2017 International Hi-Tech Manufacturing / Cleanroom ... · PDF file2017 International Hi-Tech...

Compass International Consultants Inc.Morrisville, Pennsylvania, USA

2017 International Hi-Tech Manufacturing / Cleanroom Facilities Estimating Yearbook

13TH ANNUAL EDITION

• Square Foot / M2 Estimating Data for (70 +) Hi-Tech / Pharmaceutical / Industrial / Commercial Facilities:• Benchmarking Data / Cost Estimating of Classified ISO 3 - 8 / Clean Rooms Facilities / BSL 1 – thru BSL 4:• Manufacturing Equipment Costs (45 + equipment items)• Historical Percentage Hi-Tech Facility Factors and Methods:• North American (280 + Cities) and International Location Factors (30 + Countries / Additional Cities):• 1,000 + Labor and Material Unit Prices cost line items:• Labor Rates Union and Open Shop:• Engineering, Architectural, Validation and CM Fee’s: • Value Engineering / COM / Estimating Checklist:• Required Engineering / Design Deliverables:• Glossary of Terms / Cost Data Sources:

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Copyright © 2017 Compass International, Inc.

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CONTENTS

ABOUT THE FIRM

ACKNOWLEDGEMENTS

Section 1Eight step CAPEX estimating methodLocating to the Correct SiteCost Estimating Database ObjectivesData Collection and Calibration ProcessCost Models & Basic Benchmark - Engineering ConsiderationsHi –Tech International Location Factors 30+ Countries & CitiesFacility / Building Costs (55 + Facilities)

Section 2General Estimating Background & DataSpace / Cost Considerations / Benchmarking PointsClassified Areas / BSL-1 – BSL- 4Architectural Finishes / Walls / Ceilings / Floors / BenchmarksPiping / Insulation / Welding CostsElectrical / Instrumentation / Robotics / PackersEPC / Revamp Considerations10 # Historical Pharmaceutical / Hi-Tech Cost Models280+ North American City adjustment factors50+ International Productivity MetricsPuerto Rico / USA Productivity FactorsEngineering / A & E Fees, CM and Validation DataVarious Related Cost Data Charts and Cost Models

Section 3Unit Price Capital Cost Estimating issuesProduction Equipment CostsUnit Price Library (1,094 items)Global Cost IssuesDemolition / Revamp issues of various facilitiesEstimating ChecklistChange Order / Claims IssuesValue Engineering / COM ConsiderationsContingency / Risk Issues & Checklist of Engineering Deliverables to Compile Various Cost EstimatesGlossary of Terms & Cost Information / Data Sources

I N T E R N A T I O N A L I N C .

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08. | SECTION 1


• Land purchase or lease: • Finance costs:• Front-end studies, A/E – EPCM fees, detailed

design.• Construction Management fees:• Procurement of material and major equipment: • Construction and startup of the completed facil-

ity:• Owner’s cost items / Operation and mainte-

nance costs.A large amount of additional information and

data of course needs to collected and evaluated, from any design or reports that have been previously com-pleted. In most cases this information can be found or is discussed in the following sections of this publication. The following is an eight step budgeting / decision making process, that can be used to as a front-end guide to develop a new or additional Hi-tech facility CAPEX projects: See chart next page.

The following eight steps should be completed

with thought given to the following topics:• Consider “all” existing or possibly new plant

manufacturing locations, to establish lowest cost manufacturing location:

• Perform a benchmarking study; determine if results align with industry and company standards.

• Explore the opportunity to have 3rd parties and tolling activities introduced to the manufacturing process.

• Value Engineer existing facilities and reduce operating and utility costs where possible.

LOCATING THE CORRECT HI-TECH FACILITY LO-CATION – THE SITE SELECTION PROCEDURE:The site selection procedure requires a comprehen-sive analysis of a multifaceted set of needs, require-ments and issues that needs to be completed by the future owner organization prior to moving forward with the funding, design and construction of the new or upgraded facility. For example if we know that

STEP 1: Select study team -

kick-off meeting with team members to establish initial path forward and

study goals.

STEP 2: Assess current and

future business opportunities /

Conduct survey of needs / Scope development

specific to identified business growth

STEP 3: Produce

preliminary report /

findings / case studies

models.

STEP 4: Review with management

Go / no go decision.

STEP 5: Define and

optimize current scope and facility layout / Complete

business economics ROI

STEP 6: Compile

preliminary cost estimates +/- 25%

/ schedule and study deliverables.

STEP 7: Review with management

Go / no go decision

STEP 8: Move forward

with CAPEX project if a

go decision is determined

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SECTION 1 | 09.


costs, grants, tax free loans or incentives pro-vided by cities or states, should be considered and deducted if necessary from the indicated budget.

In the below example Lincoln, Nebraska, would be the place to build if the selection criteria were solely based on cost, other considerations perhaps should include staffing, a question that needs to be asked can Lincoln, Nebraska attract 200 – 300 PhD’s (high skilled engineers and researchers) out of a fa-cility population of 700 – 800, is there enough high caliber universities in this part of the country, would this location be suitable for a Hi-Tech facility.

