EPA-660/2-75-023
JUNE 1975
COST ESTIMATING METHODOLOGY
FOR ONCE-THROUGH COOLING
WATER DISCHARGE MODIFICATIONS
by
John W. Hayden
Richard Mayer
Contract No. 68-03-2053
Program Element 1BB392
ROAP 21AZU/TASK21
Project Officer
James P. Chasse
Pacific Northwest Environmental Research Laboratory
National Environmental Research Center
Corvallis, Oregon 97330
NATIONAL ENVIRONMENTAL RESEARCH CENTER
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CORVALLIS, OREGON 97330
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ABSTRACT
This manual presents a methodology for evaluating the engi-
neering and cost implications of. constructing or modifying
once-through cooling water discharge systems of thermal
electric generating plants within the contiguous United
States. The procedures presented provide, persons not-
skilled in cost engineering with a means of preparing pre-
liminary cost estimates from conceptual or design drawings.
The user should, however, have a technical background and
be familiar with once-through cooling water discharge
systems.
Principal construction elements of discharge system con-
struction and modification are identified and grouped
into categories. Materials and installation methods are
discussed for each construction element. Data on labor,
materials, equipment, and productivity assumed in unit cost-
development is provided. A step-by-step procedure is given
for: (1) estimation of construction costs; and (2) resolu-
tion of construction costs into project arid annual costs.
An example is shown using the methodology and comparing
result with actual construction costs for modifications to
an existing discharge system.
This report was submitted in fulfillment of Contract No.
68-03-2053 by Acres American Incorporated, Buffalo, New
York, under the sponsorship of the Environmental Protection
Agency. The work was completed as of June, 1975.
11
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CONTENTS
Sections
I CONCLUSIONS 1
II INTRODUCTION 2
III APPROACH 13
IV METHODOLOGY 18
V REFERENCES 209
VI CONVERSION FACTORS 211
VII APPENDICES 212
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FIGURES
No. Page
1 Surface Discharges 4
2 Submerged Discharges 5
3 Once-Through Basic Discharge Systems
and Possible Modifications 6
4 Sample Worksheet - Carbon Steel Pipe,
Worksheet 403.1 21
5 Design Data Required for Worksheet 403.1 2.4
6 Base Cost Computation on Worksheet 403.1 25
7 Cost Graph Corresponding to Cost Account
403.1 and Worksheet 403.1 26
8 Cost Adjustments on Worksheet 403.1 27
9 Sample Cost Category, Cost Summation
Worksheet 29
10 Cost Category 10 Summation Worksheet 30
11 Example of Computations for Regional and
Time Adjustment of Construction Cost 32
12 Example of Extrapolating to Future
Start of Construction Data 34
13 Computation of Total Project Costs 35
14 Computation of Power Outage Costs 37
15 Sample Computation of Annual Costs 39
102 Removal of Concrete Slabs 56
103 Removal of Concrete (Non-Slab) 56
105 Clearing and Grubbing 57
108.1 Hauling Costs for Concrete Slabs 58
108.2 Hauling Costs for Earth, Rock, or
Broken Concrete 58
IV
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FIGURES (cont'd)
No. Page
201.1 Costs for Material and Land-Based
Placement of Riprap 71
201.2 Costs for Materials and Offshore
Placement of Riprap 71
202.1 Costs for Steel Sheet Piling
(Land Installation) 72
202.2 Costs for Steel Sheet Piling 72
(Offshore Installation)
203.1 Costs for Piles (Land Installation) 73
203.2 Costs for Piles (Offshore Installation) 73
300.1 Types of Cooling Water Circulating Pumps 75
301.1 Pumps and Motors 88
301.2 Pump and Motor Installation 89
301.3 Costs for Valves and Expansion Joints 89
401 Costs for Precast Concrete Pipe 112
402 Cost for Cast-In-Place Box Conduit 113
403.1 Cost for Carbon Steel Pipe 114
403.2 Cost for Elbows, Reducers, and Connections 114
404 Costs for Corrugated Steel Pipe 115
405 Cost for Fiberglass Pipe 115
406.2 Costs for Pipe Installation (Land) 116
406.5 Dewatering Costs for Pipe Installation 116
407.2 Costs for Pipe Installation (Marine) 117
500.1 Structural Supports 120
500.4 Diameter Relationships 134
501.1 Tunnel Excavation Costs for Dry Headings 134
v
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FIGURES (cont'd)
No. Page
501.2 Tunnel excavation Costs for Wet Headings 135
502.1 Costs for Rock Bolt Supports 135
502.2 Costs for Shotcrete Support 136
502.3 Cost for Continuous Horseshoe Rib Supports 136
502.4 Cost for Circular Rib Supports 137
502.5 Costs for Timber Lagging 137
503 Costs for Tunnel Lining 138
504 Costs for Tunnel Dewatering 138
600.1 Conduit Diffuser 139
600.2 Tunnel Diffuser 140
601 Costs for Steel Nozzles 154
603.2 Installing Individual Nozzles Into a
Tunnel Manifold 155
701.1 Costs for Structural Concrete,
Concrete Placement 164
701.2 Costs for Structural Concrete,
Reinforcing Steel 164
801 Cost for Fill Material 172
802.1 Cost for Placement of Fill (Land) 173
802.2 Cost for Placement of Fill (Marine) 173
901.1 Costs for Earth Excavation (Land) 187
901.2 Costs for Earth Excavation (Marine) 187
902.1 Costs for Rock Excavation (Land) 188
904 Costs for Excavation Dewatering 188
1100 ENR 20-City Construction Cost Index 196
1201 Discharge Arrangement at Quad Cities 21<*
vi
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TABLES
No. Page
1 Comparison of Results 1
2 Cost Accounts for Cost Category 4 20
3 Site Preparation Cost Accounts 47
4 Cost Category 1 Cost Summation 48
5 Riprap Removal, Worksheet 101 49
6 Concrete Slab Removal, Worksheet 102 50
7 Concrete Removal (Non-Slab), Worksheet
103 51
8 Sheet Piling Removal Pulling Costs,
Worksheet 104.1 52
9 Sheet Piling Removal Salvage Value,
Worksheet 104.2 52
10 Clearing and Grubbing, Worksheet 105 53
11 Reseeding, Worksheet 106 53
12 Site Grading, Worksheet 107 54
13 Hauling, Worksheets 108.1 & 108.2 54
14 Other, Worksheet 109 54
15 Mobilization, Worksheet 110 55
16 Erosion Protection Cost Accounts 63
17 Cost Category 2 Cost Summation,
Worksheet 200 64
18 Placement of Riprap (Land-Based),
Worksheet 201.1 65
19 Placement of Riprap (Marine),
Worksheet 201.2 66
20 Steel Sheet Piling (Land), Worksheet 202.1 67
21 Steel Sheet Piling (Marine)
Worksheet 202.2 68
22 Piles (Land), Worksheet 203.1 68
23 Piles (Marine), Worksheet 203.2 69
24 Concrete, Worksheet 204 69
25 Other, Worksheet 205 70
26 Mobilization, Worksheet 206 70
Vll
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TABLES (cont'd)
No. Page
27 Pump and Motor Characteristics 76
28 Pump Station Cost Accounts 80
29 Cost Category 3 Cost Summation,
Worksheet 300 81
30 Pumps and Motors, Worksheet 301.1 82
31 Installation, Worksheet 301.2 83
32 Expansion Joints and Valves,
Worksheet 301.3 83
33 Pile Foundation, Worksheet 302.1 84
34 Foundation Slab and Pit Walls,
Worksheet 302.2 85
35 Cover Slab, Worksheet 303.1 85
36 Enclosure, Worksheet 303.2 85
37 Foundation Excavation, Worksheet 304 86
38 Steel Sheet Piling, Worksheet 305 86
39 Structure Backfill, Worksheet 306 86
40 Other, Worksheet 307 87
41 Mobilization, Worksheet 308 87
42 Conduit Cost Accounts 99
43 Cost Category 4 Cost Summation,
Worksheet 400 101
44 Precast Concrete Pipe, Worksheet 401 102
45 Cast-In-Place Box Conduit,
Worksheet 402 103
46 Steel Conduit, Worksheet 403.1 104
47 Steel Pipe Fittings, Worksheet 403.2 105
48 Corrugated Metal Pipe, Worksheet 404 106
49 Fiberglass Pipe, Worksheet 405 106
50 Onshore Pipe Trench Excavation,
Worksheet 406.1 107
51 Laying Pipe on Land, Worksheet 406.2 107
52 Onshore Backfill, Worksheet 406.3 107
53 Pipe Support Systems, Worksheet 406.4 108
54 Dewatering, Worksheet 406.5 108
viii
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TABLES (cont'd)
No. Page
55 Offshore Pipe Trench Excavation,
Worksheet 407.1 108
56 Laying Offshore Pipe, Worksheet 407.2 109
57 Offshore Backfill, Worksheet 407.3 109
58 Pipe Support Systems, Worksheet 407.4 110
59 Riprap Protection, Worksheet 407.5 110
60 Cofferdams, Worksheet 407.6 110
61 Other, Worksheet 408 111
62 Mobilization, Worksheet 409 111
63 Rock Types 118
64 Rock Support Criteria 123
65 Tunnel Cost Accounts 126
66 Cost Category 5 Cost Summation,
Worksheet 500 127
67 Tunneling Excavation, Dry,
Worksheet 501.1 128
68 Tunneling Excavation, Wet,
Worksheet 501.2 128
69 Rock Bolts, Worksheet 502.1 129
70 Shotcrete, Worksheet 502.2 129
71 Horseshoe Rib Support, Worksheet 502.3 130
72 Circular Rib Support, Worksheet 502.4 130
73 Timber Lagging, Worksheet 502.5 131
74 Concrete Tunnel Lining, Worksheet 503 132
75 Tunnel Dewatering, Worksheet 504 132
76 Shafts, Worksheet 505 133
77 Other, Worksheet 506 133
78 Diffuser Cost Accounts 145
79 Cost Category 6 Cost Summation
Worksheet 600 147
80 Steel Nozzles, Worksheet 601 148
81 Concrete Manifold, Worksheet 602.1 149
IX
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TABLES (cont'd)
No. Page
82 Steel Manifold, Worksheet 602.2 149
83 Steel Manifold Fittings, Worksheet 602.3 149
84 Installation of Conduit Diffuser,
Worksheet 603.1 150
85 Installation of Nozzles Into a
TunnelDiffuser, Worksheet 603.2 150
86 Cofferdams, Worksheet 603.3 150
87 Trench Excavation, Worksheet 603.4 151
88 Diffuser Support Systems, Worksheet 603.5 151
89 Riprap Protection, Worksheet 603.6 151
90 Trench Backfill, Worksheet 603.7 152
91 Single Port, Worksheet 604 152
92 Other, Worksheet 605 152
93 Mobilization, Worksheet 606 153
94 Concrete Cost Accounts 159
95 Cost Category 7 Cost Summation
Worksheet 700 160
96 Cast-In-Place Structural Concrete,
Concrete Placement, Worksheet 701.1 161
97 Cast-In-Place Structural Concrete,
Reinforcing Steel, Worksheet 701.2 161
98 Cast-In-Place Concrete (Marine),
Worksheet 702 162
99 Grouting, Worksheet 703 162
100 Cushion Fill, Worksheet 704 163
101 Other, Worksheet 705 163
102 Mobilization, Worksheet 706 163
103 Fill Cost Accounts 167
104 Cost Category 8 Cost Summation
Worksheet 800 167
105 Material and Hauling Costs,
Worksheet 801 168
106 Placement of Fill (Land), Worksheet 802.1 169
x
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TABLES (cont'd)
No. Page
107 Placement of Fill (Marine),
Worksheet 802.2 170
108 Other, Worksheet 803 171
109 Mobilization, Worksheet 804 171
110 Excavation Cost Accounts 179
111 Cost Category 9 Cost Summation,
Worksheet 900 180
112 Earth Excavation (Land), Worksheet 901.1 181
113 Earth Excavation (Marine),
Worksheet 901.2 182
114 Rock Excavation (Land), Worksheet 902.1 183
115 Rock Excavation (Marine),
Worksheet 902.2 184
116 Shoring, Worksheet 903 185
117 Excavation Dewatering, Worksheet 904 185
118 Other, Worksheet 905 186
119 Mobilization, Worksheet 906 186
120 Mobilization Cost Accounts 191
121 Cost Category 10 Cost Summation,
Worksheet 1000 192
122 Mobilization, Worksheet 1001 192
123 Other, Worksheet 1002 193
124 Capital Cost Resolution Accounts 201
125 Cost Category 11 Cost Summation 201
126 Time and Regional Adjustment Factor,
Worksheet 1101 202
127 Project Costs, Worksheet 1102 204
128 Power Outage Costs, Worksheet 1103 205
129 Annual Costs, Worksheet 1104 205
XI
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TABLES
No. Page
B-l Labor Force and Equipment Pool,
Account 101 271
B-2 Labor Force and Equipment Pool,
Account 102 272
B-3 Unit Cost Data, Account 102 272
B-4 Labor Force and Equipment Pool,
Account 103 273
B-5 Unit Cost Data, Account 103 273
B-6 Labor Force and Equipment Pool,
Account 104 274
B-7 Labor Force and Equipment Pool,
Account 105 (Light Clearing) 275
B-8 Labor Force and Equipment Pool,
Account 105 (Medium to Heavy Clearing) 275
B-9 Unit Cost Data, Account 105 276
B-10 Labor Force and Equipment Pool,
Account 106 276
B-ll Labor Force and Equipment Pool,
Account 108 277
B-12 Unit Cost Data, Account 108 277
B-13 Labor Force and Equipment Pool,
Account 201.1 (Riprap, Stone, and
Filter) 278
B-14 Labor Force and Equipment Pool,
Account 201.1 (Cover Stone) 278
B-15 Unit Cost Data, Account 201.1 279
B-16 Labor Force and Equipment Pool,
Account 201.2 (Riprap, Stone, and
Filter) 279
B-17 Labor Force and Equipment Pool,
Account 201.2 (Cover Stone) 280
B-18 Unit Cost Data, Account 201.2 280
B-19 Labor Force and Equipment Pool,
Account 202.1 281
B-20 Unit Cost Data, Account 202.1 281
B-21 Labor Force and Equipment Pool,
Account 202.2 282
xii
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No.
B-22 Unit Cost Data, Account 202.2 282
B-23 Labor Force and Equipment Pool,
Account 203.1 283
B-24 Unit Cost Data, Account 203.1 283
B-25 Labor Force and Equipment Pool,
Account 203.2 283
B-26 Unit Cost Data, Account 203.2 284
B-27 Labor Force and Equipment Pool,
Account 301.2 285
B-28 Unit Cost Data, Account 301.2 285
B-29 Unit Cost Data, Account 402 286
B-30 Unit Cost Data, Account 403 286
B-31 Labor Force and Equipment Pool,
Account 406.2 286
B-32 Unit Cost Data, Account 406.2 287
B-33 Labor Force and Equipment Pool,
Account 407.2 287
B-34 Monthly Output Data, Account 407.2 288
B-35 Unit Cost Data, Account 407.2 288
B-36 Pumping Equipment and Labor Cost,
Account 406.5 289
B-37 Labor Force and Equipment Pool,
Account 602.3 290
B-38 Unit Cost Data, Account 602.3 290
B-39 Cost for Components of Structural
Concrete, Accounts 701.1 and 701.2 291
B-40 Labor Force and Equipment Pool,
Account 702 291
B-41 Labor Force and Equipment Pool,
Account 703 292
B-42 Labor Force and Equipment Pool,
Account 802.1 (Group 1) 293
B-43 Labor Force and Equipment Pool,
Account 802.1 (Group 2) 293
B-44 Labor Force and Equipment Pool,
Account 802.1 (Group 3) 294
B-45 Unit Cost Data, Account 802.1 294
xin
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No. Page
B-46 Labor Force and Equipment Pool,
Account 802.2 295
B-47 Unit Cost Data, Account 802.2 295
B-48 Labor Force and Equipment Pool,
Account 901.1 (Group 1) 296
B-49 Labor Force and Equipment Pool,
Account 901.1 (Group 2) 296
B-50 Labor Froce and Equipment Pool,
Account 901.1 (Group 3) 297
B-51 Unit Cost Data, Account 901.1 297
B-52 Labor Force and Equipment Pool,
Account 901.2 (Hard Material) 297
B-53 Labor Force and Equipment Pool,
Account 901.2 (Firm or Soft Material) 298
B-54 Labor Force and Equipment Pool,
Account 901.2 (Disposal) 298
B-55 Unit Cost Data, Account 901.2
(Side Cast) 298
B-56 Unit Price Data, Account 902
(Onshore Disposal) 299
B-57 Labor Force and Equipment Pool,
Account 902.1 299
B-58 Unit Cost Data, Account 902.1 300
B-59 Labor Force and Equipment Pool,
Account 902.2 300
xiv
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ACKNOWLEDGMENTS
The authors gratefully acknowledge the cooperation extended
by the following organizations:
Commonwealth Edison Company, Chicago, Illinois
Consolidated Edison Company, New York, New York
Allis-Chalmers, Custom Pump Division, Milwaukee,
Wisconsin
Long Island Lighting Company, Hicksville, New York
Philadelphia Electric Company, Philadelphia, Pennsylvania
Niagara Mohawk Power Corporation, Syracuse, New York
Cleveland Electric Illuminating Company
Pacific Gas and Electric Corporation, San Ramon,
California
Main Yankee Atomic Power Corporation, Westboro,
Massachusetts
Wisconsin Electric Power Company, Milwaukee, Wisconsin
Florida Power Corporation, St. Petersburg, Florida
Consumers Power Company, Jackson, Michigan
Duke Power Company, Charlotte, North Carolina
Detroit Edison, Detroit, Michigan
Tennessee Valley Authority, Chattanooga, Tennessee
Rochester Gas and Electric Company, Rochester, New York
Great Lakes Dredge and Dock Company, Chicago, Illinois
Morrison-Knudsen Company, Atlanta, Georgia
S. J. Grooves Construction Company, Syracuse, New York
Corban Plastics, Tampa, Florida
Beetle Plastics, Dayton, Ohio
Lock Joint Pipe Company, Parsippany, New Jersey
Armco Steel, Denver and Buffalo offices
Bethlehem Steel Corporation, Buffalo, New York
Penn Central Railroad, Buffalo, New York
xv
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ACKNOWLEDGMENTS (cont'd)
A. 0. Smith-Inland Incorporated, Reinforced Plastics
Division, Little Rock, Arkansas
Department of the Army, Corps of Engineers, Buffalo
District, Buffalo, New York
Republic Steel Corporation, Buffalo, New York
U. S. Steel, Buffalo, New York
Clarence Sand and Gravel Corporation, Clarence, New York
xvi
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SECTION I
CONCLUSIONS
This manual enables a person not expertly skilled in cost
engineering to prepare a reasonably accurate estimate of the
costs for new once-through cooling water discharge systems
for thermal electric generating plants and for modifications
to existing once-through discharge systems. Table 1 presents
four cases of modifications to existing discharge systems
and compares actual construction costs and estimates
prepared using traditional, more detailed procedures to
cost estimates prepared using the methodology in this manual.
The results obtained using this manual compare very favorably
with the actual construction costs and estimates shown,
demonstrating that this manual provides a relatively easy
means of preparing a reliable preliminary cost estimate or
testing the accuracy of another cost estimate.
Table 1. COMPARISON OF RESULTS6
Estimated Cost,
Millions of Dollars
Actual Construction Percentage
Plant Manual Cost or Estimate Difference
Quad Cities 8.9 9.2 4
Nine Mile 6.1 5.7 6
Point No. 1
Dresden .12 .12
North Port
Onshore 6.6 6.6
Offshore 14 15 9
Appendix A for an example of the derivation of the
data presented.
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SECTION II
INTRODUCTION
GENERAL
This manual presents a methodology for evaluating the engi-
neering and cost implications of constructing or modifying
once-through cooling water discharge systems of thermal
electric generating plants within the contiguous United
States. The procedures presented provide persons not
skilled in cost engineering with a means of preparing
preliminary cost estimates from conceptual or design
drawings. The user should, however, have a technical back-
ground and be familiar with once-through cooling water
discharge systems.
Principal construction elements of discharge system construc-
tion and modification are identified and grouped into
categories. Materials and installation methods are dis-
cussed for each construction element. Data on labor,
materials, equipment, and productivity assumed in unit cost
development are provided. A step-by-step procedure is given
for:
1. estimation of construction costs and
2. resolution of construction costs into project and
annual costs.
An example is shown using the methodology and comparing re-
sults with actual construction costs for modifications to
an existing system.
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DISCHARGE SYSTEMS AND POSSIBLE MODIFICATIONS
Discharge systems
For the purposes of this manual, once-through cooling water
discharge systems are classified into two categories:
surface discharge and submerged discharge.
The surface discharge category includes two distinct types
of outfalls distinguished by geometry and discharge
velocity:
1. open channel/ characterized by a low velocity
discharge from an open channel into the receiving
water at or close to the shoreline (see Figure 1);
and
2. surface jet, characterized by a high velocity
discharge from a conduit at or near the surface
of the receiving water (see Figure 1).
The submerged discharge category also includes two types of
outfalls:
1. single port, consisting of the open end of a con-
duit or other point source discharging beneath
the water surface (see Figure 2); and
2. multiport diffuser, consisting of a number of
ports or slots arranged along a manifold and
discharging at some depth below the water surface
(see Figure 2).
Discharge modifications
The four basic types of once-through cooling water discharge
systems and possible modifications thereof are shown in
Figure 3 and discussed briefly below:
1. Surface discharge open channel - Possible modifi-
cations include:
a. Surface discharge open channel (improved) -
Increase channel width and install a weir to
spread and thin the thermal plume.
3
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Discharge channel
OPEN CHANNEL
t
Conduit
SURFACE JET
Fig. 1 - Surface Discharges
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SINGLE PORT DISCHARGE
MULTIPORT DISCHARGE
Fig. 2 - Submerged Discharges
5
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Submerged
Multiport
Multiport
Improved
Submerged
Single Port
Surface
Jet
Single
Port
Improved
Surface
Jet
Improved
Submerged
Multiport
Submerged
Single
Port
Submerged
Multiport
Surface
Discharge
„
r
0 H
H EH
C/J CO
< >i
ffi en
Surface
Jet
Surface
Discharge
Improved
P
POSSIBLE
MODIFICA-
TIONS
Submerged
Single
Port
Submerged
Multiport
1
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b. Surface jet - Close off the open channel,
install a conduit with an outfall located
near the water surface and shoreline.
c. Submerged single port - Close off the open
channel, pump the heated effluent via a
conduit or tunnel to a submerged outfall off-
shore.
d. Submerged multiport - Close the open channel,
pump the heated effluent via conduit or
tunnel and discharge the water through a sub-
merged multiport diffuser.
2. Surface jet - Possible modifications include:
a. Surface jet (improved) - Attach a reducer to
the end of the conduit to increase discharge
velocity at the outfall.
b. Submerged single port - Extend a conduit or
tunnel to a submerged offshore point source
outlet.
c. Submerged multiport - Extend a conduit or
tunnel to an offshore submerged location and
discharge the heated effluent via a multiport
diffuser.
3. Submerged single port - Possible modifications
include:
a. Submerged single port (improved) - Increase
the outfall submergence depth by extending
the tunnel or conduit into deeper water
further from shore.
b. Submerged multiport - Attach a multiport
diffuser at the existing outfall point.
4. Submerged multiport - Possible modifications
include changing the diffuser angle of discharge
with respect to prevailing currents or changing
the discharge angle, spacing, number, and diameter
of individual nozzles.
-------
Other types of discharge arrangements are used in once-
through cooling water systems, including modified spray
ponds and cooling ponds. In these systems, heated water is
cooled by evaporation from ponds prior to discharge into the
receiving water via one of the systems discussed above. The
methodology in this manual can be used to estimate costs for
such cooling and spray ponds.
ECONOMIC ANALYSIS - IMPORTANT ENGINEERING AND ECONOMIC
CONSIDERATIONS
Engineering considerations
The reader should be aware that the scope of this manual is
limited to the discharge system downstream of the condenser.
Therefore, engineering considerations for modifications to
existing systems assume flow rate and condenser temperature
rise to remain unchanged.
Discharge system modifications are generally of three types:
1. changes in outfall geometry;
2. changes in orientation of the discharge relative
to predominant ambient currents; or
3. increases in the submergence of the outfall.
Key engineering factors involved in discharge system con-
struction and modification are discussed below.
1. Site preparation - Preconstruction and postcon-
struction site work includes:
a. clearing trees and brush from the site;
b. removal of existing facilities that interfere
with construction; and
c. grading and seeding after construction.
2. Erosion protection - Consideration is given to:
a. lining the outfall channel to prevent bank
erosion due to high discharge velocities;
8
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b. constructing sea walls or bulkheads to
protect shorelines from erosion due to waves,
tides, or wakes; and
c. providing offshore protection, including
riprap at the outfall for scour protection
and breakwaters for protection against waves
or to prevent recirculation between the
discharge and intake.
3. Pumping - Conversion from a gravity system or
increasing velocity at the outfall of an existing
submerged discharge system increases power require-
ments which are met by providing a new pump
station or by modifying an existing station.
4. Conveyance to discharge point - Site geology and
offshore working conditions are primary factors in
deciding between a tunnel or conduit to convey
cooling water in a submerged discharge system.
5. Outfall configuration - Outfall geometry and
orientation and type of diffuser, single port or
multiport, are important considerations.
6. Environmental protection - Consideration must be
given to control of sediment, dust, turbidity,
shock waves, noise, and other pollutants generated
as a result of construction. Provisions must be
made for disposal of materials such as contami-
nated sediments excavated from a lake bed and
trees cleared from the site. Construction methods
and schedules can be adjusted to minimize damage
to sensitive ecosystems.
7. Construction methods - Previous experience in the
area, site characteristics, and contractor
preference will determine construction methods
used. Extreme variability in methods exists in
the area between the shoreline and one-half mile
offshore.
8. Location - Hydrology, geology, and regional and
local weather conditions significantly affect the
factors listed. For example, productivity in off-
shore excavation is dependent on weather, bottom
conditions, distance to safe harbor, and depth of
water.
-------
Economic considerations
Within the discharge system requirements imposed by environ-
mental factors and the limitations of engineering practica-
bility, economic considerations are the ultimate determinant
of final design features. Both total project (first) costs
and annual costs are evaluated.
Total project costs include engineering and design, lands,
construction, supervision and administration, interest
during construction, and contingencies. These costs are
sensitive to several factors that must be considered,
including site specific conditions and construction
materials, methods, and management.
Annual costs include amortization of depreciable and non-
depreciable capital investments, interest on bonds, taxes,
insurance, and operating expenses. The annual cost figure
is sensitive to any changes in initial investment costs and
interest rates and to increased power requirements resulting
from a discharge system modification.
Generally, project costs for a submerged discharge system
are higher than for a surface discharge system, primarily
because of greater expenses for offshore and tunnel con-
struction and because of the need for more materials at
higher unit prices, for example, large diameter conduit.
Annual costs are also higher with a submerged discharge
system, partly because of the greater initial investment,
but also reflecting increased operating costs due to the
need for pumping stations.
10
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ORGANIZATION
The manual is comprised of seven main sections, including
two appendices:
Section I - Conclusions
Section II - Introduction
A general discussion of the general types of once-through
discharge systems and the engineering and economic con-
siderations used in system selection. Possible modifica-
tions to existing once-through discharge systems are dis-
cussed.
Section III - Approach
A general discussion of procedures, assumptions, and bases
for data presented in the methodology. Price levels, con-
tractor markup, unit costs, and categories of construction
elements are also discussed.
Section IV - Methodology
A step-by-step procedure for use of the manual, including
comments on interpretation of results. Technical and cost
data are given for each significant element involved in new
construction and system modification.
Section V - References
Section VI - Conversion Tables
Section VII - Appendices
11
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Appendix A - Case Study
An example showing application of procedures in manual to
an actual case of discharge system modification. The results
obtained using the methodology are compared with actual
construction costs.
Appendix B - Unit Cost Data
Background data for unit costs used in this manual.
12
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SECTION III
APPROACH
GENERAL
The basic step-by-step approach for using this manual to
cost out new once-through discharge systems or modifications
to existing once-through discharge systems is as follows:
Step 1
Select the desired system or modification either on the
basis of information in this manual or other considerations
Step 2
Prepare or otherwise obtain conceptual or detailed drawings
of the proposed system or modification. Cost estimate
accuracy depends largely on the accuracy and amount of
detail in these drawings which, in turn, depend on the
study phase and availability of site information. The
reader should note that although the information presented
in this manual may be useful in system selection, system
design is not within the scope of this manual.
Step 3
From the drawings, calculate the quantities specified in
the methodology and worksheets provided with this manual,
13
-------
Detail and accuracy of quantity take-offs should reflect
the desired accuracy of the cost estimate, but be consis-
tent with the detail and accuracy of the drawings.
Step 4
Derive project and annual costs for the proposed system or
modification by following the procedures recommended in
this manual and applying the appropriate cost factors and
curves.
The manual is organized into eleven cost categories. Cate-
gories 1-10 give unit cost data and a procedure for esti-
mating construction costs. Data for adjusting construction
costs for region and time and for calculating annual costs
are given in Category 11. Definition of the categories and
the elements of each category, cost accounts, are given in
Section IV.
TECHNICAL DATA
Engineering information on once-through discharge systems,
including system components, design features and rules-of-
thumb, and construction practices and phases, was compiled
from the following sources:
1. Analyses of existing discharge system designs
2. Contacts with engineers in the power utility
industry
3. Contacts with capital equipment manufacturers
4. Contacts with civil contractors
5. Company experience.
14
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COST DATA
Unit costs shown in this manual were developed on the basis
of December 1974 labor rates in the New York City area and
capital equipment and material prices and construction equip-
ment rates in the northeast part of the country. Results
are adjusted in Cost Category 11 for price levels in the
region and at the date of interest.
Unit costs for construction activities in Cost Categories
1 through 4 and 6 through 9 were developed using the
following five-step process:
1. Determine or assume site conditions
2. Select the appropriate labor force and equipment
pool
3. Select labor and equipment rates
4. Assume a productivity and calculate the unit
cost
5. Add material unit costs where necessary to deter-
mine the total unit cost.
Information from several sources was considered during the
unit cost analysis:
1. Civil contractors were contacted with regard to
unit costs and labor and equipment requirements
for specific construction activities
2. Published cost data books were reviewed for con-
struction material costs and labor and equipment
rates (see References 1, 2, 3, and 4)
3. Manufacturers were contacted for capital equip-
ment and material costs
4. Power utilities were consulted to determine actual
costs of cooling water discharge systems
5. Bid estimates from over 300 contracts in the
Engineering News Record were surveyed for civil
construction unit cost data to compare with the
unit costs developed for use in this manual.
15
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Contractor equipment costs for operation, maintenance, re-
placement, overhead, and profit were found to agree closely
with equipment rental fees compiled by the Associated Equip-
ment Distributors (Reference 1) plus a markup of 10 percent.
Therefore, for simplicity, the latter method was used in
the development of unit costs for this manual.
It was assumed that capital equipment and materials are
provided by the contractor. The unit cost analysis used
manufacturer-quoted prices for capital equipment (such as
pumps) and some materials (such as conduit). Costs for
construction materials (such as riprap) were derived from
cost data booKS and civil contractors. Capital equipment
and material prices were marked up 15 percent for contractor
overhead and profit.
Labor rates are those recommended in Reference 3 with a
markup of 40 percent for overhead and profit.
The unit cost data for Cost Category 5, Tunnels, were
developed from Robert S. Mayo and Associates in Reference 5
and the Corps of Engineers in Reference 6.
Mobilization and demobilization costs are not included as
part of the unit costs developed for Cost Categories 1
through 9. Instead, they are treated as a separate item
(in Cost Category 10) which is consistent with current
practice for contract bids.
