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I N T E R N AT I O N A L I N C .
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01 INTRODUCTION TO CAPITAL COST ESTIMATING:
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The General Forecast for 2016 and beyond
The Project Control Cycle
Cost breakdown of a typical Chemical process facility
The CAPEX Estimating process
Presenting the estimate to Senior Management
Optimizing the estimating effort
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27 CAPITAL COST ESTIMATING FUNDAMENTALS:
Questions that need to be asked
The Estimating four step process
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A3
55 CAPITAL COST ESTIMATING METHODS:
CAPEX estimating (10 +) approaches:
Various factoring methods:
Seven historical Ratio / M.E. percentage cost models:
Typical Solids, Fluids M.E. multiplying values:
General Process Industry Benchmarks
Summarizing the CAPEX Estimate:
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107 BASIC MAN-HOUR BENCHMARKING DATA & REFERENCE TABLES
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159 SITE SELECTION / COST DATA SOURCES / ESTIMATING CHECKLIST
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A6
179 VALUE ENGINEERING / CHANGE ORDERS / CLAIMS / CONTINGENCY
209
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SCALE OF OPERATIONS / EXPONENTS (180 + PLANTS / M.E. ITEMS)
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B2
213 ADDITIONAL ESTIMATING FACTORS COST MODELS (18 + EXAMPLES)
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B3
243 SQUARE FOOT / M2 ESTIMATING DATA (100 + BUILDINGS / FACILITIES)
B4
252 UNIT PRICE DATA (1,000 + UNIT COST ITEMS)
B5
284 GENERAL COST ESTIMATING DATA
Location Factors (200+ North American / International Cities):
International Location Factors / Productivity:
Engineering / Engineering / CM Fees:
Union Labor Costs (10 trades):
Open Shop Labor Costs (10 trades):
Sales Tax (50 US states and 10 Canadian Provinces):
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Inflation / Compass Cost Index:
Rebar / Pipe / Concrete / Bricks Pricing (14 cities):
General Condition / Preliminaries Data:
305
C1
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MAJOR EQUIPMENT / PROCESS EQUIPMENT COST & LABOR MODELS
Benchmarking Metrics:
Detailed Design / Engineering Metrics:
Civil, Structural, Architectural / Miscellaneous Costs:
Structural Steel Costs:
Facilities / Buildings Costs:
Piping / Insulation Metrics:
Electrical Systems:
Instrumentation:
Security Equipment / Robotics:
Miscellaneous estimating items:
BUSINESS
ANALYSIS
Items A G
(above)
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(Yes or no)
Abandon study
if companies
ROI investment
criteria is not
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if companies ROI
investment criteria
is achieved produced
achieved, move more defined scope
to next prospect and +/- 20% Estimate
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with numerous single point metrics that hopefully
wners, A/E, EPC, CM firms and contractors when will assist the reader in future estimating and audit-
they generate their project Front End / Concep- ing activities. The number one basic principle of
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tual and Detailed / Lump Sum estimates use many Project Management and its sub elements i.e. Proj-
different formats and configurations (i.e. estimat- ect Control Cost Estimating is to deliver the best
ing templates and summaries). There seems to be technical and business solution to the business unit
no standard approach in industry, this initially can considering or building a new facility expansion(s)
cause some problems to individuals charged with the or upgrade(s), together with value (which of course
responsibility of reviewing and checking these es- is part of the business solution) for future CAPEX
timating deliverables and was one of the drivers for investments. The project team must deliver the
the production of this database. We have endeavored correct business solution at the front end stage(s)
to standardize some of these Front End / Conceptual of CAPEX project, the scope, needs to be to some
and Detailed / Lump Sum estimating summaries in extent reasonably defined, some front end design
this particular section. The underlying principle of work needs to have been completed, various manu-
this section is to outline a number of different ap- facturing / production schemes need to have been
proaches and methodologies related to estimating considered and scoped out. The decision to engi-
the cost of Process / Manufacturing type facilities. neer / procure and construct (EPC) a new Chemical
This section contains historical estimating bench- / Manufacturing Facility, or to upgrade, revamp or
marks (based on return cost data records) together
(2) Average Historical (Multiplier) Factors - $1.00 million delivered to site the following aver-
Liquid Plants +/- 25% Accuracy (Chemicals / Fluids age percentages should be used as a starting point.
