2014 national ready mixed concrete association fleet ... · pdf file2014 national ready mixed...

Report of:

2014 National Ready Mixed Concrete Association Fleet Benchmarking and Costs Survey

July, 2014

Jeff Hinkle, Chandler Concrete Tim Kauzlick, CEMEX NRMCA OES Committee Chairman NRMCA OES Committee Vice Chairman David Williams, Chaney Enterprises Chris Cooper, CEMEX NRMCA Operations Task Group Chairman NRMCA Operations Task Group Vice-Chair Kevin Walgenbach, NRMCA Gary M. Mullings, NRMCA Senior Director, Compliance and Regulatory Affairs Senior VP, Operations and Compliance

2014 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.


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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/or plant. This policy was established to help elevate the level of 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 company results.

2014 Fleet Benchmarking Survey The 2014 Fleet Benchmarking Survey form was sent to NRMCA member company’s fleet managers, financial officers and primary contacts in January 2014 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 form to further participation from NRMCA members. The deadline for all survey responses was April 1, 2014 (extended until May 1). The survey (attached in the appendix of this report) consisted of 69 fill-in-the-blank type questions. The form for 2014 was reviewed by the OES committee and Operations Task Group and approved for distribution. The survey response represents data for calendar year 2013. 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


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Survey Responses Now in its fifteenth year, the annual survey is limited to NRMCA member companies only. NRMCA received submissions from 90 companies or divisions. 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 compiled 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 27% Rocky Mountain 3% Eastern 21% North-Central 8% Great Lakes/Mid-West 8% Pacific Northwest 1% South-Central 12% Pacific Southwest 16%

Mixer Fleets A total of 15,613 concrete mixer trucks are represented in the 2014 survey. In 2013 the survey represented just fewer than 11,000 mixer trucks. Using yards delivered per truck annually, 4,610 (median from survey question #63) and the estimated total US ready mixed concrete produced from the NRMCA website (approx. 301,000,000), one can estimate the number of ready mixed concrete trucks currently operating in the United States to be approximately 65,292. 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 173 (up about 8% from the 2013 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 mixer trucks in a fleet is 99. This means that about half of the companies who responded to the survey have 99 mixer trucks or less and the other half reported more than 99 mixer trucks.

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 90 companies/divisions who responded to this question was 9.7 years, while the average age of individual trucks was calculated to be 8.7 years as compared to 8.0 last year. The average age of a fleet of 9.7 years is the highest in the survey’s history and continues an upward trend which started in 2007.

(Individual company number of trucks x fleet age / total number of trucks surveyed)


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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 mixer trucks were higher in 2013 than 2012 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 75% of all mixers. Front discharge mixers make up the remaining 25% 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 twelve companies.

Table 2: Mixer Fleet Statistics Item Description Companies

Reporting (Percent)

Total Number

Average per company reporting

High Low Median

1 # Trucks 90 (100%) 15,613 173 810 10 99

2 Age, Years 89 (99%) 9.7 16.5 5.2 9.4

3 Front Discharge 39 (43%) 3,946 101 605 3 53

4 Rear Discharge 72 (80%) 11,340 172 654 5 93

5 All Wheel Drive 26 (29%) 1,985 76 318 2 53

6 Conveyor Equipped

11 (12%) 62 6 18 1 3

7 Trailer Mixers 3 (3%) 83 28 75 2 6


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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 2014 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 about 2-to-1. However, the 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


High Low Median

8 2-Axle 3 (3%) 13 4 10 1 2

9 3-Axle 23 (34%) 4,137 118 707 1 42

10 4-Axle/Booster 52 (58%) 4,121 79 605 2 46

11 4-Axle/Pusher 39 (43%) 2,335 60 394 1 29

12 5-Axle 40 (44%) 2,539 63 313 3 47

13 6-Axle 23 (26%) 1,959 85 347 1 45

14 7-Axle 4 (4%) 346 87 260 2 42


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Fleet Performance The survey represents ready mixed concrete trucks that traveled more than 256 million miles. That’s equal to more than 11,000 trips around the equator. The average annual mileage on a ready mixed concrete truck was 16,435 miles last year. This statistic, which is up about 3% over last year, is still 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 3.44 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 mixer truck must travel will vary depending on location, type of construction, and commitment to customers. The average one-way haul distance for the 82 companies that reported data was 14.79 miles, which is one of the highest reported in the last 14 years.

