Technical Calculation and Estimator's Man-Hour Manual

TECHNICAL CALCULATION
AND ESTIMATOR'S
MAN-HOUR MANUAL
Marko Buliæ
Marko Buliæ
TECHNICAL CALCULATION AND ESTIMATOR'S
MAN-HOUR MANUAL
ERECTION OF PROCESS OR CHEMICAL PLANTS
I. PIPING ABOVE GROUND

II. PIPELINES
III. STEEL STRUCTURES
IV. PROCESS EQUIPMENT
V. STORAGE TANKS CYLINDRICAL AND SPHEROIDAL
VI. WELDING AND FLAME CUTTING
VII. CORROSION PROTECTION
VIII. THERMAL INSULATION
IX. ESTIMATES
X. PIPING ABOVE GROUND
ESTIMATE POINTS FOR BUILD-IN ITEMS
XI. WEIGHT FACTORS
XII. TECHNICAL CALCULATION
MANNER OF DATAS COMPILING
XIII. MAN HOURS FOR OVERHAULS IN
PETROCHEMICAL PLANTS
XIV. FACTORS AND MAN HOURS FOR PIPING AND
STEEL STRUCTURE WORKS IN CALL FOR
TENDERS OF “TECHNIP” COMPANY
XV. APPENDIX
ZAGREB, 2003.
(Completed edition)
All right reserved.

This book, or parts thereof, may not be reproduced
in any form without permission of the author.
Thank you for showing interest in buying our book TECHNICAL CALCULATION AND ESTIMATOR'S
MANHOURS MANUAL
You can buy the electronic version of the Manual containing all the figurest and other related data at the
following prices:
Individuals Legal entity
1. COMPLETE MANUAL (239 pages) US$ 600 US$ 1000
2. EACH CHAPTER
I PIPING ABOVE GROUND - 36 pages + 20* US$ 180 US$ 300

II PIPELINES - 7 pages + 20* US$ 75 US$ 120
III STEEL STRUCTURES - 7 pages + 20* US$ 80 US$ 130
IV PROCESS EQUIPMENT - 10 pages + 20* US$ 70 US$ 110
V STORAGE TANKS - CYLINDRICAL &
SPHERICAL - 11 pages + 20* US$ 80 US$ 130
VI WELDING AND FLAME CUTTING - 18 pages + 20* US$ 75 US$ 120
VII CORROSION PROTECTION - 3 pages + 20* US$ 35 US$ 55
VIII THERMAL INSULATION - 3 pages + 20* US$ 35 US$ 55
IX ESTIMATES - 11 pages + 20* US$ 100 US$ 165
X PIPING ABOVE GROUND - ESTIMATE POINTS
FOR BUILD-IN ITEMS - 76 pages + 20* US$ 130 US$ 215
XI WEIGHT FACTORS - 7 pages US$ 15 US$ 25
XII TECHNICAL CALCULATION
MANNER OF DATA COMPILING - 4 pages US$ 6 US$ 10
XIII MANHOURS FOR OVERHAULS IN
PETROCHEMICAL PLANTS - 16 pages + 20* US$ 80 US$ 130
XIV FACTORS AND MANHOURS FOR PIPING AND
STEEL STRUCTURE WORKS IN CALL FOR TENDERS
OF “TECHNIP” COMPANY - 3 pages + 20* US$ 60 US$ 100
NOTE: +20* = THE FIRST 13 PAGES OF THE MANUAL AND 7 PAGES OF THE APPENDIX
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1
PREFACE
All 40 years of my working life, I spent on erection of different process plants most of which were oil industry projects
in the country and abroad, in Europe and North Africa. Since 1978 with occasional interruptions because of
simultaneous involvement in several different projects, I worked mostly on technical calculations. I have made
hundreds and hundreds calculations based on all kinds of tenders and erection of mechanical equipment. The
tenders were written in various foreign languages and alphabet, even in Cyrillic. I am fully aware of the problems an
estimator encounters when working on technical calculations for specific technologies. Very often tenders were not
complete and not detailed enough, and the time required for a good technical calculation is getting every day
shorter. It is not easy to present exact technical figures and quantities for the equipment or operations not fully
defined, hard to comprehend, or even unknown to the estimator. Technical terms and expressions written in
different languages and dialects are often incorrect and specific for individual branches. Enormous experience is
needed, an ability to assess and estimate, and even the courage to write down the technical quantities and figures.
That was the reason for collecting various technical bibliography, standards, catalogues, man hours and rates from
the European and USA countries. I have made the analyses, comparisons, simulations, new measures, and manhour
tables. A great deal of that was verified in practice during the plant erection. I surveyed the results and analyses of
as-built designs. On many occasions, I sought a compromise between different opinions and standpoints. Too many
things collected on too many places. Finally, I decided to write this manual for discriminative estimators. It is
important to understand that there are no identical projects or jobs in this business, that each project is specific and
that no automatism or copying is possible. Approach to any job should be serious and professional and a technical
calculation should be made with the assistance of this Manual. Many people try to include the man hours from the
tables into the computer systems, which I oppose. Those are the people, which instead of using a computer, a
computer uses them. An estimator himself must choose the values and define the man hours taking into account all
the elements that might have any influence on them. Only when the relevant man hours are estimated and selected,
a computer can be used. A saying “Switch on your brain before switching on the computer” should be followed.
The most complex work in developing these man hours was the work on the man hours for piping above ground. A
basis I used was a system for estimating the value of erection works of a German Company LINDE, which I
completed and modified. Generally, for elaboration of the man hours for erection/installation of process equipment,
I used the English man hours of the Oil and Chemical Plant Constructors Association, but I used other sources as
well.
The source or the author was noted for other tables and if I modified them, I provided the modification basis. Where
there are no such notes, I am the only author.
A complete edition of this manual in the Croatian language and its sections were published in 1997 and
2000. This is why I have not given a unified percentage of the production efficiency but each chapter has its own.
Marko Buliæ
Zagreb Croatia, 2003
2
CONTENTS
page
PREFACE...........................................................................................................................2
INTRODUCTION..............................................................................................................11
ABBREVIATIONS & UNITS.................................................................................................13
CHAPTER I. PIPING ABOVE GROUND................................................................................14
DERIVED OPERATING TIME STANDARD FOR
TABLES FACTOR OF BASIC ASSEMBLY
1. PIPES (ANSI B. 36.10)...................................................................................14
1.1 PIPE - INSTALLATION ON PROCESS PLANT...............................................................14
1.2 PIPE - INSTALLATION ON PIPE RACK OR SLEEPER WAY............................................15
2. FITTINGS (ANSI B. 16.9).......................................................................................16
2.1 ELBOWS...............................................................................................................16
2.2 CAPS....................................................................................................................16
2.3 TEES....................................................................................................................17
2.3.1 STRAIGHT TEE.....................................................................................................17
2.3.2 REDUCED TEE......................................................................................................17
2.4 REDUCERS - CONCENTRIC AND ECCENTRIC..........................................................18
1. PIPES (DIN 2448/2458)..............................................................................19
1.1 PIPE - INSTALLATION IN PROCESS PLANT..............................................................19
1.2 PIPE - INSTALLATION ON PIPE RACK OR SLEEPER WAY............................................21
1.3 STEAM TRACING (ANSI & DIN)..............................................................................23
1.4 INSTRUMENT AND CONTROL PIPING.....................................................................23
1.5 STEAM DISTRIBUTORS AND CONDENSATE COLLECTORS
FABRICATED FROM PIPES AND FITTINGS...............................................................23
1.6 STEAM DISTRIBUTORS AND CONDENSATE COLLECTORS FABRICATED
FROM READY MADE DISTRIBUTORS FOR 4 CONNECTIONS.....................................23
2. FITTINGS (DIN)............................................................................................24
2.1 ELBOWS..............................................................................................................24
2.2 CAPS...................................................................................................................24
2.3 TEES...................................................................................................................26
2.4 REDUCERS - CONCENTRIC AND ECCENTRIC..........................................................28
3. FLANGES.......................................................................................................30
3.1 WELDING NECKS..................................................................................................30
3.2 SLIP - ON.............................................................................................................31
3.3 SOCKET WELDING................................................................................................31
3.4 LAP JOINT + STUB END........................................................................................31
3.5 BLIND..................................................................................................................31
3.6 ORIFICE COMPLETE..............................................................................................31
4. SMALL FITTINGS...........................................................................................32
4.1 WELDOLETS, SOCKOLETS, NIPOLETS, etc..............................................................32
4.2 HALF COUPLINGS FOR WELDINGS.........................................................................32
4.3 FITTINGS WITH SOCKET ENDS..............................................................................32
4.4 THREADED FITTINGS............................................................................................32
3
5. VALVES...........................................................................................................33
5.1 VALVES WITH FLANGED ENDS...............................................................................33
5.2 VALVES WITH WELDING ENDS..............................................................................34
5.3 VALVES FOR THREADED ENDS..............................................................................34
5.4 PRESSURE GAUGES..............................................................................................34
5.5 THERMOMETERS..................................................................................................34
RATES FOR TENDER CALCULATIONS...............................................................35
1. MANHOUR ESTIMATE FOR INSTALLATION OF PIPING.............................................35
2. EFFECT ASSESSMENT FOR QUICK CALCULATION...................................................36
2.1 PIPING IN PROCESS PLANT...................................................................................36
2.2 PIPES (CARBON STEEL - NOT INSULATED) - MEAN VALUE......................................37
2.3 FITTINGS (CARBON STEEL) - MEAN VALUE.............................................................38
2.4 VALVES - MEAN VALUE..........................................................................................39
2.5 PIPE SUPPORTS....................................................................................................39
2.6 AVERAGE DIAMETER - Manner of Calculation..........................................................39
3. RATES FOR INSTALLATION OF POLYETHYLENE PIPING...........................................40
4. RATES FOR ERECTION OF PVC & FRP PIPING........................................................41
5. CARBON STEEL PIPING CEMENT LINED INSIDE......................................................41
6. PIPING MADE OF STEEL AND GREY CAST-IRON......................................................42
7. RATES FOR PIPING BASED ON INCH-DIAMETER (ID)...............................................43
8. RATES FOR UNITS OF OPERATION - BASED ON INCH-DIAMETER (ID).......................44
9. RATES FOR PIPING WELDING...............................................................................46
10. MAN HOURS FOR WELDING OF PIPING................................................................47
11. WORK CALCULATION - MAN HOURS FOR PIPING MODIFICATION AT SITE...............48
12. INSTALLATION OF PIPING ABOVE - GROUND
Prefabrication and installation breakdown..............................................................49
CHAPTER II. PIPELINES...................................................................................................50

1. PIPE TRANSPORT..................................................................................................50
2. PIPE STRINGING..................................................................................................51
3. BENDING OF PIPES...............................................................................................51
4. PIPE JOINTING.....................................................................................................52
5. WELDING.............................................................................................................53
6. WRAPPING...........................................................................................................53
7. LAYING IN TRENCH...............................................................................................53
8. SPECIAL POINTS...................................................................................................54
8.1 BORING UNDER ROADS AND RAILROADS...............................................................54
8.2 BREAK OUT OF ROADS..........................................................................................54
8.3 CONNECTING PIPELINE SECTIONS........................................................................54
8.4 CROSSING WATERCOURSES..................................................................................55
8.5 INSTALATION OF CLEANING STATIONS..................................................................55
8.6 PUTTING UP PIPELINE MARKERS...........................................................................55
8.7 OTHER SPECIAL POINTS.......................................................................................55
9. PRESSURE TESTS.................................................................................................56
10. PRELIMINARY AND FINISHING WORKS.................................................................56
4
CHAPTER III. STEEL STRUCTURE ERECTION...................................................................57
1. BASIC MAN HOURS - UNIT...........................................................................57
1.1 SORTING THE STRUCTURE....................................................................................57
1.2 PRE-ERECTION OF STRUCTURE.............................................................................57
1.3 TRANSPORT OF STRUCTURE TO ERECTION PLACE.................................................57
1.4 INSTALLATION OF ANCHOR BOLTS........................................................................57
1.5 STRUCTURE ERECTION.........................................................................................57
1.6 INSTALLATION OF LOST FORMWORK.....................................................................58
1.7 INSTALLATION OF WIRE ROPE CLAMPS..................................................................58
1.8 REAMING OF HOLES.............................................................................................58
1.9 BOLTING FROM SCAFFOLDING...............................................................................58
2. ERECTION OF MISCELLANEOUS STEEL STRUCTURES.................................59
2.1 BASIC MANHOUR RATES.......................................................................................59
3. CORRECTION FACTORS................................................................................59
4. STEEL STRUCTURES IN OIL REFINERIES AND PETROCHEMICAL PLANTS...61
4.1 LIGHT STRUCTURE (to 30 kg/m)...........................................................................61
4.2 MEDIUM-WEIGHT STRUCTURE (31 ÷ 60 kg/m)......................................................61
4.3 HEAVY STRUCTURE (above 60 kg/m).......................................................................61
4.4 MISCELLANEOUS STRUCTURES..............................................................................61
4.5 PIPE HANGERS AND SUPPORTS.............................................................................61
5. ERECTION AND DISMANTLING OF
MISCELLANEOUS STEEL STRUCTURES.............................................................62
5.1 ERECTION OF STEEL STRUCTURES - ACC. TO THE WEIGHT....................................62
5.2 MISCELLANEOUS STRUCTURES.............................................................................62
5.3 REMOVAL OF STEEL STRUCTURE AND MISCELLANEOUS ITEMS...............................66
CHAPTER IV. ERECTION OF EQUIPMENT IN PETROCHEMICAL INDUSTRY....................67

1. STATIONARY EQUIPMENT............................................................................67
1.1 ALL EQUIPMENT TO 0,5 TON.................................................................................67
1.2 TOWERS above 0,5 TON........................................................................................67
1.3 TOWERS CONSISTING OF MORE PIECES...............................................................67
1.4 PACKAGE UNIT....................................................................................................67
1.5 OTHER EQUIPMENT.............................................................................................67
1.6 BRIDGE CRANES..................................................................................................67
1.7 LIFTS...................................................................................................................67
1.8 ELECTROSTATIC PRECIPITATORS...........................................................................68
1.9 MARINE LOADING ARMS.......................................................................................68
2. ROTARY EQUIPMENT....................................................................................68
2.1 CENTRIFUGAL PUMPS...........................................................................................68
2.1.1 MAN HOURS BASED ON POWER [kW]....................................................................68
2.1.2 MAN HOURS BASED ON WEIGHT [kg]....................................................................69
2.1.3 MAN HOURS BASED ON THE CAPACITY..................................................................69
2.2 COMPRESSORS.....................................................................................................70
2.2.1 COMPRESSORS DRIVEN BY ELECTRIC MOTOR........................................................70
2.2.2 COMPRESSORS DRIVEN BY GAS TURBINE..............................................................70
5
3. TOWERS & VESSELS - INSTALLATION OF INTERIOR
COMPONENTS & EQUIPMENT...........................................................................71
3.1 INSTALLATION OF TRAYS AND DEMISTERING PADS...............................................71
3.2 VESSELS & TOWER PACKINGS...............................................................................71
3.3 OPENING AND CLOSING OF MANHOLES.................................................................71
3.4 ERECTION OF PLATFORMS, LADDERS AND FLOOR GRIDS.......................................72
4. EQUIPMENT SCAFFOLDING.........................................................................72
4.1 TUBULAR SCAFFOLD.............................................................................................72
4.2 PATENT SCAFFOLDING.........................................................................................73
CHAPTER V. STORAGE TANKS - CYLINDRICAL AND SPHEROIDAL.................................74

1. APPROX. WEIGHTS AND ERECTION EFFECTS OF CYLINDRICAL STORAGE TANKS........74
1.1 STATISTICAL PARTICIPATION OF STORAGE TANK
COMPONENTS IN TOTAL WEIGHT..........................................................................75
2. ERECTION OF CYLINDRICAL STORAGE TANKS - DETAILS........................................76
2.1 PRELIMINARY WORKS..........................................................................................76
2.2 STORAGE TANK BOTTOM......................................................................................76
2.3 STORAGE TANK SHELL..........................................................................................77
2.4 WIND BINDINGS - RINGS FOR SHELL STIFFENING.................................................77
2.5 FIXED ROOF.........................................................................................................78
2.6 FLOATING ROOF...................................................................................................79
2.7 AUXILIARY STRUCTURE........................................................................................80
2.8 CONNECTIONS AND OPENINGS.............................................................................81
2.9 STORAGE TANK EQUIPMENT..................................................................................82
2.10 FINISHING WORKS...............................................................................................83
3. ERECTION OF SPHERICAL AND SPHEROIDAL STORAGE TANKS...............................84
CHAPTER VI. WELDING AND FLAME CUTTING................................................................85

1. MANUAL ARC WELDING OF CYLINDRICAL TANKS - SMAW........................................85
2. SUBMERGED ARC WELDING..................................................................................90
3. WELDING WITH SEMIAUTOMATIC (GMAW)............................................................95
4. WELDING OF SPHERICAL STORAGE TANKS..........................................................100
5. MANUAL GAS CUTTING AND GAS CONSUMPTION.................................................102
CHAPTER VII. CORROSION PROTECTION......................................................................103

1. SAND BLASTING AND PAINTING OF PIPING.........................................................103
2. SAND BLASTING AND PAINTING OF STEEL STRUCTURES......................................104
3. SAND BLASTING AND PAINTING OF STORAGE TANKS...........................................105
CHAPTER VIII. THERMAL INSULATION..........................................................................106

1. THERMAL INSULATION FOR PIPING.....................................................................106
2. THERMAL INSULATION OF VESSELS AND KILNS...................................................108
6
CHAPTER IX. ESTIMATES.................................................................................................109
1. ESTIMATE OF SCAFFOLDS...........................................................................109
1. ESTIMATES OF SCAFFOLDING WHEN CONTRACTED TO A SPECIALIST FIRM..........109
2. ESTIMATE OF SCAFFOLDING WHEN DONE BY AN ERECTION COMPANY.................110
2. ESTIMATE OF WELDING ROD CONSUMPTION
AND ADDITIONAL WELDING MATERIAL........................................................112
1. PIPING...............................................................................................................112
2. STEEL STRUCTURES............................................................................................113
3. CYLINDRICAL STORAGE TANKS............................................................................113
4. EQUIPMENT IN PETROCHEMICAL INDUSTRY.........................................................113
3. ESTIMATE OF CONSUMPTION OF TECHNICAL
GAS AND GRINDING PLATES..........................................................................114
4. ESTIMATE OF ELECTRICITY CONSUMPTION.............................................115
5. ESTIMATE OF CONSUMPTION OF FUEL AND LUBRICANT.........................116
1. FUEL CONSUMPTION...........................................................................................116
2. LUBRICANT CONSUMPTION.................................................................................116
6. TOOL COST ESTIMATE AT THE JOB SITE...................................................117
7. ESTIMATE OF SAFETY AT WORK MEANS...................................................117
8. ESTIMATE OF ERECTION TIME...................................................................117
9. SELECTION OF HOISTING MACHINERY.....................................................118
9.1 SELECTION OF THE LARGEST CRANE...................................................................119
9.2 PIPING IN PLANTS..............................................................................................119
9.3 PIPING BETWEEN PLANTS...................................................................................120
9.4 PIPELINES.........................................................................................................120
9.5 ERECTION OF STEEL STRUCTURE.......................................................................120
9.6 INSTALLATION OF PROCESS EQUIPMENT.............................................................120
9.7 ERECTION OF CYLINDRICAL STORAGE TANKS......................................................120
10. UNLOADING, HANDLING AND SORTING OF THE MATERIAL.....................121
10.1 MATERIAL FOR PIPING.......................................................................................121
10.2 STEEL STRUCTURE.............................................................................................121
10.3 PROCESS EQUIPMENT.........................................................................................121
10.4 CYLINDRICAL STORAGE TANKS...........................................................................121
11. TEMPORARY WORKS, SPACE REQUIRED
AND CONNECTIONS AT THE SITE...................................................................122
1. TEMPORARY WORKS...........................................................................................122
2. AREA NEEDED....................................................................................................123
3. CONNECTIONS NEEDED......................................................................................123
12. ESTIMATE OF THE NUMBER OF WELDS
AND RADIOGRAMS FOR PIPING....................................................................124
1. ESTIMATE OF BUTTWELDS BASED ON A LIST OF MATERIAL
- PIPES, FITTINGS AND FLANGES.........................................................................124
2. ESTIMATE OF BUTTWELDS BASED ON A LIST OF MATERIAL
- FITTINGS AND FLANGES ONLY...........................................................................124
3. ESTIMATE OF BUTTWELDS BASED ON THE PIPING LENGTHS................................125
4. ESTIMATE OF TOTAL WELDS (ALL TYPES)............................................................125
5. ESTIMATE OF RADIOGRAMS ON THE PIPING........................................................125
7
CHAPTER X. PIPING ABOVE GROUND
EXPLANATION TO THE ERECTION ITEMS............................................................127
1.0 PIPING......................................................................................................127
1.1 PIPE INSTALLATION IN PLANTS..........................................................................127
1.2 PIPE INSTALLATION ON PIPERACKS.....................................................................127
1.3 PIPE DISMANTLING............................................................................................127
2.0 FITTING.....................................................................................................127
2.1 ADJUSTMENT OF FITTINGS WITH ONE CONNECTION END....................................128
2.2 ADJUSTMENT OF FITTINGS WITH TWO CONNECTION ENDS................................128
2.3 ADJUSTMENT OF FITTINGS WITH THREE CONNECTION ENDS..............................128
3.0 PIPEWELD MAKE-ON AND WELDING.......................................................128
3.1 BUTT WELD MAKE-ON AND WELDING..................................................................128
3.2 FILLET (SOCKET) WELD - PERFORMANCE AND WELDING......................................128
3.3 MITRE WELD MAKE-ON AND WELD......................................................................129
3.4 NOZZLE WELD MAKE-ON AND WELDING..............................................................129
3.5 WELDOLET, NIPOLET - INSTALLATION AND WELDING..........................................129
3.6 REINFORCEMENT PAD MAKE-ON AND WELDING...................................................129
3.7 SEAL RING MAKE-ON AND WELDING (ACC. TO DIN 2695).....................................129
3.8 INSERT RING (FOR AL ONLY)..............................................................................130
3.9 WELD CUTTING FOR MODIFICATIONS.................................................................130
3.10 MATERIAL MULTIPLIER FACTORS (f)....................................................................130
4.0 FLANGED AND THREADED JOINTS, BENDING OF PIPES..........................130
4.1 ÷ 4.3 FLANGED JOINT.......................................................................................130
4.4 INSTALLATION OF MEASURING ORIFICES, BLANKING PLATES, etc.........................130
4.5 PIPE BENDING....................................................................................................130
4.6 PREPARATION OF THREADED ENDS....................................................................131
4.7 THREADED CONNECTION MAKE-ON....................................................................131
4.8 DISASSEMBLING Item 4.1 ÷ 4.4 and 4.7.................................................................131
5.0 VALVES......................................................................................................131
5.1 VALVE INSTALLATION (WITH AND WITHOUT HAND DRIVE)..................................131
5.2 VALVE INSTALLATION WITH ACTUATORS (SOLENOID, AIR)...................................131
5.3 BUTTERFLY VALVE INSTALLATION WITH ACTUATOR.............................................131
5.4 BUTTERFLY VALVE INSTALLATION........................................................................131
5.5 CONTROL VALVE INSTALLATION..........................................................................131
5.6 SAFETY VALVE INSTALLATION.............................................................................132
5.7 HYDRANT INSTALLATION....................................................................................132
5.8 SPINDLE EXTENSIONS.........................................................................................132
5.9 DISMANTLING OF VALVES...................................................................................132
6.0 PRESSURE TESTING..................................................................................132
6.1 PRESSURE TEST..................................................................................................132
6.2 SERVICE TEST.....................................................................................................132
8
7.0 MISCELLANEOUS.......................................................................................132
7.1 SUPPORTS - FABRICATION AND WELDING...........................................................132
7.2 SUPPORT INSTALLATION (WITHOUT FABRICATION).............................................132
7.3 INSTALLATION OF SPRING HANGERS AND SUSPENSIONS.....................................133
7.4 GRINDING OF EXCESS MATERIAL ON WELDING ROOTS........................................133
7.5 INSTRUMENT CONNECTION - DRILLING..............................................................133
8.0 ACTIVITIES DERIVED FROM BASIC ITEMS.............................................133
8.1 PIPES...............................................................................................................133
8.1.1 PIPE HANDLLING AND CUTTING IN PREFABRICATION...........................................133
8.1.2 INSTALLATION OF PREFABRICATED SPOOLS.........................................................133
8.1.3 SPATIAL SHIFTING OF PIPES...............................................................................133
8.1.4 MAKE-ON OF OUTSIDE PIPE FOR A DOUBLE-WALL
PIPING (JACKETED PIPING)................................................................................134
8.1.5 MAKE-ON AND INSTALLATION OF LINE PIPING
DN 20/25 ON JACKETED PIPING..........................................................................134
8.2 MISCELLANEOUS FITTINGS............................................................................134
8.2.1 HALF COUPLINGS................................................................................................134
8.2.2 WELD COMPENSATOR.........................................................................................134
8.2.3 WELD METER RUNS............................................................................................134
8.2.4 PREFABRICATED OF SPOOLS FOR WELDING.........................................................134
8.2.5 MEASURING ORIFICES - MEASURING FLANGES....................................................135
8.3 WELDING........................................................................................................135
8.3.1 TACK WELDING ON VALVE SIMULATORS..............................................................135
8.3.2 LONGITUDINAL WELDS ON PIPE HALF SHELLS....................................................135
8.3.3 THERMOMETER BRANCH (TI).............................................................................135
8.3.4 PREFABRICATED WELDS AT INSTALLATION OF
PREFABRICATED SECTIONS (SPOOLS).................................................................135
8.4 FLANGED JOINTS............................................................................................135
8.4.1 REPLACEMENT OF BOLTS....................................................................................135
8.5 VALVES.............................................................................................................136
8.5.1 ROTATING THE VALVE INSTALLATED....................................................................136
8.5.2 EXPANSION JOINTS WITH FLANGED ENDS...........................................................136
8.6 WALL PASS FOR PIPES...................................................................................136
8.7 MISCELLANEOUS.............................................................................................136
8.7.1. FABRICATION AND INSTALLATION OF PIPE HOLDERS,
HANGERS, AND SUPPORTS (to 100 kg per item)...................................................136
8.7.2 DISMANTLING OF PIPE HOLDERS, HANGERS, AND SUPPORTS...............................136
8.7.3 HOLE DRILLING IN CONCRETE............................................................................136
8.8 EXTRAS............................................................................................................136
8.8.1 CHANGE IN BILL OF QUANTITIES BEFORE THE
CLIENT'S APPROVAL FOR FABRICATION..............................................................136
8.8.2 CHANGE IN ISOMETRY PRIOR TO THE
CLIENT'S APPROVAL FOR FABRICATION...............................................................136
9
8.8.3 HAND DRAFTING OF ISOMETRY ACCORDING
TO THE CLIENT'S INSTRUCTION..........................................................................137
8.8.4 INSTALLATION OF MISSING MATERIAL.................................................................137
8.8.5 PIPING MODIFICATION.......................................................................................137
8.8.6 SAND BLASTING HANDLING, PRIMER COAT ON PIPING, AND PIPE SUPPORTS...........137
8.8.7 UNDERGROUND PIPING......................................................................................137
8.8.8 FACTORS FOR CALCULATION OF MAN HOURS FOR
PREFABRICATION AND INSTALLATION OF PIPING................................................138
TABLE Item. 3.10 MULTIPL. FACTORS FOR DIFF. KIND OF MATERIALS.................139
FORMS FOR CALCULATION OF MAN HOUR RATES...................................................142
1.0 PIPES......................................................................................................142
2.0 FITTINGS................................................................................................142
3.0 FLANGES.................................................................................................143
4.0 SMALL FITTINGS......................................................................................143
5.0 VALVES....................................................................................................144
6.0 PIPE EXPANSION JOINTS AND FLOWRATE METERS....................................145
7.0 OTHER INSTALLATION WORKS.................................................................145
8.0 ESTIMATE POINTS FOR BUILD-IN ITEMS OF A. G. PIPING.........................147
CHAPTER XI. WEIGHT FACTORS.....................................................................................203

1. PIPING...............................................................................................................203
2. STEEL STRUCTURES............................................................................................206
3. PROCESS EQUIPMENT.........................................................................................208
4. CYLINDRICAL STORAGE TANKS............................................................................209
CHAPTER XII. TECHNICAL CALCULATION MANNER OF DATA COMPILING..................210
CHAPTER XIII. MAN HOURS FOR OVERHAULS IN PETROCHEMICAL PLANTS..............214

1. PIPING ERECTION AND DISMANTLING.................................................................214
2. MAN HOURS FOR OVERHAUL OF EQUIPMENT IN PETROCHEMICAL PLANTS...........229
CHAPTER XIV. FACTORS AND MAN HOURS FOR PIPING AND STEEL
STRUCTURE WORKS IN CALL FOR TENDERS OF "TECHNIP" COMPANY......230
A. PIPING BETWEEN PLANTS AND IN PLANTS...........................................................230
B. STEEL STRUCTURE ERECTION.............................................................................232
CHAPTER XV. APPENDIX..................................................................................................233