Some of the data required in Cost Category 11 to estimate
annual costs must be obtained from local sources (for
example, costs for lands, licenses, royalties, fees, rentals,
and leases). Potential local sources for this data are
16
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identified. Federal Power Commission annual reports,
References 7 and 8, give data for the cost of power and
cost of capital. The capital cost resolution procedures
were adopted from Capital and Operating Costs of Pollution
Control Equipment Modules - Volume 1 - User Guide (Reference
9).
Labor and equipment costs, production rates, and material
costs used to develop unit costs for categories 1 through
4 and 6 through 9 are tabulated in Appendix B.
The relationship between quantity and installation unit
cost is dependent largely on mobilization and demobiliza-
tion costs and the size of the equipment required on the
job site. Equipment selection, as it relates to job size,
is given in Appendix B and mobilization and demobilization
costs can be estimated from data in Category 10. Material
prices will also vary with the quantity required for the
project. Material prices used in this study are averages
and may be conservative for very large projects and low
for very small projects.
VERIFICATION
To test the validity of the unit cost data and methodology
in this manual, cost estimates were prepared for modifica-
tions to four existing once-through discharge systems and
compared to the actual construction costs or contract bids.
The results of the comparison are shown in Table 1.
17
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SECTION IV
METHODOLOGY
COST CATEGORIES
As described briefly in the previous section, the methodology
in this manual is based on dividing the construction or
modification of a once-through discharge system into eleven
cost categories (representing major components and construc-
tion phases). The first ten categories reflect major con-
struction phases and design features involved in building
and modifying once-through discharge systems. These ten
categories are broken down into elemental construction ac-
tivities and system components. When applying the procedures
in this manual to a specific case, quantity take-offs and
cost estimates are prepared for each applicable category
element. The eleventh cost category includes cost adjustment
techniques and procedures to estimate annual costs. The
eleven cost categories are as follows:
1. Category 1, Site Preparation - Preparing the site
for construction and restoring the site after
construction.
2. Category 2, Erosion Protection - Providing shore-
line protection, channel lining, and breakwaters
constructed of riprap, concrete, and sheet pilinc.
3. Category 3, Pumps - Modification of existing pump
station or installation of new facility.
4. Category 4, Conduits - Materials and installation
of various types of conduits.
5. Category 5, Tunnels - Elements of tunneling in
consolidated and unconsolidated materials, in-
cluding excavation, lining, support systems, and
dewatering.
6. Category 6, Diffusers - Materials and installa-
tion of submerged diffusers.
7. Category 7, Concrete - Material and placement of
concrete.
18
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8. Category 8, Fill - Materials, hauling, and place-
ment of earth, gravel, and sane?.
9. Category 9, Excavation - Marine and land open-cut
excavation; disposal of earth and rock spoil.
10. Category 10, Mobilization - Mobilization and de-
mobilization costs.
11. Category 11, Capital Cost Resolution - Procedures
to adjust project costs for region and time; cal-
culation of annual costs, including resolution of
project costs and estimation of other annual
expenses.
COST ACCOUNTS
Each of the eleven cost categories is broken down into
elemental system components and construction activities
(called cost accounts). For example, Cost Category 4,
Conduits, consists of the cost accounts shown in Table 2.
Cost accounts represent the limit of detail used in this
manual for estimating costs. Each cost account is pro-
vided with a worksheet giving step-by-step instructions
for computing the cost for that particular account. In
most cases, the worksheets are similar to that shown in
Figure 4, with instructions specifying the design data and
quantity take-offs required, the proper unit cost to use
or cost graph to refer to, and any cost adjustments that
are necessary to compute the final cost for that particular
cost account. In some cases, the worksheet instructions
direct the reader to use one or more other cost accounts in
19
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specified cost categories to compute the cost. Referencing
other cost accounts in this manner avoids duplications of
cost accounts, such as those involving excavation, which
are common to several cost categories.
Table 2. COST ACCOUNTS FOR
COST CATEGORY 4
Cost Account
Number
401
402
403.1
403.2
404
405
406.1
406.2
406.3
406.4
406.5
407.1
407.2
407.3
407.4
407.5
407.6
408
409
Description
Precast concrete pipe
Cast-in-place box conduit
Steel conduit
Steel conduit fittings
Corrugated metal pipe
Fiberglass pipe
Onshore excavation of pipe trench
Onshore pipe laying
Onshore backfill of pipe trench
Pipe support systems
Dewatering
Offshore excavation of pipe trench
Offshore pipe laying
Offshore backfill of pipe trench
Pipe support systems
Riprap protection for backfill
Cofferdam
Other
Mobilization
Cost accounts and corresponding worksheets and cost graphs
are given the same identifying number to avoid any confusion,
For example, Cost Account 403.1 uses Worksheet 403.1 and
Figure 403.1. Similarly, Cost Account 406.5 uses Worksheet
406.5. However, since this worksheet instructs the reader
to use another cost account for the cost computation, a
separate figure is not provided for Cost Account 406.5.
20
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Design Data Required
Pipe diameter m
Wall thickness cm
With or without stiffeners
Pipe length L = m
Shop or field fabrication
Base Cost
Enter Figure 403.1, read base BUG =$ /m
unit cost per lineal meter
Base cost = L x BUG BC =$
Cost Adjustments
adjustment factors for wall F ,«.
thickness, stiffeners and D
Enter Figure 403.1, read design
adjustment
thickness,
fabrication
Adjusted Base Cost
Adjusted base cost of materials
and fabrication = BC x Fn(l) x
FD(2) x FD(3) BC403.1
aFor diameters to 3.05 meters, assume shop fabrication,
Fig. 4 - Sample Worksheet - Carbon Steel Pipe,
Worksheet 403.1
21
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It is recommended that the reader prepare the cost estimate
for a new or modified discharge system by using the cost
categories in numerical order. This minimizes the chances
for overlooking or, more likely, double-counting certain
items. For example, if the reader uses Cost Category 8,
Fill, before Cost Category 4, Conduits, he might cost out
fill operations involved with conduit installation; and later,
when he uses Cost Category 4, he might inadvertently dupli-
cate these same costs.
The reader may find it necessary to use cost accounts more
than once. As previously mentioned, this frequently occurs
with certain accounts, such as those involving backfill
operations, which are common to several construction ac-
tivities. Multiple use of cost accounts occurs under other
circumstances as well, such as changes in conduit diameter
or changes in the type of material being tunneled which alter
design data input.
STEP-BY-STEP PROCEDURE
The following paragraphs present a step-by-step description
of this manual's cost estimating methodology. The procedures
described below are those required to complete steps 3 and
4 of the basic approach which were discussed in the pre-
vious section. Examples are provided to illustrate the
procedures involved; and comments are inserted to aid the
reader's understanding and to point out notable exceptions.
The general procedures for Cost Categories 1 through 9
are covered in steps 1 through 6 below. It is recommended
that the reader complete this entire 6-step sequence for
each cost category before proceeding to the next category
and that the reader handle Cost Categories 1 through 9 in
22
-------
numerical order. Inputs for Categories 10 and 11 are based
on results from Categories 1 through 9 and do not follow
the general procedures described in steps 1 through 5.
Accordingly, the discussion of procedures for Categories
10 and 11 begins with step 6.
Step 1
Survey the cost accounts in the cost category being evalu-
ated, selecting those accounts which apply to the proposed
system or modification.
Note that cost accounts in Cost Categories 7 through 9 are
used primarily as inputs to accounts in Categories 1 through
6 and generally are not applicable in and by themselves.
For our example, assume that all estimates for Cost Cate-
gories 1 through 3 have been completed and that in survey-
ing Cost Category 4, Conduits, Cost Account 403.1 is one of
the accounts identified as applicable.
Step 2
For each applicable account, pull out the corresponding
worksheet.
Remember that cost accounts and corresponding worksheets
and cost graphs have the same identifying number. Worksheet
403.1, which corresponds to Cost Account 403.1, is shown in
Figure 4.
23
-------
Step 3
In the spaces provided on the worksheet, enter the design
data required.
The data required, such as volume and type of material ex-
cavated, tunnel diameter and length, concrete volume and type
of reinforcing, is obtained from the drawings discussed in
the previous section in steps 2 and 3 of the basic approach.
Some worksheets provide guidelines or rules of thumb to use
in cases where the design data required are not readily
available.
In our example, we assume all necessary design data are
available and are entered as shown in Figure 5.
Design Data Required
Pipe diameter
Wall thickness
With or without stiffeners
Pipe length
Shop or field fabrication
m
I . Z 7
cm
L = 58o
m
For diameters to 3.05 meters, assume shop fabrication
Fig. 5 - Design Data Required
for Worksheet 403.1
24
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Step 4
Determine the base cost following the instructions on the
worksheet.
In some cases, the worksheet provides the unit cost, which
is simply multiplied by the quantity involved to compute
the base cost. In other cases, the worksheet references a
cost graph from which the base cost is read directly or
from which a unit cost is read and then multiplied by the
quantity involved to get the base cost.
As shown in Figure 6, Worksheet 403.1 references the
corresponding Figure 403.1 (shown as Figure 7) from which
we read a base unit cost of $l,550/meter for a pipe diameter
of 3.05 meters. This base unit cost is multiplied by the
length of pipe to get the base cost.
Base Cost
Enter Figure 403.1, read base unit BUG =$ // £60 /m
cost per lineal meter
Base cost = L x BUG BC =$
Fig. 6 - Base Cost Computation
on Worksheet 403.1
Step 5
Apply design adjustment factors to the base cost to deter-
mine the adjusted base cost.
25
-------
$100/meter
BASE UNIT COST
to
Ul
hJ
O
I-1
(Jl
M
O
5S
4
frH-ft-.-C'
^i [IH
H
i4
Ftrrt
44
r—L
1/1 I I I
fi
-t-4-H-
ffi
m
' "
rH-;
Ftt
£
ft
INSIDE DIAMETER, meters
Thickness (cm): .635 .953 1.27 1.588 1.905 2.22
Factor PD(1): -50 .75 1.0 1.25 1.5 1.75
With Stiffeners, FD(2)
Shop Fabrication, F
=1.6
= >65
Fig. 7 - Cost Graph Corresponding to
Cost Account 403.1 and Worksheet 403.1
26
-------
Design adjustment factors are provided where variations
in parameters, such as component geometry or type of
material to be excavated or tunneled, result in significant
cost differences. Some cost accounts do not require such
adjustments. In these latter cases, the base cost calculated
in the step 4 above is the value of interest.
In our example, Worksheet 403.1 (see Figure 8) instructs
the reader to obtain design adjustment factors from Figure
403.1 (see Figure 7) and to multiply the base cost by these
factors to get the adjusted base cost.
Cost Adjustments
Enter Figure 403.1, read design Fn ^ ~ /. O
adjustment factors for wall F (2) = If
thickness, stiff eners, and D - '-*-&
type of fabrication Fn ^ = Q,
Adjusted Base Cost
Adjusted base cost of materials
and fabrication = BC x Fn(l) x
FD(2)xFD(3) D BC4Q3.1
Fig. 8 - Cost Adjustments on Worksheet 403.1
Step 6
Enter the adjusted base costs (or base cost if no adjustments
are required) on the cost category cost summation worksheet
and determine total cost for category being evaluated.
27
-------
Remember that cost accounts in Cost Categories 7 through 9
are primarily used as input to cost accounts in Cost
Categories 1 through 6 and generally are not applicable in
and by themselves. Consequently, it is unusual to use cost
summation worksheets for these three categories. For Cost
Categories 1 through 6, the adjusted base costs are entered
and summed with the exception of cost accounts for mobiliza-
tion and demobilization which are entered and totaled on
the Cost Category 10 (Mobilization) summary worksheet.
In our example, the adjusted base cost for Account 403.1 is
entered on the Category 4 Cost Summation worksheet (see
Figure 9) along with all other applicable accounts. These
values are summed to get the total cost for this category.
The mobilization costs for Category 4 are entered in the
Category 10 summary worksheet (see Figure 10) and summed
with mobilization and demobilization costs for all other cost
categories to derive the total base cost for Category 10.
Step 7
Compute the regional and time adjustment factor and deter-
mine the revised total construction cost following the in-
structions in Category 11.
The total costs for Categories 1 through 10 are entered on
Worksheet 1101 (see Figure 11). The sum of these entries
is the total construction cost which must be adjusted for
the region of the country where the plant is located and
the date construction is expected to begin or the price
level of interest. The reader notes the regional adjustment
factor for the city nearest the plant site and determines
28
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Cost
Account
Number
401
402
403
403.1
403.2
406.2
406.3
406.4
406.5
'~V_ -
408
Cost Cat(
(Enter (
409
Worksheet 400
Description
Precast concrete pipe
Cast-in-place box
culvert
Steel conduit
Steel pipe
Steel fittings -.^
Onshore pipe laying
Cushion fill and
backfill
Pipe supports
Dewatering
L- - • • -^-^ ~-\__ v__ —
— — -— "- ->— -~, — ~-^~ v_^— ~
Other
agory 4 Total Cost
:ost in Account 1101)
Mobilization (Enter
Cost in Account 1001)
Base Cost
BC =S -
BC. , =$ —
BC403.2=$ 7(*,t)M>
BC40f -^$378,6>oo
BCIO 3=$ l7tO
BC4 4=$ S\0f ZZO
Bc4 c=$ Zl, loo
BC =$ —
BC4 =$!,$<.?, MO
MC, =$l*L,fi*0
Fig. 9 - Sample Cost Category,
Cost Summation Worksheet
29
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Worksheet 1001
Data Requirements
Cost Category Mobilization
Number Cost
= $ 2 &, ts>OO
2 MC = $
3 MC3 = $ ^f O,OOC>
4 MC4 = $ UL.OOO
5 MC5 = $ ^_
6 MC, = $ 5% OOP
D
7 MC? = $
8 MC8 = $_
9 MCg = $_
Base Cost
Fig. 10 - Cost Category 10 Summation Worksheet
the Engineering News Record (ENR) Construction Cost Index
(CCI) for the price level of interest or for the date con-
struction is expected to begin. For instance, if a cost
comparison is desired with an estimate based on price levels
prevailing at some past date, the reader can look up the CCI
in an issue of the ENR corresponding to that date or refer
to Figure 1100 (shown as Figure 12 in this example), a graph
30
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of the CCI for the period 1969 to 1974. If construction is
to start at some future date, the reader must project the
CCI perhaps by extrapolating Figure 1100.
In our example, we assume Minneapolis and January 1976 as
the place and start of construction. Figures 11 and 12 show
the appropriate entries, CCI extrapolation, and computations
to derive the revised total construction cost.
Step 8
Calculate the total project cost following the instructions
given in Cost Category 11.
Project costs include all first costs less any cost incurred
for a temporary power outage during the switch over to a
modified discharge system. Figure 13 shows the computations
required on Worksheet 1102 to derive the project costs. If
the percentage of total construction costs for engineering
and general and administrative items is not known, a value
of 10 percent may be assumed. There are no rules-of-thumb
for land-related costs. In cases where a discharge system
modification is being considered, the utility might already
have the necessary lands, easements, and rights-of-way. In
cases where a new system is being considered, these items
might not have been acquired. In this latter situation, real
estate appraisals might be necessary. The contingency fac-
tor varies with the detail and accuracy of the data available,
For estimates based on detailed and reliable drawings, a
contingency of 5 percent might suffice; for a planning-type
estimate based on conceptual drawings, a 25-percent contin-
gency is acceptable.
31
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Worksheet 1101
Data Requirements
Regional adjustment factor:
Atlanta - .79 Kansas City - .90
Baltimore - .84 Los Angeles - .90
Birmingham - .73 Minneapolis - .85
Boston - .90 New Orleans - .78
Chicago - .91 New York - 1.00
Cincinnati - .95 Philadelphia - .90
Cleveland - .94 Pittsburgh - .89
Dallas - .77 St. Louis - .89
Denver - .80 San Francisco - .94
Detroit - .93 Seattle - .85
City nearest to construction area
Regional adjustment factor FR = Q. gfT
Date construction is to begin or
period of price level being
considered
Engineering News Record ENRX =
Construction Cost Index
for above date (20-city avg.)
Time adjustment factor = FT =_
ENRX ( ) v 2097a
Regional and time adjustment FR(_ = Q. 132-
factor = FT x FR
aThe Engineering News Record 20-city average for
December 12, 1974.
Fig. 11 - Example of Computations for Regional
and Time Adjustment of Construction Cost
32
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Worksheet 1101
Data Requirements (Cont'd)
Total costs from Categories 1 through 10
= $ /k3, 33£>
BC3 = $ g?7, 700
BC4 = $ 1.
BC5
BC7 = $ ~
BC8
BCIO
j Total Cost = E (BC-L through BC1Q) BCT = $ 3V 7/3,700 \
Revised Construction Cost
Total cost = BCT x FRT BC1101
Fig. 11 - Example of Computations for Regional
and Time Adjustment of Construction Cost
33
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2500i
0)
&
id
M
s
(0
4J
O
O
*^
w
EH
CO
O
O
2
O
H
EH
I
EH
W
§
U
120 Or- -'-
1969 1970 1971 1972 1973 1974 1975 1976 1977 1978
DATE
Fig. 1100 - ENR 20-City Construction Cost Index
Fig. 12 - Example of Extrapolating to Future Start
of Construction Data
34
-------
Worksheet 1102
Data Required
Total construction cost
| Cost for engineering and
general and administrative =
'" * X BC110la
Cost for lands, easements, and
rights-of-way
Revised cost = BC
+ BC
+ BC
Adjustment for contingencies =
(1 + 5%/100%) x BC-L
Adjustment for escalation during
construction = BC2 x
ENRX (beginning) + ENRX (end)
2 x ENRX (beginning)
Adjustment for interest during
construction0 = BC3 x
(1 + no.yrs. of construction x
annual interest rate/100%) =
BC3 x (1 + J^ x ^ %/100%)
Royalties, licenses, fees, etc.
Total Project Cost = BC4 + R
BC
1101
BCE "
BC = $ Hit
BC, = $ 3/ff/g, 217
-1 ^
BC = $ V/ //¥/
BC = $^2.37/
BC. = $
f 0/3
R = $ "JO i OOP
BC
H02
Assume 10 percent if detailed information is not
available.
With detailed information, use a factor of 5 percent;
for a planning estimate use 25 percent.
c
See account discussion.
_ _^ _ _
Fig. 13 - Computation of Total Project Costs
35
-------
The adjustment for cost escalation during construction is
based on the average CCI for the construction period. If
the purpose of the estimate is a cost comparison with another
estimate based on a fixed price level, this adjustment is
not necessary. However, if a period of construction in the
future is specified, this adjustment will require CCI pro-
jections. The adjustment for interest during construction
is based on the assumption that interest is paid during the
entire construction period on the entire amount of capital
needed for the project. Costs for royalties, licenses, and
other one-time fees are small and may be assumed to be
negligible if figures are not readily available.
In our example, as shown in Figure 13, we assume a value of
10 percent for engineering and general and administrative
items; $111,000 for lands, easements, and rights-of-way; 5
percent for contingencies; CCI's for a one-year construction
period beginning in January 1977 (see Figure 12 for the ex-
trapolation of CCI values); 9 percent for the interest rate;
and $20,000 for royalties and other fees.
Step 9
Compute costs due to temporary power outage during switch-
over to a modified discharge system.
If a plant shutdown is necessary during the switchover,
the power is assumed to be purchased from other members of
the regional power grid.
In our example, a 750-megawatt plant with a capacity factor of
0.66 is assumed to be shut down for one week (See Figure 14).
The unit cost for power is assumed equal to $0.021/kwh(replacement
power) minus $0.018/kwh (production expenses) or $0.003/kwh.
36
-------
Worksheet 1103
Data Required
Period of outage T = / _ weeks
Power generation losses P = 8^000,000 kwh
= [capacity x outage period
x capacity factor]
Unit cost of power U = G. QQ3 $/kwh
= purchase cost - normal
production expenses
Outage Cost
T x P x U = BC
1103
Fig. 14 - Computation of Power Outage Costs
Step 10
Compute annual costs by resolving first costs and estimating
other annual expenses using the procedures recommended in
Cost Category 11.
As shown in Figure 15, annual costs include amortization of
the investment using the sinking fund method of deprecia-
tion; interest on the bond issue; rental and leasing costs;
operating expenses, assuming the only significant operating
expenses are those associated with pumping costs; insurance;
and property taxes; less tax credits for installation of
37
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capital equipment. Rules-of-thumb are provided for estimating
several of these items.
In our example, we assume the power plant to be 25 years
old at the time of modification, leaving a period of 15
years till the end of the assumed 40-year useful plant life.
This establishes the amortization period for the new invest-
ment. We assume our sinking fund earns an annual return of
8 percent and use the table of sinking fund factors pro-
vided. The salvage value of the new investment 15 years
hence is assumed to be $500,000. The computations involved
in amortizing the investment are illustrated in Figure 15.
Interest on the investment is calculated assuming the bond
issue must finance all first costs, including the cost for
a power outage during switchover. Costs for renting or
leasing equipment or processes generally may be regarded as
negligible.
Pumping costs are the only operating costs assumed to be
significant in this analysis. We use the recommended values
of 65-percent efficiency and $0.018/kwh. We also assume
an average downtime of one month per year in determining
the annual operating hours.
Insurance and property taxes on the new investment are
calculated using the recommended percentage values. The
tax credit computation assumes a straight line depreciation
and the income tax rate recommended on the worksheet.
38
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Worksheet 1104
1. Amortization of depreciable capital investment and
costs for power outage, royalties, etc.
Useful Life Sinking Fund Factor,
Years Annual Interest Rate
ii 12%
3 .30803 .29635
5 .17046 .15741
7 .11207 .09912
10 .06903 .05698
13 .04652 .03568
15 .03683 .02682
18 .02670 .01794
22 .01803 .01081
25 .01368 .00750
28 .01049 .00524
30 .00883 .00414
35 .00580 .00232
40 .00386 .00130
Remaining useful life of the plant Y = /£" _ yrs
Sinking fund factor (tabulated F =
above) for annual interest
rate of
Total project (first) cost BCno2
Salvage value S = $
Land costs L = $ ////
Royalties, fees, licenses, etc. R = S
Depreciable capital investment DC = $ ,00$ O13
BC1102 "
Power outage costs BC1103 = $ 2S2/ OOP
Fig. 15 - Sample Computation of Annual Costs
39
-------
The amount amortized is = D = $ Jjf "2 &0,
depreciable capital investment
+ power outage costs +
royalties, fees, etc.
[Dc + BCiios + Rl
Annual cost = F x D C = $
2. Amortization of the non- NC = $ /&/
depreciable capital invest-
ment (F x S) . Nc is a
credit (see No. 9 below) .
3. Interest on the capital invest- B = _
ment. Bond interest rate
Interest payment = B%/100% x I = $
(BC1102 + BC1103)
4. Rent or lease costs L = $ —- - '
Operating costs. Power re-
quired in excess of the power
required before the addition
or modification
= Theoretical Power ^ efficiency
watts x 100%/fefT %
pe = /477 W
Annual operating hours H = 8,D:£O _ hrs
4
Power costs = H x Pg x G.Q/& /kwha Z = $ /33<
6. Insurance (BC1102 ~ L - R) x I = $ /&£>,
y %b/100%
7. Property taxes (BC1102 - L - R) Pfc = $ 9*>t I t>O
x Z. %c/100%
8. Tax credit
Income tax rate I_ =
K
Fig. 15 (continued) - Sample Computation of Annual Costs
40
-------
Worksheet 1104
Methods of depreciation:
a. Straight line depreciation
Tax credit =
Dc x IR%/(100% x Y)
= $
b. Others (refer to tabulation below)
DR
Year (deprec. rt.)
D
Tl =
9. Annual costs = £ (C - N,
Ti
(annual)
increments of
depreciation)
P -
Assume $.018/kwh
DAssume 4 percent
t
'Assume 2 percent
Assume 48 percent
2Refer to a depreciation schedule
for DR for other than straight
line depreciation
If efficiency is not known,
assume a value of 65 percent
Fig. 15 (continued) - Sample Computation of Annual Costs
41
-------
INTERPRETATION OF RESULTS
Cost data presented in the methodology were developed
assuming average conditions. Therefore, the user should
not expect results from this manual to be identical with a
detailed bid estimate. Also, items not specifically in-
cluded in this tabulation of data, but which would fall
into the "other" cost account of each category might sig-
nificantly affect the cost. To further complicate the
situation, present inflationary trends make estimating for
any type of construction rather speculative, necessitating
practically a weekly update to achieve accuracy and currency.
Retrofitting involves both marine and land-based construc-
tion. Costs for construction along the land-shore interface,
i.e., the littoral zone are extremely difficult to accurately
predict. Tunneling costs are also very difficult to fore-
cast because of factors such as variable subsurface conditions
and seepage rates.
A June 20, 1974, article in the Engineering News Record
reported the results of a survey of types of estimates and
compared results with actual construction costs. Seventy-
six reported an accuracy of +6 to -4 percent using complete
quantity take-offs. The sample was primarily for construc-
tion on land where construction costs are generally more
consistent than for marine work. Therefore, for the types
of construction considered in this study, the accuracy to
be expected for a detailed estimate should be somewhat less.
The user can expect an estimate developed using the method-
ology in this manual to be in the range of ± 15 percent
when detailed site data is provided.
42
-------
COST CATEGORY 1,
SITE PREPARATION
Information on razing existing facilities, clearing and
grubbing the site, and site grading is included. Data on
hauling materials with a truck are also included. Specific
data for each account are given in the following paragraphs.
Riprap removal, Account 101
Key parameters to consider in removing riprap are the size
of the stone and where the material is located. The data
presented here do not consider offshore relocation. In
almost every case, hauling the material from the site is
not a viable consideration. However, hauling costs are
provided in Account 108.2. It was assumed a crane with a
clam shell would be used to excavate the material.
Concrete slab removal,
Account 102
The key parameters are slab thickness, reinforcing and
access to the slab. Removing a section of a slab used
for erosion protection along the shoreline or in a channel
are examples of this activity. The maximum slab thickness
considered is in the range between 30 and 45 cm. Rates of
production vary according to the following conditions:
1. Reinforcing
2. Thickness .
The data are for slabs with relatively easy access. The
unit cost was developed assuming a crane rigged with a
headache ball is used to break the slab. The same crane
43
-------
is then rigged with a clam bucket for removal and piling
or loading the material onto a truck. Reinforcing is
cut with an acetylene torch.
Concrete removal (nonslab),
Account 103
The key parameters are the quantity of reinforcing and
access to the structure. Blasting is one method to remove
the more massive type concrete structures. Plant safety
requirements place restrictions on blasting near the
plant, and in some cases, it may not be allowed. Cost
data were developed for demolition of reinforced and non-
reinforced concrete by blasting. Concrete foundations,
walls and ground slabs greater than 45 cm thick are samples
of the types of structures considered in this account.
Steel sheet piling removal,
Accounts 104.1 and 104.2
The key parameters are the depth of penetration, access to
the piling and the condition of the material. The material
may be salvaged for scrap or reused depending on the con-
dition of the material. The productivity is related to the
depth of penetration. The piling is removed with an ex-
tractor rigged on a crane. Data presented do not reflect
removing a sheet pile structure requiring considerable
labor efforts to ready the piling for extraction.
44
-------
Clearing and grubbing,
Account 105
Key parameters to consider in the clearing and grubbing
operation are the density of the vegetation and the type
of disposal. It was assumed that the material would be
disposed of on site. Larger materials are sawed and buried.
The brush and branches are chipped and used as mulch.
Reseeding, Account 106
The key parameters are the seeding method and the material
costs. Cost data reflect minimum site preparation and re-
seeding of the disturbed areas.
Site grading, Account 107
The key parameters are the area, depth of fill, and cost
of imported borrow. Data for dumping and spreading the
material are given in Cost Category 8.
Hauling, Accounts 108.1 and 108.2
Key parameters are the haul distance, capacity of the truck,
type of road and material hauled. Data reflect hauling
rock or earth over a paved road to the disposal area.
Unit costs were developed assuming two 7.6 cubic meter
trucks would haul rock or earth 3.22 kilometers (2 miles)
to the dump. For hauling materials, more than 3.22
kilometers, costs will increase $.50/m /kilometer; over
45
-------
3.22 kilometers; for broken concrete and rock and $.30/
m3/kilometer for earth. The base unit cost for hauling
slabs is based on the rate for hauling broken concrete.
In calculating the costs for hauling slabs, it was assumed
the slab would increase in volume 25 percent when broken.
Dump operations are included for material disposal.
A suggested round-trip haul distance is included on each
worksheet where hauling costs are appropriate. It was
assumed the disposal area would be closer (given here as
8 km) than a borrow site or quarry (given here as 18 km).
Although, 8 kilometers for hauling materials from the site
is within the range of values presented in reference 2,
the values suggested here are somewhat arbitrary. When-
ever possible, local conditions should be assessed to
determine hauling costs.
Mobilization, Account 110
Unit prices do not include mobilization and demobiliza-
tion (referred to as mobilization) costs. The user adds
the mobilization costs for each account that is used in
calculating the total Category costs. A discussion of
mobilization costs is given in Category 10.
Table 3 presents the correlation between cost account
number, worksheet, and figure number. Costs are cal-
culated using the procedure outlined in the introductory
remarks to this section and the worksheets in Tables 4
through 15.
46
-------
Table 3. SITE PREPARATION COST ACCOUNTS
Cost
Account
Number
Description
Figure
Number
Worksheet
Number
101
102
103
104
104.1 1
104.2
105
106
107
108
Riprap removal: Costs
for excavation and
sidecasting material.
Concrete slab removal:
Costs include break-
ing and sidecasting
the debris.
Concrete removal (non-
slab) : Costs include
breaking and side-
casting the debris.
Steel sheet piling
removal.
Pulling costs to remove
sheet piling and stock
pile on site.
Salvage credit for sheet
piling removed.
Clearing and grubbing
costs.
Costs for reseeding.
Site grading: Costs for
cut and fill opera-
tions;
hauling, and spreading
topsoil. (See Cost
Category 8)
Eauling: Costs for
hauling materials.
102
101
102
103
103
105
104.1
104.2
105
106
107
47
-------
Table 3 (continued). SITE PREPARATION COST ACCOUNTS
Cost
Account i
Number j Description
Figure
Number
Worksheet
Number
108.1 ! Hauling costs for trans-
porting debris from
breaking slabs.
108.2 Hauling costs for earth,
rock, and broken
concrete.
]
109 i Other.
110 Mobilization costs.
108.1
108.2
108.1
108.2
109
110
Table 4. COST CATEGORY 1
COST SUMMATION
Worksheet 100
Cost
Account
Number
101
102
103
104
104.1
104.2
105
106
I
Description
I
Riprap removal BCioi
Concrete slab removal BCio2
Concrete removal BCi m
(nonslab)
Sheet pile removal J
Pulling costs BC104
Salvage credit BSC, _.
; Clearing and grubbing BCios
Reseeding j BC. nfi
Base
Cost
= $
—
—
1 ~
,= (-)
=
48
-------
Table 4 (continued). COST CATEGORY 1
COST SUMMATION
Worksheet 100
Cost
Account
Number
107
109
Description
Site grading
Other
Base
Cost
^107 =
BC109 =
Cost Category 1 Total Cost (Enter
cost in Account 1101)
BC-
= $
110
Mobilization (Enter Cost
in Account 1001)
MC,
= $-
Table 5. RIPRAP REMOVAL
Worksheet 101
Design Data Required
Haul distance to disposal site
(round trip)3
Volume of riprap
V =
_km
3
m
Base Cost
Base cost for excavating riprap =
$5.40/m3 x V
Enter figure 108.2, read base
unit cost for rock haul and
disposal
Base cost for haul and disposal
of riprap = V x BUG(2)
Total base cost = BC(1) + BC(2)
BC(1) =
BUG (2) =$
BC(2) =$
BC,
'101
= $
If haul distance is not provided, assume 8-km round trip.