For this survey the average load-size was 7.97 cubic yards and the average full load was 9.82 cubic yards. Both figures are up slightly from last year’s survey. 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 65 companies reporting both numbers, the calculated average load-size coefficient was 82%, with a high of 99% and a low of 70%.

Table 4: Summary of Fleet Performance



High Low Median

15 Mixers per Mechanic 86 (96%) 13.7 46 4 12

16 Annual Miles/Truck 78 (87%) 16,435 65,000 1,800 14,969

17 Annual Engine Hours 67 (74%) 1,668 4,100 663 1,505

18 Avg. One-Way Haul Distance, miles

82 (91%) 14.8 31.5 4.7 14.0

19 Avg. Load Size, cu. yd. 86 (96%) 8.0 10.0 3.0 7.88

20 Typical Full Load Size, cu. yd.

88 (98%) 9.8 12.0 8.0 10.0


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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 yd3

In 2013, fuel costs for the ready mixed concrete industry remained at all time highs. The median fuel cost according to this survey was $3.47 per gallon; an increase about the same as the average fuel cost of the previous year. Fuel costs per cubic yard are up from $3.86 per yard in 2012 to $3.93 per yard in 2013, about a 2% 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 (IRS) 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, while the IRS has calculated it to be 30.2%.

Table 5: Summary of Fuel Usage


Average per Company Reporting

High Low Median

21 Miles Per Gallon 80 (89%) 3.32 6.8 1.67 3.30

22 Fuel, gal./hr. 53 (59%) 3.19 8.5 0.03 3.0

23 Fuel, gal./yd3 81 (90%) 1.13 4.3 0.36 1.06

24 Fuel, $/yd3 85 (94%) $3.93 $5.95 $1.20 $3.86


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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



High Low Median

25 Mixer Parts: $/ yd3

74 (82%) $ 0.68 $ 2.84 $ 0.02 $ 0.62

25B Eng Parts: $/ yd3 73 (81%) $ 0.97 $ 2.52 $ 0.10 $ 0.83

26 Shop: $/ yd3 82 (91%) $ 1.62 $ 4.22 $ 0.02 $ 1.59

27 Outside Repairs: $/ yd3

73 (81%) $ 0.44 $ 2.84 $ 0.03 $ 0.22

28 Tires & Tubes: $/ yd3

85 (94%) $ 0.50 $ 1.84 $ 0.05 $ 0.46

29 TOTAL (25-28)

84 (93%) $ 3.79 $ 8.70 $ 0.25 $ 3.77

30A Wrecker Costs: $/ yd3

59 (66%) $ 0.04 $ 0.25 $ .007 $ 0.02

30B Wrecker Costs: $/eng hr

10 (11%) $ 0.07 $ 0.25 $ 0.01 $ 0.06

31A Accident Repair Cost: $/ yd3

41 (46%) $ 0.06 $ 0.33 $ 0.004 $ 0.03

31B Accident Repair Cost: $/eng hr

11 (12%) $ 0.13 $ 0.29 $ 0.01 $ 0.13

32A Truck Wash: $/yd3

64 (71%) $ 0.13 $ 0.38 $ 0.01 $ 0.12

32B Truck Wash: $/truck/year

12 (13%) $ 483.07 $ 724.49 $ 186.16 $ 529.00


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Tires Tires are an essential factor in determining costs associated with ready mixed concrete fleets. Of the 89 companies who reported, 3% allow recaps on the steer axle tires. On the other hand, 86% 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 approximately $230 in 2013. Another interesting number derived from the data is road-calls per truck per year. On average, a ready mixed concrete company makes approximately 3.9 road calls related to tire failures per month for every 100 trucks in their fleet.

Table 7: Summary of Tire Information



High Low Median

33

Recaps for steer tires =YES 89

(99%)

3 (3%)

=NO 86

(97%)

34 If yes to 33, max # of recaps per tire 6 (7%) 1.25 2 1 1

35

Recaps for drive tires & lift axles = YES 89

(99%)

86 (97%)

= NO 3

(3%)

36 If yes to 35, max # of recaps per tire 78 (87%) 2.32 5 1 2

37

Capitalize cost of tires/new mixers? =YES 81

(90%)

35 (43%)

=NO 46

(57%)

38 Avg # road calls/month 74 (82%) 8.29 75 .5 4.0

39 Avg lost hours./road call 76 (84%) 2.13 18.0 0.45 2.0

40 Avg cost/tire-related breakdown 67 (74%) $229.07 $1200 $40 $165

41

Tire pressure checked Intervals =DAILY 28(32%)

=WEEKLY 28(32%) =BIWEEKLY 11(13%) =MONTHLY 19(22%)

42

Tire check done by: =DRIVER 56(64%)

=MECHANIC 9(10%) =TIRE SERVICE 22(25%)


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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 reveal that about 82% of producers base drain intervals on engine hours and surprisingly none base their drain intervals on oil analysis.