/ Wet Processs type facilities, high percentage of Off sites (O.S.B.L.) are excluded from the following
pumps / piping) Assume Major Equipment cost is data values.
Table 2
AVERAGE HISTORICAL (MULTIPLIER) FACTORS LIQUID PLANTS
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1 Major Equipment (M.E.) 0 1.00* 0.00 1.00 Assume $1.00 million
2 Freight (used 4%) 2.5 - 5 0.02 0.02 0.04 50/50 split
3 Overseas Freight 5 - 8 N/A N/A N/A for this example
4 M.E. Setting 1 - 7 0.01 0.05 0.06 Heavy lift cranes in line 15
6
7
8
(Millwright work)
Site work / civil
(excavation / roads)
Concrete work
Structural steel
Facilities / Buildings
(including services)
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3 - 10
8 - 25
15 - 35
3 - 15
0.02
0.03
0.10
0.03
0.03
0.10
0.11
0.02
0.05
0.13
0.21
0.05
Site clearance /
minor demolition
SOG & elevated
Including platforms
(A) = Start up costs, initial chemicals, expense items and other minor items.
Table 2
RESEARCH & DEVELOPMENT FACILITY 40 50% ISO 8 CLASS 100,000
DIV NO DESCRIPTION % TOTAL VALUE SF / COST M2 / COST
1 Preliminaries / General Requirements 9.53% 2,076,086 28.83 310.26
2 Site Works / Civil 3.76% 819,107 ** 11.38 122.41
3 Concrete 5.84% 1,272,228 17.67 190.13
4 Masonry 6.48% 1,411,651 19.61 210.96
5 Metals / Structural Steel 7.46% 1,625,142 22.57 242.87
6 Wood Plastics 4.84% 1,054,381 14.64 157.57
7 Thermal & Moisture Protection 3.55% 773,358 10.74 115.57
8 Doors & Windows 3.36% 731,968 10.17 109.39
9 Finishes 5.73% 1,248,266 17.34 186.55
10 Specialties 1.90% 413,910 5.75 61.86
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11 Equipment* 9.31% 2,028,160 * 28.17 303.10
12 Furnishings 0.72% 156,850 2.18 23.44
13 Special Construction 0.32% 69,711 0.97 10.42
14 Conveying Systems (3P / 1G) 1.97% 429,159 5.96 64.14
15A
15B
15C
16
16A
Plumbing
Electrical
BMS / HVAC Controls
SUB TOTAL
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HVAC (AHU s / Ductwork / Balancing)
Fire Protection / Sprinklers
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5.93% 1,291,835
16.79% 3,657,657
1.25% 272,309
9.59% 2,089,156
1.67% 363,805
100% 21,784,740
17.94
50.80
3.78
29.02
5.05
302.57
193.06
546.62
40.70
312.21
54.37
3,255.61
17 A/E Services 8.85% 1,927,949 26.78 288.12
18 CM 4.75% 1,034,775 14.37 154.64
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19 Validation Services N/A N/A N/A N/A
TOTAL 113.60% 24,747,465 343.71 3,698.37
(4) CHEMICAL PERCENTAGE RANGE (6) Paint Manufacturing Facility / Partial Ret-
PROCESS PLANT (CONCEPTUAL ESTIMAT- rofit located in Mid West (2004 Costs) Constructed
ING APPROACH) ACCURACY +/- 30% ISBL on an established operating site with adequate utili-
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(5) ZEOLITE PLANT SUMMARY ESTI- (7) Consumer Products Facility Personal Care
MATE RATIO / PRELIMINARY ESTIMATE Products - Central America: (Soap, Shampoo and
+/- 20% Accuracy Dental Hygiene Products)
See chart following pages Production 21,500 M2 - Admin / Laboratory
M.E. Multiplier = 5.22 with contingency / 4.99 5,700 M2 - Warehouse - 10,500 M2
w / o contingency See chart following pages
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Instrumentation devices 8 - 16
Pumps 200 GPM and above 8 - 20
Reactors high pressure 25 - 45
Turbines
Tanks (Floating Head)
Transformers / Sub stations
Spheres
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12 - 24
12 - 36
12 - 36
Vessels (Heavy wall) 20 - 40
with an understanding of the accuracy of the capital Refineries (2) Pharmaceutical / Fine Chemicals /
cost estimate deliverables (its a tall order - however Consumer Products (3) Power Generation (Oil, Gas
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these individuals are out there, the challenge is to and Nuclear facilities) (4) Food Processing (Dairies
find them and hire them and educate them to the & Bakeries) Beverage (Soft drinks and beer produc-
organizations methods). tion) (5) Manufacturing (i.e. paint, toner, plastics
The term Process / Chemical Industry or production, glass, paper manufacturing, detergents,
Manufacturing / Industrial / Chemical Production cement, man-made fibers and various automo-
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sector - as it is many times described, embraces the tive components) (6) R&D Facilities Pilot Plants
following major business sectors / industry nomen- Animal Testing / Research Facilities etc. (7) Steel
clature, (they mean the same thing to the lay person) Mills & Rolling Mills and (8) Automobile Produc-
that many times overlap each other and basically tion this one could fall into # 5 above. There are
refer to the same industry sectors. This gets more most probably others that have not been mentioned.
