Foundry Encode

TABLE 5
CAPITAL COST SUMMARY

Estimated cost, Pesos
Item Description Equipment Material
1.0 Foundry Plant Building Area
1.01 Main Building - 10,325,512
1.02 Office/Change room - 248,166
1.03 Shop/Storage room - 523,193
1.04 Ferro-alloy Storage area - 1,065,273
1.05 Air compressor 1,569,615 163,662
1.06 Overhead Crane, 10 tons 3,111,450 -
Sub- Total 4,681,065 12,325,806
2.0 Sand Handling Area

2.01 Mix Muller Available 167,211
2.02 Air scrubber system 53,125 148,789
2.03 Shake-out machine, 7 T 1,866,376 5,760
2.04 Shake-out machine, 2 T Available 4,800
2.05 Core mix muller 264,516 47,642
2.06 14" dia. X 20' Screw Conveyor 482,976 23,448
2.07 10" W x 34" L Bucket elevator 190,204 119,520
2.08 24" W Conveyor No. 1 473,345 399,996
2.09 24" W Conveyor No. 2 1,625 99,378
2.10 18" W x 20 Single trough conveyor Available 2,160
2.11 Bin No. 1, 15 tons - 105,627
2.12 Bin No. 2, 15 tons - 159,566
2.13 Bin No. 3, 8 tons - 143,898
2.14 Overhead crane bridge, 5 tons Available Incl. in rehab cost
Sub- Total 3,332,167 1,427,795
3.0 Furnace area

3.01 2 Tons furnace Available Incl. in rehab cost
3.02 3 Tons furnace Available 476,511
3.03 Sump & make-up water tank - 94,869
3.04 Burner Laddle Pre-heater Available -
3.05 Cooling tower 507,035 40,128
3.06 Centrifugal Pump 420,530 4,800
3.07 Overhead crane, 2 tons Available Incl. in rehab cost
Sub- Total 927,565 616,308
4.0 Control room/heat treatment area

4.01 Cooling tower 507,035 59,706
4.02 Centrifugal water pump 420,530 8,160
4.03 Overhead crane, 5 T Available Incl. in rehab cost
4.04 Heat treatment oven Available 763,488
4.05 Quenching and water tank - 257,541
Sub- Total 927,565 1,088,895
5.0 Finishing area

5.01 Angle grinder 53,262 -
5.02 Welding Machine Available -
5.03 100" Karatsu Boring machine Available 123,749
5.04 48" Niles boring machine Available 20,058
5.05 Planer/Grinder Available 19,943
5.06 Overhead crane, 5 T Available Incl. in rehab cost
Sub- Total 53,262 163,750
6.0 Office & Change room

6.01 Computer units, 2 units Available -
6.02 Optical emission spectrometer/lab Available -
6.03 Fire extinguisher Available -
Sub- Total - -
7.0 Shop and storage area

7.01 Oven Available -
7.02 Electric drill Available -
7.03 Electric planer Available -
Sub- Total - -
8.0 Water supply

8.01 5.70 x 6.0 m High water tank - 459,264
8.02 Deep well pump 60,000 -
8.03 Water lines - 26,266
Sub- Total 60,000 485,530
9.0 Drainage canal - 2,665,185
10.0 Service road - 1,301,170
11.0 Equipment relocation / rehab

11.01 Equipment rehab - 739,013
11.02 Dismantling cost - -
11.03 Equipment relocation - -
Sub- Total - 739,013
12.0 Electrical
12.01 Transformer, 2 MVA Available -
12.02 IDMC Switchgear, 600 A, 5kV 2,244,886 -
12.03 IDMC Switchgear, 400 A, 5kV 1,981,370 -
12.04 Distribution transformer Available -
12.05 Transformer, 50 KVA 69,738 -
12.06 Low voltage switchgear 1,700,507 -
12.07 Station battery and charger 726,794 -
12.08 Motor Control Center #1 346,047 -
12.09 Motor Control Center #2 435,403 -
12.1 Substation - 907,716
12.11 Power distribution - 849,795
12.12 Lighting system - 362,305
12.13 Grounding & Splicing - 202,576
12.14 750 KW Furnace parts/rehab - 540,000
Sub- Total 7,504,745 2,862,392
13.0 Equipment installation - -
TOTAL 17,486,369 21,275,844
14.0 Construction overhead

14.01 Project management - -
14.02 Overhead cost - -
14.03 Security services - -
14.04 Office supplies - 10,000
14.05 Transportation - -
14.06 Accommodation - -
Sub- Total - 10,000
Grand Total 17,486,369 21,285,844

d cost, Pesos
Labor Total
6,977,026 17,302,538
167,901 416,067
346,673 869,866
718,645 1,783,918
104,803 1,838,080
- 3,111,450
8,315,048 25,321,919
112,034 279,245
99,012 300,296
3,840 1,875,976
3,200 8,000
31,922 344,080
16,192 522,616
80,240 389,964
266,664 1,140,005
66,252 167,255
1,520 3,860
65,368 170,995
101,519 261,085
96,036 239,934
Incl. in rehab cost -
943,799 5,703,761

524,170 1,000,681
63,246 158,115
- -
26,752 573,915
3,200 428,530
617,368 2,161,241
39,804 606,545
5,440 434,130
508,992 1,272,480
171,694 429,235
725,930 2,742,390
- 53,262
- -
302,062 425,811
47,524 67,582
42,246 62,189
391,832 608,844
- -
- -
- -
- -
- -
- -
- -
- -
308,096 767,360
- 60,000
5,180 -
313,276 858,806
230,710 495,895
860,960 2,162,130
413,203 1,152,216
1,267,425 1,627,425
493,400 493,400
2,174,028 2,913,041
- -
- 2,244,886
- 1,981,370
- -
- 69,738
- 1,700,507
- 726,794
- 346,047
- 435,403
100,096 1,007,812
142,994 992,789
71,497 433,802
47,665 250,241
39,883 579,883
402,135 10,769,272
1,436,880 1,436,880
16,411,966 55,174,179
126,000 126,000
2,816,878 2,816,878
135,000 135,000
- 10,000
20,700 20,700
28,000 28,000
3,126,578 3,136,578
19,538,544 58,310,757
TABLE 6
Equipment List
Item QTY
1.0 Foundry plant building area
1.01 Air Compressor 1
1.02 Overhead crane
1
2.0 Sand handling area

2.01 Mix Muller 1
2
2.02 Air scrubber or wet
dust collector
1
2.03 Shake out machine 1
2.04 Shake out machine 1
2.05 Core mix muller 1
2.06 Screw conveyor
1
2.07 Bucket elavator
1
2.08 Belt Conveyor No. 1
1
2.09 Belt Conveyor No. 2
1
2.10 Single trough
conveyor
1
2.11 Overhead crane
1
3.0 Furnace area

3.01 Furnace, 2 tons 1
3.02 Furnace, 3 tons 1
3.03 Burner Laddle Pre-
Heater
2
3.04 Cooling tower 1
3.05 Water Pump
2
3.06 Overhead crane
1
4.0 Control room/heat

treatment area
4.01 Cooling tower 1
4.02 Water pump 2
4.03 Overhead crane
1
4.04 Heat treatment oven
1
5.0 Finishing area

5.01 Angle grinder 4
5.02 Welding machine 2
2
1
5.03 Boring machine
1
5.04 Boring machine
1
5.05 Planer/Grinder
1
5.06 Overhead crane
1
6.0 Office & Change room

area
6.01 Optical emission
spectrometer and
accessories
1
6.02 King Brinell Hardness
tester
1
6.03 Metallurgical
microscope
1
7.0 Shop & storage area

7.01 Electric drill 1
7.01 Electric planer 1
8.0 Water supply

8.01 Deepwell pump 1
12.0 Electrical
12.01 Power transformer
1
12.02 Medium voltage
switchgear ( For main
Protection)
1
12.03 Medium voltage
switchgear (For furnace)
1
12.04 Distribution
transformer
3
12.05 Lighting transformer
1
12.06 Low voltage
switchgear
1
12.07 Station battery and
1
Automatic Battery charger
for 120 VDC Station battery
1
12.08 Motor control center
no. 1 (Foundry plant)
1
12.09 Motor control centr
no. 2 (Found Plant)
1
TABLE 6
Equipment List
Description
area
Screw type, 420 CFM capacity, 125 PSIG output pressure
Crab type, 10 tons capacity, 18.29 m span, 10.91 m lifting height with pendant control
switch and double box girder type bridge
750 kg capacity, Model MS-2FG driven by 30 KW, 220V/440V motor