Table 8: Summary of Preventive Maintenance Statistics



High Low Median

43

Basis for PM Drain Interval,

89 (99%)

=MILAGE 7 (8%)

=ENGINE HOURS 73 (82%)

=CALENDAR DAYS 4 (4%)

=FUEL CONSUMPTION

2 (2%)

=OIL ANALYSIS 0 (0%)


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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 89% this year.

Also in this year’s survey are additional 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 than 40,000 yards of concrete. Both numbers are nearly 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



High Low Median

44 Drum Chipping by:

Driver 8 (9%)

Maint. 2 (2%)

Outside Service

79 (89%)

45 Drum Chipping Frequency (months)

90 (100%) 6.35 30 1 6

46 Cost per Cleaning 68 (76%) $220.06 $550 $25.50 $200

46B Chipping Cost (per truck per year)

48 (53%) $531.91 $2000 $132 $349

47

Capitalize Drum Cost? = YES

52 (68%)

= NO 24 (32%)

48 Avg Drum Life/years. 87 (97%) 7.4 14.0 3.5 7.0

48B Avg Drum Life/yd3 72 (80%) 40,234 120,000 14,087 40,000


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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 2,200 loaders from 90 companies/divisions, reveals the average age of a loader is 11.44 years. The data also shows that a company, on average, operates 1 loader for every 6.8 truck mixers.

Table 10: Summary of Front End Loader Statistics



High Low Median

49 # Loaders 86 (96%) 25.8 172 2 13.0

50 Avg. age, years. 85 (94%) 11.44 30.1 1.0 11.2

51

Capitalize Loader Engine Rebuilds?

= YES 80 (89%)

51 (64%)

= NO 29

(36%)

52A Loader parts: $/yd3 69 (77%) $0.19 $3.60 $0.01 $0.11

52B Loader parts: $/eng hr. 19 (21%) $4.28 $10.41 $0.49 $4.00

53A Loader shop exp.: $/yd3. 43 (48%) $0.14 $0.58 $0.01 $0.09

53B Loader. shop exp: $/eng. hr. 15 (17%) $2.31 $4.81 $0.25 $2.32

54A Loader outside repair: $/yd3 49 (54%) $0.16 $0.92 $0.01 $0.11

54B Loader outside repair: $/eng.hr.

16 (18%) $2.03 $6.75 $0.19 $1.37

55A Tire/Tube: $/yd3 63 (70%) $0.07 $0.55 $0.003 $0.04

55B Tire/Tube: $/eng. hr. 19 (21%) $1.55 $5.56 $0.07 $1.00

56A TOTAL: $/yd3 (from 53-56)

75 (83%) $0.42 $3.69 $0.02 $0.29

56B TOTAL $/eng. hr. (from 43-56)

24 (27%) $8.23 $22.07 $0.08 $8.11

57 Loader Fuel: gal/eng. hr. 47 (52%)) 3.41 8.00 .05 3.50

58 Loader Fuel: gal/ yd3 50 (56%) 0.14 1.0 0.01 0.08

59 Loader Fuel: $/yd3 63 (70%) $0.26 $.74 $0.04 $0.25


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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 (87 companies) the rollover rate per 100 trucks is 0.5 and for those companies reporting backing accident (75 companies) the rate is 6.1 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


Total # Average per Company Reporting

High Low Median

60 Driver Availability Annually, %

70 (78%) 90% 100% 19% 93%

61 Fleet Availability Annually, %

74 (82%) 90% 100% 57% 92%

62 Fleet Utilization Annually, %

70 (78%) 86% 100% 48% 89%

63 Concrete delivered per truck annually, yd3

81 (90%) 4,897 9,500 2438 4653

64 Dispatch Efficiency Annually

58 (64%) 81% 100% 45% 80%

65 Rollovers in 2013 87 (97%) 76 0.87 6 0 0

66 Backing Accidents in 2011

75 (83%) 876 11.68 149 0 7

67 Volumetric Mixers = YES

1 (3%)

