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Mechanical Estimating Manual Sheet Metal, Piping and Plumbing This page intentionally left blank Mechanical Estimating Manual Sheet Metal, Piping and Plumbing By Wendes Systems, Inc. Edited by Joseph D’Amelio Library of Congress Cataloging-in-Publication Data Mechanical estimating manual : sheet metal, piping, and plumbing/by Wendes Systems, Inc.; edited by Joseph D’Amelio. p. cm. Includes index. ISBN 0-88173-538-8 (print) -- ISBN 0-88173-539-6 (electronic) 1. Buildings--Mechanical equipment--Installation--Estimates--Handbooks, manuals, etc. I. D’Amelio, Joseph . II. Wendes Systems, Inc. TH6010.M457 2006 696--dc22 2006041262 Mechanical estimating manual : sheet metal, piping, and plumbing/by Wendes Systems, Inc.; edited by Joseph D’Amelio ©2007 by The Fairmont Press, Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information storage and retrieval system, without permission in writing from the publisher. Published by The Fairmont Press, Inc. 700 Indian Trail Lilburn, GA 30047 tel: 770-925-9388; fax: 770-381-9865 http://www.fairmontpress.com Distributed by Taylor & Francis Ltd. 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487, USA E-mail: orders@crcpress.com Distributed by Taylor & Francis Ltd. 23-25 Blades Court Deodar Road London SW15 2NU, UK E-mail: uk.tandf@thomsonpublishingservices.co.uk Printed in the United States of America 10 9 8 7 6 5 4 3 2 1 0-88173-505-1 (The Fairmont Press, Inc.) 0-8493-9210-1 (Taylor & Francis Ltd.) While every effort is made to provide dependable information, the publisher, authors, and editors cannot be held responsible for any errors or omissions. iv Quick Reference Section I—HOW TO PREPARE SHEET METAL AND PIPING ESTIMATES 1 Wendes Guide to Successful Estimating; Principles 2 Systematic and Efficient Estimating Procedures 3 Sample HVAC Estimate and Forms Section II—BUDGET ESTIMATING 4 Budget Estimating Section III—EQUIPMENT ESTIMATING 5 Heating and Cooling Equipment 6 HVAC Units and Air Distribution Equipment 7 Plumbing Fixtures and Specialties 8 Air Pollution and Heat Recovery Equipment Section IV —SHEET METAL ESTIMATING 9 Sheet Metal Estimating Basics 10 Rectangular Galvanized Ductwork 11 Spiral and Light Gauge Round Ductwork. 12 Fiber Glass Ductwork 13 Heavy Gauge Ductwork. 14 Sheet Metal Specialties and Acoustical Lining 15 Miscellaneous Labor Operations Section V—PIPING ESTIMATING 16 Piping Estimating Basics 17 Pressure Pipe and Fittings 18 Valves and Specialties 19 DNVV Pipe and Fittings Section VI—CONTRACTING FOR PROFIT 20 Markups for Overhead and Profit 21 Contracting for profit 22 Computerized Estimating v This page intentionally left blank Contents Preface ............................................................................................................................................................ xi Section I—HOW TO PREPARE SHEET METAL AND PIPING ESTIMATES Chapter 1 Successful Estimating Principles .................................................................................................. 3 Crux of Successful Contracting ....................................................................................................... 3 Primary Goals of Contracting and Bidding .................................................................................. 3 Problems and Causes of Poor Estimating...................................................................................... 3 Estimating Competence Required .................................................................................................. 4 The Eight Facets of the Estimating Diamond ............................................................................... 4 Performance Standards for Complete and Accurate Estimates ................................................. 5 Fundamental Bidding Rules ............................................................................................................ 5 How to Estimate Labor Accurately and Realistically .................................................................. 8 Do Your Homework.......................................................................................................................... 9 Use Time Saving Estimating Techniques ....................................................................................... 9 Apply Valid Overhead and Profit Markups ................................................................................ 10 2 Systematic, Efficient, Accurate Estimating Procedures ...........................................................11 Steps in the Estimating Procedure .................................................................................................11 Checking Estimates ........................................................................................................................ 12 Scope of Complete Sheet Metal Estimate, Check-off List ......................................................... 16 Heating Equipment Check-off List ............................................................................................... 17 Cooling Equipment Check-off List ............................................................................................... 18 End of Bid Factors Check-off List ................................................................................................. 18 Remodeling Work Check-off List.................................................................................................. 19 15 Bastards with No Regular Homes ........................................................................................... 20 3 Sample HVAC Estimate and Forms ............................................................................................ 23 Overview of Sample Job................................................................................................................. 23 Purpose of Forms ............................................................................................................................ 23 Specifications on Sample Job ......................................................................................................... 24 IBM Office Drawing........................................................................................................................ 25 Sample Filled Out Estimating Forms ........................................................................................... 26 Calculating Labor Costs Per Hour................................................................................................ 31 Section II —BUDGET ESTIMATING Chapter 4 Budget Estimating.......................................................................................................................... 37 Budget Estimates ............................................................................................................................. 37 Semi-Detailed Scope Budget Estimates ....................................................................................... 37 Detailed Estimates .......................................................................................................................... 38 Budget Estimating HVAC Costs and Engineering Loads ......................................................... 38 Budget Estimating Galvanized Ductwork .................................................................................. 39 Section III —EQUIPMENT ESTIMATING Chapter 5 Heating and Cooling Equipment ................................................................................................ 59 Chilled and Hot Water Pumps ...................................................................................................... 60 vii Hot Water Reheat Coils .................................................................................................................. 61 Electric Duct Heaters ...................................................................................................................... 62 Duct Heaters .................................................................................................................................... 63 Unit Heaters ..................................................................................................................................... 63 Gas Fired Cast Iron Boilers ............................................................................................................ 64 Baseboard Heating .......................................................................................................................... 65 Infra Red Units ................................................................................................................................ 66 Electric Baseboard Heating ............................................................................................................ 66 Wall Heaters ..................................................................................................................................... 67 DX Evaporator Coils ....................................................................................................................... 68 Chilled Water Coils ......................................................................................................................... 69 Centrifugal Water Cooled Chillers ............................................................................................... 70 Reciprocating Chillers .................................................................................................................... 