors
APAC-Central Ricky Osburn Ingram Concrete Christy Ludwick
ARGOS USA Andrew Reynolds Irving Materials Inc. Chris Holt
Bayou Concrete, LLC Judd Beech Irving Materials, Inc. Chad Kelley
BCM Oklahoma Jake Seay Kirkpatrick Concrete David Black
Bode Concrete LLC Jennifer McDermott Kuhlman Corporation Patrick Ferry
Boral Construction Materials Ready
Mixed Concrete Robert Haun Lafarge Craig Radke
Builder's Concrete & Supply Co.,
Inc. Bill Wiley Lehigh Hanson Matt Woods
C&D Concrete David Williams Livingston’s Concrete Service, Inc. Jo-Ann McIntire
Cal Portland Jason Faubel Mannatts Dennis Gallagher
CalPortland Gary Dykman Martin Limestone Inc Donald Graves
CalPortland Paul Moore Metro Ready Mix Concrete Michael Zagula
CalPortland Chuck Williams MMC Materials, Inc. Shane Huff
CalPortland Construction Toby Goodwin Mobley Construction Co. Bryce Mobley
Capital Concrete Inc. Wayne Bolton Ozinga Ready Mix Concrete, Inc. Jessica Miazga
Carew Concrete & Supply Co., Inc. John Carew Powhatan Ready Mix Shae Fender
Carolina Sunrock LLC Elisabeth Sasser Prairie Material Matthew Clarage
Carroll Concrete Chris Broadhurst Preferred Materials, Inc. Meg Dragoni
CEMEX Larry Bruffy Razorback Concrete Bill Johnson
CEMEX Richard Fritz Rowe Materials David Williams
CEMEX Steven Knudsen RW Sidley, Inc. David Lintern
Cemstone Products Company Tim Becken S&W Ready Mix Josh Howery
Cemstone Ready Mix Inc. Jim Dewall Smith's Ready Mix, Inc. Hix Smith
Central Concrete Supply Co.,
Inc./Subsidiary of US Concrete Steve Brussee Spurlino Materials Jim Spurlino
Chandler Concrete Company, Inc. Jeff Hinkle Staker Parson Companies Rod Griffiths
Chandler Concrete Piedmont, Inc. Jeff Hinkle Tarmac America Gary Nininger
Chaney Enterprises David Williams Teichert Readymix Allen Ketchum
Concrete Supply Co. Keith Cates The Dolomite Group Fritz Odenbach
Consolidated Concrete Co Lisa Bell Titan Virginia Ready Mix Shae Fender
Delta Industries, Inc. Les Howell Transit Mix Concrete Brett Johnston
Eastern Concrete Materials, Inc. Bill Steele TXI Thomas Zais
Essroc Ready Mix / Mid Atlantic Mark Kane United Materials, LLC James Pierce
Essroc Ready-Mix Midwest Region Brent Edwards Vulcan Construction Materials, LP Stephen Taylor
GCCA Phillip Maxwell Vulcan Materials - Northern
Concrete Division Brad Moye
Geiger Ready Mix Co Inc. Richard Tucker Vulcan Materials Company Ed Luce
Hanson Aggregates Arizona, Inc John Doerfler Vulcan Materials Company, Florida
Division Dennis Upchurch
2012 NRMCA Fleet Benchmarking and Cost Survey
16
Region
Region Region
Total # 15 Eastern Total # 19 Eastern
Total # 21 Southeastern Total # 21 Southeastern
Total # 13 G.Lakes/ Midwest Total # 12 G.Lakes/ Midwest
Total # 15 South Central Total # 16 South Central
Total # 3 North Central Total # 4 North Central
Total # 3 Rocky Mountain Total # 5 Rocky Mountain
Total # 1 Pacific Northwest Total # 3 Pacific Northwest
Total # 14 Pacific Southwest Total # 14 Pacific Southwest
Mixer Fleet Median Median
1 Total # of Truck Mixers Total # 12,602 Truck Mixers 94 Total # 15,504 Truck Mixers 94
2 Average Fleet Age Nat. Average 8.0 Years 8.0 Nat. Average 7.6 Years 7.5
Breakdown of Truck Mixers by Type % of total % of total
3 # Front Discharge Units Total # 2,249 Fronts 30.1% Total # 3,811 Fronts 24.6%
4 # Rear Discharge Units Total # 10,200 Rears 78.5% Total # 11,497 Rears 74.2%
5 # All-Wheel Drive Trucks Total # 2,129 All-Wheel Drive 22.6% Total # 2,057 All-Wheel Drive 13.3%
6 # Mixers Equipped w/ Belt Conveyors Total # 61 w/Conveyors 10.8% Total # 65 w/Conveyors 0.4%