= NO 79 (99%)

68 Number of Volumetric Mixers?

1 (1%) 1 1 1 1 1

69 Concrete delivered by volumetric mixers, yd3

0 (0%)


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Yearly Comparison Table 12: Trend Analysis

Data for Year 2013 2012 2011 2010 2009 2008 2007 2006 2005 2004 2003 2002 2001

Companies Participating 90 67 86 94 87 90 82 99 56 46 41 80 75

Number of Trucks 15,613 10,744 12,606 15504 13,839 14,588 14,609 17,080 11,591 7,114 6,211 10,120 12,116

Average Fleet Age, years 9.7 8.9 8.0 7.6 7.3 7.4 6.1 6.8 6.5 7.0 8.1 7.4 6.8

Average Truck Age, years 8.7 8.0 7.6 6.9 6.2 - - 6.2 6.2 6.7 6.7 6.7 6.4

Front Discharge, Percent 25.3% 16.7% 18% 24.6% 17.2% 17.0% 19.0% 15.7% 23% 16% 26% 29% 18%

Rear Discharge, Percent 72.6% 81.9% 81% 74.2% 82.8% 83.0% 81.0% 82.3% 77% 84% 74% 71% 82%

Avg. Annual Mileage per Truck, 16,435 14,773 14,295 13,860 13,801 15,062 17,755 17,976 18,896 16,895 16,952 18,437 16,954 Avg Haul, One Way, miles 14.8 14.3 14.3 13.8 14.4 14.2 14.1 14.6 12.1 14.3 13.0 12.1 13.4

Average Load Size, yd3 8.0 7.8 7.7 7.8 7.7 7.8 8.1 8.1 8.2 7.9 8.0 7.7 7.9 Average " Full Load" size, yd3 9.8 9.7 9.8 9.8 9.8 9.7 9.8 9.6 9.8 9.8 10 9.7 9.6

Fuel Usage: miles per gallon 3.32 3.15 3.22 3.32 3.38 3.38 3.40 3.60 3.60 3.79 3.6 3.87 3.93

Fuel Usage: gallons per yd3 1.13 1.22 1.08 1.14 1.10 1.07 1.06 1.16 0.99 0.85 1.0 0.95 0.94 Fuel Usage: $ per yd3 $3.93 $4.08 $3.91 $3.02 $2.81 $3.67 $2.80 $2.55 $2.15 $1.72 $1.36 $1.22 $1.37

Parts (mixer + truck): $ per yd3 $1.45 $1.50 $1.38 $0.99 $0.96 $1.14 $1.07 $1.12 $0.98 $0.93 $1.06 $1.05 $0.98 Shop expense: $ per yd3 $1.62 $1.52 $1.51 $1.64 $1.44 $1.53 $1.55 $1.46 $1.26 $1.33 $1.29 $1.50 $1.05

Tires & Tubes: $ per yd3 $0.50 $0.50 $0.42 $0.35 $0.35 $0.31 $0.31 $0.33 $0.31 $0.33 $0.30 $0.29 $0.34 Maintenance Cost: $ per yd3 $ $3.57 $3.30 $3.18 $3.40 $3.58 $3.52 $3.21 $2.70 $2.87 $2.79 $3.03 $2.59

Recaps for Steer Tires? 3% 3% 5% 3% 3% 7% 7% 8% 0% 7% 5% 9% 16%

Recaps for Drive Tires? 97% 91% 93% 100% - - 93% 95% 96% 93% 95% 96% 96%

Avg$ per road call (Tire Related) $229.07 $184.65 $149.91 $199.95 $146.79 175.15 $139.39 $175.57 $162.15 $147.34 $135.62 $135.11 $127.51

PM Drain Interval, Eng. Hr. 73% 81% 86% 82% 82% 78% 71% 424 447 449 419 387 375

PM Drain Interval, Days 4% 6% 6% 7% 5% 7% 18% 112 90 94 87 148 128

PM Drain Interval, miles 8% 8% 5% 5% 9% 12% 7% 6,636 6,250 4,722 4,556 5,205 5,125

Mixer to Mechanics Ratio 13.7 13.7 14.3 14.8 13.9 13.3 13.5 13.6 13.4 13.2 13.4 12.2 12.7 Avg Drum Service Life, years 7.4 7.7 7.4 7.2 7.1 6.8 5.7 5.5 5.6 5.7 5.9 6.0 5.7

