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Efficiency of the CCC-Machine

A comparison of regular hand-made cuts

and the Faber machine-made cuts

To the well-known advantages of the CCC-machine, such as work safety and precise cuts, the following cost-saving benefits have to be added:

  • Work Costs
  • Costs for Tools (Diamond cutting blades)
  • Higher Output while paving the in-situ safety barrier (here CSB)                                                                                                                                                  

In the following, we want to elaborate on this cost-saving potential.

Work Costs

Farbbalken

In this cost analysis, only the cut itself is calculated.

If the cut has to be widened by hand due to sealing measures, the balance of hand-cutting deteriorates by 30%, because the widening has to be done in a second working step. The CCC-machine can cut and widen the joint in only one working step. Operation time is reduced.

Time measuring studies have determined the following parameters as basis for calculation: 500m of CSB are built, cut-distance 5m which equals 100 cuts.

Parameter of the Handcut

At least 3 mins per cut are needed, including moving on to the next cut. To achieve the time of 3 mins per cut, at least two workers are needed, one in the front and one in the back of the CSB. The time period of 3 mins is an average value, since the physical strength decreases during the working process.

Reason for this is the Compelling Working Procedure

 In case of only one person cutting the CSB, the worker would have to switch between the front and the back of the barrier, to cut both sides simultaneously. Both sides of the CSB have to be cut in one working step, because otherwise the barrier would crack by reflecting the opposite cut.

Furthermore, handmade cuts are often wavy and not deep enough. “Banana-Cuts“ are a common problem. Wild cracks which follow the vertical axis result from wavy cuts.

Parameter of the CCC-machine-cut

A machine-cut needs 1 worker and approx. 2 mins, including moving on to the next cut.

Cost- calculation for 100 handmade cuts
3 mins x 2 workers per cut = 6 mins/cut
6 mins x 100 cuts (=500m CSB) = 600 mins = 10 working hours
10 hrs. x EUR 30.00 salary = EUR 300.00 salary
Cost-calculation for 100 machine-made cuts
2 mins x 1 worker = 2 mins/cut
2 mins x 100 cuts = 200 mins = 3,33 working hours
3,33 hrs. x EUR 30.00 salary = EUR 99.90 salary

The Impact of Waiting Periods on the Work Costs

Waiting periods, which can occur during the cutting procedure, are not considered in this calculation.

They can occur if the concrete is still too „wet“ to be cut.

Since there are 2 workers needed for the hand-cutting-process, the costs for the waiting periods are doubled.

Costs for Tools (Diamond Cutting Blade)

Farbbalken

An empirical study noted the following:

The wear of cutting blades during the hand-cutting-process is 2 to 3 times higher than during the cutting with the CCC-machine. The causes are:

Inappropriate handling of the hand cutting unit („Flex“). Pressing the hand cutting unit too fast and too deep into the concrete or the try to force control the unit. The cutting blade may burn and imbalance occurs.

By inappropriate handling of the hand cutting unit, caused by pressing the unit too fast and too deep into the concrete or trying to force control it, hand cutting devices often become overloaded. A machine damage results. The costs for the purchase of new equipment cannot be determined by us and are not included in this calculation.

The human factor: This kind of work is no fun!

It is an unpleasant work due to the forced stooped posture and the high amount of dust. It is quite understandable that the motivation to work effectively and precisely is very low.  

Basis for Calculation

500m of CSB are built, cut distance 5m which equals 100 cuts.

Cost- calculation for 100 hand-made cuts      

With one cutting blade approx. 50 cuts can be made
cost of 1 diamond cutting blade = EUR 70.00/ piece
costs per cut = EUR 1.40/ cut
Costs for Tools = EUR 140.00 for 100 cuts

Cost- calculation for 100 machine-made cuts          

With one cutting blade approx. 120 cuts can be made
cost of 1 diamond cutting blade = EUR 70.00
costs per cut = EUR 0.59
Costs for Tools = EUR 59.00 for 100 cuts

The time for changing the cutting blade is not considered.

Higher Output while Paving

Farbbalken

As already mentioned, a higher output of CSBs can be processed.

Depending on the structure of a company, the CSB is paved and cut by the same team. Manpower is needed to cut the CSB and is no longer available for paving.

However, it is not possible for us to create a valid cost-benefit-assessment.

The factor “Higher Output” shall only be mentioned.

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