SITE SELECTION CRITERIA AND BUSINESS DECISIONS:Usually a steering committee made up of Senior Management from Finance, Sales, Operations, R&D and Engineering will be established to determine a future path forward related to the new product, topics that will be covered are as follows, (usually because the project is so complex and the cost of the future investment is so significant to the business), the steering committee will bring in the expertise of key individuals to process this Site Selection Criteria Report. The individuals / team members that would produce this work effort and report deliverables include: A Project Manager, Legal assistance (Law-

yer), Purchasing, Realtors, R&D staff, Operations / Facilities Management staff, Human Resource staff, Finance staff, Estimating staff from the Corporate Engineering Group, this task force would be charged with coming up with a recommendation in say 8 –12 weeks. Research and topics that need to be evaluated include some or all of the following.

• Need for new product or expansion of current product identified.

• Decisions on where to locate new facility, in North America, Europe or in some other overseas location (closer to future markets).

• Size of facility, configuration, operating philos-ophy, future expansion considerations and flexibility (could “modules” be sent to other operating loca-tions after a period of time – thus providing manu-facturing flexibility).

• Existing facility / site – can current site(s) ac-commodate new facility, can existing buildings be reconfigured, is the current infrastructure capable of such a significant expansion - Yes or No.

• New Location – closer to marketplace, new staffing needs (where will they come from), new utilities (can we obtain them or will we have to produce them), new facilities, quality of life issues, community dedication to new facility and employ-ment opportunities, government help or interference,

Ball Park Budget / Blue Sky First Pass Estimate DATA TABLE

MAJOR NEW FACILITY RURAL / URBAN 2017 UNIT URBAN CENTER 2017 UNIT ELEMENTS LOCATION IN MID COST BASIS IN N.E. USA** COST BASIS WEST USA*

Land Purchase 25 Acres Cost of land per acre $1.0 Million Cost of land per acre $5.00 Million $40 K $200 KFacility - cost 300,000 SF Cost of facility per SF $178.50 Million Cost of facility per SF $217.50 Million to build facility $595 $725 (more expensive to build in N.E. USA than Mid West)Initial Cost $179.5 Million $222.50 Million

* say 30 miles outside Lincoln, Nebraska** say 30 miles outside Washington, D.C.

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SECTION 1 | 17.


CSI DIVISION DESCRIPTION SUB CATEGORIES 1 General Requirements / Preliminaries Preliminaries Surveys Superintendent / General Forman Testing of materials Temporary facilities Equipment rental Scaffolding Temporary Barriers and Construction Equipment2 Site Construction Site Preparation Site Remediation Demolition Drainage Utility services Roads Footpath Landscaping Plantings Earthworks and U/G Utilities3 Concrete Concrete Formwork Rebar Pre-Cast Concrete and Grouting Concrete Restoration 4 Masonry Brickwork Concrete Blocks and Stonework5 Metals Structural steel framing Metal platforms Handrails Metal decking and ornamental ironwork6 Wood & Plastics Rough and finish carpentry Architectural woodwork and structural plastics7 Thermal & Moisture Protection Damp proofing and waterproofing Thermal protection Roofing Flashing Roof accessories and joint sealers8 Doors & Windows Metal and wooden doors / frames Windows Skylights Door furniture Glazing

CSI Division DATA TABLE

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CSI DIVISION DESCRIPTION SUB CATEGORIES CONTINUED9 Finishes Metal & wooden studs & track, plaster / gypsum board Tile / flooring Terrazzo tile work Ceilings Wall finishes Acoustical treatments Painting10 Specialties Display boards Cubicles Louvers / vents Wall / corner guards Access flooring Lockers Fire protection specialties Office / toilet partitions Shelving and toilet accessories11 Equipment Library Audio - visual equipment Loading dock equipment Food service equipment Darkroom equipment and laboratory equipment12 Furnishings Casework Floor mats / frames Blinds and shades Office furniture and planters13 Special Construction Air supported structures, radiation protection, pre-engineered – structures, security access / surveillance.14 Conveying Systems Elevators Escalators and material handling15 Mechanical Piping (process), plumbing, heat / refrigeration equipment, HVAC, ductwork, AHU’ s, testing and balancing (including hook-up of production equipment)16 Electrical Power, wiring, distribution, lighting, communications, instrumentation, BMS, CCTV, security, card readers and sound system (including hook-up of production equipment)M.E. Production or Major Equipment (M.E.) Miscellaneous Robotic welding machines, stamping equipment, presses, items (that could be allocated to above divisions at ovens, autoclaves, glove boxes, glassware washers, the preference of the reader / user of this section, freeze dryers, fume hoods, tablet presses, filling / sealing typically shown separately or included with Division machines, bio-safety cabinets, reverse osmosis / EDI systems, 11 above) walk-in rooms / freezer’s, laminar flow hoods; tray dryer ovens, animal cage’s, CIP / SIP water systems, filling lines, pure steam generators, tablet coating systems and vial washers (note typically 5 - 15% of the FOB purchase value of the Production Equipment is an adequate budget for the installation and hook-up of this equipment)

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SECTION 1 | 19.