Avg Drum Service Life yd3 40,234 39,819 39,040 38,279 38,645 36,232 39,052 32,850 36,840 31,178 36,757 32,078 33,869 Number of Front-end Loaders 2,222 1,606 1,765 2,136 1,708 1,758 1,537 1495 1033 758 634 1030 1281

Average Loader age, years 11.44 12.35 11.3 11.0 10.8 9.9 9.0 9.0 10.0 10.4 12 10.6 9.0 Avg. Loader Maintenance: $/ yd3 $0.49 $0.72 $0.44 $0.48 $0.59 $0.54 $0.51 $0.43 $0.48 $0.24 $0.19 $0.24 $0.24 Avg. Loader Maintenance: $/engine hour 8.62 $10.80 $10.14 $9.40 $5.02 $12.93 $12.69 $11.26 $9.09 $6.38 $4.19 $6.61 $6.47

2014 NRMCA Fleet Benchmarking and Cost Survey

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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 next year’s Survey. Forms will be available on or about January 1, 2015 at www.nrmca.org.

Table 13: Participating Companies

Company Reported By: Company Reported By: Advance Ready-Mix Concrete Patrick Cowan Irving Materials Inc. Chad Kelly

Aggregate Industries Chris Welly Kentucky Concrete, (KCI Companies) Jeffrey Blankley

Aggregate Industries Jon Burke Kilpatrick Concrete Aggregate Industries Inc. Van Sykes Little Lisa Inc. dba Wayne Concrete William Haas Aggregate Industries US Scott Schaffler Livingston's Concrete Service, Inc. Jo-Ann McIntire

Anderson Concrete Michael Anderson Manatts Denny Gallagher Argos Mauricio Ceballos Maschmeyer Concrete Company Brian Curtis

Bayou Concrete, LLC Judd Beech Maschmeyer Concrete Company of Florida, Inc. Jessie James

CalPortland Willy Hamblen Metro Ready Mix Concrete Michael Zagula CalPortland CC David Stout MMC Materials, Inc. Shane Huff CalPortland NV Jason Faubel Ozinga Ready Mix Concrete, Inc. Jessica Miazga CalPortland NW K. Fisher C. Williams PCS Jennifer Hurst

CalPortland SCA Tony Barnett Pete Lien & Sons (AKA Birdsall Sand & Gravel) Ron Sargent

Calportland Tuc Gary Dykman Powhatan Ready Mix Shae Fender Capital Concrete Inc. Wayne Bolton Titan, Virginia Shae Fender

Carew Concrete & Supply Co., Inc. John Carew Preferred Materials, Inc. - Concrete Division Meg Dragoni

Carolina Sunrock LLC Katherine Pfohl Razorback Concrete Bill Johnson Carroll Concrete Chris Broadhurst Ready Mix USA Travis Owens Cemex Steven Knudsen Ready Mixed Concrete Co Bob Haun CEMEX Richard Fritz Redi-Mix David Behring CEMEX Chris Cooper RW Sidley, Inc David Lintern CEMEX Pat Strader S & W Ready Mix Concrete Co. Warren Sinclair Cemstone Concrete Materials Paul Daraitis Silvi Tim Kurz Central Concrete Supermix Inc Julio Suarez Southern Concrete Materials, Inc Donnie Parsell Central Concrete Supply Company, Scott Perrine Spokane Rock Products Julie Muller Chaney Enterprises David Williams Spurlino Materials Jim Spurlino Glacier North West dba Calportland Doyle Davis Staker Parson Companies Roger Rich Hanson Aggregates PSW Matt Woods Teichert Readymix Robert De Ruiter Glacier North West dba Calportland Doyle Davis Thomas Concrete Industries, Inc. Fredrik Hoeglund Ingram Concrete LLC. Christy Ludwick Titan Florida, LLC Mike Edenfield Irving Materials Inc. Chris Holt United Materials, LLC James Pierce

http://www.nrmca.org/


17

Note: for 2014 report the western States have been combined for staticticaland confidential purposes.

