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A bad haircut might be
the most visible evidence of not doing a job correctly the first
time. With that haircut, it's often only a matter of a few days
before it becomes acceptable again. With an excavation or grading
project, the problems of a poor first attempt can continue for much
longer, with complications never imagined. With the haircut, you
can't put the hair back once it's been cut off. With the excavation,
you can replace soil if you take too much, or redo the grading
if the result was inaccurate, but it makes the job more expensive
and everybody very frustrated.
Contractors dislike some
"R" words: Rain can hinder progress, rebar has been known
to jolt a few careless diggers, repairs threaten ruin, but the most
dreaded R of all is rework. Anything you can plan and do to ensure
that the first pass, or the first cut, or the first grading is correct
probably will save you time and money. In a recent issue we looked
at what is available for machine guidance; those instruments are
tools to help you avoid rework. The first step is to decide why
a past job had to be reworked and then plan to avoid the same mistake
on this job. Was it the operator? Was it the machine? Was it carelessness?
The cautions we present are not new but are worth repeating because
they are sometimes neglected or deliberately avoided.
More Than Just Saving
Money
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| How
much room will your excavator have at this project? |
"You are free to
spend more time marketing and estimating, as opposed to worrying,"
observes Diana Mucha, president of M&V Builders based in Orlando,
FL, where the market is as competitive as anywhere in the United
States. "When work is done correctly the first time, your employees
are free to work on another project, and your owner is happy because
he perceives that the item is complete and on schedule. Quick, first-time
completion of the work means that there is no callback for warranty
or guarantee work and there should be no concerns about product
liability for items built on your work." She does mention that
there might be a few attorneys unhappy when the first attempt is
successful, complete, and accepted because they have no potential
business concerning workmanship claims. "It all equates to
a savings of money," adds Mucha. "Saving money equates
to greater profits and greater profits equate to better benefits
and happier employees. Happier employees equate to pride in better
workmanship, which equates to a monetary savings. Ergo, the cycle
repeats!"
Your business is a cycle,
and it needs to go 'round and 'round smoothly. In recent
years contractors have tried to make their estimates of life cycle
costs for their equipment as accurate as possible. They will include
obvious items, including initial costs and operational costs such
as repairs, fuel, oil and grease, estimated residual value of machines,
and interest costs in purchase. Of course, labor costs will also
be included. Labor is becoming more expensive–no need to tell
you that–but consider how much it costs when work that should
take three hours takes six because it wasn't done correctly
the first time. Without wanting to sound too picky, let's look
at an excavation job and see how rework explodes its cost to you.
The job should have taken, say, eight hours. It takes 14 because
there is rework required to meet specifications (and justify your
charges). That means six extra hours of labor, six extra hours of
machine wear, six hours lost when your workers could have moved
on to their next job. There are also the daily costs of running
the company, office personnel, insurance, and so on. "Years
ago, when I was just starting, my boss kept reminding me that the
profit from a job was in the iron," recalls Rick, an
experienced operator in central Oregon who, for this comment, prefers
to keep his last name unpublished–he still has the same boss.
"Today I think we should look at the causes of losses
on jobs, many of them due to rework. Those losses could be our failure
to win the next bid or our failure to complete a project within
budget. And whatever experts like academics, engineers, and–yes–journalists
tell us, I think most rework is necessary because [some of] my fellow
operators have become careless and less proud of their work, and
few bosses seem to take steps to correct that."
We don't intend
to harp on the shortage of skilled and motivated workers; there
are thousands of others already doing that. Something that several
of them miss is this: If you have skilled, motivated workers, keep
them. Look back at that cycle previously described by Diana Mucha.
Things–and People–Change
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| What
level of earthmoving or grading is required? Make sure you know. |
When bumper stickers
were so popular, one of the most frequently seen advised us tailgating
drivers that "S**t Happens." Change is another
of those things that happens–all the time. Contract terms change,
liabilities change, machines change, tools change, materials of
construction change, and people change. One of the causes blamed
for poor-quality work is that today's workers have changed. They
don't have the pride in their work of yesterday's men, older workers
frequently lament. People have always complained about previous
generations, as much as teenagers complain about the older generation,
but in the matter of work ethics or getting the job done right the
first time, example may be everything, so honestly ask yourself
if your workers have been shown how to work well, how to use a machine
to the best of its ability, how to avoid basic mistakes with certain
materials or in specific situations. If our employees learn their
jobs in the same way that children learn to walk, there will be
crashes and damage. They'll end up finishing the job, but not with
the first attempt.
"Miscommunication–that's
what usually causes me to do things wrong the first time,"
relates Sean Schwartz from his loader, working on a project near
his small hometown's youth baseball park in eastern Montana.
"I had two incidents just last week where I didn't do
it right because I wasn't told exactly what had to be done.
