John s page estimating manual pdf

Field fabrication and erection. Alloy and non-ferrous fabrication. Pneumatic mechanical instrumentation. Underground piping. Hangers and supports. Patent scaffolding. Sample estimate.

Technical information. John S. Page Affiliations and Expertise John S. Page has wide experience in cost and labor estimating, having worked for some of the largest construction firms in the world. He has made and assembled numerous types of estimates including lump-sum, hard-priced, and scope, and has conducted many time and method studies in the field and in fabricating shops.

Cost of books or subscriptions. Cost of subcontract guard service Normally includes travel costs for quality control personnel. Cost of employee educational assistance, for overhead and indirect personnel only. Home Office Cost 1. Construction ServicesServices furnished by various home office departments such as estimating, scheduling, expediting, etc. Services are charged to the project only for time actually spent on the project.

Project General ManagementIncludes the portion of time that the contractor's management staff applies in regard to overall direction of the project.

The most important component of physical plant cost is that of process equipment. From it the prime basis can be formed for the estimation of the entire plant.

Once the production rate has been established and a rough flow sheet presented, an equipment list can be compiled noting the type, size, capacity and material of construction.

From the logarithmic graphs that appear on the following pages, an average cost of equipment material and installation manhours can be computed. Inasmuch as it is not practical within the scope of this manual to adequately describe each piece of equipment beyond the very minor description as appears on the individual graphs, I rely on the estimator's ability to realize that the items covered are of a standard nature for chemical plants, refineries, and industrial plants.

All installation manhours include offloading equipment at job site, hauling up to 2, feet and rigging, picking, setting, and aligning of the equipment. The equipment graphs include the total cost of the equipment, but do not include structural steel or miscellaneous iron such as supports, ladders, walkways, platforms, or handrails.

See other sections for these items. AU shop fabricated equipment graphs, as in the case of vessels, include the total shop cost, overhead, and profit for fabricating and furnishing of all material and components required for that piece of equipment. Packaged unit graphs include the total skid-mounted cost of the equipment and piping, electrical components and instrumentation, which may be an integral part of the package.

Sub-contract equipment graphs include the total sub-contractors cost and profit for the furnishing and installing of the equipment. All equipment graphs include an average allowance for freight cost within the continental forty-eight states.

D Single-stage, air-cooledcapacity 7. Two-stage, air-cooledcapacity 5. D Cast iron cylinders, 1, psig discharge 2 Nodular cylinders, 1, psig discharge Forged steel cylinders, 2, psig discharge Forged steel cylinders, 6, psig discharge. Motor Horsepower DOil-lubricated, , or volt. Nonlubricated, , or volt. Portable clamp mounted mixersdirect drive. Portable clamp mounted mixersgear drive. Flanged top tank mounted mixersdirect drive Flanged top tank mounted mixersgear drive.

Portable clamp mounted mixersDirect And Gear Drive. Flanged top tank and plate mounted open tank mixersdirect and gear drives. Note: Cost is for total boiler including forced draft fan assembly.

Boiler capacity pounds per hour-saturated steam at to psig. Note: Manhours are for installation of boiler including forced draft fan. D inch diameter 3 42 to inch diameter inch diameter 54 to inch diameter inch diameter Note: Cost includes stack, cable, and clamps. Stainless steel turbo-screen cyclone Carbon steel turbo-screen cyclone inch pressure sifter 3-screens. Performance range-single width-fan class. D Wing-type feeders-ratchet drive Wing-type feeders-micro master drive Conveyor type feeders 3 Sanitary wing-type feeders.

Wing-type feedersratchet drive Wing-type feedersmicro master drive Conveyor-type feeders D Sanitary wing-type feeders. D Units on casters with rubber-lined filter and pump. In addition to above, includes adequate rubber-lined steel slurry tank, rubber-lined valves, and rubberlined steel fittings. One-deck screen Two-deck screen Three-deck screen Note: Costs of all two-and three-deck screens are based on square feet of single deck area.

D One-deck screen Two-deck screen Three-deck screen Note: Manhours for two- and three-deck screens are based on square feet of single deck area. Add 1. Carbon steel shells, copper-lined heads, bronze tube sheet, two-pass, pound construction. D ANSI pumps3, rpmspecific gravity of 1.

