&EPA
United States
Environmental Protection
Agency
Office of Water
Program Operations (WH-595)
Washington DC 20460
January 1981
430/9-81-003
Construction Costs
for Municipal
Wastewater Conveyance
Systems: 1973-1979
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EPA REVIEW NOTICE
This report has been reviewed by the Environmental Protection Agency
and approved for publication. Approval does not signify that the
contents necessarily reflect the views and policies of the Environmental
Protection Agency, nor does mention of trade names or commercial products
constitute endorsement or recommendation for use. In this report there
is no attempt by EPA to evaluate the practices and methods reported.
The three technical reports listed below were prepared in conjunction
with the 1980 Update of Needs for Municipal Wastewater Treatment
Facilities, a biennial report to the U.S. Congress. This series of
reports provide construction cost relationships and also related
operations and maintenance (O&M) cost relationships for existing
facilities. The data base for all three studies is representative of the
ten regions.
Document Number
430/9-80-003
FRD-11
430/9-81-003
FRD-21
430/9-81-004
FRD-22
Title
Construction Costs for Municipal Wastewater
Treatment Plants: 1973-1978
Construction Costs for Municipal Wastewater
Conveyance Systems: 1973-1979
Analysis of Operations and Maintenance Costs
for Municipal Wastewater Treatment Systems
These reports were prepared under the direction of:
James A. Chamblee, Chief
Priority and Needs Assessment Branch (WH-595)
Facility Requirements Division
Office of Water Program Operations
U.S. Environmental Protection Agency
Washington, D.C. 20460
(202) 426-4443
Copies of these reports are available from the address below.
ordering, please include the title and FRD number.
When
General Services Administration (8FFS)
Centralized Mailing Lists Services
Bldg. 41, Denver Federal Center
Denver, CO 80225
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TECHNICAL REPORT
CONSTRUCTION COSTS FOR MUNICIPAL
WASTEWATER CONVEYANCE SYSTEMS: 1973-1979
Prepared For
U.S. ENVIRONMENTAL PROTECTION AGENCY
FACILITY REQUIREMENTS DIVISION
WASHINGTON, O.C. 20460
Project Officer: Dr. Wen H. Huang
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TABLE OF CONTENTS
1.0 INTRODUCTION
2.0, HIGHLIGHTS OF FINDINGS
3.0 DEFINITIONS AND ANALYSIS PROCEDURES
Definition of Terms
Cost Updating
Data Analysis
Data Collection
4.0 RESULTS OF THE DATA ANALYSIS
Costs for Gravity Sewers
Costs for Force Mains
Costs for Pump Stations
Nonconstruction Costs
Cost Updating Procedures
Cost Estimating Examples
Page
1-1
2-1
3-1
3-4
3-5
3-6
4-1
4-15
4-15
4-19
4-22
4-23
APPENDIX A COST UPDATING AND NORMALIZATION TECHNIQUES
Areas of Influence
Cost Updating
APPENDIX B SIMPLIFIED COLLECTION SYSTEM COST ESTIMATING
TECHNIQUES
Cost Estimating Techniques
Cost Estimating Examples
APPENDIX C TOTAL CONSTRUCTION COST PER FOOT OF PIPE -
ALL PROJECTS, SMSA, NON-SMSA
APPENDIX D TOTAL CONSTRUCTION COST PER FOOT OF PIPE -
BY PIPE MATERIALS
APPENDIX E TOTAL CONSTRUCTION COST PER FOOT OF PIPE -
BY DEPTH OF BURIAL
APPENDIX F TOTAL CONSTRUCTION COST PER FOOT OF PIPE -
BY PIPE MATERIAL AND DEPTH OF BURIAL
APPENDIX G PROJECT LIST USED FOR DATA BASE
A-l
A-2
B-l
B-6
C-l
D-l
E-l
F-l
G-l
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LIST OF TABLES
Page
1.1 Regional and Community Size Distribution - All 1-3
Projects in Data Base
1.2 Lengths of Gravity Sewer and Force Main and Number 1-5
of Pump Stations in Data Base
4.1 Gravity Sewer Total Construction Costs ($/Foot) - 4-3
Pipe Type, Burial Depth, and SMSA Classification
by Diameter
4.2 Gravity Sewer Total Construction Costs ($/Foot) - 4-5
Pipe Type and Burial Depth by Diameter
4.3 Gravity Sewer Bare-In-Pi ace Construction Costs 4-7
($/Foot) - Pipe Type, Burial Depth, and SMSA
Classification by Diameter
4.4 Gravity Sewer Pipe Costs Delivered to Site ($/Foot) 4-9
4.5 Gravity Sewer Construction Labor Costs - $/Foot of 4-10
Pipe Installed
4.6 Non-Pipe Construction Cost for Gravity Sewer as 4-12
Percentage of Bare-In-Pi ace Pipe Cost
4.7 Average Unit Construction Cost of Manholes ($/Unit) 4-13
by Diameter, Depth, and SMSA Classification
4.8 Average Unit Construction Cost of Drop Manholes 4-14
($/Unit) by Diameter, Depth, and SMSA Classification
4.9 Force Main Bare-In-Place Construction Costs ($/Foot) 4-16
4.10 Step 1 and Step 2 Costs as a Fraction of Total 4-20
Construction Costs - Sanitary Sewer Facilities
Only
4.11 Step 3 Nonconstruction Costs as a Fraction of Total 4-21
Contruction Costs - Sanitary Sewer Facilities Only
4.12 Complete Urban Sewer System Cost Index (CUSS) From 4-24
EPA
B.I Sanitary Sewer Sizing of Collector and Interceptor
Sewers
B.2 Sanitary Sewer Total In Place Costs per Linear Foot
B-3
B-4
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LIST OF TABLES (Continued)
. • - • _ - • • :... ";'.-. -
B.3. Sanitary Sewer Construction Area Multipliers
B.4 Sanitary Sewer Cultural Modifiers
C.I Total Construction Costs per Foot of Pipe for All
Projects - SMSA and Non-SMSA
C.2 Total Construction Costs per Foot of Pipe for SMSA
Projects
C.3 Total Construction Costs per Foot of Pipe for Non-
SMSA Projects
D.I Total Construction Costs per Foot of Pipe by Pine
Material - PVC Pipe ".."'
D.2 Total Construction Costs per Foot of Pipe by Pipe
Material - Asbestos Cement Pipe
D.3 Total Construction Costs per Foot of Pipe by Pipe
Material - Vitrified Clay Pipe
D.4 Total Construction Costs per Foot of Pipe by Pipe
Material - Cast Iron Pipe ,
D.5 Total Construction Costs per Foot of Pipe by Pipe
Material - Reinforced Concrete Pipe
D.6 Total Construction Costs per Foot of Pipe by Pipe
. Material - Ductile Iron Pipe
D.7 Total Construction Costs per Foot of Pipe by Pipe
Material - ABS Pipe
D.8 Total Construction Costs per Foot of Pipe by Pipe
Material - Other/Unknown
E.I Total Construction Costs per Foot of Pipe - Depth
Less Than 8 Feet
, E.2 Total Construction Costs per Foot of Pipe - Depth
8-15 Feet
E.3 Total Construction Costs per Foot of Pipe - Depth
, Greater Than 15 Feet
F.I Total Construction Costs per Foot of Pipe - PVC -
Pipe - Depth Less Than 8 Feet
. . "; . * " iii . ' ; .
- . - .•-..' :
Page :
B-5
B-7
C-2
C-3
C-4
: D-2
D-3
D-4
D-5 ,
D-6
D-7'
D-8
D-9
E-2
E-3
E-4
F-2
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LIST OF TABLES (Continued)
Page
F.2 Total Construction Costs per Foot of Pipe - PVC F-3
Pipe - Depth 8-15 Feet
F.3 Total Construction Costs per Foot of Pipe - PVC F-4
Pipe - Depth Greater Than 15 Feet
F.4 Total Construction Costs per Foot of Pipe - Asbestos F-5
Cement Pipe - Depth Less Than 8 Feet
F.5 Total Construction Costs per Foot of Pipe - Asbestos F-6
Cement Pipe - Depth 8-15 Feet
F.6 Total Construction Costs per Foot of Pipe - Asbestos F-7
Cement Pipe - Depth Greater Than 15 Feet
F.7 Total Construction Costs per Foot of Pipe - Vitrified F-8
Clay Pipe - Depth Less Than 8 Feet
F.8 Total Construction Costs per Foot of Pipe - Vitrified F-9
Clay Pipe - Depth 8-15 Feet
F.9 Total Construction Costs per Foot of Pipe - Vitrified F-10
Clay Pipe - Depth Greater Than 15 Feet
F.10 Total Construction Costs per Foot of Pipe - Cast Iron F-ll
Pipe - Depth Less Than 8 Feet
F.ll Total Construction Costs per Foot of Pipe - Cast Iron F-12
Pipe - Depth 8-15 Feet
F.12 Total Construction Costs per Foot of Pipe - Cast Iron F-13
Pipe - Depth Greater Than 15 Feet
F.13 Total Construction Costs per Foot of Pipe - Reinforced F-14
Concrete Pipe - Depth Less Than 8 Feet
F.14 Total Construction Costs per Foot of Pipe - Reinforced F-15
Concrete Pipe - Depth 8-15 Feet
F.15 Total Construction Costs per Foot of Pipe - Reinforced F-16
Concrete Pipe - Depth Greater Than 15 Feet
F.16 Total Construction Costs per Foot of Pipe - Ductile F-17
Iron Pipe - Depth Less Than 8 Feet
F.17 Total Construction Costs per Foot of Pipe - Ductile F-18
Iron Pipe - Depth 8-15 Feet
IV
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LIST OF TABLES (Concluded)
F.18 Total Construction Costs per Foot of Pipe - Ductile
Iron Pipe - Depth Greater Than 15 Feet
F.19 Total Construction Costs per Foot of Pipe - ABS
Pipe - Depth Less Than 8 Feet
F.20 Total Construction Costs per Foot of Pipe - ABS
Pipe - Depth 8-15 Feet
F.21 Total Construction Costs per Foot of Pipe - ABS
Pipe - Depth Greater Than 15 Feet
F.22 Total Construction Costs per Foot of Pipe - Other/
Unknown - Depth Less Than 8 Feet
F.23 Total Construction Costs per Foot of Pipe - Other/
Unknown - Depth 8-15 Feet
F.24 Total Construction Costs per Foot of Pipe - Other/
Unknown - Depth Greater Than 15 Feet
G.I Sewer Construction Projects in the Data Base - Listed
by State
Page
F-19
F-20
F-21
F-22
F-23
F-24
F-25
G-l
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LIST OF FIGURES
1.1 EPA Regions
4.1 Total Construction Costs for Gravity Sewers
4.2 Bare-In-Pi ace Construction Costs for Gravity Sewer
4.3 Bare-In-Pi ace Construction Costs for Force Main
4.4 Total Construction Cost Vs. Design Capacity - Pump
Stations
Page
1-2
4-4
4-8
4-17
4-19
A.I EPA CUSS Index Map With Areas of Influence
A-3
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ACKNOWLEDGEMENTS
This report was prepared by Sage Murphy & Associates, Inc., Denver, Colorado
under the direction of Dr. Wen H. Huang of the EPA Headquarters, Facility
Requirements Division.
Sincere appreciation is extended to EPA Construction Grants personnel in each
of the ten Regions. Specific appreciation is extended to the following
persons without whose cooperation and assistance this study could not have
been conducted. .