450 kg capacity, Model1-1/2 FG driven by 15 KW motor
Model FDC-7, with 5.5 KW Exhauster motor, 70mCFM capacity, 250 mm Hg air
pressure, 0.4 KW pump motor and 500 liters water tank capacity
7000 kg capacity, Model SHO-7 driven by 7.5+D25 KW, 220V/440V motor
2000 kg capacity, Model SHO-15 driven by 11 KW, 220V/440V motor
100 kg Model MS-0.5S driven by 2.2 KW, 220V/440V motor
14" diameter x 20' long complete with bearing and sprocket driven by 5.5 KW motor
10" W Belt x 34" long x 10.45 m high complete with bearings, belt bucket, sprocket,
pulleys and take-up frame driven by 3.5 KW motor
24" W Belt x 18.62 m long complete with bearings, belt, pulleys, idlers, sprockets and
frame driven by 5.5 KW, 60 Hz geared motor
24" W Belt x 6.3 m long complete with bearings, belt, pulleys, idlers, sprockets and
frame driven by 2.2 KW motor
18" W Belt x 4.22 m long complete with bearings, belt, pulleys, rollers, sprockets and
frame driven by 3 KW motor
Crab type, 10 ton capacity, 18.29 m span, 10.91 m lifting height with pendant control
switch and monorail type bridge
750 KW, 440 V inductinig furnace complete with auxiliary motors and controls
750 KW, 2300V inductinig furnace complete with auxiliary motors and controls
Low pressure type, Series 580

1170 li/min capacity with 520 CFM air fan driven by 2.25 KW motor
Centrifugal type, 150 GPM capacity, 230 TDH, horizontal, driven by 18.5 KW motor
Trolley type, 2 tons capacity, 6.05 m span, 7.5 lifting with pendant control switch and
double box girder
1170 li/min capacity with 520 CFM air fan driven by 2.25 KW
Centrifugal type, 150 GPM capacity, 230 TDH, driven by 18.5 KW motor
Crab type, 5 tons capacity, 18.29 m span, 10.91 lifting with pendant control switch and
double box girder type bridge
Mhar brand, 440V, 3 phase with 350 CFM blower, 1/2 HP fuel pump, 7.5 KW bogie
drive and combustion control and accessories
8" diameter x 6000 RPM

400 amperes capacity
Karatsu vertical type boring machine, 100" complete with auxiliaries and controls, 11
KW table motor, 20 HP rail and drive motor, 220V, 3 phase, 60Hz
Niles vertical boring machine, 48' complete with 30 Hp table motor, 15 Hp rail motor
and controls, 440V, 3 phase, 60 Hz
Machine with 20 Hp Hydro pump motor, 25 Hp grinder motor, 5 Hp head motor, all
440V, 3 phase, 60 Hz
Crab type, 5 tons capacity, 18.29 m span, 10.91 lifting with pendant control switch and
doule box girder type bridge
Makita brand electric drill, 1125 RPM, 220V
Electric driven, 220V
1 Hp drive motor
2500 KVA, 3 phase, 60 Hz, 13,800-2400 for outdoor distribution 90KV BIL HV, 60 kV BIL
LV with +2 - 2-1/2% taps above and below normal voltage. This unit shall be consists of
top mounted HV bushings with connectors for ACSR & side mounted LV cable boxes
with connectors for copper conductor.
600 AT/600 AF, 5 kV, 3 PST, 100 KVAIC, Indooor metal clad in NEMA I free standing
enclosure. Breaker shall be either air-insulated (ACB) or vacuum breakers in drawn-out
type mounting. Protective relays & watthour meters shall be draw-out type.
Instruments shall be semi-flushed mounted.
400 AT/400 AF, 5 kV, 3 PST, 100 KVAIC, Indoor metal clad in NEMA I free stNDING
ENCLOSURE. Braker shall be either air-insulated (ACB) or vacuum breakers in drawn-out
type mounting. Protective relays & watthour meters shall be draw-out type. Instrument
shall be semi-flushed mounted.
333 KVA, 1 phase, 60 Hz, 4160Y/2400-460V, for outdoor distribution, 60 kV BIL HV & LV
with +2 - 2-1/2% taps above and below normal voltage. This unit shall consists of top
mounted HV bushings and side mounted LV cable boxes with connectors for copper
conductors.
50 KVA, 460-220/110V, 3 phase, dry type

480V, 3 phase, 60 Hz, 85 KAIC indoor type in NEMA I free standing enclosure. It shall
consists of the following: I -
Instrument, metering & bus entrance compartment I - Main
breaker, 3 pole, 2000 AT/2500 AF with short and long time delay pick-up
5 - Feeder breakers, 800
AT/800 AF, 3 Phase with short and long time delay pick-up
Each breaker shall draw-out mounted
fitted with disconnecting devices. Instrument compartment will consist of ammeter,
voltmeter, kilovar meter, PF meter and kilowatt-hour meter. Breakers shall be manually
operated with stored energy mechanisms. "SEIMENS" model.
120 VDC, nominal voltage, lead acid type in non-transparent plastic container complete
w/ connectors between coils. Battery shall have an 8 hour discharge rating fromfully
charged condition. Includes Hudrometer & thermometer for the electrolyte
230 VAC supply, 1 phase, 60 Hz. Output shall be adjustable from 1 to 10A. When the
battery is fully charged, the charger shall automatically change to trickle charging. It
shall include the following: a) Fused swtich on
AC side b) Pilot light to
indicate as voltage c) Fused switch
on DC side d) DC
ammeter to indicate charging rate e) DC
voltmeter w/ transfer switch to indicate either battery voltage or charger voltage
f) Adjustable resistor
or device operated from the front to adjust charging rate
460V, 3 phase, 60 Hz, indoor type in NEMA I free standing 1
- Instrument, metering & bus entrnace compartment 1-
Main breaker, 3 pole, 600 AT/600 AF, 85 KAIC
Branch circuits:
1 set - Combination circuit breaker & magnetic starter, auto-transformer type, 250
AT/400 AF MCCB, 42 KAIC & NEMA 2 FVNR, for 75 Hp motor 1 set -
Combination circuit breaker & magnetic starter, auto-transformer type, 150 AT/225 AF
MCCB, 42 KAIC & NEMA 3 FVNR, for 40 Hp motor 2 Sets - Combination
circuit breaker & magnetic starter, 60 AT/100 AF MCCB, 42 KAIC & NEMA 2 FVNR, for
15 Hp motor 5 sets - Combination circuit
breaker & magnetic starter, 30 AT/50 AF MCCB, 42 KAIC & NEMA I FVNR, for 7.5 Hp
motor 2 sets - Combination circuit breaker &
magnetic starte, 20 AT/50 AF MCCB, 42 KAIC & NEMA 0 FVNR, for 5.0 Hp motor
1 set - Combination circuit breaker & magnetic
starter, auto-transformer type, 15 AT/50 AF MCCB, 42 KAIC & NEMA 0 FVNR, for 3.0 Hp
motor 2 sets - Combination circuit breaker & magnetic starter,
auto-transformer type, 15 AT/50 AF MCCB, 42 KAIC & NEMA 00 FVNR, for 2.0 Hp motor
1 set - Combination circuit breaker & magnetic starter, auto-transformer
type, 15 AT/50 AF MCCB, 42 KAIC, 3 poles 2
units - Molded case circuit breaker, 60 AT/100 AF, 42 KAIC, 3 poles 2 units -
Molded case sircuit breaker, 150 AT/225 AF, 42 KAIC, 3 poles Instrument
compartment will consists of ammeter, voltmeter, kilowatt-hour meter, associated
transfer switches. Each branch circuit shall consists push buttons and pilot lights.
460V, 3 phase, 60 Hz, indoor type in NEMA I free standing 1
- Instrument, metering & bus entrnace compartment 1-
Main breaker, 3 pole, 600 AT/600 AF, 85 KAIC Branch
circuits: 1 set -
MCCB, 42 KAIC & NEMA 2 RVNR, for 50 Hp motor 2 sets - Combination circuit
breaker & magnetic starter, auto-transformer type, 175 AT/225 AF MCCB, 42 KAIC &
NEMA 3 FVNR, for 50 Hp motor 2 sets - Combination circuit breaker &
magnetic starter, 100 AT/100 AF MCCB. 42 KAIC & NEMA 3 FVNR, for 30 Hp motor
1 set - Combination circuit breaker & magnetic starter, 100
AT/100 AF MCCB, 42 KAIC & NEMA 2 FVNR, for 25 Hp motor
2 sets - Combination circuit breaker & magnetic starter 60 AT/100 AF
MCCB, 42 KAIC & NEMA 2 FVNR, for 15 Hp motor
5 sets - Combination circuit breaker & magnetic starter, auto-transformer type, 40
AT/50 AF MCCB, 42 KAIC & NEMA 1 FVNR, for 10 Hp motor 3 sets -
MCCB, 42 KAIC & NEMA 0 FVNR, for 3.0 Hp motor 4 sets - Combination
circuit breaker & magnetic starter, auto-transformer type, 15 AT/50 AF MCCB, 42 KAIC
& NEMA 0 FVNR, for 1.0 Hp motor 2 units - Molded case circuit breaker,
60 AT/100 AF, 42 KAIC, 3 poles 2 units - Molded case circuikt breaker,
150 AT/225 af, 42 KAIC, 3 poles Instrument compartment will consists of
ammeter, voltmeter, kilowatt-hour meter, associated transfer switches. Each branch
circuit shall consists push buttons and pilot lights.
Remarks
New
New
New
Available
New
New
Available
New
New
New
New
New
New
New
New
Available
New
New
New
New
New
New
Available
Available
New
New
Available
Available
Available
Available
Available
New
Available
Available
Available
New
New
New
Available
New
New
Available
New
New
New
New
New
New
Table 3
CASHFLOW PLAN
PROJECTE
ACTIVITIES 1
1 Foundry plant building area 3,514,200
2 Sand handling area -
3 Furnace area -
4 Heat treatment/control room area -
5 Finishing area -
6 Office & change room -
7 Shop & storage area -
8 Ferro-alloy area -
9 Water supply -
10 Drainage canal -
11 Service road -
12 LMD equipment relocation/rehab 728,260
13 Electrical -
14 Equipment purchase/installation 5,828,790
15 Construction/overhead 522,763
TOTAL 10,594,013
Table 3
CASHFLOW PLAN
PROJECTED MONTHLY CASH FLOW (PESOS)
2 3 4 5 6
3,514,200 3,514,201 3,514,201 3,514,201 -
- 592,898 592,898 592,898 592,899
- 411,225 411,225 411,226 -
- 453,706 453,706 453,706 453,707
- - 185,194 185,194 185,194
- - 138,689 138,689 138,689
- 289,955 289,955 289,956 -
- - 289,959 289,959 -
- - 399,403 399,403 -
- - 247,947 247,948 -
- - - 1,081,065 1,081,065
728,260 728,261 728,261 - -
652,905 652,905 652,905 652,906 652,906
5,828,790 6,307,749 478,960 478,960
522,763 522,763 522,763 522,763 522,763
11,246,918 13,473,663 9,508,066 9,860,874 3,627,223

