We are currently witnessing exponential growth in the construction and infrastructure sectors. This booming industry demands mechanisation and the use of sophisticated equipment to meet project quality standards and deadlines. At the same time, it is crucial to control project costs without compromising timelines or quality. Materials used in construction and mining go through multiple stages of processing, requiring transportation at various points. For instance, in a road project, stone aggregates are blasted in a quarry using a crawler drill, powered by a portable air compressor, sized with an excavator and rock breaker, and then fed into a crushing and screening plant using another excavator. The final products, such as sand and graded aggregates, are loaded onto hauling tippers with wheeled loaders and transported to the readymade concrete (RMC) plant. Dozers, motor graders, soil compactors, and excavators handle the earthworks, while diesel generators provide auxiliary power to equipment like the crushing plant and RMC plant. The final road finish, for concrete roads, is done by a slipform paver. All these pieces of equipment rely heavily on fuel for operation. Fuel costs and their impact on project viability Fuel costs account for 10-15 per cent of the total cost of a construction project and a staggering 45-50 per cent of an equipment's total operating cost. Strict monitoring and control are necessary to increase project viability and profitability. Therefore, curbing fuel costs is a top priority for any construction company. To truly optimise fuel consumption for a fleet of equipment, it's best to implement a mix of strategies. From investing in technology-driven equipment to adopting best practices, these measures significantly help reduce fuel costs. Implementation of modern technology The implementation of modern construction equipment technology can lead to significant reductions in fuel consumption. Modern technology, such as GPS-based fleet management systems, helps track equipment and operator efficiency. These systems provide data on machine location, productivity, fuel consumption by application, idle time, and system faults. With this data, companies can analyse and adjust workflows to lower fuel expenses. Fault detection systems also help rectify issues promptly, ensuring optimal equipment performance. Some equipment offers an auto idle-stop function that automatically shuts down the engine after a pre-set period of idling, reducing fuel wastage and wear and tear. Investing in machines with these features is a long-term cost-saving measure. Deploying machines with advanced and efficient engine and hydraulic systems is essential. Engines with Common Rail Direct Injection (CRDI) technology should be preferred over conventional mechanical engines. CRDI engines use an electronic control unit (ECU) to manage fuel pumps and injectors, delivering fuel directly into the combustion chamber with 98 per cent efficiency. This results in optimal fuel usage, minimising wastage compared to mechanical engines. CRDI engines are 20-25 per cent more fuel-efficient, with added benefits of reduced emissions and enhanced performance. Efficient hydraulic systems also contribute to fuel efficiency by reducing the load on the engine. Some excavators offer a boom float function, which doesn't require pump flow when the boom is lowered. Fast lifting operations can connect the load-sensing line to the boom piston side to improve cycle times and efficiency. Regularly changing hydraulic oil, as per manufacturer recommendations, can improve system efficiency, while energy regeneration systems can capture potential energy and reduce fuel consumption. Choosing equipment with these hydraulic features can help reduce project fuel costs. Equipment maintenance Prioritising equipment maintenance is crucial for optimal performance and fuel efficiency. Poorly maintained machines strain the engine, requiring more power and fuel. Planned downtime for inspections and repairs can fix fuel-wasting issues before they worsen, reducing future repair costs and the risk of major breakdowns and accidents, which can be costly for a project. Training and up-skilling Operator training is key to maximising equipment efficiency. Operators must follow best practices to achieve optimal fuel efficiency, as improper handling increases strain on equipment. Without trained operators, achieving meaningful fuel savings is impossible. Training operators can help reduce fuel-wasting habits such as speeding, excessive idling, harsh braking and sudden acceleration. By implementing these measures, companies can reduce fuel costs, ultimately lowering the operational costs of construction or mining projects. About the author Siddhartha Rao, Managing Partner, Vertex Infracore Solutions, is an experienced professional in the field of industrial, construction, earthmoving and material handling equipment. With over 15 years’ experience in the similar domain, he is currently a Director at Vertex Infracore Solutions, authorised dealer for Kobelco Construction Equipment India and Escorts Kubota.