Mr. Charles Bishop, EPA Region I
Mr. Phil Amicone, EPA Region II
Mr. Earl Bisher, EPA Region III
Mr. Peter McGarry, EPA Region IV
Mr. E. C. (Ted) Horn, EPA Region V
Mr. Arvel Wilson, EPA Region VI
Mr. Walter Robohn, EPA Region VII
Mr. Jerry Burke, EPA Region VIII
Mr/Robert Rock, EPA Region IX
Mr. Bob Kussman, EPA Region X
Inquiries concerning this report should be directed to:
Dr. Wen H. Huang
Facility Requirements Division
U.S. Environmental Protection Agency
401 M Street, S.W. (WH-595)
Washington, D. C. 20460
(202) 426-4443
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1.0 INTRODUCTION
This report presents the results of a study of the costs for construction
of municipally owned wastewater collection systems. Collection systems
ar,e defined as gravity collector sewers, interceptors, pumping stations,
and associated force mains necessary to collect and transport wastewater
to a treatment facility. Thus, all data is from gravity sewer systems,
including all those from small communities. The cost data utilized in
this report are derived from the winning bid documents of projects funded
by the Federal Water Pollution Control Act (P.L. 92-500) and its amended
version (P.L. 95-217). All data were collected from the Construction Grant
files in the ten EPA Regional offices.
This report is an update and replacement of a previous report in this series,
entitled "Construction Costs for Municipal Wastewater Conveyance Systems:
1973-1977," EPA 430/9-77-015, MCD-38, May, 1978. The data base utilized in
that report included 455 wastewater collection system projects funded under
P.L. 92-500. ..;.'._,
Three hundred twenty-two new projects have been added to the MCD-38 data
base mentioned above, resulting in 777 collection system projects reported
herein. These projects had a total construction cost value of approximately
$2.02 billion, adjusted to first quarter 1979 dollars.
All ten EPA Regions are represented in the data base. In fact, all of
the 48 contiguous States are represented with the exception of Kentucky.
The EPA Regions are shown on Figure 1.1. Table 1.1 presents a Regional/
demographic distribution of the communities in which projects used in the
data base fall. Appendix G lists each project by grant number, name, city,
State, and county.
Over 3.0 percent of the projects in the data base received grants to assist
communities with a population of less than 2,500 people. Sixty-eight pro-
jects, or 8.75 percent of the data base, are classified as "indeterminate" for
population purposes. The population of these communities or authorities was
1-1
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unable to be discerned through available census figures. Most, if not all,
of these projects are thought to be for small communities, certainly most
with populations less than 5,000 people.
The true magnitude of the data base is only partially expressed by the
777 bid documents examined. Table 1.2 illustrates that 4,737 miles of
gravity sewers, 702 miles of force mains, and 1,165 pump stations are con-
tained in the bid documents. These represent considerable construction
expenditures. Perhaps of greater significance is the number of individual
bid items utilized in the analyses presented in this report. Each bid
document contains a single lump sum construction cost. This total con-
struction cost is made up of many separate bid items, often dozens. For a
sewerage project it is unusual that all the pipe to be laid will be of the
same diameter. Each size is itemized separately in the bid. Likewise, many
appurtenances (manholes, stream crossings, special bedding, etc.) are bid
separately. Over 11,500 individual bid items for gravity sewers alone were
available for analysis. Over 15,000 individual bid items make up the sample
used to derive the results found in this report. This information is cer-
tainly the most comprehensive empirical analysis of sewer construction
costs available for the United States to date.
All costs presented in the main body of this report have been normalized to
Kansas City, Missouri and updated to the first quarter of 1979. Appendix A
describes the procedures used for updating costs.
Simplified collection system cost estimating techniques were developed
using a substantial portion of the data base included in this report.
These techniques were used for cost estimating in the 1980 Needs Survey.
They are included in this report as Appendix B.
Only data for the contiguous 48 States have been presented. Alaska, Hawaii,
Puerto Rico, and the Pacific territories are atypical of the mainland.
Inclusion of data from these locations would severely bias national and
regional averages and trends.
1-4
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TABLE 1.2.
LENGTHS OF GRAVITY SEWER AND FORCE MAIN
AND NUMBER OF PUMP STATIONS IN DATA .BASE
State
Al abama
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Idaho
Illinois
Indiana
Iowa
Kansas
Louisiana
Maine
Maryland
Massachusetts
Michigan
Minnesota
Mississippi
Missouri
Montana
Nebraska
Nevada
New Hampshire
^New Jersey
New Mexico
New York
North Carolina
North Dakota
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas
Utah
Vermont
Virginia
Washington
West Virginia
Wisconsin
Wyoming
Length of Gravity
Sewers (Miles)
54.36
52.53
100.57
300.93 •
59.79
61.92
78.25
1.45
75.81
37.95
93.55
282.04
21.78
23.90
287.70
13.60
104.74
49.83
396.54
37.84
30.41
57.24
0.44
20.94
56.87
65.60
407.69
58.46
115.52
51.09
17.14
275.15
73.65
36.56
565.11
8.20
82.91
43.47
18.95
155.76
118.59
18.95
125.04
76.89
87.68
22.91
10.75
Length of Force
Main (Miles)
19.01
4.82 •
13.09
41.24
1.13
5.10
34.06 .
8.89
13.37
7.50
12.62
39.12 ,' .'
4.50
7.43
44.66
4.42
11.42
7.52
28.95
17.62
4.41
27.00
0.00
4.89
7.55
4.58
62.12
2.19
13.28
. 14.04
8.25
31.42
14.33
4.22
41.09
1.20
15.81
7.41 .
13.85
24.13
1.39
4.57
28.17
18.71
11.32
8.92
0.34
No. of Pump
Stations
9
7
18
-35
0
24
18
4
12
7
18
: 69
8
17
98
18
36
29
85
43
5
30
0
6
12
12
83
5
48
5 ,
7 •
53
16
13
80
9
15
, - 8
9
37
3
22
64
30
31
5- -.
2
TOTALS
4737.05
701.66
1165
1-5
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Two important purposes are served by the results contained herein. First,
an historical record of a significant number of wastewater collection system
cost data is made available to administrators and managers of the Construc-
tion Grants Program at both the Federal and State levels. The information
should be valuable in managing this Program.
The second purpose for which this document is intended will be its use in
preliminary estimation of construction costs for collection systems by
engineers, planners, sewerage authorities, and interested laymen. The
reader is cautioned that the costs stated herein are not a substitute for
normal engineering estimating procedures, but are only averages for the
specific data collected. Furthermore, unless the specific item being ad-
dressed has a substantial number of data points, site specific characteristics
can cause highly under or over-stated values for that item.
1-6
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2.0. HIGHLIGHTS OF FINDINGS
Results obtained from the analysis of the large data base gathered by this
effort fall within the normal range to be expected. The types of projects and
their geographic diversity tend to cause some unexpected variation. Some
trends are also surprising, but most are explained when the number of data
points is co'n's;1derecf.' tfre" fif§h'Ttghts presented in this section are for
various items which tiaye sufficient data to be considered accur.ate, but which
may seem to be anomalies. Some items are verification of suspected but
undocumented trends. The items discussed are by no means a complete list. It
is anticipated each reader will find similar cases upon detailed study of the
data presented. These highlights are not presented in any order of apparent
importance or significance.
Reinforced concrete was the most commonly used pipe, followed closely by
vitrified clay. At diameters less than 16 inches, the latter was more
prevalent.
ABS (acrylonitrile-butadiene-styrene) was the type least commonly
used.
Relatively small differences in costs were noted for pipes buried:
less than 8 feet deep compared with those buried between 8-15 feet
deep.
Pipes buried greater than 15 feet deep were significantly more expensive
than those in the 8-15 feet deep range.
The cost of pipe delivered to the construction site was more expensive at
construction sites located within a Standard Metropolitan Statistical
Area (SMSA) for diameters of 21 inches and less than for non-SMSA (rural)
areas. This trend was reversed for larger diameters.
The cost of labor for gravity sewer construction within SMSA's was
significantly more expensive than in non-SMSA's, as would be expected.
Average Step 3 nonconstruction costs (engineering, administrative,
legal, etc.) are approximately ten percent higher in non-SMSA areas than
in SMSA's. This is probably due to the fact that non-SMSA projects are
of smaller magnitude and., thus, these fees and expenses are a greater
percentage of the total construction costs.
Step 1 costs are nearly twice as high in SMSA areas than in non-SMSA
areas. This is attributed to the probable greater number of alternatives
which must be considered in an urban area for Step 1 planning.
2-1
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Step 2 costs are higher in non-SMSA areas as .a percentage of the con-
struction costs than in SMSA's. This is probably due to the smaller size
projects in the more rural areas, and the normal experience of engineer-
ing fees being a higher percentage for the smaller projects.
The unit construction costs for manholes were found to be less expensive
for those 8-15 feet deep than for those less than 8 feet deep within
SMSA's, and nationally.
Manholes 72 inches in diameter were more expensive in non-SMSA's than in
SMSA's, probably because a unit of that size is a special situation in
the more rural areas.
Bare-in-place construction costs for force mains smaller than 21 inches
in diameter are significantly less expensive than equivalent size gravity
sewers. This is explained by the fact that less attention to grade is
required for the former, making construction faster with the use of less
skilled labor.
Relatively few projects for only sanitary sewer construction were
available for analysis. Most sewer projects were included as part
of collection and treatment projects, at least for Step 1 grants. '
The bid items for cast iron pipe averaged less than 500 feet each,
based upon dividing total length in the data base by the number of
individual bid items. This result indicates that many of these items
were for special situations such as road or stream crossings or short
reaches of shallow burial. For instance, of 85 bid items for 8 inch cast
iron pipe, the average length per bid item was 390 feet. For the same
diameter reinforced concrete pipe and
lengths were 1,906 feet and 4,457 feet,
vitrified clay
respectively.
pipe, the average
Type of pipe was not specified for approximately 25 percent of the
bid items. Undoubtedly these were cases where the contractor had
a choice of materials and in the bid proposal did not specify the
type to be used.
The depth of burial of sewer pipe was, on the average, greater in
cities than in non-SMSA areas.
2-2
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3.0 DEFINITIONS AND ANALYSIS PROCEDURES
This section of the report defines the terms used throughout. An overview of
the data analysis techniques is presented. Data collection methodology and
cost updating techniques are also described. More specific discussions
relating to individual cost items are contained in Section 4.0, Results of the
Data Analysis.
DEFINITION OF TERMS
All projects used in this report were partially funded by the EPA Construction
Grants Program under P.L. 92-500 and P.L. 95-217. The rules and regulations
pertaining to these laws are quite specific as they relate to procedures for
design and construction of the facilities in question. They are applied
uniformly across the nation, thus adding further credibility to the data
base.
The rules and regulations require that all projects go through specific
steps prior to proceeding. These steps are all grant eligible, and are
all part of the cost of the planning, engineering, and constructing the
facility in question. These steps are referred to throughout the report.
Their definitions are as follows:
Step 1 - Facilities Planning. This is basically the preliminary engineering
[feasibility analysis) which demonstrates the need for the project and a cost
effective analysis of alternative solutions.
Step 2 - Construction Drawings and Specifications. This step is the detailed
design of the selected alternative, including all documents necessary to allow
competitive bidding on the project.
Step 3 - Actual Construction of the Facility. The monies associated with this
step are those necessary to construct the facility. These monies include
certain nonconstruction items as described below.
3-1
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The total costs associated with the above three steps of the Grants procedure
were collected and reported on herein. However, the bid documents from which
the construction costs were obtained do not include Step 1, Step 2, or Step 3
nonconstruction cost items. These data were obtained from other EPA grant
files when available, which was most of the time. Therefore, the total cost
of a project includes these items. They have been accounted for in the
various tables and analyses presented in this volume and explained in the
following paragraphs.
The definitions of the various costs associated with the construction of
sewerage projects are presented below. The reader should be completely
familiar with these terms prior to utilizing the cost data for estimation
purposes.