7 # Trailer Mixers Total # 60 Trailer Mixers 4.3% Total # 55 Trailer Mixers 0.4%
Breakdown of Truck Mixers by Chassis Configuration : % of total % of total
8 2 Axles Total # 0 2 Axles 0.00% Total # 9 2 Axles 0.06%
9 3 Axles Total # 3,604 3 Axles 40.9% Total # 4,893 3 Axles 31.6%
10 4 Axles (booster) Total # 3,266 4 Axles (booster) 46.2% Total # 4,676 4 Axles (booster) 30.2%
11 4 Axles (pusher) Total # 1,851 4 Axles (pusher) 32.3% Total # 1,847 4 Axles (pusher) 11.9%
12 5 Axles Total # 2,359 5 Axles 44.1% Total # 2,436 5 Axles 15.7%
13 6 Axles Total # 1,151 6 Axles 17.2% Total # 1,047 6 Axles 6.8%
14 7 Axles Total # 281 7 Axles 3.2% Total # 297 7 Axles 1.9%
Miscellaneous Fleet Performance Information Median Median
15 Truck Mixer-to-Mechanic Ratio Nat. Average 14.3 Mixers/Mech. 13.5 Nat. Average 14.8 Mixers/Mech. 13.1
16 Average Annual Mileage per Truck Mixer Nat. Average 14,295 Miles 14,065 Nat. Average 13,860 Miles 13,716
17 Average Annual Engine Hours per Truck Mixer Nat. Average 1,463 Eng. Hours 1,416 Nat. Average 1,444 Eng. Hours 1,400
18 Avg. Haul Distance (miles, one way ) Nat. Average 14.3 Haul Distance 14.0 Nat. Average 13.8 Haul Distance 13.5
19 Average Load Size (Yards3) Nat. Average 7.7 Yd3
7.75 Nat. Average 7.8 Yd3
7.75
20 Typical Full Load Size (Yards3
) Nat. Average 9.7 Yd3
10.0 Nat. Average 9.7 Yd3
10.0
2012 Report Results 2011 Report Results
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Appendix I 2012 Fleet Benchmarking & Costs Survey Executive Summary
2012 NRMCA Fleet Benchmarking and Cost Survey
17
Truck Mixer Diesel Fuel Consumption Median Median
21 Miles per Gallon Nat. Average 3.22 miles/gal 3.27 Nat. Average 3.32 miles/gal 3.18
22 Gallons per Engine Hour Nat. Average 2.94 Gal/Eng hr. 3.00 Nat. Average 2.90 Gal/Eng hr. 2.90
23 Gallons per Cubic Yard Nat. Average 1.16 Gals/Yd3
1.04 Nat. Average 1.14 Gals/Yd3
1.02
24 Fuel Costs per Cubic Yard Nat. Average 3.91$ $/Yd3
3.88$ Nat. Average 3.02$ $/Yd3
2.71$
Truck Mixer Maintenance Costs
25 A: Mixer Parts Expense per Cubic Yard Nat. Average 0.60$ $/Yd3
0.40$ Nat. Average 0.53$ $/Yd3
0.33$
25 B: Engine Parts Expense per Cubic Yard Nat. Average 0.78$ $/Yd3
0.67$ Nat. Average 0.73$ $/Yd3
0.66$
26 Shop Expense per Cubic Yard Nat. Average 1.51$ $/Yd3
1.47$ Nat. Average 1.64$ $/Yd3
1.50$
27 Outside Repair Costs per Cubic Yard Nat. Average 0.35$ $/Yd3
0.25$ Nat. Average 0.31$ $/Yd3
0.20$
28 Tire Expenses per Cubic Yard Nat. Average 0.42$ $/Yd3
0.41$ Nat. Average 0.35$ $/Yd3
0.35$
29 Maintenance Cost TOTAL (from questions 25-29) Nat. Average 3.30$ $/Yd3
3.10$ Nat. Average 3.18$ $/Yd3
2.97$
30 Wrecker Costs (per Cubic Yard) Nat. Average 0.04$ $/Yd3
0.03$ Nat. Average 0.03$ $/Yd3
0.02$
or ($/Engine Hour) Nat. Average 0.09$ $/Engine Hour 0.04$ Nat. Average 0.05$ $/Engine Hour 0.04$
31 Accident Repairs (per Cubic Yard) Nat. Average 0.04$ $/Yd3
0.02$ Nat. Average 0.05$ $/Yd3
0.04$
or ($/Engine Hour) Nat. Average 0.13$ $/Engine Hour 0.09$ Nat. Average 0.17$ $/Engine Hour 0.15$
32 Truck Wash Cleaning Products Costs (per Cubic Yard) Nat. Average 0.12$ $/Yd3
0.11$ Nat. Average 0.13$ $/Yd3
0.11$
or ($-per-Vehicle-per-Year) Nat. Average 408.25$ $/Truck/Year 380.12$ Nat. Average 407.63$ $/Truck/Year 397.61$
Tire-Related Information
33 Do You Use Retreads on Steer Tires? 5.0% Yes 3.3% Yes
34 . . .if yes, maximum # of recaps per casing Nat. Average 1.8 recaps/casing 1.5 Nat. Average 1.5 recaps/casing 1.0