TOTAL COST
17,571,003
2,371,593
1,233,676
1,814,825
555,582
416,067
869,866
1,783,918
798,806
495,895
2,162,130
2,913,042
3,264,527
18,923,249
3,136,578
58,310,757
Table 4
Unit cost of construction summary
Description Unit
Reinforced concrete, Class A (installed) Pesos per cubic meter
Plain concrete 1:2:4 (installed) Pesos per cubic meter
Structural steel and tanks (installed) Pesos per kilogram
Excavation Pesos per cubic meter
Perimeter Fence Pesos per meter
Equipment installation Pesos per tonne
Pipe (installed):
400 mm diameter Pesos per linear meter
Painting, installed per coat
Roofing including accessories, installed Pesos per square
Siding, installed meter
Carpentry — ceiling board, installed Pesos per square
Form works meter
Gratings, installation Pesos per square
Gate Valves, Installation cost: meter
350 mm diameter Pesos per square
250 mm diameter meter
150 mm diameter Pesos per square
100 mm diameter meter
Value
8,000
4,000
65
160
2,300
12,000
9,300
7,100
4,600
3,100
2,400
1,850
1,050
33
600
650
510
1,038
27
4,500
2,500
1,900
1,500
TABLE 1A
FINANCIAL ANALYSIS AT VARIABLE SELLING PR
ITEM YEAR 0 YEAR 1 YEAR 2 YEAR 3 YEAR 4
MONTHLY PRODUCTION 0.80 35,000 135,000 200,000 200,000
SELLING COST PER KG(P) 62.50 50.00 50.00 50.00 50.00
MONTHLY REVENUE(P) 1,750,000 6,750,000 10,000,000 10,000,000

YEARLY REVENUE(P) 21,000,000 81,000,000 120,000,000 120,000,000
CAPITAL EXPENDITURE(P) -58,310,757

OPERATING COST
MATERIAL & SUPPLIES COST
SCRAP COST 4.00 4.00 4.00 4.00
FERRO ALLOYS 9.49 9.49 9.49 9.49
MISCELLANEOUS MATLS 8.50 8.50 8.50 8.50
LABOR COST 6.21 3.18 2.35 2.35
POWER COST 5.77/kW-hr 18.00 15.84 20.26 20.26
DELIVERY COST 1.50 1.60 1.50 1.50
SUB-TOTAL 47.70 42.51 46.10 46.10
MONTHLY PRODUCTION COST 1,669,500 5,738,439 9,219,697 9,219,697
YEARLY PRODUCTION COST 20,034,000 68,861,274 110,636,370 110,636,370

DEPRECIATION COST 5,831,076 5,831,076 5,831,076 5,831,076
YEARLY OPERATING COST 25,865,970 74,692,350 116,467,446 116,467,446
NET INCOME BEFORE TAX -4,865,076 6,307,650 3,532,554 3,532,554
INCOME TAX (35%) 1,702,777 -2,207,678 -1,236,394 -1,236,394
NET INCOME -3,162,299 4,099,973 2,296,160 2,296,160
REVENUE AFTER COST -3,162,299 4,099,973 2,296,160 2,296,160
DEPRECIATION 5,831,076 5,831,076 5,831,076 5,831,076

NET CASH FLOW -58,310,757 2,668,777 9,931,049 8,127,236 8,127,236
PROJECT IRR 5%
PAYBACK PERIOD (YEAR) 7.62
TABLE 1A
NALYSIS AT VARIABLE SELLING PRICE
YEAR 5 YEAR 6 YEAR 7 YEAR 8 YEAR 9 YEAR 10 TOTAL
200,000 200,000 200,000 200,000 200,000 200,000 1,770,000
50.00 50.00 50.00 50.00 50.00 50.00
10,000,000 10,000,000 10,000,000 10,000,000 10,000,000 10,000,000

120,000,000 120,000,000 120,000,000 120,000,000 120,000,000 120,000,000 1,062,000,000
4.00 4.00 4.00 4.00 4.00 4.00

9.49 9.49 9.49 9.49 9.49 9.49
8.50 8.50 8.50 8.50 8.50 8.50
2.35 2.35 2.35 2.35 2.35 2.35
20.26 20.26 20.26 20.26 20.26 20.26
1.50 1.50 1.50 1.50 1.50 1.50
46.10 46.10 46.10 46.10 46.10 46.10
9,219,697 9,219,697 9,219,697 9,219,697 9,219,697 9,219,697
110,636,370 110,636,370 110,636,370 110,636,370 110,636,370 110,636,370 973,966,233

5,831,076 5,831,076 5,831,076 5,831,076 5,831,076 5,831,076 58,310,760
116,467,446 116,467,446 116,467,446 116,467,446 116,467,446 116,467,446 1,032,296,993
3,532,554 3,532,554 3,532,554 3,532,554 3,532,554 3,532,554 29,703,007
-1,236,394 -1,236,394 -1,236,394 -1,236,394 -1,236,394 -1,236,394 -10,396,052
2,296,160 2,296,160 2,296,160 2,296,160 2,296,160 2,296,160 19,306,955
2,296,160 2,296,160 2,296,160 2,296,160 2,296,160 2,296,160 19,306,955
5,831,076 5,831,076 5,831,076 5,831,076 5,831,076 5,831,076 58,310,760

8,127,236 8,127,236 8,127,236 8,127,236 8,127,236 8,127,236 77,617,715
MANPOWER REQUIRMENTS
The manpower requirements of the proposed Foundry Plant during the 1st year of operation is estimated at 23 men.
As production increases on the 2nd year, the manpower required will be 51 men. It is expected to reach and normalize
at 60 men on then 3rd to the 10th year depending on the market demand. Table 2 shows the manpower requirement
of the project as well as the manpower distriibution.
TABLE 2
MANPOWER REQUIRMENTS
NO DESIGNATION YEAR 1 YEAR 2
PRODUCTION (TONNE/MONTH) 35 135
1 Foundry manager 1 1
2 Secretary 1 1
3 Salesman 1 1
4 Draftsman/estimator 1 1
5 Warehouseman foundry foreman 1 1
6 Foundry foreman 1 1
7 Foundry shift supervisors 0 2
8 Quality control supervisor 1 1
9 Production planning and control 0 1
10 Quality control technician 1 3
11 Foundry leadman 1 5
12 Foundryman A 8 8
13 Foundryman B 2 10
14 Finishing/heat treatment/machining 0 9
15 Patternmaker 1 3
16 Plant mechanic/electrician
17 Security guard 3 3
SUB-TOTAL 23 51
MANPOWER DISTRIBUTION AT YEAR 1

No. Designation 1st Shift 2nd Shift
1 Foundry manager 1
2 Secretary 1
3 Salesman 1
4 Draftsman/estimator 1
5 Warehouseman 1
6 Foundry foreman 1
7 Foundry shift supervisor 0 0
8 Quality control supervisor 1
10 Quality control technician 1
11 Foundry leadman 1
12 Foundryman A 8
13 Foundryman B 2
14 Finishing/Heat treatment/Machining 0 0
15 Patternmaker 1
SUB-TOTAL (Basic) 1 21
OT/VL/SL/13TH MP/BONUS/COLA/PAG-IBIG/SSS/ECC/MED/OTHER BENEFITS
TOTAL LABOR COST

LABOR COST PER KG
MANPOWER DISTRIBUTION AT YEAR 2

1 Foundry manager 1
2 Secretary 1
3 Salesman 1
5 Warehouseman 1
6 Foundry foreman 1
12 Foundryman A 6 6
13 Foundryman B 2 2
15 Patternmaker 1 1
TOTAL LABOR COST