49
-------
Table 6. CONCRETE SLAB REMOVAL
Worksheet 102
Design Data Required
Haul distance to disposal site
(round trip)a km
Slab thickness cm
Type of reinforcing
(non-reinforced, reinforced)
o
Slab area A = m
Base Cost
Enter Figure 102, read base cost for
breaking slabs and sidecasting
debris BC(1) =$
Enter Figure 108.1, read base unit
cost for haul and disposal of
broken slab BUG (2)=$ /m
Base cost for haul and disposal =
A x BUG (2) BC (2) =$
Total base cost = BC(1) + BC(2) BC =$
102 —
If haul distance is not provided, assume 8-km round trip,
50
-------
Table 7. CONCRETE REMOVAL (NON-SLAB)
Worksheet 103
Design Data Required
Haul distance to disposal site
(round trip)a km
Reinforcing (nonreinforced or
reinforced)
3
Volume of concrete V = m
Base Cost
Enter Figure 103, read base cost for
breaking concrete and sidecasting
debris BC(1) =$
Enter Figure 108.2, read base unit
cost for haul and disposal of con-
crete debris BUG (2) =$
Base cost for haul and disposal
of concrete debris BC(2) =$
Total base cost = BC(1) +
BC(2) BC103
If haul distance is not provided, assume 8-km round trip,
51
-------
Table 8. SHEET PILING REMOVAL
PULLING COSTS
Worksheet 104.1
Design Data Required
Average depth of penetration D = m
Lineal meters of sheet piling L = m
Base Cost
2
Penetration area = D x L m
Base cost for pulling sheet piling =
A x $20.50/m2 BC104 1 =^
Table 9. SHEET PILING REMOVAL
SALVAGE VALUE
Worksheet 104.2
Design Data"Required
Type of steel sheet piling,
weight per unit area W = kg/m
2
Area of steel sheet piling A = m
Base Salvage Credit
Base salvage credit = W x A x
$330/kg BSC104.2
52
-------
Table 10. CLEARING AND GRUBBING
Worksheet 105
Design Data Required
Type of clearing and grubbing
(light, medium or heavy)a
2
Area of clearing and grubbing m
Base Cost
Enter Figure 105, read base cost
RC =S
^105 -
Light - trees to 6-inch diameter.
Medium - trees 6- to 10-inch diameter.
Heavy - trees 10- to 16-inch diameter.
Table 11 . RESEEDING
Worksheet 106
Design Data Required
2
Area of reseeding A = m
Base Cost
Base cost = A x $0.37/m2 BC, nc- =$
±(Jb —
53
-------
-------
Table 12. SITE GRADING
Worksheet 107
Base Cost
Refer to Cost Category b and 9 for
appropriate cost accounts and cost
estimating procedures.
Base cost = E (appropriate BC107 ~—
base costs).
Table 13. HAULING
Worksheets 108.1 & 108.2
Costs for these accounts are incorporated within other
cost accounts as appropriate.
Table 14. OTHER
Worksheet 109
Base Cost
Include costs not covered in this
Category but that relate to Site
Preparation. Data presented in
other accounts may be useful in
estimating "Other" Costs. BC109
54
-------
Table 15. MOBILIZATION
Worksheet 110
Data Requirement
Cost Account Mobilization
Number Cost Summationa
101 Add $3,300 for any one
102 of these accounts and
103 $6,600 if tv/o or more
104.1 are used
105 $ 700
106 $400 \
107 See Cost Cat. 8
108a $ 600
Mobilization Cost
Mobilization = the total of the
summation column (above) MC =$
1 ~
a
Add mobilization for hauling if accounts 101, 102, 103 or
106 arc used.
55
-------
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58
-------
COST CATEGORY 2, EROSION
PROTECTION MEASURES
Data on the materials and installation of riprap, concrete,
steel piling and piles are included. The emphasis is on the
application of the materials to erosion protection. How-
ever, data for steel sheet piling and piles apply to excava-
tion shoring and cofferdams. Specific data for each account
are given in the following paragraphs.
Placement of riprap (land-
based) , Account 201.1
Key parameters are the size and availability of the material.
Riprap is used in applications such as channel lining, and
sea walls (protection along a lake shore). Riprap can also
be used to construct a rubble mound breakwater which is a
rock dam extending off shore used to dissipate wave energy.
Another application of a breakwater is to separate the dis-
charge plume and intake structure for the plant to prevent
recirculation. Riprap protection is placed in layers in-
creasing in particle size from the earth to the outer face.
The gradation prevents leaching and erosion of the soil
beneath the riprap blanket. The stone sizes are grouped
into three types:
1. Filter - A gravel filter used beneath the riprap
stone. (Assume thickness is equal to one half the
stone size) •
2. Riprap stone - Stones less than 1 cubic meter
(assume a thickness equal to 0.6 meters).
3. Cover stone - Individual stones of about 10 cubic
meters volume.
Local availability will effect the material price and hauling
costs for riprap. In many areas inland and along the east
coast, riprap must be hauled from distances of hundreds of
59
-------
kilometers. A haul distance of 18 kilometers is given as a
basis for estimating the contribution of hauling to riprap
costs. However, when possible the user should consult
local sources for information.
The smaller stones can be placed by dumping the material
from the truck on the slope with a minimum of spreading.
The cover stones are usually placed one at a time using a
crane and a cable sling.
Placement of riprap
(marine), Account 201.2
Key parameters are the size of the stone and availability of
the material. The riprap stone may be used to protect the
area around the diffuser nozzles. Placing the riprap stone
and filter offshore involves:
1. loading the material into scows;
2. towing the scows to the site; and
3. dumping the material.
The cover stones are placed offshore. However, offshore
applications of cover stone are often in a rubble mound
breakwater. A typical breakwater is constructed using the
structure as a peninsula from which to place the stones.
For this type application, land-based costs are appropriate.
Costs for placing the cover stone offshore are given and
were developed by assuming?
1. a crane positioned on land loads the stones onto a
flat-top barge;
2. the barge is towed to the offshore site; and
3. a crane barge (a crane mounted on a barge) is used
to place the stones.
60
-------
Steel sheet piling
(land), Account 202.1
Key parameters are the type of soil, material costs, the
depth of penetration and the bracing required. Steel sheet
piling may be used as excavation shoring, for erosion pro-
tection, such as a bulkhead in a sea wall, or as channel
lining material. The structure may be a single line of
piling or two lines connected with braces and empty or filled
with some material. Bracing requirements vary at every site.
A conservative estimate of bracing requirements, $7/square
meter, was given in and adopted from Reference 4. The costs
for materials depend on whether the material is new or used.
Sheet piling for temporary use such as for excavation shoring
may be rented. It was assumed the piling to be left in place
is new material. For temporary applications, material costs
reflect rental rates. The piling may require trimming and
some welding work. However, the cost was neglected. The
piling is driven with a pile-driving hammer rigged on a crane
boom. Wood piling data are not given because it is not used
as often as steel.
Steel sheet piling
(marine), Account 202.2
Key parameters are the type of soil, material costs, depth
of penetration and the bracing required. Steel sheet piling
placed offshore is used for cellular cofferdams and break-
waters. The circular structures can be filled with soil,
gravel, or riprap stone. Most of the time only a minimum
of bracing and pile supports are required because the inter-
lock strength of the piling carries the net outward earth
pressure. If it is desirable to dewater a small area, indi-
vidual cells may be constructed using circular walers to
prevent collapse.
61
-------
Piles (land). Account 203.1
Key parameters are the type of pile, material, and the depth
of penetration. Three materials are used to make piles:
concrete, steel, and wood. The piles considered here are
foundation piles. One dimension of pile for each material
was selected to represent that material. The error intro-
duced should not significantly effect the results.
Piles (marine), Account 203.2
Key parameters are pile materials, depth of penetration, and
the type of pile. Piles driven offshore are used as
bearing piles for pipe support systems and to support sheet
piling driven in the water. A crane barge rigged for driv-
ing piles is used to install the piles.
Concrete, Account 204
The key parameters are the application and the volume. Two
applications are considered in this account. Concrete slabs
are used as a channel lining material and for shore protec-
tion. Costs for other concrete slabs and the cushion fill
placed between the earth and concrete are given in Category 7
Concrete is also used in the construction of sea wall bulk-
heads. Slabs are placed between steel piles. The costs for
the slabs and piles are given in Cost Category 7 and Cost
Category 2.
62
-------
Mobilization, Account 206
Unit prices do not include the cost for mobilization and
demobilization. The user includes costs in accordance with
the construction on Worksheet 206. A discussion of mobili-
zation costs is given in Cost Category 1C.
Table 16 presents the correlation between cost account num-
ber, worksheet and figure number. Costs are calculated
using the procedure outlined in the introductory remarks of
this section and Worksheets 17 through 26.
Table 16. EROSION PROTECTION
COST ACCOUNTS
Cost
Account
Number
Description
Figure
Number
Worksheet
Number
201
201.1
201.2
202
202.1
202.2
Riprap: Costs for cover
stone, riprap stone,
and filter material.
Costs for materials and
land-based placement
of riprap.
Costs for materials and
offshore placement of
riprap.
Costs for materials and
installation of steel
sheet piling.
Costs for materials and
land-based installation,
Costs for materials and
offshore installation.
63
201.1
201.2
202.1
202.2
201.1
201.2
202.1
202.2
-------
Table 16 (continued). EROSION PROTECTION
COST ACCOUNTS
Cost
Account
Number
203
203.1
203.2
204
205
206
Description
Costs for installation of
piles and the material.
Piles (land installation) .
Piles (marine installation) .
Costs for materials and
installation of concrete
erosion protective
measures.
Other
Mobilization
Figure
Number
203.1
203.2
—
—
Worksheet
Number
203.1
203.2
204
205
206
Table 17. COST CATEGORY 2
COST SUMMATION
Worksheet 200
Cost
Account
Number
Description
Base
Cost
201
201.1
201.2
202
202.1
Riprap and filter
material and place-
ment
Placement by land-
based equipment
Offshore placement
Steel sheet piling
Placement by land-
based equipment
64
BC
201.2"
BC
202.1"
-------
Table 17 (continued). COST CATEGORY 2
COST SUMMATION
Worksheet 200
Cost
Account
Number
202.2
203
203.1
203.2
204
205
1
>
Description
Offshore placement
Piles
Land installation
Marine
Concrete
Other
BC202.
BC203.
BC203.
BC204
BC205
Base
Cost
.=$
1 =
i=
=
Cost Category 2 Total Cost
(Enter cost in Account 1101)
BC.
<*
^ —
206
Mobilization
in Account
(Enter Cost
1001)
MC? =$
Table 18. PLACEMENT OF
RIPRAP (LAND-BASED)
Worksheet 201.1
Design Data Required
Material3
Volume of material
Haul distance (round trip) from ,
borrow site to construction site
V =
Hd =-
m
km
Cover stone, riprap stone, or filter stone.
If haul distance is not provided and seems appropriate, assume
18-km round trip (see the discussion for this account).
65
-------
Table 18 (continued). PLACEMENT OF
RIPRAP (LAND-BASED)
Worksheet 201.1
Base Cost
Enter Figure 201.1, read base cost
for material and placement BC(1) =£_
Enter Figure 108.2, read base unit -
cost for hauling BUG (2) =$ /m"
Base cost for haul = V x BUG(2) BC(2) =$
Total base cost = BC(1) + BC(2) BC2Q1 1 =-
Table 19. PLACEMENT OF
RIPRAP (MARINE)
Worksheet 201.2
Design Data Required
Material
3
Volume of material V = m
Haul distance (round trip) from
borrow site to shoreline
staging areab km
Cover stone, riprap stone, or filter stone.
If haul distance is not provided and seems appropriate,
assume 18-km round trip (see discussion for Account 201.1)
66
-------
Table 19 (continued). PLACEMENT OF
RIPRAP (MARINE)
Worksheet 201.2
Base Cost
Enter Figure 201.2, read base cost
for material and placement BC(1) =$
Enter Figure 108.2, read base unit -.
cost for hauling BUG (2) =$ /m
Base cost for hauling = V x BUG(2) BC(2) =$
Total base cost = BC(1) + BC(2) BC201 2=—
Table 20. STEEL SHEET
PILING (LAND)
Worksheet 202.1
Design Data Required
2
Area of sheet piling m
Intended usage
(temporary or permanent)
Base Cost
Enter Figure 202.1, read base cost
BC
202.1
67
-------
Table 21. STEEL SHEET
PILING (MARINE)
Worksheet 202.2
Design Data Required
Area of sheet piling m
Intended usage
(temporary or permanent)
Base Cost
Enter Figure 202.2, read base cost
BC
202.2
Table 22. PILES (LAND)
Worksheet 203.1
Design Data Required
Pile material (concrete, steel, or wood)
Total length of piles m
Base Cost
Enter Figure 203.1, read base cost BC.-^ ,=$
aConcrete - square 20.3 cm tip and 40.6 cm butt
Steel - 30.5 cm x 30.5 cm H 24kg
Wood - 20.3 cm tip and 35.6 cm butt
68
-------
Table 23. PILES (MARINE)
Worksheet 203.2
Design Data Required
Pile material (concrete, steel, or wood)
Total length of piles m
Base Cost
Enter Figure 203.2, read base cost BC2Q3 2=$_
aConcrete - square 20.3 cm tip and 40.6 cm butt
Steel - 30.5 cm x 30.5 cm H 24kg
Wood - 20.3 cm tip and 35.6 cm butt
Table 24. CONCRETE
Worksheet 204
Base Cost
Concrete slab shore protection
and channel lining:
Refer to Cost Category 7 for
estimating procedure (Cost
Account 701).
Bulkhead shore protection: Costs
for materials and placement. Vertical
concrete slabs are given in
Cost Account 701. Costs for
Pi-piles for supporting the
concrete slabs are derived
from Cost Account 203. BC-,.. =$_
69
-------
Table 25. OTHER
Worksheet 205
Ease Cost
Include costs not covered in this
category but that relate to
erosion protection measures.
Data presented in other accounts
may be useful in estimating
"Other" Costs. BConr = $
21) b —
Table 26. MOBILIZATION
Worksheet 206
Data Requirements
Cost Account Mobilization
Number Cost Summation
201.1 $3,700
Riprap stone
or filter
201.1
Cover stone ) $3,300 for
202.1 ) one of the accounts
203.1 ) (201.1-204) and
204 $6,600 for two or
more accounts
Haulinga $600
Mobilization for marine equipment
is included in Categories 4 and 6
Mobilization Cost
Mobilization = the total of the
summation column (above) MC~ =$
alf account 201.1 is used and hauling costs are added to
the estimate, include the mobilization cost for hauling.
70
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COST CATEGORY 3, PUMP STATION
Information on modifying an existing pump station or in-
stallation of a new facility is given. Typically the
existing pump station is located upstream from the con-
denser. Water enters the cooling system through the in-
take and is pumped into the condenser and discharged.
Installation of a new station will normally be done down-
stream of the condenser.
Pumps and, motors, Account 301.1
The key parameters are capacity, total head, type of pump,
and salinity of the water. Three types of pumps are used
for cooling water supply:
1. The vertical wet pit pump - This type is the
least costly from the standpoint of space re-
quirements. The pump is the most common type
encountered during the literature review and
case studies.
2. The vertical dry pit - A pump with the advantage
of being more easily maintained, but it is a bit
more expensive in first cost than the vertical
wet pit type.
3. Horizontal dry pit - This type requires more
space than the others and the motor is subject
to water damage because it is located below the
water surface elevation.
The types of pumps are sketched in Figure 300.1.
Cost data for the vertical wet pit pump used in fresh
water and adjustment factors for the vertical dry pit
pumps and salt water pumping are given. Costs for the
horizontal dry pit pumps are not included. Material and
installation costs are separated as follows:
74
-------
VERTICAL
WET PIT
VERTICAL
DRY PIT
HORIZONTAL
DRY PIT
Fig. 300.1 - Types of Cooling Water Circulating Pumps
75
-------
1. Pumps, motors and starter equipment and the cost
to bring power from the substation to the motor
2. Equipment and labor costs required to set the
pump and motor into place and make them opera-
tional - Pump sizes and motor characteristics
assumed in developing unit prices are given in
Table 27.
Table 27. PUMP AND
MOTOR CHARACTERISTICS
Pump
Capacity,
m3/sec
1.4
2.8
8.5
19.8
Speed,
rpm
880
587
351
220
Motor
Voltage,,
Volts
460
460
4,160
4,160
The pumps and motors are selected based on the cooling
water flow rate and the increased head loss associated
with the new discharge. A single pump is seldom chosen
to meet the pumping requirements for cooling water. A
rule of thumb is to have 20 percent in excess of capacity
as a reserve. The four sizes given here will not provide
the exact combination for every situation. However, inter-
polation will provide a reasonable cost.
The trash racks and traveling screens of the existing pump
station will collect most of the debris that are drawn
from the intake. After the water has passed through the
condenser, screening requirements are less stringent. There-
fore, an account for trash racks and traveling water
76
-------
screens is not included in pump costs. The cost for
service water pumps are generally very small compared to
the circulating water pumps. Thus, no costs are given.
Installation, Account 301.2
The key parameters are the pump and motor size and the
type of installation (new pump station or modifying an
existing one). Installation costs reflect using a crane ,
and common and skilled labor to install the pump and
motor. Costs for modifications to an existing station
will vary depending on the access to the pumps and motors.
In some installations an overhead gantry crane may be
provided while for others the equipment will have to be
hoisted out using a crane. It is assumed a crane will
be used to remove existing equipment, and the installation
and removal costs are equal. Thus, the cost for installation
of pumps and motors into an existing facility is double
that for a new facility unless there is an existing empty
bay.
The costs for installation of valves and expansion joints
are included in costs for this account.
Valves and expansion joints,
Account 301.3
The key parameters are the type of valve and diameter of
pipe.
A common type of valve placed between the outlet pipe and
the pump is a motor-operated butterfly valve. In many
77
-------
installations an expansion joint is placed between the
outlet piping and the pump to protect the pump installa-
tion. Cost data for the butterfly valve and expansion
joints for diameters to 3.05 meters are given.
Pile foundation/ Account 302.1
Pile foundations include the concrete pile cap and the
piles. A discussion of concrete is given in Cost Category
7 and the piles in Cost Category 2.
Foundation slab, pit walls and
cover slab, Accounts 302.2 and 303.1
A discussion of these types of concrete structures are
given in Category 7.
Enclosure, Account 303.2
The key parameters are volume of the building required and
the type of construction material.
In warmer climates, a building may not be required and
weather-proofing the motor will suffice. Means (Reference
4) provides data on pre-engineered steel buildings. Costs
include erection, normal doors, windows, and gutters.
Based on the data given in Means and company experience,
a value of $10/cubic meters of enclosure was selected.
78
-------
Foundation excavation,
Account 304
A discussion of structure excavation is given in Cost
Category 9. Assume the excavation will have side slopes
of at least 2:1 and the outer dimensions are 1 meter beyond
the perimeter of the station.
Steel sheet piling, Account 305
A discussion of sheet piling costs is given in Cost
Category 2.
Structure backfill, Account 306
A discussion of backfill operations is given in Cost
Category 8. Estimate the volume of backfill by subtracting
the structure volume from the value used in Account 304
above.
Mobilization, Account 308
Unit prices do not include mobilization and demobilization
costs. The user is to add the mobilization cost as in-
dicated on the worksheet provided. A discussion of mobil-
ization cost is given in Cost Category 10.
Table 28 presents the correlation between cost account
number, worksheet, and figure number. Costs are calculated
using the procedure outline in the introductory remarks to
this section and the worksheets in Tables 29 through 42.
79
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Table 28. PUMP STATION COST ACCOUNTS
Cost
Account
Number
301
Description
i
! Figure
Number
i Worksheet
i Number
Mechanical - pumps and
motors
301.1
301.2
301.3
302
302.1
302.2
303
303.1
303.2
304
305
306
307
30o
Costs for pumps and
motors
Installation costs
Costs for butterfly
valves and expansion
joints
Structural (below grade)
Pile Foundation: Costs
for the piles are given
in Cost Category 2.
Costs for concrete pile
cap are given in Cost
Category 7.
Costs for the foundation
slab and pit walls.
(see Cost Category 7)
Structural (above grade)
Costs for the cover slab.
(see Cost Category 7)
Costs for an enclosure.
Costs for foundation
excavation. (see
Cost Category 9)
Costs for piling. (see
Cost Category 2)
Structure backfill,
Cost Category 8)
Other
Mobilization
(see
301.1
301.2
301.3
301.1
301.2
301.3
302.1
302.2
303.1
303.2
304
305
306
307
30U
80
-------
Table 29. COST CATEGORY 3
COST SUMMATION
Worksheet 300
Cost !
Account {
Number \
301
301.1
301.2
301.3
302
302.1
302.2
303
303.1
303.2
304
305
306
307
Description
Mechanical: Pumps
and motors
Pumps and motors B<~-}f)i
Installation BC301
Valves and expansion
joints BC~Q,
Structural below
grade
Pile foundation BC302
Foundation slab BC302
Structural above
grade
Cover slab BC303
Enclosure BC-.^-,
Excavation BC304
Piling BC305
Backfill BCon,
JUb
Other BC3Q7
Cost Category 3 Total Cost
(Enter Cost in Account 1101) EC.,
308
Mobilization (Enter Cost MC.,
in flr>r-nnnt- TDmi
Base
Cost
— <
0 V
— — C1
A
o^?
!=$
0~$
=$
=$
= t
= c;
= $
= $
81
-------
Table 30. PUMPS AND MOTORS
Worksheet 301.1
Design Data Required
3
Individual pump capacity (m /sec) Q =
(mVsec)
Power requirements P = W
Number of pumping units N =
Type of pump
Fresh or salt water
Base Cost
Enter Figure 301.1, read base
cost per pumping unit BUG =^_
Total base cost =BUC, x N EC =$
'1
Cost Adjustment
Enter Figure 301.1, read adjust- FD,
ment factors for type of
pump (FD,) and for fresh or
salt water (FD2) FD2
Adjusted Base Cost
Adjusted base cost = EC x FD, x
FD2 BC301.1
Vertical dry pit or vertical wet pit.
82
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Table 31. INSTALLATION
Worksheet 301.2
Design Data Required
3
Pump capacity (m /sec)
New pump station or
modification to existing
Number of pumps N =
Base Cost
Enter Figure 301.2, read base
cost
BC
Total cost for installation =
1
BC1 x N BC301.2
Costs for modifications to an existing pump station
assuming the old unit is removed.
Table 32. EXPANSION JOINTS
AND VALVES
Worksheet 301.3
Design Data Required
Pump outlet pipe diameter D =
meters
Number of valves N(V) =
Number of joints N(J) =
83
-------
Table 32 (continued). EXPANSION JOINTS
AND VALVES
Worksheet 301.3
Base Cost
Enter Figure 301.3, read base
cost for valves BC-, =$_
Total cost for valves =
BC-L x N(V) BC2 =$_
Enter Figure 301.3, read base
cost for expansion joints BC., =$_
Total costs for expansion joints
= BC x N(J) BC =$
Total base cost = BC2 + BC4 BC301 3
Table 33- PILE FOUNDATION
Worksheet 302.1
Base Cost
Cost for piles (Cost Category 2) BC]L =$_
Cost for pile caps (Cost Category 7) BC0 =$_
Total base cost = BC, + BC0 BC-,.,, -, =$
84
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Table 34. FOUNDATION SLAB
AND PIT WALLS
Worksheet 302.2
Base Cost
Cost for foundation slab (Cost
Category 7) EC-^ =$_
Cost for pit walls BC7 =$
Total cost = EC, + BC0 tiC.,-,, ., =$
Table 35. COVER SLAB
Worksheet 303.1
Base Cost
Cost for cover slab or deck
(Cost Category 7) BC
303 1
Table 36- ENCLOSURE
Worksheet 303.2
Design Data Required
3
Volume of building V = m
Base Cost
Base cost = 10 x V EC?n4 2 =^
85
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Table 37. FOUNDATION EXCAVATION
Worksheet 304
Base Cost
Cost for excavation (Cost BC304
Category 9)
Table 38. STEEL SHEET PILING
Worksheet 305
Base Cost
Cost for sheet piling (Cost
Category 2) BC305
Table 39. STRUCTURE BACKFILL
Worksheet 306
Base Cost
Cost for structure backfill
(Cost Category 8) BC306
86
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307
Table 40. OTHER
Worksheet 307
Ease Costs
Include costs not covered in this
category but that relate to the
pump station. Data presented in other
accounts may be useful in estimating
"Other" costs. BC
Table 41. MOBILIZATION
Worksheet 308
Mobilization Cost
New pump station - $3,300 MC-, = $_
The costs for mobilization of the ~~
equipment to excavate and backfill
are included in Category 4 .a
For a new pump station, one crane could be used to install
the pumps and for concrete work. For a modification to an
existing station, it was assumed that a crane from some
other activity could be used.
87
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COST CATEGORY 4, CONDUITS
Information on the material and installation costs for
conduits is given in Cost Category 4. Data given in
Accounts 401 through 405 are for materials and Accounts
406 and 407 are for installation. The materials commonly
used for conduits are:
1. concrete (precast and cast-in place);
2. steel (corrugated metal and carbon steel); and
3. fiberglass.
No definite guidelines for selection of pipe materials
were encountered in the case studies and literature sur-
vey. Differences in pipe materials are most evident in
offshore pipelines. Precast concrete pipe is the heaviest
pipe and requires larger equipment to lay pipe lengths
equal to steel and fiberglass pipe. The additional weight
of concrete pipe has an advantage in water bodies where
the currents may move a lighter pipe. The steel pipe re-
quires a special coating; fiberglass does not, nor does
concrete. Each of the pipes have standard fittings
(elbows, wyes, etc.) but special carbon steel fittings
can be fabricated on site. Cast-in-place concrete and
carbon steel pipe are used most often for branching pipes
and difficult transitions. The fiberglass pipe is the
lightest and has no corrosion problems. More care is
required when laying fiberglass pipe to prevent damage
during laying. The laying rates for all the conduits are
dependent on diameter.
As a rule of thumb, a system velocity between 2.0 and 3.0
meters/second is used for sizing conduits.
Material handling can be an important consideration. If
the pipe is shipped to the site by rail, the material may
90
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be handled as many as three times before installing the
pipe into the trench. Precast pipes are usually laid from
a crane barge offshore with two support cranes on land.
Costs for excavation, laying of the pipe, and backfill of
the pipe trench are given in separate accounts. However,
the three are interrelated in the offshore work, and the
rate at which each operation is accomplished will affect
the total cost. Equipment selection and productivity
used in developing unit prices reflect the interrelation-
ship between excavation, pipe laying, and backfill.
Data on the accounts are given in the following paragraphs.
Precast concrete pipe,
Account 401
Key parameters are the pipe diameter and the application.
Material costs are for a prestressed steel cylinder con-
crete pipe. The pipe costs more for subaqueous use than
on land. Prices reflect freight costs F.O.B. railcar to
any site approximately 645 kilometers from the point of
manufacture and include contractor markup. Unit costs
include provision for the cost of fittings. A maximum
diameter of 3.97 meters, except in the Northeast, where
the maximum is 3.66 meters is used on cost data sheets
because shipping restrictions prevent transporting larger
diameters. Larger pipe diameters have been cast on the
site by the manufacturer, but these are special cases and
the costs are not given.
91
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Cast-in-place box conduit,
Account 402
Key parameters are formwork, reinforcing, placement and
finishing. A square conduit with a wall thickness equal
to 15 percent of the inside diameter is considered. The
cost reflects:
1. placing medium (3,000 psi) strength concrete;
2. 71 kilograms of rebar per cubic meter of concrete;
3. formwork costs (which vary with the diameter); and
4. finishing costs.
Adjustment factors for the wall thickness are calculated
and shown in the cost data. If this type is used off-
shore, costs for a cofferdam must be included. Trenching,
backfill, cofferdams, and other installation costs are
not included.
Steel conduit and fittings,
Account 403.1 and 403.2
Key parameters are the diameter of the pipe and the method
of fabrication. For diameters up to approximately 3.05
meters, it was assumed the pipe is shop fabricated (by the
manufacturer) and shipped to the site. Larger diameters
have been shop fabricated, but it is a special order and
costs are not given. Field fabrication for larger diameters
is done by field welding rolled steel plates. The pipe
can be fabricated in the trench or positioned for offshore
laying. If the pipe is fabricated in the trench, no
installation costs are added. Field fabrication costs are
based to a large extent on data from Reference 12. Shop
and field fabrication costs were developed for 1.27 cm
steel plate thickness. Design adjustment factors for
92
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different plate thicknesses and for using hoop stiffeners
are given. Fittings costs are given separately from the
pipe. Steel fittings cost more than straight pipe because
of the additional welding required.
Corrugated metal pipe,
Account 404
The key parameter is the diameter of the pipe. Up to 3.6 m
the pipe is shop fabricated. For diameters greater than
3.6 m the pipe is shipped to the site as galvanized plates.
The pipe is bolted together on site, whether in the pipe
trench or positioned for offshore laying in completed
sections. In either case, installation costs are added.
Fiberglass pipe, Account 405
The key parameter is the diameter of the pipe. Fiberglass
pipe is shipped to the site (except in the Northeast) in
diameters to 3.97 meters. On occasion, this pipe has been
fabricated on site. The costs for field fabricated pipe
are given.
Excavation of pipe trench
(land), Account 406.1
A discussion of land excavation is given in Cost Category 9
93
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Laying pipe on land,
Account 406.2
Key parameters are the pipe material and fabrication. The
steel pipes, corrugated metal, and carbon steel can be
fabricated in the trench. Installation costs are not
added to the material costs for cast-in-place concrete,
or carbon steel pipe greater than 3.05 m diameter. For
diameters less than 3.05 m, the carbon steel pipe can be
shop or field fabricated. Usually, the user can assume
the pipe to be shop fabricated and installation costs
should be added. Material handling is less of a problem
when installation is on land. The pipe can be offloaded
into the trench from the truck that hauls the pipe to the
site or stockpiled close enough to be handled by the crane
used to install the pipe. Therefore, no costs for a yard
crane are included in this account. The lengths of pipe
used to determine laying rates are:
1. precast concrete (4.9 meters for pipe diameters
to 3.66 meters and 3.05 meters for pipe diameters
greater than 3.66 meters);
2. corrugated metal (7.3 meters); and
3. fiberglass (14.6 meters).
Onshore backfill, Account 406.3
Discussion of placement and the material used in backfill
of the pipe trench is given in Cost Category 8.
Pipe support systems,
Account 406.4
Data for the concrete or piles can be found in the dis-
cussion for Cost Category 7.
94
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Dewatering, Account 406.5
The key parameter is the time required to lay the pipe
(see also the discussion for Account 904). Pumping costs
are given in terms of the dewatering period.
Offshore pipe trench excavation,
Account 407.1
A discussion of marine excavation is given in Cost
Category 9.
Laying pipe offshore,
Account 407.2
Key parameters are the weight of the pipe, length of the
pipe section installed, and meteorological conditions. The
lighter pipes such as steel and fiberglass pipe can be laid
in longer lengths than concrete. In some cases, manu-
factured lengths are joined on shore. The lengths of pipe
sections assumed for developing laying rates are:
1. precast concrete (9.8 meters for pipe diameters)
to 3.66 meters and 6.1 meters for pipes 3.66
or longer);
2. corrugated metal (12.2 meters);
3. carbon steel (12.2 ireters for pipe diameters to
3.66 meters and 6.1 meters for pipes 3.66 meters
or longer)/ and
4. fiberglass (15.3 meters).
In offshore laying, all the pipes are joined using a bell
and spigot joint. Divers bring together the sections
using bolts fixed to the outside of the pipe. The depth
at which the pipe is laid will affect the costs because
of special rigging and diver problems. An adjustment
95
-------
-factor for laying pipe in depths greater than 14 meters
is included.