CSI DIVISION DESCRIPTION SUB CATEGORIES CONTINUEDA/E Architectural / Engineering Fees Production of Architectural / Engineering deliverables (not a CSI Division) (drawings, specifications and reports)

PM Project Management (not a CSI Division) Project Management, Project Controls & Procurement activitiesCM Construction Management Construction Management services including H.O. and field (not a CSI Division) activities V Validation Services (not a CSI Division) The establishment of documented data to complete any required validation servicesG C ‘s O-H & Fee General Contractor’s overhead and profit General Contractor’s mark-up, overhead, profit and any (not a CSI Division) construction permits and contingency values

• Land purchase costs.• Major Demolition / Remediation work (lead

paint – asbestos removal / landscaping (indicated in some cost models).

• Front end engineering studies / Owner engi-neering costs, (indicated in some cost models).

• Free issue / owner provided manufacturing equipment, (indicated in some cost models).

• Features outside the build-ing footprint, i.e. parking areas, gatehouses, fencing etc, (indicated in some cost models).

• Office / laboratory furniture such as: tables / desks, bookcases, chairs, reception area furniture, meeting room furniture, chairs / tables for lunch rooms (micro-wave ovens and refrigerators) telephones, copy machines, spe-cial audio / TV conferencing equipment, employee’s PC computers, office supply cabinets, filing cabinets, paintings / wall pictures, soda machines and break room furniture etc.).

• Plug in / portable / bench top / laboratory equipment, such as microscopes, sampling, analysis, weighing and laboratory testing equipment.

Facets of design and construction that have a direct impact / effect on final costs of facilities and buildings:

This initial section consists of square foot / M2

cost tables for 50 + hi - tech / industrial / commercial facilities and buildings (plus a number of various cost models).

We are the earliest stages of a project (many times referred to as the definition brief, the schemat-ic phase or concept stage), no more than 5 % of the detailed design drawings and specifications (design

deliverables) have been complet-ed, we typically know the loca-tion of the building / facility, the approximate footprint area, a fairly accurate number of occupants and the job functions these individual perform, we might have an “in-kling” of the clients budget (ex-pensive or lowest cost mind set) usable square foot / M2, number of floors, number of elevators etc. At this point in the projects life cycle we typically need a budget

/ cost estimate of say +/- 15 - 20% accuracy for the owner to get full approval from their Board of Direc-tors. This is when the indispensable engineering and detailed design findings are discussed and formulat-ed. These important decisions are crucial and many times determine the future path forward, the go, no go verdict and the future viability / economics of the project.

As was indicated earlier, the following square foot / M2 costs are established on North American national averages, calibrated to Washington D.C.,

As was indicated earlier, the following square foot / M2 costs are established on North American national averages, calibrated to Washington D.C., and ad-justed to reflect first half 2017 prices.

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62. | SECTION 1


2.0 Agricultural R&D Center 1 FLOOR, 18 FT STORY HEIGHT, 72,600 SQUARE FEET SF

EXTERIOR COST PER SQUARE FOOT - M2Brick, concrete block back-up steel frame $300 - $3,225Pre cast panels, steel frame $305 - $3,286Metal and Glass or Stone Curtain wall $313 - $3,367

Building / Facility Type: Agriculture R&D DATA TABLE

CSI DIVISION DESCRIPTION % RANGE OF COST REMARKS1 General Requirements 5.50 – 10.50 Gen Conditions / Preliminaries2 Site Construction 8.50 – 12.50 3 Concrete 5.00 – 7.50 4 Masonry 3.50 – 5.50 5 Metals 3.00 – 6.50 6 Wood & Plastics 10.50 – 17.50 7 Thermal & Moisture Protection 7.50 – 9.50 8 Doors & Windows 4.50 – 6.50 9 Finishes 12.50 – 19.50 10 Specialties 1.50 – 2.50 11 Equipment 0.50 – 1.50 Excludes Production Equipment12 Furnishings 0.50 – 2.50 13 Special Construction 0.50 – 2.50 14 Conveying Systems 2.00 – 5.50 15 Mechanical 40.00 – 70.00 16 Electrical 10.00 – 15.00 Total Percentage 100.00 A / E Fees 7.50 – 15.00 Percentage of Construction Cost CM Fees 5.00 – 7.50 Percentage of Construction Cost

Excludes: New utilities outside building footprint, parking areas, roads, gatehouses, fencing, landscaping, and demolition of existing facilities:

2.0 AGRICULTURAL R&D CENTER 1 Floor, 18 Ft Story Height, 72,600 Square Feet (with 6,000 SF Greenhouse contained in 72,600 SF• See chart below

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SECTION 1 | 63.


