Cost Estimation Process
The Cost Estimation
Process as it evolves to
specific stages of project
development.
Planning Design Procurement
Identify and Prepare Feasibility Studies and Preliminary Design Perform Detailed Design Prepare Bidding Documents Receive and Evaluate Bids
BBPEE BBDEE Estimate for the ABC
Planning Service,
Cost Estimation Process
Review/Study Design Drawings
Data Collection Field Surveys
Labor Equipment Materials Materials Sources Labor
Evaluation/processing of Data Calculation (Bill Pay Item Quantity of Quantities) Cost Estimate
Unit Price Analysis Construction Pay Items Unit Rates Maintenance Unit Rates Maintenance Activities Project Cost Maintenance Cost
Project Estimate Components BBPEE BBDEE ABC A. Direct Cost √ √ √ Materials √ √ √ Labor √ √ √ Equipment √ √ √ Dayworks √ Per DO 46 s2007
Provisional Sum √ Per DO 46 s2007
B. Indirect Cost Per DO 57 s2002 Per DO 57 s2002 Per DO 57 s2002
OCM √ √ √
Profit √ √ √
Mobilization/Demobilization √ √ √
C. VAT 12% (A+B) 12% (A+B) 12% (A+B)
D. Total Civil Works Cost A+B+C A+B+C A+B+C
E. Contingency 10% of D 10% of D 5% of D
F. Engineering Costs Per NEDA Per NEDA Detailed Engineering 4-6% (D+E)
Construction Supervision* 8-10% (D+E) 8-10% (D+E)* Administrative Cost 3.5% (D+E) 3.5% (D+E) G. Feasibility Cost (Optional for Pre-FS) 1-3% (D+E)
H. IROW Acquisition Cost √ √
I. Total Estimated Project Cost D+E+F+G+H D+E+F+G+H D+E
Project Estimation Phase
• Work type – proposed improvement works of the project
• Location of the project – includes terrain types and
embankment and aggregate material sources
• Design plans and specification – working drawings and
DPWH Standard Specifications Vol. II, Ed. 2004
• Equipment rental rates – ACEL Guidebook, ed. 22, yr.
2003
• Labor rates and fringe benefits – DOLE, Regional Wage
Board, SSS, Philhealth, Pag-Ibig, & bonus
• Construction Materials List and Material Sources Map
• DPWH Department Orders – DOs relevant to cost
estimation
• NEDA Circular – Circular/memo relevant to cost
estimation
Unit Price Analysis
Two Main Parts:
• Direct Cost
• Labor
• Materials
• Equipment
• Indirect Cost
(% of Direct Cost as defined in DO 57)
• OCM (overhead, contingency & miscellaneous)
• profit
Unit Price Analysis
Elements of the Direct Cost
• Labor
• basic wage
• fringe benefits
• bonuses
• social security & other social charges
• Equipment
• bare hourly & rental operating cost
• fuels & lubricants
• repairs & maintenance
• labor
• Materials
• labor
• equipment
processing & transport
Unit Price Analysis
Labor Categories
Labor Category
Labor Index
1. Foreman, construction
2. Leadman
3. Operator, Heavy
4. Operator, Light
5. Labor, Highly Skilled
6. Driver
7. Labor, Skilled
8. Labor, Unskilled
1.80
1.65
1.50
1.40
1.40
1.30
1.30
1.00
Basic Labor Rates Calculation
• Monthly Wages based on 314 days per year, 8 hours per day (Basic Daily
Wage x (314/12))
• Leave, vacation and sick = Basic Monthly Pay / 12
• Bonus, 13th Month Pay = Basic Monthly Pay / 12
• SSS, Medicare, Employer's Compensation = Amount Representing
Employer's Contribution, Graduated Scale
• Pag-ibig, Employer's Compensation = Amount Representing Employer's
Contribution, (2% of Basic Monthly Wage or P100 max.)