API pumps3, rpmspecific gravity of 1. Motor Horsepower Ductile iron3, rpmspecific gravity of 1. Sump pumps3, rpmspecific gravity of 1. Motor Horsepower D 3, rpmspecific gravity of 1. Baffels, draw-off boxes and vortex breakers estimate weight and price at 20 percent of the vessel per-ton cost.

See other graphs for tray rings, trays, and demisting pads if required. Vessel Diameter - Inches Tray rings for single-pass removable trays D Tray rings for two-pass removable trays. Removable type single downflow valve or perforated type trays Removable type double downflow valve or perforated type trays Note: Includes shop installation only. Does not include cost of tray. Single downflow stainless steel Single downflow stainless steel Single downflow stainless steel.

D Double downflow stainless steel Double downflow stainless steel S Double downflow stainless steel. Horizontal vessels Vertical vessels Add for following if required: Remove and replace manway cover1. Check tray and tighten retaining bolts1. General preparation of the plant site for construction is included in this section.

Items include, but are not necessarily limited to, clearing, rough grading, cut, fill, borrow, disposal, soil stabilization, and finish grading. Soil tests are not considered a part of site preparation and are not included. If this is to form a part of the estimate, it must be determined from other sources. LightLight brush and grass, no trees. MediumConsiderable brush of larger size. Medium HeavyLarge brush and small trees.

HeavyMuch small brush, many small trees and occasional large trees. All manhours include cutting, stacking or piling. On site disposal manhours include hauling to on site disposal area or on site burning.

Off site disposal manhours include hauling to off site disposal area within five mile radius of site. Cost of all small tools and construction equipment is included under their respective accounts. LevelSmooth and level no hills. Slightly RollingLevel with minor contour changes and small hills. RollingConstant contour changes and small hills.

RoughPartially level with minor contour changes, slues and valleys. Very RoughConstant changes, major hills, slues and valleys. If ample fill material is available on the site delete above purchase fill cost.

Manhours include removal and on site stock piling top soil and spoil, area cuts and fills to grade and minor site drainage. Fine Grading: Use 1. LaborUse 0. This section includes items of work that provide permanent improvements to the plant site, such as security fencing, railroads or spurs including ballast, tank dikes and all sub-base materials for roads, parking areas, paved areas and railroads, concrete trenches, drainage piping, catch basins, manholes and road culverts.

Pavements for roads, parking areas and process areas are included under "Discipline, Paving " Site improvements will vary depending on site location, conditions, and project requirements. For these reasons I have listed unit costs for various items that may be required.

The scope of work or plot plan will dictate the items required for site improvements. Security Fencing Fencing is usually listed as a subcontract price in the estimate and as such includes his overhead and profit. Included in this price is installation labor at an average of 0. Railroad and Spurs Railroads including ballast, ties, tracks, switches, stops, etc.

The sub-base material. Sub-base material will average 0. Included in this subcontract price is the cost of 1. Tank Dikes Earth type dikes include the furnishing, placing, and compaction of all earth materials. Concrete type dikes include all operations for the forming and placing of concrete. Earth type dikes material will average 1. Concrete type dikes material will average 1. Drainage Drainage items such as raw water, oily water, and pressurized systems will vary depending on pipe size, elevations, etc.

Catch Basins and Manholes Catch basins and manhole size and length will vary depending on capacity and bottom elevation. Road Culverts Road culverts will vary in size depending on volume requirements. Logarithmic graphs in this section indicate the value of labor in manhours and materials in dollars of earthwork, concrete, fireproofing and grout for equipment foundations and equipment structure foundations. Earthwork and concrete for buildings are included with the buildings and are not to be considered here.

The earth and concrete graphs are average and are based on the total equipment count, even though some pieces of equipment may not require foundations. Earthwork graphs include labor in manhours for all hand and machine excavation and backfill. There is also a graph showing average quantities of required backfill in the event special fill material is required.

Should special fill material be required it should be priced at the current material value for that particular type of fill. Concrete graphs include the furnishing, fabricating, and placing of forms, reinforcing steel; miscellaneous embedments; concrete and curing; protecting and finishing concrete.