Material handling at the site is an important considera-
tion. In some cases, the pipe is off-loaded at the rail
head, hauled to a yard and reloaded onto a barge for
transport to the site. Alternatively, the pipe can be
transported to the site on a barge loaded at a port near
the manufacturer's permanent or temporary plant. Cost
data are given for ground transport to the site (the
first case).
Two support cranes on shore are considered in addition to
a flat top and crane barge used in laying the pipe.
In some areas, water currents will cause siltation of the
trench to the extent of limiting the length of pipe that
can be laid. An example is laying a pipeline in the surf
zone of a lake or ocean. A discussion of estimating costs
for laying pipe in the surf zone and river is given in
Account 408.
Offshore backfill, Account 407.3
A discussion of backfilling the pipe trench including the
cushion fill and common earth is included in Cost Category
8.
Pipe support systems,
Account 407.4
Key parameters are the foundation (earth or rock) and the
weight of the pipe. If in the area where the pipe is laid,
96
-------
the soil bearing capacity is poor, a concrete cradle
supported by piles may be required. Data to estimate the
cost for the piles and concrete are included in Cost
Category 2 and Cost Category 7, respectively. The lighter
pipes may require concrete anchors placed to restrict
movement. Data for tremie concrete are given in Category
7.
Riprap protection, Account 407.5
Riprap protection may be required to protect the backfill
from erosion. A discussion of offshore placement of rip-
rap is given in Category 2.
Cofferdam, Account 407.6
In some instances, offshore work cannot be done by divers,
A cofferdam is constructed and the area dewatered. An
example of the possible use for cofferdam is extending a
single port discharge further offshore. If the existing
outfall were encased in concrete, the area might be de-
watered to permit attaching the additional pipe.
Other, Account 408
Installation of the pipe in the river or the surf zone
is more costly than for conventional offshore laying
methods. The contractor may over-excavate the trench to
allow for siltation. However, over-excavation may not
be a viable alternative in some cases and the laying of
pipe may involve:
97
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1. building a trestle constructed of steel H-pile
bents with steel beam stringers and wooden
planks (The trestle extends from the shore to
where littoral currents no longer influence the
pipe laying operation);
2. positioning a crane on the trestle for driving
sheet piling to keep the currents from filling
the trench with silt (The crane can be used to
excavate the trench, lay the pipe and backfill
the trench);
3. placing concrete around top of the pipe to
prevent erosion of the backfill.
Costs for this type of operation are difficult to assess
because the length of the zone is not well defined. Also
this is a method of construction and probably will not be
delineated on the available drawings. A rule of thumb for
estimating the cost for building the trestle is to assume
$l,500/meter. Other costs such as shoring and pipe laying
can be estimated using the procedures outlined in the
manual. Because the crane is working from the trestle,
costs for land-based operations may be appropriate. To
estimate the length to which the special construction
method applies, assume a water depth between 2 and 3 meters
divides the surf zone and conventional laying methods.
Mobilization, Account 409
The cost for mobilization and demobilization is not in-
cluded in the unit price. The costs for mobilizing equip-
ment to excavate the pipe trench, lay the pipe and back-
fill the trench are given. A discussion of mobilization
is given in Category 10.
Table 42 presents the correlation between cost account
number, worksheet, and figure number. Costs are cal-
culated using the procedure outlined in the introductory
98
-------
remarks to this section and the worksheets in Tables 43
through 62.
Table 42. CONDUIT COST ACCOUNTS
Cost
Account
Number
Description
Figure
Number
Worksheet
Number
401
402
403
403.1
403.2
404
405
406
406.1
Precast concrete pipe costs
for materials for diameters
to 4 meters•
Cast-in-place box conduit
costs for in-place casting
of square concrete conduits.
Steel conduit and fittings
costs for materials and
fabrication for diameters
to 6 meters•
Pipe costs
Cost of fittings, including
elbows, reducers and tees.
Corrugated metal pipe
material and fabrication
costs for diameters to 6
meters. Installation
costs are not included.
Fiberglass pipe. Costs for
material and fabrication
for diameters to 6 meters.
Installation costs are not
included.
Cost for land installation
of pipe.
Costs for onshore excava-
tion of pipe trench (see
Cost Category 9)•
401
402
401
402
403.1
403.2
404
403.1
403.2
404
405
405
406.1
99
-------
Table 42 (continued). CONDUIT COST ACCOUNTS
Cost
Account
Number
Description
Figure
Number
Worksheet
Number
406.2
406.3
406.4
406.5
407
407.1
407.2
407.3
407.4
407.5
407.6
408
409
Costs for laying pipe onshore'
Costs for cushion fill and
trench backfill (see Cost
Category 8)•
Costs for pipe supports,
including concrete thrust
blocks, encasement,
cradles, and piles-
Cost for dewatering the
pipe trench.
Cost for marine installation
of pipe:
Offshore excavation costs
for pipe trench (see Cost
Category 9).
Costs for laying pipe off-
shore .
Costs for fill cushion and
trench backfill (see Cost
Category 8) .
Costs for pipe supports,
including concrete thrust
blocks, encasement,
cradles, and piles-
Costs for riprap protection
for pipe trench •
Costs for materials and
construction of coffer-
dams used in pipe in-
stallation •
Other
Mobilization
100
406.2
406.5
407.2
406.2
406.3
406.4
406.5
407.1
407.2
407.3
407.4
407.5
407.6
408
409
-------
Table 43. COST CATEGORY 4
COST SUMMATION
Worksheet 400
Cost
Account
Number
401
402
403
403.1
403.2
404
405
406
406.1
406.2
406.3
406.4
406.5
407
407.1
407.2
407.3
Description
Precast concrete pipe
Cast-in-place box
culvert
Steel conduit
Steel pipe
Steel fittings
Corrugated metal pipe
Fiberglass pipe
Land installation of
pipe
Onshore excavation
Onshore pipe laying
Cushion fill and
backfill
Pipe supports
Dewatering
Marine installation of
pipe
Offshore excavation
Offshore pipe laying
Cushion fill and
backfill
Base
Cost
BC401 =$
BC „ =
^40° 1™
BC4m ^=
BC4n4 =
BC405 =
BC4nf; i =
BC406 -=
BC4f)fi 1=
BC4nf; 4=
BC4nr R=
BC/I07 3 =
BC407 0=
BC407 3=
101
-------
Table 43 (continued). COST CATEGORY 4
COST SUMMATION
Worksheet 400
Cost
Account
Number
407.4
407.5
407.6
408
Dascription
Pipe supports
Riprap protection
Cofferdams
Other
Base
Cost
BC407.
BC407.
BC407.
BC408
A
e~
f.~
Cost Category 4 Total Cost
BC
= $
(Enter Cost in Account 1101)
409
Mobilization (Enter
Cost in Account 1001)
MC4 =$
Table 44. PRECAST CONCRETE PIPE
Worksheet 401
Design Data Required
Pipe diameter
Pipe length L =_
Land or marine installation
Base Cost
Enter Figure 401, read base unit
cost per lineal meter.
Base cost = L x BUG
BC
BUG =$_
401 =$
m
m
102
-------
Table 45. CAST-IN-PLACE
BOX CONDUIT
Worksheet 402
Design Data Required
Width or height of square conduit m
Wall thickness cm
Length of pipe L = m
Base Cost
Enter Figure 402, read base unit BUG =$
cost per lineal meter
Base cost = L x BUG BC =$
Cost Adjustments
Enter Figure 402, read design adjust-
ment factor for wall thickness F
D
Adjusted Base Cost
Base cost of materials and fabrica-
tion = BC x FD BC402=^-
103
-------
Table 46. STEEL CONDUIT
Worksheet 403.1
Design Data Required
Pipe diameter m
Wall thickness cm
With or without stiffeners
Pipe length L = rr.
Shop or field fabrication
Base Cost
Enter Figure 403.1, read base unit
cost per lineal meter BUG =$
Base cost = L x BUG BC =$
Cost Adjustments
Enter Figure 403.1, read design FD(!)=
adjustment factors for wall „ /?»_
thickness, stiffeners and Dl -
fabrica.tion F_(3) =
Adjusted Base Cost
Adjusted base cost of materials
and fabrication = BC x F (1) x
FD(2) XFD(3)
For diameters to 3.05 meters, assume shop fabrication.
104
-------
Table 47. STEEL
PIPE FITTINGS
Worksheet 403.2
Design Data Required
Type (elbow, reducer, tee,
connection)
Diameter (if a fitting diameter
varies, use largest diameter) m
Angle (for reducer or connection) °
Number N =
Wall thickness cm
With or without stiffeners
Base Cost
Enter Figure 403.2, read base unit
cost per fitting BUG =$
Base cost = N x BUG BC =$
Cost Adjustments
Enter Figure 403.1, read design FD^
adjustment factors for wall .«,
thickness and stiffeners and D
fabrication F (3)=
Adjusted Base Cost
Adjusted base cost of materials and
fabrication for particular type
of fitting = BC x F (1) x F (2) BC,^ 0=$
XFD(3) D D
105
-------
Table 48. CORRUGATED METAL PIPE
Worksheet 404
Design Data Required
Pipe diameter m
Pipe length L = m
Base Cost
Enter Figure 404, read base unit
cost per lineal meter BUG =$
Base cost = L x BUG BC404 =—
Table 49. FIBERGLASS PIPE
Worksheet 405
Design Data Required
Pipe diameter m
Pipe length L = m
Base Cost
Enter Figure 405, read base unit
cost per lineal meter BUG =$
Base cost = L x BUG BC405
106
-------
Table 50. ONSHORE PIPE
TRENCH EXCAVATION
Worksheet 406.1
Base Cost
Refer to Cost Accounts 901 or 902
for cost estimating procedure BC4Q6
Table 51. LAYING PIPE ON LAND
Worksheet 406.2
Design Data Required
Length of pipe L = m
Diameter of pipe D = m
Material
Base Cost
Enter Figure 406.2, read base unit
cost per lineal meter BUG =$
Base cost = L x BUG BC40fi 2 ~—
Table 52. ONSHORE BACKFILL
Worksheet 406.3
Base Cost
Refer to Cost Category 8 for appro-
priate cost accounts and estimating
procedures BC^Qg 3 -•$_
107
-------
Table 53. PIPE SUPPORT SYSTEMS
Worksheet 406.4
Base Cost
Refer to Cost Category 7 for concrete
costs and 2 for piling costs BC406 4 =—
Table 54. DEWATERING
Worksheet 406.5
Design Data Required
Length of pipes L =
Pipe material
Diameter m
Base Cost
Enter Figure 406.5, read base unit
cost for Dewatering BUG =j>_
Base cost = BUG x L BC,.n^ c =$
4Ub.D —
aSteel,
Concrete, or
Fiberglass Pipe
Table 55. OFFSHORE PIPE
TRENCH EXCAVATION
Worksheet 407.1
Base Cost
Refer to Cost Accounts 901 or 902
for cost estimating procedure BC407 1=—
108
-------
Table 56. LAYING OFFSHORE PIPE
Worksheet 407.2
Design Data Required
Length of pipe L = ___ m
Diameter D - __ m
Pipe material ____
Depth of water ____ m
Base Cost
Enter Figure 407.2, read base unit
cost per lineal meter BUG =$ _ ym
Base cost = L x BUG BC =$
Cost Adjustment
Enter Figure 407.2, read adjustment
factor for water depth F
Adjusted Base Cost
Adjusted base cost for laying pipe
offshore = BC x FD Bc/im
4 U /
Table 57. OFFSHORE BACKFILL
Worksheet 407.3
Base Cost
Refer to Cost Category 8 for appro-
priate cost accounts and cost
estimating procedure BC
4n7
109
-------
Table 58. PIPE SUPPORT SYSTEMS
Worksheet 407.4
Base Cost
Refer to Cost Categories 7 and 2 for
appropriate cost accounts and
estimating procedures BC^Q^ ^=
Table 59. RIPRAP PROTECTION
Worksheet 407.5
Base Cost
Refer to Cost Account 201.2 for
estimating procedure
Table 60. COFFERDAMS
Worksheet 407.6
Base Cost
Refer to Cost Category 2 for
appropriate cost accounts and
estimating procedures BC.__ *-=$_
110
-------
Table 61. OTHER
Worksheet 408
Base Cost
Include costs not covered in this
category but that relate to
conduits. Data presented in other
accounts may be useful in estimating
"Other" costs.
Also the costs for the surf zone are
to be added in this account. BC408 ~—
Table 62. MOBILIZATION
Worksheet 409
Data Requirement
Mobilization
Description Cost Summation
For offshore installation of
a conduit add $96,000a $96,000
For land installation of
the conduit add $ 6,600
For hauling fill $ 600
Mobilization Cost
Mobilization = the total of the
summation column (above) MC. =$>_
The mobilization costs are inclusive of accounts 407.1
through 407.6.
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COST CATEGORY 5, TUNNELING
Data is provided for excavation, lining, support systems,
and dewatering. A lay classification of rock characteris-
tics is adopted to simplify the discussion. The correlation
between rock types, quality designation*and classification
is given in Table 63.
Table 63. ROCK TYPES
Rock Description
Hard and intact; hard
stratified or schistose
Massive, moderately jointed;
moderately blocky and seamy
Very blocky and seamy
Shattered and/or unconsolidated
Unconsolidated or completely
crushed; gravel or sand
RQDa
> 95
75-95
50-75
25-50
< 25
Classification
Excellent
Good
Fair
Poor
Very poor
Rock Quality Designation: A modified core recovery tech-
nique based indirectly on the number of fractures and
amount of softening or alteration in the rock mass as
observed in cores from a 3-inch drill hole.
The system of using lay classifications is useful in the
discussion but often the descriptions overlap and do not
exactly fit all cases. However, the discrepancies do not
adversely affect the estimating accuracy.
Rock quality affects excavation and the type of rock support
system. In addition, costs are dependent on the type of
heading; wet or dry. A wet heading is defined as having
118
-------
more than 0.4 cubic meters/minute of water flowing into the
tunnel. If adequate information is available on conditions
expected along the proposed tunnel alignment, the tunnel
should be divided into reaches of generally similar charac-
teristics and the construction cost estimated for each
reach individually.
When the design information is limited, the user should as-
sume the best condition encountered will be classified as
fair. Four support systems are used alone or in combination
depending on site conditions:
1. Rock bolts - Bolts used to tie rock closest to ex-
cavation back into undisturbed strata.
2. Shotcrete - Mixture of sand and cement, pneumatical-
ly applied to roof and walls of tunnel. In this
study, costs include grouting for rock bolts. For
poor rock conditions, shotcrete is usually com-
bined with other support alternatives (see Figure
500.1).
3. Horseshoe ribs - As rock conditions become poorer,
continuous roof support is required. A common
support system consists of a series of horseshoe-
shaped ribs made from steel wide-flange beams and
separated by timber lagging (see Figure 500.1).
4. Circular ribs - In poor quality rock, circular
steel ribs support the circumference of the tunnel
excavation (see Figure 500.1).
Types of support and relative sizes and dimensions associated
with the lay rock classifications are given in Table 64 (see
Reference 5).
Unless specifically noted, each support system is used inde-
pendently. Thus when the user seeks the cost for a support
system, he should select the type given in his design plans
and use that cost alone (except where noted in Table 64).
119
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The design velocity for tunnels is approximately 2 to 3
meters/second. Data for the accounts of Cost Category 5
are given in the following paragraphs.
Tunnel excavation, Account 501
Key parameters are the geological condition of the tunnel
area, the size of the tunnel and the type of heading (wet
or dry). Data are given for circular tunnels with a diam-
eter of 3 to 8 meters. For other shapes, assume an equiva-
lent diameter, or the height dimension of the tunnel.
Excavation costs vary substantially with the type of rock
and with the size of tunnel. Data presented in "Tunneling-
The State of the Art", by R. S. Mayo and Associates (Refer-
ence 5) were used as the source for excavation costs.
Costs were estimated for each of the following rock condi-
tions :
1. Dry headings in:
a. stratified or schistose rock (excellent);
b. massive moderately jointed rock (good);
c. moderately blocky and seamy rock (good);
d. very blocky and seamy rock (fair); and
e. completely crushed or unconsolidated sedi-
ments (very poor).
2. Wet headings in:
a. competent rock (excellent to poor); and
b. crushed rock or unconsolidated sediments
very poor) .
Tunnels may be excavated using a boring machine or by con-
ventional means. The data given here are based on conven-
tional mining techniques. For cooling water tunnels, shaft
121
-------
headings are required and costs must be included for shaft
excavation and hoisting equipment. It was assumed for all
excavation costs that tunnel spoil would be disposed of in
the immediate vicinity (within one kilometer). For opera-
tions in which a disposal area is not located nearby, the
hauling costs should be added to the excavation costs (refer
to Category 1 for hauling costs).
Rock bolts, Account 502.1
Key parameters are the rock bolt spacing and the penetration
length. Rock bolts are installed by drilling a hole into the
rock, placing the bolt and grouting the bolt into place
(optional). The spacing is increased as the rock conditions
improve. The bolts are placed into the crown of the tunnel
bore. Refer to Table 64 for examples of rock bolt spacings
and the interrelationship of tunnel support systems.
Shotcrete, Account 502.2
Key parameters are thickness and the percent of the tunnel
crown covered. Shotcrete is a structural measure used during
construction of the tunnel and is in addition to lining
(Account 503). Shotcrete can be used alone as rock support
or in combination with other systems. For poor or very poor
rock, shotcrete is usually used in combinations with other
support systems (refer to Table 64).
122
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123
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Structural steel supports,
Accounts 502.3, 502.4 and 502.5
Key parameters are the tunnel diameter spacing and size of
the members. Mayo (Reference 5) gives the support spacing
based on the comparison between rock loading and tunnel
dimensions. The size of the members is based on the data
given in Reference 13. Timber lagging is used between the
steel sets to contain loose rocks and separate the sets.
Concrete tunnel lining,
Account 503
The key parameter is the lining thickness. An allowance
should be made for over-excavation of the tunnel and grout-
ing to fill voids between the lining. A factor of 1.2 times
"neat line dimensions" is recommended. The tunnel lining
does provide structural support. However, the primary func-
tion is to reduce hydraulic friction loss. All tunnels are
not lined but usually omitting the lining is reserved for
tunnels in excellent rock that were excavated using a boring
machine.
Tunnel dewatering, Account 504
The key parameter is the inflow rate. Pump and pipe sizes
are assumed for given inflow rates. The rental and labor
costs were calculated and related to the inflow.
124
-------
Shafts, Account 505
For cooling water tunnels, shaft headings are required and
costs must be included for shaft excavation hoisting equip-
ment and additional structural support. Costs for shaft
headings are calculated by multiplying the total horizontal
tunnel costs times 2 (Reference 5). If a shaft is to be
excavated offshore, it will probably be to connect some type
of diffuser. The costs for the shafts are given here and
the costs for cofferdams and other installation charges are
included in Cost Category 6.
Mobilization is not given an account number. Mobilization
costs are estimated to be 5 percent of the construction
costs. The calculation is done on summary worksheet number
500.
To estimate the cost for tunnel excavation and support sys-
tems, the outside diameter is used. Whereas, selection of
the tunnel for hydraulic criteria is based on inside dimen-
sion. The relationship between inside and outside diameter
for different rock quality designations is given in Figure
500.4 (placed with the cost graphs).
Table 65 presents the correlation between cost account
number, worksheet, and figure number. Costs are calculated
using the procedure outlined in the introductory remarks to
this section and the worksheets in Tables 66 through 77.
125
-------
Table 65. TUNNEL COST ACCOUNTS
Cost
Account
Number
501
501.1
501.2
502
502.1
502.2
502.3
502.4
502.5
503
504
505
506
Description
Costs for excavating tunnels.
Hauling costs are not in-
cluded.
Costs for dry tunneling.
Costs for wet tunneling.
Costs for support systems
are given for tunnel out-
side diameters from 3 to
8 meters.
Costs for rock bolt support.
Costs for shotcrete support.
Costs for horseshoe rib
support.
Costs for circular rib
support.
Costs for timber lagging
used between the ribs
to support loose stones.
Costs for concrete lining
for tunnel diameters
from 3 to 9 meters.
Costs for tunnel de-
watering.
Shafts: Costs for vertical
shafts are approximately
twice those for tunneling
horizontally.
Other
Figure
Number
501.1
501.2
502.1
502.2
502.3
502.4
502.5
503
504
—
Worksheet
Number
501.1
501.2
502.1
502.2
502.3
502.4
502.5
503
504
505
506
126
-------
Table 66. COST CATEGORY 5
COST SUMMATION
Worksheet 500
Cost ]
Account
Number ' Description
501
501.1
501.2
502
502.1
502.2
502.3
502.4
502.5
503
504
505
506
Excavation
Dry tunneling excavation
Wet tunneling excavation
Tunnel support systems
Rock bolts
Shotcrete
Horseshoe ribs
Circular ribs
Timber Lagging
Tunnel lining
Tunnel dewatering
Shafts
Other
Total Cost Category 5 Adjusted Cost
(Enter cost in Account 1101)
Base
Cost
BC =$
^m ^~^
BC50° 1=^
BCj-Q,, 0=v
BC =$
BCt?n"> c = $
BC,-no =?
•^^-crri^ ~?
BC =$
oC^ r r\ /~ =" V
BCr =$
Mobilization
EC,- x 0.05
MC
=$
127
-------
Table 67. TUNNELING EXCAVATION, DRY
Worksheet 501.1
Design Data Required
Tunnel outside diameter m
Rock classification (see Table 63)
Tunnel length L = m
Base Cost
Enter Figure 501.1, read base unit
cost per lineal meter BUG =$
Base cost = L x BUG BC501 1
Table 68. TUNNELING EXCAVATION, WET
Worksheet 501.2
Design Data Required
Tunnel outside diameter m
Rock classification (see Table 63)
Tunnel or vertical shaft length L = m
Base Cost
Enter Figure 501.2, read base unit
cost per lineal meter BUG =$
Base cost = L x BUG BC5Q1 2
Figure 500.4 gives the relationship between inside and
outside diameter.
128
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Table 69. ROCK BOLTS
Worksheet ,502.1
Design Data Required
Tunnel outside diameter m
Rock classification (see Table 63)
Tunnel length L - m
Base Cost
Enter Figure 502.1, read base unit
cost per lineal meter BUG -$
Base cost = L x BUG BCKno =$
D U ^ • X
Table 70. SHOTCRETE
Worksheet 502.2
Design Data Required
Tunnel outside diameter m
Rock classification
Tunnel length L = m
Base Cost
Enter Figure 502.2, read base unit cost
per lineal meter BUG =$
Base cost = L x BUG BCcm
j U ^ •
129
-------
Table 71. HORSESHOE RIB SUPPORT
Worksheet 502.3
Design Data Required
Tunnel outside diameter m
Rock classification
Tunnel length L = m
Base Cost
Enter Figure 502.3, estimate base
unit cost for given rock
classification zone BUG =
Base cost = L x BUG BC502 3
Good, fair or poor. For poor or very poor rock, recommend
using the costs for circular ribs (see Worksheet 502.4).
Rock classifications are given in Table 63.
Table 72. CIRCULAR RIB SUPPORT
Worksheet 502.4
Design Data Required
Tunnel outside diameter m
Rock classification
Tunnel length L = m
Poor or very poor classification (see Table 63).
130
-------
Table 72 (continued). CIRCULAR RIB SUPPORT
Worksheet 502.4
Base Cost
Enter Figure 502.4, estimate base
unit cost for given rock
classification zone BUG =$
Base cost = L x BUG BCcno A
-D U £-• » T:
Table 73. TIMBER LAGGING
Worksheet 502.5
Design Data Required
Tunnel outside diameter m
Rock classification3
Tunnel length L = m
Base Cost
Enter Figure 502.5, read base unit
cost per lineal meter BUG =$
Base cost = L x BUG BCcn?
.3 U £• •
aGood, fair, poor, or poor with wet heading (see Tables
63 and 64) .
131
-------
-------
Table 74. CONCRETE TUNNEL LINING
Worksheet 503
Design Data Required
Tunnel outside diameter m
Rock classification
Tunnel length L = m
Base Cost
Enter Figure 503, read base unit
cost per lineal meter BUC =$
Base cost = L x BUC BC503
Excellent, good to fair, poor (see Table 64).
Table 75. TUNNEL DEWATERING
Worksheet 504
Design Data Required
Seepage classification
Length of wet heading L = m
Base Cost
Enter Figure 504, read base cost BC504
for wet heading lengths
Three seepage rates are given: light, moderate, and heavy,
Unless data is available, assume a moderate flow rate for
\AI o -f- T-t o a r\ i r* rr o
wet headings.
132
-------
Table 76. SHAFTS
Worksheet 505
Data Required
Base cost for:
Account 501 BC501 =—
Account 502 BC502 =—
Account 503 BC503 =—
Total BCW =$
rl —
Base Cost
Base cost = BC x 2 BC505 =—
Table 77. OTHER
Worksheet 506
Base Cost
Include costs not covered in this
category but that relate to
tunneling. Data presented in
other accounts may be useful in
estimating "Other" costs. BC506 =—
133
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COST CATEGORY 6, DIFFUSER
Information on materials and installation of diffusers is
provided. Three types of diffusers considered are as follows;
1. Single port - A single port discharge is a simple
type of diffuser. The outfall is usually the open
end of a conduit with a concrete structure for
protection or to divert the flow vertically. Costs
for a single port discharge are given separately
from the other diffusers in Account 604.
2. Conduit diffuser - The term "conduit diffuser"
describes a series of nozzles or slots arranged
along a conduit manifold. The conduit diffuser
is set in a pipe trench on the lake bed and can
be connected to the discharge pipe or a tunnel
(see Figure 600.1).
.'fvv f'.'f:»:•*•.>."'.-*'v.-'.-;'-3*-'.'i .'.'".n^y^-'i^tg
a. 600.1
ri.. : : ': Diffuser
139
-------
3. Tunnel diffuser - The term "tunnel diffuser"
refers to a series of nozzles individually
grouted into a tunnel (See Figure 600.2).
r i •; . bUU..: - *....:<..•! Diffuser
140
-------
The diffuser can be an extension of the conduit or tunnel,
and can be perpendicular to the conveyance pipe or any angle
in between.
The estimate for a conduit diffuser is the sum of the in-
dividual costs for nozzles (601), the manifold (602.1 to
602.3) and installation of the diffuser as a unit (603.1).
In addition, Accounts 603.2 to 603.7 may apply. The pro-
cedure for estimating the cost of a tunnel diffuser is the
same as for a conduit diffuser except installation costs
are for the nozzles only (603.2).
Data for the individual accounts are presented in the
following paragraphs.
Steel nozzles, .Account 601
Key parameters are the construction material and the nozzle
diameter. Cost data are provided for shop fabrication of
steel nozzles from 1.27 cm steel plate. Precast concrete
pipe prices include an allowance for pipe sections with the
nozzles attached as part of the manufacturing process.
Therefore, separate costs for concrete nozzles are not
given. The costs for cutting the hole for the nozzles, or
for slots, into the steel pipe and welding nozzles to the pipe
can be neglected. The costs for steel nozzles are used for
the tunnel manifold application.
Manifolds, Accounts 602.1 to 602.3
If the manifold is a conduit, the pipe and fitting costs
given in Cost Category 4 can be used. One example of
141
-------
fitting costs is for reducers which are considered because
the conduit diameter may decrease as the distance from the
end of the conduit increases. Decreasing the manifold
diameter is done to maintain uniform discharge and to pre-
vent siltation in the outer ends of the manifold. If the
manifold is a tunnel-type, use the cost data given in
Category 5.
Installation of conduit
diffuser, Account 603.1
The slots will be cut or the nozzles attached to the con-
duit on land. Costs for installing this type of manifold
can be assumed to be equal to conduit installation costs.
Refer to Cost Category 4 for information. If the diffuser
is at an angle to the conduit, costs for a concrete
anchor block at the junction should be included in the
estimate (see Cost Category 7). A vertical shaft from a
tunnel can be raised to the lake bed and a conduit manifold
installed. This method may require a cofferdam (see
Category 2) during excavation and connecting the manifold
to the tunnel shaft. Connection of a conduit manifold to
the end of the pipe can be done underwater as part of the
laying operation.
Installation of nozzles into a
tunnel diffuser, Account 603.2
Key parameters are the method of installation, the number
of nozzles, and the depth of rock penetrated by the nozzle
riser. Two methods that are used to install nozzles into
a tunnel are to:
142
-------
1. first mine the tunnel manifold, then drill the
hole and grout in the nozzle (placing the nozzle
after the tunnel is mined requires tunnel de-
watering, capping the hole from the inside,
drilling the nozzle hole, and grouting the nozzle
into place); or
2. drill holes into the rock bottom and grout the
nozzle into the desired location prior to mining
the tunnel (The nozzle is capped to prevent
water from entering when the tunnel excavation
reaches the nozzle).
Costs for using a large drill mounted on a barge to drill
the nozzle holes prior to mining the tunnel, method No. 2
above, are given in this account. Grouting costs can be
neglected because the hole is only drilled 3 to 5 cm
larger than the nozzle riser diameter.
Cofferdams, Account 603.3
A cofferdam may be used when connecting a conduit manifold
to the end of the tunnel. Other applications of cofferdams
can be included in this account. See Cost Category 2 for
the discussion on cofferdams.
Trench excavation, Account 603.4
A discussion of offshore trench excavation is given in
Cost Category 9.
Diffuser support systems,
Account 603.5
A discussion of piles and concrete is included in Cost
Categories 2 and 7, respectively.
143
-------
Riprap protection, Account 603.6
To prevent bed scour caused by the jets, riprap is placed
in the area around the diffuser. Information required to
estimate the cost for material and placement of the riprap
is given in Category 2.
Trench backfill, Account 603.7
The data required to estimate the costs for backfilling
the pipe trench are included in Cost Category 8.
Single Port, Account 604
The single port outfall usually includes a concrete struc-
ture. The costs for concrete are included in Cost Category
7.
Mobilization, Account 606
The costs for mobilization and demobilization are not in-
cluded in the unit prices. If the diffuser is a tunnel
manifold, the cost for towing the drill to the site is
given as the mobilization cost. The costs for mobilizing
the drill are not included. If the diffuser is a conduit
manifold, the mobilization costs given in Category 4 are
sufficient. A discussion of mobilization is given in Cost
Category 10.
144
-------
Table 78 presents the correlation between cost account
number, worksheet, and figure number. Costs are calcu-
lated using the procedure outlined in the introductory re-
marks to this section and the worksheets in Tables 79
through 93.
Table 78. DIFFUSER COST ACCOUNTS
Cost
Account
Number
Description
Figure
Number
Worksheet
Number
601
602
602.1
602.2
Costs are provided for
fabrication of steel
nozzles.
Manifolds (material and
fabrication as appropri-
ate)
Costs for steel manifolds
(see Cost Account 403)
Costs for concrete mani-
folds (see Cost Accounts
401 and 402)
601
601
602.1
602.2
145
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Table 78 (continued). DIFFUSER COST ACCOUNTS
Cost
Account
Number
602.3
603
603.1
603.2
603.3
603.4
603.5
603.6
603.7
604
605
606
Description
Costs for fittings, such as
tees and reducers, for
steel pipe manifolds are
provided in Cost Account
403.2. For concrete mani-
folds, fitting costs are
included in straight pipe
costs .