3.0 ANIMAL RESEARCH / TESTING FACILITY (excludes central cage and washing facilities) 2 Floors, 16 Ft Floor to Ceiling Height, 96,000 SF• See chart below

3.0 Animal Research / Testing Facility2 FLOORS, 16 FT FLOOR TO CEILING HEIGHT, 96,000 SF

EXTERIOR COST PER SQUARE FOOT - M2Pre cast panels, steel frame $522 - $5,613Brick, concrete block back-up, $538 - $5,786

Building / Facility Type: Animal Research DATA TABLE

CSI DIVISION DESCRIPTION % RANGE OF COST REMARKS1 General Requirements 5.50 – 10.50 Gen Conditions / Preliminaries2 Site Construction 8.50 – 12.50 3 Concrete 5.00 – 7.50 4 Masonry 3.50 – 5.50 5 Metals 4.00 – 8.50 6 Wood & Plastics 18.50 – 22.00 7 Thermal & Moisture Protection 7.50 – 9.50 8 Doors & Windows 4.50 – 6.50 9 Finishes 15.50 – 19.50 10 Specialties 0.50 – 2.00 11 Equipment 0.50 – 1.50 Excludes Cage Equipment12 Furnishings 0.50 – 2.50 13 Special Construction 0.50 – 2.50 14 Conveying Systems 2.00 – 3.50 15 Mechanical 40.00 – 70.00 16 Electrical 10.00 – 15.00 Total Percentage 100.00 A / E Fees 7.50 – 15.00 Percentage of Construction Cost CM Fees 5.00 –7.50 Percentage of Construction Cost

EXCLUDES: New utilities outside building footprint, parking areas, roads, gatehouses, fencing, landscaping and demolition of existing facilities, animal cages, furniture and bench top equipment.

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4.0 API (ACITIVE PHARMACEUTICAL INGREDIENTS) 2 Floors, 17 Ft Story Height, 133,000 Square Feet• See chart below

4.0 API2 FLOORS, 17 FT STORY HEIGHT, 133,000 SQUARE FEET

EXTERIOR COST PER SQUARE FOOT - M2Brick, concrete block back-up steel frame $517 - $5,567Pre cast panels, steel frame $537 - $5,774Metal and Glass or Stone Curtain wall $559 - $6,016

Building / Facility Type: API Facility DATA TABLE

CSI DIVISION DESCRIPTION % RANGE OF COST REMARKS1 General Requirements 5.50 – 10.50 Gen Conditions / Preliminaries2 Site Construction 8.50 – 12.50 3 Concrete 5.00 – 7.50 4 Masonry 3.50 – 5.50 5 Metals 3.00 – 6.50 6 Wood & Plastics 10.50 – 17.50 7 Thermal & Moisture Protection 7.50 – 9.50 8 Doors & Windows 4.50 – 6.50 9 Finishes 12.50 – 19.50 10 Specialties 1.50 – 2.50 11 Equipment 0.50 – 1.50 Excludes Production Equipment12 Furnishings 0.50 – 2.50 13 Special Construction 0.50 – 2.50 14 Conveying Systems 2.00 – 5.50 15 Mechanical 40.00 – 70.00 16 Electrical 10.00 – 15.00 Total Percentage 100.00 A / E Fees 7.50 – 15.00 Percentage of Construction Cost CM Fees 5.00 – 7.50 Percentage of Construction Cost

EXCLUDES: New utilities outside building footprint, parking areas, roads, gatehouses, fencing, landscaping, and demolition of existing facilities:

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SECTION 1 | 65.


5.0 AUTOMOBILE PRODUCTION 1 Story, 20 Ft Floor to Ceiling Height, 585,000 Square Feet• See chart below

5.0 Automobile Production1 STORY, 20 FT FLOOR TO CEILING HEIGHT, 585,000 SQUARE FEET

EXTERIOR COST PER SQUARE FOOT - M2Pre cast panels, reinforced concrete frame $143 - $1,543Insulated metal panels, steel frame $139 - $1,496Fully completed facility with production equipment $623 - $6,704

Building / Facility Type: Auto ProductionDATA TABLE

CSI DIVISION DESCRIPTION % RANGE OF COST REMARKS1 General Requirements 5.50 – 10.50 Gen Conditions / Preliminaries2 Site Construction 8.50 – 12.50 3 Concrete 5.00 – 7.50 4 Masonry 3.50 – 5.50 5 Metals 7.00 – 10.50 6 Wood & Plastics 4.50 – 7.50 7 Thermal & Moisture Protection 7.50 – 9.50 8 Doors & Windows 4.50 – 6.50 9 Finishes 4.50 – 7.50 10 Specialties 0.50 – 2.00 11 Equipment 0.50 – 1.50 Excludes Production Equipment12 Furnishings 0.50 – 2.50 13 Special Construction 0.50 – 2.50 14 Conveying Systems 2.00 – 3.50 15 Mechanical 12.50 – 17.50 16 Electrical 8.00 – 10.50 Total Percentage 100.00 A / E Fees 6.50 – 11.50 Percentage of Construction Cost CM Fees 3.00 –5.50 Percentage of Construction Cost EXCLUDES: New utilities outside building footprint, parking areas, roads, gatehouses, fencing, landscaping, and demolition of existing facilities:

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6.0 BAKERY, 1 Story 24 Ft Floor to Ceiling Height, 615,000 Square Feet• See chart below

6.0 Bakery1 STORY 24 FT FLOOR TO CEILING HEIGHT, 615,000 SQUARE FEET

EXTERIOR COST PER SQUARE FOOT - M2Brick, concrete block back-up, steel frame $144 - $1,545Pre cast panels, steel frame $138 - $1,487Insulated metal panels on steel frame $135 - $1,453

Building / Facility Type: BakeryDATA TABLE

CSI DIVISION DESCRIPTION % RANGE OF COST REMARKS1 General Requirements 5.50 – 10.50 Gen Conditions / Preliminaries2 Site Construction 8.50 – 12.50 3 Concrete 5.00 – 7.50 4 Masonry 3.50 – 5.50 5 Metals 7.00 – 10.50 6 Wood & Plastics 4.50 – 6.50 7 Thermal & Moisture Protection 7.50 – 9.50 8 Doors & Windows 4.50 – 6.50 9 Finishes 5.50 – 9.50 10 Specialties 0.50 – 2.00 11 Equipment 0.50 – 1.50 Excludes Production Equipment / Ovens / Baking Trains12 Furnishings 0.50 – 2.50 13 Special Construction 0.50 – 2.50 14 Conveying Systems 2.00 – 3.50 15 Mechanical 10.50 – 14.50 16 Electrical 8.00 – 10.50 Total Percentage 100.00 A / E Fees 6.50 – 11.50 Percentage of Construction Cost CM Fees 3.00 –6.50 Percentage of Construction CostEXCLUDES: New utilities outside building footprint, parking areas, roads, gatehouses, fencing, landscaping, and demolition of existing facilities:

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Average Number of Fittings / Valves for Various C.S. / S.S. Piping diametersPER 1,000 LF OF PROCESS RELATED PIPING SYSTEMS (BASED ON 17 PROCESS RELATED PROJECTS) I.S.B.L. WORK:

PIPE COUPLINGS / ELBOWS TEES / CAPS / BLINDS / NO. OF NO. OF DIAMETER UNIONS / (90 & 45⁰) CONCENTRIC - PLUGS & MISC. / FITTINGS VALVES FLANGES (30%) ECCENTRIC WELDOLETS / (50%) REDUCERS SOCKOLETS / (10%) NIPPLES (10%)

0.5” 291 173 57 58 579 3720.75” 305 110 52 54 521 2471” 187 111 37 37 372 811.5” 119 70 25 24 238 352” 91 55 18 18 182 264” 82 49 16 16 163 146” 74 44 16 15 149 12.58” 64 38 13 13 128 6.7510” 59 35 12 12 118 6.2512” 57 35 10 11 113 5.7518” 33 21 7 6 67 4.3524” 25 16 5 5 51 3.70

Copper L Type1,000 LF OF INSTALLED PIPE WITH 50 FITTINGS

DIAMETER MATERIAL MAN HOURS 0.50” $2,107 54 x $80 = Installed cost1” $4,146 58 x $80 = Installed cost2” $12,942 67 x $80 = Installed cost

Tubing Stainless Steel 1,000 LF OF INSTALLED PIPE WITH 10 FITTINGS

DIAMETER MATERIAL MAN HOURS 0.50” $2,226 28 x $80 = Installed cost0.75” $2,500 32 x $80 = Installed cost1” $3,122 37 x $80 = Installed cost

Tubing Stainless Steel 316 PHARMACEUTICAL GRADE PIPING COST / LF OF INSTALLED PIPE (INCLUDES PIPE & FITTINGS, EXCLUDES VALVES):

DIA. MATERIAL / LABOR MATERIAL / LABOR COST PER LF COST PER M 1” $85 / LF $2791.50” $95 / LF $3122” $137 / LF $4493” $153 / LF $502

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AUTOMATIC SPRINKLER SYSTEM:• Dry System: $2.35 – $3.95 / SF• Wet System: $2.15 – $3. / SF

VALVES – INSTALLATION MAN HOURS: The following man-hours apply for all material types.

APPROXIMATE UNIT PRICING PER SF AREA BY FACILITY TYPE:

DEMOLITION & REMOVAL OF C.S. / S.S. PIPING (INCLUDE HANGARS, FITTINGS AND VALVES)

• Multiply values by 1.20 if pipe is insulated • Multiply by 1.12 if pipe is steam or heat traced• Note: credit the estimated cost if pipe is sold

for scrap.