35 Do You Use Retreads on Drive Tires & Liftable Axles? 93.0% Yes 94.0% Yes
36 . . .if yes, maximum # of recaps per casing Nat. Average 2.3 recaps/casing 2.0 Nat. Average 2.3 recaps/casing 2.0
37 Do you Capitalize the Cost of Tires on New Mixers? 52% Yes 50% Yes
38 Typical # of Road Calls per Month due to Tire Problems? Nat. Average 5.1 per 100 mixers 3 Nat. Average 5.0 per 100 mixers 3.1
39 Typical Time Lost per Tire-related Road Call? (Hours) Nat. Average 2.0 Hours Lost 2 Nat. Average 2.2 Hours Lost 2
40 Avg. Cost of Tire-related Breakdown (Not incl. Tire Cost )? Nat. Average 149.91$ $/breakdown 149.00$ Nat. Average 195.99$ $/breakdown 150.00$
41 How often is tire pressure checked?
Daily 25 29% Daily 27 29%
Weekly 35 41% Weekly 45 48%
Bi-weekly 9 10% Bi-weekly 5 5%
Monthly 16 19% Monthly 14 15%
42 Who checks tire pressure?
Driver 57 66% Driver 55 59%
Mechanic 11 13% Mechanic 19 20%
Tire Service 16 19% Tire Service 18 19%
80 responses: Totals & Percentages 91 responses: Totals & Percentages
84 responses: Totals & Percentages 92 responses: Totals & Percentages
2012 Report 2011 Report
Appendix I 2012 Fleet Benchmarking & Costs Survey Executive Summary
2012 NRMCA Fleet Benchmarking and Cost Survey
18
Crankcase Drain Interval (truck mixer engine) Median Median
43 Basis of PM Interval
Mileage 4 5% Mileage 5 6%
Engine Hours 71 86% Engine Hours 77 87%
Calendar Days 5 6% Calendar Days 7 8%
Fuel Consumption 3 4% Fuel Consumption 3 3%
Oil Analysis 0 0% Oil Analysis 0 0%
Mixer Drums, Drum Chipping, Service Life, Etc.
44 Who Performs Drum Chipping?
Driver 10 12% Driver 11 12%
Mechanic/Other 3 3% Mechanic/Other 1 1%
Outside Service 72 84% Outside Service 80 87%
45 How Often are Drums Chipped Out? (Average, in months) Nat. Average 7.1 months 6.0 Nat. Average 7.2 months 6.0
46 Average Drum Chipping Cost (per cleaning) Nat. Average 241.07$ $/per cleaning 188.00$ Nat. Average 233.50$ $/per cleaning 172.87$
Average Drum Chipping Cost per Truck Mixer-per-Year Nat. Average 345.40$ $/truck per yr. 300.00$ Nat. Average 346.81$ $/truck per yr. 300.65$
47 Do you Capitalize the Cost of Replacement Drums? 48.0% Yes 39.0% Yes
48 Average Drum Serv ice Life: (Years + 10ths, e.g., 8.5) Nat. Average 7.4 Years 7.0 Nat. Average 7.2 Years 7.0
Average Drum Serv ice Life: (Cubic Yards) Nat. Average 39,040 Yd3 38,000 Nat. Average 38,280 Yd
3 35,000
Front End Loaders
49 Total # of Front-end Loaders Total # 1,765 # Loaders Total # 2,136 # Loaders
50 Average Loader Age (Years) Average 11.3 Years 10.1 Average 11.0 Years 4.4
51 Do you Capitalize Loader Engine Rebuilds/Overhauls? 49% Yes 40% Yes
Front End Loader Maintenance Costs
52 Parts Expense (per Cubic Yard) Average 0.14$ $/Yd3
0.11$ Average 0.17$ $/Yd3
0.13$
or ($/Engine Hour) Average 3.49$ $/Eng. Hr. 3.47$ Average 3.49$ $/Eng. Hr. 3.47$
53 Shop Expense (per Cubic Yard) Average 0.25$ $/Yd3
0.13$ Average 0.21$ $/Yd3
0.12$
or ($/Engine Hour) Average 3.10$ $/Eng. Hr. 2.90$ Average 3.46$ $/Eng. Hr. 2.85$
54 Outside Repair Costs (per Cubic Yard) Average 0.12$ $/Yd3
0.04$ Average 0.12$ $/Yd3
0.10$
or ($/Engine Hour) Average 2.88$ $/Eng. Hr. 2.00$ Average 2.13$ $/Eng. Hr. 1.58$
55 Tire Expense (per Cubic Yard) Average 0.07$ $/Yd3
0.04$ Average 0.07$ $/Yd3
0.04$
or ($/Engine Hour) Average 2.13$ $/Eng. Hr. 1.20$ Average 1.47$ $/Eng. Hr. 1.29$
56 TOTAL - per Cubic Yard (from questions 53 - 56) Average 0.44$ $/Yd3
0.34$ Average 0.48$ $/Yd3
0.37$
TOTAL - per Engine Hour (from questions 53 - 56) Average 10.14$ $/Eng. Hr. 8.33$ Average 9.40$ $/Eng. Hr. 8.10$