1. ISO R7 DIN 2448/2458 SUMMARY OF PIPE SCHEDULED SIZES..............................233
2. ANSI B 36.10 SUMMARY OF PIPE SCHEDULED SIZES............................................235
3. PIPE AND FITTINGS DIMENSIONS - TABLE MANUAL.............................................236
4. STEEL STRUCTURE - SURFACES OF SECTIONS in m2/m........................................237
5. CONVERSIONS BETWEEN ENGLISH AND (SI) STANDARDS UNITS..........................238
10
INTRODUCTION
With proper and conscientious application of these data for making estimates, the estimator will calculate
hourly time requirements i.e. the man hours required for the erection.
The man hours (Mhr) do not refer to any condition or PRODUCTIVITY EFFICIENCY PERCENTAGES (PEP,
Leistungsfähigkeit - Prozentsatz), but to precisely determined below stated PEPs.
The standard ranges of productivity efficiency percentages are:
1. Very low 10 ÷ 40 %
2. Low 41 ÷ 60%
3. Average 61 ÷ 80%
4. Very good 81 ÷ 90%
5. Excellent 91 ÷ 100%
6. Extraordinary 101 ÷ 120%
Man hours in this Manual refer to the following Productivity Efficiency Percentages:
1. PIPING ABOVE GROUND IN PLANTS
1.1 Calculation based on the estimate points of basic erection items and man hours and effects
derived thereby
PEP = high average 80%
1.2 Calculation based on man hours and effects for quick calculation and special man hours
1.3 Calculation based on man hours for piping per inch - diameter (ID)
1.4 Calculation based on man hours for units of operation
PEP = very good 85 %
2. PIPELINES
PEP = high average 75 %
3. STEEL STRUCTURES
4. PROCESS EQUIPMENT IN PLANTS
PEP = average 70%
5. CYLINDRICAL STORAGE TANKS
6. WELDING AND CUTTING
PEP = average 70 %
7. CORROSION PROTECTION
8. THERMAL INSULATION
11
For each project, before the labour value is calculated, the Productivity Efficiency Percentage should
be determined. This is done by the project manager with the assistance of his collaborators.
John S. Page (USA) stated six production elements that have an impact on PEP determination.
They are:
1. Project Management and Supervision
2. Labour Conditions
3. Job Conditions
4. Machinery and Equipment
5. Weather Conditions
6. General Economy (for J. S. P. this is a leading element, which I shall not consider)
1. Project Management and Supervision

Has the company already executed such projects? How often? What is the calibre of your
supervision? Are skilled and experienced staff available? What can you afford to pay them? Will they
be satisfied with the accommodation? Will they be satisfied with the salaries? Will you have enough
money at the site (down payments)?
After evaluating these questions, estimate the percentage according to the PEP table.
2. Labour Conditions
Does the company have a good labour relations man? Has the company sufficient number of skilled
and trained labour? What are the foremen like? Will they be satisfied with their salaries? Will they be
satisfied with accommodation, food, transport? How often will they be able to visit their families?
Estimate the percentage according to the PEP table.
3. Job Conditions
What is the scope of the work and just what is involved in the job? What is the schedule? Is it tight, or
do you have ample time to complete the work? What is the condition of the site? Is it low and muddy,
and hard to drain, or is it high and dry? Does it involve a plant already in operation? Will there be tie-ins
to the existing systems? What will the relationship be between the production personnel and office
personnel? Will most of the operations be manual or mechanized? What kind of material procurement
will you have?
4. Machinery and Equipment

Do you have ample equipment to finish your job? What kind of shape is it in, and will you have good
maintenance and repair help? The qualifications and experience of crane and other operators? The
plant-hire company for the machinery? Past experience?
5. Weather Conditions
What were past weather conditions for the area? If necessary, can they be
checked? What future weather forecasts? Will there be much rain or snow? What
differences are expected in the weather with regard to Central Europe - Zagreb?
Estimate the percentage according to PEP table. When we have considered and analysed all the
percentages, we have to divide the total sum by five to arrive at an average percentage of productivity
that is the Productivity Efficiency Percentage (PEP).
Dividing the PEP declared by the average PEP we obtain a factor. This factor is
multiplied by the calculated man hours (MHr) and will give actually needed man
hours (MHr). The number of hours can be either increased or decreased.
12
ABBREVIATIONS & UNITS
PEP = Productivity efficiency percentage

Mhr = Man Hours
mm = millimeters = 0.03937 inches
m = linear meters = 3.281 feet
km = kilometers = 0.6214 miles
m2 = square meters = 10.764 feet
m3 = cubic meters = 35.314 feet
ft = linear feet = 0.3048 meters
l = liters = 61.023 cu inches = 0.03531 cu feet = 0.2642 u.s. gal
kg = kilogram = 2.2046 lbs
lbs = pound = 0.4536 kg
t or ton = metric tons = 1000 kg
ea = each
pc = piece
PN = pressure nominal or NP
bar = 14.5 psi ( lb/sq in)
Dn = diametar nominal
OD or do = outer diametar
ID = inch diametar
MID = meter inch diametar
t = thickness mm
V = volume
max. = maximum
min. = minimum
ø = phi (Greek) = round
kW = kilowatts = 1.341 horse power
kWh = kilowatthours
kVA = kilovoltampers
kg/Mhr = kilograms per man hour
Mhr/m = man hours per meter
f = factor
k = coefficient
Notice:
Decimal numbers are listed with a comma (European way).
13
I. PIPING ABOVE GROUND
DERIVED OPERATING TIME STANDARD FOR TABLES FACTOR OF BASIC ASSEMBLY
POSITION CHAPTER X, ACCORDING TO FORMS ON PAGE 142 ÷ 146
Productivity efficiency percentage (PEP) = 80% FOR PREFABRICATION : 8%
1. PIPES (ANSI B 36.10) FOR INSTALLATION : 92%
1.1 PIPE INSTALLATION ON PROCESS PLANT [Mhr/m]
CARBON STEEL - NONWRAPPED - ABOVE GROUND STAINLESS STEEL

Dn-mm ø-Inch OD-mm Sch 10 Sch 20 Sch 30 Std Sch 40 Sch 60 XS Sch 80 Sch 100 Sch 120 Sch 140 Sch 160 XXS Sch 5S Sch 10S Sch 40S Sch 80S ø-Inch
15 1/2” 21,3 0,41 0,42 0,43 0,45 0,42 0,43 0,44 0,45 1/2”
20 3/4” 26,7 0,41 0,42 0,44 0,47 0,49 0,43 0,44 0,46 0,48 3/4”
25 1” 33,4 0,45 0,46 0,48 0,52 0,55 0,45 0,48 0,50 0,52 1”
32 1 1/4” 42,2 0,48 0,50 0,53 0,57 0,64 0,48 0,51 0,54 0,58 1 1/4”
40 1 1/2” 48,3 0,50 0,53 0,57 0,62 0,69 0,49 0,54 0,57 0,61 1 1/2”
50 2” 60,3 0,53 0,57 0,63 0,74 0,81 0,52 0,57 0,62 0,69 2”
65 2 1/2” 73 0,59 0,68 0,76 0,85 1,00 0,58 0,63 0,74 0,82 2 1/2”
80 3” 88,9 0,64 0,76 0,87 1,02 1,19 0,62 0,68 0,82 0,94 3”
100 4” 114,3 0,69 0,88 1,04 1,18 1,31 1,48 0,67 0,74 0,95 1,12 4”
125 5” 141,3 0,78 1,02 1,22 1,43 1,63 1,81 0,78 0,84 1,10 1,33 5”
150 6” 168,3 1,14 1,44 1,69 1,96 2,20 0,83 0,89 1,24 1,57 6”
200 8” 219,1 1,32 1,49 1,51 1,73 1,96 2,19 2,49 2,69 2,90 2,83 1,00 1,12 1,64 2,14 8”
14
250 10” 273 1,57 1,76 1,95 2,37 2,37 2,65 3,03 3,38 3,82 4,16 3,82 1,26 1,38 2,12 2,58 10”
300 12” 323,9 1,81 2,12 2,28 2,40 2,97 2,75 3,42 3,95 4,48 4,90 5,49 4,48 1,54 1,65 2,48 2,99 12”
350 14” 355,6 1,98 2,23 2,49 2,49 2,75 3,38 3,00 3,97 4,68 5,26 5,82 6,36 1,69 1,84 14”
400 16” 406,4 2,21 2,50 2,79 2,79 3,37 4,08 3,37 4,89 5,70 6,48 7,36 7,98 1,92 2,05 16”
450 18” 457 2,44 2,76 3,42 3,09 4,06 4,98 3,74 5,90 6,95 7,95 8,81 9,78 2,11 2,26 18”
500 20” 508 2,67 3,39 4,11 3,39 4,64 5,83 4,11 7,01 8,31 9,44 10,69 11,78 2,47 2,65 20”
550 22” 559 2,90 3,68 4,47 3,68 5,24 6,73 4,47 8,21 9,63 11,05 12,43 13,80 2,67 2,88 22”
600 24” 610 3,12 3,97 5,25 3,97 6,09 7,90 4,83 9,50 11,44 13,15 14,66 16,32 3,10 3,38 24”
650 26” 660 3,79 5,18 4,26 5,18 26”
700 28” 711 3,79 5,54 6,51 4,55 5,54 28”
750 30” 762 4,30 5,90 6,94 4,84 5,90 4,10 4,66 30”
800 32” 813 4,56 6,25 7,35 5,13 7,90 6,25 32”
850 34” 864 4,81 6,60 7,77 5,41 8,35 6,60 34”
900 36” 914 5,06 6,94 8,18 5,69 9,40 6,94 36”
Man hour included next activities : Materials: k

- handling - erection - alloy steel [Mhr/m] x 1,10
- on-site transport - welding - prewrapped [Mhr/m] x 1,15 (underground install.) Mhr/m x 0,3048 = Mhr/ft
- prefabrication - pressure testing - galvanized [Mhr/m] x 0,70
- aluminium alloy [Mhr/m] x 0,85
1. PIPES (ANSI B. 36.10) FOR PREFABRICATION : 8%
1.2 INSTALLATION ON PIPE RACK OR SLEEPER WAY [Mhr/m] FOR INSTALLATION : 92%
CARBON STEEL - NONWRAPPED STAINLESS STEEL

Dn-mmø Inch OD-mm Sch 10 Sch 20 Sch 30 Std Sch 40 Sch 60 XS Sch 80 Sch 100 Sch 120 Sch 140 Sch 160 XXS Sch 5S Sch 10S Sch 40S Sch 80S ø Inch
15 1/2” 21,3 0,43 0,44 0,45 0,47 0,45 0,46 0,47 0,48 1/2”
20 3/4” 26,7 0,44 0,45 0,47 0,49 0,52 0,47 0,48 0,49 0,51 3/4”
25 1” 33,4 0,48 0,50 0,52 0,55 0,59 0,50 0,52 0,54 0,56 1”
32 1 1/4” 42,4 0,52 0,55 0,58 0,62 0,68 0,53 0,57 0,59 0,63 1 1/4”
40 1 1/2” 48,3 0,55 0,58 0,62 0,67 0,75 0,56 0,60 0,63 0,67 1 1/2”
50 2” 60,3 0,60 0,64 0,70 0,80 0,88 0,60 0,64 0,69 0,75 2”
65 2 1/2” 73 0,66 0,76 0,83 0,93 1,10 0,67 0,72 0,82 0,90 2 1/2”
80 3” 88,9 0,73 0,85 0,96 1,13 1,32 0,72 0,78 0,92 1,04 3”
100 4” 114,3 0,81 1,00 1,16 1,31 1,46 1,66 0,80 0,87 1,08 1,26 4”
125 5” 141,3 0,91 1,16 1,37 1,61 1,84 2,06 0,93 0,98 1,25 1,49 5”
150 6” 168,3 1,31 1,64 1,92 2,25 2,55 1,00 1,06 1,41 1,77 6”
200 8” 219,1 1,54 1,72 1,74 1,98 2,25 2,52 2,88 3,14 3,40 3,32 1,22 1,34 1,88 2,43 8”
250 10” 273 1,85 2,04 2,25 2,73 2,73 3,07 3,52 3,97 4,55 5,01 4,55 1,54 1,66 2,43 2,95 10”
15
300 12” 323,9 2,14 2,47 2,65 2,78 3,45 3,18 3,99 4,67 5,37 5,93 6,76 5,37 1,88 1,98 2,86 3,44 12”
350 14” 355,6 2,33 2,61 2,90 2,90 3,19 3,93 3,48 4,66 5,58 6,36 7,15 7,92 2,05 2,21 14”
400 16” 406,4 2,61 2,93 3,26 3,26 3,93 4,78 3,93 5,81 6,88 7,97 9,24 10,17 2,34 2,47 16”
450 18” 457 2,89 3,25 3,99 3,62 4,75 5,89 4,37 7,09 8,52 9,96 11,24 12,72 2,59 2,73 18”
500 20” 508 3,18 3,98 4,81 3,98 5,44 6,94 4,81 8,52 10,35 12,01 13,92 15,64 3,00 3,19 20”
550 22” 559 3,46 4,34 5,25 4,34 6,18 8,09 5,25 10,10 12,14 14,28 16,42 18,64 3,26 3,47 22”
600 24” 610 3,74 4,69 6,19 4,69 7,22 9,60 5,68 11,83 14,68 17,33 19,77 22,52 3,74 4,04 24”
650 26” 660 4,49 6,11 5,04 6,11 26”
700 28” 711 4,81 6,54 7,73 5,39 6,54 28”
750 30” 762 5,12 6,98 8,24 5,75 6,98 4,93 5,54 30”
800 32” 813 5,43 7,41 8,75 6,10 9,44 7,41 32”
850 34” 864 5,74 7,83 9,26 6,45 10,00 7,83 34”
900 36” 914 6,04 8,25 9,76 6,79 11,32 8,25 36”
Man hour include the next activities: Materials: k

- handling - erection - alloy steel [Mhr/m] x 1,10
- on-site transport - welding - galvanized [Mhr/m] x 0,70 Mhr/m x 0,3048 = Mhr/ft
- prefabrication - pressure testing - aluminium alloy [Mhr/m] x 0,85
2. FITTINGS (ANSI 36.10) FOR PREFABRICATION : 85%
2.1 ELBOWS [Mhr/ea] FOR INSTALLATION: 15%
CARBON STEEL STAINLESS STEEL

DN-mm ø-Inch OD-mm Sch 10 Sch 20 Sch 30 Std Sch 40 Sch 60 XS Sch 80 Sch 100 Sch 120 Sch 140 Sch 160 XXS Sch 5S Sch 10S Sch 40S Sch 80S ø-Inch
15 1/2” 21,3 1,29 1,31 1,33 1,60 1,60 1,62 1,64 1/2”
20 3/4” 26,7 1,43 1,45 1,47 1,52 1,78 1,79 1,81 1,84 3/4”
25 1” 33,4 1,63 1,65 1,69 1,75 1,86 2,00 2,04 2,06 2,11 1”
32 1 1/4” 42,2 1,88 1,91 1,97 2,05 2,23 2,31 2,35 2,39 2,46 1 1/4”
40 1 1/2” 48,3 2,06 2,10 2,18 2,29 2,50 2,52 2,57 2,63 2,72 1 1/2”
50 2” 60,3 2,36 2,43 2,54 2,80 3,02 2,89 2,95 3,03 3,17 2”
65 2 1/2” 73 2,73 2,90 3,07 3,34 3,88 3,34 3,41 3,62 3,84 2 1/2”
80 3” 88,9 3,13 3,37 3,62 4,11 4,76 3,82 3,92 4,21 4,53 3”
100 4” 114,3 3,66 4,03 4,44 4,91 5,39 6,18 4,46 4,57 5,03 5,55 4”
125 5” 141,3 4,24 4,75 5,34 6,10 6,95 7,83 5,21 5,30 5,93 6,67 5”
150 6” 168,3 5,41 6,38 7,35 8,66 9,94 5,79 5,90 6,76 7,97 6”
200 8” 219,1 6,73 7,20 7,26 7,97 8,87 9,87 11,31 12,42 13,64 13,22 7,39 7,63 9,08 11,09 8”
250 10” 273 8,27 8,79 9,40 10,98 10,98 12,25 14,10 16,04 18,74 21,04 9,22 9,48 11,74 13,73 10”
16
300 12” 323,9 9,75 10,65 11,20 11,62 14,00 13,00 16,17 19,11 22,39 25,20 29,58 11,08 11,33 14,00 16,25 12”
350 14” 355,6 10,83 11,55 12,42 12,42 13,38 16,09 14,41 19,13 23,33 27,16 31,24 35,45 12,32 12,69 14”
400 16” 406,4 12,30 13,14 14,13 14,13 16,42 19,75 16,42 24,23 29,36 34,97 41,89 47,23 14,09 14,41 16”
450 18” 457 13,77 14,71 17,08 15,84 19,86 24,60 18,42 30,12 37,32 45,07 52,31 61,09 15,76 16,12 18”
500 20” 508 15,25 17,56 20,44 17,56 22,89 29,33 20,44 36,90 46,45 55,74 66,97 77,56 17,85 18,36 20”
550 22” 559 16,73 19,28 22,46 19,28 26,13 34,58 22,46 44,59 55,63 67,89 80,85 94,82 19,57 20,13 22”
600 24” 610 18,21 20,99 26,42 20,99 30,69 41,71 24,48 53,24 69,23 85,02 100,27 118,15 21,91 22,76 24”
650 26” 660 22,69 26,46 26”
700 28” 711 24,40 28,48 28”
750 30” 762 26,12 30,50 28,29 30,27 30”
800 32” 813 27,84 32,51 32”
850 34” 864 29,55 34,53 34”
900 36” 914 31,24 36,52 36”
2.2 CAPS [Mhr/ea] x 0,50 Materials: f f

- Cr-Mo alloy steel 1,40 ÷ 1,60 - High temp. alloy steel 1,00 ÷ 1,80
- Copper alloy 1,20 - Alloy steel Ni 1,60
- Killed C.S. 1,00 ÷ 1,25 - Aluminium alloy 1,50
2. FITTINGS (ANSI B.36.10) FOR PREFABRICATION : 85%
2.3 TEES FOR INSTALLATION : 15%
2.3.1 STRAIGHT TEE [Mhr/ea]

15 1/2” 21,3 1,91 1,94 1,97 2,36 2,37 2,39 2,42 1/2”
20 3/4” 26,7 2,11 2,14 2,17 2,24 2,33 2,62 2,64 2,67 2,72 3/4”
25 1” 33,4 2,40 2,43 2,49 2,59 2,75 2,95 3,00 3,04 3,11 1”
32 1 1/4” 42,4 2,77 2,82 2,91 3,02 3,30 3,39 3,46 3,52 3,64 1 1/4”
40 1 1/2” 48,3 3,02 3,09 3,20 3,38 3,70 3,70 3,78 3,86 4,00 1 1/2”
50 2” 60,3 3,47 3,57 3,73 4,14 4,47 4,23 4,33 4,46 4,67 2”
65 2 1/2” 73 4,00 4,26 4,52 4,93 5,75 4,89 5,00 5,32 5,65 2 1/2”
80 3” 88,9 4,58 4,94 5,33 6,08 7,07 5,59 5,73 6,18 6,66 3”
100 4” 114,3 5,36 5,92 7,26 6,56 7,26 8,00 9,21 6,52 6,70 7,40 8,19 4”
125 5” 141,3 6,20 6,98 9,04 7,88 9,04 10,34 11,69 7,61 7,75 8,72 9,85 5”
150 6” 168,3 7,95 9,44 10,92 12,92 14,88 8,46 8,62 9,94 11,79 6”
200 8” 219,1 9,88 10,60 10,70 11,77 13,15 14,67 16,87 18,57 20,43 19,80 10,78 11,15 13,37 16,44 8”
17
250 10” 273 12,14 12,92 13,86 16,28 16,28 18,21 21,04 24,01 28,14 31,65 13,47 13,86 17,32 20,35 10”
300 12” 323,9 14,30 15,68 16,51 17,16 20,79 19,26 24,11 28,60 33,62 37,91 44,60 16,19 16,57 20,64 24,08 12”
350 14” 355,6 15,85 16,97 18,29 18,29 19,75 23,90 21,32 28,54 34,95 40,80 47,04 53,47 17,96 18,53 14”
400 16” 406,4 18,01 19,29 20,81 20,81 24,30 29,39 24,30 36,24 44,07 52,64 63,22 71,37 20,55 21,03 16”
450 18” 457 20,16 21,60 25,22 23,33 29,47 36,70 27,27 45,14 56,14 67,98 79,04 92,45 22,99 23,54 18”
500 20” 508 22,33 25,85 30,26 25,85 34,00 43,84 30,26 55,40 70,00 84,19 101,35 117,52 26,05 26,83 20”
550 22” 559 24,49 28,38 33,24 28,38 38,85 51,76 33,24 67,05 83,92 102,65 122,46 143,80 28,57 29,42 22”
600 24” 610 26,66 30,91 39,20 30,91 45,72 62,56 36,23 80,17 104,60 128,73 152,02 179,35 32,02 33,33 24”
650 26” 660 33,40 39,17 26”
700 28” 711 35,93 42,16 28”
750 30” 762 38,46 45,14 41,41 44,44 30”
800 32” 813 40,99 48,13 32”
850 34” 864 43,51 51,12 34”
900 36” 914 46,00 54,06 36”
2.3.2 REDUCED TEE [Mhr/ea] x 0,95 Materials: f f

- Killed C.S. 1,00 ÷ 1,25 - Auminium alloy 1,50
2. FITTINGS (ANSI) FOR PREFABRICATION : 85%
2.4 REDUCERS - CONCENTRIC AND ECCENTRIC [Mhr/ea] FOR INSTALLATION: 15%

20 3/4” 26,7 1,51 1,53 1,57 1,85 1,86 1,88 1,91 3/4”
25 1” 33,4 1,68 1,70 1,74 1,80 1,89 2,07 2,10 2,12 2,17 1”
32 1 1/4” 42,2 1,94 1,96 2,02 2,10 2,25 2,37 2,42 2,46 2,52 1 1/4”
40 1 1/2” 48,3 2,16 2,20 2,27 2,38 2,59 2,64 2,70 2,75 2,84 1 1/2”
50 2” 60,3 2,42 2,48 2,58 2,79 3,02 2,96 3,02 3,10 3,23 2”
65 2 1/2” 73 2,80 2,93 3,08 3,38 3,79 3,42 3,50 3,66 3,85 2 1/2”
80 3” 88,9 3,21 3,43 3,66 4,08 4,73 3,92 4,01 4,29 4,58 3”
100 4” 114,3 3,69 4,01 4,38 5,17 5,95 4,49 4,61 5,02 5,48 4”
125 5” 141,3 4,28 4,76 5,31 5,98 6,71 7,62 5,24 5,36 5,95 6,64 5”
150 6” 168,3 5,48 6,33 7,27 8,45 9,63 5,93 6,04 6,85 7,92 6”
200 8” 219,1 7,07 8,51 10,40 12,42 12,91 7,37 7,56 8,84 10,64 8”
250 10” 273 8,32 8,87 9,24 10,52 11,02 11,72 13,30 15,18 17,30 19,25 9,22 9,49 11,56 13,77 10”
300 12” 323,9 9,95 10,74 11,38 11,62 13,82 13,26 15,73 18,39 21,30 24,36 28,07 11,21 11,49 14,23 16,58 12”
18
350 14” 355,6 11,73 12,71 13,02 13,78 16,61 15,12 19,51 23,47 27,42 31,26 36,02 12,87 13,22 14”
400 16” 406,4 12,70 13,57 14,60 14,60 16,40 19,76 16,98 23,94 29,12 34,36 40,48 45,78 14,48 14,87 16”
450 18” 457 14,29 15,28 17,15 16,46 19,96 24,44 19,16 30,00 36,85 44,27 52,14 59,98 16,34 16,72 18”
500 20” 508 15,88 17,69 20,60 18,31 23,51 29,72 21,35 36,99 46,30 55,76 66,03 76,78 18,37 18,85 20”
550 22” 559 17,48 20,17 23,54 20,17 26,94 35,22 23,54 44,98 56,42 68,39 81,84 95,48 20,43 21,02 22”
600 24” 610 19,08 22,04 26,82 22,04 31,23 42,05 25,74 54,01 69,03 84,61 100,29 117,98 22,63 23,41 24”
650 26” 660 23,89 27,92 26”
700 28” 711 25,73 30,09 28”
750 30” 762 27,59 32,29 30”
800 32” 813 29,46 34,48 32”
850 34” 864 31,32 36,68 34”
900 36” 914 33,16 38,86 36”
Man hour include next activities: Materials: f f

- handling - erection - Cr-Mo alloy steel 1,40 ÷ 1,60 - High temp. alloy steel 1,00 ÷ 1,80
- on-site transport - welding - Copper alloy 1,20 - Alloy steel Ni 1,60
- prefabrication - pressure testing - Killed C.S 1,00 ÷ 1,25 - Aluminium alloy 1,50
1. PIPES (DIN 2448/2458)
FOR PREFABRICATION : 8%
1.1 INSTALLATION IN PROCESS PLANT [Mhr/m] FOR INSTALLATION : 92%
CARBON STEEL - NONWRAPPED - ABOVE GROUND - WALL THICKNESS 2 - 12,5 mm

Dn-mm OD-mm t - Std|Ext 2 2,3 2,6 2,9 3,2 3,6 4 4,5 5 5,6 6,3 7,1 8 8,8 10 11 12,5 OD-mm
15 21,3 2\2 0,39 0,40 0,40 0,41 0,41 0,42 0,42 0,43 0,43 21,3
20 26,9 2\2,3 0,41 0,41 0,42 0,43 0,43 0,44 0,44 0,45 0,46 0,47 0,48 26,9
25 33,7 2\2,6 0,43 0,44 0,44 0,45 0,46 0,46 0,47 0,48 0,49 0,50 0,52 0,53 33,7
32 42,4 2\2,6 0,45 0,46 0,47 0,48 0,49 0,50 0,51 0,52 0,54 0,55 0,57 42,4
40 48,3 2,3\2,6 0,47 0,48 0,49 0,50 0,51 0,52 0,54 0,55 0,57 0,58 0,60 0,62 0,64 0,66 0,69 0,70 0,70 48,3
50 60,3 2,3\2,9 0,50 0,51 0,52 0,54 0,55 0,56 0,58 0,60 0,62 0,64 0,66 0,69 0,72 0,74 0,77 0,80 0,81 60,3
65 73,1 2,6\2,9 0,53 0,55 0,56 0,58 0,59 0,61 0,63 0,65 0,67 0,70 0,73 0,76 0,79 0,82 0,87 0,90 0,95 73,1
65 76,1 2,6\2,9 0,54 0,56 0,57 0,59 0,60 0,62 0,64 0,66 0,69 0,71 0,74 0,78 0,81 76,1
80 88,9 2,9\3,2 0,57 0,59 0,61 0,62 0,64 0,66 0,68 0,71 0,74 0,77 0,80 0,84 0,89 0,92 0,97 1,02 1,08 88,9
100 114,3 3,2\3,6 0,62 0,64 0,66 0,68 0,70 0,73 0,75 0,79 0,82 0,86 0,90 0,95 1,00 1,05 1,12 1,17 1,25 114,3
125 139,7 3,6\4 0,71 0,73 0,76 0,79 0,82 0,86 0,90 0,94 0,99 1,05 1,11 1,17 1,25 1,31 1,41 139,7
150 168,3 4\4,5 0,78 0,83 0,84 0,88 0,92 0,96 1,02 1,07 1,14 1,21 1,27 1,37 1,44 1,56 168,3
200 219,1 4,5\6,3 0,97 1,02 1,12 1,12 1,24 1,24 1,31 1,40 1,49 1,57 1,73 1,96 2,00 219,1
19
250 273 5\6,3 1,14 1,20 1,25 1,39 1,39 1,47 1,56 1,67 1,78 1,88 2,04 2,16 2,37 273
300 323,9 5,6\7,1 1,30 1,37 1,43 1,53 1,59 1,69 1,81 1,92 2,06 2,17 2,40 2,50 2,75 323,9
350 355,6 5,6\8 1,43 1,50 1,57 1,71 1,74 1,84 1,98 2,10 2,38 2,48 2,75 2,90 3,00 355,6
400 406,4 6,3\8,8 1,66 1,74 1,90 2,06 2,06 2,21 2,34 2,66 2,86 3,07 3,17 3,37 406,4
450 457 6,3\10 1,83 1,92 2,10 2,27 2,27 2,44 2,59 2,95 2,95 3,32 3,52 3,74 457
500 508 6,3\11 2,10 2,10 2,22 2,34 2,65 2,65 2,83 3,04 3,23 3,50 3,73 4,11 508
550 559 6,3\12,5 2,40 2,53 2,90 2,90 3,08 3,31 3,51 4,05 4,25 4,47 559
600 610 6,3\12,5 2,59 2,73 2,90 3,10 3,32 3,57 3,78 4,11 4,53 4,83 610
650 660 7,1\14,2 2,92 3,10 3,32 3,56 4,06 4,36 4,70 4,90 5,18 660
700 711 7,1 3,12 3,31 3,54 3,79 4,33 4,53 4,71 5,02 5,54 711
750 762 8 3,52 3,76 4,03 4,61 4,91 5,34 5,64 5,90 762
800 813 8 3,50 3,72 3,98 4,27 4,88 4,88 5,30 5,66 6,25 813
850 864 8,8 4,20 4,51 5,15 5,45 5,77 6,00 6,60 864
900 914 10 3,88 4,13 4,41 4,74 5,10 5,42 5,89 6,28 6,94 914
Materials: k
Man hour include next activities: - Stainless steel [Mhr/m] x 1,10
- handling - erection - High temp. alloy steel [Mhr/m] x 1,10
Mhr/m x 0,3048 = Mhr/ft
- on-site transport - welding - Prewrapped [Mhr/m] x 1,15 (underground install.)
- prefabrication - pressure testing - Galvanized [Mhr/m] x 0,70
- Aluminium alloy [Mhr/m] x 0,85
1. PIPES (DIN 2448/2458) FOR PREFABRICATION : 8%
1.1 INSTALLATION IN PROCESS PLANT [Mhr/m] FOR INSTALLATION : 92%
CARBON STEEL - NONWRAPPED - ABOVE GROUND - WALL THICKNESS 14,2 - 60 mm