WELDINGWelding is the activity and work effort that joins metals together. Numerous situations impact the cost of welding including the following main items:

• Labor cost - union vs. non union applications:• Material costs - welding materials and gases

etc:• Type of welding to be performed (Manual,

Automated, Orbital, Laser, Horizontal, Vertical and Overhead – SMAW / OFW / SAW / PAW / GMAW / GTAW Process or other applications):

• Various specifications, applicable codes and welder certification issues:

• Electrical Energy costs:• Types of joints and welds to be accomplished

i.e. fillet, tee, butt, V’s groove, bevel, J and U groove etc.

• Electrode various types of electrodes (materi-als and coatings): Warehousing and documentation related to electrodes.

• Construction Equipment costs – scaffold, cherry pickers and welding machines:

• Robotic Equipment / Orbital Tube welder re-lated costs.

• Any required special treatments, grinding, electro-polishing and passivation activities.

• Testing of completed welds i.e. Mechanical tests, bore scope, destructive tests, bend tests, ultra-sonic, x-ray, dye-penetration, test coupons, etc. To-gether with appropriate documentation that supports the testing effort.

In welding there are perhaps more than sev-enty distinct categories or methods of “welding” or brazing and soldering. One of the most widely used methods is Shielded metal arc welding (SMAW) also known as stick or manual metal arc welding. This type of welding is by far the most widely used welding method for construction and on repair type

DIAMETER MAN HOURS 2” 2.50 3” 3 4” 4 6” 5 8” 7 10” 10 12” 12/16

FACILITY TYPE UNIT MATERIAL / LABORWarehouse plumbing SF 3.50 – 4.90Warehouse heating SF 6.55 – 8.75Warehouse cooling SF 6.60 – 8.90Office plumbing SF 1.80 – 3.25Office heating SF 6.30 – 9.80Office cooling SF 5.25 – 8.50Laboratory plumbing SF 12.30 – 20.60Laboratory heating SF 6.40 - 11.20Laboratory cooling SF 5.80 – 11.55Fire protection (sprinklers) SF 2.35 – 4.80Ditto extra hazardous area SF 5.45 – 10.45CO2 / Haylon SF 5.50 – 12.60

DIAMETER $ COST / 100 LF 1” 16.73 2” 31.05 3” 41.68 4” 55.71 6” 69.50 8” 89.04 10” 106.90 12” 131.90

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157. | SECTION 2


work. The preparation work, including cutting and grinding, required to form the welding joints, makes the process time consuming. Welding, by its very nature are very time consuming and a labor inten-sive effort. The (SMAW) welding method uses a consumable welding rod – electrode (stick) where an electrical current, AC or DC, is passed though the welding rod / stick. Great heat is generated and the welding rod melts to form a weld between the item being welded and the welding rod. In this process, the welding rod is used up. Other widely used weld-ing applications include TIG welding (i.e. tungsten inert gas this application which utilizes individual welding rods). It has a wide application and is used to join carbon steel, stainless steel, alloys and other metals together (pipe and plates). The welder strikes an arc on the pipe, plate, or fabricated element being welded as described above. Another widely used welding process is MIG welding (i.e. metal inert gas). MIG welding can be considered more of a “factory” method of welding. MIG welding make use of a reel(s) of wire feed of welding rod metal that allows long runs of welding / metal deposit to be competed. Its ideal application is welding steel plates and sections together. A good example where one can see this welding method is in a shipyard.

Other welding processes include Oxyfuel Gas Welding (OFW), Semi Automatic Submerged Arc Welding (SAW), Manual and semi automatic Plasma welding (PAW) and Semi Automatic Gas Tungsten Arc Welding (9GTAW). Brazing and soldering uses liquefied hot metal(s), to connect metals together. Brazing creates a stronger linkage than is the case with soldering. Soldering is generally utilized to link / tie small diameter cables / wire, as well as, electrical components and minor metal apparatus / fabrications. Autogenous welding (completed welds are required to be completely smooth on the inter-nal and external surface of the tube / piping – no

joints should be present that could capture particles flowing through the tube / pipe) is used primarily on Pharmaceutical / Microchip facilities in piping / tubing applications, such as Clean in place (CIP), Steam in Place (SIP), Water for Injection (WFI) and other critical finished product lines. It is used to mitigate contamination (bacterial build up). Stainless Steel 316 L is used extensively, in that the welding approach utilized, is where all the completed welds and the internal surface of the pipe / tube is required to be joint free / entrapment-free is done internally to prevent any bacterial contamination to the finished product. Full penetration (100%) welds should be aimed for. It is important to understand that any

gaps, fissures, fractures includ-ing any imperfect weld joints can entrap the product / fluid flowing through the pipe / tubing. If any gaps, fissures, fractures are pres-ent they can develop into a haven for future problems and possible product contamination. Automat-ed welding is many times utilized to lower welding production costs

(i.e. the main element being the cost of employing a workforce for labor costs). However, the cost of purchasing the welding equipment together, with its subsequent maintenance costs can be substantial. Never the less, automated welding is usually the best avenue to proceed on. For major welding projects, the best example of this is in ship building; just about all the welding is done using an automated process. Orbital welding is used in Pharmaceutical, Aerospace, Microchip and other Hi-Tech industries. Orbital welding uses the Gas Tungsten Arc Weld-ing (GTAW) methodology; it is used primarily on small-bore piping and tubing 2” diameter and below. Stainless Steel 316 L and some other alloys that work well in extreme / harsh operating conditions are usually the specified materials that are utilized. Other industry sectors that are embarking on orbital welding in their construction process include:

• Food Production:

One of the most widely used methods is Shielded metal arc welding (SMAW) also known as stick or manual metal arc welding.