Loader Diesel Fuel Consumption
57 Gallons per Engine hour Average 3.69 Gal/Eng Hr. Average 3.27 Gal/Eng Hr.
58 Gallons per Cubic Yard Average 0.13 Gals/Yd3
Average 0.14 Gals/Yd3
59 Loader Fuel Costs per Cubic Yard Average 0.28$ $/Yd3
Average 0.25$ $/Yd3
83 responses: Totals & Percentages 92 responses: Totals & Percentages
84 responses: Totals & Percentages 90 responses: Totals & Percentages
2012 Report 2011 Report
Appendix I 2012 Fleet Benchmarking & Costs Survey Executive Summary
2012 NRMCA Fleet Benchmarking and Cost Survey
19
Additional Benchmarking Items Median Median
60 Driver Availability % (Available Drivers/Total Drivers) Average 91.9% % Annually 92.0% Average 91.0% % Annually 92.0%
61 Fleet Availability % (Available Mixers / Total Mixers) Average 91.1% % Annually 93.5% Average 91.5% % Annually 94.0%
62 Fleet Utilization % (Available Drivers/ Available Mixers) Average 81.5% % Annually 81.0% Average 83.6% % Annually 85.0%
63 Cubic Yards Delivered per Truck Mixer Average 4,331 Yd3/Truck/Year 4,050 Average 4,097 Yd
3/Truck/Year 3,861
64 Dispatch Efficiency (Drivers Hr. - Standby Hr./Drivers Hr.) Average 78.7% % Annually 80.0% Average 80.9% % Annually 83.0%
65 Number of Rollover Incidents (on or off road) Average 1.2 per 100 mixers Average 1.3 per 100 mixers
66 Number of Truck Mixer Backing Accidents Average 6.6 per 100 mixers Average 6.9 per 100 mixers
67 Does Fleet include any Volumetric Mixers? 0% Yes 0% Yes
68 If Yes, How Many Volumetric Mixers? Total # na # Volumetrics Total # na # Volumetrics
69 If Yes, how Many cu. yd. per Volumetric Mixer per Year Average na Yd3/Year Average na Yd
3/Year
2012 Report 2011 Report
Appendix I 2012 Fleet Benchmarking & Costs Survey Executive Summary
2012 NRMCA Fleet Benchmarking and Cost Survey
20
Note: for 2012 report the western States have been combined for statictical
and confidential purposes.
Region
Easte
rn
So
uth
easte
rn
G.L
akes/ M
idw
est
So
uth
Cen
tral
Weste
rn r
eg
ion
s c
om
bin
ed
(N C
en
tral, R
ocky M
ts.,
Pacif
ic N
W, P
acif
ic S
W)
Region Total # 15 21 13 15 21
Mixer Fleet
1 Total # of Truck Mixers Total # 1,499 4,093 1,589 2,439 2,982
2 Average Fleet Age Average 8.7 7.2 8.8 7.5 8.3
Breakdown of Truck Mixers by Type
3 # Front Discharge Units Total # 159 867 831 28 364
4 # Rear Discharge Units Total # 1,319 3,095 757 2,411 2,618
5 # All-Wheel Drive Trucks Total # 96 931 656 28 418
6 # Mixers Equipped w/ Belt Conveyors Total # 29 26 1 0 5
7 # Trailer Mixers Total # 2 0 3 0 55
Breakdown of Truck Mixers by Chassis Configuration :
8 2 Axles Total # 0 0 0 0 0
9 3 Axles Total # 403 1,808 20 1,363 10
10 4 Axles (booster) Total # 549 671 639 447 960
11 4 Axles (pusher) Total # 406 1,179 139 107 20
12 5 Axles Total # 142 337 691 436 753
13 6 Axles Total # 1 92 79 0 979
14 7 Axles Total # 0 0 21 0 260
Miscellaneous Fleet Performance Information
15 Truck Mixer-to-Mechanic Ratio Average 15.4 15.7 14.4 14.8 12.0
16 Average Annual Mileage per Truck Mixer Average 12794.4 14268.7 12284.9 16524.7 15188.5
17 Average Annual Engine Hours per Truck Mixer Average 1423.7 1366.0 1371.7 1624.1 1507.7
18 Avg. Haul Distance (miles, one way ) Average 14.7 15.1 11.0 12.6 16.0
