le) ate eae) Eliminates guesswork. Now, turn out fast and accurate construction labor estimates.Estimator’s General Construction Man-Hour Manual Second Edition John S. Page iw Gulf Professional Publishing PNY An Imprint of EkevierTo my wife, Gelesta, who has spent many lonely nights that this book might become a reality. Estimator’s General Construction Man-Hour Manual Second Edition Copyright © 1999 by Butterworth-Heinemann. All rights reserved. Printed in the United States of America. This book, or parts thereof, may not be reproduced in any form without permission of the publisher. Permissions may be sought directly from Elsevier's Science and Technology Rights Department in ‘Oxford, UK. Phone: (44) 1865 843830, Fax: (44) 1865 853333, e-mail: permissions @elsavier.co.uk. You may also complete your request on-line via the Elsevier homepage: fili/iwwe.alsardor carn by ‘selecting “Customer Support" and then "Obtaining Permissions". Originally published by Gulf Professional Publishing, Houston, TX. ISBN-13: 978-0-87201-320-9 ASBN-10: 0-87201-320-0 16 15 14 13 12 For information, please contact: Manager of Special Sales Butterworth-Heinemann 225 Wildwood Avenue Woburn, MA 01801-2041 Tel: 781-904-2500 Fax: 781-904-2620 For information on ali Butterworth-Heincmann publications available, contact our World Wide Web home page at: http:“/www.bh.com This book was reviewed by the author and reprinted August 1997, iiCONTENTS Preface ...... Introduction 6.66626 Section 1 - DEMOLITION Section Introduction Remove Site Drainage Items seuss Remove Fencing. Guard Rails, Railroads. & Bituminous Pavement»... Core Drilling Concrete Slabs . Break Out Concrete Items... . Saw Cutting Asphalt, Concrete, & Masonry. Torch Cutting Steel 02... Masonry & Wood Items Removal of Steel. Equipment, & Pipe . Remove Special Flooring ..... boeeeeee bevee teens Miscellaneous Materials ........... : veceea 1 Section 2 - SITE-GRADING & STRUCTURAL EXCAVATION Section Introduction Hi Removing Trees 3 Remove Tree Stumps .. - 14 Clearing Trees & Brush . 15 General Site Grading~9 Cubic Yard Payload 16 General Site Grading—9 Cubic Yard Payload . . 7 General Site Grading—11 Cubic Yard Payload 18 General Site Grading—11 Cubic Yard Payload . 19 General Site Grading—23 Cubic Yard Payload - 20 General Site Grading—23 Cubic Yard Payload - 2 Shape, Compact, & Fine Grade Fill & Remove Top Soil 2 Major Fills & Strippings for Building Sites 23 24 Machine Excavation—Back Hoe . . 25 Machine Excavation—Trenching Machine & Dragline . 26 Rock Excavation a Hand Excavation . 28 Disposal of Excavated Materials 29 Disposal of Excavated Materials . 30 Machine & Hand Backfill . : 31 Loading Dirt from Stockpile with Clamshell. 32 Dike Construction for Storage Tanks . . . - 33 Gunite Banks for Slope Protection 34Section 3 - SITE DRAINAGE PIPE & STRUCTURES Section Introduction - Cast Iron Soil Pipe . . Concrete Drain Pipe : Reinforced Elliptical Concrete Pipe Vitrified Clay and Asbestos Cement Drain Pipe Corrugated Metal Drain Pipe Hand Shape Trench Bottom ... . Headwall, Catch Basin, and Manhole Forms . _- Box Type Culverts . Headwall, Catch Basin. and Manhole Concrete. Brick and Block Manholes and Plaster . . . Installation of Manhole Frames & Covers Section 4 - SITE IMPROVEMENTS Section Introduction Place Road Base Material . Asphalt Concrete Pavement. Curb & Gutter Wood Forms Curb & Gutter Metal Forms : Curb. Gutter, and Road Pavement Finish Curb, Gutter, & Road Pavement Miscellaneous Paving Items Bituminous and Concrete Walks Chain Link Fencing. Landscaping .. . Section 5 - SHEET & FOUNDATION PILING Section Introduction Set-Up & Remove Pile Driving Equipment . . Hand Placed Wood Sheet Piling, Shoring & Bracing : Pneumatic Driven Wood Sheet Piling, Shoring & Bracing .. . . Wood & Steel Sheet Piling Driven with Pile Driver Wood Pole & Stee! Shell Piling Steel “H" or Precast Concrete Piling Beam Piling & Caissons . iv 35 36 37 37 38 39 40 aL a 43 45 a7 43 49 51 52 53 54 55 56 57 58 59 61 62 63Section 6 - FORMWORK Section Introduction... -- 0.6... 005 . wee wee . bees 65 Footing & Heavy Mat Forms... . . 66 Foundation, Tilt-Up Walls. & Grade Beams . or Square Wood Pier Forms . . wee 8 Fiber Tube Pier Forms=12" Through 18" Round . - Cy Fiber Tube Pier Forms—20” Through 28” Round... 6.06.00 2s eee 70 Fiber Tube Pier Forms-30” Through 38” Round... 2.0.60... 5 n Fiber Tube Pier Forms—40” Through 48” Round... .. fee n Metal Wall Forms for Continuous Foundations feet e eee B Metal Wall Forms for Continuous Above Grade Walls . . . 