LABOR COST PER KG
MANPOWER DISTRIBUTION AT YEAR 3 TO 10

1 Foundry manager 1
2 Secretary 1
3 Salesman 1
5 Warehouseman 1
6 Foundry foreman 1
12 Foundryman A 6 6
13 Foundryman B 4 4
15 Patternmaker 1 1
TOTAL LABOR COST

LABOR COST PER KG
on is estimated at 23 men.
cted to reach and normalize
he manpower requirement
YEAR 3
200
1
1
1
1
1
1
2
1
1
3
5
8
19
9
3
3
60
3rd Shift Total Basic rate Monthly total

1 20,000.00 20,000.00
1 6,000.00 6,000.00
1 8,500.00 8,500.00
1 7,500.00 7,500.00
1 6,500.00 6,500.00
1 12,000.00 12,000.00
0 0- -
1 10,00.00 10,00.00
0 0- -
1 6,500.00 6,500.00
1 5,850.00 5,850.00
8 5,070.00 40,560.00
2 4,810.00 9,620.00
0 0- -
1 5,200.00 5,200.00
0- -
1 3 4,805.83 4,805.83
1 23 152,647.49
42.30% 64,569.89
217,217.38
6.21

1 20,000.00 20,000.00
1 6,000.00 6,000.00
1 8,500.00 8,500.00
1 7,500.00 7,500.00
1 6,500.00 6,500.00
1 12,000.00 12,000.00
1 2 8,500.00 17,00.00
1 10,00.00 10,00.00
0 0- -
1 6,500.00 6,500.00
1 5,850.00 5,850.00
6 18 5,070.00 91,260.00
2 6 4,810.00 28,860.00
3 9 4,810.00 43,290.00
1 3 5,200.00 15,600.00
0- -
1 3 4,805.83 14.417.49
14 51 301,777.49
42.30% 127,652.00
429,429.49
3.18

1 20,000.00 20,000.00
1 6,000.00 6,000.00
1 8,500.00 8,500.00
1 7,500.00 7,500.00
1 6,500.00 6,500.00
1 12,000.00 12,000.00
1 2 8,500.00 17,00.00
1 10,00.00 10,00.00
0 1 8,500.00 8,500.00
1 6,500.00 6,500.00
1 5,850.00 5,850.00
6 18 5,070.00 91,260.00
4 12 4,810.00 57,720.00
3 9 4,810.00 43,290.00
1 3 5,200.00 15,600.00
0- -
1 3 4,805.83 14,417.49
16 57 330,637.49
42.30% 139,860.00
470,497.49
2.35
CAPITAL EXPENDITURE
The total capital requirement of the Foundry Project is FIFTY EIGHT MILLION THREE HUNDRED TEN THOUSAND EIGHT HUNDR
Equipment = P17,486,369.00
Material = 21,286,844.00
Labor = 19,538,544.00
Total = P58,310,800.00
The project capital cost were estimated based on the general layout, flowsheets, specifications, quotations from suppliers, in-h
The projected monthly cash flow requirements for the six months construction period is shown in Table 3.
Table 4 shows the unit cost of construction used in the cost estimate. The equipment list is shown in table 5.
The capital cost summary is shown in Table 6. The equipment cost is shown in Table 7. The material and labor cost estimate is
D TEN THOUSAND EIGHT HUNDRED PESOS(P 58,310,800.00) summarized as follows:
ns, quotations from suppliers, in-house knowledge of construction cost and productivities experienced in the foundry and construction ind
wn in Table 3.
hown in table 5.
aterial and labor cost estimate is shown in Tbale 8. The Equipment capital and installation cost estimate is shown in Table 9.
e foundry and construction industry.
hown in Table 9.
ITEM DESCRIPTION QUANTITY
14.0 CONSTRUCTION OVERHEAD
PROJECT MANAGEMENT (6 MONTHS)
14.01
Manager = 15% x P100,000.00 x 6 months
Others = 15% x P40,000.00 x 6 months
14.02 OVERHEAD COST

Installation permit 42 units
DENR inspection 6 days
Construction power 505,920 kW-hr
14.03 SECURITY SERVICES

6 months x 30 days/month x P750.00/day
14.04 OFFICES SUPPLIES

1 lot x P10,000.00
14.05 TRANSPORTATION
Rental 18 days
14.06 ACCOMMODATION
Lodging
Meals 20 times
20 tmes
TOTAL CONSTRUCTION OVERHEAD
B. LABOR COST
1 - Electrical supervisor 10 days
1 - Electrical capataz 10 days
5 - Lineman/electrician 10 days
4 - Project employee 10 days
Total labor cost
5. 750 KW FURNACE PARTS/REHAB

A. MATERIAL COST
Station contact, 148-6203-7 10 pcs
Contact tip, 148-6204-5 10 pcs
Primary capacitor, 19-F-487 1 pc
Secondary fine trq capacitor 2 pcs
Capacitor course, 300 KVAR 2 pcs
Capacitor switches, No. 1490108 1 pc
Main connector tips, No. 316B-948 6 pcs
Main line fuse, 390A, No. 1F161 2 pcs
Fuse, 10A, 250V, No. 161-03 12 pcs
Micro switch, 250W, 15A 3 pcs
Fuse, 15A, 250V, No. 161-02 12 pcs
Fuse, 16A, 600V, No. 161-06 10 pcs
Lamp, 10W, 230V, No. 165-06 3 pcs
Overvoltage, No. 155-1041-5 1 pc
Tip kit, 461A 759017 1 pc
Rectifier, 6A, 230V 2 pcs
Micro switch, 15A 1 pc
Contactor coils, 148 2 pcs
CR9500 solenoid assembly AC & DC service, GE 2 pcs
CR9500 C100CA51A, pull type, coil, 115V 2 pcs
Throat mounted, stroke, 60 Hz, 1-inch max PN 128 2 pcs
Total material cost 1 lot
B. LABOR COST
1 - Electrical capataz 20 days
3 - Lineman/electrician 20 days
TOTAL ELECTRICAL
13.0 EQUIPMENT INSTALLATION
TOTAL MATERIAL AND LABOR COST

UNIT COST TOTAL COST
P 90,000.00
36,000.00
P 126,000.00
170 P 7,140.00
2,000.00 12,000.00
5.53 2,797,738.00
P 2,816,878.00
P 135,000.00
P 10,000.00
1,150.00 P 20,700.00
900.00 18,000.00
500.00 10,000.00
p 28,000.00
P 3,136,578.00
963.00 P 9,630.00
510.27 5,103.00
494.64 24,732.00
205.00 8,200.00
P 47,665.00
540,000.00 P 540,000.00
510.27 P 10,205.00
494.64 29,678.00
P 39,883.00
p 3,264,527.00
p 1,436,880.00
P 37,622,046.00
Table 9
Equipment capital and Installation cos
EXTENDED
UNIT COST COSTMEX- OCEAN
EX-WORKS WORKS (US FREIGHT
ITEM DESCRIPTION QTY (US $) $) (US $)
1 FOUNDRY PLANT BUILDING AREA

Compressor, 400 CFM, 100 PSIG 1
Overhead crane, crab type, 10 tons 1 48,100 3,615
Sub-total 2
2 SAND HANDLING AREA
Mix muller, 900 kg capacity 1 34,000 3,400
Air scrubber fan, 1-1/2 Hp 1
Shake-out machine, 7000 kg capacity 1 28,300 2,830
Shake-out machine, 2000 kg capacity 1
Core mixer muller, 100 kg capacity 1 4,000 400
14" dia x 20' Screw conveyor 1
10" W x 34" Bucket elevator 1
24" W Conveyor no. 1 1
24" W Conveyor no. 2 1 3,760
18" W Single trough conveyor 1
Overhead crane, crab type, 5 tons 1
Sub-total 11 70,060 6,630
3 FURNACE AREA
Furnace, 2 tons 1
Furnace, 3 tons 1
Burner laddle pre-heater 2
Cooling tower 1
Centrifugal water pump 2 3,500
Overhead crane, crab type, 2 tons 1
Sub-total 8 3,500
4 HEAT TREATMENT AREA
Cooling tower 1
Centrifugal water pump 2 3,500
Overhead crane, 5T 1
Heat treatment oven 1
Sub-total 5 3,500 0
5 FINISHING AREA
Angle grinder 4 214
Welding machine 2
100" Karatsu boring machine 1
48" Niles boring machine 1
Planer/grinder 1
Overhead crane, 5 tons 1
Sub-total 10 214
6 OFFICE & CHANGE ROOM
Optical emiision spectrometer 1
Computer 2
Fire extinguisher 1
Sub-total 4
7 SHOP & STORAGE AREA
Oven 1
Computer 1
Fire extinguisher 1
Sub-total 3
8 WATER SUPPLY
Deep well pump 1
Sub-total 1
9 ELECTRICAL
Power transformer, 2.5 MVA 1
IDMC Switchgear, 600 A, 5 KV 1 34,000 34,000 3,400
IDMC Switchgear, 400 A, 5 KV 1 30,000 30,000 3,000
Distribution transformer, 333 KVA, 1 Ph 3
Transformer, 50 KVA, 460V/220V, 3 Ph 1 1,154 1,154
Low voltage switchgear 1 28,302 28,302
Station battery and charger 1 11,000 11,000 1,100
Motor control center #1, Foundry plant 1 5,705 5,705
Motor control center #2, Foundry plant 1 7,197 7,197
Sub-total 11 117,358 117,358 7,500
TOTAL 55 194,632 117,358 14,130