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213. | SECTION 2


PROCESS UNIT / MAJOR EQUIPMENT / CONSTRUCTION RELATED COST - CAPACITY EQUATIONS / EXPONENTSCONTINUEDColumn fractionating 0.60 Conveyor Belt 0.75Ditto Bucket 0.55Ditto screw 0.80Ditto Vibrating 0.85CO and CO2 hydrogen stripper 0.71Cooling towers 0.65Coke oven gas stripping unit 0.78Coking (delayed) top entry unit 0.58Coking (Fluid) 0.46Compressor recip, air cooled 2 stage, 100 psi 0.70Cracking unit, catalytic (cat cracker) 0.62Cracking – hydro 0.55Cracking – thermal 0.68Cracking, thermal reforming unit 0.68Crusher cone 0.83Crystallizer 0.72Cyclohexane unit 0.55Cyclone dust collector 0.76Delayed Coker 0.58Desalter unit 0.67De-sulfurization unit (Clause-tail gas) 0.59Distillation (atmosphere) 0.87Distillation (vacuum) 0.73Double cone blender 0.46Dryer, drum 0.50Dryer, pan 0.42Dust collector 0.77Ductwork 0.58Economizer 0.78Ejector 0.50Electric Motor 5-25 HP 0.65Electric static precipitator 0.75Ethanol plant 0.70Ethylene unit 0.80 Ethylene glycol 0.75Ethylene Oxide unit 0.75Evaporator vertical tube 0.55Evaporator horizontal tube 0.58Evaporator 1,000 - 10,000 gallon 0.50Fan, centrifugal 0.66Filter press plate / press 0.57Ditto wet leaf type 0.55

PROCESS UNIT / MAJOR EQUIPMENT / CONSTRUCTION RELATED COST - CAPACITY EQUATIONS / EXPONENTSCONTINUEDDitto dry 0.51Flare - elevated 0.60Flare - ground mounted 0.40Formaldehyde facility 0.60Furnace box 0.75Furnace cylindrical 0.80Gas-recycling unit 0.73Gas dehydration unit 0.65Glycol unit 0.70Hammer mill 0.81Heaters, gas fired 0.45Heat Exchanger u tube 0.55Heat Exchanger S/T, floating head c.s. 200 SF 0.62Heat Exchanger S/T fixed sheet c.s. 200 SF 0.48Hopper / Silo conical 0.65 Hydrochloric acid facility 0.70Hydrogen production facility 0.67Hydrogen Peroxide 0.72Hydrofluoric Acid plant 0.71Hydrogen sulfide stripping unit 0.61Hydro treating unit (desulfurization) 0.68Isomerization unit 0.65Isoprene 0.59Kettle, glass line 500 gallon and above 0.40Jacketed reactor 0.55Liquefied Petroleum-gas recovery plant 0.66Lube oil plant 0.68Methanol plant 0.66MTBE facility 0.65Natural gas facility 0.63Nitric acid 0.65Nylon facility 0.63Oxo – Alcohols unit 0.73Oxygen production plant 0.68Paraffins facility 0.65Paraxylene facility 0.60PET facility 0.58Phenol plant (High Purity) 0.70Phthalic Anhydride facility 0.68Phosphoric Acid plant 0.64Polyethylene plant (High Density) 0.62Polymer plant, large unit 0.66Polymerization 0.55

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SECTION 2 | 214.


PROCESS UNIT / MAJOR EQUIPMENT / CONSTRUCTION RELATED COST - CAPACITY EQUATIONS / EXPONENTSCONTINUEDPolymer plant, small unit 0.75Polyvinyl Chloride facility 0.63Power Plant Coal 150 – 1,500 MW 0.85 Power Plant Gas 150 – 1,500 MW 0.82Power Plant Oil 150 – 1,500 MW 0.85Power Plant Nuclear 150 – 1,500 MW 0.77Precipitator dust collector 0.75Pressure Vessel (CS) 0.60Pressure Vessel (SS) 0.65Propane Deasphalting plant 0.60Propane Dewaxing plant 0.54Propylene unit 0.72Pulverizer mill 0.37Pump centrifugal 400 GPM and above 0.37Reactor, C.S. or S.S. 1,000 gallon and above 0.50Reactor SS glass lined 1,000 gallon and above 0.55Refineries, 50,000 barrels / day & above and larger 0.63Refineries, 50,000 barrels / day & smaller 0.65Reforming, catalysts units 0.60 Refrigeration plant 0.65Rotary Drum Filter 0.66Roller mill 0.63Scrubber 0.70Separator centrifugal 0.55Soda bicarbonate facility 0.68Solvent extraction plant 0.88Solvent dewaxing unit 0.72Soybean extraction plant 0.73Sphere storage tank 0.72Styrene plant 0.77Steam Boiler / Production 100 psi 0.63Steam Boiler / Production 500 psi 0.77Sulfur production / recovery unit (Clause / Amine) 0.63Sulfuric acid plant 0.67Tanks C.S. Floating head 10,000 gallon and above 0.54 Tank C.S. Glass lined 0.51 Topping Unit 0.66Tower C.S. W/o trays 0.60Toluene facility 0.67Transformer 0.58Tray sieve type 0.83Turbine 0.66Urea plant 0.75