Installation costs
Conduit manifold (see Cost
Category 4)
Costs for installing indi-
vidual nozzles into a
tunnel
Costs for cofferdams
(see Cost Category 2)
Excavation costs (Cost
Category 9)
Costs for support systems
(see Cost Category 2 &7 )
Costs for riprap protec-
tion (see Cost Category 2)
Costs for backfill (see
Cost Category 9)
Single Port
Other
Mobilization
Figure
Number
—
603.2
—
—
—
—
__
—
__
;
Worksheet
Number
602.3
603.1
603.2
603.3
603.4
603.5
603.6
603.7
604
605
606
146
-------
Table 79. COST CATEGORY 6
COST SUMMATION
Cost
Account
Number
601
602
602.1
602.2
602.3
603
603.1
603.2
603. 3
603.4
603.5
603.6
603.7
604
605
Worksheet
Description
Nozzles
Manifolds
Concrete manifold
Steel manifold
Steel fittings
Installation
Conduit manifold
Nozzles
Cofferdams
Excavation
Diffuser Support
Scour protection
Backfill
Single Port
Other
600
BC601
BC602.1
BC602.2
BC602.3
BC603.1
BC603.2
BC603.3
BC603.4
BC603.5
1 BC603.6
BC603.7
BC604
BC .
000
Cost Category 6, Total Cost BCfi
(Enter cost in Acct. 1101)
606
Mobilization (Enter
Cost in Acct. 1001)
; MC6
i
Base
Cost
= $
= $
= $
=$
= $
= $
=$
= $
(^«
= S
= $
= £
=$
=$
=$
147
-------
Table 80. STEEL NOZZLES
Worksheet 601
Design Data Required
Nozzle inside diameter m
Riser length
m
Number of nozzles N =
Base Cost
Enter Figure 601, read base unit
cost per nozzle BUG =$
Base cost = N x BUG BC =$
Cost Adjustments
Enter Figure 601, read design adjust-
ment factor for the riser length(f) F =
Adjusted Base Cost
Adjusted cost = BC x FD BC601 =—
The riser length "f" is the distance from the (horizontal)
nozzle centerline to the top of the manifold minus 1.5
times the nozzle diameter.
148
-------
Table 81. CONCRETE MANIFOLD
Worksheet 602.1
Base Cost
Select Cost Account 401 for precast
concrete pipe or Cost Account 402
for cast-in-place conduit, whichever
is appropriate.
Base cost = BC4Q1 or BC4Q2 BC602.1
Table 82. STEEL MANIFOLD
Worksheet 602.2
Base Cost
Refer to Cost Account 403' Steel
Conduit. Base cost = BC4Q3 BC602 7
Table 83. STEEL MANIFOLD FITTINGS
Worksheet 602.3
Base Cost
Refer to Cost Account 403.2
Base cost = BC4Q3>2 BC6Q2>3 =$_
149
-------
Table 84. INSTALLATION OF
CONDUIT DIFFUSER
Worksheet 603.1
Base Cost
Select cost account 406.2 for dry in-
stallation within an offshore coffer-
dam or 407.2 for underwater installation.
Base cost = BC4Q6>2 or BC407>2 ^ =$
Table 85. INSTALLATION OF NOZZLES
INTO A TUNNEL DIFFUSER
Worksheet 603.2
Design Data Required
Number of nozzles
Length of the riser L = m
Base Cost
Enter Figure 603.2, read base
cost
Base cost = BC,A~ ,=$
OUJ.z —
Table 86. COFFERDAMS
Worksheet 603.3
Base Cost
Refer to Cost Account 202.2
Base cost = BC 2Q2 ^ BC603.2
150
-------
Table 87. TRENCH EXCAVATION
Worksheet 603.4
Base Cost
Refer to Cost Category 9 and select
the cost from either Cost
Account 901 or 902
Base cost = BCgoi or BC9Q2 BC603.4
Table B8. DIFFUSER SUPPORT SYSTEMS
Worksheet 603.5
Ease Cost
Refer to Cost Category 7
Base cost = the base cost from the
appropriate account in Cost
Category 7 BC603.5
Table 89. RIPRAP PROTECTION
Worksheet 603.6
Base Cost
Refer to Cost Account 201.2
Base cost = BC^..,, - EC =?
201.2 603.6—
151
-------
Table 90. TRENCH BACKFILL
Worksheet 603.7
base Cost
Base cost = base cost from the
appropriate accounts in Cost
Category 8. BC603 7
Table 91. SINGLE PORT
Worksheet 604
Base Cost
Refer to Cost Category 7 for
estimating procedure BC A -$_
Table 92. OTHER
Worksheet 605
Base Cost
Include costs not covered in this
category but that relate to the
diffuser. Data presented in
other accounts may be useful in
estimating "Other" costs. BCfinc- =$_
152
-------
Table 93. MOBILIZATION
Worksheet 606
Mobilization Cost
Mobilization = $30,000 if the diffuser
is a tunnel diffuser. If the total
length of offshore pipe is the
manifold for a conduit diffuser,
add $96,000. (Caution: do not
duplicate costs in Account 408.) MCg =$_
153
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("OriT CATEGORY 7, CONCRETE
TrirormaLiori on material and placement costs for concrete are
given in this category. Data for each of the accounts are
given in the following paragraphs.
Structural concrete, Accounts
701.1 and 701.2
The key parameters are concrete material and placement costs,
reinforcing quantity, the area of formwork, and finishing
costs. The data presented in References 2 and 4 suggest
grouping structural members with similar values for the
key parameters. For example, concrete costs for a wall or
suspended slab will be more expensive than a pipe cradle or
encasing a pipe in concrete without formwork. Therefore,
three general groups of structural members were selected.
The groups are:
1. suspended slabs, beams and walls;
2. spread footings, grade slabs, and pile caps; and
3. concrete structures with no reinforcing steel
and little or no formwork requirements.
The deck and walls for a pump station or other box type
structure would fit into Group 1. Channel lining or the
floor of the pump station and the pile caps used for a
structure foundation would fit into Group 2. Concrete cradles
cast on site are an example of Group 3.
Material costs for concrete can vary according to special
admixture requirements and strength. Costs given are for
medium strength (3000 psi) concrete without special admix-
tures. The cost differential between low strength (2,500 psi)
156
-------
and high strength (5,000 psi) concrete is $7/cubic meter.
It was not considered in presentation of the costs.
Concrete for the type of structures considered here can be
placed with a crane and concrete bucket. The crane can also
be used in formwork and placing the steel.
Reinforcing is separated in the accounting because this is
common practice for presenting estimates. The costs for
rebar reinforcing are given. A rule of thumb for mesh re-
inforcing is: It costs about twice as much as rebar rein-
forcing installed.
Concrete(marine), Account 702
The key parameters are the thickness of the structure and
waste. Tremie concrete ir>ay be used for pipe support, par-
tial encasement of a pipe to give the conduit added weight,
or thrust blocks for nozzles and the manifold. The concrete
is transported to the offshore site and placed using a flex-
ible hose extending down to within the formwork for the
structure being placed. Because the concrete is being placed
underwater, the top layer of the structure will be destroyed
by the mixing of concrete and water. Therefore, an allowance
for waste should be included in the quantity measured from
the neat lines on a drawing. A waste allowance of 20 percent
is appropriate. The unit cost was developed using the costs
for:
1. a flat-top barge and a tug boat to tow concrete
trucks to the site;
2. two cranes mounted on barges, one to swing a hop-
per between the concrete trucks and the flexible
hose and the other to support the flexible hose; and
157
-------
3. costs for labor and a diver are also included.
Grouting, Account 703
The key parameter is the rock conditions. Data are for
foundation grouting or forming a grout curtain to cut off
a water bearing strata. Grouting quantities can be mea-
sured in terms of the take.
The term "take" is defined as the ratio of the volume of
material that is pumped into a hole(s) to the drilled hole
volume. The unit costs for grout will vary inversely to
the take. Costs given are for a badly fractured rock. The
take is assumed to be double the hole volume for a 1.22 cm
diameter hole. Estimating take is difficult even with de--
tailed site data. In many cases, grouting is bid in terms
of cost per bag of cement and quantity of sand. Although
the data given will provide some measure of the cost, the
user should recognize the limitations. Costs for chemical
additives are not included.
Cushion fill, Account 704
The gravel base placed beneath a grade slab is similar to
the gravel filter used beneath riprap. Data for cushion fill
are obtained from Cost Account 201.1 (Filter material).
Mobilization, Account 706
Unit prices do not include mobilization and demobilization
costs. Costs for mobilizing equipment should be added only
158
-------
if a large concrete structure, other than the pump station,
is included in the modification. Otherwise, mobilization
costs given in Category 3 will suffice. A discussion of mo-
bilization is given in Cost Category 10.
Table 94 presents the correlation between cost account number,
worksheet, and figure number. Costs are calculated using the
procedure outline in the introductory remarks to this section
and the worksheets in Tables 95 through 102.
Table 94. CONCRETE COST ACCOUNTS
Cost
Account
Number
701
701.1
701.2
702
703
704
705
706
Description
Cast-in-place structural con-
crete costs for material and
placement of concrete and
reinforcing steel
Concrete placement
Reinforcing steel
Cast-in-place concrete
(marine)
Costs for grouting
Cushion fill (see Cost
Account 201.1)
Other
Mobilization
Figure
Number
701.1
701.2
—
—
--
—
--
Worksheet
Number
701.1
701.2
702
703
704
705
706
159
-------
Table 95. COST CATEGORY 7
COST SUMMATION
Worksheet 700
Cost
Account
Number
701
701.1
701.2
702
703
704
705
Description
Structural concrete
Concrete placement
Reinforcing steel
Concrete (marine)
Grouting
Cushion fill
Other
Cost Category 7 Total Cost
(Enter cost in Account 1101)
706
Mobilization (Enter
cost in Acct. 1001)
Base
Cost
BC701
BC701
BC702
BC703
BC704
BC705
BCy
MC-,
! = $
-, =5
• <-
<*•
= $
= $
= $
= $
<^
~~v
The user is cautioned that most of the time the costs for
these accounts are used in other categories. Do not enter
here if they are used in another category.
160
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Table 96. CAST-IN-PLACE
STRUCTURAL CONCRETE, CONCRETE PLACEMENT
Worksheet 701.1
Design Data Required
Category of structure
Volume of concrete m
Base Cost
Enter Figure 701.1, read base cost BC7Qi i "$
1. Suspended slabs, beams, walls.
2. Spread footings, grade slabs, and pile caps.
3. Structures with little or no reinforcing.
Table 97. CAST-IN-PLACE STRUCTURAL
CONCRETE, REINFORCING STEEL
Worksheet 701.2
Design Data Required
Category of structure
•T-
Weight of reinforcing steel kg
Base Cost
Enter Figure 701.2 read base cost BC7oi 2 =—
al. Suspended slabs, beams, and walls.
2. Spread footings, grade slabs, and pile caps.
3. Structures with little or no reinforcing.
If weight of reinforcing steel is not available, assume
values shown in the following table:
161
-------
Table 97 (continued). CAST-IN-PLACE STRUCTURAL
CONCRETE, REINFORCING STEEL
Worksheet 701.2
Weight of Reinforcing
Category to assume/ kg/rn^ of cone.
1 89
2 71
3 0-20
Table 98. CAST-IN-PLACE
CONCRETE (MARINE)
Worksheet 702
Design Data Required
Volume of concrete V = m
Base Cost
Base cost = V x $86.30/m3 BC702
Unless detailed data is available, add 20 percent to
design volume of concrete for waste during underwater
placement.
Table 99. GROUTING
Worksheet 703
Design Data Required
Volume of drilled holes V = m
Base Cost
Base cost = 2V x $231.90/m3 BC703 =^
162
-------
Table 100. CUSHION FILL
Worksheet 704
Base Cost
Refer to Cost Account 201.1 for
cost estimating procedure BC7f. . =$_
Table 101. OTHER
Worksheet 705
Base Cost
Include costs not covered in this
category but that relate to
concrete. Data presented in
other accounts may be useful in
estimating "Other" costs. BC7QC5 =£-
Table 102. MOBILIZATION
Worksheet 706
Mobilization Cost
For a large structure other than
the pump station, add $3,300 MC_ =$_
163
-------
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164
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COST CATEGORY 8, FILL
Data on the costs of material and placement of fill are
Given in this category.
Data for the accounts of Cost Category 8 are given in the
following paragraphs.
Material and hauling
costs, Account 801
The key parameters are the cost of the material and the
haul distance. A discussion of hauling costs is given in
Cost Category 1. The types of fill considered in this
account are unclassified earth, sand, gravel (either bank
run or graded) and topsoil. Costs for stone fill such as
riprap are included in Cast Category 2. Costs for operating
the borrow are included in the material costs.
Placement of fill (land),
Account 802.1
Key parameters are the working area, methods of compaction,
and extent of compaction. Placement of material can be
classified into three groups. The groups are as follows:
Group 1 - The costs for a grader to spread fill that
has been dumped from a truck are given. Compaction
costs are not included. Spreading topsoil or filling
swales are examples of activities included in this
group.
Group 2 - Placement and compaction of fill around
structures. Costs for placement of the material with
a loader and using hand tampers to compact the fill
are given. Placing fill around conduits and the pump
stations are examples of this group.
165
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Group 3 - Placement and compaction of fill in an open
area. Costs were developed assuming that a vibrating
roller is used for compacting granular material and a
sheepsfoot roller for compacting earth material. When
the area immediately around the pipe has been compacted
by hand, any additional compaction requirements can be
met using machine compaction.
Placement of fill (marine),
Account 802.2
The key parameter is the type of placement. Backfill of the
pipe trench or placing cushion fill in the pipe trench can
be done by loading the material into scows, towing the scows
offshore and releasing the material into the trench from the
scow. If the fill is to be used in a cell cofferdam, costs
for off-loading the material using a crane mounted on a barge
are given. Costs for backfill using material that was side
cast are included.
Mobilization, Account 804
Unit prices do not include mobilization and demobilization
costs. Mobilization costs for the equipment used to backfill
the pipe trench and pump station are given in Cost Category 4
and Category 3, respectively. Therefore, mobilization costs
for dumping and spreading fill will generally be the only
costs added from this account. A discussion of mobilization
is given in Category 10.
Table 103 presents the correlation between cost account num-
ber, worksheet, and figure number. Costs are calculated
using the procedure outline in the introductory remarks to
this section and the worksheets in Tables 104 through 1Q9.
166
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Table 103. FILL COST ACCOUNTS
Cost
Account
Number
801
802
802.1
802.2
803
804
Description
Material and
Placement of
hauling costs
fill
Cost placement and com-
paction of fill on land
Placement of
(marine)
Other
Mobilization
fill offshore
Figure
Number
801
802.1
802.2
—
—
Worksheet
Number
801
802.1
802.2
803
804
Table 104. COST CATEGORY 8
COST SUMMATION
Worksheet 800
Cost
Account
Number
Description
Base
Cost
801
802
802.1
Material and hauling
costsa
Placement of fill
Placement of fill
(land)
BC
801
=$
BC
802,
aThe user is cautioned that most of the time the costs
for these accounts are used in other categories. Do
not enter here if they are used in another category.
167
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Table 104 (continued). COST CATEGORY 8
COST SUMMATION
Worksheet 800
Cost
Account
Number
Description
Base
Cost
802.2 Placement of fill
(marine)
803 Other
BC802.2"$-
BC
803
Cost Category 8 Total Cost
(Enter cost in Acct. 1101)
BC,
804
Mobilization (Enter
cost in Acct. 1001)
MC,
— $
Table 105. MATERIAL AND HAULING COSTS
Worksheet 801
Design Data Required
Type of fill material
Haul distance (round trip)
from the borrow site
Volume of fill V =
Jem
m3
If haul distance is not known, assume an 18-km haul,
168
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Table 105 (continued). MATERIAL AND HAULING COSTS
Worksheet 801
Base Cost
Enter figure 108.2, read base BUC = $_
unit cost for hauling.
Base cost for hauling = BUC x V BC. = $_
Enter Figure 801, read base cost BC,, = $_
£* "
Cost Adjustment
Enter Figure 801, read adjustment F = __
factor for material
Adjusted Base Cost
Adjusted base cost = (BC-> x F_^ ) BCon, = $
D 801 -
Table 106. PLACEMENT OF FILL (LAND)
Worksheet 802.1
Design Data Required
iture of the j
group number
Nature of the placement operation3
Volume of fill V «= m3
Group 1 - Dump and spread fill
Group 2 - Hand compaction of fill
Group 3 - Machine compaction
169
-------
Table 106 (continued). PLACEMENT OF FILL (LAND)
Worksheet 802.1
Base Cost
Enter Figure R02.1, read base cost BCori_ , = $
o (.) 2. . X
Table 107. PLACEMENT OF FILL (MARINE)
Worksheet 802.2
Design Data Required
Nature of the placement operation3
Volume of fill V = m
Base Cost
Enter Figure 802.2, read base cost BC0 ,, =$
O U £.. • £.,
aBackfill of a pipe trench; placing fill into a cofferdam
or backfill using excavated material side cast along the
trench.
170
-------
Table 108. OTHER
Worksheet 803
Base Cost
Include costs not covered in this
category but that related to
Fill. Data presented in
other accounts may be useful in
estimating "Other" costs.
Table 1Q9. MOBILIZATION
Worksheet 804
Data Requirements
802.1 Mobilization costs for Group Summation
1 of the land placement of
fill is $1,700
dThe costs for Group 2 is $900
The costs for Group 3 is $800 ]
Mobilization Cost
Mobilization = the total of the summation
column. Usually only Group 1 of account
802.1 will be considered (see the
discussion for this account). MC0 =$
o —
Use the costs for group 2 and 3 only if there is a large
structure other than the pumping station that requires
backfill.
171
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173
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COST CATEGORY 9, EXCAVATION
Data are given for land and marine open cut excavation. Tun-
nel excavation is not included in this category.
Data for each account are given in the following paragraphs.
Earth excavation (land),
Account 901.1
Key parameters considered are volume of excavation and the
physical size of the excavation.
The volume of excavation and the physical size of the trench
or foundation will affect the choice of equipment. For the
relatively small excavation volumes encountered in this type
of construction, the size of the excavation has the greater
influence on equipment costs.
Land-based earth excavation, therefore, is grouped according
to size of the excavation. The volume of excavation is im-
plied in the choice of equipment. The groups are:
1. Structures and trench excavation for small buildings,
for additions to existing buildings and for smaller
pipes - Production rates are low, yet the labor and
equipment costs are relatively high. Unit costs
were developed for using a hydraulic backhoe to
excavate the material.
2. Structure excavation for larger structures such as
a pumping station - The sizeof the equipment used
and the associated costs do increase. However, the
production rates improve. Unit costs include the
cost for a crane rigged with a clam or dragline.
3. When pipe diameters approach the size that require
a trench width equal to that of a scraper, less costly
excavation methods can be used - The costs for
using a scraper to excavate the material was used
in unit cost development.
174
-------
Water problems and the necessity for shoring add to the cost
of excavation, see Accounts 903 and 904 and may reduce pro-
ductivity. The cost data given in this account were developed
assuming the area enclosed in shoring can be dewatered and is
large enough not to hamper production significantly.
Earth excavation (marine),
Account 901.2
Key parameters are the volume of excavation, type of material,
the method of disposal, and production rates. It is assumed
the equipment production time will be 16 days per month, and
the work periods will be 24 hours per day for a six-day week.
The production for days spent actually excavating material
will vary according to weather delays, maintenance require-
ments, and the distance to a protected harbor. The working
season affects annual production time. In the northern
climate, the work season is 7 to 8 months compared to 12
months in the south. All these variables affect the costs
making an "average" unit cost difficult to assess.
The information presented for this type of excavation is
related to the consistency of the material and method of
disposal. Materials are classifed into three groups and a
type of excavation equipment assumed for each. The groups
and equipment are:
1. A hard material (a till or weathered rock) - It was
assumed excavation is done with a barge-mounted
backhoe (dipper dredge) with spuds that secure it
to the bottom for leverage.
2. A firm cohesive material - Excavation of this type
of material will be done using a barge-mounted
clamshell dredge. (Sand is an example of firm
material).
3. Soft material (unconsolidated silt) - Excavation
of this material will also be done with a clamshell
dredge. Production rates will improve over (2) above.
175
-------
The minimum bottom width that can be dug with the dipper
dredge is 7 to 8 meters. The clam can excavate a 3-meter
wide trench. When this equipment works in shallow water the
trench will be excavated to 30 meters wide.
Offshore excavation relates exclusively to digging the pipe
trench. The materials excavated from the trench can be side
cast along the trench or disposed of on shore in designated
areas. On-shore disposal requires the addition of scows
and tug boats to the equipment pool for transporting the
spoil to shore. The haul distance offshore then becomes a
factor. It is assumed the distance to the shore offloading
point is within a kilometer of the excavation area. Costs
for maintenance of the disposal area are left to the user.
Data presented in this manual will be useful.
Rock excavation (land),
Account 902.1
Key parameters are the dimensions of the trench and disposal
of the material. A narrow deep trench will require more
control holes per unit volume of rock, and cleanup costs are
more because of the equipment size limits. Differences in
unit prices for a narrow and wide trench are reflected, in
the productivity assumed. An arbitrary division between a
narrow and wide trench is 5 meters. The trench in many
cases will be over-excavated to allow .8 meters of sand for
pipe bedding. The user should include an allowance for this
in the estimate. Costs for a rock drill and a crane with
clam to remove the rock from the trench are used in developing
unit costs for this account.
176
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Powder costs are included as a lump sum of $3/cubic meter.
Rock excavation (marine),
Account 902.2
Key parameters are the volume, the disposal of the materials,
and production rates. A production time of 16 days per month
and a work period of 6 days per week is assumed. For some of
the work, a period of 24 hours per day is assumed. The same
limitations on production exist for this account as for account
901.2.
The methodology assumed for excavation of rock offshore is
to:
1. blast the rock;
2. load the blasted material with a dipper dredge into
a scow;
3. tow the material to shore; and
4. transfer material from the scows to trucks or to
a stockpile for disposal.
Powder costs are added as a lump sum of $3/per cubic meter.
The trench is often over-excavated to minimize clean-up
work and to allow for placing a sand bedding for the pipe.
Assume over-excavation to be 1 meter.
Shoring, Account 903
A discussion of sheet piling used for excavation shoring is
given in Cost Category 2.
177
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Excavation Dewatering,
Account 904
Key parameters are the initial and the sustained dewatering
requirements. The procedxire used here is to:
1. assume an inflow rate;
2. develop the costs for pumping on a per week basis?
3. equate the excavation time and the pumping time;
4. divide the production rate into the total volume
of excavation; the quotient is the pumping time
(production rates used are the same as those used
in developing the unit costs).
Therefore, given the inflow, the volume of excavation and
the group number, (see Account 901.1) sustained dewatering
costs can be estimated. Initial dewatering costs are not
given.
Mobilization, Account 905
Unit prices do not include the cost for mobilizing and de-
mobilizing equipment. Mobilization costs were added for
marine and land installation in Category 4. A discussion of
mobilization costs is given in Cost Category 10.
Table 110 presents the correlation between cost account num-
ber, worksheet, and figure number. Costs are calculated
using the procedure outline in the introductory remarks to
this section and the worksheets in Tables 111 through 119.
178
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Table 110. EXCAVATION COST ACCOUNTS
Cost
Account
Number
Description
Figure Worksheet
Number Number
901
901.1
901.2
902
902.1
902.2
903
904
905
906
Earth excavation
Earth excavation (land):
Costs for earth excava-
tion of channels, founda-
tions, and pipe trenches
Earth excavation (marine):
Costs for excavation of a
pipe trench for three
general types of material
and for alternative
disposal methods
Rock excavation
Rock excavation (land):
Costs for onshore rock
excavation
Rock excavation (marine):
Costs for excavation of
pipe trench offshore in
rock material
Shoring: Shoring costs for
foundation and trench ex-
cavation using steel sheet
piling (see Category 2)
Dewatering: The cost of de-
watering for foundation
and trench excavation
Other
Mobilization
901.1
901.2
904
901.1
901.2
902.1
902.2
903
904
905
906
179
-------
Cost
Account
Number
Table 111. COST CATEGORY 9
COST SUMMATION
Worksheet 900
Description
Base
Cost
901
901.1
901.2
902
902.1
902.2
903
904
905
Earth excavation
Earth excavation (land)
Earth excavation
(marine) a
Rock excavation
Rock excavation (land)
Rock excavation
(marine) a
Shoring for excavation
Dewatering during
excavationa
Other
.1
=?
BC =$
Bt-901.2 £-
.1
RC =$
BS02.2 -
BC904 =1
BC905 =1
Cost Category 9 Total Cost
(Enter cost in Account 1101)
=$
906
Mobilization (Enter
cost in Acct. 1001)
=$
The user is cautioned that most of the time the costs
for these accounts are used in other categories. Do
not enter here if they are used in another category.
180
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Table 112. EARTH EXCAVATION (LAND)
Worksheet 901.1
Design Data Required
Type of excavation
Volume of excavation V = m
Haul distance (round trip) from ,
excavation site to disposal site km
Base Cost
Enter Figure 901.1, read base cost
for excavation EC(1) =$
Enter Figure 108.2, read base unit
cost for hauling BUG(2) =$
Base cost for hauling = V x
BUG (2) BC(2)
Total base cost = BC(1) + BC(2) BC901
1. Trench or small foundation
2. Large foundation
3. Channel or large trench
If haul distance is not given and hauling is known to
be a factor assume 8-km round trip.
181
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Table 113. EARTH EXCAVATION (MARINE)
Worksheet 901.2
Design Data Required
Type of excavation (soft, firm, hard)
Volume of excavation V =
!„
Disposal method
Haul distance (round trip) km
Base Cost
Enter Figure 901.2, read base cost
for excavation BC(1)=$
Enter Figure 108.2, read base
unit cost for haul BUG(2)=$
Base cost for hauling = V x
BUG(2) EC(2)=$
Cost Adjustment
Enter Figure 901.2, read design adjust-
ment factor for disposal method Fn
Adjusted Base Cost
Adjusted cost = ((BC(1) x F,) +
BC(2))
Soft - Sand or unconsolidated silt.
Firm - Clay or other cohesive material
Hard - Till or soft, weathered rock.
Side cast or hauled to shore
From the shoreline to a land disposal area. If this haul
distance is unknown, assume an 8-km round trip.
182
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Table 114. ROCK EXCAVATION (LAND)
Worksheet 902.1
Design Data Required
Volume of excavation V = m
Haul distance (round trip) from ex-
cavation site to disposal site km
Bottom width of the trench m
Base Cost
Enter Fig. 902.1, read base
cost for excavation BC(1) =$
Enter Figure 108.2, read base
unit cost for hauling BUG(2)=$
Base cost for hauling =
V x BUG (2) BC(2) =$_
Total base cost = BC(1) + BC(2) BCQn9 -,=$
.7 (J £ * JL *"
If haul distance is not given and hauling is known to
be a factor, assume 8-km round trip.
183
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Table 115. ROCK EXCAVATION (MARINE)
Worksheet 902.2
Design Data Required
Volume at excavation V = m
Haul distance (round-trip)
from shoreline to disposal
area km
Base Cost
Base cost for offshore rock
excavation = $55.40/m3 x V BC(1) = $
Enter Figure 108.2, read base
unit cost for rock haul and
disposal BUG(2) = $
Base cost for haul and
disposal of waste rock
V x BUG (2) BC(2) = $_
Total base cost = BC(1) +
BC(2) BC = §
If haul distance is not given and hauling is known
to be a factor assume 8-km round-trip.
184
-------
Table 116. SHORING
Worksheet 903
Base Cost
Reder to Cost Category 2 for cost
estimating Procedures. Base cost =
E (appropriate base costs from
Account 202) . BC
903
Table 117. EXCAVATION DEWATERING
Worksheet 904
Design Data Required
Volume of excavation V r m
Type of excavation group
Base Cost
Enter Figure 904, read base cost BCQ04
Group 1 - Trench or small foundation
Group 2 - Large foundation
Group 3 - Channel or large trench
185
-------
Table 118. OTHER
Worksheet 905
Base Cost
Include costs not covered in this
category but that relate to
excavation. Data presented in
other accounts may be useful in
estimating "Other" costs.
gOl.l^Gr
902. la
oup No. )
1
2
3
$1,000
$3,300
$1,500
$4,000
Table 119. MOBILIZATION
Worksheet 906
Data Requirement
Cost Account Mobilization
NumberCostsSummation
Mobilization Cost
Mobilization = the total of the
summation column (above) MCg = $>_
These costs are included only if there is excavation other
than for a pump station or a pipe trench.
186
-------
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188
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COST CATEGORY 10, MOBILIZATION
Information on the costs for mobilization and demobilization
of equipment used in construction of the facilities is given.
The costs for field offices, mobilization of supervisory peo-
ple, etc., is included in overhead costs. The key parameters
affecting mobilization are the location of the site relative
to equipment location and whether the contractor uses his
equipment or rents the equipment. Obviously, if the job is
in the immediate area of the equipment, the cost for mobili-
zation will be minimal. Also, the contractor may choose to
rent the equipment from a local firm, thus effectively eli-
minating the cost for mobilization. It is not possible to
predict the location of equipment nor whether or not the
contractor will rent or use his own equipment. Therefore,
it is assumed the equipment will have to be towed (marine) or
shipped to the site.
Data for estimating mobilization costs are given for all the
categories except tunnels. Equipment for tunneling is
specialized, and there is very little published data available
to base an estimate for mobilization. Therefore, mobilization
costs for tunnels are given as a percentage of the total
costs for that category. Data from contracts listed in the
Engineering News Record were used to develop a reasonable
percentage to apply to tunneling costs for mobilization.
Analysis of 50 contracts given by Engineering News Record
revealed that approximately 5 percent of the total construc-
tion cost is included in mobilization and demobilization.
No trend with regard to total construction cost was found.
For costs ranging from 0 to 1 million, 1 million to 10 mil-
lion, and 10 million to 100 million, the percentages for
mobilization and demobilization were 4.0, 4.9, and 5.0, re-
spectively.
189
-------
The mobilization data are grouped into two accounts. The
first account included data for all categories except tun-
neling. The second account relates to tunneling only.
Mobilization, Account 1001
Land Based -
The key parameters are equipment location, type, and weight.
Mobilization costs may include:
1. shipping costs expended in getting the equipment to
the construction site (rail freight plus the cost
to off-load and truck the equipment to the site is
on weight basis), and
2. the labor, supplies, and equipment required to pre-
pare the equipment for operation (Equipment shipped
by rail is partially disassembled. Crane booms are
taken off and the tracks are removed from a crawler
tractor, for example. In addition, most of the
lubricants are removed).
Demobilization costs include preparation of the equipment for
shipping and hauling it to the railroad loading area. The
data given for mobilization include trucking and equipment
preparation costs. The mobilization costs given represent
the assumed upper limit of costs; beyond which the contrac-
tor would rent local equipment.
Marine -
The key parameters are the location of the equipment relative
to the job site and the number of pieces of equipment.
The equipment is towed to the site with tug boats. To de-
velop the mobilization costs, the towing time required and
190
-------
the number of equipment items requiring towing must be con-
sidered. The construction is grouped into categories based
on the type of conveyance to the offshore discharge.
1. Tunnel - If a tunnel is used, the offshore require-
ments will be equipment for the activities of Cost
Category 2 and Category 6. The rental rate for one
tug boat for two weeks is assumed.
2. Conduit - If a conduit is used, the offshore re-
quirements increase. The rental rate for three
tug boats for two weeks is assumed; one for excava-
tion, one for the lay barge, and one for backfill
of the trench.
Mobilization for tunneling,
Account 1002
Mobilization for tunneling work includes electrical, ventila-
tion, and other equipment. Insufficient published data was
located to prepare an estimate for mobilizing tunneling
equipment. Therefore, based on the Engineering News Record
data, a markup of 5 percent is suggested.
Table 120 presents the correlation between cost accounts and
worksheets. Costs are calculated using the introductory re-
marks to this section and the worksheets in Tables 121-123.