Equipment spares
GRAND TOTAL
Table 9
t capital and Installation cost estimate
TAXES & TOTAL W/

TOTAL FOREX DUTIES TAXES & FREIGHT TO LANDED
C&F MLA 1US$=P TOTAL (PESOS) DUTIES WEIGHT SITE COST
(US $) 53.00 (PESOS) @ 13% (PESOS) (TONNES) P2,500/Mt (PESOS)
26,000 1,378,000 179,140 1,557,140 4.99 12,475 1,569,615

51,815 2,746,195 357,005 3,103,200 3.30 8,250 3,111,450
77,815 4,124,195 536,145 4,660,340 20,725 4,681,065
Available 1.20 Available

1,000 53,000 53,000 0.05 125 53,125
31,130 1,694,890 214,486 1,864,376 0.80 2,000 1,866,376
4,400 233,200 30,316 263,516 0.40 1,000 264,516
7,950 421,350 54,776 476,126 2.74 6,850 482,976
3,568 189,104 189,104 0.44 1,100 190,204
8,865 469,845 469,845 1.40 3,500 473,345
5,175 274,275 0.65 1,625 1,625
Available Available
62,088 3,290,664 299,577 3,315,966 16,200 3,332,166

Available Available
9,520 504,560 504,560 0.99 2,475 507,035
7,000 371,000 48,230 419,230 0.26 1,300 420,530
16,520 875,560 48,230 923,790 3,775 927,565
9,520 504,560 504,560 0.99 2,475 507,035

7,000 371,000 48,230 419,230 0.26 1,300 420,530
16,520 875,560 48,230 923,790 3,755 927,565
854 45,262 45,262 0.80 8,000 53,262

854 45,262 45,262 8,000 53,262
Available Available
Available Available
Available Available
Available Available
Available 0 Available
Available 0 Available
- -
60,000 60,000 0.08 60,000

60,000 60,000 60,000

37,400 1,982,200 257,686 2,239,886 2.00 5,000 2,244,886
33,000 1,749,000 227,370 1,976,370 2.00 5,000 1,931,370
1,154 61,162 7,951 69,113 0.25 625 69,738
28,302 1,500,006 195,001 1,695,007 2.20 5,500 1,700,507
12,100 641,300 83,369 724,669 0.85 2,125 726,794
5,705 302,365 39,307 341,672 1.75 4,275 346,047
7,197 381,441 49,587 431,028 1.75 4,375 435,403
124,858 6,617,474 860,272 7,477,746 27,000 7,504,746
298,655 15,888,715 1,792,454 17,406,894 79,475 17,486,369

INSTALLATION
COST P12,000/Mt
59,880
39,600
99,480
14,400
600
9,600
4,200
4,800
32,880
5,280
16,800
7,800
35,160
131,520
91,200
136,800
11,880
6,240
14,040
260,160
11,880
6,240
35,160
60,000
113,280
38,400
1,920
241,200
37,560
31,200
35,160
385,440
960
960
100,440
24,000
24,000
216,000
3,000
26,400
10,200
21,000
21,000
446,040
1,436,880
TABLE 8 MATE
ITEM
1
1.01
B.
2
3
1.02
7
B.
1.03
4
5
B.
1.04
A.
1
2
6
7
1.05
4
5
2.01
2.02
2.03
A
2.04
2.05
2.06
A
B
A
2.09
2.1
2.11
A
2.12
2.12
3
3.01-3.02
3.03
3.04
3.05
B
A
3.06
B
4.01
4.02
4.03
4.04
4.05
5
5.01
5.02
5.03
5.04
5.05
B
6.0
7.0
8.0
1
1
5
4
1
1
5
4
1
1
5
4
TABLE 8 MATERIAL AND LAB
DESCRIPTION
FOUNDRY PLANT BUILDING AREA:
MAIN BUILDING
MATERIAL COST
EARTHWORKS
Excavation
Backfill
Fill Material
CONRETE & MASONRY WORKS

Heavy reinforced concrete, Class A
Light reinforced concrete, Class A
Masonry works (4" x 8" x 16" CHB)
STRUCTURAL STEELS, A36

Weight
CARPENTRY WORKS
Area
TINSMITHRY WORKS
Roof
Cladding
PAINTING WORKS
Area
CYCLONE WIRE WALLS

Area
LABOR COST
EARTHWORKS
Excavation
Backfill
Fill Material

Heavy reinforced concrete, Class A
Light reinforced concrete, Class A
Masonry works (4" x 8" x 16" CI•IB)
Weight
CARPENTRY WORKS
Area
TINSMITHRY WORKS
Roof
Cladding
PAINTING WORKS
Area
CYCLONE WIRE WALLS

Area
OFFICE/CHANGE ROOM:
A. MATERIAL COST
EARTHWORKS
Excavation
Backfill

Reinforced concrete, Class A
Glazing, Ceramic Tiles

Weight
CARPENTRY WORKS
Area
PAINTING WORKS
Area
STEEL CASEBIENT WINDOWS

Area
COMFORT ROOM SHOWCASE (complete with

Rough Plumbing and Waterlines)
Area
LABOR COST
EARTHWORKS
Excavation
Backfill

Reinforced concreter Class A
Glazing, Ceramic Tiles

Weight
CARPENTRY WORKS
Area
PAINTING WORKS
Area
STEEL CASEMENT WINDOW INSTALLATION

Area
COMFORT ROOM SHOWCASE INSTALLATION

(complete with Rough Plumbing and Waterlines)
Area
PATTERN SHOP/CORE ROOM LABORATORY
MATERIAL COST
EARTHWORKS
Excavation
Backfill


Weight
CARPENTRY WORKS
Area
TINSMITHRY WORKS
Roofing
Cladding
STEEL CASEMENT WINDows

Area
PAINTING WORKS
Area
LABOR COST
EARTHWORKS
Excavation
Backfill


Weight
CARPENTRY WORKS
Area
TINSMITHRY WORKS
Roofing
Cladding
STEEL CASEMENT WINDOWS

Area
PAINTNG WORKS
Area
FERRO-ALLOY STORAGE AND FURNACE
MATERIAL COST
EARTHWORKS
Excavation
Backfill


Weight
INSMITHRY WORKS
Roofing
Cladding
PAINTING WORKS
Area
CYCLONE WIRE WALLS

Area
CARPENTRY
Area
B. LABOR COST
EARTHWORKS
Excavation
Backfill

Masonry works (4" x 8" x 16" CID)

Weight
TINSMITHRY WORKS
Roofing
Cladding
PAINTING WORKS
Area
CYCLONE WIRE WALLS

Area
CARPENTRY WORKS
Area
AIR COMPRESSOR
A. MATERIAL COST
EARTHWORKS
Excavation
Backfill
CONRETE WORKS
Area
STRUCTURAL STEELS, A.36

Weight
TINSMITHRY WORKS
Roofing
Cladding
PAINTING WORKS
Area
PIPE INSTALLATION
2" dia. x 20' long Sch. 40 Bl Pipe
2" dia. Gate Vlave
2" dia. x 900 Elbow
2" dia. BI Tee
B. LABOR COST
EARTHWORKS
Excavation
CONRETE WORKS
Ärea

Weight
TINSMITHRY WORKS
Roofing
Cladding
PAINTING WORKS
Area
PIPE INSTALLATION
TOTAL FOUNDRY PLANT BLDG. AREA
SAND HANDLING AREA
MIX MULLERS
MATERIAL COST
Concrete Works
Steelworks
Painting Works
LABOR COST
Concrete Works
Steelworks
Painting Works
Excavation
Backfill
AIR SCRUBBER SYSTEM
MATERIAL COST
Concrete Works
Steelworks
Painting Works
Gl Pipe, 1" dia. x 20'
Gl Elbow, 1" dia. x 900
Gate Valve, 1" dia.
LABOR COST
Concrete Works
Steelworks
Painting Works
Excavation and Backfill
I 't Pipe Installation
SHAKE-OUT MACHINE, 7 Tons

MATERIAL COST
Concrete Works
LABOR COST
Concrete Works
SHAKE-OUT MACHINE, 2 Tons
MATERIAL COST
Concrete Works
LABOR COST
Concrete Works
CORE MIX MULLER, 100 kg
MATERIAL COST
Concrete Works
Steelworks
Painting Works
LABOR COST
Concrete Works
Steelworks
Painting Works
14" DIA. X 20' SCREW CONVEYOR