Dn-mm OD-mm t - Std|Ext 14,2 16 17,5 20 22,2 25 28 30 32 36 40 45 50 55 60 65 70 OD-mm
15 21,3 2\2 21,3
20 26,9 2\2,3 26,9
25 33,7 2\2,6 33,7
32 42,4 2\2,6 42,4
40 48,3 2,3\2,6 48,3
50 60,3 2,3\2,9 0,87 60,3
65 73,1 2,6\2,9 1,01 73,1
65 76,1 2,6\2,9 76,1
80 88,9 2,9\3,2 1,14 1,22 88,9
100 114,3 3,2\3,6 1,34 1,43 1,50 114,3
125 139,7 3,6\4 1,52 139,7
150 168,3 4\4,5 1,69 1,81 1,96 2,20 2,50 168,3
200 219,1 4,5\6,3 2,11 2,28 2,49 2,69 2,83 3,32 3,72 219,1
250 273 5\6,3 2,55 2,76 2,93 3,22 3,47 3,82 4,16 273
20
300 323,9 5,6\7,1 2,97 3,21 3,42 3,76 4,06 4,48 4,90 5,49 6,00 323,9
350 355,6 5,6\8 3,24 3,74 4,00 4,45 4,85 5,26 5,82 6,02 6,36 7,00 355,6
400 406,4 6,3\8,8 3,64 3,96 4,22 4,65 5,03 5,50 6,48 6,98 7,36 7,96 9,00 406,4
450 457 6,3\10 4,06 4,40 4,69 5,00 5,60 6,13 6,95 7,45 7,95 8,81 9,78 11,00 457
500 508 6,3\11 4,44 4,83 5,16 5,70 6,17 6,76 7,31 8,31 8,81 9,44 10,69 11,78 13,00 508
550 559 6,3\12,5 4,83 5,33 5,63 6,22 6,73 7,38 8,21 9,13 9,63 10,75 11,05 12,43 13,80 15,00 559
600 610 6,3\12,5 5,25 5,70 6,09 6,73 7,29 8,00 8,70 9,50 11,44 12,14 12,85 13,65 14,66 16,32 17,50 610
650 660 7,1\14,2 5,61 6,54 6,94 7,84 8,54 660
700 711 7,1 6,00 7,00 7,40 8,34 711
750 762 8 6,38 7,45 8,40 8,85 762
800 813 8 6,77 7,90 8,60 9,15 9,49 813
850 864 8,8 7,15 8,35 9,00 9,45 864
900 914 10 7,52 8,79 9,59 9,94 10,57 914
Materials: k
Man hour include next activities: - Stainless steel [Mhr/m] x 1,10
- handling - erection - High temp. alloy steel [Mhr/m] x 1,10
- on-site transport - welding - Prewrapped [Mhr/m] x 1,15
1. PIPES (DIN 2448/2458) FOR PREFABRICATION : 8%
CARBON STEEL - NONINSULATED - WALL THICKNESS - 2 mm - 12,5 mm

15 21,3 2\2 0,42 0,42 0,43 0,43 0,44 0,44 0,44 0,45 0,45 21,3
20 26,9 2\2,3 0,44 0,44 0,45 0,46 0,46 0,47 0,47 0,48 0,49 0,50 26,9
25 33,7 2\2,6 0,47 0,47 0,48 0,49 0,49 0,50 0,51 0,52 0,53 0,54 0,55 33,7
32 42,4 2\2,6 0,50 0,51 0,52 0,53 0,54 0,55 0,56 0,57 0,58 0,60 42,4
40 48,3 2,3\2,6 0,53 0,54 0,54 0,55 0,56 0,58 0,59 0,60 0,62 0,63 0,65 0,67 0,70 0,72 0,74 0,76 0,77 48,3
50 60,3 2,3\2,9 0,57 0,58 0,59 0,60 0,61 0,63 0,64 0,66 0,68 0,70 0,73 0,75 0,78 0,81 0,84 0,88 0,89 60,3
65 73,1 2,6\2,9 0,61 0,63 0,64 0,66 0,67 0,69 0,70 0,73 0,75 0,77 0,80 0,84 0,87 0,90 0,95 0,99 1,04 73,1
65 76,1 2,6\2,9 0,62 0,64 0,65 0,67 0,68 0,70 0,72 0,74 0,76 0,79 0,82 0,86 76,1
80 88,9 2,9\3,2 0,67 0,68 0,70 0,72 0,73 0,75 0,78 0,80 0,83 0,86 0,90 0,94 0,98 1,02 1,08 1,12 1,19 88,9
100 114,3 3,2\3,6 0,74 0,75 0,78 0,80 0,81 0,84 0,87 0,90 0,93 0,97 1,01 1,07 1,12 1,17 1,25 1,31 1,40 114,3
125 139,7 3,6\4 0,83 0,85 0,87 0,89 0,92 0,95 0,99 1,03 1,07 1,12 1,18 1,25 1,31 1,40 1,47 1,58 139,7
150 168,3 4\4,5 0,95 0,99 1,01 1,04 1,09 1,13 1,18 1,24 1,31 1,38 1,45 1,56 1,64 1,77 1,90 168,3
200 219,1 4,5\6,3 1,19 1,23 1,33 1,33 1,45 1,45 1,53 1,72 1,72 1,81 1,98 2,15 2,20 2,27 219,1
250 273 5\6,3 1,41 1,47 1,52 1,66 1,66 1,74 1,84 1,95 2,07 2,18 2,35 2,49 2,73 3,00 273
300 323,9 5,6\7,1 1,62 1,69 1,75 1,85 1,91 2,01 2,14 2,25 2,40 2,53 2,78 2,90 3,18 3,31 323,9
21
350 355,6 5,6\8 1,78 1,85 1,92 2,06 2,09 2,20 2,34 2,47 2,77 2,90 3,09 3,19 3,48 3,65 355,6
400 406 6,3\8,8 2,07 2,15 2,31 2,47 2,47 2,63 2,77 3,12 3,22 3,37 3,67 3,93 4,08 406,4
450 457 6,3\10 2,28 2,37 2,55 2,73 2,73 2,91 3,07 3,46 3,66 3,89 4,10 4,37 4,57 457
500 508 6,3\11 2,60 2,60 2,72 2,85 3,17 3,17 3,37 3,60 3,80 4,11 4,37 4,81 4,99 508
550 559 6,3\12,5 2,96 3,10 3,48 3,48 3,67 3,92 4,14 4,76 5,00 5,25 5,44 559
600 610 6,3\12,5 3,20 3,35 3,52 3,73 3,97 4,24 4,48 4,85 5,38 5,68 6,00 610
650 660 7,1\14,2 3,59 3,78 4,00 4,26 4,81 5,00 5,54 5,84 6,11 6,34 660
700 711 7,1 3,84 4,04 4,28 4,56 5,15 5,25 5,57 5,93 6,54 6,79 711
750 762 8 4,30 4,56 4,85 5,48 5,88 6,32 6,52 6,98 7,22 762
800 813 8 4,33 4,56 4,83 5,15 5,82 6,02 6,30 6,71 7,41 7,67 813
850 864 8,8 5,11 5,44 6,15 6,55 7,09 7,29 7,83 8,11 864
900 914 10 4,82 5,08 5,38 5,73 6,12 6,48 7,02 7,47 8,25 8,54 914
Man hour include next activities: Materials: k

- handling - erection - Stainless steel [Mhr/m] x 1,10 Mhr/m x 0,3048 = Mhr/ft
- on-site transport - welding - High temp. alloy steel [Mhr/m] x 1,10
- prefabrication - pressure testing - Prewraped [Mhr/m] x 0,70
1. PIPES (DIN 2448/24 58) FOR PREFABRICATION : 8%
CARBON STEEL - NONINSULATED - WALL THICKNESS 14,2 - 60 mm

Dn-mm OD-mm t - Std|Ext 14,2 16 17,5 20 22,2 25 28 30 32 36 40 45 50 55 60 OD-mm
15 21,3 2\2 21,3
20 26,9 2\2,3 26,9
25 33,7 2\2,6 33,7
32 42,4 2\2,6 42,4
40 48,3 2,3\2,6 48,3
50 60,3 2,3\2,9 0,96 60,3
65 73,1 2,6\2,9 1,11 73,1
65 76,1 2,6\2,9 76,1
80 88,9 2,9\3,2 1,27 1,36 88,9
100 114,3 3,2\3,6 1,49 1,60 1,69 114,3
125 139,7 3,6\4 1,70 139,7
150 168,3 4\4,5 1,94 2,06 2,25 2,45 2,55 168,3
200 219,1 4,5\6,3 2,44 2,62 2,88 3,14 3,32 3,66 3,96 219,1
250 273 5\6,3 3,11 3,20 3,41 3,77 4,08 4,55 5,01 273
22
300 323,9 5,6\7,1 3,48 3,74 3,99 4,42 4,81 5,37 5,93 6,46 6,76 323,9
350 355,6 5,6\8 4,11 4,38 4,68 5,27 5,57 5,82 7,15 7,45 7,82 8,02 355,6
400 406,4 6,3\8,8 4,44 4,63 4,95 5,50 5,98 6,61 7,97 8,47 9,00 9,44 10,17 406,4
450 457 6,3\10 4,77 5,16 5,52 6,00 6,69 7,39 8,52 9,96 10,66 11,24 12,72 14,00 457
500 508 6,3\11 5,70 5,69 6,09 6,78 7,39 8,18 9,75 10,75 11,35 12,01 13,92 15,64 17,00 508
550 559 6,3\12,5 6,22 6,66 7,00 7,41 8,09 8,96 10,10 12,14 13,14 14,28 15,36 16,42 18,64 20,00 559
600 610 6,3\12,5 6,42 6,73 7,22 8,04 8,78 9,73 11,00 11,83 13,68 14,68 16,00 17,33 19,77 22,52 25,00 610
650 660 7,1\14,2 7,00 7,77 8,37 9,46 10,46 660
700 711 7,1 7,76 8,33 8,83 9,69 711
750 762 8 8,27 8,89 9,29 9,92 762
800 813 8 8,79 9,44 9,74 10,54 11,52 813
850 864 8,8 9,30 10,00 10,40 11,16 864
900 914 10 9,79 10,54 11,04 11,76 12,87 914
Man hour include next activities: Materials: k

- handling - erection - Stainless steel [Mhr/m] x 1,10
- on-site transport - welding - High temp. alloy steel Mhr/m x 0,3048 = Mhr/ft
1. PIPES (ANSI and DIN)
1.3 STEAM TRACING ( Values in this table apply only to piping in plants. For steam tracing of pipe lines on piperacks or
[Mhr/m] sleepeways other table for the installation of pipes on piperacks are applied.)
CARBON STEEL STAINLESS STEEL STEAM TRACING ON PROCESS LINES
Dn-mm ø-Inch OD-mm Sch 10 Std Sch 40 XS Sch 80 Sch 160 XXS Sch 5S Sch 10S Sch 40S Sch 80S (manhour per meter of process line incl.
15 1/2” 21,3 0,60 0,61 0,63 0,66 0,62 0,63 0,65 0,67 steam supply and condensate return)
20 3/4” 26,7 0,61 0,63 0,65 0,69 0,72 0,65 0,66 0,68 0,71 ø number [Mhr/m]
25 1” 33,4 0,67 0,69 0,72 0,77 0,82 0,68 0,72 0,74 0,78 Dn tracer of tubes (proc.)
32 1 1/4” 42,2 0,72 0,75 0,80 0,85 0,95 0,73 0,78 0,82 0,87 to 3" 1/2” 1 0,80
40 1 1/2” 48,3 0,76 0,80 0,86 0,93 1,04 0,76 0,82 0,86 0,93 4” ÷ 8” 3/4” 1 0,88
50 2” 60,3 0,82 0,88 0,96 1,11 1,22 0,82 0,88 0,95 1,04 10” ÷ 16” 3/4” 2 1,30
65 2 1/2” 76,1 0,91 1,04 1,15 1,29 1,52 0,91 0,98 1,13 1,25 18” ÷ 36” 3/4” 3 1,78
80 3” 88,9 0,99 1,17 1,32 1,56 1,82 0,98 1,07 1,27 1,44 above 36 ” 3/4” 4 2,20
CARBON STEEL - WALL THICKNESS 2 - 7,1 mm

Dn-mm OD-mmt -Std|Ext 2 2,3 2,6 2,9 3,2 3,6 4 4,5 5 5,6 6,3 7,1 COPPER TUBES - DUCTILE
15 21,3 2\2 0,58 0,59 0,59 0,60 0,60 0,61 0,62 0,63 0,63 OD-mm Mhr/m OD-mm [Mhr/m]
20 26,9 2\2,3 0,61 0,62 0,62 0,63 0,64 0,65 0,66 0,67 0,68 0,69 0,70 10 0,12 22 0,29
25 33,7 2\2,6 0,64 0,65 0,66 0,67 0,68 0,69 0,71 0,72 0,73 0,75 0,77 0,79 12 0,14 25 0,32
23
32 42,4 2\2,6 0,69 0,70 0,71 0,73 0,74 0,76 0,77 0,79 0,80 0,83 0,85 14 0,18 28 0,35
40 48,3 2,3\2,6 0,72 0,73 0,75 0,76 0,77 0,79 0,81 0,83 0,85 0,88 0,90 0,93 15 0,20 30 0,36
50 60,3 2,3\2,9 0,77 0,79 0,81 0,82 0,84 0,86 0,88 0,91 0,93 0,97 1,00 1,04 16 0,21 35 0,40
65 73 2,6\2,9 0,84 0,86 0,87 0,90 0,91 0,94 0,96 0,99 1,03 1,07 1,11 1,16 18 0,24 38 0,44
65 76,1 2,6\2,9 0,85 0,87 0,89 0,91 0,93 0,96 0,99 1,02 1,05 1,09 1,13 1,18 20 0,27 42 0,52
80 88,9 2,9\3,2 0,9 0,93 0,95 0,98 1,00 1,03 1,06 1,10 1,13 1,18 1,23 1,29
` COPPER TUBES - STRONG : x 1,30
1.4 INSTRUMENT AND CONTROL PIPING

All activityes on installation and supporting these lines, also sizes to 1/2", are included.
Lines to 3 m ( 10 ft ) 5 [Mhr] totally
Lines above 3 m ( 10 ft ) 1,30 [Mhr/m] 1.6 STEAM DISTRIBUTORS AND CONDENSATE
COLLECTORS FABRICATED FROM
READY-MADE DISTRIBUTORS FOR 4 CONNECTIONS
1.5 STEAM DISTRIBUTORS AND CONDENSATE COLLECTORS (ready-made distributors for 4, 8 or 12 connections)
FABRICATED FROM PIPES AND FITTINGS
1.5.1 STEAM DISTRIBUTORS 1.6.1 STEAM DISTRIBUTORS
Fabrication :7,50 [Mhr/ea] + 1,60 [Mhr/connect.] Fabrication : 0,80 [Mhr] x number of connections
Erection :12 [Mhr/ea] (supporting included) Erection : 12 [Mhr/ea] (supporting included)
1.5.2 CONDENSATE COLLECTORS 1.6.2 CONDENSATE COLLECTORS
Fabrication :4,80 [Mhr/ea] + 2,40 [Mhr/ connect.] Mhr/m x 0,3048 = Mhr/ft Fabrication: 1,40 [Mhr] x number of connections
Erection :10 [Mhr/ea] (supporting included) Erection: 10 [Mhr/ea] (supporting included)
2. FITTING (DIN ) FOR PREFABRICATION : 85%
2.1 ELBOWS [Mhr/ea] FOR INSTALLATION: 15%

Dn-mm OD-mm ?Std|Ext 2 2,3 2,6 2,9 3,2 3,6 4 4,5 5 5,6 6,3 7,1 8 8,8 10 11 12,5 OD-mm
15 21,3 2\2 1,28 1,29 1,29 1,29 1,30 1,31 1,32 1,32 1,33 21,3
20 26,9 2\2,3 1,43 1,44 1,45 1,45 1,46 1,47 1,48 1,49 1,51 1,52 1,54 26,9
25 33,7 2\2,6 1,61 1,62 1,63 1,64 1,65 1,66 1,67 1,69 1,71 1,73 1,76 1,79 33,7
32 42,4 2\2,6 1,86 1,87 1,88 1,89 1,90 1,92 1,94 1,96 1,98 2,01 2,05 42,4
40 48,3 2,3\2,6 2,03 2,04 2,05 2,06 2,08 2,10 2,11 2,14 2,17 2,20 2,25 2,29 2,35 2,40 2,49 2,56 2,67 48,3
50 60,3 2,3\2,9 2,32 2,34 2,35 2,37 2,38 2,41 2,43 2,47 2,50 2,54 2,60 2,66 2,74 2,81 2,91 3,01 3,16 60,3
65 73,1 2,6\2,9 2,66 2,68 2,70 2,72 2,74 2,77 2,80 2,84 2,88 2,93 3,00 3,08 3,17 3,26 3,39 3,51 3,69 73,1
65 76,1 2,6\2,9 2,72 2,74 2,76 2,78 2,80 2,83 2,86 2,91 2,95 3,01 3,07 3,16 3,26 76,1
80 88,9 2,9\3,2 3,05 3,07 3,09 3,12 3,14 3,18 3,21 3,26 3,31 3,38 3,46 3,56 3,67 3,78 3,95 4,10 4,32 88,9
100 114,3 3,2\3,6 3,56 3,58 3,61 3,64 3,67 3,71 3,76 3,82 3,89 3,97 4,07 4,19 4,34 4,48 4,70 4,89 5,18 114,3
125 139,7 3,6\4 4,11 4,15 4,18 4,23 4,29 4,36 4,44 4,53 4,66 4,80 4,98 5,14 5,40 5,63 6,00 139,7
150 168,3 4\4,5 4,65 4,72 4,75 4,81 4,89 4,98 5,09 5,23 5,41 5,61 5,80 6,11 6,38 6,80 168,3
200 219,1 4,5\6,3 5,98 6,06 6,25 6,25 6,52 6,52 6,70 7,10 7,30 7,46 7,97 8,47 8,87 219,1
24
250 273 5\6,3 7,33 7,43 7,53 7,82 7,82 8,00 8,24 8,52 8,86 9,19 9,70 10,16 10,98 273
300 323,9 5,6\7,1 8,63 8,74 8,87 9,07 9,21 9,43 9,75 10,05 10,46 10,84 11,62 12,01 13,00 323,9
350 355,6 5,6\8 9,59 9,72 9,86 10,15 10,23 10,47 10,83 11,15 12,03 12,03 13,38 13,88 14,41 355,6
400 406,4 6,3\8,8 11,03 11,19 11,53 11,90 11,90 12,30 12,68 13,69 14,29 15,16 15,76 16,42 406,4
450 457 6,3\10 12,34 12,52 12,90 13,32 13,32 13,77 14,20 15,33 16,30 17,08 17,78 18,42 457
500 508 6,3\11 13,86 13,86 14,11 14,39 15,19 15,19 15,73 16,38 16,99 17,98 18,85 20,44 508
550 559 6,3\12,5 15,48 15,78 16,73 16,73 17,25 17,97 18,65 20,70 21,70 22,46 559
600 610 6,3\12,5 16,84 17,17 17,60 18,13 18,78 19,57 20,31 21,50 24,48 24,78 610
650 660 7,1\14,2 18,55 19,01 19,58 20,29 21,95 22,95 23,88 25,38 26,46 660
700 711 7,1 19,94 20,44 21,06 21,82 23,60 24,60 24,99 26,23 28,48 711
750 762 8 21,86 22,53 23,35 25,26 26,26 28,00 29,08 30,50 762
800 813 8 22,72 23,29 24,00 24,88 26,92 27,92 28,51 30,00 32,51 813
850 864 8,8 25,47 26,40 28,58 29,58 30,78 32,78 34,53 864
900 914 10 25,48 26,13 26,93 27,91 29,09 30,22 32,01 33,61 36,52 914
2.2 CAPS [Mhr/ea] x 0,50 Materials: f

- Cr-Mo alloy steel 1,40÷1,60 - High temp. alloy steel 1,00 ÷ 1,80
- Killed C.S 1,00÷1,25 - Aluminium alloy 1,50
2. FITTINGS (DIN) FOR PREFABRICATION : 85%
2.1 ELBOWS [Mhr/ea] FOR INSTALLATION : 15%
CARBON STEEL - WALL THICKNESS 14,2 - 60 mm

15 21,3 2\2 21,3
20 26,9 2\2,3 26,9
25 33,7 2\2,6 33,7
32 42,4 2\2,6 42,4
40 48,3 2,3\2,6 48,3
50 60,3 2,3\2,9 3,32 60,3
65 73,1 2,6\2,9 3,90 73,1
65 76,1 2,6\2,9 76,1
80 88,9 2,9\3,2 4,59 4,90 88,9
100 114,3 3,2\3,6 5,53 5,93 6,28 114,3
125 139,7 3,6\4 6,43 139,7
150 168,3 4\4,5 7,35 7,89 8,66 9,94 11,00 168,3
200 219,1 4,5\6,3 9,49 10,26 11,31 12,42 13,22 16,33 18,00 219,1
250 273 5\6,3 11,76 12,75 13,62 15,14 16,56 18,74 21,04 273
25
300 323,9 5,6\7,1 14,00 15,12 16,17 18,02 19,74 22,39 25,20 29,58 32,00 323,9
350 355,6 5,6\8 15,44 17,92 19,00 21,88 23,18 24,45 28,24 31,24 35,45 38,00 355,6
400 406,4 6,3\8,8 17,61 19,13 20,47 22,84 25,05 28,03 34,97 36,97 41,89 44,89 47,23 406,4
450 457 6,3\10 19,86 21,49 23,01 25,21 28,21 31,60 37,32 42,07 45,07 52,31 61,09 65,09 457
500 508 6,3\11 21,94 23,87 25,57 28,58 31,39 35,20 40,45 46,45 50,45 55,74 66,97 77,56 80,00 508
550 559 6,3\12,5 24,12 26,13 28,13 31,45 34,58 38,79 44,59 50,63 55,63 60,89 67,89 80,85 94,82 100,00 559
600 610 6,3\12,5 26,42 28,63 30,69 34,34 37,76 42,39 49,24 53,24 60,22 69,22 75,02 85,02 100,27 118,15 136,00 610
650 660 7,1\14,2 28,44 30,20 33,20 36,89 40,89 660
700 711 7,1 30,61 33,76 36,76 40,04 711
750 762 8 32,79 34,32 38,32 42,93 762
800 813 8 34,96 37,88 40,88 45,81 50,44 813
850 864 8,8 37,14 38,44 43,44 48,68 864
900 914 10 39,28 40,95 45,95 51,52 56,75 914
2.2 CAPS [Mhr/ea] x 0,50 Materials: f Stainless steel 1,25

- Cr-Mo alloy steel 1,40 ÷ 1,60 High temp. alloy steel 1,00 ÷ 1,80
- Copper alloy 1,20 Alloy steel Ni 1,60
Killed C.S 1,00 ÷ 1,25 Aluminium alloy 1,50
2.3 TEES [Mhr/ea] FOR INSTALLATION: 15%
2.3.1 STRAIGHT TEE
CARBON STEEL - WALL THICKNESS 2 mm - 12,5 mm
15 21,3 2\2 1,89 1,90 1,91 1,91 1,92 1,93 1,94 1,96 1,97 21,3
20 26,9 2\2,3 2,11 2,12 2,13 2,14 2,15 2,17 2,18 2,20 2,23 2,25 2,28 26,9
25 33,7 2\2,6 2,38 2,39 2,40 2,42 2,43 2,45 2,47 2,49 2,52 2,56 2,60 2,64 33,7
32 42,4 2\2,6 2,73 2,75 2,76 2,78 2,80 2,83 2,85 2,89 2,93 2,97 3,02 42,4
40 48,3 2,3\2,6 2,97 2,99 3,01 3,03 3,05 3,08 3,11 3,15 3,19 3,25 3,31 3,38 3,47 3,55 3,68 3,79 3,96 48,3
50 60,3 2,3\2,9 3,41 3,43 3,45 3,48 3,50 3,54 3,58 3,62 3,68 3,75 3,83 3,93 4,04 4,15 4,31 4,46 4,68 60,3
65 73,1 2,6\2,9 3,90 3,93 3,95 3,98 4,01 4,06 4,11 4,17 4,23 4,31 4,42 4,54 4,68 4,81 5,01 5,19 5,46 73,1
65 76,1 2,6\2,9 3,99 4,02 4,05 4,08 4,11 4,15 4,20 4,27 4,33 4,42 4,53 4,65 4,80 76,1
80 88,9 2,9\3,2 4,46 4,49 4,52 4,56 4,60 4,65 4,71 4,78 4,86 4,96 5,08 5,23 5,41 5,57 5,83 6,06 6,40 88,9
100 114,3 3,2\3,6 5,20 5,24 5,28 5,33 5,37 5,44 5,51 5,61 5,70 5,83 5,98 6,17 6,40 6,61 6,94 7,23 7,69 114,3
125 139,7 3,6\4 6,01 6,06 6,12 6,20 6,28 6,39 6,51 6,66 6,84 7,07 7,33 7,59 7,98 8,33 8,89 139,7
150 168,3 4\4,5 6,79 6,90 6,94 7,04 7,17 7,30 7,48 7,69 7,95 8,26 8,56 9,03 9,44 10,09 168,3
200 219,1 4,5\6,3 8,74 8,86 9,15 9,15 9,56 9,56 9,84 10,20 10,60 10,99 11,77 12,25 13,15 219,1
26
250 273 5\6,3 10,70 10,85 11,01 11,44 11,44 11,73 12,09 12,52 13,04 13,54 14,32 15,02 16,28 273
300 323,9 5,6\7,1 12,59 12,77 12,96 13,26 13,47 13,81 14,30 14,76 15,38 15,97 17,16 17,75 19,26 323,9
350 355,6 5,6\8 13,97 14,16 14,37 14,82 14,94 15,32 15,85 16,35 17,69 18,69 19,75 20,75 21,32 355,6
400 406,4 6,3\8,8 16,08 16,31 16,83 17,39 17,39 18,01 18,59 20,13 21,13 22,38 23,38 24,30 406,4
450 457 6,3\10 17,98 18,25 18,83 19,47 19,47 20,16 20,81 22,55 23,55 25,22 26,22 27,27 457
500 508 6,3\11 20,20 20,20 20,59 21,02 22,23 22,23 23,06 24,05 24,99 26,49 27,83 30,26 508
550 559 6,3\12,5 22,58 23,04 24,49 24,49 25,29 26,39 27,43 30,56 32,56 33,24 559
600 610 6,3\12,5 24,57 25,08 25,73 26,54 27,54 28,73 29,87 31,68 36,23 37,23 610
650 660 7,1\14,2 27,08 27,78 28,66 29,74 32,27 33,27 35,99 37,99 39,17 660
700 711 7,1 29,11 29,87 30,82 31,98 34,71 35,71 36,83 38,72 42,16 711
750 762 8 31,95 32,97 34,22 36,15 38,15 40,45 41,45 45,14 762
800 813 8 33,17 34,04 35,13 36,46 39,59 39,59 42,02 44,19 48,13 813
850 864 8,8 37,28 38,70 42,03 44,03 46,92 48,92 51,12 864
900 914 10 37,20 38,18 39,41 40,91 42,72 44,43 47,17 49,61 54,06 914
2.3.2 REDUCED TEE [Mhr/ea] x 0,95 Materials: f - Stainless steel 1,25

- Killed C.S 1,00 ÷ 1,25 - Aluminium alloy 1,50
2.3 TEES FOR PREFABRICATION : 85%
2.3.1 STRAIGHT TEE [Mhr/ea] FOR INSTALLATION : 15%
CARBON STEEL - WALL THICKNESS 14,2 - 60 mm

