Concrete Bridge Development Group

Technical Guide No 14
Best Construction Methods for Concrete Bridge Decks - Cost Data

Bridge Cost Breakdown

1-Jul-15

TG 14 SAMPLE TABLE input to yellow cells only

all other cells calculated

Span 40 m Width 15 m
Length 200 m Depth 2.0 m
Span/Depth ratio 20

Concrete area 10.0 m3/m Concrete rate 120 £/m3

Concrete volume 2,000 m3 Concrete cost 240,000 £
Rebar density 200 kg/m3 Rebar rate 900 £/t
Rebar tonnage 400 t Rebar cost 360,000 £
Prestress density 50 kg/m3 Prestress rate 2,500 £/t
Prestress tonnage 100 t Prestress cost 250,000 £
Total formwork perimeter 30 m Formwork/Falsework rate 95 £/m2 per total formwork area
Total formwork area 6,000 m2 Formwork/Falsework cost 567,400 £

Production rate 20 m/week Total cost 1,417,400 £

Learning curve 20 % Total deck rate 472 £/m2 per total deck plan area
Overall erection programme 12 weeks

Men Weeks Quantity Rate Cost (£) Notes

Casting
Mould, formwork or travellers 1 item 100,000 £ 100,000 consider shutter or mould requirements and re-uses
Ancillary shutters 1 item 25,000 £ 25,000 consider other pier, stitch, diaphragm and end shutters
Casting area and foundations 100 m2 250 £/m2 25,000 consider scaffolding, casting bed/area and shed requirements
Shuttering labour 8 10 80 man-weeks 900 £/week 72,000 consider labour numbers and timescale
Cranes or lifting 10 weeks 3,000 £/week 30,000 consider crane or gantry requirements
Storage area 8 weeks 2,000 £/week 16,000 consider storage requirements and timescale
Transport
Vehicles 6 weeks 2,500 £/week 15,000 consider vehicle requirements and timescale
Transport labour 1 6 6 man-weeks 900 £/week 5,400 consider labour numbers
Erection
Formwork 200 m2 40 £/m2 8,000 consider erection shutters
Cranes or lifting 12 weeks 5,000 £/week 60,000 consider crane requirements
Gantry, girders or noses 1 item 50,000 £ 50,000 consider main falsework requirements and re-uses
Falsework and temp works 10 t 3,000 £/t 30,000 consider other falsework requirements and re-uses
Ancillary items 1 item 25,000 £ 25,000 consider other temporary works requirements and re-uses
Erection area and foundations 100 m2 100 £/m2 10,000 consider scaffolding or hardstanding for cranes
Erection labour 8 12 96 man-weeks 1,000 £/week 96,000 consider labour numbers

Total 567,400
Formwork/Falsework cost

Quoted figures are only indicative of the spreadsheet behaviour - all users must verify their own data, using TG 14 as a guide.
Concrete Bridge Development Group

Technical Guide No 14
Best Construction Methods for Concrete Bridge Decks - Cost Data

Bridge Cost Breakdown

1-Jul-15

BRIDGE SPECIFIC RATES (used in TG 14 - April 2015)

In-situ span by span In-situ span by span In-situ balanced Standard precast SY Bespoke precast U Bespoke precast I
Bridge Type In-situ slabs In-situ twin ribs In-situ twin ribs boxes boxes cantilever beams beams beams Precast segmental Precast segmental Whole span precast Incremental launching Modular precast Modular precast
Erection Method Scaffolding Scaffolding Gantry Scaffolding Gantry Travellers Crane Crane Gantry Crane Gantry Gantry Launched Scaffolding Launched
Main Length (m) 150 150 600 150 600 600 150 150 600 600 1200 5000 600 150 150
Other Lengths (m) 50, 600 50, 600 1200 50, 600, 1200 1200, 5000 150, 1200 50, 600, 1200 50, 600, 1200 1200, 5000 1200, 5000 5000 150, 1200 50, 600 50, 600
Cost Item Range