• Rate per Hour = Total rate per month x (12/314/8)
Unit Price Analysis
Take the value of non-agricultural sector
Unit Price Analysis
Take the values under the column of total monthly contributions in reference with range of compensation
Unit Price Analysis
Take the values under the column of total monthly contributions
Equipment Category Sample Equipments • Earthmoving equipment • Compaction equipment • Lifting equipment • Excavating equipment • Foundation equipment • Asphalting equipment • Concreting equipment • Hauling equipment • Air equipment • Pumping equipment
• Power generating equipment • Shop equipment
• Special support equipment • Miscellaneous equipment • Plants
• Offshore equipment
• Cable stringing equipment • Others
– wheel loader, grader, tractor dozer – vibratory steel drum, plate compactor – cranes, forklifts
– backhoe, trenchers
– pile vibratory driver, pile hammer, drill rig – asphalt paver/finisher, asphalt distributor – paver/finisher, mixer, transit mixer
– dump truck, cargo truck, trailer
– compressor, pneumatic breakers handheld – submersible pump, diaphragm pump
– generator set
– welding machine, shop machine – truck water wagon/pump
– joint sealer, rebar cutter/bender
– asphalt concrete plant, concrete batching plant – dredger, crane barge, tugboat
– cable tensioner/puller, splicing machine – chip spreader, power broom
Equipment Unit Rate Analysis
Basic Calculation
• Bare Month Rental – Bare monthly rate ÷ 200h/mo.
• Repair & Miscellaneous
•
Repair - 6.3% of Bare Rental
•
Spare Parts – 5.1% of Bare Rental
•
Miscellaneous – 0.6% of Bare Rental
• Fuel
•
Fuel – Price/lit. x HP x 0.1514
•
Oil & Lubricant – Price/lit. x HP x 0.003
• Labor
•
Operator or driver – Labor rate/hr
Unit Price Analysis
Sample calculation of
adjusted equipment
rates in spreadsheet
Materials Category Sample Materials • Commercial Materials
• Contractor’s processed materials
– Portland Cement
– Reinforcing Steel Bars (RSB or Rebars) – Lumber
– Plywood – Tie Wire
– Structural Steel
– Common Wire Nails (CWN) assorted sizes – Emulsified Asphalt (SS-1)
– Cut-Back Asphalt (MC-70/MC-250) – Asphalt Cement Penetration 85/100 – Joint Sealer
– Reflective Paints
– Metal Beam Guard Rails, – Guard End Pieces
– Reflective Pavement Stud (raised or low profile) – Fuel (Diesel/gasoline/premium gasoline
– Lubricants
– Reinforced Concrete Pipe Culvert (RCPC) – Base/Subbased Courses
Unit Price Analysis
Sample of contractor’s process
materials
Unit Price Analysis
Hauling Unit Rate Analysis
• Basic Consideration
– Terrain type
– Road condition
– Dump truck capacity
– Selection of loader capacity, output, bucket fill factor and operating
factor (to estimate loader production rate)
– Material type
• Cycle time
• Loader
– Load bucket and shift gears
– Turn and dump the load
– Travel distance and time from dumping to loading position and return to
the loading position
Total Cycle T
Hauling Unit Rate Analysis (cont.)
• Cycle time
• Dump Truck
– Average hauling distance
– Terrain type
– Loading time
– Loaded travel time
– Initial traveled distance during acceleration
– Succeeding traveled distance at an average speed
– Final speed at a distance until it stops
– Unload and maneuver
– Return empty
– Same as loaded but at a greater speed
– Allowance for delay
• Number of dump truck trips, n
Unit Price Analysis
Total Cycle
T
ime,
Unit Price Analysis
Hauling Unit Rate Analysis (cont.)