15 21,3 2\2 21,3
20 26,9 2\2,3 26,9
25 33,7 2\2,6 33,7
32 42,4 2\2,6 42,4
40 48,3 2,3\2,6 48,3
50 60,3 2,3\2,9 4,92 60,3
65 73,1 2,6\2,9 5,79 73,1
65 76,1 2,6\2,9 76,1
80 88,9 2,9\3,2 6,81 7,28 88,9
100 114,3 3,2\3,6 8,22 8,82 9,36 114,3
125 139,7 3,6\4 9,55 139,7
150 168,3 4\4,5 10,92 11,75 12,92 14,88 16,00 168,3
200 219,1 4,5\6,3 14,09 15,27 16,87 18,57 19,80 22,00 24,54 219,1
27
250 273 5\6,3 17,47 18,98 20,31 22,64 24,81 28,14 31,65 273
300 323,9 5,6\7,1 20,79 22,51 24,11 26,94 29,57 33,62 37,91 44,60 50,00 323,9
350 355,6 5,6\8 22,90 25,69 28,69 31,74 33,74 36,66 40,04 47,04 53,47 58,00 355,6
400 406,4 6,3\8,8 26,12 28,44 30,49 34,11 37,49 42,04 48,64 52,64 58,22 63,22 71,37 406,4
450 457 6,3\10 29,47 31,96 34,28 38,22 42,22 47,40 56,14 62,98 67,98 79,04 92,45 100,00 457
500 508 6,3\11 32,55 35,50 38,09 42,69 46,99 52,80 58,00 65,00 70,00 84,19 101,35 117,52 117,52 130,00 508
550 559 6,3\12,5 35,78 38,90 41,90 46,99 51,76 58,20 67,05 83,92 93,92 102,65 112,65 122,46 143,80 150,00 559
600 610 6,3\12,5 39,20 42,58 45,72 51,30 56,53 63,60 70,17 80,17 95,60 104,60 118,73 128,73 152,02 179,35 190,00 610
650 660 7,1\14,2 42,19 45,47 49,47 55,21 61,21 660
700 711 7,1 45,42 49,28 53,28 59,83 711
750 762 8 48,64 52,09 57,09 64,14 762
800 813 8 51,87 54,91 60,91 68,44 75,52 813
850 864 8,8 55,10 60,72 64,72 72,74 864
900 914 10 58,27 63,47 68,47 76,97 84,97 914
2.3.2 REDUCED TEE [Mhr/ea] x 0,95 Materials: f - Stainless steel 1,25

- Killed C.S 1,00 ÷ 1,25 - Aluminium alloy 1,50
2.4 REDUCERS - CONCENTRIC AND ECCENTRIC [Mhr/ea] FOR INSTALLATION: 15%

15 21,3 2\2 21,3
20 26,9 2\2,3 1,49 1,50 1,50 1,51 1,52 1,53 1,54 1,55 1,56 1,58 1,26 26,9
25 33,7 2\2,6 1,67 1,68 1,69 1,70 1,71 1,72 1,73 1,75 1,77 1,79 1,81 1,84 33,7
32 42,4 2\2,6 1,91 1,92 1,93 1,95 1,96 1,97 1,99 2,01 2,04 2,07 2,10 42,4
40 48,3 2,3\2,6 2,13 2,14 2,15 2,16 2,18 2,20 2,22 2,25 2,27 2,31 2,35 2,40 2,46 2,51 2,60 2,64 2,70 48,3
50 60,3 2,3\2,9 2,38 2,39 2,41 2,43 2,44 2,46 2,49 2,52 2,56 2,60 2,65 2,72 2,79 2,86 2,96 3,05 3,19 60,3
65 73,1 2,6\2,9 2,74 2,76 2,78 2,80 2,82 2,85 2,88 2,92 2,96 3,01 3,08 3,16 3,25 3,34 3,47 3,58 3,76 73,1
65 76,1 2,6\2,9 2,91 2,93 2,95 2,97 3,00 3,03 3,06 3,11 3,16 3,22 3,29 3,38 3,49 3,59 3,74 3,87 4,08 76,1
80 88,9 2,9\3,2 3,16 3,18 3,20 3,22 3,25 3,29 3,32 3,37 3,43 3,49 3,58 3,68 3,79 3,90 4,07 4,22 4,45 88,9
100 114,3 3,2\3,6 3,59 3,61 3,64 3,67 3,69 3,74 3,78 3,84 3,91 3,99 4,09 4,21 4,35 4,48 4,69 4,88 5,16 114,3
125 139,7 3,6\4 4,19 4,22 4,26 4,31 4,36 4,44 4,52 4,61 4,73 4,88 5,06 5,22 5,48 5,71 6,07 139,7
150 168,3 4\4,5 4,72 4,78 4,82 4,88 4,95 5,04 5,14 5,27 5,43 5,62 5,82 6,08 6,37 6,73 168,3
200 219,1 4,5\6,3 5,94 6,02 6,15 6,18 6,38 6,42 6,59 6,94 7,04 7,30 7,69 8,36 8,51 219,1
28
250 273 5\6,3 7,39 7,44 7,54 7,80 7,80 8,06 8,19 8,45 8,91 9,09 9,52 10,06 11,02 273
300 323,9 5,6\7,1 8,77 8,87 9,00 9,16 9,40 9,52 9,80 10,10 10,49 10,89 11,50 12,00 12,81 323,9
350 355,6 5,6\8 10,02 10,09 10,23 10,46 10,62 10,83 11,15 11,51 12,16 12,39 13,35 13,78 14,57 355,6
400 406,4 6,3\8,8 11,31 11,47 11,73 12,10 12,14 12,50 12,91 13,65 14,14 14,96 15,70 16,40 406,4
450 457 6,3\10 12,79 12,89 13,19 13,61 13,81 14,06 14,53 15,37 15,93 16,90 17,72 18,46 457
500 508 6,3\11 14,31 14,55 14,92 15,59 15,59 16,15 16,74 17,72 18,26 19,72 20,60 508
550 559 6,3\12,5 16,01 16,32 17,00 17,44 17,73 18,43 19,17 20,65 21,20 22,66 559
600 610 6,3\12,5 17,62 17,81 18,21 19,03 19,40 20,12 20,93 21,97 23,76 24,76 610
650 660 7,1\14,2 19,28 19,72 20,28 20,96 22,25 22,68 24,45 25,11 27,92 660
700 711 7,1 20,95 21,23 21,83 22,57 23,96 24,88 25,65 27,69 28,94 711
750 762 8 22,75 23,40 24,19 25,68 26,67 28,24 29,01 31,04 762
800 813 8 24,57 24,96 25,82 27,41 28,47 29,36 31,71 33,14 813
850 864 8,8 26,53 27,44 29,13 30,27 32,05 32,93 35,24 864
900 914 10 28,50 29,05 30,22 32,05 33,05 35,71 37,33 914
Man hour include next activities: Materials: f - Stainless steel 1,25

- handling - erection - Cr Mo alloy steel 1,40 ÷ 1,60 - High temp. alloy steel 1,00 ÷ 1,80
- prefabrication - pressure testing - Killed C.S. 1,00 ÷ 1,25 - Aluminium alloy 1,50
2.4 REDUCERS - CONCENTRIC AND ECCENTRIC [Mhr/ea] FOR INSTALLATION : 15%
CARBON STEEL - WALL THICKNESS 14,2 -60 mm

15 21,3 2\2 21,3
20 26,9 2\2,3 26,9
25 33,7 2\2,6 33,7
32 42,4 2\2,6 42,4
40 48,3 2,3\2,6 48,3
50 60,3 2,3\2,9 3,32 60,3
65 73,1 2,6\2,9 3,97 73,1
65 76,1 2,6\2,9 76,1
80 88,9 2,9\3,2 4,73 5,05 88,9
100 114,3 3,2\3,6 5,50 5,88 6,23 114,3
125 139,7 3,6\4 6,50 139,7
150 168,3 4\4,5 7,22 7,75 8,18 8,89 9,80 168,3
200 219,1 4,5\6,3 9,09 9,82 10,70 11,75 12,91 14,63 15,00 219,1
29
250 273 5\6,3 11,45 12,34 13,25 14,68 16,09 17,75 20,75 273
300 323,9 5,6\7,1 13,82 14,88 16,01 17,52 19,32 21,59 24,36 28,07 30,00 323,9
350 355,6 5,6\8 15,70 17,63 18,25 21,03 22,06 24,45 29,70 31,26 36,02 38,00 355,6
400 406,4 6,3\8,8 17,64 19,06 21,18 22,49 25,92 27,58 32,86 36,63 40,48 42,82 45,78 406,4
450 457 6,3\10 19,96 21,53 23,22 26,85 28,16 31,28 36,11 44,27 48,27 52,14 57,02 59,98 457
500 508 6,3\11 22,18 24,05 25,90 28,42 32,87 34,98 43,12 46,30 50,60 55,76 66,03 70,78 76,78 508
550 559 6,3\12,5 24,47 27,53 28,60 31,39 34,80 38,70 44,03 50,42 56,42 63,23 68,39 81,83 90,48 95,48 559
600 610 6,3\12,5 26,82 28,97 32,34 34,37 38,12 42,42 50,79 54,01 60,03 69,03 75,61 84,61 100,29 117,98 130,00 610
650 660 7,1\14,2 29,01 32,74 33,97 39,38 41,41 660
700 711 7,1 31,28 35,24 37,88 40,27 711
750 762 8 33,56 37,82 40,68 43,24 762
800 813 8 35,84 40,40 43,48 46,22 51,35 813
850 864 8,8 38,13 42,99 46,27 49,19 864
900 914 10 40,39 45,55 49,05 52,14 57,96 914

- prefabrication - pressure testing - Killed C.S. 1,00 ÷ 1,25 - Aluminium alloy 1,50
3. FLANGES FOR PREFABRICATION : 80%
3.1 WELDING NECK [Mhr/ea] FOR INSTALLATION: 20%
CARBON STEEL
150# 300# 400# 600# 900# 1500# 2500#

PN6-16 PN25-40 PN64 PN100 PN160 PN250 PN320
Dn-mm ø-Inch [kg] [Mhr/ea] [kg/Mhr] [kg] [Mhr/ea] [kg/Mhr] [kg] [Mhr/ea] [kg/Mhr] [kg] [Mhr/ea][kg/Mhr] [kg] [Mhr/ea] [kg/Mhr] [kg] [Mhr/ea] [kg/Mhr] [kg] [Mhr/ea] [kg/Mhr] ø-Inch
15 1/2” 0,5 1,15 0,43 0,8 1,29 0,62 0,9 1,29 0,70 0,9 1,38 0,65 1,9 1,64 1,16 1,9 1,97 0,96 3,6 2,39 1,51 1/2”
20 3/4” 0,7 1,22 0,57 1,3 1,37 0,95 1,5 1,37 1,09 1,5 1,46 1,03 2,6 1,73 1,50 2,6 2,07 1,26 4,0 2,52 1,59 3/4”
25 1” 1,1 1,32 0,83 1,7 1,48 1,15 1,9 1,48 1,28 1,9 1,57 1,21 3,8 1,86 2,04 3,8 2,21 1,72 6,0 2,68 2,24 1”
32 1 1/4” 1,5 1,46 1,03 2,2 1,63 1,35 2,6 1,63 1,60 2,6 1,73 1,50 4,4 2,03 2,17 4,4 2,40 1,83 9,0 2,90 3,10 1 1/4”
40 1 1/2” 1,8 1,56 1,15 3,2 1,73 1,85 3,3 1,73 1,91 3,3 1,83 1,80 6,1 2,16 2,82 6,1 2,55 2,39 13,0 3,10 4,19 1 1/2”
50 2” 2,7 1,73 1,56 3,6 1,91 1,88 4,7 1,91 2,46 4,7 2,02 2,33 11,1 2,39 4,64 11,1 2,80 3,96 19,0 3,45 5,51 2”
65 2 1/2” 4,4 1,99 2,21 5,4 2,19 2,47 6,5 2,16 3,01 6,5 2,31 2,81 15,5 2,75 5,64 15,5 3,19 4,86 24,0 3,90 6,15 2 1/2”
80 3” 5,2 2,26 2,30 7,4 2,48 2,98 8,7 2,48 3,51 8,7 2,61 3,33 14,0 3,08 4,55 20,5 3,61 5,68 43,0 4,49 9,58 3”
100 4” 7,5 2,63 2,85 11,9 2,87 4,15 14,0 2,87 4,88 18,1 3,02 5,99 23,0 3,51 6,55 30,5 4,19 7,28 66,0 5,12 12,89 4”
125 5” 9,2 3,05 3,02 16,0 3,32 4,82 19,0 3,32 5,72 30,0 3,48 8,62 37,0 3,94 9,39 58,0 4,87 11,91 111,0 6,05 18,35 5”
150 6” 1,0 3,06 3,59 20,0 3,74 5,35 26,0 3,74 6,95 36,0 4,46 8,07 49,0 4,96 9,88 70,0 6,90 10,15 172,0 8,44 20,38 6”
200 8” 18,3 4,30 4,26 31,0 4,98 6,23 40,0 4,98 8,04 50,0 6,10 8,19 84,0 6,75 12,45 119,0 8,96 13,28 261,0 11,11 23,50 8”
30
250 10” 25,0 5,30 4,72 44,0 6,40 6,87 54,0 6,40 8,44 90,0 7,57 11,89 123,0 9,08 13,55 204,0 11,18 18,25 485,0 15,10 32,12 10”
300 12” 39,0 6,29 6,21 64,0 7,67 8,35 78,0 7,90 9,87 110,0 9,02 12,20 168,0 11,75 14,30 303,0 14,68 20,64 730,0 18,12 40,28 12”
350 14” 51,0 7,07 7,21 88,0 8,64 10,18 105,0 9,17 11,45 150,0 10,16 14,77 186,0 13,25 14,03 400,0 16,98 23,55 14”
400 16” 60,0 8,10 7,41 113,0 9,91 11,40 131,0 11,18 11,72 190,0 11,65 16,30 224,0 15,24 14,70 510,0 19,56 26,08 16”
450 18” 71,0 9,14 7,77 134,0 11,20 11,97 159,0 12,63 12,59 240,0 13,97 17,17 300,0 17,25 17,40 18”
500 20” 88,0 11,02 7,99 171,0 12,51 13,67 190,0 14,11 13,47 295,0 16,08 18,34 373,0 19,29 19,34 20” Notice:
550 22” 103,5 11,28 9,18 204,5 13,83 14,78 232,5 15,60 14,90 330,0 18,33 18,01 526,5 21,36 24,65 22” Unit weights in this table
600 24” 119,0 12,36 9,62 238,0 15,18 15,68 275,0 17,11 16,07 365,0 21,33 17,12 680,0 23,46 28,99 24” refer to welding neck flanges acc.
650 26” 136,0 14,22 9,57 304,0 16,53 18,39 340,0 18,62 18,26 404,0 23,21 17,41 715,0 25,56 27,98 26” to ANSI B 16-5.1977.
700 28” 143,0 14,94 9,57 367,0 17,90 20,50 400,0 20,17 19,83 480,0 25,13 19,10 840,0 27,70 30,33 28”
750 30” 168,0 16,58 10,14 422,0 19,29 21,87 454,0 21,72 20,90 560,0 27,07 20,69 975,0 29,86 32,65 30” for to 24”
800 32” 197,0 17,77 11,09 465,0 20,70 22,47 522,0 23,29 22,41 680,0 29,02 23,43 1170,0 32,04 36,52 32” and BS-3293-1960 (1)
850 34” 211,0 18,98 11,12 545,0 22,11 24,65 590,0 24,88 23,72 750,0 30,99 24,20 1375,0 34,24 40,16 34” for26” ÷ 36”
900 36” 236,0 20,18 11,70 590,0 23,53 25,08 670,0 26,45 25,33 795,0 34,89 22,78 1565,0 38,39 40,77 36”

- prefabrication - pressure testing - Killed C.S. 1,00 ÷ 1,25 - Aluminium alloy 1,50 kg x 0,4536 = lbs
kg/Mhr x 2,2046 = lbs/Mhr
3. FLANGES kg x 0.4536 = lbs FOR PREFABRICATION: 80%
3.2 SLIP - ON [Mhr/ea] kg/Mhr x 2,2046 = lbs/Mhr FOR INSTALLATION : 20%
CARBON STEEL
150# 300# 400# 600# 900# 1500# 2500#
PN6-16 PN25-40 PN64 PN100 PN160 PN250 PN320
Dn-mm ø-Inch [kg] [Mhr/ea] [kg/Mhr] [kg] [Mhr/ea] [kg/Mhr] [kg] [Mhr/ea] [kg/Mhr] [kg [Mhr/ea] [kg/Mhr] [kg] [Mhr/ea] [kg/Mhr] [kg] [Mhr/ea] [kg/Mhr] [kg] [Mhr/ea] [kg/Mhr] ø-Inch
15 1/2” 0,4 1,27 0,31 0,7 1,42 0,49 0,8 1,42 0,56 0,8 1,51 0,53 1,7 1,75 0,97 1,7 2,08 0,82 3,0 2,49 1,20 1/2”
20 3/4” 0,7 1,36 0,51 1,1 1,51 0,73 1,4 1,51 0,93 1,4 1,60 0,88 2,3 1,86 1,24 2,3 2,19 1,05 4,0 2,62 1,53 3/4”
25 1” 0,8 1,49 0,54 1,4 1,65 0,85 1,6 1,65 0,97 1,6 1,74 0,92 3,4 2,00 1,70 3,4 2,35 1,45 5,0 2,79 1,79 1”
32 1 1/4” 1,1 1,66 0,66 1,8 1,83 0,98 2,1 1,83 1,15 2,1 1,93 1,09 3,9 2,20 1,77 3,9 2,57 1,52 8,0 3,03 2,64 1 1/4”
40 1 1/2” 1,4 1,78 0,79 2,6 1,96 1,33 3,1 1,96 1,58 3,1 2,06 1,50 5,4 2,35 2,30 5,4 2,73 1,98 11,0 3,21 3,43 1 1/2”
50 2” 2,2 2,01 1,09 3,4 2,19 1,55 3,7 2,19 1,69 3,7 2,30 1,61 9,8 2,60 3,77 9,8 3,01 3,26 17,0 3,52 4,83 2”
65 2 1/2” ,6 2,35 1,53 4,4 2,55 1,73 5,4 2,55 2,12 5,4 2,67 2,02 13,7 3,00 4,57 13,7 3,45 3,97 24,0 4,01 5,99 2 1/2”
80 3” 4,1 2,70 1,52 6,1 2,92 2,09 7,3 2,92 2,50 7,3 3,05 2,39 11,6 3,42 3,39 18,0 3,91 4,60 36,0 4,52 7,96 3”
100 4” 5,6 3,24 1,73 10,1 3,48 2,90 11,5 3,48 3,30 15,8 3,63 4,35 19,8 4,03 4,91 27,8 4,57 6,08 55,0 5,25 10,48 4”
125 5” 6,3 3,84 1,64 12,5 4,11 3,04 14,5 4,11 3,53 24,5 4,27 5,74 32,0 4,72 6,78 52,0 5,33 9,76 93,0 6,09 15,27 5”
150 6” 7,5 4,54 1,65 14,1 4,84 2,91 19,0 4,84 3,93 29,5 5,02 5,88 41,2 5,52 7,46 61,0 6,19 9,85 142,0 7,02 20,23 6”
200 8” 12,6 6,28 2,01 24,8 6,66 3,72 29,0 6,66 4,35 43,0 6,89 6,24 71,0 7,54 9,42 104,0 8,40 12,38 214,0 9,48 22,57 8”
31
250 10” 18,5 7,78 2,38 37,1 8,26 4,49 39,5 8,26 4,78 70,0 8,55 8,19 100,0 9,35 10,70 175,0 10,42 16,79 407,0 11,76 34,61 10”
300 12” 28,0 9,25 3,03 50,0 9,82 5,09 58,0 9,82 5,91 86,0 10,17 8,46 133,0 11,14 11,94 264,0 12,44 21,22 573,0 14,06 40,75 12”
350 14” 36,0 10,33 3,48 70,0 11,01 6,36 82,0 11,01 7,45 100,0 11,42 8,76 152,0 12,57 12,09 308,0 14,10 21,84 14”
400 16” 46,0 11,83 3,89 97,0 12,62 7,69 105,0 12,62 8,32 142,0 13,10 10,84 184,0 14,43 12,75 352,0 16,21 21,71 16”
450 18” 50,0 13,34 3,75 123,0 14,25 8,6 126,0 14,25 8,84 175,0 14,79 11,83 258,0 16,32 15,81 18”
500 20” 64,0 14,88 4,30 133,0 15,90 8,3 152,0 15,90 9,56 221,0 16,52 13,38 317,0 18,24 17,38 20” Notice:
550 22” 76,5 16,43 4,66 170,5 17,58 9,70 185,0 17,58 10,52 268,0 18,26 14,68 462,5 20,19 22,91 22” Unit weights in this table refer
600 24” 89,0 18,00 4,94 208,0 19,27 10,79 218,0 19,27 11,31 315,0 20,03 15,73 608,0 22,16 27,44 24” to slip on flanges
650 26” 106,0 19,55 5,42 255,0 20,95 12,17 295,0 20,95 14,08 425,0 21,79 19,50 692,0 24,14 28,67 26” acc. to
700 28” 126,0 21,14 5,96 321,0 22,67 14,16 354,0 22,67 15,62 470,0 23,59 19,92 817,0 26,16 31,23 28” ANSI B 16-5. 1977.
750 30” 140,0 22,74 6,16 362,0 24,41 14,83 408,0 24,41 16,71 533,0 25,40 20,98 942,0 28,20 33,40 30” for to 24”
800 32” 168,0 24,36 6,90 398,0 26,15 15,22 465,0 26,15 17,78 624,0 27,23 22,92 1135,0 30,25 37,52 32” and BS-3293-1960
850 34” 179,0 25,98 6,89 480,0 27,91 17,20 522,0 27,91 18,70 681,0 29,08 23,42 1339,0 32,33 41,42 34” for 26” ÷ 36”
900 36” 205,0 27,59 7,43 540,0 29,67 18,20 601,0 29,67 20,26 726,0 30,91 23,49 1521,0 34,40 44,22 36”
3.3. SOCKET WELDING [Mhr/ea] x 0,60 Man hour include next activities: Materials: f - Stainless steel 1,25
3.4. LAP JOINT + STUB END [Mhr/ea] x 0,60 - handling - erection - Cr Mo alloy steel 1,40 ÷ 1,60 - High temp. alloy steel 1,00 ÷ 1,80
3.5. BLIND [Mhr/ea] x 0,30 - on-site transport - welding - Copper alloy 1,20 - Alloy steel Ni 1,60
3.6. ORIFICE COMPLETE [Mhr/ea] x 2,50 - prefabrication - pressure testing - Killed C.S. 1,00 ÷ 1,25 - Aluminium alloy 1,50
4. SMALL FITTINGS [Mhr/ea]
4.1 WELDOLETS, SOCKOLETS, NIPOLETS, etc. 4.2 HALF COUPLINGS FOR WELDING FOR PREFABRICATION : 85%
FOR INSTALLATION: 15%
CARBON STEEL CARBON STEEL
1500# 3000# 6000# 3000# 6000#
Dn-mm ø-Inch OD-mm Std XS XXS Dn-mm ø-Inch OD-mm XS XXS
15 1/2” 21,3 1,39 1,44 1,57 15 1/2” 21,3 1,27 1,31
20 3/4” 26,7 1,56 1,63 1,84 20 3/4” 26,7 1,44 1,53
25 1” 33,4 1,8 1,92 2,24 25 1” 33,4 1,69 1,82
32 1 1/4” 42,2 2,12 2,28 2,80 32 1 1/4” 42,2 2,00 2,16
40 1 1/2” 48,3 2,33 2,53 3,21 40 1 1/2” 48,3 2,23 2,47
50 2” 60,3 2,72 3,02 4,04 50 2” 60,3 2,66 3,17
65 2 1/2” 73 3,42 3,85 5,46 65 2 1/2” 73 3,38 3,90
80 3” 88,9 4,05 4,67 7,00 80 3” 88,9 4,10 5,03
100 4” 114,3 4,99 6,02 9,64 100 4” 114,3 5,27 6,17
125 5” 141,3 6,05 7,50 12,78
150 6” 168,3 7,07 9,42 16,89 4.3 FITTINGS WITH SOCKET ENDS 4.4 THREADED FITTINGS
200 8” 219,1 9,96 13,83 23,28 CARBON STEEL 4.4.1 CARBON STEEL
250 10” 273 13,47 17,30 WITH ONE END WITH ONE END
32
300 12” 323,9 16,23 20,61 Dn-mm ø-Inch OD-mm [Mhr/ea] Dn-mm ø-Inch OD-mm [Mhr/ea]
350 14” 355,6 17,97 22,83 15 1/2” 21,3 0,77 WITH 2 ENDS x 2 15 1/2” 21,3 0,17
400 16” 406,4 20,50 26,12 20 3/4” 26,7 0,89 WITH 3 ENDS x 3 20 3/4” 26,7 0,18
450 18” 457 23,03 29,41 25 1” 33,4 1,02 25 1” 33,4 0,20
500 20” 508 25,58 32,72 32 1 1/4” 42,2 1,19 32 1 1/4” 42,2 0,23
550 22” 559 28,12 36,02 40 1 1/2” 48,3 1,34 40 1 1/2” 48,3 0,27
600 24” 610 30,67 39,34 50 2” 60,3 1,57 50 2” 60,3 0,32
650 26” 660 33,18 42,59 65 2 1/2” 73 1,90 65 2 1/2” 73 0,42
700 28” 711 35,75 45,93 80 3” 88,9 2,23 80 3” 88,9 0,53
750 30” 762 38,27 49,21 100 4” 114,3 2,68 100 4” 114,3 0,70
Materials:
Man hour include next activities: (FOR WELDED FITTINGS ONLY) f 4.4.2 NON-FERROUS METALS
- handling - erection - Stainless steel 1,25 VALUES FOR
- on-site transport - welding - Cr Mo alloy steel 1,40 ÷ 1,60 CARBON STEEL x 0,50
- prefabrication - pressure testing - High temp. alloy steel 1,00 ÷ 1,80 4.4.3 "HERMETO" COUPLINGS
- Copper alloy 1,20 VALUES IN
- Alloy steel Ni 1,60 TABLE 4.4.1 x 0,25
- Killed C.S. 1,00 ÷ 1,25
- Aluminium alloy 1,50
5. VALVES
5.1 VALVES WITH FLANGED ENDS
5.1.1 GATE, GLOBE, CHECK, SWING CHECK, BONNET, VF - Factor for installation of flanged valves
BALL, BUTTERFLY, FILTER, etc [Mhr/ea]
for flanged valves Dn to 100 Dn 125 ÷ 200 Dn above 250

150# 300# 400# 600# 900# 1500# 2500# ø to 4” ø 5” ÷ 8” ø above 10”
Dn-mm ø-Inch PN6-16 25-40 PN64 PN100 PN160 PN250 PN320 PN 6 ÷ 16 150# 1,00 1,00 1,00
15 1/2” 0,26 0,28 0,34 0,35 0,35 0,39 0,40 PN 25 ÷ 40 300# 1,20 1,15 1,10
20 3/4” 0,35 0,37 0,44 0,45 0,46 0,51 0,52 PN 64 400# 1,41 1,29 1,16
25 1” 0,43 0,45 0,55 0,56 0,57 0,63 0,65 PN 100 600# 1,44 1,32 1,21
32 1 1/4” 0,55 0,58 0,70 0,72 0,73 0,80 0,83 PN 160 900# 1,66 1,45 1,33
40 1 1/2” 0,67 0,71 0,86 0,88 0,89 0,99 1,02 PN 250 1500# 1,90 1,60 1,46
50 2” 0,83 0,87 1,06 1,08 1,10 1,21 1,25 PN 320 2500# 2,19 1,76 1,61
65 2 1/2” 1,05 1,11 1,35 1,38 1,39 1,54 1,59
80 3” 1,27 1,33 1,62 1,66 1,68 1,85 1,91
100 4” 1,51 1,60 1,94 1,98 2,01 2,21 2,28 (included in table)
33
125 5” 1,81 1,90 2,12 2,17 2,38 2,40 2,64