Table 120. MOBILIZATION COST ACCOUNTS
Cost
Account
Number
1001
1002
Description
Mobilization
Other
Figure
Number
--
--
Worksheet
Number
1001
1002
191
-------
Table 121. COST CATEGORY 10
COST SUMMATION
Worksheet 1000
Cost
Account
Number
Description
Ease
Cost
1001
1002
Mobilization
Other
'1001
Cost Category 10 Total Cost
(Enter cost in Acct. 1101)
BC
10
Table 122. MOBILIZATION
Worksheet 1001
Data Requirements
Cost Category
Number
1
2
3
4
5
6
7
Mobilization
Cost
MC2 =
MC- =
MC6 =
MC =
$_
$_
$
$_
$_
$_
$
Base Cost
Total
192
BC
1001
-------
Table 123. OTHER
Worksheet 1002
Base Cost
Include costs not covered in this
category but that relate to
mobilization. Data presented in
other accounts may be useful in
estimating "Other" costs. BC1002 = —
193
-------
COST CATEGORY 11, CAPITAL
COST RESOLUTION
The information provided in this category gives the user the
capability to:
1. adjust the unit price for regional and time varia-
tions;
2. determine project costs; and
3. resolve the capital costs into annual costs.
Most of the data that are used to develop project and annual
costs are in the form of percentages applied to the construc-
tion costs or added cost items such as land or leasing costs,
The values for some cost burdens cannot be included in the
manual. An approximate value is given for the factors or a
source for the data is identified. Whenever possible, local
data sources should be used. Data for the accounts of this
category are given below.
Time and regional adjustment
factor, Account 1101
The key parameters are cost escalation, regional price dif-
ferences and the initial price levels. The prices are for
the New York City area in December 1974. The regional ad-
justment factors were derived using the average of the ad-
justments given in References 2, 3, and 4. Regional adjust-
ment factors are tabulated on the worksheet provided for this
account.
Data provided in the Engineering News Record (ENR) were cho-
sen to reflect price escalation because it is readily avail-
able, the indexes are revised weekly, and the data are consi-
dered good indicators of price trends in the construction
industry. Two indexes are presented in the ENR that reflect
194
-------
the cost trends in construction wages and material: the
Building Cost Index and the Construction Cost Index. The
Building Cost Index is based on material costs and skilled
labor. Common labor is substituted for skilled labor in the
Construction Cost Index. The authors of Engineering News
Record suggest the Construction Cost Index should be used
when the costs for common labor are a large percentage of the
total cost. That description for common labor hours
applies to the type of work considered here. Therefore,
the 20-cities average Construction Cost Index was adopted.
The December 1974 value of the ENR Construction Cost Index,
2097, is given in the worksheet for this account. Use
Figure 1100 to project beyond December 1974. Data are provi-
ded from 1969 to 1974, projection beyond December 1974 is
left to the user.
Total project costs,
Account 1102
The key parameters are the percentages and values selected
and the order in which they are applied. Project costs in-
clude, in addition to the construction costs, burdens
to the owner for:
1. engineering and general and administrative costs
(Engineering costs include design costs, model
studies, and construction supervision. General
and administrative costs include payrolls, records,
and construction management. A value of 10 percent
is considered representative for this cost markup);
2. land costs (Costs for easements, rights-of-way,
and purchase of land required to accommodate the
discharge system or its modification must be con-
sidered. Local county officials and real estate
salesmen are sources for data);
3. contingency (The value of contingency should re-
flect the type of input data used. If the quanti-
ties were taken from detailed drawings, a contingency
195
-------
0)
2500
2400
2300
2200
H
I
U
S
X
w
Q
H
EH
O
U
is
0
H
U
«
C/3
O
U
2
w
2100
2000
1900
1800
1700
1600
1500
1400
n on r\
1200
1969 1970 1971 1972 1973 1974 1975 1976 1977 1978
DATE
Fig. 1100 - ENR 20-City Construction Cost Index
196
-------
of 5 percent may be appropriate. A contingency of
25 percent may be more appropriate for a planning
type estimate);
escalation during construction (Construction costs
are calculated in base year dollars. Because of
inflation, the prices will rise over the construc-
tion period. The procedure used to calculate es-
calation is to assume a cash flow and apply escala-
tion to the costs in each year. In most cases,
the construction period for this type of work will
be less than three years. Values of the construc-
tion cost index for the period from 1969 to Decem-
ber 1974 are plotted in Figure 1100. Dividing the
project average ENR Index for the construction
period by its base year value provides an adjust-
ment factor for escalation. Projection beyond
December 1974 is left to the user);
interest during construction (The cost for inter-
est on the capital required at the time of con-
struction. The interest rate depends on the capi-
tal structure of the utility. The user should
contact a stock broker to determine the interest
rate on bonds for the utility considered); and
royalties, licenses, fees, etc. (One-time costs for
licenses and miscellaneous fees should be consi-
dered. State and Federal agencies can provide the
data for estimating license costs. If no data are
available, because this item is small, it may be
assumed as zero).
Power outage costs,
Account 1103
The key parameters are the time, the plant capacity factor
and the unit cost of equivalent or replacement power. It
was assumed the utility can purchase the power. Outage costs
do not imply cost for interim power generation equipment.
In many cases the actual conversion from the old to new sys-
tem will not cause an interruption in power genera-
tion. Extended plant downtime may be avoided by construction
of a temporary discharge system. Construction costs for a
197
-------
temporary discharge can be estimated using the data in Cate-
gories 1 through 10 and should be included in the total
construction costs. The annual maintenance period may be an
appropriate time to complete the conversion. However, there
will be cases where interruption of power is unavoidable.
The power outage period is a value that the user must supply.
The unit cost for power during the outage period is equal
to the cost to purchase the replacement power from another
utility minus normal production expenses. The region, the
utility and the regional power grid demand at the time of
outage will all affect the unit power costs. The user should
contact the utility for specific data, including an appropriate
plant capacity factor.
Annual Costs, Account 1104
Annual costs are useful in comparing systems because the
costs are resolved to a common base. The remaining useful
life of the plant and the life discharge system should be
assumed to be equal. The date the thermal electric plant
became operational can be found in Reference 7, which lists
data for all the plants in the United States. Assume the
initial plant life is 40 years in calculating the remaining
useful life. Annual costs include those listed below:
1. Amortization of the depreciable capital investment,
royalties, licenses, fees, etc., and power outage
costs •
Depreciable capital investment represents the
amount of the original value (or worth) that
will decrease with time. The depreciable capital
is calculated by subtracting the land costs and
198
-------
salvage value from the total project costs. Costs
for royalties, licenses, fees, etc. and power out-
ages 'are one-time charges that are neither depre-
ciable nor exactly non-depreciable. Amortization
of these one-time charges is lumped with the de-
preciable investment. Annual costs for the items
considered here are calculated by establishing a
sinking fund payment. At the end of the useful
life of the facility, the sum of the payments plus
interest will equal the original investment. Sink-
ing fund factors for interest rates of 8 and 12 per-
cent are given in the worksheet for this account.
2. Amortization of the non-depreciable capital invest-
ment
It is assumed land costs are recoverable at any time
Therefore, the non-depreciable investment is the
salvage value of the facility. The annual costs
for depreciation are calculated using the sinking
fund factors given for amoritzation of the depre-
ciable capital investment. Salvage value is a
credit and is included as a negative fixed charge.
The pumps will have some salvage value, but the
costs to remove tfre pumps at the end of the useful
life may exceed the credit. Therefore, the salvage
credit can be assumed to be negligible in most cases.
3. Interest on the capital investment
If the initial investment is financed by a bond
issue the interest payments on the bond issue are
included in the annual costs. Interest rates on
bonds will vary with the area and the capital struc-
ture of the utility. The interest rate value for
utility bonds can be obtained from a local stock
broker.
4. Rent or lease costs
The costs for renting or leasing equipment or pro-
cesses. Generally this type of cost is not im-
portant for the systems considered.
5. Operation costs
Additional operating costs attributed to the dis-
charge modification. Only the differential cost
for pumping is included in this item.
6. Insurance
Insurance rates will be based on the utility's
total system and will depend on the type of in-
surance. A value of 4 percent is considered
appropriate to apply to the total project cost.
199
-------
7. Property taxes
Property taxes can be determined from county
agencies in the area. The property taxes may
be assumed at 2 percent of the total project
costs.
8. Tax credit
The tax credit for installation of capital equip-
ment is included here. A tax credit is based
on:
a. the income tax rate (assume 48 percent is
applied to the depreciable capital);
b. depreciation rate (The depreciation rate
varies according to useful life. Tables of
depreciation rates are readily available);
c. depreciable capital (The total project costs
less the land costs and salvage value of the
facility equals the depreciable capital); and
d. depreciation schedules (Straight-line double
declining, sum of digits, etc. are some
schedules used. Depreciation schedules are
readily available. Therefore, no values are
given).
The differential cost for maintenance of the pumps is consi-
dered negligible.
Table 124 presents the correlation between cost account
number, worksheet, and figure number. Costs are calculated
using the procedure outlined in the introductory remarks
to this section and the worksheets in Table 125 through 129.
200
-------
Table 124. CAPITAL COST
RESOLUTION ACCOUNTS
Cost
Account 1
Number ]
1101
1102
1103
1104
Description
Time and regional adjustment
factor
Project costs
Power outage costs
Annual costs
Figure Worksheet
Number Number
1101
1102
1103
i — 1104
i
Table 125. COST CATEGORY 11
COST SUMMATION
Cost i
Account j
Number [
1101
i
1102
1103
1104
Description ,
Construction costs
Project costs
Power outage costs
Annual costs
Ease
Cost
BC1101 =^
BC,-,QO =$
BC1103 =-^
BC-1-1Q4 -$
201
-------
Table 126 (continued) . TIME AND
REGIONAL ADJUSTMENT FACTOR
Worksheet 1101
Data Requirements
Regional adjustment factor
Atlanta -
Baltimore -
Birmingham
Boston -
Chicago -
Cincinnati
Cleveland -
Dallas -
Denver -
Detroit -
.79
.84
.73
.90
.91
.95
.94
.77
.80
.93
Kansas City -
Los Angeles -
Minneapolis -
New Orleans -
New York -
Philadelphia
Pittsburgh -
St. Louis -
San Francisco
Seattle -
.90
.90
.85
.78
.00
.90
.89
.89
.94
.85
City nearest to construction area
Regional adjustment factor
Date construction is to begin or
period of price level being
considered
Engineering News Record
Construction Cost Index for
above date (20-city average)
Time adjustment factor =
ENRX ( ) : 2097a
Regional and time adjustment
factor = F x F
-L X\
R
ENRX =
F =
RT " —
The Engineering News Record 20-city average for
December 12, 1974
202
-------
Table 126. TIME AND
REGIONAL ADJUSTMENT FACTOR
Worksheet 1101
Data Requirements (cont'd)
Total costs from Categories 1 through 10
bC1 = $
BC2 =
BC =
BC7 = §_
BC8 =
BC10= 1
Total Cost = 5: (BC-L through BC1Q) EC =$_
Revised Construction Cost
Total cost = BCT x PRT BCH01
203
-------
Table 127. PROJECT COSTS
Worksheet 1102
Data Required
Total construction cost BC1101 ~ —
Cost for engineering and EC = $_
general and administrative
p. „ rj/-> 3.
° x
_
100 %
Costs for lands, easements, and BC = $>_
rights-of-way
Revised cost = BC, , A, + BC^ + BCT BC, = $
-LJ-U-L t Li X —
Adjustment for contingencies = BC« = $_
BC-. x (1 + %7100%)
1
Adjustment for escalation during BC., = $_
construction = BC? x
ENRX (beginning) J ENRX (end)
2 x ENRX (beginning)
Adjustment for interest during BC. = j?_
c _ -„ __ - 4
construction = BC., x
(1 + no.yrs. of construction
x annual interest rate/100%) =
BC3 x (1 + x %/100%)
Royalties, licenses, fees, etc. R = $_
Total Project Cost = BC4 + R BCH02 = —
Assume 10 percent.
With detailed information, use a factor of 5 percent;
for a planning estimate, use 25 percent.
£
See account discussion.
204
-------
Table 128. POWER OUTAGE COSTS
Worksheet 1103
Data Required
Period of outage T = weeks
Power generation losses P = kwh
= [capacity x outage
period x capacity factor]
Unit cost of power U = $/kwh
= Purchase cost - normal
production expenses
Outage Cost
T x P x U = BC1103 = ^
Table 129. ANNUAL COSTS
Worksheet 1104
1. Amortization of depreciable capital
investment and costs for power outage,
royalties, etc.
Useful Life Sinking Fund Factor,
Years Annual Interest Rate
li 12%
3 .30803 .29635
5 .17046 .15741
7 .11207 .09912
10 .06903 .05698
13 .04652 .03568
15 .03683 .02682
18 .02670 .01794
22 .01803 .01081
25 .01368 .00750
28 .01049 .00524
30 .00883 .00414
35 .00580 .00232
40 .00386 .C0130
205
-------
Table 129 (continued). ANNUAL COSTS
Worksheet 1104
Remaining useful life of the plant Y = yrs
Sinking fund factor (tabulated above) F =
for annual interest rate of % ~
Total project (first) cost BCH02 = —
Salvage value
Land costs
Royalties, fees, licenses, etc. R = $
Depreciable capital investment = D,
BC1102 ~
Power outage costs BC = $
The amount amortized is =
depreciable capital investment D = $_
+ power outage costs +
royalties, fees, etc. or
Dc + BC1103 * R
Annual cost = F x D C = $
2. Amortization of the non- N = $_
depreciable capital invest-
ment (F x S). NC is a credit
(see No. 9 below) .
3. Interest on the capital invest- B = _
ment. Bond interest rate
Interest payment = B%/100% x I = $_
(BC1102 + BC1103)
4. Rent or lease costs L = $
206
-------
Table 129 (continued). ANNUAL COSTS
Worksheet 1104
5. Operating costs. Electric power
in excess of the power required
before the addition or modification
= Theoretical Power v efficiency P = w
watts x 100%/ %
Annual operating hours H = hrs
Power costs = H x P x /kwha Z = $
6. Insurance (BC,ino - L - R) x I = $
%b/100%
7. Property taxes (BC1in9 - L - R) P^_ = $
x %c/100%
8. Tax credit
Income tax rate I =
!\
Methods of depreciation:
a. Straight line depreciation
Tax credit = Dc x IR%/ T., = $
(100% x Y)
= $ x %/(100% x Y)
b. Others (refer to the following tabulation)
aAssume $.018/kwh GAssume 2 percent
•i _
Assume 4 percent Assume 48 percent
207
-------
Table 129 (continued). ANNUAL COSTS
Worksheet 1104
T.
(annual
D T increments of
Yeojr (deprec. rt.) R Dc depreciation)
T T
1 = X i =
9. Annual costs = I (C - NC + I ^ + L^ + Z + I + Pt - 1'
Refer to a depreciation schedule for D for other than
straight line depreciation
208
-------
SECTION V
REFERENCES
1. Associated Equipment Distributors. 1974 Rental Distri-
butors, 25th Edition. Associated Equipment Distributors,
Oak Brook, Illinois. 1974. I65p.
2. McKee-Berger-Mansueto Inc. Building Cost File - 1974
Unit Prices, Eastern Edition. Construction Publishing
Company, Inc., New York. 1973. 266p.
3. McGraw-Hill Information Systems Company, and Wood and
Tower Inc. 1974 Dodge Manual for Building Construction
Pricing and Scheduling. McGraw-Hill Inc., New York.
1974. ?02p.
4. Godfrey, R.S. Means Building Construction Cost Data -
1974. Robert Snow Means Company, Inc., Broxbury,
Massachusetts. 1974. 290p.
5. Mayo, R.S., Thomas Adair, and Robert J. Jenny. Tunneling •
The State of the Art, R.S. Mayo and Associates, Lancaster,
Pennsylvania, for U.S. Department of Housing and Urban
Development, Washington, D.C. Contract H-76fi. January
196R. 270p.
6. Corps of Engineers. Engineering and Design, Tunnels and
Shafts in Rock. Department of the Arrry, Office of the
Chief of Engineers, Washington, D.C. Engineer Manual
Number 1110-2-2901. December 1973. 300p.
7. Bureau of Power. Steam - Electric Plant Construction
Cost and Annual Production Expenses, Twenty-third Annual
Supplement - 1970. Federal Power Commission, Washington,
D.C. Publication Number FPC S-209. 166p.
209
-------
REFERENCES (cont'd)
R. Federal Power Commission. The 1970 National Power
Survey, Part 1. U.S. Government Printing Office,
Washington, D.C. December 1971. 400p.
9. Blecker, II.G. and T.W. Cadman. Capital and Operating
Costs of Pollution Control Equipment Modules, Volume 1.
U.S. Environmental Protection Agency, Washington, D.C.
Publication Number EPA-R5-73-023a. July 1973. 225p.
10. Study Suggests Quantity Take-Off Estimating Most Accurate.
Engineering News Record, 192 (26):84-89. June 1974.
11. Rown, A.M., F.R. Bowerman, and N.H. Brooks. Diffusers
For Disposal of Sewerage in Sea Water. Transactions
ASCE, Volume 126, Part III: pp344-3R8. March 1961.
12. Herkimer, H. Cost Manual for Piping and Mechanical
Construction. New York, Chemical Publishing Company, Inc.,
195B. 176p.
13. Proctor, R.V. and T.L. White. Rock Tunneling With Steel
Supports. Commercial Shearing and Stamping Company,
Youngstown, Ohio. 1969. 290p.
14. Construction Scoreboard. Engineering News Record,
193 (25):21. December 1974.
210
-------
SECTION VI
CONVERSION FACTORS
Data for converting from English to the International System
of Units is given below:
One acre =
One cubic foot =
One cubic yard =
One foot =
One foot per second =
One gallon =
One gallon per minute =
One horse power =
One inch =
One mile =
One pound =
One pound per =
square inch
One square foot =
One square yard =
One ton (short) =
One yard =
4047 square meters
0.0283 cubic meters
0.7646 cubic meters
.3048 meters
18.29 meters per minute
3.785 x 10~3 power
.0630 liters per second
745.7 watts
2.54 centimeters
1.6093 kilometers
0.4536 kilometers
703.1 kilograms per square meter
.0929 square meters
0.8361 square meters
907.2 kilograms
0.9144 meters
211
-------
SECTION VII
APPENDICES
Page
APPENDIX A - Case Study 213
APPENDIX B - Background Unit Cost Data 269
212
-------
APPENDIX A
CASE STUDY
GENERAL
An example is included here to illustrate the application
of the procedures in the manual to an actual case of once-
through cooling water discharge system modifications. A
project description and step-by-step procedure for estimat-
ing the costs are given. The results using the method-
ology in the manual are compared with the actual construc-
tion costs.
The cost data for this project and the others listed in
Table 1, not included here, are not part of the information
used to develop the unit costs for the manual.
The basis for comparison of the costs is as follows:
1. Manual - Construction costs are December 1974
level and are adjusted for the project location.
A contingency of 5 percent is added (the data
were considered as detailed information).
2. Plant data - Actual construction costs for the
modifications to the once-through cooling water
discharge were furnished by the utility owner.
The costs are escalated from the mid-point of
the construction period to December 1974.
PROJECT DESCRIPTION
Project: Quad Cities - Station Units 1 and 2
Commonwealth Edison Company
Chicago, Illinois
213
-------
Quad-Cities Station is a nuclear fueled steam electric
generating plant located about 34 kilometers north1 of Moline,
Illinois on the Illinois shore of the Mississippi River,
(Pool 14). The plant consists of two-809 mWe boiling water
reactors which withdraw 65 cubic meters per second from the
Mississippi River for condenser cooling. The plant has an
open cycle condenser cooling system which discharges heated
cooling water into the river.
The original shoreline "side-jet" discharge system consisted of
a concrete lined channel with sheet pile slot jet emptying
into the Mississippi River. This was used as an interim
systen to meet the scheduled start-up date. In 1972, the
interim discharge system was modified to a multiport dif-
fuser type consisting of two underwater carbon steel diffuser
pipes with nozzles discharging water perpendicular to the
shoreline. The discharge arrangement is shown in Figure 1201.
All quantities and related information used in the cost de-
velopment were determined from drawings provided by Common-
wealth Edison Company.
Multiport
Diffuser
Flow
Existing
Discharge^
Channel
Permanent
Cofferdam Structure
Mississippi River
Discharge
Crib
House
Inlet Structure
Fig. 1201 - Discharge Arrangement at Quad Cities
214
-------
ESTIMATE
The following estimate includes costs for:
1. construction of a cofferdam across the discharge
channel;
2. removal of riprap from the existing channel bank
and excavation of a new channel to divert the flow
into the inlet structure;
3. construction of a concrete and steel sheet pile
inlet structure; and
4. installation of carbon steel pipe on land and a
multiport diffuser offshore. (Nozzles are arranged
along the conduit from near the shore to the off-
shore end of the pipe.)
The inlet structure is constructed by first driving piling
to form a rectangular area, excavating the material from
within the rectangle, installing the pipes and concrete
structure and finally backfilling with sand to the original
ground level.
Cost Category 1
Account 101, Riprap removal (Worksheet 101) -
The riprap removed from the channel is assumed to be stock-
piled on site and used for lining the new channel section.
Therefore, hauling costs are not included.
215
-------
Table 5. RIPRAP REMOVAL
Worksheet 101
Design Data Required
Haul distance to disposal site /V, f{. km
(round trip)a
Volume of riprap V =
Base Cost
Base cost for excavating riprap =
$5.40/n\3 x V BC(1) ~
Enter figure 108.2, read base
unit cost for rock haul and * j
disposal BUG (2)=$ /Vs/l, /m
Base cost for haul and disposal . ,
of riprap « V x BUG (2) BC(2) =$ /4< >f.
Total base cost = BC(1) + BC(2) BCioi =?
If haul distance is not provided, assume 8-km round trip.
Accounts 102, 103, 104.1, 104.2,
and 105 do not apply
216
-------
Account 106, Resceding (Worksheet 106) -
Table 11. RESEEDING
Worksheet 106
Design Data Required
Area of reseeding
= 5 *f
m
Base Cost
Base cost = A x $0.37/m^
BC
106
^
Account 107, Site Grading
(Worksheets 802.1, 901.1 and 107) -
A cut and fill operation is assumed. Material and hauling
costs are not included because earth excavated from the pipe
trench and from within the sheet piling enclosure can be
used to balance cut and fill. Costs are calculated on Work-
sheets 802.1 and 901.1, then transferred to Worksheet 107.
Table 108. PLACEMENT OF FILL (LAND)
Worksheet 802.1
Design Data Required
Nature of the placement operation
group number
Volume of fill
aGroup 1 - Dump and spread fill
Group 2 - Hand compaction of fill
Group 3 - Machine compaction
.
/
V -
m
-------
Base Cost
Enter Figure 802.1, read base
cost
Table 114. EARTH EXCAVATION (LAND)
Design Data Required
Type of excavation
Worksheet 901.1
3
Volume of excavation V = //&& m
Haul distance (round trip) from
excavation site to disposal site •" "" km
Base Cost
Enter Figure 901.1, read base
cost for excavation BC(1) =$
Enter Figure 108.2, read base
unit cost for hauling BUG(2) =$
Base cost for hauling = V x
BUG(2) BC(2) =$
Total base cost = BC(1) + BC(2) BC9oi 1 = $ ^/ Sf>O
T~r#vs •&
1. Trench or small foundation
2. Large foundation
3. Channel or large trench
If haul distance is not given and hauling is known to
be a factor, assume 8-km round trip.
218
-------
Table 12. SITE GRADING
Worksheet 107
Base Cost
Refer to Cost Category 8 and 9 for 4
appropriate cost accounts and cost '
estimate procedures. -S-
Base cost = I (appropriate
base costs) . BC107 =$
Accounts 108and 109 do not apply
Account 110 Mobilization (Worksheet 110) -
Table 15. MOBILIZATION
Worksheet 110
Data Requirement
Cost Account Mobilization
Number Cost Summation5
101 Add $3,300 for any one
102 of these accounts and
103 $6,600 if two or more
104.1 are used
105 $700
106 $400
107 See Cost Cat. 8 FZoo
108a $600
219
-------
Mobilization Cost
Mobilization = the total of the
summation column (above)
MCn
Add mobilization for hauling if accounts 101, 102, 103 or
106 are used.
The costs from each account are entered on cost summary
shent for Category 1.
Table 4. COST CATEGORY 1
COST SUMMATION
Worksheet 100
Cost
Account
Number
101
102
103
104
Description
Riprap removal
Concrete slab removal
Concrete removal
(nonslab)
Sheet pile removal
Base
Cost
BC,01 = Sbt0
BC = A/. 4.
BC - A, A.
JL U J
104 Sheet pile removal
104.1 Pulling costs
s
104.2 | Salvage credit
105 | Clearing and grubbing
i
106 Reseeding
107 ; Site grading
BC104.1 =
BSC104.2=
BC105 =
BC106 =
BC107 =
MA.
(-) At.A.
MA-
£., 0 &&
-7,&e
220
-------
109
Other
BC
109
Cost Category 1 Total Cost
(Enter cost in Account 1101)
BC,
=$ ;/, JZ.Q
110
Mobilization (Enter
Cost in Account 1001)
MC, =$ £>?^£>
x
Cost Category 2
Account 201.1, Placement of riprap
(land-based) (Worksheet 201.1) -
A total of 835 in of riprap is needed to line the new channel
to the inlet structure. Costs for material and hauling are
not included for the riprap stockpiled from removal opera-
tions (Account 101). The costs for placement and material
and hauling of riprap are included for the remaining 535
cubic meters of riprap.
Table 18. PLACEMENT OF
RIPRAP (LAND-BASED)
Worksheet 201.1
Design Data Required
Material
Volume of material
Haul distance (round trip) from ,
borrow site to construction site
221
-------
Base Cost
Enter Figure 201.1, read base
cost for material and place-
ment BC(1) =$ I2t 000
Enter Figure 108.2, read base _ _
unit cost for hauling BUG (2) =$
Base cost for haul = V x BUG (2) BC(2) = $
Total base cost = BC(1) + DC (2) BC2oi 1 = $
Cover stone, riprap stone, or filter stone.
If haul distance is not provided and seems appropriate,
assume 18-km round trip (see the discussion for this
account).
Table 18. PLACEMENT OF
RIPRAP (LAND-BASED)
Worksheet 201.1
Design Data Required
Material
(
Jfr/*./)
' 3
Volume of material V = 3 QQ m
Haul distance (round trip) from ,
borrow site to construction site H, = "~~ km
222
-------
Base Cost
Enter Figure 201.1, read base
cost for material and place-
ment BC(1)
Enter Figure 108.2, read base *-*s<3? ,.~-.rfr-
unit cost for hauling BUG(2) =$ /m
Base cost for haul = V x BUG(2) BC(2)
Total base cost = BC(1) + BC(2) BC2Q1 1
Cover stone, riprap stone, or filter stone.
If haul distance is not provided and seems appropriate,
assume 18-km round trip (see discussion for this
account).
Account 201.2 does not apply
Account 202.1, Steel sheet piling (land) -
Refer to Worksheet for costs of the piling used in the inlet
structure.
Table 20. STEEL SHEET
PILING (LAND)
Worksheet 202.1
Design Data Required
Area of sheet piling 21 5 ^>&
Intended usage
(temporary or permanent) TVv>y?*_/t//gj£
223
2
m
-------
Base Cost
Enter Figure 202.1, read base
cost BC
202.1
Accounts 203, 204, and 205 do not apply.
Account 206 Mobilization (Worksheet 206) -
Table 26. MOBILIZATION
Worksheet 206
Data Requirements
Cost Account Mobilization
Number Cost Summation
201.1 $3,700 3i 70£>
Riprap stone
or filter
201.1
Cover stone ) $3,300 for one
202.1 ) of the accounts
203.1 ) (201.1-204) and
204 $6,600 for two or
more accounts 3} 3 &O
Hauling9 $600 (e>OO
Mobilization for marine equipment
is included in Categories 4 and 6
Mobilization Cost
Mobilization = the total of the
summation column (above) MC? = "7f
If account 201.1 is used and hauling costs are added to the
estimate, include the mobilization cost for hauling.
224
-------
Costs for each account are entered on the summary worksheet
for Category 2.
Table 17. COST CATEGORY 2
COST SUMMATION
Worksheet 200
Cost
Account
Number
201
201.1
201.2
202
202.1
202.2
203
203.1
203.2
204
205
Description
Riprap and filter
material and place-
ment
Placement by land-
based equipment
Offshore placement
Steel sheet piling
Placement by land-
based equipment
Offshore placement
Piles
Land installation
Marine
Concrete
Other
Base
Cost
BC =$ /e,ei*&
BC 0 =$ /^X
BC =$ /6S,000
ZU^..-L L r
BC 0 =$ A/, j.
BC . =$ MA.
^ U -3 • X
BC n =$ A/.#f
BC =$ MA.
BConr =$ —
Cost Category 2 Total Cost
(Enter cost in Account 1101)
BC,
=$
206
Mobilization (Enter
Cost in Account 1001)
=$ 7, boo
225
-------
Cost Category 3 does not apply.
Cost Category 4
Accounts 401 and 402 do not apply.
Account 403.1, Steel pipe (Worksheet 403.1) -
Information supplied by Commonwealth Edison indicates that
the pipe was shop fabricated and shipped to site. Pipe costs
are for onshore piping only. The conduit offshore is used
as a manifold for the diffuser. Therefore, costs are given
in Category 6.
Table 46. STEEL CONDUIT
Worksheet 403.1
Design Data Required
Pipe diameter ^ && m
Wall thickness "2 ,5^ cm
With or without stiffeners t^tS j^-Ji oof
Pipe length L 715"
Shop or field fabrication
226
-------
Base Cost
Enter Figure 403.1, read base
unit cost per lineal meter BUG =$
Base cost = L x BUG BC =$
Cost Adjustments
Enter Figure 403.1, read design F
adjustment factors for wall p ,„.
thickness, stiffeners and D( '
fabrication F^^
Adjusted Base Cost
Adjusted base cost of materials
and fabrication = BC x Fn(l) x
FD(2) x FD(3) ° BC403.1
For diameters to 3.05 meters, assume shop fabrication
Account 403.2, Carbon Steel pipe
fittings (Worksheet 403.2) -
Table 47. STEEL
PIPE FITTINGS
Worksheet 403.2
Design Data Required
Type (elbow, reducer, tee,
connection)
Diameter (if a fitting diameter
varies, use largest diameter)
227
-------
Angle (for reducer or connection)
Number N =
Wall thickness 2*, £*f cm
With or without stiffeners
Base Cost
Enter Figure 403.2, read base
unit cost per fitting BUG =$ 27*VO
Base cost = N x BUG BC =$
Cost Ad j ustments
Enter Figure 403.1, read design FD(D = "2.tQ
adjustment factors for wall ,_, _ A/ A.
thickness and stiffeners and D( ' - *** *
fabrication
Ad j usted Base Cost
Adjusted base cost of materials
and fabrication for particular
type of fitting = BC x F (1) x
FD(2) x PD(3) BC -$ 701.0
Accounts 404 and 405 are not applicable,
Account 406.1, Onshore pipe trench
excavation (Worksheets 901.1 and 406.1)
The pipe trench is large and. excavation can be done with a
minimal amount of dewatering. Costs for excavation are
calculated on Worksheet 901.1 and transferred to 406.1.
228
-------
Table 112. EARTH EXCAVATION (LAND)
Worksheet 901.1
Design Data Required
Type of excavation "Z^
Volume of excavation V = 2! Ot (&S'O ~~
m
Haul distance (round trip) from ,
excavation site to disposal site A km
Base Cost
Enter Figure 901.1, read base
cost for excavation BC(1) =$
Enter Figure 108.2, read base
cost for hauling oTm3 BUC(2) =$ .3*
Base cost for hauling = V x
=$ 7
Total base cost = BC(1) + BC(2) BC . =$ JS, OZ-D
.7 U J_ * J-
1. Trench or small foundation
2 . Large foundation
3. Channel or large trench
If haul distance is not given and hauling is known to
be a factor assume 8-km round trip.