There is also a graph showing estimated cubic yards of concrete for cost control and reporting purpose. Piling as such has been excluded.

The graphs represent the use of spread type footings and reflect enough manhour and material values to include this item if required. Graphs are included for fireproofing vessel skirts and structural steel. Should this not be required, simply disregard these graphs. The graphs for grouting show average square feet required, for labor manhours and material value based on total equipment count for equipment support and total tons of steel for base plates.

The curves in this section represent the material cost in dollars and the erection manhours required for equipment supports, equipment structures and piperacks, and miscellaneous steel and iron for equipment platforms, walkways, and ladders. All steel items are based on the total pieces of equipment even though some pieces will require no steel. If pipe racks are not required, delete these curves from the estimate. All building steel is included with the buildings and is not a part of this section.

The scope of work, for a proposed project should include information as to type and size of buildings required. The logarithmic graphs included in this section show average labor in manhours and material dollar cost per square foot of floor area for various types of one-story buildings that are more or less standard.

All buildings listed include building earthwork, concrete foundations, concrete ground floor slabs, structural framing, exterior and interior finishes, sprinkler system, plumbing, HVAC, and electrical power and lighting. AU utilities extend five feet outside of building. Following is a listing of buildings with a brief description of their types and inclusions. Exterior WallsMasonry and curtain wall with aluminum entrance. Interior WallsMetal studs and drywall with hollow metal doors and frames.

CeilingsSuspended and insulated. RoofMetal deck with built-up roof, roof ventilators, gutters and drains. Dining FacilitiesCoffee bar and dining area. PlumbingWater, utility lines, toilets, drains and sprinklers. HYkC-Ample for size of structure. ElectricalLighting and power. Note: No furniture is included.

Laboratory Building: Same type construction as office building with additional plumbing and electrical outlets for laboratory equipment.

Note: No laboratory equipment or furniture is included. Control Building StructureStructural steel framing. Exterior WallsConcrete block, hollow metal frames and doors and steel sash. Interior WallsOffice and toilet with metal studs and drywall, hollow metal frames and doors.

RoofPre-cast concrete slabs with insulation and built up roof. PlumbingToilet utilities and drinking fountain. HVACAmple for size of structure.

Note: No instrumentation included. Warehouse Building: StructureStructural steel framing. Exterior WallsCorrugated asbestos or insulated metal siding with hollow metal doors and frames, truck doors and steel sash. Interior WallsOffice and toilet room partitions of metal studs and drywall with hollow metal doors and frames, storage shelving and bins included. RoofSame as exterior wall siding. CeilingsExposed except office and toilet area with same type construction as interior partitions.

PlumbingToilet utilities and drinking fountains. HVAC-Office area only. ElectricalPower and lighting. Maintenance Shop Building Same type construction as warehouse with additional foundations for shop equipment and including an overhead crane. Note: No shop equipment is included. Change House Building Same type construction as control building with concrete locker bases, lockers and additional toilet and shower facilities for men and women.

In the absence of plot plans, piping and instrument diagrams, and flow sheets the cost of process piping can be determined from the following logarithmic graphs. The graphs are based on total equipment count. All dollar costs on the material graphs are average and include the costs of all pipe, valves, and fittings that should be required.

Control valve material cost is included in the instrumentation section. Labor manhour graphs are average and include all necessary installation operations. Installation of control valves furnished under the instrumentation section is included here. The offsite fabrication graphs include all labor, material, and shop costs for furnishing and fabricating pipe spools and delivery within reasonable distance of job site.

Graphs for underground potable water, fire loops, etc. The field x-ray and stress relief graphs are to be considered as subcontract work. Building piping for plumbing, etc. Note: All items include installation of control valves.

D Carbon steel underground Steam tracing Alloy 2" and under. Logarithmic graphs in this section reflect the average cost of project power and lighting excluding building electrical that is included with the building section. Power and lighting graphs for material in dollars and labor in manhours are included for the battery limit requirements and are based on total pieces of equipment. Instrumentation graphs are included for the cost of miscellaneous hookup materials in dollars and installation of this material in manhours.