19 Average Load Size (Yards3) Average 7.5 7.6 7.2 8.0 8.1
20 Typical Full Load Size (Yards3
) Average 9.9 9.6 9.4 9.8 10.0
2012 Report Results
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Appendix II 2012 Fleet Survey Regional Data
2012 NRMCA Fleet Benchmarking and Cost Survey
21
Truck Mixer Diesel Fuel Consumption
Region
Easte
rn
So
uth
easte
rn
G.L
akes/ M
idw
est
So
uth
Cen
tral
Weste
rn r
eg
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ined
(N
Cen
tral, R
ocky M
ts.,
Pacif
ic N
W, P
acif
ic
SW
)
21 Miles per Gallon Average 3.37 3.31 2.91 3.02 3.30
22 Gallons per Engine Hour Average 1.94 3.18 3.11 2.93 3.07
23 Gallons per Cubic Yard Average 1.10 1.57 1.07 1.00 1.05
24 Fuel Costs per Cubic Yard Average 4.00 4.35 3.73 3.59 3.76
Truck Mixer Maintenance Costs
25 A: Mixer Parts Expense per Cubic Yard Average 0.49$ 0.88$ 0.55$ 0.45$ 0.55$
25 B: Engine Parts Expense per Cubic Yard Average 1.00$ 0.81$ 0.79$ 0.57$ 0.68$
26 Shop Expense per Cubic Yard Average 1.55$ 2.11$ 1.24$ 1.40$ 1.13$
27 Outside Repair Costs per Cubic Yard Average 0.31$ 0.39$ 0.12$ 0.40$ 0.46$
28 Tire Expenses per Cubic Yard Average 0.46$ 0.45$ 0.33$ 0.41$ 0.41$
29 Maintenance Cost TOTAL (from questions 25-29) Average 3.72$ 4.07$ 2.67$ 2.90$ 2.91$
30 Wrecker Costs (per Cubic Yard) Average 0.03$ 0.03$ 0.02$ 0.07$ 0.04$
or ($/Engine Hour) Average 0.06$ 0.62$ 0.05$ 0.05$ 0.03$
31 Accident Repairs (per Cubic Yard) Average 0.04$ 0.03$ 0.03$ 0.03$ 0.05$
or ($/Engine Hour) Average -$ 0.05$ 0.20$ 0.00$ 0.13$
32 Truck Wash Cleaning Products Costs (per Cubic Yard) Average 0.12$ 0.14$ 0.08$ 0.18$ 0.09$
or ($-per-Vehicle-per-Year) Average 378.50$ 646.07$ 218.70$ 526.15$ 428.02$
Tire-Related Information
33 Do You Use Retreads on Steer Tires? Yes 0.0% 10.0% 7.7% 0.0% 4.5%
34 . . .if yes, maximum # of recaps per casing Average 0.0% 166.7% 100.0% 400.0% 100.0%
35 Do You Use Retreads on Drive Tires & Liftable Axles? Yes 87.5% 95.0% 100.0% 85.7% 95.5%
36 . . .if yes, maximum # of recaps per casing Average 2.4 2.4 2.3 2.4 2.2
37 Do you Capitalize the Cost of Tires on New Mixers? Yes 62.5% 63.2% 46.2% 50.0% 38.1%
38 Typical # of Road Calls per Month due to Tire Problems? Average 4.6 6.8 2.3 6.1 5.6
39 Typical Time Lost per Tire-related Road Call? (Hours) Average 2.0 3.0 1.6 1.6 1.7
40 Avg. Cost of Tire-related Breakdown (Not incl. Tire Cost )? Average 168.29$ 187.69$ 116.36$ 107.39$ 152.78$
41 How often is tire pressure checked? Daily 0 0 2 1 1
Weekly 11 18 11 10 21
Bi-weekly 1 1 0 3 0
Monthly 3 0 0 0 0
42 Who checks tire pressure? Driver 13 19 9 11 5
Mechanic 2 0 4 1 4
Tire Service 1 1 0 2 12
2012 Report
Appendix II 2012 Fleet Survey Regional Data
2012 NRMCA Fleet Benchmarking and Cost Survey
22
Region
Easte
rn
So
uth
easte
rn
G.L
akes/
Mid
west
So
uth
Cen
tral
Weste
rn r
eg
ion
s
co
mb
ined
(N
Cen
tral, R
ocky
Mts
., P
acif
ic N
W,
Pacif
ic S
W)
43 Crankcase Drain Interval (truck mixer engine) Mileage 0 0 2 1 1
Basis of PM Interval Engine Hours 11 18 11 10 21
Calendar Days 1 1 0 3 0
Fuel Consumption 3 0 0 0 0
Oil Analysis 0 0 0 0 0
Mixer Drums, Drum Chipping, Service Life, Etc.