MATERIAL COST
Concrete Works
Steelworks
Painting Works
LABOR COST
Concrete Works
Steelworks
Painting Works
2.07 10" W x 34" LONG BUCKET ELEVATOR
A. MATERIAL COST
Concrete Works
Steelworks
Painting Works
B. LABOR COST
Concrete Works
Steelworks
Painting Works
2.08 24" W CONVEYOR NO. 1
MATERJAL COST
Concrete Works
Steelworks
Painting Works
LABOR COST
Concrete Works
Steelworks
Painting Works
24" W CONVEYOR NO. 2
MATERIAL COST
Concrete Works
Steelworks
Painting Works
LABOR COST
Concrete Works
Steelworks
Painting Works
18" W x 200 SINGLE TROUGH CONVEYOR
MATERIAL COST
Concrete Works
LABOR COST
Concrete Works
BIN NO. 1, 15 Tons

MATERIAL COST
Concrete Works
Steelworks
Painting Works
4" dia. x 24-1/2" long Air Cylinder Gate
LABOR COST
Concrete Works
Steelworks
Painting Works
Cylinder Installation
BIN No. 2, 15 Tons
MATERIAL COST
Concrete Works
Steelworks
Painting Works
4" dia. x 24-1/2"
LABOR COST
Concrete Works
Steelworks
Painting Works
long Air Cylinder Gate
4" dia. Cylinder Installation
BIN NO. 3, 8 Tons
MATERIAL COST
Concrete Works
Steelworks
Painting Works
LABOR COST
Concrete Works
Steelworks
Painting Works
FURNACE SECTION
FURNACE, 2 Tons and 3 Tons
MATERIAL COST
Concrete Works/Foundation
Steelworks/Platforms
LABOR COST
Concrete Worksmoundation
Steelworks/Platforms
Earthworks
Excavation
Backfill
Freight
Dismantling
3.03 SUMP AND MAKE-UP WATER TANK
MATERIAL COST
Concrete Works
Steelworks
LABOR COST
Concrete Works
S teelworks
3.04 BURNER LADDLE PRE-HEATER
COOLING TOWER
MATERIAL COST
Concrete Works
LABOR COST
Concrete Works
CENTRIFUGAL
MATERIAL COST
Concrete Works
LABOR COST
Concrete Works
CONTROL ROOM/HEAT TREATMENT AREA

4.01 COOLING TOWER
A, MATERIAL COST
Concrete Works
Steelworks
B. LABOR COST
Concrete Works
Steelworks
4.02 CENTRIFUGAL WATER PUMP
MATERIAL COST
Concrete Works
LABOR COST
Concrete Works
4.03 5 TONS OVERHEAD CRANE
4.04 HEAT TREATMENT OVEN
MATERIAL COST
Concrete Works
Steelworks
LABOR COST
Concrete Works
Steelworks
QUENCHING AND WATER TANK
MATERIAL COST
Concrete Works
Steelworks
LABOR COST
Concrete Works
Steelworks
TOTAL CONTROL ROOM/ HEAT TREATMENT AREA
FINISHING AREA
ANGLE GRINDER
WELDING MACHINE
100" KARATSU BORING MACHINE
MATERIAL COST
Concrete Works
Steelworks
Carpentry Works
LABOR COST
Concrete Works
Steelworks
Carpentry Works
Excavation
Backfill
Freight
Dismantling
48" NILES BORING MACHINE
MATERIAL COST
Concrete Works
Steelworks
Carpentry Works
LABOR COST
Concrete Works
Steelworks
Carpenty Works
Excavation
Freight
Dismantling
PLANER/GRINDER
MATERIAL COST
Concrete Works
Steelworks
Carpentry Works
LABOR COST
Concrete Works
Steelworks
Carpentry Works
Excavation
Freight
Dismantling
OFFICE & CHANGE ROOM
SHOP & STORAGE AREA
WATER SUPPLY
8.01 5.70 X 6.0 M HIGH WATER TANK
A. MATERIA!, COST
1. EARTHWORKS
Excavation
2. CONRETE WORKS
Volume
3. STRUCTURAL STEELS, A36
Weight
4. PAINTING WORKS
Area
B. LABOR COST
1. EARTHWORKS
Excavation
2. CONRETE WORKS
Volume
3. STRUCTURAL STEELS, A36
Weight
4. PAINTING WORKS
Area
8.02 DEEP WELL PUMP
8.03 WATER LINES
MATERIAL COST
2" dia. x 90˚ BI elbow
2" dia. Gate valve
2" dia. x Bl Tee
I " dia. x 20' long Sch. 40 Bl Pipe
l" dia. x 900 Gl Elbow
1" dia Gate valve
3/4" dia. x 20' long Sch. 40 GI Pipe
3/4" dias x 90 Gl Elbow
3/4" dia. Gate Valve
3/4" dia. GI Coupling
LABOR COST
2" dim x 20' long Sch. 40 BI Pipe
l" dia. x 20' long Sch. 40 BI Pipe
3/4" dia. x 20' long Sch. 40 GI Pipe
TOTAL WATER SUPPLY
DRAINAGE CANAL
A. MATERIAL COST
1. EARTHWORKS
Excavation
Backfill
2. CONRETE AND MASONRY WORKS

LABOR COST
1. EARTHWORKS
Excavation
Backfill

SERVICE ROAD
Length
MATERIAL COST
1. EARTHWORKS
Excavation
Backfill
Gravel Ballast
2. CONRÉTE WORKS
LABOR COST
1. EARTHWORKS
Excavation
Backfill
Gravel Ballast

TOTAL SERVICE ROAD

EQUIPMENT RELOCATION / REHAB
11.01 EQUIPMENT REHAB COST
MATERIAL COST
MIX MULLERS, 2 Tons

Painting Works
18" W X 200 SINGLE TROUGH CONVEYOR

Mechanical Patts
Steelworks
Paintinig Works
3. OVERHEAD CRANE, 5 Tons

Steelworks, Bridge
Painting Works
'FURNACE, 2 Tons
Parts
FURNACE, 3 Tons
Parts
B, LABOR COST
MIX MULLERS, 2 Tons

Paintinig Works
18" w x 20 SINGLE TROUGH CONVEYOR

Mechanical Patts
St.eelworks
Paintinig Works
3. OVERHEAD CRANE, 5 Tons - 3 units

Steelworks, Bridge
Painting Works
4. OVERHEAD CRANE, 2 Tons

Steelworks, Bridge
Painting Works
FURNACE, 2 Tons
1 - Electiical Capaiaz
3 - Electrician
FURNACE, 3 Tons
I - Electrical Capataz
3 - Electrician
11,02 EQUIPMENT DISMANTLING
A. MATERIAL COST
B. LABOR COST
Mix Muller, 900 kgs

Shake-out Machine, 2 Tons
Overhead Crane, 5 Tons (3 t 'nits)
Overhead Crane, 2 Tons
Fumace, 2 Tons
Burner Laddle Pre-heater
Heat Treatment Oven
100" Karatsu Boring Machine
48" Niles Boring Machine
Planer/Grinder
Total Labor Cost
11.03 EQUIPMENT RELOCATION
A. MATERIAL COST
B. LABOR COST
Mix Muller, 900 kgs
Shake-out N/lachine,. 2 Tons
Overhead Crane, 5 Tons (3 units)
Overhead Crane, 2 Tons
Furnace, 2 Tons (LMD)
Furnace, 2 Tons ('Ex, AG&P)
3 Tons (Ex, AG P)
Bumer Laddle Pre-healer
100" Karatsu Boring Machine
48" Niles Boring Machine
Planer/Grinder
Power Transformer
Distribution Transformer
TOTAL EQUIPMENT RELOCATION/REHAB
ELECTRICAL
12.01 SUBSTATION
A. MATERIAL COST
Air break switch, manually group operated, 200 A,