• Number of dump trucks
• Average hauling output
• Total hauling cost per hour
– Equipment
1 – Wheel loader, ___ m
3/hr --- _____ P/hr
N – Dump trucks, ___ m
3--- _____ P/hr
– Labor
1 – Leadman, rate --- _____ P/hr
2 – Laborers, rate --- _____ P/hr
Total Cost per hour _____ P/hr
Sample of hauling cost analysis using spreadsheet
Production Rate Derivation of a Pay Item
Unit Price Analysis
Elements of the Indirect Cost
• Profit – contractor’s profit
• Overhead Expenses
•
Office Expenses (office equipment and supplies)
•
Engineering and Administrative Cost
•
Transportation allowances
•
Contractor’s All Risk Insurance
•
Premiums on Bid Security and Performance Security
•
Premium/charges/fees on credit lines
• Contingencies
• Miscellaneous Expenses
•
Laboratory Tests
•
Other expenses
Estimated
Direct Cost
(EDC)
Indirect Cost % for OCM
and Profit (Maximum
Ranges)
% Cost for
Mob/Demob
(Maximum)
Total
Maximum
Indirect
Cost % for
OCM, Profit
and Mob/
Demob
OCM (% of
EDC)
Profit (% of
EDC)
Up to P1Million
13
15
1
29
Above P1M to
P5M
12
14
1
27
Above P5M to
P10M
12
13
1
26
Above P10M to
P20M
11
12
1
24
Above 20M to
P50M
11
11
1
23
Above P50M
10
10
1
21
Unit Price Analysis
Unit Price Analysis
Cost Currency Components:
• Foreign Cost Component
•
imported equipment & spare parts
•
foreign currency component of locally goods
•
& services
•
wages of expatriate personnel
•
foreign overheads & profits
• Local Cost Component
•
local materials
•
equipment & supplies
•
wages, local supervision
•
transport & freight
•
overhead & profits
• Tax Component
Cost Component of Selected Construction Items
Unit Price Analysis
Description
Components
Foreign Local Tax (%) (%) (%) Heavy Equipment Light Equipment Reinforcing Steel Structural Steel Lumber Asphalt Cement Diesel fuel Engine oil Tires
Imported Miscellaneous Materials
Locally Produced Miscellaneous Materials Skilled Foreign Labor
Unskilled Labor Royalty 68 65 54 85 33 76 40 60 60 47 64 17 65 0 0 10 15 35 4 57 2 45 13 13 43 7 69 25 90 90 22 20 11 11 10 22 15 27 27 10 29 14 10 10 10
Quantity Calculations for Pay Items Bill of Quantities
Pointers in the conduct of quantity calculations:
• Based on the design plans and specifications
• Units of measurement are all in metric based on
DPWH Standard Specifications.
• Solid mensuration is extensively used and other
mathematical formulae.
• Used of computer softwares in calculations.
• Used of calculators (simple or scientific)
• Conversion factors
• Rates of application of materials such as, liquified
asphalt materials, paints, etc.
Unit Price Analysis
Sample Formula of Plane Shapes & Figures
Area of a Triangle
A = ½ x base x height = ½ (bh)
Perimeter of a Triangle
P = side1 + side2 + side3
Area of a Parallelogram A = ½ x base x height = ½ (bh) Perimeter of a Parallelogram P = 2a + 2b Area of a Rectangle A = width x length = (wl) Perimeter of a Rectangle P = 2(lwidth) + 2(length) = 2(w) + 2(l) Area of a Circle A = πr2 Circumference of a Circle C = 2πr = πD π = 3.14 159
Sample Formula of Solid Geometric Figures
Unit Price Analysis
Volume of Rectangular Solid
V = abc Surface Area SA = 2(ab + ac + bc) Volume of Cube V = a3 Surface Area SA = 6a2 Volume of Sphere V = 4/3 πr3 Surface Area SA = 4πr2
Volume of Circular Cone
V = 1/3 πr2h
Surface Area
SA = πr2 + πrl
Volume of Circular Cylinder
V = πr2h or πD2 ÷ 4
Surface Area
Unit Price Analysis
● Estimating the work output of a piece of equipment is determined in 2 ways:
• Using work output formula based on the cycle of operation and other factors which controlled production.
• Using tables based on past experiences of average work output under varying conditions for different operations.
● To calculate earthmoving equipment consider the volume changes in earth caused by handling. These volume changes have the following terms, to wit:
• Swell – increase in volume of earth that results when it is dug from its natural position. • Shrinkage – decrease in volume of earth when compacted.
• Loose yards – volume of earth after it has been removed from its natural location and swell has taken place.
• In-place yards – volume of earth in its natural location before handling.
• Compacted yards – volume of earth that has been properly compacted in embankment on fill.
● Basis of calculations for excavation and fill
• Loose yards – are used to express the carrying capacity of earth moving equipment.
• In-place yards – are converted to compacted yards to determine the volume of materials in a fill that will be realized from a given amount of materials in its natural location.
• In-place yards – are converted to loose yards to determine the amount of earth moving equipment required to handle the materials.