Who Performs Drum Chipping? Driver 10 10 10 10 10
44 Mechanic/Other 3 3 3 3 3
Outside Service 72 72 72 72 72
45 How Often are Drums Chipped Out? (Average, in months) Average 6.4 8.9 6.4 7.7 5.9
46 Average Drum Chipping Cost (per cleaning) Average 328.1 305.7 169.0 144.0 206.7
Average Drum Chipping Cost per Truck Mixer-per-Year Average 344.5 360.5 259.7 399.5 350.2
47 Do you Capitalize the Cost of Replacement Drums? Yes 29% 39% 85% 43% 50%
48 Average Drum Serv ice Life: (Years + 10ths, e.g., 8.5) Average 7.1 7.3 8.9 7.7 6.8
Average Drum Serv ice Life: (Cubic Yards) Average 34254.2 36639.1 42800.0 43166.4 40184.2
Front End Loaders
49 Total # of Front-end Loaders Total # 178 759 212 364 252
50 Average Loader Age (Years) Average 12 9 12 13 11
51 Do you Capitalize Loader Engine Rebuilds/Overhauls? 40% 42% 67% 33% 61%
Front End Loader Maintenance Costs
52 Parts Expense (per Cubic Yard) Average 0.15$ 0.16$ 0.16$ 0.15$ 0.10$
or ($/Engine Hour) Average 2.69$ 6.64$ 3.15$ 2.90$ 3.62$
53 Shop Expense (per Cubic Yard) Average 0.56$ 0.10$ 0.30$ 0.18$ 0.18$
or ($/Engine Hour) Average 2.35$ 7.78$ 1.07$ 1.52$ 3.76$
54 Outside Repair Costs (per Cubic Yard) Average 0.16$ 0.16$ 0.13$ 0.08$ 0.07$
or ($/Engine Hour) Average 3.00$ 3.38$ 1.15$ 4.01$ 2.72$
55 Tire Expense (per Cubic Yard) Average 0.05$ 0.07$ 0.06$ 0.09$ 0.04$
or ($/Engine Hour) Average 1.29$ 2.71$ 1.35$ 3.77$ 1.46$
56 TOTAL - per Cubic Yard (from questions 53 - 56) Average 0.66$ 0.32$ 0.49$ 0.41$ 0.33$
TOTAL - per Engine Hour (from questions 53 - 56) Average 8.00$ 17.88$ 6.71$ 10.84$ 9.18$
Loader Diesel Fuel Consumption
57 Gallons per Engine hour Average 3.00 3.00 3.10 5.31 3.81
58 Gallons per Cubic Yard Average 0.11 0.15 0.09 0.13 0.17
59 Loader Fuel Costs per Cubic Yard Average 0.34$ 0.27$ 0.33$ 0.26$ 0.21$
2012 Report
Appendix II 2012 Fleet Survey Regional Data
2012 NRMCA Fleet Benchmarking and Cost Survey
23
Additional Benchmarking Items Region
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rn
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acif
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60 Driver Availability % (Available Drivers/Total Drivers) Average 91.4% 91.8% 92.8% 93.3% 90.5%
61 Fleet Availability % (Available Mixers / Total Mixers) Average 93.6% 89.8% 94.7% 91.5% 88.2%
62 Fleet Utilization % (Available Drivers/ Available Mixers) Average 76.4% 79.7% 86.9% 83.9% 82.1%
63 Cubic Yards Delivered per Truck Mixer Average 3,686.25 4,334.13 4,191.77 4,896.64 4,539.66
64 Dispatch Efficiency (Drivers Hr. - Standby Hr./Drivers Hr.) Average 79.8% 0.0% 84.5% 70.1% 77.9%
65 Number of Rollover Incidents (on or off road) Total # 8 17 0 15 12
66 Number of Truck Mixer Backing Accidents Total # 58 164 53 70 103
67 Does Fleet include any Volumetric Mixers? Yes 0% 0% 0% 0% 0%
68 If Yes, How Many Volumetric Mixers? Total # 0 0 0 0 0
69 If Yes, how Many cu. yd. per Volumetric Mixer per Year Average 0 0 0 0 0
2012 Report
Appendix II 2012 Fleet Survey Regional Data
2012 NRMCA Fleet Benchmarking and Cost Survey
24
Appendix III 2012 Fleet Survey Electronic Submission Form
Region
In which region are you located? (If deliveries cross regional boundaries, select the highest
volume region, or fill out a separate survey form for each region)
Mixer Fleet This section pertains to truck mixers ONLY . (Try to isolate mixer costs from the other equipment in fleet.)