Total Project Cost. A "project" is defined as the construction associated
with a single contract. A project for this study consists of the construction
of gravity sewers, force mains, and pump stations. It may include only one of
these items, all three, or any combination. The Total Project Cost is the
total monies spent to put the facility into operation. This is the sum of all
planning costs (Step 1 and Step 2), Step 3 construction costs, and Step 3
nonconstruction costs. Each of these components is more fully described
below.
Total Construction Cost. The Total Construction Cost, as defined in this
report, is the total of all construction bid items plus the nonconstruction
costs directly associated with the construction phase of the project.
Construction Costs. Construction costs are the sum of all individual
items submitted in the successful contractor's winning bid. This report
has separated these bid items into broad categories of gravity sewers,
force mains, and pump stations. These are further defined below.
Gravity Sewers. The cost to construct gravity sewers includes the
pipe itself, its placement, and various non-pipe construction
costs. These are:
3-2
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Bare-In-Place' Costs v" The bare-in-place" pipe cost for gravity
sewers is the sum of the costs for the labor and materials
necessary to install^a gravity sewer. These costs include only
the.costs of the pipe delivered to the site plus all trenching
and backfilling. National average costs are summarized for
these items.
Non-Pipe Construction Costs. In any project there are a
number of/non-pipe, appurtenance, and special costs associated
with the construction. These construction items are separately
itemized in the bid documents. The majority are listed below:
Appurtenances (tees, wyes, valves, gates, etc.)
Bedding/Backfill (special)
Drop Manholes
Manholes
Miscellaneous
Mobilization
Pavement Replacement
Rock Excavation
Stream Crossings
Thoroughfare Crossings
Utility Reconnection or Relocation
Force Mains. As in the case of gravity sewers, the cost to con-
struct force mains is the pipe itself, its placement, and various
non-pipe construction costs. These are:
"•-"' Bare^In-Place Costs. The bare-in-place costs for force
mains are the sum of the costs for the labor and materials
necessary to install a force main. These costs include only
the costs of the.pipe delivered to the site plus all trenching
and'backfill ing. •.. • ''••
Non-Pipe Construction Costs. Force mains, like gravity
sewers, require appurtenances and special construction in
addition to the actual construction of the main. These are
similar to those itemized above for gravity sewers. However,
in most projects they make up a lower percentage of the total
• work. ' .
3-3
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Pump Stations. In most cases pump stations are bid as a single
item. Little or no other construction costs (i.e., non-pump station
construction costs) are associated with their construction.
Step 3 Nonconstruction Costs. Step 3 nonconstruction costs are defined
as those monies spent during the construction of a project which are not
directly paid to the contractor but which must be borne by the owner.
They are considered to be part of the Total Construction Cost. The most
common nonconstruction costs found in the Step 3 phase of a project are:
Administrative/Legal Fees
Preliminary (preconstruction planning)
Land, Structures, and Right-of-Way
Architect/Engineer Basic Fees
Project Inspection
Land Development
Relocation Expenses
Relocation Payments
Demolition and Removal
Bond Interest
Contingencies
Indirect Costs
Miscellaneous
Equipment
(The reader is reminded that Step 1 and Step 2 costs must be added to the
Total Construction Cost to estimate the Total Project Cost.)
The results presented in Section 4.0 and in the Appendices detail most
of the construction and nonconstruction costs discussed above.
COST UPDATING
All costs initially were updated to first quarter 1979 dollars using the
updating procedure described in Appendix A. Step 1 and 2 planning and design
costs were updated from their respective grant award date, while Step 3 costs
were updated from the project bid date.
The updating procedure described in Appendix A uses the EPA Complete Urban
Sewer System Index (CUSS) for 25 cities in the contiguous 46 States. The
areas each of these cities have a predominant influence over were also
3-4
-------
developed. The cos't informat'ion'for each project, was updated using the
-* .,, - „ ,„, \ „-,.,!, T,'-1'^^ V -**1* vr f 1^ * • ;-- •. '- ' --:" 'f^3'-.'-^^r-'-^,!''~^':-^ f "• =
approp'riate1 index'foih the city having'influence in the area. Although
the CUSS Index"applies to urban areas,' and therefore by inference to SMSA's,
it was used for all projects whether urban or rural. Other available indexes
were investigated for these normalizing calculations but none resulted in as
accurate or consistent results as did the CUSS Index.
All data were normalized to a single location - Kansas City, Missouri. The
index for the' city in question and that for Kansas City for first quarter
1979 were used to adjust all cost data to Kansas City costs. This proce-
dure was utilized to allow data analysis in a mathematical and logical manner
for the complete data base, not just by region or city of influence. Examples
of adjusting data to a specific location are provided in Section 4.0 and
Appendix C. • ,
DATA ANALYSIS
The more than 15,000 bid items available from the 777 projects in the data
base lend,themselves to a vast array of analyses. A large number of analyses
were performed. Those which had sufficient data elements to be considered
statistically reasonable have been included in this publication.
Both nonconstruction and construction costs were developed for gravity
sewers, force mains,, pump stations, and common appurtenances. Bare-in-piace
pipe costs for various depths and .-diameters of pipe were calculated and are
included in this report.
Non-pipe costs, as well as Step 3 nonconstruction costs, were added to the
unit costs for-bare-in-place pipe using a ratio of the volume of each bid item
for pipe in each project to the total volume of pipe in each project. All
non-pipe costs not specifically related to force mains or pump stations in the
bid tabulations were assumed to relate to the gravity sewer portion and were
apportioned accordingly. Volume of pipe was used in these calculations
because it is influenced less by special construction items and proved to
yield statistically.better results. Volume of pipe was calculated by the
3-5
-------
pipe's cross sectional area in square feet (using the nominal pipe diameter)
times the length, in feet of pipe, for that bid item.
Linear regression relationships of design flow and total dynamic head (TDH)
versus costs were determined for pump stations. These costs included all
costs for the basic pump station in addition to any other bid items speci-
fically related to the pump station. When more than one pump station was
present in a single project, all related costs were apportioned among each of
the pump stations in a project on the basis of a ratio of the cost for each to
the total cost for all pump stations. A computerized statistics package (The
Biomedical Computer Program developed by the University of California, Los
Angeles) was utilized to determine the significance of these relationships and
to plot the resulting linear regression curves.
DATA COLLECTION
Construction cost data from wastewater collection system projects were
collected from the EPA Construction Grant files in all ten Regional EPA
offices. All data were collected from active or recently completed Step 3
projects. Costs were derived from the winning contract bid tabulations
plus the costs associated with all change orders issued up to the time of data
collection. All information was collected on specially designed forms using a
coding system. Contractor personnel performed all data collection in the
Regional offices and had access to the complete project files, including most
of the backup engineering information.
The data base includes projects providing new collection systems, as well as
projects to enlarge or extend existing collection systems. Many projects also
include the construction or modification of wastewater treatment plants. The
wastewater treatment plant portion of such projects, however, was segregated
into a separate data base which was used to compile a companion report to this
document, entitled "Construction Costs for Municipal Wastewater Treatment
Facilities: 1973-1978," EPA 430/9-80-003, FRD-11, April 1980.
As previously mentioned in Section 1.0, the data base now includes a total of
777 sanitary sewer projects which started construction between 1973 and 1978.
3-6
-------
A total of 348 of these projects have a contract award date of January 1977 or
later. All of the projects resulted from grants awarded in accordance with
P.I. 92-500 and its successor, P.L. 95-217.
Following a quality assurance check at the contractor's home office, the data
were entered into an ADP file. The format of the data base used in the
original MCD-38 report was adjusted to conform with the newly acquired data,
after which the two files were merged.
3-7
-------
-------
4.0 RESULTS OF THE DATA ANALYSIS
The results of the analyses of 777 municipal wastewater collection system
projects funded by the EPA Construction Grants Program are presented in this
section. These data constitute a significant portion of the total projects
funded by the Program.
The data base includes information concerning the type, size, and depths of
gravity sewer pipe and force main and the number and capacity of pumping
stations. All costs associated with the construction of these facilities are
a part of the data base. Most commonly used types of pipe and appurtenances
are present in the data base and have been analyzed and presented in the
following pages.
The construction cost data were identified as to whether the project was
located in a metropolitan or a rural area. The basis for this designation is
the Bureau of Census defined Standard Metropolitan Statistical Area (SMSA).
Most populated urbanized areas in the country have been made an SMSA. Much of
the cost data was analyzed to judge trends between urban and rural areas.
This factor will have increasing significance as more facilities are planned
for the smaller communities throughout the country. SMSA's have the county as
the smallest area! delineation. Some Targe counties are very densely popu-
lated in one section, yet are truly rural in another. The data base does not
differentiate between these extremes, all facilities being considered in the
SMSA.
The national averages shown for the various pipe diameters are without
regard to type of pipe material, depth of burial, or whether in an SMSA.
COSTS FOR GRAVITY SEWERS ,
Cost data for gravity sewers were the most voluminous and readily available.
Nearly 12,000 individual bid items make up the sample analyzed. Results are
presented detailing total construction costs, bare-in-place pipe costs, labor
and material component costs, and Step 3 non-pipe construction costs. Each
series of analyses is presented"with discussions below.
4-1
-------
Total Construction Costs
Table 4.1 summarizes the total construction costs for gravity sewers.
Step 1 and Step 2 costs are not included, as explained in Section 3.0.
Average Step 3 nonconstruction costs were added to bare-in-place costs
(see Table 4.3) to arrive at these cost figures.
The data presented in Table 4.1 have been segregated into three different
groupings: pipe type (the material the pipe is made of), depth of burial, and
by SMSA classification. Each bid item did not have all data elements avail-
able. If type of pipe was not specified, the cost data were accumulated under
the heading "other/unknown."
Figure 4.1 presents this same data in a graphical format to permit the
reader to judge basic trends. Only national data are shown.
The unit cost presented for each individual item is the average cost per foot
of pipe for that item. The cost per foot of pipe for each bid item was
calculated, and then averaged with all the other items of the same nature.
This same data base was used to develop Table 4.2, which presents the cost by
pipe type and depth of burial for each pipe diameter. This table is a summary
of a more detailed printout which is located in Appendix F. This printout
itemizes the unit costs, non-pipe costs, Step 3 nonconstruction costs, and
sample footage for each item. There was sufficient documentation for 8,274
bid items to be included in this subset of data.
It should be stressed that the data presented for total construction costs are
based upon average pipe costs to which are added average costs for appurte-
nances and nonconstruction items. These costs represent accurate averages for
the national base. However, if, for a particular project, the reader has
sufficient knowledge to be able to estimate appurtenance costs, it is recom-
mended the bare-in-place costs plus individual appurtenance costs be used for
estimation purposes.
4-2
-------
TABLE 4.1
GRAVITY SEWER TOTAL CONSTRUCTION COSTS* ($/FOOT.)
PIPE TYPE, BURIAL DEPTH, AND SMSA CLASSIFICATION BY DIAMETER
BY PIPE TYPE:
Diameter . PVC
Asbestos
Cement
04 15.36 ( 18) 10.01
06 13.96 ( 43) 18.79
08 38.29 (392) 38.17
10 44.44 (252) 49.70
12 55.73 (169) 60.64
15 50.01 (
16
18 37.66 (
21 78.12 (
24 82.54 (
27 ' — -
30
36
42
48
54
60 . • — •
66 —
72
78
84
90 ---
96 ' —
102
Total No
82) 120.65
88.77
1) 63.65
3) 98.19
3) 82.13
34.48
32.16
- —
—
—
--
—
- . —
. ...
.
—
—
378*
229
174
88
40
132
45
50
«
3
of Bid Items 963 H62
BY PIPE DEPTH: .. , .