4 Continuous Wood Wall Forms . 5 Gang Wall Forms . bebe etter eens vee 16 Square Wood Column Forms... : : n Fiber Tube Column Forms=12" Through 18” Round . boven! £ 8 Fiber Tube Columa Forms-20" Through 28” Round . oe tees 9 Fiber Tube Column Forms~30" Through 38” Round ......----+-2..-. 80 Fiber Tube Column Forms—40” Through 48” Round «0.0... 0202005. 81 Steel Column Capitals for Round Columns ........ beeen 82 Radial & Retaining Wood Wall Forms 83 Wood Beam & Girder Forms . a4 Column Drop Heads & Box Out fo ening Forms coe 85 Sheet Metai Box-Out Forms and Sleeves . Le 86 Wood Forms for Ground Floor Slabs cece . a7 Wood Forms for Elevated Slabs... . . . on 88 Metal Floor Pan Forms ............ 89 Wood Trench & Curb Forms 90 Stairwell & Stair Forms . 1 Loading Dock, Platforms & Canopy Wood Forms . 92 Sills, Lintels, Coping & Balcony Form Wood . 93 Column & Beam Pockets & Encasements, Chamber, Screeds, & Keyways 94 Equipment Foundations—Simple Layout sete ees 95 Equipment Foundations—Complex Layout . 96 Re-Use Factors . cess -- ” Section 7 - REINFORCING STEEL AND MESH Section Introduction ......... bce 98 Reinforcing Rods. . 9 Reinforcing Mesh . 100Section 8 - MISCELLANEOUS EMBEDDED ITEMS Section Introduction Hook Type Anchor Bolt Installation»... 0... Hook Type Anchor Bolt Installation . . - Installation of Straight Type Anchor Bolts . . Loops and Screw Anchors Angles, Sleeves, Inserts, Slots & Unistrut - Section 9 - CONCRETE Section Introduction. . Footings Foundation Walls & Grade Beams Piers . Columns. Above Grade Walls ‘Tilt-Up Concrete Panels Radial & Retaining Walls . Floor Slabs, Beams, & Girders . Metal Pan & TC Tile, & Rib Floors - - Placing Lightweight and Insulating Concrete and Foam Fills on Floors and Decks - Ramps, Platforms & Canopies - Sills, Lintels & Coping Stairwells & Stairs... . Trench & Curb Concrete - Equipment Foundations . Runways & Hoist Towers Topping Finish . Vapor Barrier, Concrete Finishing, Grout and Sandblasting « Waterproofing, Dampproofing. & Insulmastic . be vet eee teeeees Hardeners and Joint Materials .. 0... 0... 00000 e cece eee eens Section 10 - MASONRY Section Introduction . . - General Notes - : Double Size Common Brick Walls. Common Brick Walls Common Brick Walls - Face Brick with Common Brick Back: Up Walls. Face Brick with Common Brick Back-Up Walls Modular Brick vi 101 102 103 104 104 105 106 108 109 M0 ML 2 13 14 us 116 7 ug 119 120 121 122 123 124 125, 126 127 128 129 131 132 133 134 135, 136Brick with Load Bearing Clay Tile Back-Up Brick with Concrete Block Back-Up . Concrete Brick Walls... . Load Bearing Concrete Block Walls . Spectra-Glaze and Screen Wail Block Fire Brick & Tile ..... Hollow Clay Partition & Furring Tile Gypsum Tile... . Load Beacing Tite Walls vee Glazed One Side Structural Facing Tile . Glazed Two Sides Structural Facing Tile Glass Block & Accessories : Architectural Terra Cotta . seve Ashlar Veneer Stone & Granite Facing Sills. Lintels. & Copings : Miscellaneous Interior Marble Work Close Up Openings with Brick or Tile Wall Reinforcing and Ties........ . Grouting and Caulking Masonry Walls - Bolts, Flashings, Fills and Insulations Unloading Masonry Materials... . Point & Caulk Around Sash & Clean Walls. Conversion Factors for Various Bonds & Joints Section 11 - STRUCTURAL STEEL & MISCELLANEOUS IRON Section Introduction ........ Erect Structural Steel—1 to $00 Tons. Erect Structural Steel—Over 500 Tons . . . .. Concrete Fireproofing for Columns and Beams Fireproofing Structural Steel... 0........- Miscellaneous Structural Steel... .- Dock & Canopy Framing, Floors, & Platforms vee Bar Joist, Partition Framing, Monorail. & Equipment Supports... Pipe and Square Tube Columns . Steel Grating ......-... Unload Miscellaneous Steel Items—Fabricate and Erect Stairs and Ladders . Pipe and Angte Handrails and Toe Plates Miscellaneous Iron & Steel . . Door, Louver, & Duct Frames Miscellaneous Steel Items - Comparison Percentages~Other Metals to Mild Steel vit 137 138 139 140 14h 142, 143 144 145 146 147 148 49 150 151 152 153 154 155, 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 ii 172 173 174 175Section 12 - CARPENTRY & MILLWORK Section Introduction... . Structural Lumber - : Metal Bases and Caps for Wood Columns. Posts, and Beams. . Metal Joist Hangers . Wood Framing . : Loading Docks & Sub Flooring . Glued Laminated Beams~Hangers and Connectors : Install Laminated Beams with Structural Fasteners . . . . : Install Laminated Beams with Two Machine Bolts Each End - Roof Lumber - Wall Coverings .... . . Laying & Finishing Floors - Furring, Grounds. Blocking & Caulking Exterior Trim . . Interior Trim... Wall, Ceiting & Floor Insulation « Exterior Wood Doors & Transoms Exterior Wood Doors & Transoms . . . Prehung Doors... ... Folding Doors & Room Div Wood Sash & Screens ........ Finish Hardware For Wood Doors & Sash Section 13 - METAL DOORS, SASH, GLASS, & GLAZING ‘Section Introduction . . - oe Exterior Hollow Metal Doors Exterior Press Steel Doors wee Exterior Aluminum Doors é& Frames... Interior Hollow Metal Doors Interior Press Steel Doors . Interior Aluminum Doors & Frames . Interior Kalamein or Metal Covered Doors Steel Access Doors . . Erect Steel & Aluminum Sash Glass & Glazing Sash & Doors . . - Caulking and Sealants For Doors and Sash . Section 14 - SPECIAL FLOORING Section Introduction ...... . Brick & Marble Floors & Walks 176 7 178 179 180 181 182 183 184 185 186 187 188 139 190 191 192 193 194 195 196 197 198 199 210 2 meant PONS HTZO AWM ozza098eNOME UNH Ow meee CHI AUnEenHovoe Marble Wainscot ......... ++ bce eee eee eee neces 212 Ceramic Tile . cone : tee 213 Terrazzo Floors . . 24a Mastic Floors~Asphalt & Rubber Tile : sees 215 Mastic Floors—Lino Tile & Linoleum... 2.6.06 216 Quarry Tile 8 Wood Block Flooring ......-. 22-2. Levee eee ee eee 27 Section 15 - SPECIAL WALLS & CEILINGS Section Introduction. 00... 600000 e cece eee eee eee beeee 218 Furring & Grounds «0.2.2.2... cece 219 Lathing 220 Metal Lath . 221 Plastering - 222 Stucco . cee ee cece vee ees 23 Wall Coverings ©... 2.0600 eee eee eee scene beeen 224 Drywall, Steel Studs. and Suspended Ceiling System |=. . 225 Gunite & Pargeting : eee . 26 Acoustical Tile Ceiling 27 Section 16 - ROOFING & SIDING Section Introduction ............ wes cone 228 Asphalt, Tar & Gravel Roofing - vee - 229 Insulation Board & Flashing wee 230 Roof Plank & Tile........ ferent eee eeeeeee O31 Roof Hatches and Plastic Domed Skylights. Concrete Roofing & Roofing Items cee 233 Metal & Wood Roofing.......... fee ee eens 234 Metal Roofing, Siding & Panels . ee Asbestos and Asbestos Protected Metal Roofing & Siding... 0.0... 236 Section 17 - ORNAMENTAL METAL & SPECIAL PARTITION Section Introduction ............ Bete 237 Entrances, Canopies. Building Fronts & Metal Clad Plywood Facing .............. 238 Prefabricated Metal, Metal Toilet & Wire Mesh Partitions . 239 Section 18 - PAINTING Section Introduction .... . . eee wes . cececee ee 240 Exterior Iron & Steel... 2... ne 2a Exterior Masonry, Concrete & Stucco 242Brush Exterior Wood Items . Interior Spray Work Interior Wood Floors sees : Interior Sheetrock, Plaster & Masonry Watls & Ceilings . . Miscellaneous Finishes for Interior Plastered Walls & Ceilings Miscellaneous Interior Brush Paint Finishes . Brush Work—Interior Trim . Brush Interior—Metal Work. .... - Patented Scaffolding Conversion Table~Minutes to Decimal HoursPREFACE It is not the intention of this manual to hold anything new for the top flight general construction estimator whose ability, know-how and knowledge in the Industry is the product of many years of schooling, actual competitive bidding, hard knocks and time-consuming analyses of both good and bad estimates. This type of estimator knows that to prepare an accurate labor estimate in dollar value one must first have @ basis or reason for the use of monetary units. Simply to say that a unit or block of work is worth so many dollars because it cost your company that on a previous project is absurd, ridiculous and tends to show the weakness of the inexperienced estimator, The purpose of this manual is to offer assistance or a basis, in direct labor manhours, for this type estimator. ‘The following direct Labor manhours, or in some cases, comparison percentages, are the product of obtaining many hundreds of time and methods and preptanned studies, coupled with actual cost of various operations both in the field and fabricating shops, on many varied types of large commercial and industrial pro- jects throughout the country, ranging in cost from $10,000 to $100,000,000. After careful analysis of these reports we found that a productivity of seventy (70) percent was a fair average for all crafts with the exception of brick masons whose productivity was equal to only fifty-five (55) percent. The direct labor manhour tables throughout this manual are based on these percentages. We do not attempt to define construction items or supply description or directions as to how a take-off should be made, or what quantity or quality of material make up a unit or block of work