complicated when discussing this in the context of These Process / Chemical Industry facilities
building new facilities in this industry. The names production plants utilize equipment (many times
bandied around when discussing this is that it is an referred to as Major Equipment (M.E.)) that carries
industrial project, or it is an Oil & Gas project, or it out the following actions - heating, cooling, grind-
is a Petro-Chemical project. Its hard to have a col- ing, drying, mixing, blending, hammering, pressing,
lective name for all these project types, the best way compacting, conveying, transporting / moving and
forward is to refer to them all as Process Manu- pumping - conveying powders, fluids and gases.
facturing type projects. Some of the most prominent Typically a fair amount of rotating equipment i.e.
sectors include (1) Petroleum / Gas Production / pumps and agitators and mixers are required in these
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FOR POWER, STEEL, PHARMACEUTICAL & CHEMICAL FACILITIES
TYPE OF PLANT LOW RANGE M.E. MULTIPLIER MEDIAN M.E. MULTIPLIER HIGH RANGE M.E. MULTIPLIER
Chemical - Liquids
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Chemical - Liquids / Solids (Hybrid)
Chemical - Solids
Ethanol Facility (corn / sugar cane)
Pharmaceutical
3.75
3.25
2.50
2.75
1.75
5.00
4.50
3.75
3.25
2.50
6.25
5.75
5.25
3.75
4.50
Power 2.00 3.30 4.00
Steel 1.50 2.00 2.50
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Typically major equipment multipliers (to arrive a combination of union construction workforce and a
at a total installed cost of the proposed facility, this normal construction schedule.
multiplier would cover, materials, labor, in directs, High Range: Characteristically the major equip-
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detailed design, construction management) for pow- ment is housed in an enclosed structure / building,
er, steel, pharmaceutical, chemical facilities (liquids, has an assortment of carbon steel and a high content
solids and a hybrid of both) type facilities fall into of stainless steel piping (30% C.S. and the balance
one of the following categories / major equipment 70% S.S. or better), has a state of the art instrumen-
(M.E.) multipliers. tation / control system TDC 3000 or equal, open
Low Range: Typically is an open structure, has shop or a combination of union construction work-
a high level of carbon steel piping, an unsophisti- force and a fast track construction schedule, is a
cated instrumentation / control system, open shop hazardous process, is based on new technology.