The boss said there was a job to be done and told me to go and do
it. He didn't give me all the details until I'd made the
mistake." Schwartz and coworker Brent Kutzler grin ruefully
at each other again and repeat that miscommunication causes too
many errors. The culprits might be the owner of the job or the workers'
boss. "I don't enjoy doing rework," Kutzler remarks.
"It wastes time, and it's an unnecessary waste of money."
"It's never intentional or a lack of willingness on our
part when the first attempt goes wrong," adds Schwartz. "We
enjoy doing our job well, but it always helps to know what the job
entails."
Tim Timmins is an owner
of Eagle Ridge Builders in Coeur d'Alene, ID. His longtime
experience tells him that there always will be mistakes, but some
of them should not occur. "I'm a working owner, and I
think that the key to first-time success is supervision, whether
the workers being supervised are my own or those of a subcontractor
for a specific part of the job." Timmins describes himself
as a hands-on boss as opposed to a paper pusher who might not even
understand techniques well enough to know when something has gone
wrong. "It all starts with good supervision. I make sure that
all my operators and I know how to get the best from their machines
and tools. How else could I expect them to do things right?"
Are the Machines Good
Enough for Today's Work?
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| There
are many machine attachments available to give you the best
results. |
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| Precision
in grading depends on both machine and operator. |
The old adage about bad
workmen blaming their tools might be true, but in our conversations
we have heard few operators of loaders, graders, excavators, and
dozers blaming their machines. Even if they wish they had all the
advantages of the newest models, they usually understand why they
can't have every new product offered, and they still believe that
the operator plays a vital role in the success of the work. In grading
and excavation, they perceive the operator and machine as a partnership.
"Everybody would like the latest model, but the business climate
makes new purchases unlikely for a while," observes Terry Nelson,
working on a grading project in Mandan, ND. "We are used to
that situation, just as we put off our purchase of a new car or
taking a vacation away from home till next year. What has surprised
me is that some operators don't take advantage of the time-saving
and accuracy features on newer machines when they do get them, but
that might be because nobody has shown them how to do so. I've been
driving these types of machines longer than some of my coworkers
have been alive, but I'm the first to admit that new controls will
mean retraining for me. It doesn't take long, and it's worth it."
Excavators were the first
machines to offer work modes, which allow the operator to adapt
the performance to the current application. There's a mode
for light digging, where fuel is saved, and another for demanding
digs, where as much power as possible is required to do the work
and fuel conservation cannot be the main priority. There are modes
between the extremes too. So why have the original types of work
mode virtually vanished? Owners and manufacturers discovered that
many operators asked their machines for full power, whatever the
application, by selecting the strongest work mode, and that tended
to cancel out the advantages of the different modes. So the machine
itself is choosing the best mode, with a primary goal of reducing
cycle times (and getting the job done right, quickly, the first
time). Volvo, for example, offers the Automatic Sensing Mode, Kobelco
has a system called the NeuralNet Command System, and Case promotes
its Pro Control System. Caterpillar offers similar control, based
on the movements of the joystick, and an optional Tool Control System
for attachments. HydrauMind from Komatsu has been familiar to us
for some years, and Link-Belt LX Series excavators use hydraulic
pressure readings (rather than any hand movement) to select the
best mode for a particular job. Your manufacturers have engineered
improvements to help operators get it right (and fast) the first
time. Rather than fill up space here, we encourage you to contact
your favorite distributor or manufacturer. They have all the information
you need.
Before You Start the
Machines
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| There
are specialized attachments available for special excavating
jobs. |
Site preparation is an
industry in itself for some contractors; they clear trees and brush
and remove stumps and rubble. They leave the surface in good condition
for the next stage of construction. That kind of site preparation
tends to be recognized at large sites rather than the smaller ones
that are most contractors' daily workplace. It takes only a few
minutes to prevent those "Whoops!" about the water pipe
by the front window or the gas main that makes a bend by the junipers.
Before your workers start excavating, make sure you know what is
already in the ground where they will be working. If it's a residence,
the owner might not be the best authority on where everything is,
so bear in mind that location devices are inexpensive compared to
errors in digging. If you are excavating trenches, take no chances.
Use shields or shoring for the safety of everyone. A man who lives
near me was caught in a trench cave-in and will be on crutches for
as long as he lives. "We were always so careful," he tells
me. "That was the first time we didn't bother to shore the
trench, and the earth just came down like a tidal wave. The loader
came with it."
Making sure that your
site is safe for that first, fast work is plain common sense. Barton
Malow Company, headquartered in Southfield, MI, has been in contracting
since 1924 and has done successful work in 37 states; they know
about doing it right. "The consequences of not doing it right
the first time, in terms of safety, mean that you often have no
second chance," states John Gleichman, director of safety and
loss control at Barton Malow. "Accidents always have permanent
consequences. You risk schedule, budget, and customer goodwill,
but even more importantly, you risk permanent injury and death."