Instruments, instrument standards, tray supports, trays, tubes and tube bundles are discussed in Section 10, "Instrumentation. Note: Pneumatic instruments and other instrument materials are included under "Instruments. Note: Manhours for installation of electrical instrument materials only. All other instrument manhours included under "Instruments". The following graphs represent the average number of instruments required, their material value in dollars and installation in manhours based on total pieces of equipment.

Included with the instrument graphs are dollars and manhours for the furnishing and installation of panel boards. Other graphs are included for the cost and installation of standards, tray supports, trays, tubes, and tube bundles. Material value of control valves is included under this section.

The installation of these valves is discussed in Section 8, "Piping. The following piping and equipment insulation graphs are based on total pieces of equipment for a project and are average for various types and thickness that are more or less standard for refinery and petrochemical work.

All building insulation is discussed in Section 7, "Buildings. Based on total pieces of equipment the following graphs are average cost of materials in dollars and labor in manhours for painting. Labor manhours include time required for sandblasting and painting. Building painting is discussed in Section 7, "Buildings. This section includes items of work for the installation of road, parking area and yard pavements.

The placement of sub-base materials for these items is described in Section 4, "Site improvement. The scope of work or other proposal documents should indicate the pavement requirements.

In the absence of this information, the following allowances can be added based on the total equipment count. Asphalt Pavement Concrete Pavement4. Materials costs in dollars and labor in manhours on the following graphs reflect the average cost and time required for daily area clean-up, all project scaffolding and final test, start-up, and pre-commissioning assistance.

The average cost of equipment to construct a project can be estimated from the following logarithmic graphs. The rental or purchase curve represents the average cost of rental or purchase of construction equipment to construct the project.

This does not include small tools. The fuel, oil, grease, and supply curve includes the cost of these items to operate and maintain the equipment.

The equipment service labor curve represents all labor required to service and maintain the construction equipment. This does not include the operating labor of the equipment when working. Operators are included in the direct account labor. Included in this section are logarithmic graphs reflecting average cost of labor, materials, temporary facilities, small tools, consumable supplies, burdens and benefits, etc. Various items have been grouped together on the following graphs for ease of listing and application.

For a comprehensive listing of total coverage of items under this section refer to the overhead and indirect listings under Section 1 "Disciplines of Work. Payroll burdens and benefits 2 Other indirect materials H Temporary construction materials Note: See next page for continuation of these items. Total engineering design, including construction services such as estimating, scheduling, expediting, etc.

Manhour range tables listing manhour ranges for single and duplicate pieces of equipment are included to establish the total home office manhours required. After total manhours are established they are to be spread, on a percentage basis, to the various personnel disciplines, as outlined in the following manhour spread percentage table. Simply by multiplying the established discipline manhours by your established discipline rates a total labor manhour and dollar cost is obtained.

Other cost such as blueprints, reproductions, computer use, miscellaneous expenses, travel expenses, telephone, telex, postage, and burdens and benefits are to be established as a percent of the total labor dollars in accordance with the following percentage spread table for these items. After the total labor and material dollars are established, the estimator need only apply a cost for design allowance and fee for a complete home office engineering design cost. See Section 19, "Definition of Estimate Adjustments," for design allowance and fee definitions.

Manhour Allowance For Duplicate Single Unit Range Unit Range , 1,, 1,, , , , Ratio estimating factors are simply the relationship, in percentage ranges, between two or more things and are the transformation of statistical data into combinations of variables that are usually not correlated. The minimum basic information required to assemble an estimate of this type is: 1. Information regarding plant capacity, product form, basic process and raw material.

A complete process equipment list with individual shipping dates and total material dollar cost. The general plant location. The direct cost percent ranges in the following tables are to be applied against the total material dollar value of the process equipment. The construction equipment and overhead and indirects percent ranges are a percent of the direct field labor dollar value.

The home office percent range is applied against the total direct and indirect cost of the project. The percentages for the various disciplines of work are averages of many projects located in the Gulf Coast Area. When determining a percentage to be applied for a specific project from the percentage range tables consideration should be given to this fact.

The percentages for labor are for open or merit shop type operations. If closed shop methods are to be employed additional consideration should be given and applied against the labor dollar value.

Manhours for the various disciplines of work can be obtained by dividing the labor percentage dollars by the established hourly activity rate.

A construction schedule can be executed utilizing the discipline manhours coupled with equipment shipping dates. For a description of items included under the various disciplines of work see Section 1, "Disciplines of Work.