Vitrified
Clay
Cast
Iron
12.37 (16) 10.15
17.37 (119) 24.38
29.24 (784) 66.53
33.71 (421) 99.34
41.59 (420) 57.85
53.03 (284) 120.01
92.08
14
68.03 (208
.. 69.14
104
88.66 (120
116.56
135.47
154.74
79.47
132.95
—
. —
—
—
—
—
—
—
• *
22
31
18
. 3
4
2568
93.84
89.11
163.29'
188.08
114.96 (
109.61 (
—
—
—
.
—
—
—
—
Reinforced
Concrete
5 11.86
15 13.54
85 21.44
52 31.49
49 62.54
Ductile
Iron
4) 18.11
4) 25.32
49) 42.16
23) 44.46
56) 61.45
4 74.08 (149) 73.26
18 69.81
12
) 68.17
19 161.57 (299) 82.80
1 83.74
212
105.92
28) 116.13 (400) 107.26
117.52
2) 168.60
1) 225.90
181.06
- 209.63
313.59
349.47
360.64
416.46
415.44
559.90
444.64
369.76
583.58
— .*-••- - :-
133
357
358
187
96
152
104
39
71
—
173.36
212.61
550.52
—
—
—
4) 17.!
22) 24.4
252) 49. 5
99) 40.!
94) 73.9
7
112
Other/
ABS Unknown
6 2 15.36 ( 61}
6 2 21.12 (160)
3 17 32.75 (847)
7 2 36.49 (421)
2 5 42.64 (381)
110.10 ( 1) 61.79
—
109)
4
—
67.93
95.17
60.39
218
24
206
71
97) 44.60 ( 1) 92.39 (122)
48
24
11
.
-—
,
—
36)
6
3
1
1
—
—
.
279 2752
883
:.
—
—
—
,- - •
106.83 ( 51
115.81 1114
147.24
202.81
79
29
232.56 (' 27)
411.14
361.31
321.52
373.87
737.73
385.55
632.95
462.21
21
42
7
13
5
8
1
27)
--- — -."'
30 2935
c-
: .- . , BY CLASSIFICATION: ,
Diameter 15 Feet
23.94 ( 10)
45.57 (441)
47.25 (231)
55.94 (234)
6!. 55 (130)
78.93 ( 38)
82.15 (176
86.17 (101)
110.57 (200)
7.72 54)
i.03 170.
1.92 159)
i :39 77)
246.29 ( 27)
383.77 ( 89)
384.11 ( 65)
314.22 { 10)
313.08 ( 26)
—
- ^
—
435.23 ( 25)
—
2238
SMSA
16.51 ( 35)
22.31 ( 169)
44.16 (1211)
54.69 ( 714)
60.28 ( 656)
73.18
70.68
141.93
80.46
115.78
115.76
162.28'
216.42
164.78
205.04 i
335.
348.
352.
426.
^496.
481.
531.
466.
583.
-
74
52
90
02 i
38 (
33 (
59 I
25 1
58 (
420)
121)
504)
101)
379)
134)
344)
316)
138)
92)
148)
96)
39)
65)
41)
14)
4)
28)
1)
5970
Non-SHSA
13.41 ( 81
17.40 209
30.81 1493
36.79 785
43.69 695
57.88 413
78.71 99
65.32 475
72.47 289
100
103
125
168
247
225
270
357
341
372
—
—
.57 446
National
Averaoe
) 14.37
19.60
36.92
44.95
i ' . 51.65
64.73
74.97
106.92
76.24
109.67
.97 ( 76) 111.52 |
.02 ( 219) 151.44
.84 ( 165) r 204.37
.48 ( 92) 198.81
.85 ( 35) ' 210.09
.89 ( 25
.35 ( 50
.90 i 7
.57 ( 19
— —
5623
116)
378)
2804)
1499)
1351)
833
220
979
440
825
•
210)
563)
481)
230)
127)
326^38 '( 173
348.11
353.23
415.65
496.38
481.33
531.59
466.25
583.58
146
46
84
41
it
4
28
1
_
11593
* Includes all non-Dine construction costs and Step 3 nonconstruction costs. Steo 1 and 2 costs excluded.
Notes:, All costs normalized to Kansas City, HO 1st Otr 1979
( ) Number of bid items in samole
4-3
-------
600-
o
o
DC
UJ 500
o.
CO
8
1
O
CO
O
e
UJ
o
oc
UJ
400-
300-
200-
100-
0-
2OOO-
UJ
Q
m
u.
oc
UJ
m
1000-
FIGURE 4.1
TOTAL CONSTRUCTION COSTS*
FOR GRAVITY SEWERS
2804
4
I I M I .
"Includes all non-pipe construction
costs and Step 3 nonconstruction
costs. Stepl and 2 costs excluded.
Note: All costs normalized to
Kansas City, MO 1st Qtr.1979
12 24 36 48 60
PIPE DIAMETER (IN.)
f r i r •,
72 84 96
96 102
4-4
-------
i
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4-5
-------
Bare Pipe Costs
Bare pipe costs are defined herein to be the costs for materials and labor to
install and backfill the pipe. Appurtenances, manholes, etc., and Step 3
nonconstruction costs are not included in these figures. Step 1 and 2 costs
are also excluded. These costs, therefore, are only one component of the
total construction costs for gravity sewers as presented in Tables 4.1 and
4.2.
Table 4.3 summarizes the bare pipe costs by pipe type, depth of burial,
and SMSA classification in the same manner done for total construction
costs in Table 4.1. This summary includes the identical data base presented
previously for total construction costs.
As would be expected, the same general trends are apparent as for the total
construction costs. Figure 4.2 graphically depicts these data to indicate the
trends for the national average costs.
t ' . '
Some bid documents broke out the cost of pipe and labor as separate com-
ponents. These data were analyzed to the degree the sample permitted. Table
4.4 summarizes the 816 bid items which delineated the cost of the pipe
delivered to the site. Insufficient data were available to summarize the
results by type of pipe or depth of burial. The sample size presents some
anomalies, but the trends are consistent with those of the larger data base.
Somewhat more data were available for the labor required to install the pipe.
An analysis was made of 1,009 bid items in this category and is summarized in
Table 4.5. These data have been broken down into depth of burial and SMSA
classifications. As would be expected, the data reveal labor costs for
similar bid items are higher in the SMSA's.
The sum of the pipe and labor costs (Tables 4.4 and 4.5) should equal the
bare-in-place pipe costs (Table 4.3). For most cases, particularly for
smaller diameter pipe, the sum is greater than either the bare-in-place costs
or the total construction costs. The cause of this is attributed primarily to
4-6
-------
,.,,., TABLE 4.3
GRAVITY SEWER BARE-IN-PLACE CONSTRUCTION COSTS* ($/FOOT)
PIPE TYPE, BURIAL DEPTH, AND SMSA CLASSIFICATION BY DIAMETER
IIY PIl'l TYPE:
04
06_
08
10
12
15
16
IB
21
24
27
30
36
42
48
54
60
66
72
78
90
96
102
Total No.
of Bid Hems
PVC
13.46 ( 18)
9.79 ( 43)
21.81 (392)
23;76 (252)
25.52 (169)
30.18 ( 82)
12.24 ( 1)
49.17 ( 3)
44.72 ( 3)
I" .
Asbestos
Cement
8.91 ( . 6)
12.86 ( 13)
23.52 (378)
23.01 (229)
27.59 <174)
30.19 ( 88)
45 70 ( 40)
.26.67 (132)
37.54 ( 45)
38.63 ( 50)
25.34 ( 4)
•26.63'( 3)
___
".""
Vitrified"
Clay
Cast
Iron
10.22 { 16) 9.04 ( 5)
13..00 (119) 16.44 ( 15)
19.90 (784) 27.41 ( 85)
20.97 (421) 29.70 ( 52)
25.61 (420) .39.28 ( 49)
30.05 (284
33.87 ( 14
36.55 (208
41.41 (104
51.57 (120
83.38 ( 4) .
55.30 ( 18)
53.13 ( 19)
. 142.13 (1)
135.85 ( 28)
72.18 ( 22)
71.63 ( 31) 62.87 ( 2)
75.05 ( 18) 75.22 ( 1)
64.53 ( 3
71.46 ( 4
...
Reinforced Ductile
Concrete Iron
10.50
10.48
15.78
19.65
20.51
29.66
54.61
42.32 2
48.99 2
46.56 (4
4) 16.05 ( 4
4) 18.25 ( 22
49 28.21 (252
23 31.42 ( 99
56) 35.83(94
12) 40!?1 (112
99) . 49.91 (109
12) 62.60 ( 4
00) 70.57 ( 97
55.43 (133) ' —
65.58 (357) 100.34 ( 48
85.80 (358) 157.49 ( 24
111.89 (1
114.07 (
87) 434.50 ( 11
96)
A8S
) . 11.79 ( 2)
12.16 ( 2)
' 25.65 (.17)
17.97 ( 2)
) 27.58 ( 5).
33.17 ( 1)
— -
19.25 ( 1)
— -
~
— - -
216.42(152) — -.-
— - —- .. — ,.. 198.31(104) — •• '
— -
~"~
, •
......
— _- •
... -
- ^ •
—
— _
—
~~~
—
: --;
'--- "' '
186.83 .(
248.10 (
253.21 (
352.74 (
216.52 (
239.46 (
304.47 (
39
71 — •
36
6)
3).
1) ..........
1)
— '-
— -
.
,
' .
• —
Other/
Unknown
13.17 ( 61
11.59 (160
22.37 (847
23.18 (421
27.18 (381
38.93 (218
37.89 ( 24
35.30 (206
33.33 ( 71
51.89 (122
57.85 ( 51)
73.34 (114;
91.94 ( 79;
122.81 ( 291
147,09 (,2?;
257.19 ( 21)
249.25 ( 42]
262.04 ( 7)
230.83 ( 13)
466.25 ( 5)
318.19 ( 8)
564.33 ( 1)
366.15 ( 27)
1162 ,
883
; Stei I and ? costs. Step 3 nonconstruction costs, and non-o.ipe construction .costs excluded.
BY PIPE DEPTH:. .... .. . ..'.--
. .".'."'leXer • <8 Feet 8=, 15 Feet
04 11.86 2) 11.17 ( 3
06 11.28 26) 12.98 ( 65
08 17.18 523J 21.14 (1233
10 17,41 224) 20.53 ( 673
12 22,27 190) 23.15 ( 553
15 22.67 (127) 27.35 ( 359
16 39.94 ( 45) 38.75 ( 83
18 31.14 (150) 33.88 ( 415
21 " 35.51 ( 57) . 49.57 ( 173
24 42.74 (95) 45.48 ( 316
27 74.11 ( 16) 49.42 ( 58
30 61.39 ( 61) . 63.49 ( 191
36 91.55 ( 24) 78.68 ( 156
42 104.57 ( 11) 121.69 ( 63
48 84.78 ( 4) 88.25 ! 20
"--. --'.- - • ' • : BY CLASSIFICATION: -
>15 Feet SMSA . Non-SMSA Ai/»°"n»
18.66
33.89
33.75
38.50
40.66
50.33
51.59
47,53
63.86
61.23
74.29
99.71
169.07
129.51
54 119.50 ( 8) 176.56 ( 44) 251.57
«° 470.39 ( 1) 221.12 ( 33) 226.85
66 . — 94.68 ( 1) 181.75
7| — 159.21 ( 6) 199.38
.
.84 . , — . :
Total No.
of Bid Items , 1564 4445
—
•i—
---__
348.35
~~~
14.68
'10) 13.99,
'441) . 23.90
251) 23.99
!234) 27.20
130) 30.09 '
38) 44.02
176) 40.27
101) 47.28
200) - ' 47.34
54) 57.88
170) 67.64
159) 83.36
77) 92.93
27) . 116.39
89) 229.57
65) 214.28
10)' 196.68
26) 255.14
279.19
333.00 (
- 303.47
25) 361.63
304.47 (
2283
35) 11.41
169) 11.20
1311) 20.96
: 714) 22.74
i 656) .27.42
( 420
: 121
504
201
379
'134
344
316
138
92
148
96
39
65
41
35.29
41.37
36.61
40.95
•58.54.