71 Cooling Towers................................................................................................................................ 73 Heat Pumps ..................................................................................................................................... 74 Condensing Units ........................................................................................................................... 75 6 HVAC Units and Air Distribution Equipment ........................................................................ 77 Rooftop Units ................................................................................................................................... 78 Air Handling Units ......................................................................................................................... 80 Self Contained Air Conditioning Units........................................................................................ 83 Dampers ........................................................................................................................................... 87 Louvers ............................................................................................................................................. 89 Estimating Registers ....................................................................................................................... 90 Ceiling Diffusers.............................................................................................................................. 91 VAV Terminal Units, Components etc. ........................................................................................ 92 Filter Labor ....................................................................................................................................... 96 7 Plumbing Fixtures and Specialties ............................................................................................. 97 8 Air Pollution and Heat Recovery Equipment......................................................................... 101 Air pollution equipment .............................................................................................................. 101 Section IV— SHEET METAL ESTIMATING Chapter 9 Sheet Metal Estimating Basics................................................................................................... 109 Requirements of a Proficient Sheet Metal Estimator ............................................................... 109 Types of Ductwork .........................................................................................................................111 Procedure for Taking Off Ductwork ............................................................................................112 Types of Ductwork Connections ..................................................................................................113 Methods of Figuring Ductwork Weight......................................................................................114 Methods of Calculating Ductwork Labor ..................................................................................115 Material Data ................................................................................................................................. 124 Correction Factors ......................................................................................................................... 125 10 Galvanized Ductwork ................................................................................................................. 129 Estimating Galvanized Ductwork by the Piece ........................................................................ 129 Estimating Galvanized Ductwork by the Pound ..................................................................... 136 Medium and High Pressure Ductwork ..................................................................................... 142 Automatic Duct Coil Line Fabrication ....................................................................................... 143 viii 11 Spiral and Light Gauge Round Ductwork .............................................................................. 145 Round Duct Gauge Data .............................................................................................................. 146 Furnace Pipe Flexible Tubing and Flues .................................................................................... 146 Spiral Pipe and Fittings ................................................................................................................ 147 12 Estimating Fiberglass Ductwork ............................................................................................... 155 Introduction ................................................................................................................................... 155 Fiberglass Ductwork Construction ............................................................................................. 156 Pricing Sheet Metal Components ............................................................................................... 158 Estimate Summary and Extension Sheet .................................................................................. 158 13 Heavy Gauge Ductwork ............................................................................................................. 159 Types of Industrial Exhaust Ductwork ...................................................................................... 159 Rectangular Black Iron ................................................................................................................. 159 Round Black Iron Ductwork........................................................................................................ 166 Rolled Steel Angle Rings .............................................................................................................. 171 Example of Round Black Iron ..................................................................................................... 172 Aluminum ...................................................................................................................................... 173 Stainless Steel ................................................................................................................................. 175 FRP Ductwork ............................................................................................................................... 177 FRP Coated Galvanized Ductwork ............................................................................................ 179 Labor Multipliers for Heavy Gauge Ductwork ........................................................................ 180 Air Pollution Estimating .............................................................................................................. 180 14 Sheet Metal Specialties and Acoustical Lining...................................................................... 187 Access Doors, Belt Guards, Drain Pans ..................................................................................... 187 Flexible Connections, Hoods, Stands and Platforms ............................................................... 188 Roof Hoods .................................................................................................................................... 189 Turning Vanes ................................................................................................................................ 190 Splitter Dampers ........................................................................................................................... 191 Sheet Metal Housings ................................................................................................................... 192 Acoustic Lining ............................................................................................................................. 192 15 Miscellaneous Labor Operations .............................................................................................. 195 Drafting and Sketching Labor ..................................................................................................... 195 Field Measuring and Sketching Labor ....................................................................................... 196 Estimating Air Testing and Balancing ........................................................................................ 196 Estimating Ductwork Leak Testing ............................................................................................ 199 Section V —PIPING ESTIMATING Chapter 16 Piping Estimating Basics ............................................................................................................ 203 Requirements of a Proficient Piping Estimator ........................................................................ 203 Sample Estimate ............................................................................................................................ 207 17 Pressure Pipe, Fittings and Insulation ..................................................................................... 217 Pressure Piping and Fittings Tables for Threaded, Welded, Flanged, Grooved and Associated Labor ................................................ 218 Copper Tubing, L, K, K Labor and Pricing etc. ......................................................................... 236 18 Valves and Specialties ................................................................................................................. 253 ix