150 6” 1,88 2,16 2,42 2,48 2,72 2,74 3,02
200 8” 2,88 2,90 3,23 3,30 3,63 3,65 4,03
250 10” 4,25 4,68 4,93 5,14 5,65 6,21 6,84
300 12” 5,61 5,92 5,92 6,17 6,78 7,45 8,21
350 14” 5,95 6,55 6,90 7,20 7,91 8,69
400 16” 7,48 7,89 7,89 8,23 9,04 9,93 5.1.2 CONTROL VALVES [Mhr/ea] x 4,0
450 18” 7,65 8,42 8,87 9,26 10,17 11,17 5.1.3 SAFETY VALVES [Mhr/ea] x 4,50
500 20” 9,35 9,86 9,86 10,29 11,31 12,41 5.1.4 HYDRANTS [Mhr/ea] x 2,0
550 22” 9,85 10,29 10,85 11,31 12,44 13,65 5.1.5 FLOW RATE METER [Mhr/ea] x 5,0
600 24” 10,20 11,22 11,83 12,34 13,57 14,89 5.1.6 LEVEL GAUGES [Mhr/ea] x 2,70
650 26” 11,05 12,16 12,82 13,37 14,70 5.1.7 CONDENSATE SEPARATORS [Mhr/ea] x 2,50
700 28” 11,90 13,09 13,80 14,40 15,83 5.1.8 SIGHT GLASS [Mhr/ea] x 1,80
750 30” 12,75 14,03 14,79 15,43 16,96 5.1.9 VENTURI TUBE [Mhr/ea] x 1,50
800 32” 13,60 14,96 15,78 16,46 18,09 5.1.10 VALVES WITH E.M. DRIVE [Mhr/ea] x 3,0
850 34” 14,45 15,90 16,76 17,48 19,22
900 36” 15,30 16,83 17,75 18,51 20,35
5. VALVES
5.2 VALVES WITH WELDING ENDS [Mhr/ea]
5.2.1 BUTT WELD 5.2.2 VALVES WITH SOCKET ENDS 5.3 VALVES WITH THREADED ENDS
CARBON STEEL 150# 300# 400# 600# 800# 900# 1500# 2500# CARBON STEEL
Dn-mm ø-Inch OD-mm PN6-16 25-40 PN64 PN100 PN160 PN250 PN320 Dn-mm ø-Inch OD-mm [Mhr/ea] ø-Inch OD-mm [Mhr/ea]
15 1/2” 21,3 1,40 1,42 1,48 1,48 0,71 1,49 1,52 1,54 15 1/2” 21,3 0,96 1/2" 21,3 0,52
20 3/4” 26,7 1,61 1,63 1,71 1,72 0,83 1,72 1,77 1,79 20 3/4” 26,7 1,12 3/4” 26,7 0,63
25 1” 33,4 1,88 1,90 2,00 2,01 0,98 2,02 2,08 2,10 25 1” 33,4 1,32 1” 33,4 0,75
32 1 1/4” 42,2 2,23 2,26 2,39 2,40 1,16 2,41 2,49 2,51 32 1 1/4” 42,2 1,59 1 1/4” 42,2 0,92
40 1 1/2” 48,3 2,50 2,54 2,69 2,71 1,33 2,72 2,81 2,84 40 1 1/2” 48,3 1,81 1 1/2” 48,3 1,11
50 2” 60,3 2,95 3,00 3,19 3,21 1,59 3,22 3,34 3,37 50 2” 60,3 2,15 2” 60,3 1,35
65 2 1/2” 73 3,62 3,68 3,92 3,95 1,94 3,97 4,11 4,16 65 2 1/2” 73 2,65 2 1/2” 73 1,73
80 3” 88,9 4,31 4,38 4,66 4,70 2,30 4,72 4,89 4,95 80 3” 88,9 3,16 3” 88,9 2,13
100 4” 114,3 5,31 5,39 5,74 5,78 5,80 6,01 6,08 100 4” 114,3 3,87 4” 114,3 2,63
125 5” 141,3 6,40 6,50 6,71 6,76 6,98 6,99 7,24
150 6” 168,3 6,62 7,08 7,38 8,46 9,00 10,00 11,42
200 8” 219,1 8,02 8,61 8,61 10,40 10,40 13,10 15,23
34
250 10” 273 11,01 12,26 12,26 14,03 15,43 17,49 5.4 PRESSURE GAUGES 0,25 [Mhr/ea]
300 12” 323,9 13,04 14,65 15,12 16,65 20,18 23,44 5.5 THERMOMETERS 0,20 [Mhr/ea]
350 14” 355,6 14,63 16,40 17,46 18,61 22,51 26,91
400 16” 406,4 16,65 18,69 21,23 21,23 25,73 30,82
450 18” 457 18,67 20,97 23,84 25,44 28,94 34,72
500 20” 508 20,71 23,27 26,47 29,20 32,17 38,64
550 22” 559 22,74 25,56 29,10 33,18 35,40 42,57
600 24” 610 24,77 27,86 31,73 38,63 38,63 46,49
650 26” 660 28,30 30,13 34,32 41,81 41,81
700 28” 711 29,55 32,42 36,95 45,04 45,04
750 30” 762 32,60 34,72 39,58 48,27 48,27
800 32” 813 34,75 37,01 42,21 51,50 51,50 Materials: f
850 34” 864 36,91 39,31 44,83 54,73 54,73 - Cr Mo alloy steel 1,40 ÷ 1,60
900 36” 914 39,03 41,57 47,43 61,82 61,82 - Copper alloy 1,20
- Killed C.S. 1,00 ÷ 1,25
Man hour include next activities: - Stainless steel 1,25
- handling - erection - High temp. alloy steel 1,00 ÷ 1,80
- on-site transport - welding - Alloy steel Ni 1,60
- prefabrication - pressure testing - Aluminium alloy 1,50
RATES FOR TENDER CALCULATIONS
1. MANHOUR ESTIMATE FOR INSTALLATION OF PIPING
BASED ON DIAMETERS AND WEIGHTS (FOR CARBON STEEL ONLY)
(Origin: Technical Journal "3R International" of April 4, 1985)
Productivity Efficiency Percentage (PEP) = 75%
Type AS Type AF Type BS Type BF

Dn-mm ø-Inch [Mhr/ton] [kg/Mhr] [Mhr/ton] [kg/Mhr] [Mhr/ton] [kg/Mhr] [Mhr/ton] [kg/Mhr] Type AS Piping in the plant with prefabricated weld joints
25 1” 417 2,40 431 2,32 172 5,81 225 4,44
32 1 1/4” 359 2,80 373 2,68 155 6,45 204 4,90 Type AF Piping in the plant with prefabricated
40 1 1/2” 330 3,00 344 2,91 146 6,85 193 5,18 flanged joints
50 2” 286 3,50 299 3,34 131 7,63 176 5,68 Type BS Piping outside the plant (pipe racks, sleeper ways, etc.)
65 2 1/2” 246 4,10 258 3,88 118 8,47 159 6,29 with prefabricated weld joints
80 3” 209 4,80 220 4,55 105 9,52 143 7,00 Type BF Piping outside the plant (pipe racks, sleeper ways etc.)
100 4” 165 6,10 175 5,71 88,5 11,30 122 8,20 with prefabricated flanged joints
125 5” 135 7,40 144 6,94 76,8 13,02 108 9,26
150 6” 111 9,00 119 8,40 66,7 15,00 94,7 10,56
35
200 8” 93,6 10,70 101,0 9,90 59,1 16,92 84,7 11,81

250 10” 75,9 13,20 82,2 12,17 50,8 19,70 73,8 13,55
300 12” 63,2 15,80 68,7 14,56 44,5 22,47 65,5 15,27
350 14” 59,5 16,80 64,8 15,43 42,7 23,42 63,0 15,87 kg/Mhr x 2,2046 = lbs/Mhr
400 16” 50,6 19,80 55,3 18,08 38,0 26,32 56,7 17,64
500 20” 43,8 22,80 48,1 20,79 34,2 29,24 61,5 19,42
600 24” 38,9 25,80 42,9 23,31 31,5 31,75 47,7 20,96
1000 40” 20,8 48,00 23,3 42,92 20,1 49,75 31,6 31,60
Above standards do not include: Time allowance for

- storing and store handling (calculate separately) - space obstruction to 15 %
site grading and facilities (add 5 - 7%) - connection to the existing lines to 15 %
- decrease effect of due to bad weather (add 2 - 4%) - erection at higher elevations 10 ÷ 20 %
- scaffolding (calculate separately) (above 4 m)
- radiographic inspection (calculate separately)
- performance tests (calculate separately)
2. EFFECT ASSESSMENT FOR QUICK CALCULATION (Use only if not possible acc. to man hours derived from basic estimate points)
2.1 PIPING IN PROCESS PLANT
Prefabrication and erection [kg/Mhr] Productivity efficiency percentage (PEP) = 75%
Dn-mm ø-Inch OD-mm Sch 10 Sch 20 Sch 30 Std Sch 40 Sch 60 XS Sch 80 Sch 100 Sch 120 Sch 140 Sch 160 XXS ø-Inch
15 1/2” 21,3 1,34 1,50 1,59 1/2”
20 3/4” 26,7 1,44 1,46 1,67 1,76 3/4”
25 1” 33,4 1,92 1,94 2,03 2,27 2,30 1”
32 1 1/4” 42,2 2,19 2,21 2,82 2,55 2,69 1 1/4”
40 1 1/2” 48,3 2,40 2,43 2,66 3,05 3,06 1 1/2”
50 2” 60,3 2,67 2,69 2,90 3,06 3,18 2”
65 2 1/2” 73,0 3,35 3,41 3,56 3,63 3,92 2 1/2”
80 3” 88,9 4,35 4,47 4,80 5,06 5,60 3”
100 4” 114,3 5,30 5,67 6,36 7,46 7,67 7,89 4”
125 5” 141,3 2,40 2,43 2,85 3,84 4,04 4,01 5”
150 6” 168,3 7,58 8,96 11,27 12,12 12,29 6”
200 8” 219,1 10,67 10,75 10,86 11,15 12,35 14,00 15,74 16,10 16,85 16,94 8”
250 10” 273 11,46 12,10 12,89 15,30 15,20 16,50 17,50 18,48 19,00 20,09 20,30 10”
300 12” 323,9 12,44 13,50 14,61 15,60 16,10 16,25 17,22 18,00 18,93 19,50 20,55 20,90 12”
36
350 14” 355,6 14,62 16,13 16,77 16,77 17,64 18,20 18,83 19,56 19,80 20,07 20,50 21,51 14”
400 16” 406,4 15,17 17,42 18,33 18,33 20,64 20,90 20,94 21,22 22,00 22,98 23,20 24,01 16”
450 18” 457 16,62 18,12 20,00 19,11 22,40 23,00 21,83 23,73 24,00 24,19 25,00 25,68 18”
500 20” 508 18,80 21,90 25,23 21,90 27,14 27,70 25,23 28,26 28,70 29,69 30,10 30,74 20”
550 22” 559 20,88 22,25 26,73 22,25 29,49 29,70 26,73 30,14 30,60 31,13 32,00 32,88 22”
600 24” 610 21,14 24,00 28,80 24,00 30,80 31,00 28,29 31,98 32,10 32,25 33,00 33,43 24”
650 26” 660 22,87 28,76 29,80 25,11 28,16 26”
700 28” 711 24,11 29,15 30,20 26,36 29,15 28”
750 30” 762 26,15 30,51 31,60 28,75 30,51 30”
> 800 > 32” > 813 28 35,72 36,5 30 36,17 35,715 above 32”
Included: pipes, fittings, flanges, valves and supports

Material: carbon steel
Approximate division of hours for prefabrication and erection Piping between plants:
Prefabrication Erection
to 11/2” - 100% ON PIPE RACKS [kg/Mhr] x 1,35
2” ÷ 5” 60% 40% kg/Mhr x 2,2046 = lbs/Mhr
6” ÷ 10” 55% 45% ON SLEEPER WAYS [kg/Mhr] x 1,50
2. RATES FOR QUICK CALCULATION (Used only when such data provided in tendering documents )
2.2 PIPES (CARBON STEEL - NOT INSULATED) [Mhr/m] [ kg/Mhr]
MEAN VALUE Productivity Efficiency Percentage (PEP) = 75%
FOR " TECHNIP" COMP.
Sch 10 Sch 20 Std Sch 40 XS Sch 80 Sch 120 Sch 160 Average
Dn-mm ø-Inch OD-mm [Mhr/m] [kg/Mhr][Mhr/m][kg/Mhr] [Mhr/m][kg/Mhr][Mhr/m][kg/Mhr] [Mhr/m][kg/Mhr] [Mhr/m] [kg/Mhr] [Mhr/m] [kg/Mhr] [Mhr/m] [kg/Mhr] diameter[inch] Mhr/ ton*
15 1/2" 21,3 0,42 3,05 0,42 3,05 0,43 3,74 0,43 3,74 0,44 4,45 < 0,66 118,40
20 3/4" 26,7 0,43 2,99 0,44 3,91 0,44 3,91 0,46 4,81 0,46 4,81 0,48 6,06 0,67-0,87 89,11
25 1" 33,4 0,47 4,54 0,48 5,25 0,48 5,25 0,50 6,54 0,50 6,54 0,54 7,96 0,88-1,12 56,35
32 1 1/4” 42,2 0,50 5,44 0,53 6,51 0,53 6,51 0,56 8,11 0,56 8,11 0,60 9,48 1,13-1,37 43,15
40 1 1/2” 48,3 0,53 5,98 0,56 7,33 0,56 7,33 0,60 9,13 0,60 9,13 0,65 11,18 1,38-1,75 37,07
50 2” 60,3 0,57 7,03 0,61 8,98 0,61 8,98 0,67 11,19 0,67 11,19 0,77 14,42 1,76-2,25 28,48
65 2 1/2” 73 0,63 8,56 0,72 12,08 0,72 12,08 0,80 14,34 0,80 14,34 0,89 16,74 2,26-2,75 16,04
80 3" 88,9 0,69 9,58 0,81 14,04 0,81 14,04 0,92 16,61 0,92 16,61 1,08 19,81 2,76-3,50 12,97
100 4" 114,3 0,75 11,33 0,94 17,02 0,94 17,02 1,10 20,36 1,10 20,36 1,25 22,73 1,39 24,26 3,51-4,50 9,76
125 5" 141,3 0,85 13,73 1,09 20,09 1,09 20,09 1,30 23,86 1,30 23,86 1,52 26,51 1,74 28,36 4,51-5,50 7,60
150 6" 168,3 1,22 23,11 1,22 23,11 1,54 27,73 1,54 27,73 1,80 30,17 2,11 32,16 5,51-7,00 6,09
200 8" 219,1 1,43 23,50 1,63 26,22 1,63 26,22 2,11 30,69 2,11 30,69 2,68 33,81 3,15 35,24 7,01-9,00 4,66
250 10" 273 1,71 24,62 2,10 28,81 2,10 28,81 2,55 32,02 2,86 33,63 3,67 36,24 4,58 37,55 9,01-11,0 3,74
37
300 12" 323,9 1,98 25,37 2,46 29,92 2,59 30,79 2,90 32,55 3,71 35,63 4,92 38,05 5,86 38,55 11,01-13,0 3,51
350 14" 355,6 2,16 25,51 2,42 28,03 2,69 30,15 2,97 31,80 3,24 33,08 4,31 36,89 5,80 38,79 7,13 39,55 13,01-15,0 3,48
400 16" 406,4 2,42 26,13 2,72 28,58 3,02 30,79 3,65 33,70 3,65 33,70 5,34 38,01 7,22 39,75 9,07 40,26 15,01-17,0 3,41
450 18" 457 2,67 26,67 3,00 29,17 3,35 31,34 4,40 35,45 4,05 34,32 6,49 39,17 8,95 40,58 11,24 40,85 17,01-19,0 3,35
500 20" 508 2,93 27,03 3,68 31,79 3,68 31,79 5,04 36,54 4,46 34,77 7,76 40,10 10,71 41,27 13,72 41,17 19,01-21,0 3,30
550 22" 559 3,19 27,38 4,01 32,21 4,01 32,21 5,71 37,30 4,86 35,22 9,14 40,92 12,65 41,68 16,20 41,49 21,01-23,0 3,26
600 24" 610 3,44 27,67 4,33 32,56 4,33 32,56 6,65 38,50 5,25 35,62 10,66 41,48 15,22 41,98 19,39 41,62 23,01-25,0 3,23
650 26" 660 4,15 30,60 5,65 35,96 4,65 32,72 5,65 35,96 25,01-27,0 3,21
700 28" 711 4,22 32,46 6,04 36,26 4,97 33,03 6,04 36,26 27,01-29,0 3,18
750 30" 762 4,72 31,14 6,43 36,55 5,29 33,30 6,43 36,55 29,01-31,0 3,15
800 32" 813 5,01 31,37 6,82 36,80 5,61 33,54 8,67 39,58 6,82 36,80 31,01-33,0 3,13
850 34" 864 5,29 31,60 7,21 37,03 5,93 33,76 9,16 39,85 7,21 37,03 33,01-35,0 3,11
900 36" 914 5,56 31,83 7,60 37,13 6,24 34,00 10,35 40,77 7,60 37,13 35,01-37,0 3,09
950 38 966 6,56 34,19 7,98 37,35 37,01-39,0 3,07
1000 40" 1016 6,87 34,38 8,36 37,56 >39,0 3,06
1050 42" 1066 7,18 34,54 8,75 37,74
1100 44" 1118 7,49 34,71 9,13 37,90
1150 46" 1168 7,80 34,81 9,51 38,07
1200 48" 1219 8,11 34,90 9,89 38,24 *Mhr/ton for one millimetre of average wall thickness

2. EFFECT ASSESSMENT FOR QUICK CALCULATION (Used only if such data provided in tendering documents)
Productivity efficiency percentage (PEP) 75%
2.3 FITTINGS (CARBON STEEL) - MEAN VALUE [kg/Mhr]
All types of fittings included. FOR "TECHNIP" COMP.
Average
diameter [inch] [Mhr/ton]*
Dn-mm ø-Inch OD-mm Sch 10 Sch 20 Std Sch 40 XS Sch 80 Sch 120 Sch 160 XXS "SOCKET"
15 1/2” 21,3 0,15 0,15 0,17 0,17 0,17 0,23 < 0,66 2.087,00
20 3/4” 26,7 0,17 0,17 0,18 0,18 0,18 0,31 0,67-0,87 1.760,00
25 1” 33,4 0,23 0,23 0,23 0,23 0,24 0,24 0,36 0,88-1,12 1.178,00
32 1 1/4” 42,2 0,26 0,26 0,35 0,35 0,27 0,29 0,42 1,13-1,37 893,30
40 1 1/2” 48,3 0,29 0,29 0,3 0,3 0,33 0,33 0,62 1,38-1,75 739,10
50 2” 60,3 0,35 0,35 0,38 0,38 0,36 0,38 1,76-2,25 698,20
65 2 1/2” 73 0,45 0,45 0,47 0,47 0,44 0,48 2,26-2,75 420,50
80 3” 88,9 0,69 0,69 0,71 0,71 0,68 0,78 2,76-3,50 256,80
100 4” 114,3 0,9 0,9 0,96 0,96 1,07 1,1 1,14 3,51-4,50 166,10
125 5” 141,3 1,1 1,1 1,23 1,23 1,47 1,37 1,49 4,51-5,50 119,10
150 6” 168,3 1,64 1,64 1,82 1,82 2,1 2,22 2,25 5,51-7,00 73,10
200 8” 219,1 2,61 2,55 2,55 2,73 2,73 3,27 3,35 3,33 7,01-9,00 42,80
250 10” 273 2,67 3,12 3,12 3,36 3,47 3,98 4,05 9,01-11,0 32,40
300 12” 323,9 2,84 3,38 3,47 3,62 3,87 4,23 3,98 11,01-13,0 29,00
38
350 14” 355,6 4,29 3,9 4,07 4,23 4,41 4,29 4,73 5,91 13,01-15,0 23,40
400 16” 406,4 4,82 4,32 4,65 5,25 5,16 4,82 5,48 4,86 15,01-17,0 21,40
450 18” 457 5,4 4,5 4,8 5,72 5,42 6,18 5,3 5,06 17,01-19,0 20,00
500 20” 508 6,75 6,0 5,94 7,97 6,75 6,17 6,21 6,93 19,01-21,0 16,30
550 22” 559 6,98 5,91 6,08 7,11 6,11 6,57 7,38 21,01-23,0 15,80
600 24” 610 7,52 6,62 6,65 9,74 7,68 6,68 7,14 8,25 23,01-25,0 13,70
650 26” 660 7,56 8,46 25,01-27,0 13,10
700 28” 711 7,62 8,9 27,01-29,0 12,60
750 30” 762 7,95 7,22 Materials: f 29,01-31,0 12,10
800 32” 813 8,21 9,66 Stainless steel 1,25 31,01-33,0 11,80
850 34” 864 8,69 9,96 High temp. alloy steel 1,00 ÷ 1,80 33,01-35,0 11,20
900 36” 914 9,87 9,54 Killed C.S 1,00 ÷ 1,25 35,01-37,0 10,80
950 38” 966 14,28 16,19 Cr Mo alloy steel 1,40 ÷ 1,60 37,01-39,0 6,93
1000 40” 1016 14,84 16,91 Alloy steel Ni 1,60 39,01-41,0 6,62
1050 42” 1066 16,52 18,96 Copper alloy 1,20 41,01-43,0 5,90
1100 44” 1118 17,42 19,67 Aluminium alloy 1,50 43,01-45,0 5,67
1150 46” 1168 18,26 20,61 45,01-47,0 5,36
1200 48” 1219 19,38 21,74 >47,0 5,15
Note:
Generally, socket fittings to Ø 1 1/2"
are used in petrochemical plants. kg/Mhr x 2,2046 =lbs/Mhr
*[Mhr/ton] for one millimetre of average wall thickness
2.4 VALVES MEAN VALUE 2.5 PIPE SUPPORTS
(ALL KINDS OF VALVES INCLUDED) Productivity Efficiency Percentage (PEP) = 80%
2.4.1. WITH FLANGED ENDS [Mhr/kg] 2.5.1. PARTICIPATION IN THE PIPING QUANTITY
to be estimated with 7 ÷ 9%
150# 300# 600# 900# 1500# 2.5.2. FABRICATION AND INSTALLATION
Dn-mm ø-Inch NP6-16 NP25 NP40 NP64 100-160 2.5.2.1 DIVISION BASED ON THE UNIT WEIGHT OF SUPPORT
15 1/2” 0,266 0,222 0,185 0,160 0,140 Unit Fabrication Installation Fabrication+
20 3/4” 0,259 0,216 0,180 0,156 0,136 weight installation
25 1” 0,234 0,195 0,163 0,141 0,123 [kg/pc] [kg/Mhr] [kg/Mhr] [kg/Mhr]
32 1 1/4” 0,180 0,150 0,125 0,108 0,095 to 5 3,0 6,0 2,0
40 1 1/2” 0,161 0,134 0,112 0,097 0,085 5 ÷ 20 7,0 10,0 4,12
50 2” 0,107 0,089 0,074 0,064 0,056 20 ÷ 50 10,0 12,5 5,55
65 2 1/2” 0,102 0,085 0,071 0,061 0,054 50 ÷ 75 12,0 14,0 6,46
80 3” 0,077 0,079 0,066 0,057 0,050 75 ÷100 13,0 15,0 6,96
100 4” 0,077 0,064 0,053 0,046 0,040 100÷150 15,0 16,0 7,74
150 6” 0,056 0,049 0,043 0,039 0,035 above 150 16,0 20,0 8,90
200 8” 0,052 0,046 0,040 0,036 0,033 Spring supports 10,0
250 10” 0,049 0,044 0,040 0,036 0,033
300 12” 0,045 0,041 0,038 0,034 0,031 2.5.2.2 DIVISION BASED ON THE PIPING DIAMETER
39
350 14” 0,040 0,037 0,033 0,030 0,028 Fabrication Installation Fabrication+
400 16” 0,036 0,033 0,030 0,027 0,025 installation
450 18” 0,031 0,029 0,026 0,024 0,022 DN [kg/Mhr] [kg/Mhr] [kg/Mhr]
500 20” 0,029 0,027 0,024 0,022 0,020 15 ÷ 50 ½”÷2” 2,80 5,1 1,80
550 22” 0,024 0,022 0,020 0,018 0,017 65 ÷ 100 2 ½”÷4” 5,75 6,25 3,0
600 24” 0,020 0,019 0,017 0,015 0,014 125÷150 5”÷6” 8,25 8,15 4,10
200÷350 8”÷14” 14,10 9,10 5,50
2.4.2. WITH WELDING ENDS above 350 above 14” 16,0 11,50 6,70
2.5.2.3 EFFECT OF SUPPORT FABRICATION AND INSTALLATION WITH ALREADY
2.4.2.1. BUTT WELDING: [Mhr/kg] x 3,0 KNOWN AVERAGE DIAMETER OF PIPING
2.4.2.2. SOCKET WELDING: [Mhr/kg] x 1,5 The effect of the fabrication and installation [kg/Mhr] is equal to
the average diameter in inches.
2.6 AVERAGE DIAMETER - Manner of Calculation

Average diameter of all pipings in the plant or on the project shall be
Mhr/kg x 0,4536 = Mhr/lbs calculated in the following way:
kg/Mhr x 2,2046 = lbs/Mhr Sum of the multiplication product of the diameter and length of each pipe
shall be divided by the sum of all pipe lengths.
(Dn1 x l1) + (Dn2 x l2) + (Dn3 x l3) + ...

l1 + l2 + l3 + ...
3. RATES FOR INSTALLATION OF POLYETHYLENE PIPING
3.1 PE Pipes DIN 8074
PIPES FITTINGS AND VALVES
PN 6 PN 10 Straight pipes Coils Bends Tees Reducers Caps Flanges Valves
Dn-mm t [mm] [kg/m] t [mm] [kg/m] [Mhr/m] [Mhr/m] [Mhr/ea] [Mhr/ea] [Mhr/ea] [Mhr/ea] [Mhr/ea] [Mhr/ea]
16 0,24 0,12 0,62 0,19
20 2,0 0,12 0,24 0,12 1,05 1,58 0,51 0,62 0,25
25 2,0 0,15 2,3 0,17 0,28 0,14 1,05 1,58 1,05 0,51 0,62 0,31
32 2,0 0,17 2,9 0,27 0,29 0,15 1,11 1,67 1,08 0,54 0,66 0,40
40 2,3 0,29 3,6 0,42 0,32 0,16 1,27 1,92 1,19 0,64 0,77 0,40
50 2,8 0,43 4,5 0,65 0,45 0,20 1,29 1,95 1,28 0,65 0,78 0,63
63 3,6 0,68 5,7 1,03 0,47 0,25 1,49 2,28 1,41 0,76 0,92 0,81
75 4,3 0,97 6,8 1,47 0,52 0,28 1,64 2,46 1,58 0,82 1,00 0,90
90 5,1 1,38 8,2 2,11 0,54 0,30 1,78 2,67 1,71 0,89 1,08 1,00
110 6,2 2,04 10,0 3,14 0,58 0,40 1,90 2,82 1,96 1,02 1,23 1,56
140 7,9 3,60 12,7 5,07 0,69 2,11 3,21 2,07 1,07 1,28 1,70
40
160 9,1 4,33 14,6 6,66 0,73 2,46 3,72 2,31 1,24 1,51 1,88
180 10,2 5,45 16,4 8,41 0,77 2,64 4,02 2,58 1,34 1,63 2,20
200 11,4 6,77 18,2 10,40 0,83 2,81 4,23 2,75 1,41 1,73 2,50
225 12,8 8,55 20,5 13,10 0,89 3,02 4,56 2,93 1,52 1,85 3,15
250 14,2 10,50 22,8 16,20 0,95 3,30 4,98 3,18 1,66 2,03 4,25
280 15,9 13,20 25,5 20,30 1,02 3,77 5,67 3,55 1,89 2,32 4,50
315 17,9 16,70 28,7 25,70 1,11 3,98 6,00 3,89 2,00 2,46 5,10
355 20,1 21,10 32,3 32,60 1,21 4,27 6,45 4,15 2,15 2,63 5,95
3.2 Rates for installation of PE reinforcement pads for branch connection [Mhr/ea]
PIPE BRANCH
Dn-mm 20 25 32 40 50 63 mm x 0,03937 = inch
40 1,15 kg/m x 0,672 = lbs/ft
63 1,27 1,28 1,30 1,40 1,41 1,52 Mhr/m x 0,3048 = Mhr/ft
90 1,40 1,41 1,43 1,53 1,54 1,65
110 1,45 1,45 1,56 1,64 1,65 1,75
125 1,70 1,70 1,71 1,82 1,92
160 1,93 1,93 1,96 2,07 2,10 2,15
180 2,05 2,13 2,15 2,24
200 2,12 2,12 2,15 2,23 2,24 2,34
225 2,27 2,35 2,36 2,46
4. RATES FOR ERECTION OF PVC & FRP PIPING 5. CARBON STEEL PIPING (SCH 40)
CEMENT LINED INSIDE
Productivity Efficiency Percentage (PEP) 80%
Productivity Efficiency Percentage (PEP) 80%
Pipes Socket Nozzle at Valves SYNTHETIC MATERIALS Sleeve joint Nozzle Repair of
handling joint 90° and PVC ABBREVIATIONS & Pipes with two at 90° concrete
reinforce housing INTERPRETATION handling Pipe cutting Butt weld fillet welds lining on
ment (handling) joints
Dn-mm ø-Inch [Mhr/m] [Mhr/ea] [Mhr/ea] [Mhr/ea]
15 1/2” 0,115 0,10 0,38 0,13 FRP - FIBREGLASS RESIN Dn-mm ø-Inch [Mhr/m] [Mhr/cut.] [Mhr/ea] [Mhr/joint] [Mhr/ea] [Mhr/joint]
20 3/4” 0,120 0,11 0,39 0,16 POLYESTER 150 6” 0,66 0,65 2,00 3,30 6,05 0,35
25 1” 0,125 0,13 0,40 0,17 PE - POLYETHYLENE 200 8” 0,82 1,00 2,60 4,60 7,30 0,50
30 1 1/4” 0,130 0,14 0,43 0,20 PVDF - POLYVINYLDENFLUORIDE 250 10” 1,08 1,20 3,10 5,70 8,30 0,60
40 1 1/2” 0,135 0,15 0,45 0,25 PVC - POLYVINYLCHLORIDE, 300 12” 1,30 1,45 4,10 6,90 11,35 0,65
50 2” 0,150 0,17 0,50 0,35 HARD 350 14” 1,58 2,30 5,00 7,90 13,90 0,80
65 2 1/2” 0,155 0,19 0,65 0,58 PP - POLYPROPYLENE 400 16” 2,05 2,95 6,60 9,20 18,15 0,95
80 3” 0,165 0,23 0,80 0,85 FPM - (VITON A ®) 500 20” 2,30 3,70 8,60 10,40 22,80 1,10
100 4” 0,180 0,28 1,00 1,25 FLUOR INDIAN RUBBER (KAUTSCHUK) 600 24” 2,88 4,65 9,40 12,40 26,95 1,25
41
150 6” 0,185 0,35 1,30 1,60 EPDM - (APTK) 700 28” 3,63 5,90 13,30 15,50 33,60 1,50
200 8” 0,230 0,40 1,80 1,90 ETHYLENE PROPYLENE- 800 32” 3,95 6,40 14,90 17,35 36,50 1,72
250 10” 0,280 0,50 2,30 2,50 INDIAN RUBBER 900 36” 4,20 6,90 16,40 19,15 40,30 1,93
300 12” 0,330 0,63 2,90 3,00 CR - (NEOPRENE ®) 1000 40” 4,45 7,25 17,90 20,85 43,80 2,15
350 14” 0,400 0,78 3,60 CHLOROPRENE INDIAN RUBBER 1100 44” 4,65 7,55 19,30 22,45 47,30 2,36
400 16” 0,460 0,94 4,10 PTFE - (TEFLON ®) 1200 48” 4,80 7,85 20,60 24,00 50,50 2,60
450 18” 0,520 1,08 4,80 POLYTETRAFLUORETHYLENE
500 20” 0,560 1,22 5,50 PVC-C - POLYVINYLCHLORIDE,
550 22” 0,620 1,36 6,20 ADDITIONALLY CHLORINATED Note:
600 24” 0,660 1,46 7,00 PB - POLYBUTENE 1. Piping of synthetic materials
650 26” 0,720 1,57 POM - POLYXYMETHYLENE to be calculated acc. to the tables for
700 28” 0,760 1,66 NBR - NITRIL INDIAN RUBBER PE or PVC piping
750 30” 0,800 1,74 IIR BUTYL INDIAN RUBBER 2. For diameters larger than 40” (1000 mm),
800 32” 0,820 1,81 CSM - (HYPALON ®) to be calculated proportionally
850 34” 0,850 1,87 CHLORSULFONYLPOLYETHYLENE to 40”
900 36” 0,870 1,92 PEHD - POLYETHYLENE HIGH DENSITY
950 38” 0,890 1,98 PRFV - POLYESTER RESIN FIBREGLASS REINFORCED,
1000 40” 0,920 2,05 INTERNAL CORE OF PVC
6. PIPING MADE OF STEEL AND GREY CAST-IRON 6.2 FITTINGS
I made an exception and included steel and grey cast piping in (DIN: A, E, F, FF, K, FFK, Q, MQ,
the Chapter Piping Above Ground although they are in most cases laid underground. MMQ, MMK, FFR, T, TT, U, MMA, MMB, MMR, X, N)
According to these man hour rates only the pipes are determined according to the unit When calculating man hours for each fitting each
of length whereas the man hour rates for all other fittings end is calculated according to its type, except for the
should be calculated acc. to the type and number of joints. For example, straight end.
Tpiece with a flange at one end and a socket at two ends should be calculated as
1 x flanged end and 2 x socket end. Nominal Socket Flanged
diameter end end
Productivity efficiency percentage (PEP) = 80% DN [Mhr/ea] [Mhr/ea]
6.1 CAST IRON PIPES 80 (3”) 0,6 0,5
100 (4”) 0,75 0,58
Nominal 125 (5”) 0,8 0,65
diameter Pipe length 150 (6”) 0,86 0,71
42
DN [m] [Mhr/m] * * Note: 200 (8”) 1,05 0,92