56.00'
73.65
102.33
180.80
128.57
172.83
210.42
207.13
212.18
.
14) — .
4)
,28)
1)
5970
.. • • a
81) 12.40 ( 116)
209) 12.45 ( 378)
:i493) ' 22.34 (2804)
[ 785) 23.34 (1499)
( 695) " 27.31 (1351)
i 413) 32.67 ( 833
'99) . 42,83 ( 220
'. 47,5) , . 38.49 ( 979
239) . 43.84 ( 440
446) 53.39 ( 825
76) 57.20 ( 210)
219) 69.98 ( 563)
165) -• 89:87 ( 481)
92) '128.08 ( 230)
35) 119.75 ( 127) •
25) 221.37 ( 173)
50) 212.96 ( 146)
7) 198.27 (46)
19) 245.43 ( 84)
279.19 (41)
333.00 ( 14
303 47 ( 4
361.63 ( 28
304.47 ( 1
5623 11593
Motes: All costs normalized to Kansas Citv, MO 1st Otr 1979
( ) Number of bid items in sanmle
4-7
-------
600-
^^
§ -
U.
CC
UJ 500-
D.
H
O
I Z
1 O 400-
1-
o
CC
CO
z
0
o
UJ 300-
O
_j
Q.
1
I
LU
CC 200-
CO
LU
O
CC
UJ
< 100-
f
0-
co 2000'
s
UJ
Q
CO
u.
1000
CC
LU
CO
s
Z
0
FIGURE 4.2
BARE -IN- PLACE CONSTRUCTION
COSTS * FOR GRAVITY SEWER
*
^
0 *
•
•
• 9
*
9
•
^.
2804
« Step 1 and 2 costs, Step 3 non-
construction costs, and non-pipe
construction costs excluded.
I Note: All costs normalized to
• Kansas City, MO 1st Qtr.1979
I M I T • f T 1 T T T I 1 T
i 1 r-M — *-f — T " T " T 1 T in ' 1 ~
1
1
•
0 12 24 36 48 60 72 84 96 102
PIPE DIAMETER (IN.)
4-8
-------
Diameter
04
06
08
10
12
15
16
.18
21
24
27
30
36
42
48
54
60
66
Total No.
of Bid Items
Note: All costs
— —
GRAVITY
DELIVERED
SMSA
8.80 ( 4)
11.05 (12)
13.25 (84)
16.21 (47)
14.96 (57)
18.44 (44)
20.07 (16)
20.91 (48)
26.60 (28)
27.77 (39)
25.22 ( 8.)
46.24 (23)
45.65 (29)
46.24 ( 8)
68.28 (13)
63.75 (13)
68.43 (20)
91.44 (18)
511
TABLE 4.4
SEWER PIPE COSTS
TO SITE ($/FOOT)
:. Non-SMSA
7.48 (11)
7.8.8 (25)
7.98 (78)
8.01 (39)
14.33 (41)
13.44 (22)
24.20 (13)
15.63 (29)
17.64 (10)
29.01 (14)
33.10 (7)
58.53 (4)
57.35 (10)
75.68 (2)
___ - '-
305 '.
normalized to Kansas City, MO 1st
:" -.' ' ' ,„ .-",• .'.,.- ...
National Average
7,83 (15)
8.91 (37)
10.71 (162) •:
12.49 (86)
14.70 ( 98)
•16.78 ( 66)
21.92 ( 29)
18.92 (77)
24.24 (38)
28.10 ( 53)
28.90 ( 15)
48.06 ( 27)
48.65 ( 39)
52.13 ( 10)
68.28 (13)
:63.75 ( 13)
68.43 ( 20)
91.44 ( 18)
, 816
Qtr 1979
4-9
-------
£
8
TABLE 4.5
SEWER CONSTRUCTION LABOF
5/FOOT OF PIPE INSTALLED
i—
D:
CD
(U
"io in
O 1
•r- co
re
z:
4->
OJ
QJ
LL.
•5
I
a
-L
•r
/
cn a
z: a
cn u
C J
O r-
z:
a
+
c
<
j
°
t/i
in
OJ r-l
o co
I | tO 1 CO
ii • ' ;
i i r-» i OJ
to OJ cn co oj
to oj
cn LOtd- oj oj
cn o »-H r^. o
I— 1 OJ i-H OJ
r-. I-H oj
T-H OJ LO
i i cn co r-.
i i ...
i i cn o r-.
t-H
i-H ^f
T-H
CO CO
> | 1 CO 1 T-H
I 1 LO 1 O
OJ
J LO CO LO
U OJ
J -w-^ — '*. —
to co «*
•> i i co «*• r-*
H 1 1 • • •
I 1 CO ^f CO
3 i-HOJ
J CO i-H
i! o ^
i i r-N i LO
Si i • i
1 1 O 1 OJ
cn r —
p
Q) *— ' *— '
1)
u to co
oj cn
O 1 I • I
-H i i cn i **•
A i i cn i LO
4-1 LO oj ^~ LO r--
QJ CO i-H
cn LO ^ cn co
to **• OJ r- I-H r-.
i cr, O r-- co ro
CO i-H OJ T-H OJ
4J *± T-H T-H
QJ — r ~~~ —
QJ
U. CO OJ tO
1 1 CO CO O*»
v i i cn o oj
TH t-H
i.
O "-H
z:
-a
ra CQ
0 M-
|— O
1
Ol
CT>
I— 1
i-
4->
c
l/l
I-H
^
•r- QJ
0 r—
o
to E
(/) I/)
O LO
QJ -r-
N*
fl3 -Q
EM-
0 O
i-
cn GJ
0 3
a zr
u)
_p
4-10
-------
.the'Tabor costs. Labor often is broken out separately on projects requiring
special skills or inordinate time.
Non-Pipe Costs for Gravity Sewers
.Construction costs for non-pipe items which are part of the total project are
often itemized separately by the contractors bidding on a job. Table 4.6
summarizes the bid items for the ten most common non-pipe construction cost
items. These numbers represent the cost; of the items as a percentage of the
bare-in-place pipe costs on a national basis. If all categories were required
..for all projects, 46 percent of the bare pipe costs would be indicated. This
percentage also was calculated for the total national data base by adding all
the non-pipe construction costs associated with gravity sewers and dividing
that total by all the gravity sewer construction costs. The resulting
number is 43.7 percent. Over 10,000 individual bid items were used in
this analysis.
Considerable data on non-pipe costs are presented in the Appendices. Tables
C.I, C.2, and C.3 have non-pipe costs by diameter of pipe for SMSA, non-SMSA,
and combined projects. Tables in Appendix D summarize the non-pipe' construc-
tion costs by diameter of pipe for each type of material. Tables in Appen-
dices E and F present the same data for various depths of burial.
The most common non-pipe construction bid item in the data base is for
manholes. These data were analyzed and are presented in Table 4.7 for
regular manholes and Table 4.8 for drop manholes. The data are presented by
depth range and for SMSA and non-SMSA locations, as well as the national
averages.
These tables present some anomalies when examined in detail. Of these,
the most conspicuous is the nearly uniform fact that manholes 8-15 feet
deep have,a lower cost than those less than 8 feet in depth.
Other non-pipe construction costs were examined in detail but statistically
valid or useful information was not produced.
4-11
-------
TABLE 4.6
NON-PIPE CONSTRUCTION COST FOR GRAVITY SEWER
AS PERCENTAGE OF BARE-IN-PLACE PIPE COST
Category
Sanitary Sewer Appurtenances
Thoroughfare Crossings
Stream Crossings
Rock Excavation
Pavement Replacement
Utility Reconnect!' on
Special Bedding & Backfill
Mobilization & Miscellaneous
Manholes
Drop Manholes
SMSA
1
8
4
6
8
2
7
9
5
3
Non-SMSA
1
4
4
7
6
1
3
6
5
1
National
Average
1 (340)
6 (376)
4 (145)
6 (183)
7 (426)
2 ( 63)
5 (336)
8 (512)
5 (602)
2 (249)
Total No.
of Bid Items
3232
Note: Numbers in parentheses indicate the number of bid items,
not the number of actual units.
4-12
-------
TABLE 4.7
AVERAGE UNIT CONSTRUCTION COST OF MANHOLES* ($/UNIT)
BY DIAMETER, DEPTH, AND SMSA CLASSIFICATION
Diameter
SMSA Projects:
48
60
72
, Unknown/
Other
<8 Feet
Depth of Manholes
8-15 Feet
>15 Feet
902.46(363) 800.98 (190) 1664.82(107)
1847.66 (118) 1709.43"( 65) 2225.71 (68)
2179.67(29) 1621.37(22) 3156.20(20)
2166.56 ( 40) 1982.13 ( 20) 4305.70 (11)
Non-SMSA Projects:
48 786.21 (340)
60 1512.58 ( 57)
72 2504.92 ( 31)
868.62 (161) 1488.83 ( 64)
1612.96 ( 26) 5633.65 ( 6)
2848.38 (9)
Unknown/
Other
5426.95 ( 26) 2825.49 ( 27) 3695.26 ( 18)
National Average:
48 846.08 (703)
60 1738.52 (175)
72 2347.72 ( 60)
832.01 (351) 1587.15 (171)
1681.87 ( 91) 2502.03 ( 74)
1977.60 ( 31) 3156.20 ( 20)
Unknown/
Other
3450.96 ( 66) 2466.61 ( 47) 3926.81 ( 29)
Step 3 nonconstruction costs excluded
Notes: All costs normalized to Kansas City, MO 1st Qtr 1979
Numbers in parentheses indicate the number of bid
items, not the number of manholes.
4-13
-------
TABLE 4.8
AVERAGE UNIT CONSTRUCTION COST OF DROP MANHOLES* ($/UNIT)
BY DIAMETER, DEPTH, AND SMSA CLASSIFICATION
Pi ameter
SMSA Projects:
48
60
72
Unknown/
Other
<8 Feet
Depth of Manholes
1348.55 ( 49)
3367.09 ( 7)
3833.00 ( 1)
2070.56 ( 18)
8-15 Feet
1169.64 ( 20)
2325.20 ( 5)
1783.50 ( 2)
>15 Feet
4718.70 ( 24)
2774.85 ( 10)
4557.62 ( 9)
Non-SMSA Projects:
48 1174.11 ( 52)
60 1870.89 ( 15)
72 2970.17 ( 1)
Unknown/
Other
1100.71 ( 24) 1589.34 ( 9)
2194.83 ( 3)
1573.80 ( 9) 4128.50 ( 2) 3508.00 ( 4)
National Average:
48 1258.74 (101)
60 2346.95 ( 22)
72 3401.58 ( 2)
Unknown/
Other
1132.04 ( 44) 3865.24 ( 33)
2276.31 ( 8) 2774.85 ( 10)
1783.50 ( 2) 4557.62 ( 9)
1904.97 ( 27) 4128.50 ( 2) 3508.00 ( 4)
* Step 3 nonconstruction costs excluded
Notes: All costs normalized to Kansas City, MO 1st Qtr 1979
Numbers in parentheses indicate the number of bid
items, not the number of drop manholes.
4-14
-------
COSTS FOR FORCE MAINS
The terms force mains and pressure sewers were used synomously and all
data were aggregated under force mains. The data base contains 1,085 indi-
vidual bid items for force mains. These force mains were, in all but a few
cases, a single bid item in a much larger project containing gravity sewers
and other non-pipe construction costs. Therefore, bare-in-place force main
costs were readily obtainable. Table 4.9 summarizes the 1,085 force main bid
items for the nation. Bare-in-place costs are presented for each diameter of
force main in place. Figure 4.3 graphically presents the same information.