• The output of equipment in loose yards must be converted to compacted yards to determine the final volume of fill
Methods of Estimating Work Output
1.0 m3 in natural condition (in-place yards) 1.25 m3 after digging (loose yards) 0.9 m3 after compaction (compacted yards)
Volume Changes in Common Earth Caused by Handling
Bowl Capacity of Dozer
Illustrations of Soil Handling
Formula for Earthmoving Equipment Work Output
where:
Q = bowl capacity in loose cubic meters
f = soil conversion factor
60 = minutes per hour
E = efficiency factor
Cm = total cycle time in minutes
The working capacity of construction equipment is expressed by
the work practically done by the operation of equipment per unit
time ( 1 hour or day)
Conversion Factors, f
Soil Type Present Condition
Converted to
In-place Loose Compacted Sand Common Earth Clay In-place Loose Compacted In-place Loose Compacted In-place Loose Compacted 1.00 0.90 1.05 1.00 0.80 1.11 1.00 0.70 1.11 1.11 1.00 1.17 1.25 1.00 1.39 1.43 1.00 1.59 0.95 0.86 1.00 0.90 0.72 1.00 0.93 0.63 1.00 Tractor Model Bulldozer Angle Dozer
D4 D6 D7 D8 1.25 m3 1.44 m3 2.20 m3 2.40 m3 1.82 m3 2.01 m3 2.58 m3 2.97 m3
Bowl Capacity of Dozers (loose yards)
Unit Price Analysis
Sample Calculation for Work Output
Given: Average haul distance one way – 30 m
Soil type - common earth Efficiency factor (E) - 80%
Speed - 2.5 kph
Required: Determine in place cubic meters moved per hour if D7 tractor dozer is to be used. Solution:
Step 1. From conversion factor table, the soil conversion factor (f), soil type common earth loose to in-place, f = 0.80
From dozer bowl capacity table, D7 tractor dozer, Q = 2.2 m3
Step 2. Determine fixed time
@ 2 gear shift @ 10 sec. per shift = 20 sec = 0.33 min Step 3. Determine variable time
Travel forward 30 m @ 2.5 kph
Travel backward 30 m @ 5.0 kph
Step 4. Add fixed and variable time
Total cycle time, Cm = 0.33 + 0.72 + 0.36 = 1.41 min. Step 5. Substitute in work output formula
Unit Price Analysis
Sample Typical Cross-Section of Drainage Structures
Sample Quantity Calculation for Volume of Excavation:
Sample: Given a RCPC 1220mmØ and a length of 5.0 meters, compute volume of excavation. Solution: Size of excavation as given from the above drawings for 1220mmØ:
width = 1.60m, height = 2.0 m, length = 5.0 m
Volume = w x h x l = 1.6 x 2 x 5 = 16 m3 compacted volume (stated in the plans)
Applying the soil conversion factor, common earth from compacted to loose, use factor, f = 1.39 the excavated loose volume = 16 x 1.39 = 22.24 m3
Volume of Backfill and Bedding Materials:
Sample: Using the same sample, calculate backfill and bedding materials Solution: Size of excavation as given from the above drawings for 1220mmØ: width = 1.60m, height = 2.0 m, length = 5.0 m
Volume of trench = w x h x l = 1.6 x 2 x 5 = 16 m3
Volume of bedding materials at compacted state, using thickness of 15cm = 1.6 x 0.15 x 5 = 1.2 m3
Using soil conversion factor, compacted to loose, f = 1.17
Volume of bedding materials required to purchase = 1.2 x 1.17 = 1.404m3
Volume of backfill = Voltrench – (VolRCPC + Volbedding) = 16 – (7.371+1.2) = 7.429 m3
Applying conversion factor, compacted to loose, f = 1.39 Volume of backfill required = 7.429 x 1.39 = 10.326 m3
Sample Quantity Calculation
Composition and Strength of Concrete for Use in Structures
This composition of concrete is used for concrete batching plant.
Mixture
Class of
Concrete
Proportion Cement
in Bags
Sand
cu. m.
Gravel
cu. m.
AA
A
B
C
1:1½:3
1:2:4
1:2½:5
1:3:6
12.0
9.0
7.5
6.0
0.5
0.5
0.5
0.5
1.0
1.0
1.0
1.0
Concrete Proportion
This concrete proportion is used for manual mix.
Mixture
Class of
Concrete
Proportion
Cement
in Bags
40 kgs.
Sand
cu. m.