14.4 k V class, continuous ratings 3 PST outdoor type
Power fuse, 200 A, 14.4 kv class, 400 MVAIC, outdoor installation
Power fuse, 300 A, 5 kv class, 400 MVAIC, outdoor installation
Lightning arrester, station type, 14.4 KV class, outdoor mounting
Lightning arrester, station type, 5 KV class, outdoor mounting
Power cable, 300 MCM, 5 type MV-90, XLPE insulated single
Power cable, 4/0 AWG, 5 KV, MV-90, XLPE insulated single
Stranded copper conductor , 100mm² THW 600 VAC single Insulated
Rigid Steel Conduit coupline, 80 mm dia. x 3 m
Rigid Steel Conduit Elbow , 80 mm dia x 90°
Rigid Steel Conduit Locknut and Bushing 80 mm dia
Terminal kit, for 200-400 MCM power cable outdoor use cold shrink
Terminal lug, compression type, long barrel, 1 hole 300 MCM cable
Terminal lug, compression type, long barrel, 1 hole for 4/0 AWG cable
Top pole insulator, 14 KV class, outdoor mounting
Bolt & nut, stainless steel, 3/8" dia. x 1-1/2" L complete with lock washer
Cable ties, standard, 0.18" W x 12" long, 100 pcs/bag
Nikolite Soldering Bar, 50/50
Soldering Paste
Weatherproof service entrance cap, 80 mm hub size
LABOR COST
Electrical Supervisor
Electrical Capataz
Lineman/Electrician
Project Employee
12.02 POWER DISTRIBUTION
A. MATERIAL COST
Stranded copper conductor, 150 mm2 THW, 600 VAC, single insulated
Stranded copper conductor, 125 mm2 THW, 600 VAC, single insulated
Stranded copper conductor, 38 mm2 THW, 600 VAC, single insulated 150m/roll
Power cable, 400 MCM, 5 kV XLPE insulated,
PVC jacketed, single conductor
Royal cable, 80 mm2, 3/C, 600 VAC, 75 m/roll
Royal cable, 5.5 mm2, 3/C, 600 VAC, 75 m/roll
Royal cable, 3.5mm2 3/C, 600 VAC, 75 m/roll
Control cable, stranded, AWG/6C, 600 VAC, colored, 300 m/roll
Rigid steel conduit w/ coupling, 15 mmdia. x 3 m
Rigid Steel Conduit, elbow, 15 mm dia. x 90 degrees
Rigid Steel Conduit, locknut & bushing, 15 mm dia-
Rigid Steel Conduit, locknut & bushing, 25 mm dia.
Rigid Steel Conduit, locknut & bushing, 40mm dim
Liquid tight flexible conduit w/ PVC cover, 15 mm dia.
Liquid tight flexible conduit w/ PVC cover, 25 mm dia-
Liquid tight flexible conduit w/ PVC cover, 40 mm dia.
Liquid tight flexible conduit connector, straight type, 15 mm C
Liquid tight flexibie conduit connector, straight type, 25 mm
Liquid tight flexible conduit connector, straight type, 40 mm
Condulet bodies, form 85 series, aluminum, threaded type,type LL. 15 mm hub size
Terminal lug, compression type, long barrel, one hole in pad for 250 MCM 300 MCM copper
Terminal lug, compression type, long barrel, one hole in pad for #6 - # I AWG copper
Cable ties, miniature, 0.1" width x 6" long, 100 pcs/bag
Cable ties, standard, 0.18" width x 12" long, 100 pcs/bag
Pushbutton station, start-stop w/ indicating light, in NEMA 3R enclosure
Pullbox, GL 4" x 4" x 2" c/w cover & screws
Pullbox, GI, 8" x 8" x 4" c/w cover & screws
Pullbox, GI, 12" x 12" x 6" c/w cover & screws
U-bolt, 1/4" dia. hot dip galvanized steel, for 1/2" dia. pipe complete with nuts & washers
U-bolt, 1/4" dia. hot dip galvanized steel, for 1" dia. pipe complete with nuts & washers
U-bolt, 1/4" dia. hot dip galvanized steel, for 1-1/2" dia. pipe complete with nuts & washers
Cable tray system, Ga. 12 hot dip galvatized steel extruded in channel side rails & structural cross ratngs; it shall include the following
Ladder type tray, 14" W x 4" D x 10' long - 20 lgths.

Vertical bend, 90 degrees
Vertical bend, 45 degrees
Horizontal bend, 90 degrees
Horizontal bend, 45 degrees
Horizontal tee
Barrier strip, 4" D
Complete assembly shall be furnished w/ splice plates, tray covers, bolts, nuts and washers
Cable tray, channel type, slotted bottom, Ga. # 16 hot dip galva steel, 4" width x 2" depth x 10' long wd/ cover and splice plate
LABOR COST
Electrical Capataz
Lineman/Electrician
Project Employee
12.03 LIGHTING SYSTEM
MATERIAL COST
Lighting panelboard, 300V, 2PST, main breaker: 125A, 2 PSI
Wall mounted lumiaire, 400W, 220 V, 60 Hz, Mogul base,high pressure sodium GE-WM7M17MTA1 SN4DB complete HPS lamp
EHB high bay luminaire, open type, pendant mounting, 400W 220V, 60 Hz, Mogul base, metal halide, GE-EHBA25MTA5V6 complete wit
Fluorescent fixture, double, 40W, 220V, 60 Hz, industrial type rapid start c/w reflector & tubes rapid start c/w reflector & tubes
Rigid steel conduit w/ coupling, 15 mm dia. x 3 m
Rigid Steel Conduit, locknut & bushing, 15 mm dia.
Royal cable, #12/2c, 600V, 75 m/roll
Junction box, GI 4" x 4" x 2" w/ 1/2" dia. knockcut, complete cover & screws
Watertight strain relief cord grips & connectors, straight type, 15 mm hub size
LABOR COST
Electrical Capataz
Lineman/Electrician
Project Employee
GROUNDING & SPLICING
A. MATERIAL COST
Grounding conductor, 2/0 AWG bare copper, soft drawn
Ground rod, copperweld, 1/2" dia. x 8'
Ground connector, cable to rod
Ground connector, cable to bar
Vinyl electrical tape, 3/4" x 66', 3M-Super 33+D, 10 pcs/carto
Rubber splicing tape, 3/4" x 30" 3M-23, 50 pcs/cartoon
Varnished cambric tape, 3/4N x 60', 3M-2510, 10 pcs/cartoon
Wire marker
QUANTITY UNIT COST TOTAL COST
469 m³
103 m³
469 m³
469 m³
469 m³
469 m³
8.36 cubic meter 4,800.00 P 40,128.00
502 kgs 39.00 19,578.00
P 59,706.00
8.36 cubic meter 3,200.00 P 26,752.00

502 kgs. 26.00 13,052.00
P 39,804.00
1.70 cubic meter 4,800.00 8,160.00

P 8,160.00
3,200.00 5,440.00
1.70 cubic meter P 5,440.00
21.65 cubic meter 4,800.00 P 103,920.00

16,912 kgs 39.00 659,568.00
P 763,488.00
21.65 cubic meter 3,200.00 P 69,280.00

16,912 kgs 26.00 439,712.00
P 508,992.00
44.40 cubic meter 4,800.00 P 213,120.00

1,139 kgs 39 44,421.00
P 257,541.00
44.40 cubic meter 3,200.00 P 142,080.00

1,139 kgs 26 29,614.00
P 171,694.00
P 1,814,825.00
25.00 cubic meter 4,800.00 P 120,000.00
75 kgs 39 2,925.00
206 bdft. 4 824
P 123,749.00
25.00 cubic meter 320.00 P 8,000.00

75 kgs 26.00 1,950.00
206 bdft. 2.50 515.00
78 cubic meter 1.50 117.00
20 cubic meter 1.50 30.00
20.1 mt 2,500.00 50,250.00
20.1 mt 12,000.00 241,200.00
P 302,062.00
3.90 cubic meter 4,800.00 P 18,720.00

30 kgs 39.00 1,170.00
42 bdft 4.00 168.00
P
3.90 cubic meter 320.00 P 1,248.00

30 kgs 26.00 780.00
42 bdft 2.50 105.00
4 cubic meter 1.50 6.00
3.13 mt 2500.00 7,825.00
3.13 mt 12,000.00 37,560.00
P 47,524.00
3.20 cubic meter 4,800.00 P 15,360.00

109 kgs 39 4,251.00
83 bdft 4 332.00
P 19,943.00
3.20 cubic meter 320.00 P 1,024.00

109 kgs 26.00 2,834.00
83 bdft 2.50 208.00
3 cubic meter 160.00 480.00
2.60 mt 2500.00 6,500.00
2.60 mt 12000.00 31,200.00
P 42,246.00
P 555,582.00
12 cubic meter
18.0 cubic meter 4,800.00 P 86,,400.00
9,520 kgs 39.00 P 371,280.00
240 square meters 6.60 P 1,584.00

P 459,264.00
12 cubic meter 160.00 P 1,920.00
18.0 cubic meter 3200.00 P 57,600.00
9,520 kgs 26.00 P 247,520.00
240 square meters 4.40 P 1,056.00

P 308,096.00
16 lgths 878.00 P 14,048.00
10 pcs 143.00 1,430.00
12 pcs 300.00 3,600.00
8 pcs 100.00 800.00
10 lgths 370.00 3,700.00
3 pcs 15.00 45.00
2 pcs 145.00 290.00
8 ;gths 250.00 2,000.00
4 pcs 11.00 44.00
3 pcs 87.00 261.00
6 pcs 8.00 48.00
P 26,266.00
16 lgths 170.00 P 2,720.00

10 lgths 150.00 1,500.00
8 lgths 120.00 960
P 5,180.00
275 cubic meter

62 cubic meter
32.2 cubic meter 4,800.00 P 154,560.00

295.0 square meter 375.00 110,625.00
P 265,185.00
275 cubic meter 160.00 P 44,000.00

62 cubic meter 160.00 9,920.00
332.2 cubic meter 3200.00 P 103,040.00

295.0 square meter 250.00 73,750.00
P 230,710.00
190 m
171 cubic meter

410 cubic meter 237.00 P 97,170.00
200 cubic meter 500.00 100,000.00
230 cubic meter 4,800.00 1,104,000.00

P 1,301,170.00
171 cubic meter 160.00 P 27,360.00

410 cubic meter 160.00 65,600.00
200 cubic meter 160.00 32,000.00
230.0 cubic meter 3,200.00 736,000.00