PROCESS UNIT / MAJOR EQUIPMENT / CONSTRUCTION RELATED COST - CAPACITY EQUATIONS / EXPONENTSCONTINUEDVacuum Distillation unit 0.62Vacuum Flash unit 0.64 Vibrating screen 0.65Vinyl acetate 0.68Vinyl chloride unit 0.83Visbreaker 0.63Non Equipment – Facility items:Civil works 0.67Construction Labor 0.45Piping 0.87Structural steel 0.67Engineering / Drafting work 0.47

SAMPLE

215. | SECTION 2


General Hi-Tech Facility Front End Benchmarks TO BE REVIEWED AND ADDED TO THE PREVIOUS COST MODELS IF APPLICABLE OR USED AS A SINGLE POINT REFERENCE SOURCE

DESCRIPTION RANGE COST OF FACILITY COST OF ACTIVITY COMMENTS

1 Off sites (OSBL) 5% - 50% of Inside Battery Limits (ISBL) 2 Fringes (vacations, holidays, 22% - 30% of sick days) base wage rate 3 Worker Compensation Insurance 10% - 17.5% of base wage rate 4 Inspections / QA-QC services 1.5% of TIC 5 Front End Studies / 0.5 – 2.5% of $1 - $100 + millionScoping study / BOD TIC of facility. 6 Builders all risk insurance (BAR) 0.15% - 0.60% $1 - $100 + million 7 Contractors O/H (Supporting 4 00% - 15.00% The larger the TIC construction / field activities) value of the project, the lower the % typically is. 8 Profit 3.5% - 15% Typically on a $20 million new building / facility a profit margin between 5%-8.5% can be realized dependent on economic climate and number of bidders - 5 + or more bidders generally translates to lower profit margins.9 Performance Bond 0.35% - 1.25% 10 Procurement activities 0.50 – 1.00% Purchase orders of TIC and contracts11 Engineering support 0.50 – 1.00% Field questions, v of TIC vendor visits, answers to RFI 12 H.O Project Controls 0.50 – 1.50% Estimating, cost of TIC engineering and planning activities13 Value Engineering Study $5 million $20 - $40 K $10 million $30 - $60K $50 million $40 - $100K

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SECTION 2 | 216.


DESCRIPTION RANGE COST OF FACILITY COST OF ACTIVITY COMMENTS

CONTINUED 14 Risk Mgmt Review $5 million $20 - $30 K $10 million $30 - $40K $50 million $40 - $60K15 Project Reviews / Audit / $5 million $20 - $45 K Benchmarking Analysis $10 million $35 - $70K $50 million $45 - $100K16 General Conditions / 5% - 8% of TIC (CSI Division 1 - Preliminaries Preliminaries)17 Small Tools 1.5 – 5% of Direct - Hand tools / S/C Labor typically valued less than $100 per item Typically $2.50- $4.00 per construction man-hour18 Consumables 1.25 – 3.5% of (Gasses, welding Direct - S/C Labor rods, grease, etc.)19 Temporary Services 0.75% – 1.50% of Direct - S/C Labor 20 Field Supervision 2.5 – 12.5% of Direct - S/C Labor 21 Major Equipment multiplier 3.0 – 5.0 Could be 5.0 – 7.0 Multiplier of d/d for remote plants and M.E item (cost). facilities using SS and An example of a exotic metals high multiplier would be Canadian Tar Sands projects 22 Construction Equipment 2 – 7% of Direct - S/C Labor 23 Protection materials 0.20 – 0.40% of Direct Tarpaulins / S/C Labor temporary screens / worker rain gear.24 Contractors Fee 2 – 4% of Total Installed Large projects Cost of Facility on CM would see fee in General Construction Projects the 2 – 3% range. On Refinery / Process / Power type construction fees can range from 6% - 10% of TIC 25 Vendor Assistance 0.50 – 1.50% of Major Equipment Another approach is to obtain pricing from vendors for this activity26 Spare Parts 2.5 – 5.50% of Major Equipment, Another approach is typically in the 2-4% range on 1.5% – 7.5% of complex facilities use 55 – 7.5% rotating equipment of the M.E. cost (Pumps, compressors etc)

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