80 (3”) 3; 4; 5 0,25 According to John S. Page's manual 250 (10”) 1,28 1,15
100 (4”) 3; 4; 5 0,295 each joint between the pipes is also 300 (12”) 1,85 1,4
125 (5”) 3; 4; 5 0,33 added man hour for the socket joint. 350 (14”) 2,67 1,64
150 (6”) 3; 4; 5 0,36 I do not agree with that. This could 400 (16”) 3,42 1,9
200 (8”) 5 0,46 apply only if the fittings are 450 (18”) 4,02 2,18
250 (10”) 5 0,56 not calculated separately. Just to 500 (20”) 4,8 2,46
300 (12”) 5 0,79 mention that his man hour for a socket 600 (24”) 6,0 3,05
350 (14”) 5 1,15 joint is 1/3 lower than the man hour 700 (28”) 7,2 3,67
400 (16”) 5 1,48 in this table. 800 (32”) 8,3 4,32
450 (18”) 5 1,74
500 (20”) 5 2,07 6.3 VALVES
600 (24”) 5; 6 2,59 Valves to be estimated by considering the
700 (28”) 6 3 handling as for the piping above ground and by adding
800 (32”) 6 3,25 2 x Mhr/ea for a flanged end.
7. RATES FOR PIPING BASED ON INCH-DIAMETER (ID) CORRECTION FACTORS:
- Different materials
Productivity efficiency percentage (PEP) 80% CS 1,00 3,5 Ni 1,60
Low alloy (0,5 Mo) 1,10 SS 304 1,25
Some world companies ask in their call for tender for a price review according to 1,25 Cr 1,30 SS 316 1,25
inchdiameter (ID) and inclusion of all the operations and works involved in installation of piping. 5 Cr 1,40 SS 321 1,25
9 Cr 1,50 SS 347 1,25
Composite pipe 0,75
Item 3.1 x F = Mhr Non-ferrous material 2,00
D ID Plastic resin 0,60
CS pipe - - cement 1,20
lined inside - resin 1,10
Item 3.1 - Estimate points for butt joint of a relative diameter and (Lining CS): - glass 1,15
wall thickness ( Chapter X. Pages 147 ÷ 201)
F - sum of factors for the activities required (see below) - Place of installation:
D - diameter (or average diameter) of piping in inches
Above Ground 1,00
ACTIVITY FACTORS Under Ground 1,20
43
- PIPES - prefabrication 0,300 Pipe rack 1,15

- PIPES - installation 0,080 Bridge 1,30
- FITTINGS - prefabrication 1,200 Around equipment 1,20
- FITTINGS - installation 0,200 Line pipe - Sleeper way 0,90
- FLANGES - prefabrication 0,320
- FLANGES - installation 0,050 - Prefabrication 0,90
- VALVES - installation 0,130
- PRESSURE TEST - hydrostatic 0,100 - Type of joint:
- PRESSURE TEST - pneumatic 0,020 Butt weld 1,00
- ELEVATION IMPACT 0,012 90° Nozzle weld 1,60
- IMPACT OF SPACE OBSTRUCTION 0,010 90° Reinforced nozzle weld 3,00
Sum 2,422
Socket weld 0,60
Every company has its own way of listing the prices for each activity Seal weld 0,50
in its call for tenders. Therefore, only the factors for the activities that are required by tenderin Threaded joint 0,35
documents are summed up. Root pass 0,35
Fabrication and installation of pipe supports is considered separately according Fillet weld 0,65
to the tables on page 39.. Mitre weld 1,50
(Sockolet, weldolet, coupling, etc.) 1,60

Tie-in to existing piping 4,00
8. RATES FOR UNITS OF OPERATION (BASED ON INCH-DIAMETER)
Productivity efficiency percentage (PEP) = 80%
1. Cuts, bevels and welds

1.1 Cuts and bevels - all materials 1.2.2 Stainless steel
- Schedule 10 0,24 [Mhr/ID] - Schedule 5S 0,35 [Mhr/ID]
- Schedule 40 0,36 [Mhr/ID] - Schedule 20 0,53 [Mhr/ID]
- Std 0,29 [Mhr/ID] - Schedule 40S 0,65 [Mhr/ID]
- XS 0,31 [Mhr/ID] - Schedule 80 1,29 [Mhr/ID]
- XXS 0,61 [Mhr/ID]
- Shop fabrication 90% - Shop fabrication 90%
44
- Field fabrication 125% - Field fabrication 125%
1.2 Welding
1.2.1 Carbon Steel 1.2.3 Alloy Steel
- Std 0,25 [Mhr/ID] - Std 0,35 [Mhr/ID]
- XS 0,30 [Mhr/ID] - XS 0,43 [Mhr/ID]
- XXS 0,53 [Mhr/ID] - XXS 0,85 [Mhr/ID]
- Shop fabrication 90% - Shop fabrication 90%

- Field fabrication 125% - Field fabrication 125%
8. RATES FOR UNITS OF OPERATION (BASED ON INCH-DIAMETER)
2. Pipe - Handling 3. Miscellaneous

Based on MID (meter-inch-diameter)
3.1 Temporary Items
- Temporary Supports 0,17 [Mhr/kg]

- Schedule 10 0,15 [Mhr/MID]
- Schedule 20 0,18 [Mhr/MID] - Temporary Spacers 0,50 [Mhr/kg]
- Std 0,17 [Mhr/MID]
- Schedule 60 0,28 [Mhr/MID] 3.2 Tapering Wall Thickness for Fittings and Flanges
45

- XS 0,21 [Mhr/MID]
- Schedule 120 0,43 [Mhr/MID] - to 5 mm 0,25 [Mhr/ID]
- Schedule 160 0,51 [Mhr/MID] - 5 ÷ 10 mm 0,45 [Mhr/ID]
- XXS 0,44 [Mhr/MID] - 10 ÷ 15 mm 0,68 [Mhr/ID]
- 15 ÷ 20 mm 0,90 [Mhr/ID]
- 20 ÷ 25 mm 1,25 [Mhr/ID]
- Shop fabrication 12%
- Shop fabrication 90%
- Field fabrication 105%
- Field fabrication 110%
3.3 Bending of pipe
Mhr/kg x 0,4536 = Mhr/ft

- Bending of pipe to 1 1/2” 1,0 [Mhr/bend]
9. RATES FOR PIPING WELDING- (Fitter's work not included)
BUTT WELD (C. S.) - COMPLETE [Mhr/weld]
ø-Inch 10 20 30 Std 40 60 XS 80 100 120 140 160 XXS ø-Inch

1/2” 0,29 0,30 0,31 0,32 1/2”
3/4” 0,32 0,33 0,34 0,36 3/4” Factors for
1” 0,37 0,38 0,40 0,43 1” different kinds
1 1/4” 0,43 0,45 0,47 0,52 1 1/4” of materials
1 1/2” 0,47 0,49 0,53 0,59 1 1/2”
2” 0,55 0,59 0,67 0,73 2”
2 1/2” 0,67 0,72 0,81 0,97 2 1/2” 1. Carbon steel 1,00
3” 0,79 0,87 1,03 1,24 3” 2. Stainless steel 1,50
4” 1,00 1,14 1,29 1,46 1,72 4” 3. Chromium-Molibden steel 1,40
6” 1,49 1,84 2,20 2,68 3,15 6”
8” 1,82 1,88 2,02 2,27 2,61 2,97 3,50 3,91 4,35 4,20 8”
10” 2,23 2,42 2,64 3,23 3,23 3,69 4,37 5,08 6,07 6,91 6,07 10”
12” 2,62 2,95 3,15 3,31 4,18 3,81 4,98 6,05 7,26 8,29 9,89 7,26 12”
46
14” 2,86 3,13 3,45 3,45 3,80 4,79 4,18 5,91 7,45 8,85 10,35 11,89 14”
16” 3,25 3,56 3,92 3,92 4,76 5,98 4,76 7,63 9,51 11,56 14,10 16,06 16”
18” 3,64 3,98 4,85 4,40 5,87 7,61 5,34 9,63 12,27 15,11 17,77 21,00 18”
20” 4,03 4,87 5,93 4,87 6,83 9,19 5,93 11,96 15,47 18,87 23,00 26,87 20”
22” 4,42 5,35 6,52 5,35 7,86 10,96 6,52 14,63 18,69 23,17 27,93 33,05 22”
24” 4,81 5,83 7,82 5,83 9,38 13,42 7,10 17,65 23,51 29,30 34,90 41,45 24”
26” 5,69 7,68 6,30 7,68 26”
28” 6,12 8,27 10,00 6,77 8,27 28”
30” 6,55 8,85 10,71 7,25 8,85 30”
32” 6,98 9,44 11,42 7,73 12,51 9,44 32”
34” 7,41 10,03 12,14 8,20 13,29 10,03 34”
36” 7,83 10,60 12,84 8,67 15,35 10,60 36”
Factors for 1. Nozzle weld 90° 1,50 6. Fillet weld "socket weld" 0,60
calculating 2. Nozzle weld 90° w. reinforcement 2,50 7. Fillet weld "dummy" 90° 0,90
the rates acc. 3. Nozzle weld bevelled 1,90 8. Fillet weld "dummy" on elbow 1,35
to type of weld 4. Nozzle weld bevelled w. reinforcement 3,00 9. Fillet weld closing dummy 0,30
5. Weldolet, sockolet, nipolet, etc. 2,00 10. Mitre weld 1,30
10. MAN HOURS FOR WELDING OF PIPING
BUTT WELD - ROOT PASS AND FILLER PASSE
Root pass
- GTAW FILLER AND COVER PASSES - SMAW [ Mhr/weld]
ø-Inch [Mhr/weld] 10 20 30 Std 40 60 XS 80 100 120 140 160 XXS ø-Inch
1/2” 0,10 0,19 0,20 0,21 0,22 1/2”
3/4” 0,12 0,20 0,21 0,22 0,24 3/4”
1” 0,15 0,22 0,23 0,25 0,28 1”
1 1/4” 0,17 0,26 0,28 0,30 0,35 1 1/4”
1 1/2” 0,19 0,28 0,30 0,34 0,40 1 1/2”
2” 0,21 0,34 0,38 0,46 0,52 2”
2 1/2” 0,26 0,41 0,46 0,55 0,71 2 1/2”
3” 0,29 0,50 0,58 0,74 0,95 3”
4” 0,33 0,67 0,81 0,96 1,13 1,39 4”
47
6” 0,42 1,07 1,42 1,78 2,26 2,73 6”

8” 0,55 1,27 1,33 1,47 2,27 2,06 2,42 2,95 3,36 3,80 3,65 8”
10” 0,70 1,53 1,72 1,94 3,23 2,53 2,99 3,67 4,38 5,37 6,21 5,37 10”
12” 0,83 1,79 2,12 2,32 2,48 4,18 2,98 4,15 5,22 6,43 7,46 9,06 6,43 12”
14” 0,91 1,95 2,22 2,54 2,54 2,89 4,79 3,27 5,00 6,54 7,94 9,44 10,98 14”
16” 1,03 2,22 2,53 2,89 2,89 3,73 5,98 3,73 6,60 8,48 10,53 13,07 15,03 16”
18” 1,16 2,48 2,82 3,69 3,24 4,71 7,61 4,18 8,47 11,11 13,95 16,61 19,84 18”
20” 1,28 2,75 3,59 4,65 3,59 5,55 9,19 4,65 10,68 14,19 17,59 21,72 25,59 20”
22” 1,40 3,02 3,95 5,12 3,95 6,46 10,96 5,12 13,23 17,29 21,77 26,53 31,65 22”
24” 1,53 3,28 4,30 6,29 4,30 7,85 13,42 5,57 16,12 21,98 27,77 33,37 39,92 24”
26” 1,65 4,04 6,03 4,65 6,03 26”
28” 1,78 4,34 6,49 8,22 4,99 6,49 28”
30” 1,90 4,65 6,95 8,81 5,35 6,95 30”
32” 2,03 4,75 7,41 9,39 5,70 10,48 7,41 32”
34” 2,15 5,26 7,88 10,09 6,05 11,14 7,88 34”
36” 2,28 5,55 8,32 10,56 6,39 13,07 8,32 36”
48
12. INSTALLATION OF PIPING ABOVE - GROUND
Unit standards as per integral elements

Prefabrication and installation breakdown
(Technical calculation manual, year 2003.)
1. Pipes Prefabrication Installation

1.1. Pipes in the plant to 1 1/2" _ 100%
2"- 48" 8% 92%
above 48" _ 100%
1.2. Pipes on pipe rack _ 100%
2. Fittings
2. 1. Elbows
2.1.1. Elbows and mitre
bends prefabricated to to 1 1/2" _ 100%
2" - 48" 85% 15%
2.2.2. Mitre bends to be
manufactured to 48" 85% 15%
above48" 50% 50%
2.2. Tee - pieces to to 1 1/2" _ 100%
2"- 48" 85% 15%
2.3. Reducing pieces completed to1 1/2" _ 100%
2"- 36" 85% 15%
2.4. Caps - all bores 100% _
2.5. O' lets, half - couplings and the like 85% 15%
3. Flanges
3.1. Flanges - for welding all
types and bores, 80% 20%
3.2. Blind flanges, orifice plates, spectacle _ 100%
blind and the like
4. Valves -all kinds, types pad bores _ 100%
5. Pipe supports to 2" 65% 35%

3" - 6" 55% 45%
8"- 14" 50% 50%
16" and above 45% 55%
6. Miscellaneous
6. 1. All branch welds 100% _
6. 1. Stiffener rings and reinforcing pads 100% _
7. Bolts and gaskets - not to be taken into account
49
II. PIPELINES - Basis for calculation of man hours
Contents:
1. PIPE TRANSPORT 8.1 BORING UNDER ROADS OR RAILROADS

2. STRINGING 8.2 BREAK OUT OF ROADS
3. BENDING 8.3 CONNECTING PIPELINE SECTIONS
4. JOINTING 8.4 CROSSING WATERCOURSES
5. WELDING 8.5 INSTALLATION OF CLEANING STATIONS
6. WRAPPING 8.6 PUTTING UP PIPELINE MARKERS
6.1 MACHINE WRAPPING 9. PRESSURE TESTS
6.2 HAND WRAPPING 10. PRELIMINARY & FINISHING WORKS
7. LAYING IN TRENCHES 10.1 PRELIMINARY WORKS
8. SPECIAL POINTS 10.2 FINISHING WORKS
To make an estimate for laying a pipeline is a very “sensitive” operation, particularly for estimators
lacking experience in the laying and installation of such pipelines. World recognized companies specializing
in this kind of work have empirical rates based on diameter and length, and on “inch-meter” respectively. A
widely recognized manual for that purpose is John S. Page's Cost Estimating Manual for Pipelines and
Marine Structures.
The impact of climate, ground and the state is quantified empirically. Since our company does not
specialize only in pipelines, we developed rates and elements for calculation of the time needed. However,
these rates cannot substitute an estimator. They can assist estimators in making their estimates. In
principle, call for tenders do not provide all the elements needed to determine precisely the time needed for
erection/installation/laying. Therefore, there are many variables to be taken into account and evaluated by
the estimator in order to foresee in detail the conditions under which the works may be executed. The
estimator has to make an accurate estimate of the rates, and when and which rates to apply. Similarly, he
can change them depending on the case.
1. PIPE TRANSPORT
Basic rate for pipe transport is..............................0,8 [Mhr/ton]
The basic rate changes with the conditions by adding or deducting the following rates:
Distance: for each kilometre more than 5 km..............plus 0,06 [Mhr/ton]
Roads: - city roads+............................................ plus 0,20 [Mhr/ton]

- asphalt roads to 50 %............... not considered
- asphalt roads above 50 %.............. plus 0,15 [Mhr/ton]
Means of - trailer truck long vehicle......................... not considered

transport: ÿ- trailer with HIAB................................... minus 0,10 [Mhr/ton]
- tracktor with a trailer............................... plus 0,20 [Mhr/ton]
Loading: - special crane for loading.......................... not considered

- loading by HIAB......................................plus 0,15 [Mhr/ton]
- crane used also for loading.......................plus 0,20 [Mhr/ton]
Unloading: - unloading by a special crane to

- a temporary pipe storage.........................minus 0,20 [Mhr/ton]
- unloading with pipe stringing along the right-of-way
by a special crane.................................. not considered
- unloading and pipe stringing by HIAB.........plus 0,20 [Mhr/ton]
50
Pipe Diameter: to 4”....................................plus 0,30 [Mhr/ton]
6” ÷ 8”....................................not considered
10” ÷ 12”..................................minus 0,15 [Mhr/ton]
14” ÷ 16”..................................minus 0,30 [Mhr/ton]
18” ÷ 24”..................................minus 0,40 [Mhr/ton]
26” and above............................minus 0,50 [Mhr/ton]
Pipe Type: - not wrapped..................................not considered

- wrapped....................................plus 0,10 [Mhr/ton]
Continuity of continuous transport:..................................minus 0,15 [Mhr/ton]

- with occasional stoppages..........not considered
- acc. to circumstances.................plus 0,15 [Mhr/ton]
* Crane operators and drivers included in the price of machinery
2. PIPE STRINGING
If pipe stringing is done as a separate operation by stringing pipes along the right-of-way
from the reference storage, the following rates apply:
to 3” ..........................plus 0,21 [Mhr/pc]
to 4”...........................plus 0,25 [Mhr/ pc]
6” ÷ to 8”............................plus 0,29 [Mhr/ pc]
10” ÷ to 14”..............................plus 0,34 [Mhr/ pc]
16” ÷ to 20”.............................plus 0,38 [Mhr/ pc]
22” and above..............................plus 0,41 [Mhr/ pc]
If no data is available on the number of pipes, it should be estimated. The manhour does not
include transport of temporary timber supports. Drivers and crane operators are not included.
3. BENDING OF PIPES
- Pipe bending on the right-of-way

to 3”.................................4,5 [Mhr/bending]
4”..................................5,6 [Mhr/bending]
6” ÷ 8”.............................. ....6,5 [Mhr/bending]
10” ÷ 14”....................................7,5 [Mhr/bending]
16” ÷ 20”.....................................9 [Mhr/bending]
22” and above.............................12,5 [Mhr/bending]
- Shop bending: contractors

- Bending for special points is not calculated according to this rate but is included under special points.
51
4. PIPE JOINTING
It includes pipefitter works for joining of pipes. Welding is not included.
- Basic rates:
3”....................0,75 [Mhr/joint] 14”.....................3,75 [Mhr/joint]
10”...................2,75 [Mhr/joint] 22”.....................5,75 [Mhr/joint]
12”...................3,25 [Mhr/joint] 24”.....................6,25 [Mhr/joint]
The rate for pipe joining is calculated by increasing or decreasing the basic rate by the following
percentages:
a. Place of jointing:
- near trench on temp. timber supports 0%
- above trench +10%
- in trench +25%
b. Type of pipe:
- iron pipes 0%
- prewrapped pipes +10%
c. Right-of-way quality:
- city street +20%
- along a road -10%
- dry rocky right-of-way 0%
- possible mud +15%
d. Means of production:
- crane +5%
- pipe laying machine 0%
e. Average pipe length:

- shorter than 8 m 0%
- longer than 8 m +10%
Example: pipe Ø 6" basic rate is 1,75 [Mhr/joint]

- a. + 10%
- b. + 10%
- c. - 10%
- d. + 5%
- e. + 0%
Total + 15%
The final manhour rate is a sum of the basic rate 1,75 [Mhr/joint] + 15% = 2,01[Mhr/joint]
52
5. WELDING
SMAW vertical up (conventional):Mhr/weld= X x Ø x t / 440

SMAW verical down (Fallnaht): Mhr/weld= X x Ø x t / 735
X = values from below table; Ø = pipe diameter in inches; t - wall thickness in mm
X-value table
Ø X Ø X
2” 54 14” 20,30
3” 42 16” 20,05
4” 36 18” 19,80
6” 27 20” 19,60
8” 24 22” 19,40
10” 21 24” 19,20
12” 20,60 above 24” 19,00
6. WRAPPING
6.1 MACHINE WRAPPING (acc. t John S. Page)
Ø to 2” 3” 4” 6” 8” 10” 12” 14” 16” 18”

[Mhr/m] 0,23 0,30 0,39 0,52 0,66 0,82 0,92 1,05 1,21 1,35
Ø 20” 22” 24” 26” 28” 30” 32” 34” 36”
[Mhr/m] 1,48 1,64 1,77 1,94 2,07 2,23 2,40 2,56 2,69
I find above values overestimated, which is based on my monitoring the wrapping works.
Therefore, I suggest that the following percentages of the above values are considered.
Diameter % Mhr/m2 Mhr/sqft

2"-8" 36% 0,37 0,0344
10"-16" 40% 0,40 0,0372
18"-24" 45% 0,43 0,04
26"-36" 50% 0,47 0,044
6.2 HAND WRAPPING
Single-layer wrapping: Machine wrapping x 2

Double-layer wrapping: Machine wrapping x 2,5
Weld wrapping: Mhr/weld= Mhr/m for hand wrapping
7. LAYING IN TRENCH
This kind of laying is considered only when the pipeline is hand wrapped near a trench or above a
trench. Man hours include also collection and transport of timber supports and possible installation of
concrete weights in case of an underwater pipeline.
to 4”......................................................0,12 [Mhr/m]
6” ÷ 8”......................................................0,13 [Mhr/m]
10” ÷ 12”......................................................0,15 [Mhr/m]
14” ÷ 16”......................................................0,17 [Mhr/m]
18” ÷ 24”......................................................0,18 [Mhr/m]
above 24”......................................................0,20 [Mhr/m]
53
8. SPECIAL POINTS
The term “special points” means the works on pipelines where a point crew cannot do
the work and the special points are left for later on. This requires special teams for executing such
works. The special points are:
8.1 BORING UNDER ROADS AND RAILROADS
Generally, the erection company does not perform the boring. The erection company performs the
following activities:
Supply of the material needed for protection and header pipe
Cutting of protection conduit to the length dictated by a boring team
Protection conduit welding
Protection conduit wrapping
Header pipe assembling and wrapping
Header pipe leak test
Installation of spacers and pulling in the main pipe
Installation of "Z" seals (sleeve)
Construction of air vents on both sides of the road/railroad
Putting up necessary signs for the road/railroad works
to4”......................................................100 [Mhr]
6” ÷ 8”......................................................130 [Mhr]
10” ÷ 12”......................................................160 [Mhr]
14” ÷ 16”......................................................190 [Mhr]
18” ÷ 24”......................................................220 [Mhr]
above 24”......................................................250 [Mhr]
Connection to the header is included.
8.2 BREAK OUT OF ROADS
These special points can be performed without stopping the road traffic or by bypassing the traffic.
This rate does not include the excavation and repair of the right-of-way.
w/o protection pipe w/o traffic with traffic

to 4”...............................16 [Mhr]...............................30 [Mhr]
6” ÷ 8”...............................25 [Mhr]...............................35 [Mhr]
10” ÷ 12”...............................30 [Mhr]...............................40 [Mhr]
14” ÷ 16”...............................40 [Mhr]...............................50 [Mhr]
18” ÷ 24”...............................50 [Mhr]...............................60 [Mhr]
above 24”...............................60 [Mhr]...............................70 [Mhr]
with protection pipe w/o traffic with traffic

to 4”...............................32 [Mhr]...............................40 [Mhr]
6” ÷ 8”...............................50 [Mhr]...............................60 [Mhr]
10” ÷ 12”..............................60 [Mhr]...............................75 [Mhr]
14” ÷ 16”..............................80 [Mhr]..............................100 [Mhr]
18” ÷ 24”.............................100 [Mhr]..............................120 [Mhr]
above 24”.............................120 [Mhr]..............................140 [Mhr]
The connection to the header is included.
8.3 CONNECTING PIPELINE SECTIONS
This item includes the works on interconnecting two pipeline sections.

to 4”.....................................................10 [Mhr]
6” ÷ 8”.....................................................12 [Mhr]
10” ÷ 12”.....................................................15 [Mhr]
14” ÷ 16”.....................................................18 [Mhr]
18” ÷ 24”.....................................................20 [Mhr]
above 24”.....................................................25 [Mhr]
54
8.4 CROSSING WATERCOURSES
The watercourses are rivers, streams and canals with or without water, etc. Generally,
specialist firms undertake the works on river crossings whereas crossings under streams and
canals are executed by erection companies, which undertake also the straight sections. The
following operations are included under this item.
- Bending - Laying in trench

- Connecting & welding of sections - Installation of concrete weights
- Leak test of sections - Backfilling
- Wrapping (Other works are the responsibility of a civil
contractor)
Canal Canal Stream

w/o water with water with water
to 4”.............................70 [Mhr]......................130[Mhr]....................150 [Mhr]
6” ÷ 8”...............................90 [Mhr]......................155[Mhr]....................175 [Mhr]
10” ÷ 12”............................110 [Mhr]......................180[Mhr]....................220 [Mhr]
14” ÷ 16”............................130 [Mhr]......................205[Mhr]....................260 [Mhr]
18” ÷ 24”............................150 [Mhr]......................230[Mhr]....................300 [Mhr]
above 24”............................160[Mhr]......................250[Mhr]....................320 [Mhr]
- Connecting to the header:

- one side included
- the other side according to the rate for “Connecting Pipeline Sections”
8.5 INSTALLATION OF CLEANING STATIONS
This item includes the installation of pipes coming out of the ground and installation of a
pig launcher and a pig trap. The construction of the station is not included but it can be rated as
prefabrication:
to 4”...........................................20 [Mhr/station]
6”÷ 8”...........................................27 [Mhr/station]
10”÷ 12”..........................................33 [Mhr/station]
14”÷ 16”..........................................40 [Mhr/station]
18”÷ 24”..........................................46 [Mhr/station]
above 24”.........................................55 [Mhr/station]
8.6 PUTTING UP PIPELINE MARKERS
This item covers all the operations relating to putting up the pipeline markers. Their
fabrication is not included.
Each marker = 2,50 [Mhr]
8.7 OTHER SPECIAL POINTS
- Make-on of branches on a pipeline

- Installation of measuring and control stations
- Installation of reducing stations
- Installation of condensate drain stations
- Bridge crossings
- Watercourse crossings
Man hours for these special points are calculated according to the manhour rates for
fabrication and installation of the piping in plants.
55
9. PRESSURE TESTS
Generally, the pressure tests on the pipelines are performed by teams specialized for this kind of
work. The team must be provided with all necessary equipment.
The pipelines are constructed in sections, which start and end at a stream that is at a place with
sufficient water to wash and test the pipeline washing and testing. The section length depends on the
pipeline right-of-way configuration. This rate determines the time needed to test a 5 km (3 miles) long
section. The following time allowances to be considered for longer sections:
- Pipeline section to 5 km or 3 miles......................................= 150 [Mhr]