Region

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Region Total # 19 21 13 15 21Mixer Fleet

1 Total # of Truck Mixers Total # 1,775 5,454 1,601 2,866 3,9172 Average Fleet Age Average 10.5 9.2 9.1 8.3 10.2

Breakdown of Truck Mixers by Type 3 # Front Discharge Units Total # 330 1,478 742 224 1,1724 # Rear Discharge Units Total # 1,445 3,649 859 2,642 2,7455 # All-Wheel Drive Trucks Total # 319 807 361 10 4886 # Mixers Equipped w/ Belt Conveyors Total # 18 37 2 0 57 # Trailer Mixers Total # 0 0 6 0 77

Breakdown of Truck Mixers by Chassis Configuration : 8 2 Axles Total # 11 2 0 0 09 3 Axles Total # 295 2,651 10 1,173 8

10 4 Axles (booster) Total # 363 740 800 459 1,75911 4 Axles (pusher) Total # 718 978 49 531 5912 5 Axles Total # 346 524 655 301 71313 6 Axles Total # 1 465 81 391 1,02114 7 Axles Total # 0 64 0 0 282

Miscellaneous Fleet Performance Information15 Truck Mixer-to-Mechanic Ratio Average 14.3 13.7 12.8 12.1 13.416 Average Annual Mileage per Truck Mixer Average 13357.9 17850.1 11615.0 23654.5 17215.417 Average Annual Engine Hours per Truck Mixer Average 1599.7 1641.6 1302.0 2012.1 1719.518 Avg. Haul Distance (miles, one way ) Average 14.8 15.2 10.1 13.7 16.419 Average Load Size (Yards3) Average 7.6 7.8 7.6 8.3 8.4

20 Typical Full Load Size (Yards 3 ) Average 9.8 9.7 9.5 9.8 10.1

2014 Fleet Benchmarking & Cost Survey Regional Summary

2014 Regional Report Results

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Appendix I 2014 Regional Summary


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Truck Mixer Diesel Fuel Consumption

Region

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21 Miles per Gallon Average 3.27 3.29 2.76 3.42 3.5422 Gallons per Engine Hour Average 3.46 3.38 3.01 2.92 3.1323 Gallons per Cubic Yard Average 1.09 1.35 1.06 0.92 1.0924 Fuel Costs per Cubic Yard Average 4.18 4.62 3.71 3.24 3.50

Truck Mixer Maintenance Costs25 A: Mixer Parts Expense per Cubic Yard Average 0.56$ 0.86$ 0.60$ 0.77$ 0.57$ 25 B: Engine Parts Expense per Cubic Yard Average 1.14$ 1.12$ 0.85$ 0.68$ 0.80$ 26 Shop Expense per Cubic Yard Average 1.70$ 1.54$ 1.66$ 1.24$ 1.79$ 27 Outside Repair Costs per Cubic Yard Average 0.36$ 0.47$ 0.22$ 0.50$ 0.53$ 28 Tire Expenses per Cubic Yard Average 0.61$ 0.57$ 0.34$ 0.39$ 0.45$ 29 Maintenance Cost TOTAL (from questions 25-29) Average 4.17$ 4.00$ 3.55$ 3.06$ 3.70$ 30 Wrecker Costs (per Cubic Yard) Average 0.04$ 0.03$ 0.02$ 0.08$ 0.02$

or ($/Engine Hour) Average 0.25$ 0.05$ 0.03$ #DIV/0! 0.07$ 31 Accident Repairs (per Cubic Yard) Average 0.10$ 0.08$ 0.04$ 0.01$ 0.04$

or ($/Engine Hour) Average -$ 0.16$ 0.14$ #DIV/0! 0.10$ 32 Truck Wash Cleaning Products Costs (per Cubic Yard) Average 0.10$ 0.16$ 0.15$ 0.12$ 0.12$

or ($-per-Vehicle-per-Year) Average 218.08$ 689.00$ 518.40$ 700.00$ 483.30$ Tire-Related Information

33 Do You Use Retreads on Steer Tires? Yes 0.0% 8.7% 11.1% 0.0% 0.0%34 . . .if yes, maximum # of recaps per casing Average 0.0% 133.3% 100.0% #DIV/0! #DIV/0!35 Do You Use Retreads on Drive Tires & Liftable Ax les? Yes 94.7% 100.0% 100.0% 90.9% 96.3%36 . . .if yes, maximum # of recaps per casing Average 2.2 2.5 2.3 2.5 2.237 Do you Capitalize the Cost of Tires on New Mixers? Yes 50.0% 57.1% 66.7% 36.4% 24.0%38 Typical # of Road Calls per Month due to Tire Problems? Average 3.8 11.4 2.9 26.4 4.739 Typical Time Lost per Tire-related Road Call? (Hours) Average 2.0 2.2 1.5 4.2 1.740 Avg. Cost of Tire-related Breakdown (Not incl. Tire Cost )? Average 267.33$ 262.37$ 101.00$ 159.00$ 224.94$ 41 How often is tire pressure checked? Daily 1 2 0 0 4