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| Preparing
the site with the most suitable equipment is always a good start. |
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| A box
grader could be the best solution for a county road. |
The simple rules–such
as wearing gloves and the right clothing and not giving rides on
your machine–work not only for safety at the site but for a
good start to every stage of the project. Some engineers have studied
the best way to move an excavator into its work or a dozer into
the slope. An engineer at Caterpillar once showed us how the movements
of a loader could save dollars each shift by adjusting the angle
of approach and departure. Positioning the truck in an ideal position
(and having a size to match the excavator) can speed efficient digging.
How many bucketsful does
your operator get before he has to reposition the excavator? Such
aspects are worth checking.
Unclear instructions
are as much a hindrance to a start as debris on the lawn or cables
under the driveway. Keith Mitchell of Pine Street Construction says
grading areas has been a frequent request in his many years of excavation
and grading in the Western states. "You must understand that
the customer probably does not know as much about grading as you
do," he points out. "Many of the sites we've graded have
allowed a variance of 4 inches or more because that was all that
was necessary for the next stage of the owner's project. But some
people expect all grading to be blue topping. They imagine that
all grading is fine grading. Before putting that blade on the ground,
make sure [you are] clear as to what fineness of grading your machine
must work." Mitchell says he has heard of projects in which
the contractor thought his first effort was perfectly good, only
to discover that the customer had a totally different perception
of what the ground would look like. "That turns out to be not
doing it right the first time," notes Mitchell. "But whose
fault is it? I think the wise contractor will be certain precisely
what is expected of him before the job starts."
Once you know what is
required for a specific job, you might find that a particular machine
is the ideal tool. If you don't have exactly what you need,
you can rent it. For digging ground and laying new pipeline where
there are already utility lines that must not be damaged, contractor
Daniel Hawkins in Charlotte, NC, found the Allmand backhoe to be
practical. "We needed a machine that could give precise control
as well as power," notes Hawkins. "Our workers' safety
was a major consideration. After we had calculated the best position
for each piece of sewer line we laid, we had to work carefully around
existing gas and utility lines. The compact backhoe was ideal."
Why do we see so many
skid-steer loaders at sites where the work involves grading, excavation,
and all those tasks related to site preparation? Look at the attachments
available for skid-steers from such manufacturers as Bobcat, Gehl,
Takeuchi, Case, Deere, Cat, Volvo, New Holland, Mustang, and Komatsu.
The machine to get your job done right and fast at the first attempt
is available. If you don't own one, consider leasing it for
a specific job. Rather than using a loader that is too big for the
job, consider renting a smaller one (or vice versa).
How careful should you
be? Does it matter much if you have to excavate further or grade
one more time? How much could it cost you to make a grading or excavation
mistake on the first attempt? "In northern Nevada, you'd
better check with a soil engineer first," advises Jesse Haws,
an owner in Hawco Properties north of Reno, NV. "His soil report
is critical, whether you're doing the work yourself or having
a subcontractor do it. The report will tell you if the soil is clay,
how elastic it is, how many rocks you may find. You may want to
replace the clay before you proceed. Everything is dealt with on
a case-by-case basis, and every job is the most important at the
time."
How costly can mistakes
be? "The worst thing you can do when you are developing properties
in places like Eagle Canyon is have to move the dirt twice,"
says Haws. "There is a story of a contractor, a big one, who
came into the Reno area, unfamiliar with soil conditions. His men
and machines had to do the grading, the earthmoving, three times.
Rumor has it that it cost $20,000 per lot to correct that mistake."
The soils in upstate
New York, Michigan by the lake, Iowa, West Virginia and southern
Illinois where the coal has been mined, New Mexico, Colorado in
the foothills, Florida with its unusual water table, and Louisiana
are all different. Local excavating contractors usually know the
problems to expect–not because they were born there but because
they have taken the trouble to find out. Earthmoving specialists
know which types of scraper work best in their local soils, and
they have profitable projects to prove it. Excavating workers for
Haws in Nevada take out the clay before construction of the new
homes; Carl Clausen in Montana brings in clay to make ponds for
ranchers. "You have to get that slope right too," emphasizes
Clausen, who at 72 years old is still going strong and looking for
better ways to complete his county road and pond work without rework.
"Dig a hole with a vertical edge and you'll have to do
it all again."
Everybody agrees that
doing it right the first time is ideal. The ways suggested–and
there are many more not mentioned here–to achieve that do not
appear to be as difficult as we first thought; most of them are
common sense and simply involve using the knowledge and skills of
your profession that you already possess.
Frequent contributor
Paul Hull writes on construction and environmental topics for several
international magazines.
GEC
- November/December 2002
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