- Each kilometre longer than 5 km or 3 miles.......................plus 20 [Mhr/km] or [Mhr/mile]
10. PRELIMINARY AND FINISHING WORKS
10.1 PRELIMINARY WORKS
They include:
- Setting up a camp
- Setting up offices
- Setting up warehouses and stores
- Setting up workshops
- Erection of necessary fences
- Preparation of machinery
- Construction of auxiliary devices
The rate for the preliminary works is 4% of the total man hours for the works from 1 through 9.
10.2 FINISHING WORKS
The finishing works include:
-Cleaning the right-of-way from residual material, pipes, timber supports, construction material,
and other debris
- Dismantling temporary works
- Loading the equipment and material
- Other finishing works
The rate for the finishing works is 50% of manhours for preliminary works.
56
III. STEEL STRUCTURE ERECTION (Acc. to MONTMONTAŽA Co. 1980) [Productivity efficiency percentage (PEP)=75%]
1. BASIC MAN HOURS - UNIT Unit weight of elements in [t] and man hours [Mhr/ton]
Kind of Work 0,05 0,1 0,15 0,2 0,25 0,35 0,5 0,8 1 2 3 4 5 8 10 12 15 20
1.1 Sorting the structure and preparation
for erection and pre-erection 6,6 5,5 5,0 4,4 3,8 3,7 3,3 3,1 2,9 2,6 2,4 2,2 1,1 - - - - -
1.2 Pre-erection of structure
a) by crane:
1.2.1. a Columns - - - - - - - - 6,6 5,8 5,5 5,41 4,93 4,27 3,66 3,3 2,92 2,88
1.2.2. a Beams and columns - - - - - - - - 5,5 4,7 4,47 4,41 3,63 3,02 2,95 2,64 2,39 1,82
1.2.3. a Lattice beams - - - - - - - - 7,04 6,17 4,95 4,4 4,09 3,76 3,19 2,56 2,86 -
b) by hand:
1.2.1. b Columns and beams - - - - - - - - 11,0 10,6 10,3 9,58 9,09 7,63 6,92 6,87 6,38 3,74
1.2.2. b Lattice beams - - - - - - - - 10,5 9,43 8,87 7,98 5,08 6,87 6,05 5,8 5,44 -
1.3 Transport of structure to erection place
1.3.1. Columns and beams - - - - - - - - 2,44 2,12 1,93 1,6 1,57 1,52 1,03 0,92 0,82 0,69
1.3.2. Lattice beam - - - - - - - - - 2,86 2,12 2,05 1,99 1,81 1,76 1,72 1,55 -
1.3.3. Small structure 5,94 5,83 5,72 5,5 4,84 4,4 4,18 3,85 - - - - - - - - - -
1.4 Installation of anchor bolts and break in - - - - - - - - 1,1 1,1 1,1 1,32 1,32 1,32 1,65 1,65 1,65 -
1.5 Structure erection
(hoisting and putting up the structure)
a) by crane:
57
1.5.1.a Columns - - - - - - - - 4,23 3,74 2,84 2,35 1,96 1,47 1,33 1,29 1,14 0,96
1.5.2.a Beams - - - - - - 6,05 3,5 5,33 4,78 3,52 2,94 2,23 1,63 1,57 1,6 1,46 1,33
1.5.3.a Lattice beam - - - - - - - - 11,0 9,9 8,8 6,6 4,95 4,4 3,85 3,3 2,75 2,8
1.5.4.a Different diagonal small items - - - 14,9 13,2 12,6 12,1 11,6 10,5 9,9 - - - - - - - -
b) by el. winches:
1.5.1.b Columns by supporting arms - - - - - - - - 4,95 4,62 4,34 3,96 3,74 3,63 2,87 - - -
1.5.2.b Beams " " " " - - - - - - - - 4,62 4,18 3,75 3,47 3,26 2,92 2,75 - - -
1.5.3.b Lattice supports by masts - - - - - - - - 7,81 6,7 5,72 5,28 4,95 4,4 4,18 3,85 - -
1.5.4.b Binding joists 34,4 25,4 19,9 16,9 12,8 12,1 - - - - - - - - - - - -
1.5.5.b Longitudinal beams 15,9 15,9 15,4 14,3 13,2 12,6 12,6 - - - - - - - - - - -
1.5.6.b Floor grids and chequered sheets 22,0 20,1 19,8 18,7 17,6 16,5 15,4 12,1 - - - - - - - - - -
c) By hand operated winches
or haulage cranes:
1.5.1.c Columns by supporting arms - - - - - - - - 8,8 6,6 5,05 5,5 4,95 4,4 - - - -
1.5.2.c Beams " " " " - - - - - - - - 7,7 6,0 5,5 5,06 4,4 3,85 - - - -
1.5.3.c Trusses supports by sup. arms - - - - - - - - 14,3 12,1 9,9 9,35 8,8 8,25 7,7 - - -
1.5.4.c Binding joists 4,0 33,0 26,4 22,4 18,9 16,7 - - - - - - - - - - - -
1.5.5.c Longitudinal beams
1.5.6.c Floor grids and chequered sheets 24,2 23,1 20,9 19,8 18,7 17,6 16,5 13,2 - - - - - - - - - -
1.5.7.c Wall windows 44,0 36,0 30,0 25,0 - - - - - - - - - - - - - -
1.5.8.c Misc. construct, diagonals
& small items pcs. - - - - - 23,1 22,0 20,9 - - - - - - - - - -
1.5.9.c Staircase treads [Mhr/ea] 0,8 - - - - - - - - - - - - - - - - -
1.6 INSTALLATION OF LOST FORMWORK Trapezoidal sheets for concrete slabs
- Bolting of binding beams is performed by the manufacture the structure supplier.

- Sheets are fastened by nails driven in by pistols.
1.6.1 Type "HOLORIB" or "MONTANA" (length c. 4 m, width 620 mm)
to 100 m2 100 ÷ 500 500 ÷ 1000 1000 ÷ 10000 10000 ÷ 50000 above
weight m2 m2 m2 m2 50000 m2
[kg/m2] to 1000 sqft 1000 ÷ 5000 5000 ÷ 10 000 10000 ÷ 100 000 ÷ above 500 000
sqft sqft 100 000 sqft 500 000 sqft sqft
t = 0,75 mm 11,4 0,13 Mhr/m2 0,12 Mhr/m2 0,11 Mhr/m2 0,105 Mhr/m2 0,10 Mhr/m2 0,09 Mhr/m2
1.6.2 Type "KRUPP HÖSCH" (length 3,6 ÷ 5,8 m, width 700 ÷ 800 mm)
to 100 m2 100 ÷ 500 500 ÷ 1000 1000 ÷ 10000 10000 ÷ 50000 above
weight m2 m2 m2 m2 50000 m2
[kg/m2] to 1000 sqft 1000 ÷ 5000 5000 ÷ 10 000 10000 ÷ 100 000 ÷ above 500 000
sqft sqft 100 000 sqft 500 000 sqft sqft
Note: 1. Steel brackets for trapezoidal plates (Stahlknagge) are generally shop welded.
If site welded, the rate of 5 ÷ 6 % is added.
2. Above rates include also placement of Z sections and seal caps.
1.7 INSTALLATION OF WIRE ROPE CLAMPS
ø Mhr/ea ø Mhr/ea ø Mhr/ea ø Mhr/ea ø Mhr/ea

to 20 mm 8,0 26 ÷ 30 mm 11,0 36 ÷ 40 mm 16,0 46 ÷ 50 mm 24,0 56 ÷ 60 mm 32,0
21 ÷ 25 mm 9,0 31 ÷ 35 mm 14,0 41 ÷ 45 mm 20,0 51 ÷ 55 mm 28,0 > 60 mm 40,0
1.8 REAMING OF HOLES
M 20 M 22 M 24 M 27 M 30 M 36 M 42 M 48 M 56 M 64
a) by pn. or el. drilling machine from scaffold - manhour/hole
0,1 0,11 0,12 0,13 0,14 0,15 0,16 0,18 0,19 0,2
b) by a reamer - man hour/hole
0,44 0,49 0,5 0,52 0,57 0,61 0,66 0,76 0,78 0,79
1.9 BOLTING FROM SCAFFOLDING - MANHOUR PER 100 PIECES mm x 0,03937 = inch
m x 3,28 = ft
Mhr/m2 x0,0929 = Mhr/sqft
M 20 M 22 M 24 M 27 M 30 M 36 M 42 M 48 M 56 M 64 kg/m2 x 0,2048 = lbs/sqft
16,5 18,1 18,7 19,2 20,3 23,1 26,6 30,8 33 37,4
When tightening the bolts by a torque wrench, manhours are multiplied by 1,5 factor.
Note: The above manhours do not include scaffolding.
58
2. ERECTION OF MISCELLANEOUS STEEL STRUCTURES (PEP = 75%)
2.1 BASIC MANHOUR RATES - TOTAL
2.1.1 BUILDINGS AND CANOPY FRAMING
Cubic Cubic Cubic Cubic

weight Rate weight Rate weight Rate weight Rate
[kg/m3] [Mhr/ton] [kg/m3] [Mhr/ton] [kg/m3] [Mhr/ton] [kg/m3] [Mhr/ton]
2 18,1 12 16,7 22 15,7 35 14,6
4 17,8 14 16,5 24 15,5 40 14,2
6 17,5 16 16,3 26 15,3 45 13,9
8 17,3 18 16,1 28 15,1 50 13,5
10 17,0 20 15,9 30 14,9 55 13,2
Cubic weight [kg/m3] = Structure weight [kg] .

Width [m] x Length [m] x Height [m]
Mhr/ton
Type of structure Light Medium Heavy
2.1.2 Equipment & bridging supports 17,5 15,5 13,2
2.1.3 Towers for transmission lines 12 9 6
2.1.4 Stairs structure 20 - -
2.1.5 Tower structure for chimney or similar 44 40 -
2.1.6 Antennas and torches 46 - -
2.1.7 Single member support 7 6 4,5
2.1.8 Bridging between the buildings 32 30 -
2.1.9 Conveyor bridges - 33,6 -
2.1.10 Crane tracks outside buildings - 18 16
2.1.11 Bridge crane 25 22 20
2.1.12 Portal crane 28 25 -
2.1.13 Port crane 60 55 -
2.1.14 Construction crane 55 - -
2.1.15 Stationary crane 36 - -
2.1.16 Piping bridges (outside oil refinieres) 35 - -
Structure: light to 30 kg/m; medium-weight 30 ÷ 60 kg/m; heavy above 60 kg/m
3. CORRECTION FACTORS
The rate for calculation is computed by multiplying the basic rate by a medium correction factor.
The medium correction factor is computed by adding up all selected factors and dividing them by 10.
K1 Weather impact
Month : I II III IV V VI VII VIII IX X XI XII

K1 : 1,2 1,15 1,05 1,0 1,0 1,0 1,0 1,0 1,0 1,03 1,06 1,09
K2 Abnormal impact of temperature
Average temp. : below - 10° C (-10)° C ÷ (- 5)° C (- 5)° C ÷ 30° C above 30° C
K2 : 1,6 1,3 1,0 1,15
kg/m x 0,672 = lbs/ft

kg/m3 x 2,2046 = lbs/m3
59
K3 Impact of elevation at which the works are executed
Heght in [m] to: 15 25 35 45 60 75 80 100

K3 : 1 1,06 1,12 1,18 1,24 1,35 1,5 1,65
K4 Impact of the job site ground
- hard and flat ground 0,9

- fill ground consolidated by a roller
and provided with drainage 0,95
- loose ground with drainage 1,0
- fill ground without drainage 1,05
- levelled out ground without drainage 1,1
- muddy ground 1,15
K5 Impact of the structure engineering level

- documentation fully developed 1,0
- only erection process with written
instruction 1,05
- documentation not developed 1,1
K6 Impact of installation joint type

- min. 90 % bolted joints 1,0
- min. 90 % welded joints 1,33
- min. 90 % riveted joints 1,5
K7 Impact of pre-assembling practicability

- pre-erection possible - smooth 0,75
- pre-erection possible - restricted 1,00
- pre-erection not possible 1,20
K8 Impact of the structure design

- very simple 0,85
- simple 0,95
- normal 1,00
- complex 1,05
- very complex 1,15
K9 Impact of the structure complexity

- welded plate structure 1,30
- rolled sections structure 1,00
- pipe structure 1,20
K10 Impact of the component bulking

- delivery in bulk 1,60
- basic assembling 1,25
- assembled for normal transport 1,00
- assembled for special transport 0,90
60
4. STEEL STRUCTURES IN OIL REFINERIES AND PETROCHEMICAL PLANTS (PEP = 75%)
4.1 LIGHT STRUCTURE (to 30 kg/m)

4.1.1 Ladders and step irons 40,0 [Mhr/ton]
4.1.2 Floors - treads 50,0 [Mhr/ton] or 0,56 [Mhr/ea]
4.1.3 Light platforms and landings 35,0 [Mhr/ton]
4.1.4 Railing - straight 80,0 [Mhr/ton] or 1,6 [Mhr/m]
Railing - round 100,0 [Mhr/ton] or 2,0 [Mhr/m]
4.2 MEDIUM-WEIGHT STRUCTURE (31 ÷ 60 kg/m)

4.2.1 Air coolers 18,5 [Mhr/ton]
4.2.2 Medium platforms and landings 14,5 [Mhr/ton]
4.2.3 Structure on towers 20,0 [Mhr/ton]
4.2.4 Staircases 22,0 [Mhr/ton]
4.2.5 Torch structure 14,0 [Mhr/ton]
4.2.6 Pipe supports, trestles, supports
on prepared foundations 25,0 [Mhr/ton]
4.3 HEAVY STRUCTURE (above 60kg/m)

4.3.1 Pipe racks 8,5 [Mhr/ton]
4.3.2 Kiln structure 12,0 [Mhr/ton]
4.3.3 Reactor and regenerator
structure 11,0 [Mhr/ton]
4.3.4 Large workshops
- span to 10 m 12,0 [Mhr/ton]
- 10 ÷ 20 m 14,0 [Mhr/ton]
- above 20 m 15,0 [Mhr/ton]
4.4 MISCELLANEOUS STRUCTURES

4.4.1 Floor grids 1,2 [Mhr/m2]
4.4.2 Chequered plate flooring
- fabrication 1,2 [Mhr/m2]
- installation 1,0 [Mhr/m2]
4.4.3 Lining of large workshops and hangars
- corrugated sheets 0,4 [Mhr/m2]
- sandwich elements - roof 1,0 [Mhr/m2]
- sandwich elements - fasade 1,2 [Mhr/m2]
4.5 PIPE HANGERS AND SUPPORTS

4.5.1 Fabrication 7,0 [kg/Mhr]
4.5.2 Erection 10,0 [kg/Mhr]
4.5.3 Spring supports
erection 12,0 [kg/Mhr]
(Classification of steel structures acc. to UHDE Dortmund)
61
5. ERECTION AND DISMANTLING OF MISCELLANEOUS STEEL STRUCTURES
(PEP = 75%)
5.1 ERECTION OF STEEL STRUCTURES - ACC. TO THE WEIGHT
Bulking,
raising,
Unloading positioning
Structure weight and on-site and Structure fastening TOTAL
hauling temporary
bolting
[Mhr/ton] [Mhr/ton] [Mhr/ton] [Mhr/ton]
to 20 tons 5,50 9,50 welding of 6,0 19,60
bolted joint 5,0 18,66
20 ÷ 50 tons 5,0 9,0 welding of 5,30 18,0
50 ÷ 100 tons 4,0 8,50 welding of 4,50 15,86
100 ÷ 250 tons 3,50 8,0 welding of 4,30 14,75
250 ÷ 500 tons 3,0 7,50 welding of 4,10 13,72
500 ÷ 750 tons 2,90 7,30 welding of 3,80 13,06
750 ÷ 1000 tons 2,80 7,0 welding of 3,50 12,40
1000 ÷ 1500 tons 2,60 6,60 welding of 3,20 11,57
1500 ÷ 3000 tons 2,40 6,30 welding of 2,80 10,73
3000 ÷ 5000 tons 2,20 6,0 welding of 2,40 9,90
above 5000 tons 2,0 5,50 welding of 2,0 8,86
Above man hours do not include painting and scaffolding.
5.2 MISCELLANEOUS STRUCTURES
5.2.1 STRAN STEEL FRAMING

- stud system 0,16 [Mhr/m2]
- rafter system 0,39 [Mhr/m2]
- joist system 0,22 [Mhr/m2]
Man hours do not include covering, painting and scaffolding.
5.2.2 STEEL OVERHEAD PIPE, BRIDGES, ETC.

- unloading 2,33 [Mhr/ton]
- bulking, hoisting, positioning and temporary bolting 11,20 [Mhr/ton]
fastening:
- welded design 2,33 [Mhr/ton]
- bolted design 1,87 [Mhr/ton]
Total: -welded design 15,86 [Mhr/ton]

62
5.2.3 DOCK AND CANOPY FRAMING
- raising, positioning and temporary bolting 7,00 [Mhr/ton]
- fastening:
- welded design 1,96 [Mhr/ton]
Total: - welded design 10,83 [Mhr/ton]

5.2.4 PLATFORMS AND FLOORS

- erection:
- platform framing 37,5 [Mhr/ton]
- catwalk framing 35,5 [Mhr/ton]
- chequered floor plate 25 [kg/Mhr] or 40,0 [Mhr/ton]
Man hours do not include painting and scaffolding.
5.2.5 BAR JOISTS, PARTITION FRAMING, MONORAILS AND EQUIPMENT SUPPORTS
a) bar joists
- erection and fastening 11,20 [Mhr/ton]
Total: 14,00 [Mhr/ton]
b) partition framing
- fabrication cutting out 41,00 [Mhr/ton]
c) monorails
d) equipment supports
- fabrication cutting out 51,24 [Mhr/ton]
Man hours do not include erection of equipment, painting and scaffolding.
5.2.6 STAIRS & LADDERS

- unloading miscellaneous steel items 2,80 [Mhr/ton]
a) stairs:
- fabrication of all sizes 71,74 [Mhr/ton]
- field erection 915 mm (3' 0”) wide 2,00 [Mhr/ton]
- landing fabrication 41,00 [Mhr/ton]
63
b) ladders
- fabrication of straight ladders 123,0 [Mhr/ton]
- fabrication of ships ladders 102,5 [Mhr/ton]
- fabrication of safety cages 123,0 [Mhr/ton]
- erection of straight ladders 0,92 [Mhr/ton]
- erection of ships ladders 0,76 [Mhr/ton]
- erection of safety cages 0,92 [Mhr/ton]
- rung erection ø 19 mm (3/4”) 0,47 [Mhr/ton]
5.2.7 HANDRAILS
a) Standard Pipe Handrails - 1067 mm (3' 6”) High
- fabrication 1 1/4” & 1 1/2” - straight runs 3,3 [kg/Mhr] or 303,0 [Mhr/ton]
- fabrication 1 1/4” & 1 1/2” - angled runs 2,76 [kg/Mhr] or 362,0 [Mhr/ton]
- erection 1 1/4” pipe - straight free standing 0,49 [Mhr/m]*
- erection 1 1/4” pipe - angled free standing 0,58 [Mhr/m]*
- erection 1 1/2” pipe - straight free standing 0,61 [Mhr/m]*
- erection 1 1/2” pipe - angled free standing 0,73 [Mhr/m]*
b) Single Pipe Handrail - Wall Attached:
- fabrication 1 1/4” & 1 1/2” pipe 7,35 [kg/Mhr] or 136,0 [Mhr/ton]

- erection 1 1/4” pipe 0,37 [Mhr/m]*
- erection 1 1/2” pipe 0,49 [Mhr/m]*
- erection of wall brackets 0,50 [Mhr/ea]
c) Standard Angled Iron Handrail - 1067 mm (3' 6”) High
- fabrication - straight runs 1,39 [kg/Mhr] or 719,0 [Mhr/ton]

- fabrication- angled runs 1,16 [kg/Mhr] or 862,0 [Mhr/ton]
- erection 50x50x6 mm - straight free standing 0,61 [Mhr/m]*
- erection 50x50x6 mm - angled free standing 0,7 [Mhr/m]*
- erection 50x50x6 mm - straight free standing 0,73 [Mhr/m]*
- erection 50x50x6 mm - angled free standing 0,86 [Mhr/m]*
d) STANDARD TOE OR KICK PLATES
3,5 mm x 150 (6”) 0,46 [Mhr/m]

4,76 mm x 150 (6”) 0,61 [Mhr/m]
6,35 mm x 150 (6”) 0,76 [Mhr/m]
[Mhr/m]* refers to the length of handrail and not the length of a pipe or a section.
- Straight runs are those with all connecting members at 90o angles.
- Angles runs are those with all connecting members at an angle larger or smaller than 90o.
- For erection of handrails made of light tubes and solid round and flat sections, use the man hours for
angled handrails.
- For handrails with expanded metal panels, increase angle iron man hours thirty (30) percent.
- Man hours do not include painting.

5.2.8 DOOR, LOUVER AND DUCT FRAMES Mhr/m x 0,3048 = Mhr/ft
a) Door Frames
- unloading 195,0 [kg/Mhr] or 5,13 [Mhr/ton]
- fabrication 21,0 [kg/Mhr] or 47,62 [Mhr/ton]
- installation 21,60 [kg/Mhr] or 46,30 [Mhr/ton]
64
b) Louver Frames
- erection 24,30 [kg/Mhr] or 41,10 [Mhr/ton]
c) Duct Frames

5.2.9 MISCALLANEOUS IRON & STEEL
a) Bins & Hoppers

b) Miscallaneous Hangers
- fabrications 19,41 [kg/Mhr] or 51,52 [Mhr/ton]
c) Metal Thresholds
- Installation 1,40 [Mhr/ea]
d) Wheel Guards
- installation 0,47 [Mhr/ea]
e) Trench Framing
- Unloading 194,15 [kg/Mhr] or 5,15 [Mhr/ton]
- Fabrication 21,57 [kg/Mhr] or 46,36 [Mhr/ton]
- Installation 27,73 [kg/Mhr] or 36,06 [Mhr/ton]
f) Trench Covers
- Plates installation 1,0 [Mhr/m2]
- Grating installation 1,40 [Mhr/m2]
g) Curb Angles
h) Steel Curbing
i) Pipe Sleeves
j) Anchor Bolts
k) Ledger Angles
65
5.2.10 STEEL GRATING
- Installation of floor grids

Grating Bar Size Weight [kg/m2] [Mhr/m2]
19,05 x 4,76 mm 28,80 1,1
25,04 x 3,18 mm 25,39 1,0
25,04 x 4,76 mm 37,11 1,4
31,3 x 3,18 mm 30,76 1,2
31,3 x 4,76 mm 44,92 1,7
38,1 x 3,18 mm 36,13 1,4
38,1 x 4,76 mm 53,22 1,8
44,45 x 4,76 mm 61,52 1,9
50,8 x 4,76 mm 69,82 2,0
57,15 x 4,76 mm 77,64 2,2
63,5 x 4,76 mm 85,94 2,4
- Fabrication and modification of floor grids:
- straight and diagonal cutting 0,30 [Mhr/m]
- circular cutting 0,45 [Mhr/m]
- straight and diagonal banding 0,36 [Mhr/m]
- circular banding 0,60 [Mhr/m]
- welding of curb angles 0,76 [Mhr/m]
- rounding of curbs by grinding 1,07 [Mhr/m]
5.2.11 SIDING OF LARGE WORKSHOPS AND HANGARS

- section sheets 0,40 [Mhr/m2]
- section aluminium plates 0,42 [Mhr/m2]
- stainless steel sheets 0,71 [Mhr/m2]
- insulation boards (sandwich) 0,82 [Mhr/m2]
Man hours do not include sealing and scaffolding.
5.3 REMOVAL OF STEEL STRUCTURE AND MISCELLANEOUS ITEMS
- Steel structure 8,65 [Mhr/ton]

- Miscellaneous steel items 15,15 [Mhr/ton]
- Machinery:
light 14,90 [Mhr/ton]
heavy 12,40 [Mhr/ton]
- Pipes (C.S.)
to 2” 0,48 [Mhr/m]
3” ÷ 6” 0,86 [Mhr/m]
8” ÷ 12” 1,84 [Mhr/m]
14” ÷ 16” 3,19 [Mhr/m]
18” ÷ 24” 4,60 [Mhr/m]
26” ÷ 36” 5,50 [Mhr/m]
- Railroads:
Ties and tracks 0,95 [Mhr/m]
Turnouts 30,0 [Mhr/ea]
- Miscellaneous
Fence of three strand barbed wire 0,24 [Mhr/m]
Fence of five strand barbed wire 0,28 [Mhr/m]
Chain link fence 0,46 [Mhr/m]
Guard rail 0,77 [Mhr/m]
Man hours do not include loading, transport and unloading and scaffolding.
kg/m2 x 0,2048 = lbs/ft

Mhr/m2 x 0,0929 = Mhr/sqft
kg/Mhr x 2,2046 = lbs/ft
66
IV. ERECTION OF EQUIPMENT IN PETROCHEMICAL INDUSTRY
1. STATIONARY EQUIPMENT (towers, heat exchangers, reactors, regenerators, small storage

tanks, air coolers, etc.)
These man hours include the erection of equipment delivered as a whole or in sections that are
completed but not fully assembled because of their overall dimensions (transport).
Man hours include:

- Unloading
- Hauling from storage to the place of erection
- Hoisting by usual hoisting means
- Putting up to the design elevation
- Positioning of connection points
- Position inspection
TIME ALLOWANCE FOR ERECTION OF EQUIPMENT AT ELEVATION
All stated below, man hours for erection of equipment are applicable when the equipment base is
at an elevation of up to 2 m above the site zero level.
Apply the following factors for higher elevations:
Elevation Factor
0 ÷ 2 m..............................................1,00
2 ÷ 4 m..............................................1,10
4 ÷ 6 m..............................................1,20
6 ÷ 10 m..............................................1,25
above 10 m..............................................1,30
1.1 All Equipment to 0,5 ton 10[Mhr/ea] or 25,0[kg/Mhr]
1.2 Towers above 0,5 ton 25 [Mhr/ea] + 3 [Mhr/ton]
1.3 Towers consisting of more pieces: 50 [Mhr/ea] + 3 [Mhr/ton] + joint

Joint: 60 [Mhr/m] of joint circumference
1.4 Package Unit

to 10 tons : 30 [Mhr/ea] + 5 [Mhr/ton]
above 10 tons : 50 [Mhr/ea] + 5 [Mhr/ton]
1.5 Other Equipment

0,5 ÷ 2 tons : 12 [Mhr/ea] + 3 [Mhr/ton]
above 20 tons : 10 [Mhr/ea] + 5 [Mhr/ton]
1.6 Bridge Cranes
- Erection of crane track (rails) 2,50 [Mhr/m]
- Erection of crane with a trolley and a drive 25,0 [Mhr/m] span
1.7 Lifts
25 [Mhr/m2] shaft + 15 Mhr per meter of elevation
67
1.8 Electrostatic Precipitators
Weight [ton] Effect [kg/Mhr]

to 100 ton/unit 25,0
100 ÷ 250 ton/unit 30,0
above 250 ton/unit 35,0
1.9 Marine loading arms

(acc. to John S. Page)
- assembling and erection [Mhr/ea]
Load. arm
diam. Total length of loading arm (meters)
inch to 6 6÷9 9 ÷ 12 12 ÷ 15 15 ÷ 18 18 ÷ 21 21 ÷ 24 24 ÷ 27 27 - 30
4” 40 51 62 79 100 125 156 186 235
6” 50 63 78 97 120 150 188 235 294
8” 70 88 108 132 163 200 244 296 356
10” 91 114 134 159 171 224 265 315 375
12” 115 144 167 194 217 315 370 434 509
14” 128 161 183 208 283 321 381 447 523
16” 150 186 206 228 301 333 396 472 563
18” 163 205 223 240 313 341 405 482 575
20” 187 237 256 276 356 386 422 502 598
24” 224 281 295 308 386 419 457 536 628
NOTE: I find above man hours for loading arms too stringent, so I suggest they are
increased by 20 ÷ 25 %.
2. ROTARY EQUIPMENT (pumps, compressors, fans, blowers, mixers, etc.)
These man hours include the following:
- Hauling from storage to the place of erection

- Placing onto previously built foundations
- Vertical positioning
- Machine positioning and inspection
- Installation of guards and covers
- Completion with pertaining parts m x 3,281 = ft
2.1 CENTRIFUGAL PUMPS
2.1.1 MAN HOURS BASED ON POWER [kW]
Power [kW] [Mhr/kW] [Mhr/ea] Minimum hours

to 10 kW 2,00 + 5 5
10 ÷ 50 kW 1,60 + 10 26
50 ÷ 100 kW 1,30 + 20 90
100 ÷ 150 kW 1,20 150
150 ÷ 200 kW 1,00 180
200 ÷ 250 kW 0,90 200
above 250 kW 0,75 225
68
- Pumps supplied with a coupling on one pedestal x 1,00
- Pumps and drive motors supplied separately x 1,20
- Pumps, drive motors and reduction gears supplied separately x 1,40
- Vertical pumps x 0,80
- Fans x 1,25
- Blowers x 0,85
- Gear pumps x 0,70
- Mixers x 0,75
- Compressors to 200 kW x 1,00
2.1.2 MAN HOURS BASED ON WEIGHT [kg]
Weight [kg] Effect [kg/Mhr] Min. [Mhr/ea]

to 100 11,0 5
101 ÷ 200 12,0 9
201 ÷ 300 14,0 17
301 ÷ 400 16,0 21
401 ÷ 500 18,0 25
501 ÷ 600 20,0 28
601 ÷ 700 22,0 30
701 ÷ 800 24,0 32
801 ÷ 900 26,0 34
901 ÷ 1000 280 35
1001 ÷ 1250 30,0 36
1251 ÷ 1500 32,0 42
1501 ÷ 2000 34,0 47
2001 ÷ 2500 36,0 56
above2500 38,0 70
- vertical pumps [kg/Mhr] x 1,0