Because of the relatively small data base, individual variations in the cost
data are more pronounced than for those presented for gravity sewers.
Non-pipe construction costs were separately identified in the data base
when available. Analysis of these data resulted in inconclusive ratios.
In an attempt to arrive at a trend for the total non-pipe construction
costs, the national data base was examined. The total force main bare-in-
place construction costs were divided into all non-pipe construction costs
associated with these mains. The result indicated, on a national basis, the
non-pipe construction costs were 25.7 percent of the bare-in-place costs. The
fact that this number is.18 percentage points lower than gravity sewers is
realistic since the construction of a force main is normally less complicated
than a gravity sewer.
COSTS FOR PUMP STATIONS
The total construction costs of municipal wastewater pump stations were
often available from the bid tabulations. Figure 4.4 presents a graph
of the pump capacity in gallons per minute (gpm) versus cost in thousands of
dollars for three ranges of total dynamic head (TDH) in feet. The costs
presented in Figure 4.4 include the cost for the basic pump station in place,
as well as the appurtenances and other construction costs associated with the
pump station. Step 3 nonconstruction costs and Step 1 and 2 engineering costs
are not included.
It should be noted that the design capacity for pump stations in Figure 4.4 is
defined as the average design capacity for the facility and not the total
4-15
-------
TABLE 4.9
FORCE MAIN BARE-IN-PLACE CONSTRUCTION COSTS* ($/FOOT)
Diameter
1
2
3
4
6
8
10
12
14
16
18
20
21
24
30
36
42
Total No.
of Bid Items
National Average Cost
4.93 ( 7)
4.23 ( 42)
5.77 ( 21)
14.28 (221)
10.39 (251)
14.89 (172)
14.26 ( 88)
31.20 ( 71)
26.00 ( 36)
25.48 ( 41)
29.28 ( 25)
33.40 ( 30)
43.06 ( 1)
51.44 ( 34)
63.11 ( 17)
113.30 ( 24)
198.14 ( 4)
1085
National Average non-pipe construction cost for force
mains is 25.7 percent of bare-in-place costs.
* Step 1 and 2 costs, Step 3 nonconstruction costs, and
non-pipe construction costs excluded.
Note: All costs normalized to Kansas City, MO 1st Qtr
1979.
4-16
-------
fc
o
200-
i
o
o
FIGURE 4.3
BARE - IN - PLACE CONSTRUCTION
COSTS* FOR FORCE MAIN
«
o
o
Z
Q isoH
o
100-
i
UJ
00
UJ
g
cc
UJ
50-
o-
300-
(S)
UJ
g
OQ
UL
O
cc
m
03
200-
Ji
» Step 1 and 2 costs, Step 3 non-
construction costs, and non-pipe
construction costs excluded.
Note: All costs normalized to
Kansas City.MO 1st Qtr.1979
12 18 24 30
PIPE DIAMETER (|N.)
36
42
4-17
-------
a.
o
a.
q
H
t.
ii
-------
-installed pumping capacity. Since proper performance of pumping equipment is
critical to the operation 6f; a wastewater collection system, multiple pumps
are usually installed in all bat the smallest pump stations. Generally the
pump stations in the_ data base used to Derive Figure 4.4 will produce the
stated capacity with the largest installed pump out of service.
Non-pump station construction costs for the national data base were calculated
in a manner analogous to gravity sewers and force mains. The non-pump station
construction costs are 5.0 percent of the pump station construction cost's.
This low percentage, as compared with sewers, is expected since most pump
stations are.bid complete, with only occasional requirements for special or
unusual items bid separately. -
NONCONSTRUCTION COSTS . /
Grant eligible nonconstruction costs related to EPA funded projects consist of
Step i preliminary engineering costs, Step 2 detailed engineering costs, and
Step 3 nonconstruction costs for engineering services and administrative fees
related to the construction phase of the project. ;
Table 4.10 presents the ratios of Step 1 and Step 2 costs to the total
construction cost for the wastewater collection systems in the data base.
These data are taken from projects involving only the construction of waste-
water collection systems and which had received both a Step 1 and 2 grant.
The data indicate that the national average Step 1 and 2 costs are approxi-
mately five percent and ten percent, respectively, of the total construction
cost for collection system projects. The reason the number of facilities in
the sample is so low is because most projects have both sewer and treatment
plants as part of the Step 1 and/or Step 2 grants..
The ratios of Step 3 nonconstruction costs; to the construction costs for
projects in the wastewater collection system data base are presented in Table
4.11. Data are. presented for facilities inside and outside SMSA areas. The
data .indicate, that the national average Step 3 nonconstruction costs are equal
to approximately 36 percent of the total construction costs.
4-19
-------
TABLE 4.10
STEP 1 AND STEP 2 COSTS AS A FRACTION OF
TOTAL CONSTRUCTION COSTS - SANITARY SEWER FACILITIES ONLY
Region
01
02
03
04
05
06
07
08
09
10
Average Stei
—
.0177
—
.3227
.0288
.0439
.0436
.0670
.0175
.0667
Average Step 2/TCC
—
.0145
—
.0457
.0961
.0525
.1219
.1335
.0337
.1116
No. of
Bid Items
0
1
0
1
5
6
10
6
4
4
TOTAL
37
Weighted Average:
SMSA .0718
Non-SMSA .0382
National .0520
.0956
0.1384
.0978
* Developed from data for sanitary sewer facilities with both
Step 1 and Step 2 grants for sewer construction only.
4-20
-------
TABLE 4.11
STEP 3 NONCONSTRtfCTION COST§ :AS A FRACTION OF
TOTAL CONSTRUCTION COSTS - SANITARY SEWER FACILITIES
'Nonconstruction Item
Admi ni strati ve/Legal
Preliminary
Land, Structures,
Right of Way
Archi tect/Engi neer
Basic Fees
Other Architect/
Engineer Fees
Project Inspection
Land Development
Relocation Expenses
Relocation Payments
Demolition & Removal
Bond Interest
Contingencies
Indirect Costs
Miscellaneous
Equipment
Average Total
Step 3 NCC/TCC:
SMSA
Average
Non-SMSA
Average
.0096 ( 318) .0114 (336)
.0093 ( 35) .0109 ( 18)
.0266 ( 21) ,0176 ( 24)
.0673 ( 349) .0664 ( 308)
.0329 (174) .0310 (181)
.0397 ( 125) .0484 ( 152)
.0098 ( 1)
.0024 (
.0039 (
.0296 ( 11)
1)
2)
.0006 ( 1)
.0353 ( 6)
.0487 ( 359) .0441 ( 341)
.0122 ( 17) .0083 ( 8)
.0312 ( 55) .0158 ( 36)
.0215 ( 14) .0682 (13)
ONLY
National
Average
.0101 ( 654)
.0095 ( 53)
.0213 ( 45)
.0667 ( 657)
.0323 (' 355)
.0432 ( 277)
.0098 ( 1)
.0024 ( 1)
.0039 ( 2)
.0006 ( 1)
.0326 ( 17)
.047,2 ( 700)
.0118 ( 25)
.0261 ( 91)
.0391 ( 27)
.3372 (1477) .3615 (1429) .3566 (2906)
Note: ( ) Number of projects with nonconstruction items in Step 3
grant awards
4-21
-------
The use of 36 percent would result in an excessively high value for Step 3
nonconstruction costs. The individual percentages accurately represent the
cost for that item. However, not all projects had all items, thus using the
sum of all is misleading. A more reasonable, but subjective, estimate is
derived by totaling the percentages for the most commonly occurring items:
administrative/legal services, A/E basic fees, other A/E fees, project in-
spection, and contingencies. These total approximately 20 percent of the
construction costs.
An analysis of the complete data base was performed to determine a national
trend for Step 3 nonconstruction costs. All Step 3 nonconstruction costs were
divided by all construction costs for the complete data base. The resulting
number was 0.174. Thus, 17.4 percent of the construction costs is the na-
tional average for Step 3 nonconstruction costs. Similarly, 1.174 times the
construction costs equals the total construction costs as defined in this
study. Without better information, the reader should use a percentage of
17.4. If special or unusual conditions are known to exist, various noncon-
struction cost items found in Table 4.11 can be added.
The total project costs are the sum of the Step 1 and 2 costs presented
in Table 4.10, Step 3 nonconstruction costs of Table 4.11, or variances
presented above, plus the construction costs for pipe or pump stations.
Examples of calculating these costs are presented at the end of this section.
COST UPDATING PROCEDURES
The construction cost data utilized for this report were obtained from
projects with bid dates falling between 1973 and 1979. In order to make the
information suitable for statistical analysis, the costs were normalized to a
single point in time, the first quarter of 1979. To account for regional cost
variations, all data were further normalized to a single location, Kansas
City, Missouri. These techniques were performed on all the data before any
analysis work commenced. The techniques and rationale for these normaliza-
tions are explained in detail in Appendix A. The primary purpose of this
section is to explain the use of the indexes.
4-22
-------
The EPA publishes, on a quarterly frequency, the Complete Urban Sewer System
Index (CUSS). The Journal of the Water Pollution Control Federation routinely
'. -••••- • ;•*.'-;«':: ' , •' '^•'v*-;:- ':'; •'-.'. "'•" •. -.• ' ' .
publishes this same information. The reader using the data presented in this
report will certainly want to make estimates in present dollars, or at least
those of the most recent quarter available. The CUSS Indexes for 1979 and the
first two quarters of 1980 are presented in Table 4.12. Since all costs
presented in this report were normalized to Kansas City first quarter 1979,
the CUSS Index number upon which all data are based is 170. The cost for any
of the other 24 cities for a particular item can be found by using the
following formula:
Cost Cost Item CUSS Index
(City x, Time t) = (K.C.. MO, 1st Qtr 1979) X (City x, Time t)
— . - -_ _ __ __
The following example is presented on the use of the indexing procedure:
The total construction cost of 24 inch gravity reinforced concrete
sewer for Atlanta, Georgia in the first quarter of 1980 is to be de-
termined.
1st Qtr 1979 24" RCP Sewer Cost = $116.13/ft. (Table 4,1)
CUSS Index, Atlanta, GA 1st Qtr 1980 = 145 (Table 4.12)
Atlanta Cost (1st Qtr 1980) = ($116. 13) (145) = $99.05/ft.
~
The same pipe in Chicago, Illinois would cost:
Chicago Cost (1st Qtr 1980) .= ($116.13)(213) = $145.50/ft.
170
The 25 CUSS Index cities are located in all regions of the country. However,
most readers will require the cost information for one particular area. An
elaborate analysis, explained in Appendix A, was used to define the sur-
rounding geographic area which each of the 25 cities has a predominant in-
fluence over. The map, Figure A.I, found in Appendix A, should be used to
select the city code. For example, Omaha, Nebraska is in area 110. Denver,
Colorado CUSS Index would be used.