Ratio Estimating Factors The Refinery Process Systems table is based on any one or all of the following process systems and includes all discipline requirements.

Atmosphere and vacuum crude distillation Saturates gas plant Naphtha hydrodesulphurization Distillate hydrotreater Flexicoker Heavy oil hydrodesulphurization Fluid catalytic cracker Unsaturates gas plant Cycle oils hydrodesulphurization C5, C6 isomerization Catalytic reformer Aromatics extractions Steam reforming hydrogen plant Butane alkylation Olifin poly plant H2S recovery and sulphur manufacturing.

Tables on Chemical Plants are self-explanatory. Discipline 1. Process Equipment 2. Site Preparation 3. Site Improvements 4. Concrete 5. Structural Steel 6. Buildings 7. Underground Piping 8. Above-ground Piping 9. Underground Electric Above-ground Electric Instrumentation Insulation Painting Paving Roman Numeral Codes: I.

Discipline, Other Materials as a percent of Process Equipment costs. Discipline, Subcontracts as a percent of Process Equipment costs. Discipline, Direct Labor as a percent of Process Equipment costs. Discipline, Material cost as a percent of Total Material costs. Discipline, Subcontract cost as a percent of Total Subcontract costs. Discipline, Labor cost as a percent of Total Labor cost. Discipline, Total cost as a percent of Total Direct cost. Description Burdens and Benefits Small Tools and Consumables Construction Services Project General Management Tbtal.

Each estimate, in all probability, will need some or all of the following adjustments dependent upon the scope of work, amount of pre-bid information available, and the type of estimate to be prepared. The following are definitions of these adjustments: Design Allowance. The design allowance is an adjustment to the estimated mechanical equipment cost to provide for nominal and routine changes in equipment design.

The design allowance is included in the details of the estimate and is considered as part of the direct base cost.

The magnitude of the design allowance is a function of the amount of design information available to the estimator, and it decreases as the accuracy level of the estimate increases. An example of a design allowance is the addition of money for routine nozzle and clip changes on a fabricated vessel.

It is expected that all design allowance money will be expended during the project. Quantity Allowance. The quantity allowance is an adjustment to the estimated construction activity take-off quantities to provide for 1 the difference between neat take-off quantities and in-place quantities and for 2 consideration of fabrication waste.

The quantity allowance is included in the details of the estimate and is considered as a part of the direct base cost. The magnitude of the quantity allowance is a function of the amount of design information available to the estimator and decreases as the accuracy level of the estimate increases.

An example of a quantity allowance is adding to the piping take-off an allowed quantity of small diameter pipe and valves for vents and drains not shown on estimate drawings. It is expected that all quantity allowance money will be expended during the project. The escalation is the amount of dollars or percentage of cost added to the estimated base cost to provide for procurement at a future date later than the estimate. The magnitude of the escalation is a.

It is expected that all escalation money will be expended during the project. A percentage of base cost plus escalation and taxes or amounts added to same providing coverage for human calculation or judgement error in accumulation of estimate scope. Contingencies are anticipated to be spent and form a part of the cost of the project.

Contingencies vary directly with the accuracy level of the estimate. The more gross the method of estimating, the higher the contingencies. Contingencies do not provide any funds for scope changes.

Examples of items covered by contingency are: piping lines missed on take-off, extension errors, dimension errors, etc. An amount of money or percent of base cost plus lower level additives except fee normally added to the base cost plus additives to cover the chances of probabilities that the base cost estimate plus additives is not ample for financing of the project. Risk is normally associated with the monies applied by a contractor's management in the case of a "lump sum" or "guaranteed maximum" or an owner for other contractual arrangements to cover costs that might occur, but hopefully will not.

Risk monies may or may not be spent. These monies are added to provide financial protection and quantify management or executive judgements for final project cost outcome.

Considerations of changes in scope normally generated by an organization should be covered in these amounts.

In rare cases, risk could be expressed as a deduction from the base cost plus additives. Examples of items covered by risk are: inclement weather conditions, time extensions of the project, prototype processes, productivity loss, etc. The amount of money anticipated to be recovered by the contractor to provide funds for payments of his non-project overhead and profit.