229
-------
Table 50. ONSHORE PIPE
TRENCH EXCAVATION
Worksheet 406.1
Base Cost
Refer to Cost Accounts 901 or
902 for cost estimating pro-
cedure BC
406
Account 406.2, Onshore pipe
laying (Worksheet 406.2) -
Table 51. LAYING PIPE ON LAND
Worksheet 406.2
Design Data Required
Length of pipe L =
Diameter of pipe D - ^ 8 &
Material
Base Cost
Enter Figure 406.2, read base
unit cost per lineal meter BUG =$
Base cost = L x BUC BC..,. ,, =$ 2-O. £->
4 U b .
-------
Account 406.3, Onshore fill
(Worksheets 802.1 and 406.3) -
The material used for backfill is that excavated from the
pipe trench. Hand compaction is assumed for 25 percent of
backfill placed. The remaining fill is machine compacted.
Table 106. PLACEMENT OF FILL (LAND)
Worksheet 802.1
Design Data Required
Nature of the placement opera-
tion group numbera
Volume of fill V =
Base__Cost
Enter Figure 802.1, read base
cost
Group 1 - Dump and spread fill
Group 2 - Hand compaction of fill
Group 3 - Machine compaction
231
-------
Table 106. PLACEMENT OF FILL (LAND)
Worksheet 802.1
Design Data Required
Nature of the placement opera-
tion group numbera *5
Volume of fill V /^ / 3 Q
Base Cost
Enter Figure 802.1, read base
cost
Group 1 - Dump and, spread fill
Group 2 - Hand compaction of fill
Group 3 - Machine compaction
Table 52. ONSHORE BACKFILL
Worksheet 406.3
Base Cost
Refer to Cost Category 8 for appro-
priate cost accounts and esti-
mating procedures BC406 3 ~$
232
-------
Acounts 406.4, 406.5 and 407.1
Through 407.6 do not apply
The offshore conduit is used as a manifold for the diffuser.
Therefore, costs for offshore pipe is included in Category 6.
(If a pipe were used to convey the water to a diffuser, costs
for the pipe would be included here.)
Account 409, Mobilization (Worksheet 409) -
Table 62. MOBILIZATION
Worksheet 409
Data Requirement
Mobilization
Description Cost Summation
For offshore installation $96,000 ——
of a conduit add
$96,000a
For land installation $ 6,600
of the conduit add
For hauling fill $ 600
Mobilization Cost
Mobilization = the total of the
summation column (above) MC. = $ f,
The mobilization costs are inclusive of accounts 407.1
through 407.6.
233
-------
Enter costs from each account onto the summary worksheet
for Category 4.
Table 43. COST CATEGORY 4
COST SUMMATION
Worksheet 400
Cost
Account
Number
401
402
403
403.1
403.2
404
405
406
406.1
406.2
406.3
406.4
406.5
Description
Precast concrete pipe
Cast-in-place box
culvert
Steel conduit
Steel pipe
Steel fittings
Corrugated metal
pipe
Fiberglass pipe
Land installation
of pipe
Onshore excavation
Onshore pipe laying
Cushion fill and
backfill
Pipe supports
Dewatering
"" " — -
Base
Cost
BC =$ //.A.
1 V -L
BC =$ MA.
l\\! £. ,,.*
BC4Dl 1 ~^ "Z.^C>; VY*)
BC4m "> ~^ 7O*»&
't U J . Z
BC4n4 "$ M'*' -
t U 1
BC =$ M/t.
RC =^ 9S* & Z-&
^nr i v ' /
T-J ^» _ £• *S ^^ ^ ^J t
B^Jlns- ^ ""•? C't'JC'f^-3
q\J<3 . £
BC4or 4 =$ ^ ^-
'i U O . **
BC4nf- q -$ A/# fit
4 U D . D
234
-------
407
407.1
407.2
407.3
407.4
407.5
407.6
408
Marine Installation
of pipe
Offshore excavation
Offshore pipe laying
Cushion fill and
backfill
Pipe supports
Riprap protection
Cofferdams
Other
"D/"1 — £ J\ J iU
.oL. . * — - — 9 /V * rf •
An i l Z . r , ,
r»p — £ A/ Ju
407 ° "^ /Kr '
ct\J f m ^
"D/^ — C; Jw M
407 1 ~~^ /^' *'
^^407 4 ~^ " * "'
nr* —
-------
stub nozzle costs, adjustment factors for two conventional
nozzles of the same diameter are read from Figure 601. If
the difference in "f" values used to select the adjustment
factors is equal to the stub nozzle height, a second adjust-
ment factor is derived (FD2). Multiply this factor times
the value read from graph in figure 601.
Table 80. STEEL NOZZLES
Worksheet 601
Design Data Required
Nozzle inside diameter
Riser length
Number of nozzles
m
m
N =
Base Cost
Enter Figure 601, read base
unit cost per nozzle
Base cost = H x BUG
BUG =$ 3IO&
BC =$
Cost Adjustments
Enter Figure 601, read design
adjustment factor for the
riser length (f)
Adjusted Base Cost
Adjusted cost = BC x F
BC
601
BO
=$
The riser length "f" is the distance from the (horizontal)
nozzle centerline to the top of the manifold minus 1.5
times the nozzle diameter.
236
-------
Table 80. STEEL NOZZLES
Worksheet 601
Design Data Required
Nozzle inside diameter O, ty/ m
Riser length £t fc> / _ m
Number of nozzles N =
Base Cost
Enter Figure 601, read base
unit cost per nozzle BUG =$
Base cost = N x BUG BC =$
Cost Adjustments
Enter Figure 601, read design
adjustment factor for the
riser length (f ) F
Adjusted Base Cost
Adjusted cost = BC x FD BC601 =$
The riser length "f" is the distance from the (horizontal)
nozzle centerline to the top of the manifold minus 1.5
times the nozzle diameter.
237
-------
Table 80 .___STEEL_NOZZLES
Worksheet 601
Design Data Required
Nozzle inside diameter ,/ 3 £ m
Riser length _ C>, fa/ m
Number of nozzles N -_
Base Cost
Enter Figure 601, read base
unit cost per nozzle BUG :-£_
Base cost = N x BUG BC ~$
Cost Adjustments
Enter Figure 601, read design
adjustment factor for the
riser length (f)
^
u
Adjusted Base Cost
Adjusted cost = BC x FD BC "$ 3 78O
aThe riser length "f" is the distance from the (horizontal)
nozzle centerline to the top of the manifold minus 1.5
times the nozzle diameter.
238
-------
Table 80. STEEL NOZZLES
Worksheet 601
Design Data Regui_red:
Nozzle inside diameter £>'7/ m
Riser length &*£/ m
Number of nozzles N :=
Base Cost
Enter Figure 601, read base
unit cost per nozzle BUG
Base cost = N x BUG BC ^$_
Cost Adjustments
Enter Figure 601, read design
adjustment factor for the
riser length (f) F --__
Adjusted Base Cost
Adjusted cost = BC x FD BC601 ^~
The riser length "f" is the distance from the (horizontal)
nozzle centerline to the top of the manifold minus 1.5
times the nozzle diameter.
239
-------
Table_J3 0 . STEEL _NO Z Z LE S
Worksheet 601
Design Data Required
Nozzle inside diameter ^xfo/ m
Riser length ___ C>t£>( m
Number of nozzles N ~_
Base Cost
Enter Figure 601, read base
unit cost per nozzle BUG $
Base cost = N K BUG BC --$ S(o,&C>O
Cost Adjustments
Enter Figure 601, read design
adjustment factor for the
riser length (f ) FD :- O, /3
Adjusted Base Cost
Adjusted cost --= BC x FD BCfiO]
The riser length "f" is the distance from the (horizontal)
nozzle centerline to the top of the manifold minus 1.5
times the nozzle diameter.
V, Boo
240
-------
Account 602.1 does not apply.
Account 602.2, Steel manifolds
(Worksheets 403.1 and 602.2) -
Costs for installation of conduit offshore is calculated on
Worksheet 403.1 and transferred to Worksheet 602.2.
Table 46. STEEL CONDUIT
Worksheet 403.1
Design Data Required
Pipe diameter */, & & m
Wall thickness £« Sif cm
With or without stiffeners
Pipe length L = S/00 m
Shop or field fabrication
Base Cost
Enter Figure 403.1, read base
unit cost per lineal meter BUC =$
Base cost = L x BUC BC =$
Cost Adjustments
Enter Figure 403.1, read design Fn^^
adjustment factors for wall ,„, _ ^ .
thickness, stiffeners and *DU; "•#,
fabrication Fn ^ = ^
241
-------
Adjusted Base Cost
Adjusted base cost of materials
and fabrication = DC x FD(1) x
FD(2) x FD(3) BC403.1
For diameters to 3.05 meters, assume shop fabrication
Table 82. STEEL MANIFOLD
Worksheet 602.2
Base Cost
Refer to Cost Account 403, Steel
conduit. Base cost = BC...., BC^rt^ ., =S
Account 603.1, Installation of conduit
diffuser (Worksheets 407.2 and 603.1) -
Table 56. LAYING OFFSHORE PIPE
Worksheet 407.2
Design Data Required
Length of pipe L // 0& m
Diameter D ^ $ & m
Pipe material
Depth of water jLL&^, -fh-c*-*^ /*/ m
242
-------
Hfi.so Cost
Enter Figure 407.2, read base
unit cost per lineal meter BUG =$
Base cost = L x BUG BC =$
Cost Adjustment
Enter Figure 407.2, read
adjustment factor for water .
depth FD - /_
Adjusted Base Cost
Adjusted base cost for laying
pipe offshore = BC x FD BC407 2 =$ 9*7% 000
fe-i- ^ ccef*// £03. J
Table 84. INSTALLATION OF
CONDUIT DIFFUSER
Worksheet 603.1
Base Cost
Select cost Account 406.2 for dry
installation within an offshore
cofferdam or 407.2 for under-
water installation.
Base cost = *C^.2 or BC^^ ^^^ = $ 9 7?,
243
-------
Ac c ount GO 3.2 and 603.3 do not apply.
Account 603.4, Trench excavation
(Worksheets 901.2 and 902.2 and 603.4)
Table 113. EARTH EXCAVATION (MARINE)
Worksheet 901.2
Design Data Required
Type of excavation (soft, firm,
hard)a
Volume of excavation
Disposal method
Haul distance (round trip)
Base Cost
Enter Figure 901.2, read base
cost for excavation BC(1) =$ €>2>Of QOO
Enter Figure 108.2, read base
unit cost for haul BUG(2) =$
Base cost for hauling = V x
BUC(2) BC(2) =$
Cost Adjustment
Enter Figure 901.2, read design
adjustment factor for dis-
posal method F f.
244
-------
Adjusted Base Cost
Adjusted cost = (BC(1) x F ) +
BC9oi.2
Soft - Sand or unconsolidated silt.
Firm - Clay or other cohesive material.
Hard - Till or soft, weathered rock.
Side cast or hauled to shore.
From the shoreline to a land disposal area. If this haul
distance is unknown, assume an 8-km round trip.
Table 115. ROCK EXCAVATION (MARINE)
Worksheet 902.2
Design Data Required
Volume at excavation V = *r-&D m
Haul distance (round trip)a
from shoreline to disposal
area cb km
Base Cost
Base cost for offshore rock
excavation = $55.40/m3 x V BC(1) =$
Enter Figure 108.2, read base
unit cost for rock haul and
disposal (curve A) BUG (2) =$ fc>/ /
Base cost for haul and
disposal of waste rock
V x BUC(2) BC(2) = $
Total base cost = BC(1)+BC(2) ' BC902 2 "$
If haul distance is not given and hauling is known to be a
factor, assume 8-km round-trip.
245
-------
Table 87. TRENCH EXCAVATION
Worksheet 603.4
Base Cost
Refer to Cost Category 9 and £
select the cost from either V
Cost Account 901.1 or 901.2 *?-¥,&>£>
Base cost = BC9Q1<1 or BC90U2 BC6Q3>4 =$__
Accounts 603.5 and 603.6 do not apply
Account 603.7, Trench backfill
(Worksheets 801, 802.2 and 603.7) -
Table 105. MATERIAL AND HAULING COSTS
Worksheet 801
Design Data Required
Type of fill material
Haul distance (round trip)a
from the borrow site _ / & km
Volume of fill V = /3£. *J.e& m3
246
-------
Base Cost
Enter figure 108.2, read base
unit coat for hauling BUG = $ £>. ? &
Base cost for hauling = BUG x V BC =$
Enter Figure 801, read base
cost BC2 = $ //£>,f>£>O
Cost Adjustment
Enter Figure 801, read.
adjustment factor for
material F = /
Adjusted Base Cost
Adjusted base cost = (BCo x F_)
+ BCi
fer Jv
If haul distance is not known, assume an 18-km haul.
Table 1Q5. MATERIAL AND HAULING COSTS
Worksheet 801
Design Data Required
Type of fill material S4&?t£ r'//^
Haul distance (round trip)
from the borrow site /&km
Volume of fill V = /3y^?^ m3
247
-------
Base Cost
Enter Figure 108.1, read base
unit cost for hauling BUG =$ -S~t $ O
Base cost for hauling = BUG x V BC, =$ B>2 / & I O
Enter Figure 801, read base
cost EC, =$ /lt
~
Cost Adjustment
Enter Figure 801, read
adjustment factor for
material F
Adjusted Base Cost
= (BC x F )
BC801 =$ / 23,
Adjusted base cost = (BC0 x F )
2 D
alf haul distance is not known, assume an 18-km haul.
Table 107. PLACEMENT OF FILL (MARINE)
Worksheet 802.2
Design Data Required
Nature of the placement
B*e k. ////
operation3 ^_
3
Volume of fill V = /
-------
Base Cost
Enter Figure 802.2, read base
cost BC
802 2
Backfill of a pipe trench; placing fill into a cofferdam
or backfill using excavated material side cast along
the trench.
Table 90. TRENCH BACKFILL
Worksheet 603.7
Base Cost
/. e> S.
Base cost = base cost from the
appropriate accounts in Cost
Category 8. BC603 7 =$
/ 2 3
Accounts 604 and 605 do not apply.
Account 606, Mobilization (Worksheet 605) -
249
-------
Table 93. MOBILIZATION
Worksheet 606
Mobilization Cost
Mobilization = $30,000 if the diffuser
is a tunnel diffuser. If the total
length of offshore pipe is the
manifold for a conduit diffuser,
add $96,000. (Caution: do not
duplicate costs in Account 408.)
MC£ =$
o —
Enter costs for each account onto the summary worksheet for
Category 6.
Table 79. COST CATEGORY 6
COST SUMMATION
Worksheet 600
Cost
Account
Number
601
602
602.1
602.2
602.3
603
603.1
•
603.2
Description
Nozzles
Manifolds
Concrete manifolds
Steel manifolds
Steel fittings
Installation
Conduit manifold
Nozzles
Base
Cost
BC601
BC602.1
BC602.2
BC602.3
BC603.1
BC603.2
=$ E<«
=$
=$
=$ 1'
=$
,*/, Z7
-------
603.3
603.4
603.5
603.6
603.7
604
605
Cofferdams
Excavation
Diffuser Support
Scour protection
Backfill
Single Port
Other
Cost Category 6, Total Cost
(Enter cost in Account 1101)
606
Mobilization (Enter
cost in Account 1001)
BC603 3 =$
"D /"* — — O
JjV^ , — . ,* _ ., " — O
BC603 5 =$
O U J . D
6036
603.7
BCpp. =$
A/,4,
At, A.
M4,
AS, A.
zl£>eifi*i5*
A/,4,
M/l,
BC =$
MC =$
g.*.a*/7
-------
Table 96. CAST-IN-PLACE
STRUCTURAL CONCRETE, CONCRETE PLACEMENT
Worksheet 701.1
Design Data Required
Category of structure /
Volume of concrete V =_ /fc> Q
Base Cost
Enter Figure 701.1, read base
cost BC701.1 =^-
3
m~
1. Suspended slabs, beams, walls
2. Spread footings, grade slabs, and pile caps.
3. Structures with little or no reinforcing.
Table 96. CAST-IN-PLACE
STRUCTURAL CONCRETE, CONCRETE PLACEMENT
Worksheet 701.1
Design Data Required
a *y
Category of structure ,5
Volume of concrete V - I/O 0O m
252
-------
Base Cost
Enter Figure 701.1, read base
cost BC701 1 = $ "?&/&& &
1. Suspended slabs, beams, walls.
2. Spread footings, grade slabs, and pile caps.
3. Structures with little or no reinforcing.
Account 701.2, Reinforcing (Worksheet 701.2) -
3
The unit weights of reinforcing assumed are 89 kg/m and
10 kg/m for structure categories 1 and 3, respectively.
Table 97. CAST-IN-PLACE STRUCTURAL
CONCRETE, REINFORCING STEEL
Worksheet 701.2
De s i gn Pat a Regui red
Category of structure __ /
Weight of reinforcing steel
Base Cost
Enter Figure 701.2 read base
cost BC701.2
1. Suspended slabs, beams, and walls.
2. Spread footings, grade slabs, and pile caps.
3. Structures with little or no reinforcing.
If weight of reinforcing steel is not available, assume
values shown in the following table:
253
-------
Weight of Reinforcing
Category to assume, kg/m^ of cone,
1 89
2 71
3 0-20
Table 97. CAST-IN-PLACE STRUCTURAL
CONCRETE, REINFORCING STEEL
Worksheet 701.2
Design Data Required
Category of structure
Weight of reinforcing steel
Base Cost
Enter Figure 701.2 read base
cost BC
701 2
1. Suspended slabs, beams, and walls.
2. Spread footings, grade slabs, and pile caps.
3. Structures with little or no reinforcing.
If weight of reinforcing steel is not available, assume
values shown in the following table:
Weight of Reinforcing
Category to assume, kg/m3 of cone.
1 89
2 71
3 0-20
Accounts 702, 703, 704, and 705 do not apply.
254
-------
Account 706, Mobilization (Worksheet 707) -
Refer to worksheet.
Table 102. MOBILIZATION
Worksheet 706
Mobilization Cost
For a large structure other
than the pump station, add
$3,300
=$
Enter the charts from each account onto the summary worksheet
for Category 7.
Table 95. COST CATEGORY 7
COST SUMMATION
Worksheet 700
Cost
Account
Number
701
701.1
701.2
702
703
Description
Structural concrete
Concrete placement
Reinforcing steel
Concrete (marine )a
Grouting
Base
Cost
BC =$ IZb.CCO
j U .L • -L '
BC „ =$ 2.^,000
BC =$ MA.
BC =$ /V'fl,
255
-------
704
705
Cushion fill
Other
BC
BC
704
705
MA.
Cost Category 7 Total Cost
(Enter cost in Account 1101)
BC
$
706
Mobilization (Enter
cost in Account 1001)
MCv =$ 3, 3£>£>
The user is cautioned that most of the time the costs for
these accounts are used in other categories. Do not enter
here if they are used in another category.
Cost Category 8
Account 801, Material and
hauling costs (Worksheet 801)
Sand fill is placed within the steel sheet piling enclosure,
Costs are given here and in Account 802.1.
Table 105. MATERIAL AND HAULING COSTS
Worksheet 801
Design Data Required
Type of fill material
Haul distance (round trip)
from the borrow site
Volume of fill
Jem
m3
256
-------
Base Cost
Enter Figure 108.1, read base
unit cost for hauling BUG -$
Base cost for hauling = BUG x V BC- = $
Enter Figure 801, read base
cost BC =$
Cost Adjustment
Enter Figure 801, read adjust-
raent factor for material F = 3 ,
Adjusted Base Cost
Adjusted base cost = (BC2 x F )
+BC, BCon1 =$
If haul distance is not known, assume an 18-km haul
Account 802.1, Backfill (land) Worksheet 802.1) -
It is assumed the sand is hand compacted.
Table 106. PLACEMENT OF FILL (LAND)
Worksheet 802.1
Design Data Required
Q
Nature of the placement operation
group number _ _
Volume of fill V ^ &O
257
-------
Base Cost
Enter Figure 802.1, read base
cost BC
802.1
Group 1 - Dump and spread fill
Group 2 - Hand compaction of fill
Group 3 - Machine compaction
Table 106. PLACEMENT OF FILL (LAND)
Worksheet 802.1
Nature of the placement operation ,.,
Design Data Required
iture of the i
group number
Volume of fill V 7/t^>C> m3
Base Cost
Enter Figure 802.1, read base
cost BC
802 1
Group 1 - Dump and spread fill
Group 2 - Hand compaction of fill
Group 3 - Machine compaction
Accounts 802.2 and 803 do not apply.
Account 804, Mobilization (Worksheet 804) -
258
-------
Table 109. MOBILIZATION
Worksheet 804
Data Requirements
802.1 Mobilization costs for Group Summation
1 of the land placement of
fill is $1,700 —
The costs for Group 2 is $900a
The costs for Group 3 is $800a B OO
Mobilization Cost
Mobilization = the total of the
summation column. Usually only
Group 1 of Account 802.1 will be
considered (see the discussion
for this account). MCQ =$
o —
aUse the costs for groups 2 and 3 only if there is a large
structure other than the pumping station that requires
backfill.
Enter the costs from each account onto the summary worksheet
for Category 8.
Table 104. COST CATEGORY 8
COST SUMMATION
Worksheet 800
Cost
Account
Number
801
802
Description
Material and
costsa
Placement of
1
[
I
hauling ' BC801
filla i
Base
Cost
=$ z/
.SID
259
-------
802.1 i Placement of fill
(land)a
BC
802.1
802.2 Placement of fill
(marine)3 iBC
802 2
803 Other BC£03
Cost Category 8 Total Cost
(Enter cost in Account 1101) BCg = $ $7, 82O
804 Mobilization (Enter
cost in Account 1001) 'MCg =$
The user is cautioned that most of the time the costs for
these accounts are used in other categories. Do not enter
here if they are used in another category.
Cost Category 9
Account 901.1, Earth excavation (Worksheet 901.1) -
It is assumed excavation of material from within the sheet
pile inlet structure is comparable to excavation of a large
foundation. Excavated material is used for on-site back-
fill. Therefore, hauling costs do not apply.
260
-------
Table 112. EARTH EXCAVATION (LAND)
Worksheet 901.1
Design Data Required
Type of excavation 2-
Volume of excavation V = 7&&>& m
Haul distance (round trip) from
excavation site to disposal
siteb km
Base Cost
Enter Figure 901.1, read base
cost for excavation BC(1) =$ 3 5
Enter Figure 108.2, read base
unit cost for hauling BUG (2) =$
Base cost for hauling = V x
BUG (2) BC(2) =$
Total base cost = BC(1) + BC(2) BCQ 1 =$
• -L
1. Trench or small foundation
2. Large foundation
3. Channel or large trench
If haul distance is not given and hauling is known to
be a factor, assume 8-km round trip.
261
-------
Table 112. EARTH EXCAVATION (LAND)
Worksheet 901.1
Design Data Required
Type of excavation
Volume of excavation V = 6>
Haul distance (round trip) from
excavation site to disposal
site" —— km
Base Cost
Enter Figure 901.1, read base ^_
cost for excavation BC(1) =$ y&C>C>
Enter Figure 108.2, read base
unit cost for hauling BUG(2) =$ '
Base cost for hauling = V x
BUC(2) BC(2) -$
Total base cost = BC(1) + BC(2) BC901 1 = $ 1 & &O
1. Trench or small foundation
2. Large foundation
3. Channel or large trench
If haul distance is not given and hauling is known to be a
factor, assume 8-km round trip.
Account 901.2, Earth excavation (marine) -
All costs for earth excavation (marine) are included in
Account 406.1.
Accounts 902.1 - 903 do not apply.
262
-------
Account 904, Dewatering during excavation -
Seepage is assumed to be minimal and dewatering costs are
neglected.
Account 907 does not apply.
Account 908, Mobilization (Worksheet 908) -
Mobilization costs for group 3 are shown on the worksheet.
Table 119. MOBILIZATION
Worksheet 906
Data Requirement
Cost Account Mobilization
Number Costs Summation
901.la (Group No.)
1 $1,000 —
2 $3,300
3 $1,500 /
902.la $4,000
Mobilization Cost
Mobilization = the total of the
summation column (above) MCq =$ /
These costs are included only if there is excavation other
than for a pump station or a pipe trench.
Enter the costs from each account onto the summary worksheet
fcr Category 9.
263
-------
Table 111. COST OF CATEGORY 9
COST SUMMATION
Cost
Account
Number
901
901.1
901.2
902
902.1
902.2
903
904
905
Cost Ca
(Ente
906
Worksheet
Description
Earth excavation
Earth excavation
(land)a
Earth excavation
(marine) a
Rock excavation
Rock excavation
(land) a
Rock excavation
(marine) a
Shoring for excava-
tiona
Dewatering during
excavation3
Other
tegory 9 Total Cost
r cost in Account 1101)
Mobilization (Enter
cost in Account 1001)
900
Base
Cost
BCnni , =$ '<^t B&O
BC =$ M A.
BC „ =$ M A,
BC =$ A/, A.
BC =$ A/. A,
J U ft
lar* — <5 ^J K
Bt-r)nc ^ />' Hf
'J U 3
BCn =$ ^^t^>OO
J '
MCq =$ /^(^^
The user is cautioned that most of the time the costs for
these accounts are used in other categories. Do not
enter here if they are used in another category.
264
-------
Cost Category 10
Table 122. MOBILIZATION
Worksheet 1001
Data Requirements
Cost Category
Number
1
2
3
4
5
6
7
8
9
Mobilization
Cost
=$
MC2 =-
MC3 =<-
MC4 =5
=$
MC? =i
MCg =!
MCg =i
1-00
Base Cost
Total
BC
IOOI
265
-------
Table 122. COST CATEGORY 10
COST SUMMATION
Worksheet 1000
Cost
Account
Number
1001
1002
I
Description
Mobilization
Other
Base
Cost
BC1001 =$ /<2
-------
Birmingham - .73 Minneapolis - .85
Boston - .90 New Orleans - .78
Chicago - .91 New York - 1.00
Cincinnati - .95 Philadelphia - .90
Cleveland - .94 Pittsburgh - .89
Dallas - .77 St. Louis - .89
Denver - .80 San Francisco - .94
Detroit - .93 Seattle - .85
City nearest to construction area
Regional adjustment factor F =
i\
Date construction is to begin or
period of price level being
considered
Engineering News Record
Construction Cost Index for
above date (20-city average) ENRX =
Regional and time adjustment
factor = FT x FR FRT
Total costs from Categories 1 through 10
BC1 = $ H, I 2 0
BC3 = $
BC4 = 1
BC5 = £-
BC- = $
b —
BC7 = L
=
8 $ B7,
BC9 =
BC10=
Total Cost = E (BC-j^ through BC1Q) BCT =$_
Time adjustment factor =
ENRX ( ) ^ 2097a FT (. DO
267
-------
Revised Construction Cost
Total cost = BCT x FRT BCH01 =^-
g
The Engineering News Record 20-city average for
December 12, 1974.
Comparison to actual costs - Commonwealth Edison indicated
that the total construction costs added up to the amount
of $7,748,000 (excluding the costs of engineering and model
studies).
According to information obtained from the owner, most of
the construction was carried out during the 1972 fiscal
year. For purposes of comparison, the above amount must
be adjusted to 1974 price levels.
Assuming June 1972 as a base for actual construction, the
ENR index corresponding to this date equals 1761. The ENR
for December 1974 equals 2097.
The adjustment factor for the actual cost is:
F= 2097
1761
= 1.19
Adjustment of the actual construction cost gives a total
amount = $7,748,000 x 1.19 « $9,220,120, rounded to
$9,220,000.
A comparison of the actual cost in terms of 1974 prices and
the estimated cost using the manual indicates a variation
of $43,000 or approximately 3.7 percent of the actual cost.
268
-------
APPENDIX B
BACKGROUND UNIT COST DATA
GENERAL
This appendix gives the user a detailed description of the
components of unit cost development. Cost levels, data
sources and provision for contractor overhead are as given
in Section III, Approach.
It is assumed time for one shift in excess of 8 hours per
day or 40 hours per week is charged at double the normal
labor rates. Installation costs for land based operations
are based on 5-8 hour days per week. A 4-week month is used
as the base time period when the work includes marine oper-
ations. Work periods, days per week and hours per day, vary
depending on the type of marine operation. Marine work periods
are given in a footnote below the appropriate table. Labor
and equipment costs are not separated for offshore operations.
Rates for the equipment operator and foreman are based on the
type of equipment on the job site. The cost of an equipment
operator for a bulldozer, for example, is less than for a
crane operator. Also, a foreman that oversees an operation
with a bulldozer is assumed to receive less than a foreman
in charge of work requiring a crane.
The data presented here include the following:
1. Identification of a representative labor force
(number and type of workers) and equipment pool
(size and number of pieces of equipment) for the
activity considered
2. Labor and equipment costs
269
-------
3. Production rates
4. Installation costs
5. Where appropriate, material costs which are added
to installation costs to obtain the total unit
cost.
The unit cost background information is grouped according to
the cost categories used in the methodology. However, the
system of cross referencing between categories is not adopted,
Unit cost data are given only for the accounts where the
figures are located or calculations are done. For example,
to [locate the background information on unit costs for pipe
trench excavation, the user must go to Cost Category 9 and
not Category 4.
The data are tabulated as follows:
1. Labor force and equipment pool - The information
pertinent to items (1) and (2) above is given in
table (s) for each account.
2. Unit cost data - The unit cost for labor and equip-
ment, equal to the total of labor and equipment
costs divided by the production rate, is presented
in the second table(s). In addition, where mater-
ials are a part of the total unit cost, material
costs are given.
The format of the tables is modified for some of the accounts
of cost categories 4 and 7 to improve the clarity of presen-
tation.
Data for Cost Category 5 and accounts that have only material
costs are not included.
270
-------
COST CATEGORY 1
Riprap removal, Account 101
Table B-l. LABOR FORCE AND
EQUIPMENT POOL, ACCOUNT 101
Labor
Equipment
Operator
Oiler
Laborer
Foreman
Cost,
$/week
861
726
654
034
TOTAL 3,175
1
Equipment
Crane
(5.44 x 10 kg)a
Clam Bucket
(2.3m3)
TOTAL
Cost,
$/week
1,100
167
1,267
The capacity of equipment is given within parentheses
Costs, productivity, and the unit cost for Account 101 are
listed below:
1. Labor and Equipment $4442/week
2. Productivity B20m3/week
3. Unit Cost $5.40/m3
271
-------
Concrete slab removal, Account 102
Table B-2. LABOR FORCE AND
EQUIPMENT POOL, ACCOUNT 102
Labor
Foreman
Equipment
Operator
Oiler
2 Laborers
TOTAL
Cost,
$/week
934
861
726
1,308
3,829
Equipment
Crane
(5.44 x 104 kg)
Clam (2.3 m3)
Headache ball
TOTAL
Cost,
$/week
1,100
167
60
1,327
Table B-3. UNIT COST DATA, ACCOUNT 102
Description
Labor and Equipment,
$/week
Productivity, m'/week
Installation unit
cost, $/m2
Reinforced
Thickness, 30-45
to 30 cm cm
5,156
1,000
5.20
5,156
750
6.90
Non-Reinforced
Thickness, 30-45
to 30 cm cm
5,156
1,500
3.40
5,156
1,225
4.20
272
-------
Concrete removal, Account 103
Table B-4. LABOR FORCE AND
EQUIPMENT POOL, ACCOUNT 103
Labor
Foreman
2 Equipment
Operators
Driller
Blaster
4 Laborers
2 Oilers
TOTAL
Cost,
$/week
934
1,722
825
800
2,616
1,452
8,349
Equipment
Crane
(5.44 x 104kg)
Clam Bucket
(2.3m3)
Track Drill
f T /I <-"•»« A
Air conprnnnor
(25.5 mVmin. )
TOTAL
Cost,
$/week
1,100
167
3*4
->r o
1,961
Table B-5. UNIT COST DATA, ACCOUNT 103
De s c ription
Reinforced
Non-Reinforced
Labor and Equipment,
$/week
O
Productivity, m /week
Installation Unit Cost,
10,310
125
82.50
10,310
250
41.20
Material, powder, etc.,
TOTAL UNIT COST, $/m3
85.50
44.20
273
-------
Sheet piling removal, Account 104
Table B-6. LABOR FORCE AND
EQUIPMENT POOL, ACCOUNT 104
Labor
Foreman
4 Pile Drivers
Equipment
Operator
? Oilers
TOTAL
Cost,
$/week
934
3,300
861
1,452
6,547
Equipment
Crane .