A
B
C
D
1:2
1:3
1:4
1:5
18.0
12.0
9.0
7.5
1.0
1.0
1.0
1.0
Cement and Sand Proportion for Mortar and Plastering
Unit Price Analysis
Sample Calculation:
Given: Volume = 10 m3 of mortar, use class A
Solution: Refer to the above table
Cement = 10 x 18 = 180 bags Sand = 10 x 1.0 = 10 m3
Sample Calculation for Asphalt Concrete Pavement:
Given: Carriageway width = 6.7m, Length = 1 km., thickness = 50cm, use 301(1) - MC-70 Cut-Back Asphalt
Solution:
Determine Item 301(1) - Bituminous Prime Coat
Determine Item 310 – Bituminous Concrete Surface Course, Hot-Laid (AC – Asphalt Concrete)
The derived quantities are then summarized in the bill of quantities and subsequently, manually entered in the estimated construction cost spreadsheet which are multiplied by the unit prices to come up with total cost of that item and summed up all the pay items to calculate the total direct cost. After which, indirect cost is applied to determined the total estimated project cost.
Unit Price Analysis
Item Number
Description
Unit
Quantity
100(1)
102(1)
102(2)
103(3)
103(6)
104(1)
105(1)
105(3)
200
201
301(1)
310
500(1)
Clearing and Grubbing
Unsuitable Excavation
Surplus Common Excavation
Foundation Fill
Pipe Culverts and Drainage Excavation
Embankment
Subgrade Preparation (Common Material)
Subgrade Preparation (Unsuitable Material)
Aggregate Subbase Course
Aggregate Base Course
Bituminous Prime (MC-70 Cut-Back Asphalt)
Bituminous Concrete Surface Course, Hot-Laid
RCPC 610mmØ
ha.
m
3m
3m
3m
3m
3m
2m
2m
3m
3ton
m
2l.m.
20
1,000
11,000
2,000
1,858
7,500
3,000
5,000
10,455
12,156
30,780
5,689
3,105
Sample of unit
price analysis in
spreadsheet
Unit Price Analysis
Unit Price Analysis
Unit Price Analysis
Unit Price Analysis
Unit Price Analysis
Maintenance Cost
Highway Maintenance
- is defined as the act of preserving and keeping each
highway type of highway as nearly as possible in its
original conditions as constructed or as subsequently
improved. It does not include rehabilitation, betterment
and improvement
Two calculation methods for maintenance cost
- EMK (Equivalent Maintenance Kilometrage)
- Traffic Dependent Method
Two Categories:
• Routine Maintenance
•
vegetation control
•
cleaning and repairing culverts
•
cleaning ditches
•
cleaning and repairing traffic signs
•
climatic loss of gravel on shoulder
• Periodic Maintenance
•
road surface repairs
•
resurfacing
•
shoulder repair & resurfacing
General Cost
Maintenance Cost
EMK Factors
Source: BOM/ DPWH 0 AADT AADT Basic Formula: Road:MCR = EMKbudget x Ft x Fw x Length where:
MCR = maintenance cost for road EMKbudget = annual allocation Ft = factor for surface type
Fw = factor for carriageway width
Length = in kilometer Bridge:
MCB = EMKbudget xFb x Length where:
MCB = maintenance cost for bridge
EMKbudget = annual allocation Fb = factor for bridge type Length = in meter
Traffic Dependent Method
Traffic volume in terms of vehicle units:
• Light vehicles → 0.4 vehicle units
• Buses → 2.5 vehicle units
• Trucks → 3.0 vehicle units
Maintenance Cost
Basic assumptions in calculating routine maintenance unit rates : • Vegetation Control
• 0.5 ha/km/year • 400 m2/crew day • 2 - knapsack movers • 2 - unskilled laborers
• Cleaning and Repair of Culverts
• 1 – 4 number units/day/km • 1 – dump truck
• 3 – unskilled laborers • Materials
• Replace, Clean and Repair Traffic Signs