P 860,960.00
P 2,162,130.00
120 square meter
1 lot 165,000.00 165,000.00

1,210 kgs 39.00 47,190.00
10 square meter 6.60 66.00
10,910 kgs 39.00 425,490.00

1 lot 50,000.00 50,000.00

1 lot 50,000.00 50,000.00
P 739,013.00
10 square meter 4.40 P 44.00
284 kgs 12.00 3408.00

1,210 kgs 26.00 31460.00
10,910 kgs 26.00 283,660.00

2,086 kgs 26.00 54236.00

10 days 511.00 5,110.00

10 days 495.00 14,850.00
10 days 511.00 5,110.00

10 days 495.00 14,850.00
P 413,203.00
120.00 mt 7,500.00 P 900,000.00

0.35 mt 7,500.00 2,625.00
8.79 mt 7,500.00 65,925.00
1.17 mt 7,500.00 8,775.00
7.60 mt 7,500.00 57,000.00
0.25 mt 7,500.00 1,875.00
5.00 mt 7,500.00 37,500.00
20.10 mt 7,500.00 150,750.00
3.13 mt 7,500.00 23,475.00
2.60 mt 7,500.00 19,500.00
P 1,267,425.00
120.00 mt 2,500.00 P 300,000.00

0.35 mt 2,500.00 875
8.79 mt 2,500.00 21,975.00
1.17 mt 2,500.00 2,925.00
7.60 mt 2,500.00 19,000.00
7.60 mt 2,500.00 19,000.00
11.40 mt 2,500.00 28,500.00
0.25 mt 2,500.00 625
20.10 mt 2,500.00 50,250.00
3.13 mt 2,500.00 7,825.00
2.60 mt 2,500.00 6,500.00
8.37 mt 2,500.00 20,925.00
6.00 mt 2,500.00 15,000.00
P 493,400.00
P 2,913,041.00
1 set 72,000.00 P 72,000.00
3 units 56,000.00 168,000.00

3 units 45,000.00 135,000.00
3 units 30,000.00 90,000.00
3 units 20,000.00 60,000.00
300 m 400.00 120,000.00
100 m 250.00 25,000.00
300 m 190.00 57,000.00
10 lgths 562.00 5,620.00
2 pcs 376.00 752.00
6 pcs 52.00 312.00
5 kits 7,000.00 35,000.00
12 pcs 849.00 10,188.00

56 pcs 749.00 41,944.00
12 pcs 6,000.00 72,00.00
40 pcs 9.00 360.00
40 bags 11.00 440.00
4 bags 500.00 2,000.00
50 pcs 220.00 11,000.00
6 pcs 50.00 300.00
2 pcs 400.00 800.00
P 907,716.00
21 days 963.00 P 20,223.00

21 days 510.27 10,716.00
21 days 494.64 51,937.00
21 days 205.00 17,220.00
P 11,096.00
400 m 274 P 109,600.00

460 m 231 106,260.00
4 rolls 12,200.00 48,800.00
3 rolls 6,200.00 18,600.00
5 rolls 4,400.00 22,000.00
250 m 600.00 150,000.00
1 roll 6,237.00 6,237.00

5 rolls 3,517.00 17,585.00
16 rolls 2,740.00 43,840.00
8 rolls 10,000.00 80,000.00
200 lgths 92.00 18,400.00
40 lgths 146.00 5,840.00
20 lgths 250.00 5,000.00
50 pcs 25.00 1,250.00
12 pcs 48.00 576.00
8 pcs 121.00 968.00
150 pcs 18.00 2,700.00
30 pcs 25.00 750.00
12 pcs 37.00 444.00
40 m 65.00 2,660.00
6m 97.00 582.00
3m 219.00 657.00
100 pcs 46.00 4,600.00
20 pcs 75.00 1,500.00
10 pcs 265.00 2,650.00
45 pcs 92.00 4,140.00
25 pcs 110.00 2,750.00
4 pcs 168.00 672.00
48 pcs 849.00 40,752.00
30 pcs 500.00 15,000.00
6 bags 300.00 1,800.00
18 bags 500.00 9,000.00
45 pcs 220.00 9,900.00
38 pcs 85.00 3,230.00
18 pcs 148.00 2,664.00
6 pcs 178.00 1,068.00
300 pcs 5.00 1,500.00
60 pcs 8.00 480.00
40 pcs 10.00 400.00
1 lot 85,000.00 85,000.00
8 lgths 2,500.00 P 20,000.00
P 849,795.00
30 days 963.00 P 28,890.00

30 days 510.27 15,308.00
30 days 494.64 74,196.00
30 days 205.00 24,600.00
P 142,994.00
1 assy 12,500.00 P 12,500.00
6 sets 8,500.00 51,000.00
22 sets 10,000.00 220,000.00
30 sets 870.00 26,100.00
90 lgths 92.00 8,280.00
25 pcs 25.00 625.00
50 pcs 18.00 900.00
20 rolls 2,026.00 40,520.00
70 pcs 16.00 1,120.00
70 pcs 18.00 1,260.00
P 362,305.00
15 days 963.00 P 14,445.00

15 days 510.27 7,654.00
15 days 494.64 37,098.00
15 days 215.00 12,300.00
P 71,497.00
180 m 120.00 P 21,600.00

15 lgths 498.00 7,470.00
28 pcs 56.00 1,568.00
24 pcs 62.00 1,488.00
40 ctn 1760.00 70,400.00
3 ctn 19850.00 59,550.00
25 ctn 1380.00 34,500.00
5 sets 1200.00 6,000.00
P 202,576.00

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TABLE 5

CAPITAL COST SUMMARY

2.0 Sand Handling Area

3.0 Furnace area

4.0 Control room/heat treatment area

5.0 Finishing area

6.0 Office & Change room

7.0 Shop and storage area

8.0 Water supply

9.0 Drainage canal - 2,665,185

10.0 Service road - 1,301,170

11.0 Equipment relocation / rehab

13.0 Equipment installation - -

TOTAL 17,486,369 21,275,844

14.0 Construction overhead

Grand Total 17,486,369 21,285,844

Incl. in rehab cost -

2.0 Sand handling area

3.0 Furnace area

4.0 Control room/heat

5.0 Finishing area

6.0 Office & Change room

7.0 Shop & storage area

8.0 Water supply

750 kg capacity, Model MS-2FG driven by 30 KW, 220V/440V motor

Low pressure type, Series 580

8" diameter x 6000 RPM

50 KVA, 460-220/110V, 3 phase, dry type

11,246,918 13,473,663 9,508,066 9,860,874 3,627,223

MONTHLY REVENUE(P) 1,750,000 6,750,000 10,000,000 10,000,000

CAPITAL EXPENDITURE(P) -58,310,757

MONTHLY PRODUCTION COST 1,669,500 5,738,439 9,219,697 9,219,697

YEARLY PRODUCTION COST 20,034,000 68,861,274 110,636,370 110,636,370

YEARLY OPERATING COST 25,865,970 74,692,350 116,467,446 116,467,446

NET INCOME BEFORE TAX -4,865,076 6,307,650 3,532,554 3,532,554

INCOME TAX (35%) 1,702,777 -2,207,678 -1,236,394 -1,236,394

NET INCOME -3,162,299 4,099,973 2,296,160 2,296,160

REVENUE AFTER COST -3,162,299 4,099,973 2,296,160 2,296,160

DEPRECIATION 5,831,076 5,831,076 5,831,076 5,831,076

10,000,000 10,000,000 10,000,000 10,000,000 10,000,000 10,000,000

4.00 4.00 4.00 4.00 4.00 4.00

9,219,697 9,219,697 9,219,697 9,219,697 9,219,697 9,219,697

110,636,370 110,636,370 110,636,370 110,636,370 110,636,370 110,636,370 973,966,233

116,467,446 116,467,446 116,467,446 116,467,446 116,467,446 116,467,446 1,032,296,993

3,532,554 3,532,554 3,532,554 3,532,554 3,532,554 3,532,554 29,703,007

-1,236,394 -1,236,394 -1,236,394 -1,236,394 -1,236,394 -1,236,394 -10,396,052

2,296,160 2,296,160 2,296,160 2,296,160 2,296,160 2,296,160 19,306,955

2,296,160 2,296,160 2,296,160 2,296,160 2,296,160 2,296,160 19,306,955

5,831,076 5,831,076 5,831,076 5,831,076 5,831,076 5,831,076 58,310,760

MANPOWER DISTRIBUTION AT YEAR 1

OT/VL/SL/13TH MP/BONUS/COLA/PAG-IBIG/SSS/ECC/MED/OTHER BENEFITS

TOTAL LABOR COST

MANPOWER DISTRIBUTION AT YEAR 2

OT/VL/SL/13TH MP/BONUS/COLA/PAG-IBIG/SSS/ECC/MED/OTHER BENEFITS

TOTAL LABOR COST

MANPOWER DISTRIBUTION AT YEAR 3 TO 10

OT/VL/SL/13TH MP/BONUS/COLA/PAG-IBIG/SSS/ECC/MED/OTHER BENEFITS