COST ESTIMATING EXAMPLES -
A number of examples are presented to illustrate the use of the cost infor-
mation presented in this report. These cost estimating techniques are useful
when some design information is available. ...... ,,
4-23
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TABLE 4.12
COMPLETE URBAN SEWER SYSTEM COST INDEX (CUSS)
FROM EPA
City
1979
1980
Code
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
Name
Atlanta, 6A
Baltimore, MD
Birmingham, AL
Boston, MA
Charolotte, NC
Chicago, IL
Cincinnati, OH
Cleveland, OH
Dallas, TX
Denver, CO
Detroit, MI
Houston, TX
Kansas City, MO
Los Angeles, CA
Miami, FL
Milwaukee, WI
Minneapolis, MN
New Orleans, LA
New York, NY
Philadelphia, PA
Pittsburgh, PA
St. Louis, MO
San Francisco, CA
Seattle, WA
Trenton, NJ
1st
Qtr
127
153
122
175
92
187
178
184
113
132
184
129
170
185
136
170
154
158
210
192
172
192
176
185
177
2nd
Qtr
130
158
131
179
98
195
180
187
114
135
189
130
183
188
137
111
156
159
211
193
172
200
177
188
180
3rd
Qtr
136
160
136
180
103
207
186
195
121
151
190
133
185
203
140
187
167
162
215
199
176
205
195
191
185
4th
Qtr
137
161
137
192
106
209
186
199
123
155
190
135
187
212
144
190
167
164
222
200
180
206
197
191
187
1st
Qtr
145
165
142
191
111
213
192
205
129
159
198
140
191
214
152
195
171
168
225
203
185
213
201
194
188
2nd
Qtr
147
168
142
191
111
213
192
205
129
160
199
142
191
214
153
195
173
167
229
205
191
213
208
200
188
4-24
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Example No. 1 ,
An estimate is needed for ^the. total consjt^ux:tion cost of 4,000 ft. of 8
inch gravity sewer in Tucson, AffBna. The^project is in a very preliminary
stage and no details are known for appurtenances, special conditions, or depth
of burial. .
a. From Table 4.1, cost of 8" pipe in an SMSA = $44.16/ft.
; • - , - -- - . r . -. '- "-."/-'.-.- .,, . • y , .-:„-:,- „;-. .. ' - - • ',
b. From Table 4.12 and Figure A.I, use Denver, CO CUSS Index = 159
c. Tucson, AZ (1980 cost) = ($44.16)(159) = $41.30/ft. .
: -• . ..' •- . -'- , .170 . .. - . .• - :. •-'.-.. •,
d. Total Construction Cost = $41.30/ft. x 4,000 ft. = $165,200
Note: This cost provides an allowance for Step 3 nonconstruction
costs and non-pipe construction costs. Step 1 and Step 2 costs
• are excluded.
Example No. 2
A project near Tucson, Arizona of a very similar nature to that in Example No.
1 is to be constructed. However, more technical information is known about
the project. An estimate of the total project cost is required. The fol-
lowing data are known:
Reinforced^Concrete Pipe, <8 ft. burial
Reinforced Concrete Pipe, 8-15 ft. burial
Reinforced Concrete Pipe, >15 ft. burial
Non-pipe construction costs are unknown
1,000 ft.
2,000 ft.
1,000 ft.
a. Pipe Costs (Total Construction Cost) -From Table 4.2
8" RCP, <8 ft. = $18.57/ft.
8" RCP, 8-15 ft. = $23.84/ft.
8" RCP, >15 ft. = $35.49/ft.
b. Total Kansas City, MO 1st Qtr 1979 Construction Cost
($18.57)(1,000) + ($23.84) (2,000) + ($35.49)(1,000) = $101,740
c. Using Table 4.12 and Figure A.I, use Denver, CO CUSS Index = 159
1st Qtr 1980 m . 7dnUl(-Qx
Total Construction Cost =. f^p J^ J = $95,157
d. The above cost excludes Step 1 and Step 2 planning and engineering
costs. Using the SMSA average from Table 4.10, these costs are 16.7
percent of the total construction cost.
Total Project Cost =($95, 157) (1.167) - $110,048 .
4-25
-------
Example No. 3
A facility near Alliance, Ohio is planning an addition to their sewerage
system. The following information is known about their needs and the probable
materials to be utilized for construction:
8" Vitrified Clay Pipe, 8-15 ft. burial
12" Reinforced Concrete Pipe, 8-15 ft. burial
10" Cast Iron Pipe, 8-15 ft. burial
6" Force Main
48" Diameter Manhole, 8-15 ft. deep
Stream Crossing
Rock Excavation
Pump Station
6,200 ft.
2,150 ft.
500 ft.
850 ft.
20 each
1 (12" RCP sewer)
None
1 @ 100 gpm <40 ft.
discharge head
Using the data base presented in this report, there are a number of approaches
possible to estimate this project. The one chosen uses the most basic data
and builds upon it.
a. Bare-In-Place Gravity Sewer Costs
8" Vitrified Clay,
8-15 ft. (Table F.8) = $19.06/ft. x 6,200 ft. = $118,172
12" Reinforced Concrete Pipe,
8-15 ft. (Table F.14) = $30.22/ft. x 2,150 ft. = $ 64,973
10" Cast Iron Pipe,
8-15 ft. (Table F.ll) = $24.29/ft. x 500 ft. = $ 12.145
Total Bare-In-Place Gravity Sewer Cost = $195,290
b. Force Main Bare-In-Place Costs - From Table 4.9
6" Force Main = $10.39/ft. x 850 ft. = $8,832
c. Manhole Costs - From Table 4.7
48", non-SMSA, 8-15 ft. = $869.00/ea. x 20 ea. = $17,380
d. Stream Crossings - From Table 4.6
4.0% of total bare-in-place pipe costs = ($195,290)(0.04) = $7,812
e. Other Non-Pipe Construction Costs for Gravity Sewers
Rock excavation, stream crossing, and manholes have been accounted
for on an itemized basis above. Additional non-pipe construction
costs are judged to be reasonable, and as shown below. These figures are
percentages of bare-in-place pipe costs obtained from Table 4.6.
4-26
-------
Appurtenances
Rock Excavation
Thoroughfare Crossings
Pavement Replacement
Utility Reconnection
Mobilization
1%
7%
1%
6%
Total 25% -
Other Non-Pipe Construction Costs = ($195,290)(0.25) = $48,822
Construction Cost for Gravity Sewers
Bare-In-Place Pipe (a)
Manhole Costs (c)
Stream Crossings (d)
Other Non-Pipe Costs (e)
= $195,290
= 17,380
= 7,812
= 48,822
Gravity Sewer Construction Cost = $269,304
Note: ...The non-pipe construction costs for this project are 37.9 percent
of the bare-in-place pipe costs. This compares with the data base
national average of 43.7 percent.
g. Force Main Construction Costs
Non-pipe construction costs associated with force main construction were
found to be 25.7 percent of the bare-in-place costs (Table 4.9).
Force Main Construction = ($8,832)(1.257) = $11,102
h. Pump Station Costs - From Figure 4.4
Using Equation "A": Cost =1.59 x I03q0.59 = $24,066
,r ' '' i ""' • , , ' - '
Other construction costs associated with pump stations.are five
percent of the above figure.
Pump Station Construction Cost = ($24,066)(1.05) = $25,269
i. Total Construction Costs
As defined herein, total construction costs include all construction
costs plus Step 3 nonconstruction costs. The above calculations do not
include the Step 3 costs.
Construction Costs:
Gravity Sewer
Force Main
Pump Station
Total
= $269,304
= 11,102
= 25,269
= $305,675
4-27
-------
From the discussion of Table 4.11, the national average Step 3 noncon-
struction costs are 17.4 percent of the construction costs.
Total Construction Costs = ($305,675)(1.174) = $358,862
j. Total Project Cost
The total project cost is the total construction cost plus the Step 1 and
Step 2 planning and engineering costs. From Figure 4.10, these costs are
3.82 and 13.84 percent for Step 1 and Step 2, respectively.
Total Project Cost = ($358,862)(1.1766) = $422,237
k. Compute Alliance, Ohio 1st Qtr 1980 costs - From Table 4.12 and Figure
A.I.
From Figure A.I, use Cleveland, OH (City Code 107)
From Table 4.12, Cleveland, OH CUSS Index = 205
Alliance, OH Cost = ($422,237)(205) = $509,168
170
Example No. 3 is illustrative of the detail and judgment which can be used for
estimation purposes. If more information is available, more refined estimates
may be provided using the information from the tables in the Appendices.
Also, if type of pipe, depth of burial, types of non-pipe construction items,
and nonconstruction items are known, more definitive estimates may be made.
Conversely, if none of these factors are known, strict national averages may
be applied (using Table 4.1 for gravity sewers). Such estimates will normally
be accurate within 20 percent.
Simplified estimation techniques have been developed for other EPA projects.
They are presented in Appendix B. These should be considered "rule of thumb"
methods.
4-28
-------
A ,t
COST UPDATING AND NORMALIZATION TECHNIQUES
The data base utilized for this report includes costs from wastewater col-
lection system projects fn 47 of the. contiguous States for the period 1973 to
1978. In order to achieve a meaningful analysis of the data, it;was necessary
to normalize all dollar values to a specific time.and location.
To accomplish this, the EPA Complete Urban Sewer System Index (CUSS) was
used. This Index has been calculated quarterly by EPA since the third
quarter of 1973 for 25 U.S. cities ,(see Table 4.12). The CUSS Index is
based on a hypothetical sewage system project in Kansas City, Missouri
which includes the following components: a gravity collection system con-
sisting of 16,700 feet of gravity sewer; 3,400 feet of force main; and a 550
gpm pumping station plus an interceptor consisting of 9,600 feet of 30 inch
diameter pipe.
AREAS OF INFLUENCE
EPA publishes the CUSS Index as an indicator of the cost trends over time and
as a basis of comparison for one city to another. The specific areas of cost
influence relatingrto each of the 25 Index cities are not defined. .Therefore,
prior to using the Index for updating the costs acquired for this work, the
area of influence for each of the Index cities was assessed and mapped. Two
sources of informatipn were employed in this effort - Bureau of Labor Statis-
tics (BLS) Union W.ages and Hours: Building Trades 1973-1978 for selected U.S.
cities, and the Bureau of Economic Analysis (BEA) map of U.S. economic areas.
The BLS data consist of union labor rates for various building trades recorded
annually for 65 to 70 U.S. cities. Some cities have been added and others
have been dropped between 1973 and 1979 resulting in a total of 87 cities for
which at least three years of data were available. In order to utilize this
information, a weighted average of four building trades - carpenter, cement
finisher, equipment operator, and laborer - were calculated for the six
A-l
-------
calendar years from 1973 to 1978. Data from each city were compared with data
from all the other 86 cities. Since all the EPA CUSS Index cities are in-
cluded in the list of BLS cities, this process permitted the BLS cities to be
related to the CUSS Index cities, thus defining the general area of influence
for each of the CUSS Index cities.
The BEA economic areas were used to set the boundaries of economic influence
surrounding each EPA Index city. A BEA economic area was composed of a
central city and surrounding counties that are economically related to the
central city as determined by BEA. Each of these areas includes both the
place of work and place of residence of the labor force. The resulting map of
the CUSS Index city areas of influence is presented in Figure A.I.
COST UPDATING
In order to update all costs to Kansas City, Missouri as of the first quarter
of 1979, all projects were related to a specific CUSS Index city using the map
in Figure A.I. Using the index values contained in Table 4.12, the costs were
then normalized according to the following procedure:
Construction Cost at x
(City x, Time t)
Kansas City, MO
1st Qtr 1979 Index
(City x, Time t)
Index
Construction Cost at
Kansas City, MO
1st Qtr 1979
The data base was thus normalized to the base city of the CUSS Index.
The effects on the results of the analyses of a large or small quantity
of data from different areas of the U.S. or from a particular time period
were thus minimized.
A-2
-------
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LU
u_
u_
o
oo
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oo
oo
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FIGURE A.I
A-3
-------
-------
APPENDIX B
SIMPLIFIED COLLECTION, SYJTJM COST ESTIMATINGTECHNIQUES
This Appendix presents simplified techniques for the estimation of the
project costs for the construction of new sanitary sewers and pumping sta-
tions. These procedures are intended for the use of State and municipal
officials, as well as laymen, in determining the approximate capital costs for
wastewater collection systems.