• 2 – 5 units repaired, repainted or replace daily • 1 – pick-up vehicle
• Materials
• Clearing Side Ditches
• 40 – 1000 l.m./day (half by grader and half by hand or manual) • 1 – grader
• 3 – unskilled laborers
Maintenance Cost
Periodic Maintenance
• Road Surface Repair
•
Regravelling gravel road and gravel shoulder
•
Grading & reshaping gravel road
•
Joint & crack sealing for PCCP
•
Pothole repair (spot regravel) for gravel road
•
Patch potholes for ACP
•Crack sealing for ACP
•
Edge break for ACP
• Resurfacing
•
Asphalt Concrete Overlay
• Shoulder Repair & Resurfacing
•
Regravelling
•
Grading and reshaping
Maintenance Cost
Sample of routine maintenance unit price analysis
Maintenance Cost
Maintenance Cost
General Formula for Maintenance Cost Calculations
• Routine Maintenance (peso/km)
– Maintenance Task = Qtytable x Lshoulder x W x 365 days x unit rateactivity – General Cost
• Periodic Maintenance (peso-vehicle unit/km)
– Maintenance Task = (Qtytable x L x W x 365 days x unit rateactivity) ÷ Frequencyvehicle where:
L = length in meters W = width in meters
Qtytable = Periodic Maintenance Task Table unit rateactivity = maintenance unit price analysis
Frequency = benchmark of traffic volume in terms of v.u. as shown in Periodic Maintenance Task Table
Maintenance Cost
Routine Maintenance Unit Cost
Road Segment Economic Financial
a. Vegetation control
b. Cleaning and repair culverts
c. Replace, clean and repair traffic signs d. Clearing side ditches
P 5,312.58/km 4,880.19/km 5,384.64/km 10,813.92/km P 6,498.57/km 7,055.90/km 6,667.53/km 13,250.68/km Total per annum P 26,391.34/km P 33,472.67/km
Routine Maintenance Unit Cost
Bridge Segment Economic Financial
a. Concrete bridge b. Steel bridge
P 568.79/l.m. 3,714.14/l.m.
P 721.41/l.m. 4,710.72/l.m.
Maintenance Cost
Maintenance Tasks Unit Cost
Economic Financial 1. Gravel ( Surface )
2. Regrade and Reshape a. Carriageway b. Shoulder
3. AC Resurfacing ( 3 cm.) 4. AC Overlay ( 5 cm. )
5. Replacement of Failed Bay a. t = 230 mm
b. t = 200 mm
6. Repair of Cracks/Joints 7. Patching and Pothole Repair
a. Pothole Repair ( Gravel ) b. Pothole Repair (AC)
c. Sealing and Patching (AC) 8. Road Stripping (painted lines)
P 481.87/m3 5.14/m2 15.41/m2 94.36/m2 135.51/m2 2,527.25/m2 2,197.69/m2 18,066.78/m2 498.56/m3 494.06/m2 510.81/m2 48.53/m P 579.45/m3 6.29/m2 18.87/m2 113.28/m2 162.25/m2 3,089.00/m2 2,686.20/m2 22,123.42/m2 598.08/m3 597.05/m2 617.50/m2 57.48/m
Summary of Maintenance Costs
Road Type Maintenance Category
Routine Periodic
Economic Financial Economic Financial Gravel Roads (5.0m roadway)
AC with gravel shoulders a. 0.5+6.1+0.5 b. 1.0+6.1+1.0 c. 1.5+6.1+1.5 d. 3.0+6.7+3.0 PCC with gravel shoulders
a. 0.5+6.1+0.5 t = 230 mm t = 200 mm b. 1.0+6.1+1.0 t = 230 mm t = 200 mm c. 1.5+6.1+1.5 t = 230 mm t = 200 mm d. 3.0+6.7+3.0 t = 230 mm t = 200 mm 49,521.08 31,210.03 36,028.73 40,847.42 55,303.51 31,210.03 31,210.03 36,028.73 36,028.73 40,847.42 40,847.42 55,303.51 55,303.51 61,286.05 39,267.13 45,061.58 50,856.03 68,239.39 39,267.13 39,267.13 45,061.58 45,061.58 50,856.03 50,856.03 68,239.39 68,239.39 737.36a 80.05a 100.55a 121.06a 186.01a 62.77a 62.12a 83.27a 82.62a 103.77a 103.12a 166.34a 165.69a 896.59a 96.33a 121.40a 146.47a 225.81a 75.81a 75.01a 100.88a 100.08a 125.95a 125.15a 202.43a 201.63a
Maintenance Cost
Sample of Summary Maintenance Cost