1 Total # of Truck Mixers >>>>>> Truck Mixers
2 Average Age (years + 10ths, e.g., 8.5) >>>>>> Years
Breakdown of Truck Mixer Fleet by Type (Note: Answer #1 total should equal sum of #8-#14)
3 # Front Discharge Units >>>>>> Fronts
4 # Rear Discharge Units >>>>>> Rears
5 # All-Wheel Drive Trucks >>>>>> All-Wheel Drive
6 # Mixers Equipped w/ Belt Conveyors >>>>>> w/Conveyors
7 # Trailer Mixers >>>>>> Trailer Mixers
Chassis Configuration : # of (straight truck) mixers with:
8 2 Axles >>>>>> 2 Axles
9 3 Axles >>>>>> 3 Axles
10 4 Axles (booster or tag) >>>>>> 4 Axles (booster)
11 4 Axles (pusher) >>>>>> 4 Axles (pusher)
12 5 Axles >>>>>> 5 Axles
13 6 Axles >>>>>> 6 Axles
14 7 Axles >>>>>> 7 Axles
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2012 NRMCA FLEET MAINTENANCE BENCHMARKING AND COST SURVEYElectronic Version
Fleet Supervisors: Fill out this survey (NOTE: type data only in yellow-highlighted cells or use provided drop-down boxes) as accurately and completely as possible . E-mail form to NRMCA’s Operations Department by April 1, 2012. If applicable, you may either compile data from all the plants within a state or region (see map) or submit a separate survey from each divisionor
business unit. If you cannot answer all the questions, please complete and submit what you can. Please use data from calendar year 2011.
The data gathered via this survey will be presented in an excutive summary report in NRMCA’s Infocus Quarterly Magazine. Persons completing the survey will receive an electronic copy of the report.
Instructions: All cells on this sheet are protected, except for the yellow-highlighted data entry cells. Please tab from line to line to enter data in the highlighted cells. Where provided, use drop-down boxes instead of typing data into yellow cells. When completed, please save file as <your company name>.xls and email to [email protected]
All proprietary company information shall remain confidential.
2012 NRMCA Fleet Benchmarking and Cost Survey
25
Appendix III 2012 Fleet Survey Electronic Submission Form, cont’d
Miscellaneous Fleet Performance Information
15 Truck Mixer-to-Mechanic Ratio (e.g., 13.5 trucks per mechanic )>>>>>> Mixers/Mech.
16 Average Annual Mileage per Truck Mixer >>>>>> Miles
17 Average Annual Engine Hours per Truck Mixer >>>>>> Hours
18 Avg. Haul Distance (miles, one way ) >>>>>> miles
19 Average Load Size (Yards3) >>>>>> Yd3
20 Typical Full Load Size (Yards3
) >>>>>> Yd3
Diesel Fuel Consumption
21 Miles per Gallon >>>>>> miles/gal
22 Gallons per Engine Hour >>>>>> Gal/Eng hr.
23 Gallons per Cubic Yard >>>>>> Gals/Yd3
24 Fuel Costs per Cubic Yard >>>>>> $/Yd3
Truck Mixer Maintenance Costs
25A Mixer Parts Expense per Cubic Yard >>>>>> $/Yd3
(parts purchased solely for the repair of mixer chassis, body and drum assemblies)
25B Truck & Engine Parts Expense per Cubic Yard >>>>>> $/Yd3
26 Shop Expense per Cubic Yard >>>>>> $/Yd3
27 Outside Repair Costs per Cubic Yard >>>>>> $/Yd3
(parts and labor for repairs to truck mixers performed by an outside party)
28 Tire Expenses per Cubic Yard >>>>>> $/Yd3
(Includes new, used and recapped tires plus repairs, mounting, balancing and other related costs)
29 TOTAL (from questions 25-28) >>>>>> -$ $/Yd3
30 Wrecker Costs (per Cubic Yard) >>>>>> $/Yd3
or ($/Engine Hour) >>>>>> $/Engine Hour
31 Accident Repairs (per Cubic Yard) >>>>>> $/Yd3
or ($/Engine Hour) >>>>>> $/Engine Hour
32 Truck Wash Cleaning Chemicals & Detergents (per Cubic Yard) >>>>>> $/Yd3
or ($-per-Vehicle-per-Year) >>>>>> $/Truck/Year
Tire-Related Information
33 Use Retreads on Steer Tires? (Yes or No) >>>>>>
34 . . .if yes, maximum # of recaps per casing >>>>>> recaps/tire
35 Use Retreads on Drive Tires & Liftable Axles? (Yes or No) >>>>>>
36 . . .if yes, maximum # of recaps per casing >>>>>> recaps/tire
37 Do you Capitalize the Cost of Tires on New Mixers? (Yes or No)>>>>>>
38 Typical Number of Road Calls per Month Due to Tire Problems?>>>>>>
39 Typical Time Lost per Tire-related Road Call? (Hours + 10ths) >>>>>> Hours
40 Typical Cost of a Tire-related Breakdown (Not Including Tire Cost )? $/breakdown
41 How often is tire pressure checked? >>>>>>
42 Who checks tire pressure? (Driver, Mechanic or Tire Serv ice) >>>>>>
2012 NRMCA Fleet Benchmarking and Cost Survey
26
Appendix III 2012 Fleet Survey Electronic Submission Form, cont’d
Mixer Drums, Drum Chipping, Service Life, Etc.