Weekly 14 21 9 6 23Bi-weekly 2 0 0 2 0

Monthly 2 0 0 0 042 Who checks tire pressure? Driver 15 20 5 9 7

Mechanic 2 1 2 1 3Tire Service 2 2 1 0 17

2014 Report


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Region

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43 Crankcase Drain Interval (truck mixer engine) Mileage 1 2 0 0 4Basis of PM Interval Engine Hours 14 21 9 6 23

Calendar Days 2 0 0 2 0Fuel Consumption 2 0 0 0 0

Oil Analysis 0 0 0 0 0Mixer Drums, Drum Chipping, Service Life, Etc.Who Performs Drum Chipping? Driver 2 0 3 2 1

44 Mechanic/Other 1 1 0 0 0Outside Service 16 22 6 9 26

45 How Often are Drums Chipped Out? (Average, in months Average 6.7 8.9 5.4 7.2 5.646 Average Drum Chipping Cost (per cleaning) Average 175.2 305.7 230.8 213.5 219.0

Average Drum Chipping Cost per Truck Mixer-per-Year Average 480.2 360.5 394.8 541.7 587.547 Do you Capitalize the Cost of Replacement Drums? Yes 78% 39% 100% 56% 70%48 Average Drum Serv ice Life: (Years + 10ths, e.g., 8.5) Average 7.3 7.3 9.0 8.0 6.6

Average Drum Serv ice Life: (Cubic Yards) Average 35355.6 36639.1 46300.0 42177.6 36966.3Front End Loaders

49 Total # of Front-end Loaders Total # 214 759 185 432 38450 Average Loader Age (Years) Average 12 9 10 12 1351 Do you Capitalize Loader Engine Rebuilds/Overhauls? 67% 42% 75% 78% 72%

Front End Loader Maintenance Costs52 Parts Expense (per Cubic Yard) Average 0.17$ 0.16$ 0.08$ 0.14$ 0.30$

or ($/Engine Hour) Average 4.08$ 6.64$ 2.14$ 3.91$ 5.32$ 53 Shop Expense (per Cubic Yard) Average 0.18$ 0.10$ 0.12$ 0.16$ 0.14$

or ($/Engine Hour) Average 0.89$ 7.78$ 2.50$ 2.90$ 54 Outside Repair Costs (per Cubic Yard) Average 0.14$ 0.16$ 0.06$ 0.13$ 0.20$

or ($/Engine Hour) Average 3.65$ 3.38$ 0.77$ 2.18$ 2.02$ 55 Tire Expense (per Cubic Yard) Average 0.11$ 0.07$ 0.03$ 0.05$ 0.04$

or ($/Engine Hour) Average 1.25$ 2.71$ 0.78$ 1.69$ 1.65$ 56 TOTAL - per Cubic Yard (from questions 53 - 56) Average 0.42$ 0.32$ 0.19$ 0.37$ 0.56$

TOTAL - per Engine Hour (from questions 53 - 56) Average 4.09$ 17.88$ 8.31$ 7.74$ 9.48$ Loader Diesel Fuel Consumption

57 Gallons per Engine hour Average 3.81 3.00 3.01 2.98 4.1558 Gallons per Cubic Yard Average 0.14 0.15 0.08 0.23 0.1259 Loader Fuel Costs per Cubic Yard Average 0.26$ 0.27$ 0.25$ 0.28$ 0.23$

2014 Report


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Additional Benchmarking Items Region