or how a particular unit or block of work should be constructed. Before anyone engaged in construction work becomes an estimator, even inexperienced, he must have some knowledge of this. Neither will you find any cost as to materials, equipment usage, warehousing, and storage, fabticating shop set-up or overhead. If a material take-off is avail- able this cost can be obtained, at current prices, from vendors who are to furnish the materials. Warehousing and storage, fabricating shop set-up, equipment usage and overhead can readily be obtained by a good estimator who can visual- ize and consider the job schedule size and location, These are items which can and must be considered for the individual project. Before an attempt is made to epply the following direct labor manhour tables we caution the estimator to be thoroughly familiar with the introduction on the following pages entitled “Production and Composite Rate”, which is the answer to this type of estimating, xINTRODUCTION Production and Composite Rate Here is the switch that will turn on the light and show the way to correct appli- cation of the many manhour tables that follow. There should be sound reasoning and understanding to back up @ monetary unit before it is applied to an item for labor value. The best reasoning that we know is manhours based on what we call productivity efficiency coupled with produc- tion elements. ‘ After comparison of many projects, constructed under varied conditions, we have found that production elements can be grouped into six different classifications and that production percentages can be classified into five different categories. ‘The six different classifications of production elements are: GENERAL ECONOMY PROJECT SUPERVISION LABOR RELATIONS JOB CONDITIONS EQUIPMENT WEATHER av eepr The five ranges of productivity efficiency percentages are: Type Percentage Range 1. Very low 10 through 40 2. Low 41 through 60 3. Average 61 through 80 4. Very good 81 through 90 5, Excellent 91 through 100 Since there is such a wide range between the productivity percentages, let us attempt to evaluate each of the six elements, giving an example with each, and see just how a true productivity percentage can be obtained.. GENERAL ECONOMY: This is nothing more than the state of the nation or area in which your project is to be constructed. The things that should be reviewed and evaluated under this category are: a. Business trends and outlooks b. Construction volume c, The employment situation Let us assume that after giving due consideration to these items you find them to be very good or excellent, This sounds good, but actually it means that your productivity range will be very low. This is due to the fact that with business being excellent the top supervision and craftsmen will be mostly employed and all that you will have to draw from will be inexperienced personnel. Because of this, in all probability, it will tend to create bad relationship between Owner representatives, Contract supervision, and the various craftsmen, thus making very unfavorable job conditions. On the other hand, after giving consideration to this element you may find the general economy to be of a fairly good average. Should this be the case, you should find that productivity efficiency tends to rise, This is due to the fact that under normal conditions there are enough good supervisors and craftsmen to go around, they are satisfied, thus creating good job conditions and under- standing for all concerned. We have found, in the past, that general economy of the nation or area where your project is to be constructed, sets off a chain sreaction to the other five elements. We, therefore, suggest that very careful consideration be given this item. As an example, to show how a final productivity efficiency percentage can be arrived at, let us say that we are estimating a project in a given area and after careful consideration of this element, we find it to be of a high average. Since it is of @ high average, but by no means excellent, we estimate our productivity percentage at seventy-five (75) percent. . PROJECT SUPERVISION: What is the calibre of your supervision? Are they well-seasoned and experienced? What can you afford to pay them? What supply do you have to draw from? Things that should be looked at and evaluated under this element are: a. Experience b. Supply c. Pay Like general economy this too must be carefully analyzed. If business normal, in all probability, you will be able to obtain good supervision, but if xiv