These cost estimating procedures were developed for EPA for use in the
1980 Needs Survey. Needs Surveys are conducted biennially by the Agency in
order to assess the cost of providing sewage collection and treatment as
required by Public Law 95-217, and to report the results to Congress. Pre-
vious Needs Surveys were conducted in 1973, 1974, 1976, and 1978.
COST ESTIMATING TECHNIQUES
The essential elements for estimating the cost of a sewerage system are
as follows:
1. The length of the sewers.
2. The diameter of the sewers.
3. The unit cost or cost per foot of the sewers.
4. The number and capacity of required pump stations.
"'• . - ' • -, '!- •.',..
Methods for estimating the above data are presented below along with examples
of the use of estimating techniques.
Length
The length of the sewers may be determined by direct measurement on a map or
from other information on actual distances to be traversed. In the absence of
other information, EPA suggests the following per capita lengths be utilized
as estimates:
B-l
-------
Collector Sewers
Interceptor Sewers
Diameter
16 feet/capita
1 feet/capita
The diameter of the sewer is dependent upon the flow required to be trans-
ported. Generally, collector sewers may be assumed to be 8 inches in di-
ameter. Interceptor sewer diameter may be estimated from Table B.I which
presents the required approximate diameters for a range of wastewater flows.
In the absence of better information, a domestic and commercial wastewater
flow of 100 gallons per capita may be assumed. Known industrial flows should
be added, if present.
Unit Cost
Unit costs for sewer systems are dependent upon a number of factors including
the diameter of the sewer, burial depth, type of pipe, geographical area, and
the degree of ubranization.
Table B.2 presents the cost per foot of installed sanitary sewer for pipe
diameters from 8 to 72 inches. The costs include all appurtenance costs and
non-pipe construction costs and also include an allowance for Step 3 noncon-
struction costs and Step 1 and Step 2 costs.
The cost data include pipe of all types and all depths from the wastewater
collection system projects in the data base. This is considered adequate for
preliminary estimates since specific information concerning the type of pipe
required and the depth would normally not be available at this stage in
planning.
The costs shown in Table B.2 have been normalized to first quarter 1979
dollars in Kansas City, Missouri using the cost indexing procedure described
in Appendix A. In order to adjust the unit costs for other geographical areas
of the U.S., the multipliers in Table B.3 must be utilized. Multipliers are
provided for each of the 25 cities accounted for in the EPA CUSS Index. The
map in Appendix A (Figure A.I) illustrates the area of influence for each of
the CUSS Index cities.
B-2
-------
TABLE B.
SANITARY SEWER SIZING
AND INTERCEPTOR
Pipe Diameter
(Inches)
08
10
12
15
18
21
24
27
30
36
42
48
54 ,
60
66
72
1 . •''•..'" •'.
OF COLLECTOR
SEWERS
Average Flow Range
(mgd)
0.2 or Less
0.21 - 0.3
0.31 - 0.5
0.51 - 0.7
0.71 - 1.1
1.11 - 1.5
1.51 - 2.1
2.11 - 2.8
2.81 - 3.5 :
3.51 - 5.5 I
5.51 - 7.7
7.71 - 10.1
10.11 - 12.9
12.91 - 17.2
17.21 - 2Q.6
20.61 - 26.4
B-3
-------
TABLE B.2
SANITARY SEWER TOTAL IN PLACE COSTS*
PER LINEAR FOOT
Pipe Diameter
(Inches)
08
10
12
15
18
21
24
27
30
36
42
48
54
60
66
72
Average Cost
($/Foot)
35
44
51
64
83
99
112
129
139
168
227
270
315
398
418
522
* Includes associated appurtenance and nonconstruction
costs.
Note: All costs normalized to Kansas City, MO 1st
Qtr 1979
B-4
-------
TABLE B.3
SANITARY SEWER CONSTRUCTION AREA MULTIPLIERS
Area Code
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
Area
Atlanta, Georgia
.. Baltimore, Maryland
Birmingham, Alabama
Boston, Massachusetts
Charlotte, North Carolina
Chicago,Illinois
Cincinatti, Ohio
Cleveland, Ohio
Dallas, Texas
Denver, Colorado
Detroit, Michigan
Houston, Texas
Kansas City, Missouri
Los Angeles, California
Miami, Florida
Milwaukee, Wisconsin
Minneapolis, Minnesota
New Orleans, Louisiana
New York, New York
Philadelphia, Pennsylvania
Pittsburgh, Pennsylvania
St. Louis, Missouri
San Francisco, California
Seattle, Washington
Trenton, New Jersey
State and Territorial Multipliers:
Alaska
Guam
Hawaii
Puerto Rico
Trust Territories
Multiplier
0.77
, 0.96
0.75
1.08
0.55
1.12
1.09
1.11
0.70
0.79
1.10
0.80
1.00
1.14
0.83
1.00
0.94
0.97
1.28
1.17
1.08
1.18
1.08
1.12
1.08
2.74
1.40
1.71
0.98
1.40
B-5
-------
In order to account for the degree of urbanization, an additional set of
multipliers has been devised. These multipliers are presented in Table B.4.
They should be applied on a county-wide basis according to the degree of
urbanization as defined in the table. The multipliers were developed using
the wastewater collection system cost data base and the Calvin Beale Metro/
Adjacency Coding System developed by the U.S. Department of Agriculture.
Depending upon such factors as terrain, length of the collection system, and
flow, pump stations can be a significant portion of the total system cost. If
the number and design capacity of proposed pump stations are known, the costs
can be derived from Figure 4.4. In most cases, however, this information will
not be known because sufficient planning will not have been completed.
In such cases, EPA recommends that a rule of thumb of one pump station
of 1.2 mgd capacity for each 65,000 feet of sewer be used. The pump station
is estimated to cost $185,000. No pump station cost should be included when
the estimated collection system length is less than 39,000 feet. Otherwise, a
ratio of the estimated sewer length to the unit length of 65,000 feet may be
used. Thus, the cost may be estimated as follows:
Projected Total Sewer Length x $i85,000/Pump Station =
65,000 l-eet
COST ESTIMATING EXAMPLES
Cost of
Pump Stations
The following examples are presented to illustrate the use of the cost
estimating procedures presented in this Appendix. These procedures should be
used when no additional source of planning information is available. The
costs represent the entire grant eligible portion of the project, including
the Step 1 and Step 2 portions, and the Step 3 construction phase.
Example No. 1
Estimate the total project cost to construct 5,000 ft. of 30 inch sewer
in Louisville, Kentucky.
a. From Table B.2, cost for 30" sewer = $139/ft.
b. From Table B.3 and Figure A.I, use Cincinnati, OH CUSS Index = 1.09
B-6
-------
TABLE B.4
SANITARY-sllER CULTURAf'MjLTIPLIERS
Cultural Definition
Urban:
Counties with metropolitan areas
of 50,000 or more population
Multiplier
1.15
Suburban:
Counties contiguous to an SMSA
and having 2,500 or more urban
residents. Also counties not
contiguous to an SMSA having
20>000 or more urban residents
0.90
Rural:
Counties less urbanized than
the above
0.75
B-7
-------
c. From Table B.4, use the Urban Area Multiplier = 1.15
d. Total Project Cost = ($139)(5,000 ft.)(1.09)(1.15) = $871,000
Note: This cost provides an allowance for Step 3 nonconstruction
costs and non-pipe construction costs. Step 1 and Step 2 costs
are also included.
Example No. 2
Estimate the total project cost for a wastewater collection system to serve a
population of 2,500 persons in Mankato, Minnesota.
a. Collectors
Using a rule of thumb of 16 ft./capita for 8" collector sewers and
costs from Table B.2, collector costs are estimated as follows:
2,500 x 16 ft./capita x $35/ft. = $1,400,000
b. Interceptors
Since no flow information is presented, a per capita flow of 100 gallons
may be assumed. From Table B.I, it is determined that a 10" interceptor
would be necessary to transport the resulting 250,000 gpd total flow.
The cost may be determined allowing one linear foot of interceptor/capita
and using the unit costs from Table B.2.
2,500 x $44/ft. = $110,000
c. Pump Station
The total sewer length is 42,500 ft., thus a pump station should
be estimated as follows:
42,500 ft./65,000 ft. x $185,000 = $121,000
d. Total Project Cost
Collectors
Interceptors
Pump Station
= $1,400,000
110,000
121,000
Total Project Cost = $1,631,000 (Kansas City, MO 1st Qtr 1979)
Mankato, MN Cost - From Table B.3 and Figure A.I
From Figure A.I, use Minneapolis, MN (City Code 117) = 0.94
From Table B.3, use Suburban Multiplier = 0.90
Total Project Cost = ($1,631,000)(0.94)(0.90) = $1,380,000
B-8
-------
APPENDIX C
TOTAL CONSTRUCTION COST PER FOOT OF PIPE
-;.-;;:;• ALL PROJECTS, SMSA, NON-SMSA
Explanatory Notes
Tables C.I, C.2, and C.3 summarize gravity sewer construction cost data
for all 'projects in the data base. Each table presents the bare-in-place
costs, the non-pipe construction costs, the Step 3 nonconstruction costs, the
total footage, the'sample size, and the total construction cost for each
diameter of pipe. Table C.I is for all projects, while Tables C.2 and C.3 are
separated into those projects within an SMSA and those outside an SMSA,
respectively.
A comparison for equivalent sewers in various sections/of the country may be
determined by using the normalized figures from Tables C.1, C.2, or C.3 and
the appropriate Index city figures found in Figure A.I and Table 4.12. As an
example, to compare the total, construction costs per foot of pipe in second
quarter 1980 dollars, for 8 inch pipe between Atlanta and New York City, the
following calculation is performed using Table C.2 (both projects i'n an
SMSA):
Atlanta, GA (Area: 101) = ($44.16)(147) = $38.18/ft
. • , . : : 170
York, NY (Area 119); = ($44.16)(229) = $59.49/ft.
New
Another example is appropriate. The same cost comparison as above is made,
but the projects are not in the SMSA. Table; C.3 is .used in this example'
Atlanta, 6A (Area 101) = ($30.81)(147) = $26.64/ft
-• ' ' :. 170 ._ '. ; - ••-' . -••
New York, NY (Area 119) = ($30.81)(229) = $41.5Q/ft
• , • - '• .../ 170 ~ '"-... - '. -- ' :'. •
C-l
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APPENDIX D
TOTAL CONSTRUCTION COST PER FOOT OF PIPE
BY PIPE MATERIAL
Explanatory Notes
Tables D.I through D.8 summarize gravity sewer pipe total construction
costs for the various pipe materials (PVC9 RCP, etc.) by diameter of the
pipe. The tables reflect the unit, non-pipe, and Step 3 nonconstruction items
for each pipe material. The national costs are also summarized in Table
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APPENDIX E
TOTAL CONSTRUCTION COST PER FOOT OF PIPE
BY DEPTH OF BURIAL
Explanatory Notes
Tables E.I through E.3 are a subset of the complete data base (all pipe
materials) separated into groups based upon depth of burial of the pipe. The
tables reflect the unit, non-pipe, and Step 3 nonconstruction costs for each
depth range. The national costs are also summarized in Table 4.1.
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APPENDIX F
TOTAL CONSTRUCTION COST PER FOOT"OF PIPE
BY PIPE MATERIAL AND DEPTH OF BURIAL
Explanatory Notes
Tables F.I through F.24 provide a breakdown on the costs of gravity sewers
based upon depth of burial and type of pipe material. These data are sum-
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APPENDIX G
PROJECT LIST USED FOR DATA BASE
Explanatory Notes
Table G.I lists the projects which make up the data base reported upon in this
report. The projects are sorted alphabetically by State, and numerically by
ascending grant number within each State. Many projects had multiple grants.
The number shown is for the last grant associated with the project.
In addition, the name of the facility, and the city and county in which
it is located, are identified.
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T'JH 547
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