construction workforce and a normal construction Other considerations: (refer to other benchmarks
schedule. Solids has a limited amount of piping, the on page 28 - 33)
major equipment is usually material handling, crush-
ers and grinders. (D) Front End Semi-Detailed / Square Foot /
Median Range: Typically is a combination Conceptual Estimates (+/- 25% Accuracy)
of enclosed / open structure, has an assortment of Front end semi detailed, conceptual, capital
carbon steel and stainless steel piping (60% C.S. and cost estimates are usually compiled in the more
the balance S.S. or better), a reasonably sophisti- advanced stage of the front end / conceptual defini-
cated instrumentation / control system, open shop or tion / design development effort, or early on in the
Table 18
USA MODULE BENCHMARKS 2015 COST BASIS:
20 TON AND 40 TON GENERIC PRICING
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DESCRIPTION MATERIAL LABOR ENGINEERING / OTHER $ TOTAL
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Purchase of Major Equipment, Purchase
cost is included, would be free issued to
module fabricator to install in module
by owner or EPC
Install Major Equipment into module
Piping Material (Pipe, fittings & valves)
Pipe Fabrication
38,967
8,225
8,324
26,487
38,967
8,324
8,225
26,487
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Heat treat & NDT of pipe systems 745 4,182 4,927
Paint for steel material 6,506 6,506
Labor to paint steel material 9,655 9,655
Paint for pipe material 1,324 1,324
Labor to paint pipe material 879 879
Insulation material 6,413 6,413
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Apartments 5 25 Floors (Spec A) 335,000 31,134 142 180 161 1,735
API Pharmaceutical Facility 133,000 12,361 470 594 532 5,725
Auditorium 2 Story (Spec A)
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Auditorium 2 Story (Spec D) 45,700 4,247 150 189 170 1,825
Auditorium 2 Story (Spec C) 45,700 4,247 145 184 165 1,771
Automobile Production Facility 585,000 54,368 120 151 136 1,460
Bakery 615,000 57,156 120 152 136 1,466
Bank 1 Story (Spec A) 9,200 855 187 236 212 2,279
Bank 1 Story (Spec B) 9,200 855 193 243 218 2,345
Bank 1 Story (Spec C) 9,200 855 187 239 213 2,291
Biological Manufacturing 340,000 31,599 1,937 2,378 2,157 23,214
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Bio Medical / R&D Center 3 Floors 92,500 8,597 427 539 483 5,198
Bleach Manufacturing Facility 388,000 36,059 134 169 152 1,633
Brewery 181,000 16,822 120 151 136 1,460
Cable TV Facility 12,700 1,180 120 152 136 1,466
Chemical Process Plants 3 Floors 56,000 5,204 104 131 117 1,262
Computer / Telecommunications Center 27,700 2,574 137 171 154 1,657
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2 Floors
cGMP ISO 6 8 117,500 10,920 1,004 1,276 1,140 12,264
cGMP ISO 7 8 88,600 8,234 837 1,056 947 10,187
Dairy / Cheese / Butter Production 74,000 6,877 131 165 148 1,591
Data Processing Office 11,000 1,022 158 199 178 1,920
Fiber Production Facility 88,000 8,178 136 170 153 1,645
Food Production Facility 2 Floors 73,000 6,784 133 168 151 1,621
GMP Production Facility 80% ISO 5,6,7 & 8 137,000 12,732 998 1,263 1,131 12,168
GMP Production Facility 60% ISO 5,6,7 & 8 137,000 12,732 943 1,192 1,067 11,486
GMP Production Facility 60% ISO 6,7 & 8 137,000 12,732 728 918 823 8,859
GMP Production Facility 50% ISO 7 & 8 137,000 12,732 593 744 668 7,190
GMP Production Unclassified 2 Floors 137,000 12,732 208 262 235 2,530
Heavy Manufacturing Facility 40,000 3,717 117 147 132 1,418
Hospital 2 - 4 Story (Spec A) 166,700 15,493 239 301 270 2,907
Hospital 2 - 4 Story (Spec D) 166,700 15,493 245 309 277 2,979
Hospital 2 - 4 Story (Spec H) 166,700 15,493 249 315 282 3,033
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The above USA city indexes / location factors facility (engineering / construction endeavor will ini-
are intended for calibrating building / facility costs. tially experience a steep learning curve as the staff
The base / standard benchmark city is Washington, navigates it way through local import regulations
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D.C; i.e. which is fixed at a value of 1.00. Less built and various permitting issues) if company has built
up areas close to major cities, i.e. suburbs outside or has operating facilities already in country reduce
major cities generally have a lower cost basis than location factor value by 0.04 0.08 points):
major city center costs by 1 5 basis points. Re- Location Factor A: is applicable to Refiner-
mote locations, such as, Anchorage or Fairbanks ies, Chemical Plants, Power Stations, Hi-Tech Type
in Alaska, will generally have, to a greater degree, Facilities (Pharmaceutical / Chip Manufacturing
higher prices compared to lower 48 states compara- Facilities), these facilities typically contain sophis-
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ble cities, due to increases in logistics and increased ticated manufacturing / production equipment, these
shipping / transportation costs of materials and facilities more often than not require complex piping
equipment to Alaska, also keep in mind that weather / air conditioning systems, more often than not these
conditions in Alaska can be significantly different to facilities are highly automated systems, many times
lower the 48 states. these complex equipment items / materials need to
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5,000 $76,132 $15.23
7,500 $103,826 $13.84
10,000 PL $130,147 $13.01