(5.44 x 10 kg)
Extractor
Leads
Compressor
(25.5 m3/min. )
TOTAL
Cost,
$/week
1,100
190
30
350
1,670
Costs, productivity, and the unit cost for Account 10^ are
listed below:
1. Labor and Equipment $R,217
2. Productivity 400 m2/weeks
3. Unit cost $20.50/m2
4. Salvage credit $330/kg
Clearing and grubbing, Account 105
274
-------
Table B-7. LABOR FORCE AND EQUIPMENT POOL,
ACCOUNT 105 (LIGHT CLEARING)
Labor
3 Laborers
Equipment
Operator
Oiler
Foreman
TOTAL
Cost,
$/week
1,962
825
726
898
4,411
Equipment
Dozer
(67,113 W)
TOTAL
Cost,
$/week
586
586
Table B-8. LABOR FORCE AND EQUIPMENT POOL,
ACCOUNT 105 (MEDIUM TO HEAVY CLEARING)
Labor
3 Laborers
2 Equipment
Operators
1 Oiler
Foreman
TOTAL
Cost,
$/week
1,962
1,650
726
R98
5,236
Equipment
Chipping
Machine
Dozer
(67,113 W)
TOTAL
Cost,
$/week
200
5R6
786
275
-------
Table B-9. UNIT COST DATA, ACCOUNT 105
Description
Labor and Equipment,
$/week
2
Productivity, m /week
Unit Cost, $/m2
Vegetation Density
Light
4,997
28,400
.18
Medium
6,022
20,400
.30
1 Heavy
6,022
16,200
.37
Reseeding, Account 106
Table B-10. LABOR FORCE AND
EQUIPMENT POOL, ACCOUNT 106
Labor
2 Laborers
Teamster
TOTAL
Cost,
$/week
1,308
649
1,957
Equipment
Truck (3.8m3)
York Rake
TOTAL
Cost,
$/week
104
250
354
Costs, productivity, and the unit costs for Account 106 are
listed below:
1. Labor and Equipment
2. Productivity
Installation Unit Cost
3.
4.
5.
$2,311/week
13,500 m2/week
$0.17/m2
Material - seed $0.20/m"
fertilizer & limestone
TOTAL UNIT COST $0.37/m
2
276
-------
Hauling, Account 10R
Table B-ll. LABOR FORCE AND
EQUIPMENT POOL, ACCOUNT 108
Labor
2 Drivers
1 Laborer
Equipment
OperatOT-
Oiler
TOTAL
Cost,
$/week
1,298
654
825a
726a
1,952
Equipment
2 Trucks
Dozer
(67,113 W)
TOTAL
Cost,
$/week
550
586a
550
Additional costs for operation of the disposal area.
Table B-12. UNIT COST DATA, ACCOUNT 108
Description
Labor and Equipment,
$/week
Productivity,
m^/week
Unit Cost, $/m:'
Earth Rocka
Haul
2,502
1,850
1.35
Disposal
4,639
1,850
2.50
Haul
2,502
1,250
2.00
Disposal
4,639
1,250
3.70
For slabs it is assumed the in-place volume increases 25
percent; productivity is assumed to be 4,200 m2/week for
slabs 0-30 cm thick and 2780 m^/week for slabs 30-45 cm
thick.
277
-------
COST CATEGORY 2
Placement of riprap (land-based),
Account 201.1 (Sheet 1 of 2)
Table B-13. LABOR FORCE AND EQUIPMENT POOL,
ACCOUNT 201.1 (RIPRAP, STONE_ AND
Labor
Foreman
Equipment
Operator
2 Laborers
1 Oiler
TOTAL
Cost,
$/week
934
825
1,308
726
3,793
Equipment
Hydraulic -,
Backhoe (1.9 m )
TOTAL
Cost,
$/week
1,750
1,750
Table B-14. LABOR FORCE AND EQUT.PMFJIT POOL,
ACCOUNT 201.1 (COVER STONE)
Labor
Foreman
3 Laborers
Oi Inr
Equipment
Operator
TOTAL
Cost,
$/week
934
1,962
726
361
4,483
Equipment
Crane .
(5.4 x 10 kg)
Leads
TOTAL
Cost,
$/week
1,100
30
1,130
278
-------
Table B-15. UNIT COST DATA, ACCOUNT 201.1
Description
Labor and Equipment,
Productivity, m /week
Installation Unit Cost,
$/m3
3
Material, $/m
TOTAL UNIT COST, $/m3
Riprap
Stone
5,543
925
6.00
16.00
22.00
Filter
5,543
925
6.00
9.50
15.50
Cover
Stone
5,613
300
18.70
13.00
31.70
Background data for Placement
of Riprap (marine). Account 201.2
Table B-16. LABOR FORCE AND EQUIPMENT POOL,
ACCOUNT 201.2 (RIPRAP STONE AND FILTER)
Labor
Equipment
Operator
Oiler
2 Laborers
Foreman
TOTAL
Cost,
$ /month
4,322
4,066
7,325
5,230
21,443
Equipment
Crane (5.4 x 104kg)
Tug Boat3
2 Scowsa
Clam (2.3m3)
TOTAL
Cost,
$ /month
4,400
60,000
6,000
664
71,064
Equipment is fully manned 6 days/week, 8 hours/day.
279
-------
Table B-]7. LABOR FORCE AND EQUIPMENT POOL,
ACCOUNT 201.2 (COVER STONE)
Labor
~ - - -
Equipment
Operator
Foreman
Oiler
4 Laborers
TOTAL
Cost,
$ /month
4,82?
5,230
4,066
14,650
28,768
Equipment
Crane (5.4 x 104kg)
Crane Rargec
Flat Top Barge
Tug Boata
TOTAL
Cost,
$ /month
4,400
60,000
5,000
60,000
129,400
'Equipment as fully manned 6 days/week, R hours/day.
Table R-18. UNIT COST DATA, ACCOUNT 201.2
Description
Labor and Equipment
$/month
Productivity, m /month
Installation Unit Cost,
Material, $/m
TOTAL UNIT COST, $/m3
Riprap
Stone
92,507
12,500
7.40
16. 00
23.40
Filter
92, 507
12,500
7.40
9.50
16.90
Cover
Stone
158,1
3,0
52.
13.
65.
280
-------
Steel sheet piling (land),
Account 202.1
Table B-19. LABOP FORCE AND
EQUIPMENT FOOT,, ACCOUNT 202.1
Labor
Foreman
2 Equipment
Operators
2 Oilers
4 Pi le Drivers
TOTAL
Cost,
$/week
934
1,686
1,452
3,300
7,372
F,
C
H
L
A
T
Equipment
Crane (5.4 x 10 kg)
Hammer (Diesel)
Leads & Misc.
Air Compressor
(25 m-
TOTAL
Cost,
$/week
1,100
300
150
350
1 ,900
Table B-20. UNIT COST DATA, ACCOUNT 202.1
Descript j on
Labor and Equipment,
$/week
2
Productivity, m
Installation Un i
$/ni
2
Material , $/m
TOTAL UNIT COST,
/week
t Cost,
$/m2
Application
Permanent
9,272
500
18.55
50.00
68.55
temporary
9,272
300
30.90
10.00
40.90
281
-------
Steel sheet piling (marine),
Account 202.2
Table B-21. LABOR FORCE AND
EQUIPMENT POOL, ACCOUNT 202.2
Labor
4 Pile Drivers
Foreman
2 Laborers
Equipment
Operator
Oiler
TOTAL
Cost,
$/month
18,480
5,230
7,325
4,822
4,066
39,923
Equipment
Crane Barge
Air Compressor
(25 m3/min.)
Hammer (Diesel)
Leads & Misc.
Tug Boata
Flat Top Barge
TOTAL
Cost,
$ /month
60,000
1,400
1,200
600
60,000
5,000
128,200
Equipment is fully manned, 6 days/week, 8 hours/day.
Table B-22. UNIT COST DATA, ACCOUNT 202.2
Description
Labor and Equipment,
$/month
Productivity, m /month
Installation Unit Cost,
$/m2
2
Material , $/m
TOTAL UNIT COST, $/m2
Permanent
ICC, 12 3
3,300
51
50
101
Temporary
168,123
2,200
76.40
10
86.40
282
-------
Piles (land), Account 203.1
Table B-23. LABOR FORCE AND
EQUIPMENT POOL, ACCOUNT 203.1
~~ ~1
Labor
Foreman
2 Equipment
Operators
2 Oilers
4 Pile Drivers
TOTAL
Cost,
$/week
934
1,686
1,452
3,300
7,372
Equipment
Crane (5.4 x lC4kg)
Hammer (Diesel)
Leads & Fisc.
Air Compressor
(25 mVmin. )
TOTAL
Cost,
$/week
1,100
300
150
350
1,900
Table B-24. UNIT COST DATA, ACCOUNT 203.1
Desor ipt i on
Labor and Equipment ,
$/week
Productivity, n/week
Installation Unit Cost*
$/m
Material, $/ir
TOTAL UNIT COST, $/rn
Materials
Wood
9,272
1,500
6.18
7.50
13.68
Concrete
9,272
750
]2.36
22.00
34.36
Steel
9,272
1,050
8.83
30.00
38.83
Piles (marine), Account 203.2
Table B-25. LABOR FORCE AND
EQUIPMENT POOL, ACCOUNT 203.2
Labor
4 Pile Drivers
Cost,
$/month
18,480
Equipment
Crane Barge .
(5.44 x 10 kg)
Cost,
$ /month
60,000
283
-------
Table B-25 (continued). LABOR FORCE AND
EQUIPMENT POOL, ACCOUNT 203.2
Labor
Foreman
2 Laborers
1 Equipment
Operator
1 Oiler
TOTAL
Cost,
$ /mo nth
5,230
7,325
4,822
4,066
39,923
Equipment
Air Compressor
(25 m3/min. )
Hammer (Diesel)
Tug Boat
Flat Top Bargea
TOTAL
Cost,
$/month
1,400
1,200
60,000
5,000
128,200
cEquipment is fully manned 6 days/week, 8 hours/day.
Table B-26. UNIT COST DATA, ACCOITNT 203.2
Materials
Description
Labor and Equipment,
$ /mo nth
Productivity, m/month
Installation Unit Cost,
$/m
Material, $/ir
TOTAL COST, $/m
Wood
168,123
6,500
25.85
7.50
33.35
Concrete
168,123
3,500
48.00
22.00
70.00
Steel
168,123
4,500
37.35
30.00
67.35
284
-------
COST CATEGORY 3
Installation, Account 301.2
Table B-27. LABOR FORCF AND
EQUIPMENT POOL, ACCOUNT 301.2
Labor
Equipment
Operator
2 Millwrights
1 Pipe fitter
2 Laborers
For eman
Oiler
TOTAL
Cost,
$/week
861
882
1,017
1,308
934
726
5,728
Equipment
Crane .
(5.4 x 10 kg)
Leads
TOTAL
Cost,
$/week
1,100
30
1,130
Table B-28. UNIT COST DATA, ACCOUNT 301.2
Descript ion
Labor and Equipment,
$/week
Productivity,
Pumps /week
Installation Cost,
$/pump
PUMP SIZE (m3/sec)
1.4 2.8 8.49 19.8
6,858
3
2,286
6,858
2
3,429
6,858
1
6,858
6,85
6,85
285
-------
COST CATEGORY 4
Cast-in-place box conduit, Account 402
Table B-29. UNIT COST DATA, ACCOUNT
Description
Formwork
Concrete Placement
Steel Reinforcing
Finish Work
Unit Cost
$40.90/m2
83.20/m3
55.40/m3
5.00/m2
Steel conduit and fittings, Account 403
Table B-30. UNIT COST DATA, ACCOUNT 403
Description
Field Fabricated Pipe
Shop Fabricated Pipe
Cost, $/kg
1.60a
1.00
of Steel
Material, labor and equipment for erection and welding are
reflected in the unit cost.
Laying pipe on land, Account 406.2
Table B-31. LABOR FORCE AND
EQUIPMENT POOL, ACCOUNT 406.2
Labor
Equipment
Operator
Oiler
Cost,
$/day
172
145
Equipment
Crane (5.4 x ] 04kg)
Cost,
$/day
220
286
-------
Table B-32.
UNIT COST DATA, ACCOUNT 406.2
(Unit Cost, $/meter)a
Diam. ,
meters
1.52
1.83
2.44
3.05
3.66
4.27
4.88
5.49
6.10
Precast
Concrete
48
52
62
77
164
197
247
—
—
Corrugated,
Steel Pipe
56
62
79
99
263
295
328
394
394
Fiberglass
Pipe
44
51
64
79
108
128
154
180
—
Carbon Steel
Pipe
90
104
125
157
—
—
—
—
— —
Joint sealing costs and/or connecting costs are included
in installation prices.
3If the diameter exceeds 3.66 meters, installation costs for
multiplate pipe are based on installation costs quoted by
manufacturers.
Laying pipe offshore, Account 407.2
Table B-33. LABOR FORCE AND
EQUIPMENT POOL, ACCOUNT 407.2
Labor
Foreman
2 Equipment
Operators
2 Oilers
5 Laborers
6 Divers
TOTAL
Cost,
$ /month
5,232
9,644
8,131
18,312
23,500
64,819
Equipment
2 Cranes (on land)
(5.4 x 104kg)
3
Flat Top Barge
Lay Barge
Tugboat3
TOTAL
Cost,
$ /month
8,800
5,000
60,000
60,000
133,800
Equipment is fully manned 6 days/week, 8 hours/day.
287
-------
Table B-34. MONTHLY OUTPUT DATA, ACCOUNT 407.2
Diam.
meter s
1.52
1.83
2.44
3.05
3.66
3.96
4.88
5.49
6.10
Precast
Concr ete
351
351
293
234
146
146
146
—
—
Corrugated
Steel Pipe
439
439
365
365
292
292
220
220
220
Figerglass
Pipe
640
640
550
550
457
457
365
365
—
Carbon
Steel Pipe
439
365
365
29?
292
220
220
220
—
Laying pipe offshore, Account 407.2
Table B-35. UNIT COST DATA, ACCOUNT 407.2
(unit cost, ($/m) )
Diam. ,
meters
1.52
1.83
2.44
3.05
3.66
3.96
4.88
5.49
6.10
Precast
Concrete
566
566
678
849
1,360
1,360
1,360
—
— —
Corrugated
Steel Pipe
452
452
544
544
680
680
903
903
903
Fiberglass
Pipe
310
310
361
361
435
435
544
544
—
Carbon
Steel Pipe
452
544
544
680
680
903
903
903
—
For water depths greater than 14 meters, it was assumed
production was curtailed by 20 percent. The data presented
in Table B-36 are for water depths less than 14 m. An ad-
justment factor is given in Figure 407.2.
288
-------
Background data Sheet for
dowatering, Account 406.5
Table B-36. PUMPING EQUIPMENT AND
LABOR COST, ACCOUNT 406.5
Labor
1 Oiler
Cost,
$/week
726
Pump Capacity,
m^/min.
.252
.630
1.260
2.520
5.670
7.875
Cost
$/week
72
86
110
175
289
408
aThe unit cost for dewatering, per meter of pipe installed,
is calculated by dividing the assumed laying rate for
each pipe material into the pumping costs (not shown).
289
-------
COST CATEGORY 6
Installation of nozzles into
a tunnel cliff user. Account 602.3
Table B-37. LABOR FORCE AND
EQUIPMENT POOL, ACCOUNT 602.3
Labor
Foreman
^tester
Mechanic
3 Equipment
Operators
2 Oilers
2 Pile Drivers
4 Laborers
2 Divers
Tenant
TOTAL
Cost,
$/month
9,714
8,580
26,860
15,100
17.160
f
27,206
14,560
8,580
127,760
Equipment
Platform
Derrick
Big Bore Drilling
Rig w/Dril] Wt.
& Boring Unit
2 Compressor Units
(25 mVmin.)
Flat Top Barge
Cherry Picker
4
Crane (5.4 x 10 kg)
Concrete Pump
( 1 wk/month
Tug Boat
TOTAL
Cost,
$/month
70,000
25,000
75,000
2,800
5,000
1,500
4,400
500
60,000
244,200
Equipment is fully manned 6 days/week, 12 hours/day-
Table B-38. UNIT COST DATA, ACCOUNT 602.3
Description
Labor and Equipment,
$ /month
Productivity,
nozzle/month
Installation Unit Cost,
$/nozzle
Rounded Unit Cost
$/nozzle
0-6m
Depth
371,960
3
123,990
124,000
6m to
15m Depth
371,960
2
185,980
186,000
Over 15m
Depth
371,960
1
371,960
372,000
290
-------
COST CATEGORY 7
Structural concrete,
Accounts 791.1 and 701.2
Table B-39. COST FOR COMPONENTS OF
STRUCTURAL CONCRETE, ACCOUNTS 701.1 AND 701.2
Component
Placement, $/m
3
Formwork, $/m
Finishing, $/m
Sub-Total for 3
Concrete Work, $/m
Reinforcing, $/kg
Group Number
1
63
166
76
305
1.06
2
63
97
20
180
.90
3
63
15
—
78
.90
Concrete marine, Account 702
Table B-40. LABOR FORCE AND
EQUIPMENT POOL, ACCOUNT 702
Labor
4 Laborers
Foreman
TOTAL
Cost,
$/month
14,650
5,230
19,880
Equipment
Crane Barge
w/two cranes
Tug Boat
Hopper , truck
Flat Top Barge3
TOTAL
Cost,
$ /month
60,000
60,000
500
5,000
125,500
Equipment if fully manned 6 days/week, 8 hours/day.
291
-------
Costs, productivity, and the unit cost for Account 702 are
listed below:
1. Labor and Equipment
2. Productivity
3. Installation Unit Cost
4. Material
5. TOTAL UNIT COST
$145,380/month
4,000 m /month
$36.30/m3
$50/m3
$86.30/m3
Grouting, Account 703
Table B-41. LABOR FORCE AND
EQUIPMENT POOL, ACCOUNT 703
Labor
Foreman
Driller
4 Laborers
Equipment
Operator
Oiler
TOTAL
Cost,
$/week
898
825
2,616
825
726
5,890
Equipment
Air Compressor
(25 m^/min.)
Track Drill
(14 cm)
Concrete pump
TOTAL
Cost,
$/week
350
344
500
1,194
Costs, productivity, and the unit cost for Account 703 are
listed below:
1. Labor and Equipment
2. Productivity
3. Installation Unit Cost
4. Material Cost
(1:1 cement grout mix)
5. TOTAL UNIT COST
$7,084/week
3
40 m /week
$177.10/m3
$54.80/m3
$231.90/nf
292
-------
COST CATEGORY 8
Placement of fill (land), Account 802.1
Table B-42. LABOR FORCE AND EQUIPMENT POOL,
ACCOUNT 802.1 (GROUP 1)
Labor
Equipment
Operator
Laborer
Foreman
Oiler
TOTAL
Cost,
$/week
825
654
898
726
3,103
Equipment
Grader
TOTAL
Cost,
$/week
300
300
Table B-43. LABOR FORCE AND EQUIPMENT POOL,
ACCOUNT 802.1 (GROUP 2)
Labor
Foreman
Equipment
Operator
Oiler
4 Laborers
TOTAL
Cost,
$/week
898
825
726
2,616
5,065
Equipment
4 Hand
Compactors
Industrial
tractor with
loader and
backhoe
TOTAL
Cost,
$/week
352
516
868
293
-------
Table B-44. LABOR FORCE AND EQUIPMENT POOL,
ACCOUNT 802.1 (GROUP 3)
Labor
Foreman
2 Equipment
Operators
Oiler
TOTAL
Cost,
$/week
898
1,650
726
3,274
Equipment
Dozer (67,113 W)
Vibratory Roller9
(towed)
TOTAL
Cost,
$/week
586
480
1,066
Add $163 for a self-propelled sheepsfoot roller used for
compaction of earth.
Table B-45. UNIT COST DATA, ACCOUNT 802.1
(Group Number)
Description
Labor and Equipment ,
$/week
Productivity, m /week
UNIT COST, $/m3
1
3,403
3,000
1.13
2
5,933
1,800
3.30
3
Eartha
4,503
2,500
1.80
Gran.b
4,340
2,500
1.74
Self propelled sheepsfoot roller.
Vibrating roller (towed).
294
-------
Placement of fill (marine), Account 802.2
Table B-46. LABOR FORCE AND
EQUIPMENT POOL/ ACCOUNT 802.2
Labor
Foreman
Equipment
Operator
Oiler
2 Laborers
TOTAL
Cost,
$ /month
5,230
4,822
4,066
7,325
21,443
Equipment
Crane (5.4 x 104kg)
Tug Boata
2 Scowsa
Clam (2.3m3)
Crane Barge
TOTAL
Cost,
$/month
4,400
60,000
6,000
668
60,000
71,068
Equipment is fully manned 6 days/week, 8 hours/day.
Crane barge for filling offshore cofferdam.
Table B-47. UNIT COST DATA, ACCOUNT 802.2
Placements
Description
Labor and Equipment,
$/month
Productivity, m /month
UNIT COST, $/m3a
Dumped
92,511
12,800
7.20
Offloaded
152,511
13,600
11.20
Unit cost for backfill with side cast material is assumed
to equal 75 percent of excavation costs for a firm
material or $4.62/m3.
295
-------
COST CATEGORY 9
Earth excavation (land), Account 901.1
Table B-48. LABOR FORCE AND EQUIPMENT POOL,
ACCOUNT 901.1 (GROUP 1)
Labor
Equipment
Operator
Foreman
Laborer
TOTAL
Cost,
$/week
825
898
654
2,377
Equipment
Hydraulic Backhoe
(.76 m3)
TOTAL
Cost,
$/week
753
753
Table B-49, LABOR FORCE AND EQUIPMENT POOL,
ACCOUNT 901.1 (GROUP 2)
Labor
Foreman
Equipment
Operator
Oiler
Laborer
TOTAL
Cost,
$/week
934
861
726
654
3,175
Equipment
Crane (5.44 x 104kg)
Clam (2.3 m3)
TOTAL
Cost,
$/week
1,100
167
1,267
296
-------
Table B-50. LABOR FORCE AND EQUIPMENT POOL,
ACCOUNT 901.1 (GROUP 3)
Labor
Foreman
2 Equipment
Operators
2 Oilers
Laborer
TOTAL
Cost,
$/week
934
1,650
1,452
654
4,690
L Equipment
2 Scrapers
(15.2 m3)
Push Dozer
(223,710 W)
TOTAL
Cost,
$/week
4,414
990
5,404
Table B-51. UNIT COST DATA, ACCOUNT 901.1
Group Numbers
Description
Labor and Equipment,
$/week
Productivity, m3/week
UNIT COST, $/m3
1
3,130
500
6.26
2
4,442
1,000
4.44
3
10,094
7,500
1.35
Earth excavation (marine), Account 901.2
Table B-52. LABOR FORCE AND EQUIPMENT POOL,
ACCOUNT 901.2 (HARD MATERIAL)
Labor
Foreman
TOTAL
Cost,
$ /month
15,691
15,691
Equipment
Tug Boata
Crew Boata
Dipper Dredgea
TOTAL
Cost,
$ /month
100,000
13,000
270,000
383,000
aEquipment is fully manned 24 hours/day, 6 days/week.
297
-------
Table B-53. LABOR FORCE AND EQUIPMENT POOL,
ACCOUNT 901.2 (FIRM OR SOFT MATERIAL)
Labor
Foreman
TOTAL
Cost,
$ /month
15,691
15,691
Equipment
Clamshell Dredge
Tug Boat9
Crew Boata
TOTAL
Cost,
$/month
180,000
100,000
13,000
293,000
Equipment is fully manned 24 hours/day, 6 dayrVweek.
Table B-54. LABOR FORCE AND EQUIPMENT POOL,
ACCOUNT 901.2 (DISPOSAL)
Liibor
Equipment
Operator
Oiler
Laborer
TOTAL
Cost,
$ /month
14,465
12,197
10,987
37,649
Equipment
Crane (5.44 x 104kg)
3 Scows (1500 m3)a
TOTAL
Cost,
$/month
4,400
15,000
19,400
Equipment is fully manned 24 hours/day, 6 days/week. The
scows are towed to shore using the tug boats listed in
tables B-53 and B-54.
Table B-55. UNIT COST DATA, ACCOUNT 901.2 (SIDE CAST)
Description
Labor and Equipment,
$/month
3
Productivity, n /month
UNIT COST, $/month
Hard
Material
398,691
50,000
7.97
Firm
Material
308, £91
50,000
6.17
Soft
Material
308,691
100,000
3.09
298
-------
Table B-56. UNIT PRICE DATA,
ACCOUNT 902 (ONSHORE DISPOSAL)
Description
Labor and Equipment
$/month
Productivity, m /month
UNIT COST, $/month
Hard
Material
455,740
50,000
9.11
Firm
Material
365,740
50,000
7.31
Soft
Material
365,740
100,000
3.66
Rock excavation (land), Account 902.1
Table B-57. LABOR FORCE AND
EQUIPMENT POOL, ACCOUNT 902.1
Labor
Foreman
2 Equipment
Operators
Driller
Blaster
4 Laborers
2 Oilers
TOTAL
Cost,
$/week
934
1,686
825
800
2,616
1,452
8,313
Equipment
Crane (5.4 x 104kg)
Clam Bucket
(2.3m3 rigged)
Track Drill (14 cm)
Air compressor
(25.5 m3/min.)
TOTAL
Cost,
$/week
1,100
167
344
350
1,961
299
-------
Table B-58. UNIT COST DATA, ACCOUNT 902.1
Description
Labor and Equipment,
$/week
Productivity, m /week
Unit Cost, $/m3
Material (powder) , $/m
TOTAL UNIT COST, $/m3
Wide Trench
> (75 meters)
10,274
575
17. 86
3.00
20.86
Narrow Trench
< (25 meters)
10,274
400
25.70
3.00
28.70
Rock excavation (marine). Account 902.2
Table B-59. LABOR FORCE AND
EQUIPMENT POOL, ACCOUNT 902.2
Labor
Foreman
Equipment
Operator
Oiler
Laborer
TOTAL
Cost,
$ /month
15,691
14,465
12,197
10,987
53,340
Equipment
Drill Boata
Powder Scow^
Tug Boat
Dipper Dredge
Crewboat
Crane (5.44 x 104kg)
TOTAL
Cost,
$ /month
225,000
3,000
60,000
270,000
13,000
4,400
575,400
Equipment is fully manned 24 hours/day, 6 days/week.
300
-------
Costs, productivity, and the unit cost for Account 902.2 are
listed below:
1. Labor and Equipment $628,740/month
m~
3
2. Productivity $12,000 m /month
3. Installed Unit Cost $52.40/irf
4. Material (powder) $3.00/m
5. TOTAL UNIT COST $55.40/m3
301
-------
U.S. Environmental Protection Agency
Region 5, Library (PL-12J)
77 West Jackson Boulevard, 12th Floor
Chicago, IL 60604-3590
-------
TECHNICAL REPORT DATA
(I'lfusf read Imtructions on tin- reverse be/ore com/rlviing)
\ MI r< in i NO y
UPA-660/2-75-023
.) 1 1 I 1 1 AND MID 1 1 1 l.L
Cost Estimating Methodology for Once-Through Cooling
Water Discharge Modification
/ AUttUlMIS)
John W. Hayden and
Richard Mayer
ip PI HI OMMINU OHC, MMIZATION NAME AND ADDRESS
Acres American Incorporated
The Liberty Bank Building, Main at Court
Buffalo, New York 14202
17 ! I'OMSOHINC, ACit NCY NAME AND ADDRESS
National Environmental Research Center
Office of Research and Development
U.S. Environmental Projection Agency
Corvallis, Oregon 97330
3. RECIPIENT'S ACCESSION-NO.
5. REPORT DATE
6. PERFORMING ORGANIZATION CODE
8. PERFORMING ORGANIZATION REPORT NO
1O. PROGRAM ELEMENT NO.
1 BB 392
11. CONTRACT/GRANT NO.
68-03-2053
13. TYPE OF REPORT AND PERIOD COVERED
Final
14. SPONSORING AGENCY CODE
10 SUPI'L 1 Ml NTARY NOTES
tfi ABSTRACT
The manual presents a methodology for evaluating the engineering and cost implica-
tions of constructing or modifying once-through cooling water discharge systems of
thermal electric generating plants. The procedures presented provide persons not
skilled in cost engineering with a means of preparing preliminary cost estimates
from conceptual or design drawings. The user should, however, have a technical
background and be familiar with once-through cooling water discharge systems.
Principal construction elements of discharge system construction and modification
are identified and grouped into categories. Materials and installation methods
are discussed for each construction element. Data on labor, materials, equipment,
and productivity assumed in unit cost development is provided. A step-by-step
procedure is given for: (1) estimation of construction costs; and (2) resolu-
tion of construction costs into project and annual costs.
An example is shown using the methodology and comparing result with actual con-
struction costs for modifications to an existing discharge system.
);. KEY WORDS AND DOCUMENT ANALYSIS
.1 DESCRIPTORS
Construction costs, Engineering costs,
Cost Estimates, Cooling systems, Cooling
Water, Discharge (water) , Thermal
Pollution
HI Ul1. 1 IIIIIUI ION SI A ITMENT
Release unlimited
b. IDENTIFIERS/OPEN ENDED TERMS
pipes, pumps, concrete,
construction materials,
cost resolution
Waste heat rejection
19. SECURITY CLASS (This Report)
20. SECURITY CLASS (This page/
c. COSATI l-icld/Group
5C, 13B
21. NO. OF PAGES
317
22. PRICE
EPA fo\m 2220-1 (9-73)
-------
INSTRUCTIONS
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I cnvc blank
15. SUPPLEMENTARY NOTES
l.ntci information not included elsewhere but useful, such as. Prepared in cooperation with, Translation of, Presented al conference of,
lo IK published in. Supersedes, Supplements, etc.
18. ABSTRACT
Include a briel (200 words or least factual summary of the most significant information contained in the report. If the report contains a
significant bibliography or literature survey, mention it here.
17. KEY WORDS AND DOCUMENT ANALYSIS
(a) DESCRIPTORS - Select from the Thesaurus of Engineering and Scientific Te(ms the proper authorized terms that identify the major
concept of the research and are sufficiently specific and precise to be used as index entries for cataloging.
(b) IDI'.NTiriliKS AND OPEN-ENDED TERMS - Use identifiers for project names, code names, equipment designators, etc. Use open-
ended U-tm\ written in descriptor form for those subjects for which rto descriptor exists.
U ) COSA 11 I II• I.I) C.ROUP - Held and group assignments are to be taken from the 1965 COSATI Subject Category List Since the nia-
lority of documents are multidtsciplinary in nature, the Primary Held/Group assignment(s) will be specific discipline, area of human
endeavor, or type of physical object. The application(s) will be cross-referenced with secondary Field/Group assignments that will follov
the primary postmg(s).
18. DISTRIBUTION STATEMENT
Denote iclcasubihty to the public or limitation for reasons other than security for example "Release Unlimited." Cite any availability to
the public, with address and price.
10. &20. SECURITY CLASSIFICATION
IX) NOT .submit classified reports to the National Technical Information service.
21. NUMBER OF PAGES
Insert (lie total number of pages, including this one and unnumbered pages, but exclude distribution list, if any.
22. PRICE
Insert (he ptae set by the National Technical Information Service or Ihe Government Printing Office, if known.
EPA Form 2220-1 (9-73) (R*v*ru)
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