44 Who Performs Drum Chipping? >>>>>>
45 How Often are Drums Chipped/Cleaned, on Average? (Months)>>>>>> months
46 Average Drum Chipping Cost (per cleaning) >>>>>> $/per cleaning
or per Truck Mixer-per-Year >>>>>> $/truck per year
47 Do you Capitalize the Cost of Replacement Drums? (Yes or No)>>>>>>
48 Average Drum Serv ice Life: (Years + 10ths, e.g., 8.5) >>>>>> Years
Average Drum Serv ice Life: (Cubic Yards) >>>>>> Yd3
Front End Loaders
(Information in this section pertains to front-end loaders only . Try to isolate loader costs, from the other equipment in fleet)
49 Total # of Front-end Loaders >>>>>> # Loaders
50 Average Loader Age (Years) >>>>>> Years
51 Do you Capitalize Loader Engine Rebuilds/Overhauls? (Yes or No)>>>>>>
Front End Loader Maintenance Costs
52 Parts Expense (per Cubic Yard) >>>>>> $/Yd3
or ($/Engine Hour) >>>>>> $/Eng. Hr.
(Front-end Loader parts ONLY)
53 Shop Expense (per Cubic Yard) >>>>>> $/Yd3
or ($/Engine Hour) >>>>>> $/Eng. Hr.
(All Costs Charged to Loader, including Internal Labor )
54 Outside Repair Costs (per Cubic Yard) >>>>>> $/Yd3
or ($/Engine Hour) >>>>>> $/Eng. Hr.
(Parts & Labor for Repairs Performed by Outside Party)
55 Tire Expense (per Cubic Yard) >>>>>> $/Yd3
or ($/Engine Hour) >>>>>> $/Eng. Hr.
(Includes Tires + Repairs, Mounting, and Related Costs)
56 TOTAL - per Cubic Yard (from questions 53 - 56) >>>>>> -$ $/Yd3
TOTAL - per Engine Hour (from questions 53 - 56) >>>>>> -$ $/Eng. Hr.
Loader Diesel Fuel Consumption
57 Gallons per Engine hour >>>>>> Gal/Eng Hr.
58 Gallons per Cubic Yard >>>>>> Gals/Yd3
59 Loader Fuel Costs per Cubic Yard >>>>>> $/Yd3
2012 NRMCA Fleet Benchmarking and Cost Survey
27
Appendix III 2012 Fleet Survey Electronic Submission Form, cont’d
Additional Benchmarking Items
60 Driver Availability % (Available Drivers/Total Drivers) >>>>>> % Annually
61 Fleet Availability % (Available Mixers / Total Mixers) >>>>>> % Annually
62 Fleet Utilization % (Available Drivers/ Available Mixers) >>>>>> % Annually
63 Cubic Yards Delivered per Truck Mixer >>>>>> Yd3/Year
64 Dispatch Efficiency
(Drivers Hours Worked - Standby Hours/Drivers Hours Worked) >>>>>> Disp. Eff %
65 Number of Rollover Incidents in 2011(on or off road) >>>>>> # Rollovers
66 Number of Truck Mixer Backing Accidents in 2011 >>>>>> # Back. Acc.
67 Does Fleet include any Volumetric Mixers? >>>>>>
68 If Yes, How Many? >>>>>> # Volumetrics
69 If Yes, how Many Cubic Yards per Volumetric Mixer per Year >>>>>> Yd3/Year
Submitted by:
First Name
Last Name
Title:
Company:
Address:
City
State
Zip
Phone:
Fax
e-mail address:
Please e-mail completed form to NRMCA's Operations Staff by April 1, 2012 to: [email protected]