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60 Driver Availability % (Available Drivers/Total Drivers) Average 90.5% 91.8% 94.0% 83.7% 91.9%61 Fleet Availability % (Available Mixers / Total Mixers) Average 89.4% 89.8% 94.9% 87.5% 90.1%62 Fleet Utilization % (Available Drivers/ Available Mixers) Average 85.9% 79.7% 88.3% 87.9% 86.9%63 Cubic Yards Delivered per Truck Mixer Average 4,023.38 4,334.13 4,406.00 6,389.32 4,958.9364 Dispatch Efficiency (Drivers Hr. - Standby Hr./Drivers Hr Average 78.8% 0.0% 83.4% 79.2% 77.8%65 Number of Rollover Incidents (on or off road) Total # 4 27 3 27 1566 Number of Truck Mixer Backing Accidents Total # 109 185 61 285 23667 Does Fleet include any Volumetric Mixers? Yes 0% 0% 0% 0% 0%68 If Yes, How Many Volumetric Mixers? Total # 0 0 0 0 069 If Yes, how Many cu. yd. per Volumetric Mixer per Year Average 0 0 0 0 0

2014 Report


21

RegionIn 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 Mixers2 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 >>>>>> Fronts4 # Rear Discharge Units >>>>>> Rears5 # All-Wheel Drive Trucks >>>>>> All-Wheel Drive6 # Mixers Equipped w/ Belt Conveyors >>>>>> w/Conveyors7 # 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

Miscellaneous Fleet Performance Information15 Truck Mixer-to-Mechanic Ratio (e.g., 13.5 trucks per mechanic >>>>>> Mixers/Mech.16 Average Annual Mileage per Truck Mixer >>>>>> Miles17 Average Annual Engine Hours per Truck Mixer >>>>>> Hours18 Avg. Haul Distance (miles, one way ) >>>>>> miles19 Average Load Size (Yards3) >>>>>> Yd3

20 Typical Full Load Size (Yards 3 ) >>>>>> Yd3

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2014 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, 2014. 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 division orbusiness unit. If you cannot answer all the questions, please complete and submit what you can.

Please use data from calendar year 2013.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.

Appendix II 2014 Electronic Submission Form


22

Diesel Fuel Consumption21 Miles per Gallon >>>>>> miles/gal22 Gallons per Engine Hour >>>>>> Gal/Eng hr.23 Gallons per Cubic Yard >>>>>> Gals/Yd3

24 Fuel Costs per Cubic Yard >>>>>> $/Yd3

Truck Mixer Maintenance Costs25A 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 Information33 Use Retreads on Steer Tires? (Yes or No) >>>>>>34 . . .if yes, maximum # of recaps per casing >>>>>> recaps/tire35 Use Retreads on Drive Tires & Liftable Ax les? (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 N >>>>>>38 Typical Number of Road Calls per Month Due to Tire Problems>>>>>>39 Typical Time Lost per Tire-related Road Call? (Hours + 10ths) >>>>>> Hours40 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) >>>>>>

Crank case Drain Interval (truck engine) >>>>>>43 Basis of Interval (e.g., mileage, engine hours, calendar days, fuel use, oil analysis)

Mixer Drums, Drum Chipping, Service Life, Etc.44 Who Performs Drum Chipping? >>>>>>45 How Often are Drums Chipped/Cleaned, on Average? (Months)>>>>>> months46 Average Drum Chipping Cost (per cleaning) >>>>>> $/per cleaning

or per Truck Mixer-per-Year >>>>>> $/truck per year47 Do you Capitalize the Cost of Replacement Drums? (Yes or No>>>>>>

48 Average Drum Serv ice Life: (Years + 10ths, e.g., 8.5) >>>>>> YearsAverage Drum Serv ice Life: (Cubic Yards) >>>>>> Yd3


23

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 >>>>>> # Loaders50 Average Loader Age (Years) >>>>>> Years51 Do you Capitalize Loader Engine Rebuilds/Overhauls? (Yes or N>>>>>>

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

Additional Benchmarking Items60 Driver Availability % (Available Drivers/Total Drivers) >>>>>> % Annually61 Fleet Availability % (Available Mixers / Total Mixers) >>>>>> % Annually62 Fleet Utilization % (Available Drivers/ Available Mixers) >>>>>> % Annually63 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 2013 (on or off road) >>>>>> # Rollovers66 Number of Truck Mixer Backing Accidents in 2013 >>>>>> # Back. Acc.67 Does Fleet include any Volumetric Mixers? >>>>>>68 If Yes, How Many? >>>>>> # Volumetrics69 If Yes, how Many Cubic Yards per Volumetric Mixer per Year >>>>>> Yd3/Year

Submitted by:

First NameLast Name

Title: Company: Address:

City StateZip

Phone: Fax

e-mail address: Please e-mail completed form to NRMCA's Operations Staff by April 1, 2014 to: [email protected]

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