Concrete rate (all-up) £/m3 100 to 160 120 120 100 140 140 160 120 120 100 120 120 100 120 120 120

Rebar rate (all-up) £/t 900

Prestress rate (all-up) £/t 2,250 to 2,500 2,500 2,500 2,500 2,500 2,500 2,500 2,250 2,250 2,500 2,500 2,500 2,500 2,500 2,500 2,500

Mould or shutters - material item 40,000 to 750,000 300,000 750,000 125,000 (for one traveller) 100,000 200,000 150,000 200,000 200,000 750,000 400,000 40,000 40,000
Ancillary shutters - material item 10,000 to 150,000 10,000 10,000 150,000 50,000 50,000 100,000 10,000

Casting bed/area and foundations £/m2 100

Casting shed (all-up) £/m2 400
Piled launching area £/m2 350
Launching area - modular £/m2 100

Scaffolding and foundations (all-up£/m2 40 to 90 60 (40 for 600m) 90 (60 for 600m) 75 (50 for 600, 1200m) 60
Pier scaffolding for in-situ bal cantitem 20,000 to 80,000 80,000 (20,000 for 150m)

Plain formwork - material £/m 2

20
GRC formwork - material £/m2 60

Shuttering labour £/week 900

Casting area gantry incl operators item 100,000 to 600,000 100,000 400,000 400,000 600,000

50t crawler crane incl operator £/week 3,000

100t crawler crane incl operator £/week 4,250
150t crawler crane incl operator £/week 5,000
300t crawler crane incl operator £/week 7,500
Tower crane incl operator £/week 3,000
50t mobile crane incl operator £/week 2,500
100t mobile crane incl operator £/week 4,500
300t mobile crane incl operator £/week 12,500
500t mobile crane incl operator £/week 15,000

Crane hardstandings £/m2 50

Storage area £/week 1,000 to 12,000 1,500 (3,000 for 1200m) 1,500 1,500 (6,000 for 5000m) 3,000 (12,000 for 5000m) 3,000 (12,000 for 5000m) 3,000 1,000 1,000

Transport vehicles £/week 1,500 to 10,000 1,500 (3,000 for 1200m) 2,500 2,500 (10,000 for 5000m) 2,500 (5,000 for 5000m) 2,500 1,500 1,500

Transport labour £/week 900

Gantries, girders or noses item 50,000 to 2,500,000 800,000 1,200,000 800,000 1,500,000 2,500,000 150,000 50,000

Ancillary erection items item 10,000 to 250,000 25,000 25,000 50,000 (25,000 for 150m) 25,000 25,000 25,000 50,000 250,000 (100,000 for 150m) 10,000 50,000

Falsework and temp works £/t 3,000

Erection labour £/week 1,000

Concrete Bridge Development Group

Technical Guide No 14
Best Construction Methods for Concrete Bridge Decks - Cost Data

Bridge Cost Breakdown

1-Jul-15

AVERAGE RATES and FACTORS

Average Major Rates used in TG 14 - April 2015

Concrete average rate (all-up) £/m3 120 Labour, plant and materials

Rebar average rate (all-up) £/t 900 Labour, plant and materials

Prestress average rate (all-up) £/t 2,500 Labour, plant and materials

Labour average rate £/week 900 Labour

Plain formwork rate £/m2 20 Material

50t mobile crane (incl operator) rate £/week 2,500 Plant and labour

Average Major Rates applicable to your current time and region, for example

Concrete average rate (all-up) £/m3 140 input to yellow cells only
all other cells calculated
Rebar average rate (all-up) £/t 1,100

Prestress average rate (all-up) £/t 3,000

Labour average rate £/week 1,100

Plain formwork material rate £/m2 25

50t mobile crane (incl operator) rate £/week 3,000

Factors for your current time and region, for example

Concrete factor 1.17 Labour, plant and materials

Rebar factor 1.22 Labour, plant and materials

Prestress factor 1.20 Labour, plant and materials

Labour factor 1.22 Labour

Plain formwork factor 1.25 Material

50t mobile crane factor 1.20 Plant and labour

AVERAGE COST FACTOR 1.21 Labour, plant and materials

If the cost factors are broadly the same for each of the six Major Rates, then use this AVERAGE COST FACTOR to factor up each of the Bridge Specific Rates used in TG 14 (dated April 2015) - see the Factored Sample Table tab.

If the six cost factors are not similar, then use engineering judgement to determine which of the six are the most appropriate factors to form the AVERAGE COST FACTOR.

Alternatively, or additionally, use the correct current rate for any items for which you also have current figures in your region.

Together with the quantities in TG 14, or your own quantities, this will generate a set of costs that are broadly applicable to your current time and region.

Quoted figures are only indicative of the spreadsheet behaviour - all users must verify their own data, using TG 14 as a guide.
Concrete Bridge Development Group

Technical Guide No 14
Best Construction Methods for Concrete Bridge Decks - Cost Data

Bridge Cost Breakdown

1-Jul-15

FACTORED SAMPLE TABLE input to yellow cells only

all other cells calculated

Span 40 m Width 15 m
Length 200 m Depth 2.0 m
Span/Depth ratio 20

Concrete area 10.0 m3/m Concrete rate 140 £/m3 use current rate for your region
Concrete volume 2,000 m3 Concrete cost 280,000 £
Rebar density 200 kg/m3 Rebar rate 1,100 £/t use current rate for your region
Rebar tonnage 400 t Rebar cost 440,000 £
Prestress density 50 kg/m3 Prestress rate 3,000 £/t use current rate for your region
Prestress tonnage 100 t Prestress cost 300,000 £
Total formwork perimeter 30 m Formwork/Falsework rate 114 £/m2 per total formwork area
Total formwork area 6,000 m2 Formwork/Falsework cost 686,540 £

Production rate 20 m/week Total cost 1,706,540 £

Learning curve 20 % Total deck rate 569 £/m2 per total deck plan area 1.21 AVERAGE COST FACTOR from Cost Factors tab
Overall erection programme 12 weeks Alternatively, use current rate for any items
for which you also have figures in your region
Men Weeks Quantity TG 14 Rate AVERAGE COST FACTOR Cost (£) Notes
Casting
Mould, formwork or travellers 1 item 100,000 £ 1.21 121,000 consider shutter or mould requirements and re-uses
Ancillary shutters 1 item 25,000 £ 1.21 30,250 consider other pier, stitch, diaphragm and end shutters
Casting area and foundations 100 m2 250 £/m2 1.21 30,250 consider scaffolding, casting bed/area and shed requirements
Shuttering labour 8 10 80 man-weeks 1,100 £/week use current rate for your region 88,000 consider labour numbers and timescale
Cranes or lifting 10 weeks 3,000 £/week 1.21 36,300 consider crane or gantry requirements
Storage area 8 weeks 2,000 £/week 1.21 19,360 consider storage requirements and timescale
Transport
Vehicles 6 weeks 2,500 £/week 1.21 18,150 consider vehicle requirements and timescale
Transport labour 1 6 6 man-weeks 1,100 £/week use current rate for your region 6,600 consider labour numbers
Erection
Formwork 200 m2 40 £/m2 1.21 9,680 consider erection shutters
Cranes or lifting 12 weeks 5,000 £/week 1.21 72,600 consider crane requirements
Gantry, girders or noses 1 item 50,000 £ 1.21 60,500 consider main falsework requirements and re-uses
Falsework and temp works 10 t 3,000 £/t 1.21 36,300 consider other falsework requirements and re-uses
Ancillary items 1 item 25,000 £ 1.21 30,250 consider other temporary works requirements and re-uses
Erection area and foundations 100 m2 100 £/m2 1.21 12,100 consider scaffolding or hardstanding for cranes
Erection labour 8 12 96 man-weeks 1,200 £/week use current rate for your region 115,200 consider labour numbers

Total 686,540
Formwork/Falsework cost

Quoted figures are only indicative of the spreadsheet behaviour - all users must verify their own data, using TG 14 as a guide.