- fans [kg/Mhr] x 1,0
- blowers [kg/Mhr] x 1,0
- gear pumps [kg/Mhr] x 1,0 kg x 0,4536 = lbs
- mixers [kg/Mhr] x 1,0 kg/Mhr x 2,2046 = lbs/Mhr
- compressors [kg/Mhr] x 1,0
NOTE: If the data on power and weight are available, perform the calculation on both bases and take the
mean value.
2.1.3 MAN HOURS BASED ON THE CAPACITY [m3/hr]

(FOR LIQUID MEDIA ONLY)
[m3/hr] Mhr x [m3/hr] [m3/hr] Mhr x [m3/hr]

to 10 1,06 160,1 ÷ 170 0,28
10,1 ÷ 20 0,96 170,1 ÷ 180 0,27
20,1 ÷ 30 0,87 180,1 ÷ 190 0,26
30,1 ÷ 40 0,78 190,1 ÷ 200 0,24
40,1 ÷ 50 0,71 200,1 ÷ 210 0,23
50,1 ÷ 60 0,65 210,1 ÷ 220 0,39
60,1 ÷ 70 0,59 220,1 ÷ 230 0,21
70,1 ÷ 80 0,54 230,1 ÷ 240 0,20
80,1 ÷ 90 0,50 240,1 ÷250 0,19
90,1 ÷ 100 0,46 250,1 ÷260 0,185
100,1 ÷ 110 0,42 260,1 ÷270 0,18
110,1 ÷ 120 0,39 270,1 ÷280 0,175
120,1 ÷ 130 0,36 280,1 ÷290 0,17
130,1 ÷ 140 0,34 290,1 ÷300 0,165
140,1 ÷ 150 0,32 300,1 ÷750 0,16
150,1 ÷ 160 0,30 above 750 0,15
69
Conversion of Units
l/s x 3,6 = m3/hr l/min x 0,06 = m3/hr
US gallons per minute: US gpm x 0,227 = m3/hr
Cubic feet per minute: cfpm x 1,7 = m3/hr
Cubic feet per hour: cfphr x 0,283 = m3/hr
2.2 COMPRESSORS
2.2.1 COMPRESSORS DRIVEN BY ELECTRIC MOTOR
to 200 kW Acc. to Table 2.1.1

201 ÷ 300 kW 1,30 [Mhr/kW] (min. 220 Mhr)
301 ÷ 500 kW 1,19 [Mhr/kW] (min. 390 Mhr)
501 ÷ 750 kW 0,88 [Mhr/kW] (min. 595 Mhr)
751÷ 1000 kW 0,70 [Mhr/kW] (min. 660 Mhr)
1001 ÷ 1500 kW 0,55 [Mhr/kW] (min. 700 Mhr)
1501 ÷ 2250 kW 0,44 [Mhr/kW] (min. 825 Mhr)
2251 ÷ 3000 kW 0,41 [Mhr/kW] (min. 990 Mhr)
3001 ÷ 4000 kW 0,35 [Mhr/kW] (min. 1230 Mhr)
4001 ÷ 5000 kW 0,30 [Mhr/kW] (min. 1400 Mhr)
above 5000 kW 0,25 [Mhr/kW] (min. 1500 Mhr)
2.2.2 COMPRESSORS DRIVEN BY GAS TURBINE
to 250 kW 1,62 [Mhr/kW] (min. 250 Mhr)

251 ÷ 350 kW 1,52 [Mhr/kW] (min. 400 Mhr)
351 ÷ 450 kW 1,34 [Mhr/kW] (min. 530 Mhr)
451 ÷ 600 kW 1,18 [Mhr/kW] (min. 600 Mhr)
601 ÷ 750 kW 1,05 [Mhr/kW] (min. 700 Mhr)
751 ÷ 900 kW 0,97 [Mhr/kW] (min. 785 Mhr)
901 ÷ 1100 kW 0,89 [Mhr/kW] (min. 870 Mhr)
1101 ÷ 1300 kW 0,84 [Mhr/kW] (min. 975 Mhr)
1301 ÷ 1500 kW 0,82 [Mhr/kW] (min. 1090 Mhr)
1501 ÷ 1750 kW 0,80 [Mhr/kW] (min. 1230 Mhr)
1751 ÷ 2000 kW 0,77 [Mhr/kW] (min. 1400 Mhr)
2001 ÷ 2500 kW 0,73 [Mhr/kW] (min. 1540 Mhr)
2501 ÷ 3000 kW 0,69 [Mhr/kW] (min. 1825 Mhr)
3001 ÷ 4000 kW 0,64 [Mhr/kW] (min. 2070 Mhr)
above 4000 kW 0,50 [Mhr/kW] (min. 2500 Mhr)
70
3. TOWERS & VESSELS - INSTALLATION OF INTERIOR COMPONENTS & EQUIPMENT
3.1 INSTALLATION OF TRAYS AND DEMISTERING PADS
Tower Diameter [Mhr/m2] [kg/Mhr]

[mm] 1. 2. 3. 4. 5. 6. * 6.
to 1000 9,2 10,0 11,2 12,3 7,7 30,0 3,30
1001 ÷ 1200 8,3 9,9 10,7 11,8 6,4 23,0 3,97
1201 ÷ 1400 7,8 9,3 10,2 11,2 5,6 20,0 4,18
1401 ÷ 1600 7,4 8,8 10,0 11,0 4,8 18,0 4,70
1601 ÷ 1800 6,8 8,2 9,4 10,3 4,1 15,5 5,34
1801 ÷ 2000 6,5 7,8 8,7 9,5 3,7 13,8 5,63
2001 ÷ 2250 6,3 7,5 8,4 9,2 3,4 12,5 6,16
2251 ÷ 2500 6,15 7,3 8,0 8,8 3,3 11,0 6,45
2501 ÷ 2750 5,75 6,9 7,7 8,5 3,2 10,3 6,72
2751 ÷ 3000 5,5 6,6 7,5 8,2 3,1 9,4 7,06
3001 ÷ 3250 5,3 6,3 7,2 7,9 3,0 9,0 7,38
3251 ÷ 3500 5,2 6,2 6,75 7,4 2,9 8,5 7,70
above 3500 5,0 6,0 6,4 7,0 2,8 8,0 8,00
1. Single downflow valve type trays

2. Double downflow valve type trays
3. Single downflow bubble cap type trays
4. Double downflow bubble cap type trays
5. Sieve or perforated type trays
6. Demisting pads*
*If the bottom and roof of a demisting pads are already installed, the man hours should be
decreased by 25%.
3.2 VESSELS & TOWER PACKING
Packing the vessels and towers with different solid packings in bulk condition:
towers : 20,0 [Mhr/ea] + 3,0 [Mhr/m3] or 12,0 [Mhr/ton]

vessels : 10,0 [Mhr/ea] + 2,5 [Mhr/m3] or 10,0 [Mhr/ton]
3.3 OPENING AND CLOSING OF MANHOLES ON VESSELS AND TOWERS
Manhole Size [Mhr/ea]
to 14” 10,0
16” 12,0
18” 13,0 Class :
20” 16,0
24” 18,0 150# x 1,0
28” 20,0 300# x 1,15
30” 21,0 600# x 1,30
32” 22,0
Mhr/m2 x 0,0929 = Mhr/sqft
36” 24,0 Mhr/m3 x 0,02831 = Mhr/cuft
40” 26,0 kg/Mhr x 2,2046 = lbs/Mhr
42” 28,0
71
3.4 ERECTION OF PLATFORMS, LADDERS AND FLOOR GRIDS ON VESSELS AND TOWERS (PREDRESSING)
3.4.1 Erection average effect :

60,0 [kg/Mhr]
3.4.2 Estimate of quantity of platforms, ladders and floor grids

It is calculated per [m2] of the shell surface area (without bottom and roof).
Elevation [kg/m2]* [Mhr/m2]*

to 10 m 37,00 0,62
10,1 ÷ 15 m 33,50 0,56
15,1 ÷ 20 m 31,00 0,52
20,1 ÷ 25 m 28,00 0,47
25,1 ÷ 30 m 25,00 0,42
30,1 ÷ 35 m 22,00 0,37
35,1 ÷ 40 m 20,00 0,33
40,1 ÷ 45 m 18,00 0,30
45,1 ÷ 50 m 16,00 0,27
50,1 ÷ 55 m 14,00 0,23
55,1 ÷ 60 m 13,50 0,22
above 60 m 13,20 0,21
* These data should be regularly monitored and occasionally revised.
4. EQUIPMENT SCAFFOLDING
4.1 Tubular scaffold (for each piece of equipment separately)
3 3 3 3 3 3
to 10 m 10 ÷ 50 m 50 ÷ 100 m 100 ÷ 500 m 500 ÷ 1000 m above 1000 m
Scaffold
erection
3
[Mhr/m ] or 0,60 0,58 0,55 0,52 0,50 0,47
2
[Mhr/m ]
Scaffold
dismantling
3
[Mhr/m ] or 0,30 0,27 0,25 0.23 0,20 0,18
2
[Mhr/m ]
Total 0,90 0.85 0,80 0,75 0,70 0,65
Elevation factor at which the scaffold is erected or dismantled:
0 ÷ 5m 1,00
5 ÷ 10 m 1,25
10 ÷ 15 m 1,35
15 ÷ 20 m 1,40 kg/Mhr x 2,2046 = lbs/Mhr
kg/m2 x 0,2048 = lbs/sqft
20 ÷ 25 m 1,65 Mhr/m2 x 0,0929 = Mhr/sqft
25 ÷ 30 m 2,00 Mhr/m3 x 0,02831 = Mhr/cuft
above 30 m 2,50 m3 x 35,32 = cuft
72
4.2 Patent Scaffolding
Sections:
Length : 7 feet;2,1 m
Width : 5 feet;1,5 m
Height : 5 feet;1,5 m
Manhours per section

Length One or Two Sections More Than Two
High Sections High
Erection Dismantling Total Erection Dismantling Total
One to Two
Sections Long 1,40 1,00 2,40 1,70 1,20 2,90
Three to Five
Sections Long 0,90 0,60 1,50 1,00 0,70 1,70
Six and More
Sections Long 0,70 0,40 1,10 0,90 0,50 1,40
73
VII. CORROSION PROTECTION Productivity Efficiency Percentage (PEP) = 80%
1. SAND BLASTING AND SURFACE AREA OF PIPING ELEMENTS RATES FOR PIPES
PAINTING OF PIPING Pipe Elbow TEE Reducer Flange Valve Blast and Two Middle Covering TOTAL TOTAL
1m r=1,5d First Coat Coats Coat Four Coats Four Coats
Dn-mm ø-Inch OD-mm [m2] [m2] [m2] [m2] [m2] [m2] [Mhr/m2] [Mhr/m2] [Mhr/m2] [Mhr/m2] [Mhr/m] ø-Inch
15 1/2” 21,3 0,067 0,003 0,003 0,002 0,012 0,030 0,60 0,45 0,30 1,34 0,09 1/2”
20 3/4” 26,7 0,083 0,005 0,004 0,003 0,017 0,036 0,60 0,40 0,30 1,30 0,11 3/4”
25 1” 33,4 0,105 0,008 0,007 0,005 0,020 0,043 0,57 0,38 0,29 1,24 0,13 1”
32 1 1/4” 42,2 0,132 0,013 0,011 0,006 0,023 0,054 0,55 0,38 0,25 1,18 0,16 1 1/4”
40 1 1/2” 48,3 0,151 0,017 0,015 0,009 0,030 0,065 0,53 0,33 0,25 1,11 0,17 1 1/2”
50 2” 60,3 0,19 0,027 0,023 0,013 0,035 0,147 0,47 0,32 0,21 1,00 0,19 2”
65 2 1/2” 73 0,24 0,039 0,035 0,019 0,046 0,185 0,42 0,29 0,21 0,92 0,22 2 1/2”
80 3” 88,9 0,28 0,058 0,050 0,022 0,056 0,173 0,39 0,29 0,20 0,88 0,25 3”
100 4” 114,3 0,36 0,097 0,082 0,033 0,080 0,297 0,36 0,28 0,20 0,84 0,30 4”
125 5” 141,3 0,44 0,120 0,124 0,050 0,096 0,390 0,34 0,25 0,20 0,79 0,35 5”
150 6” 168,3 0,53 0,210 0,178 0,067 0,120 0,460 0,34 0,25 0,19 0,78 0,41 6”
200 8” 219,1 0,69 0,472 0,302 0,094 0,170 0,660 0,33 0,25 0,17 0,75 0,52 8”
250 10” 273 0,86 0,552 0,470 0,138 0,230 0,890 0,33 0,23 0,16 0,72 0,62 10”
300 12” 323,9 1,02 0,776 0,661 0,186 0,260 1,190 0,32 0,23 0,16 0,70 0,72 12”
350 14” 355,6 1,12 0,936 0,797 0,333 0,300 1,570 0,31 0,22 0,16 0,69 0,77 14”
400 16” 406,4 1,28 1,222 1,040 0,410 0,350 1,790 0,31 0,22 0,16 0,69 0,89 16”
450 18” 457 1,43 1,545 1,307 0,490 0,390 2,220 0,31 0,22 0,16 0,69 0,99 18”
103
500 20” 508 1,60 1,910 1,626 0,732 0,420 2,520 0,30 0,20 0,15 0,65 1,04 20”
550 22” 559 1,75 2,312 1,957 0,800 0,460 3,220 0,30 0,20 0,15 0,65 1,14 22”
600 24” 610 1,92 2,754 2,342 0,878 0,490 3,920 0,30 0,20 0,15 0,65 1,25 24”
650 26” 660 2,07 3,223 2,732 1,136 0,520 3,800 0,30 0,20 0,15 0,65 1,35 26”
700 28” 711 2,24 3,741 3,185 1,230 0,560 3,850 0,30 0,20 0,15 0,65 1,46 28”
750 30” 762 2,39 4,297 3,642 1,312 0,600 4,330 0,30 0,20 0,15 0,65 1,55 30”
800 32” 813 2,56 4,891 4,163 1,405 0,630 4,820 0,30 0,20 0,15 0,65 1,66 32”
850 34” 864 2,71 5,524 4,683 1,488 0,670 5,320 0,30 0,20 0,15 0,65 1,76 34”
900 36” 914 2,88 6,182 5,265 1,581 0,700 5,820 0,30 0,20 0,15 0,65 1,87 36”
950 38” 965 3,03 6,891 5,848 1,663 0,740 6,450 0,30 0,20 0,15 0,65 1,97 38”
1000 40” 1016 3,20 7,639 6,502 1,757 0,780 7,100 0,30 0,20 0,15 0,65 2,08 40”
1050 42” 1067 3,35 7,639 7,149 2,144 0,800 0,30 0,20 0,15 0,65 2,18 42”
1100 44” 1118 3,52 8,425 7,871 2,252 0,840 0,30 0,20 0,15 0,65 2,29 44”
1150 46” 1168 3,66 10,095 8,550 2,342 0,980 0,30 0,20 0,15 0,65 2,38 46”
1200 48” 1219 3,83 10,996 9,338 2,451 0,920 0,30 0,20 0,15 0,65 2,49 48”
1350 54” 1372 4,31 13,930 11,827 2,758 1,020 0,30 0,20 0,15 0,65 2,80 54”
1500 60” 1524 4,79 17,187 14,600 3,065 1,120 0,30 0,20 0,15 0,65 3,11 60”
1.1 RATES FOR PIPING ELEMENTS 1.2 MATERIAL CONSUMPTION - acc. to Item 2 (page 104)
- Pipes: above table - Reducers: [Mhr/m2] x 1,1
2
- Elbows: [Mhr/m2] x 1,4 - Flanges: [Mhr/m2] x 1,5 m x 10764 = sq ft
2
- Tees: [Mhr/m2] x 1,3 - Valves: [Mhr/m2] x 1,6 Mhr/m x 0,0929 = Mhr/sq ft
2. SAND BLASTING AND PAINTING OF STEEL STRUCTURES
2.1 Sand blasting and primer: 0,33 [Mhr/m2] + 0,08 [Mhr/m2] = 0,41 [Mhr/m2]
Material Consumption:
— siliceous sand for the purity grade SA 2 1/2

15 ÷ 25 [kg/m2]
or: — corrund (Al2O3) for the purity grade SA 2 1/2

5 ÷ 9 [kg/m2]
or: — ground dross for the purity grade SA 2 1/2

15 ÷ 20 [kg/m2]
or: — hot (metal sand)

1,5 ÷ 2,0 [kg/m2]
2.2 Next Coats
2.2.1 Up to 100 microns: by brush 0,25 [Mhr/m2]

by spray gun 0,10 [Mhr/m2]
Material consumption: colour 0,30 [kg/m2]
2.2.2 Above 100 microns: by brush 0,33 [Mhr/m2]

by spray gun 0,15 [Mhr/m2]
Material consumption: 0,40 [kg/m2]
NOTE:
1. Consumption of the abrasive material depends on the corrosion pitting of the structure, wind,
space and the possibility of regeneration of the abrasive used.
2. Paint consumption depends on the corrosion pitting, coat thickness, wind, and the
manufacturer's instructions.
2.3 Time allowances for job conditions
2.3.1 Work at elevations

to 2 m — no allowances
2÷ 4m — + 10 %
4 ÷ 10 m — + 20 %
above 10 m — + 30 %
2.3.2 Work inside

- with ventilation + 10 %
- no ventilation + 50 %
2.3.3 Work in lumbered rooms (space obstruction) + 20 %
104
2.4 MEASUREMENT AND CALCULATION OF QUANTITIES FOR CORROSION PROTECTION
2.4.1 Machines, motors, pumps, conveyors
A surface area of parallelopiped shape x 1,5
2.4.2 Steel Structure
- Heavy structure (above 60 kg/m): 15 ÷ 20 [m2/ton]

- Medium-weight structure (31 ÷ 60 kg/m): 25 ÷ 30 [m2/ton]
- Light structure (to 30 kg/m): 35 ÷ 40 [m2/ton]
- Floor grids: length x width x 5

- Ladders and step iron: length x width
- Mesh railings: length x height x 3
- Flat sheets: actual painting area
- Corrugated sheets: actual painting area x 2
2.4.3 Pipe Supports
- for piping to 4” 40 [m2/ton]

- for piping above 4” 30 [m2/ton]
3. SAND BLASTING AND PAINTING OF STORAGE TANKS
3.1 Outer surfaces of storage tank

- Sand blasting SA 2 ½ : 0,33 [Mhr/m2]
- First coat 75 µ : 0,07 [Mhr/m2]
- Second coat 40 µ : 0,05 [Mhr/m2]
- Third coat 125 µ : 0,09 [Mhr/m2]
- Fourth finishing coat 50 µ : 0,06 [Mhr/m2]
Total = 290 µ : 0,60 [Mhr/m2]
3.2 Inner surfaces of storage tank

- Sand blasting SA 2 ½: 0,35 [Mhr/m2]
- First coat 40 µ : 0,05 [Mhr/m2]
- II + III + IV coat 400 µ : 0,30 [Mhr/m2]
Total = 440 µ : 0,70 [Mhr/m2]
NOTE: These man hours refer to the climate conditions prevailing in the Central Europe.
105
VIII. THERMAL INSULATION
Productivity Efficiency Percentage (PEP) =85%
Generally, specialized companies make calculations for insulation. This rule also applies if
insulation accounts for a large portion of a project. When the scope of insulation is not so great or the
bidding time is very tight, an estimator for the mechanical works should also provide the calculation
elements for the insulation. That is why I worked out the manhour rates for insulation based on the
manhour rates of several specialized German insulation contractors.
1. THERMAL INSULATION FOR PIPING
Prefabrication of the insulation holders, sheet cutting, placing mineral wool, aluminium foil
cladding, installation of sheets and sealing with durable elastic compound.
1.1 Pipe insulation

Manhours per linear metre [Mhr/m]
Piping Insulation Thickness [mm]

ND Ø 30 40 50 60 80 100 120 150
25 1” 0,53 0,54 0,56 0,59 0,60 0,64 0,68 0,71
32 1 1/4” 0,57 0,59 0,60 0,62 0,67 0,67 0,71 0,74
40 1 1/2” 0,60 0,62 0,65 0,67 0,68 0,71 0,74 0,77
50 2” 0,65 0,66 0,68 0,69 0,71 0,73 0,76 0,79
65 2 1/2” 0,66 0,68 0,69 0,71 0,74 0,76 0,79 0,83
80 3” 0,68 0,70 0,73 0,75 0,77 0,80 0,83 0,86
100 4” 0,73 0,75 0,77 0,78 0,83 0,85 0,89 0,93
125 5” 0,75 0,79 0,81 0,83 0,86 0,90 0,95 1,01
150 6” 0,80 0,83 0,85 0,89 0,92 0,98 1,03 1,09
200 8” 0,92 0,96 0,98 1,01 1,05 1,11 1,15 1,22
250 10” 1,01 1,05 1,10 1,13 1,19 1,23 1,28 1,37
300 12” 1,13 1,14 1,20 1,24 1,29 1,37 1,44 1,54
350 14” 1,20 1,26 1,29 1,35 1,43 1,50 1,58 1,74
400 16” 1,31 1,35 1,41 1,46 1,54 1,62 1,73 1,84
450 18” 1,47 1,50 1,56 1,59 1,70 1,79 1,88 1,97
500 20” 1,52 1,58 1,62 1,69 1,78 1,88 1,97 2,12
600 24” 1,76 1,80 1,88 1,95 2,04 2,16 2,25 2,44
700 28” 1,95 2,03 2,10 2,18 2,29 2,42 2,55 2,76
800 32” 2,18 2,25 2,34 2,44 2,55 2,70 2,85 3,08
900 36” 2,40 2,48 2,57 2,64 2,81 3,00 3,15 3,38
1000 40” 2,63 2,70 2,97 2,89 3,08 3,23 3,41 3,68
- Insulation of pipes and fittings, except for pipe bends is included.

- Insulation of valves not included.
- Scaffolding not included.
mm x 0,03937 = inch
106
1.2 Insulation of pipe bends
[Mhr / ea]
Piping Insulation Thickness [mm]

ND Ø 30 40 50 60 80 100 120 150
25 1” 0,58 0,59 0,60 0,62 0,68 0,71 0,75 0,83
32 1 1/4” 0,63 0,65 0,68 0,71 0,75 0,79 0,83 0,89
40 1 1/2” 0,68 0,71 0,74 0,75 0,81 0,84 0,89 0,94
50 2” 0,75 0,79 0,83 0,84 0,89 0,93 0,98 1,05
65 2 1/2” 0,84 0,88 0,90 0,93 0,98 1,05 1,10 1,16
80 3” 0,91 0,95 0,98 1,02 1,08 1,13 1,20 1,28
100 4” 1,07 1,13 1,16 1,20 1,28 1,35 1,43 1,50
125 5” 1,22 1,28 1,31 1,35 1,43 1,50 1,59 1,69
150 6” 1,36 1,43 1,49 1,52 1,61 1,70 1,80 1,91
200 8” 1,67 1,73 1,80 1,92 1,95 2,06 2,18 2,33
250 10” 1,99 2,06 2,14 2,21 2,33 2,48 2,59 2,78
300 12” 2,33 2,40 2,48 2,55 2,70 2,85 3,00 3,23
350 14” 2,63 2,70 2,81 2,90 3,08 3,26 3,49 3,68
400 16” 2,93 3,04 3,15 3,23 3,45 3,64 3,83 4,13
450 18” 3,24 3,38 3,49 3,60 3,83 4,05 4,28 4,58
500 20” 3,56 3,71 3,83 4,01 4,20 4,43 4,69 5,03
600 24” 4,16 4,31 4,43 4,58 4,88 5,14 5,40 5,85
700 28” 4,80 4,99 5,14 5,29 5,63 5,96 6,29 6,75
800 32” 5,40 5,59 5,78 5,96 6,34 9,71 7,09 7,65
900 36” 6,00 6,23 6,45 6,64 7,09 7,50 7,95 8,55
1000 40” 6,68 6,90 7,16 7,39 7,88 8,33 8,78 9,45
1.3 Valve Insulation
ND Ø [Mhr/ea] ND Ø [Mhr/ea] Factors acc. to

Insulation Thickness
25 1” 0,71 300 12” 1,54 30 mm x 0,91
32 1 1/4” 0,74 350 14” 1,67 40 mm x 0,95
40 1 1/2” 0,77 400 16” 1,84 50 mm x 1,0
50 2” 0,80 450 18” 1,97 60 mm x 1,02
65 2 1/2” 0,83 500 20” 2,12 80 mm x 1,07
80 3” 0,86 600 24” 2,44 100 mm x 1,13
100 4” 0,93 700 28” 2,76 120 mm x 1,18
125 5” 1,01 800 32” 3,08 150 mm x 1,25
150 6” 1,09 900 36” 3,38
200 8” 1,22 1000 40” 3,68
250 10” 1,37
1.4 Piping insulation based on the surface area
1.4.1 Surface area calculation
The pipe surface area is calculated by adding two insulation thicknesses to the pipe diameter.
do = pipe OD [mm]
( do + 2t ) x 3,14 2
A= [m ] t = insulation thickness [mm]
1000
107
- Pipe bend surface area
A = ( do+ 2t ) ( 2do + t ) x 4,93 [m2]
do = pipe OD [m]
t = insulation thickness [m]
- Valve surface area
Surface area of 1 m pipe x 1,5
1.4.2 Manhour rates [Mhr/m2]
Insulation Thickness
[mm] 30 40 50 60 80 100 120 150
[Mhr /m2] 1,15 1,13 1,11 1,10 1,07 1,05 1,04 1,00
Included: - pipes
- all fittings
- valves
- insulation holders
Not includes: - scaffolding
1.4.3 Division based on the operations
- Insulation holders 30 % - Prefabrication 60 %

- Erection 40 %
- Mineral wool and al. foil 25 %
- Sheets 45 % - Prefabrication 30 %
- Erection 70 %
2. THERMAL INSULATION OF VESSELS AND KILNS
2.1 Insulation with mineral wool, smooth aluminium sheets, durable elastic sealing including
substructure
Insulation Thickness [Mhr/m2]

80 mm 0,92
100 mm 0,94
120 mm 0,99
150 mm 1,01
180 mm 1,09
2.2 Insulation with mineral wool, trapezoidal galvanised E 40 sheets, 1-mm thickness,
both side painting, durable elastic sealing substructure included.
Insulation thickness [Mhr/m2]

80 mm 0,78
100 mm 0,80
120 mm 0,84
150 mm 0,88
180 mm 0,96
Scaffolding not included. mm x 0,03937 = inch

m x 3,281 = ft
m2 x 10,764 = sq ft
Mhr/m2 x 0,0929 = Mhr/sq ft
108
IX. ESTIMATES
1. ESTIMATE OF SCAFFOLDS
Quick estimates of scaffolding and the scaffolds are very difficult to make and not reliable.
Estimators usually do not have the drawings, the dimensions and what is most important they do not have
enough time to perform a proper calculation. Therefore, they have to make quick estimates of the
quantities starting first with a decision on who is going to undertake the scaffolding. Will they subcontract
this job to a specialist firm or do the scaffolding themselves?
It is also necessary to see who will use the scaffolds. Will they be used for erection only, or for
painting and insulation works as well?
If there are several users, the rental period is longer but in that case the expenses can be shared.
1. ESTIMATES OF SCAFFOLDING WHEN CONTRACTED TO A SPECIALIST FIRM
The most usual categorization and the rates of the scaffolding specialist firms are:
a) Scaffold Erection
- standing scaffolds [m3] - cantilever scaffolds [m3]

- hanging scaffolds [m3] - platform floors [m2]
b) Scaffold Dismantling
- same categorization as for erection
c) Rental
- same categorization per week and month
The price of erection and dismantling of scaffolding varies by its height every 5 ÷ 10 m.
When estimating the scaffolding quantity, the quantity for erection in [m3] and an average erection height
are determined.
1.1 PIPING IN PLANTS

- Quantity: 2,5 ÷ 3,0 [m3/t] piping weight
- Type : standing scaffolds 65 ÷ 80 %
hanging scaffolds 10 ÷ 15 %
cantilever scaffolds 5 ÷ 15 %
platforms landings 10 ÷ 15 %
1.2 PIPING ON PIPERACKS

- Quantity: Option I Pipe rack surface area = [m2] scaffold
Option II 2 [m3/t] piping weight
- Type : standing scaffold 10 %
hanging scaffold 10 - 15 %
cantilevel scaffold 0÷ 5%
platforms floors 75 ÷ 85 %
- Height : 4÷6m
- Rental : average 2 ÷ 3 months
1.3 STEEL STRUCTURES
- Quantity: 1,5 ÷ 2,0 [m3/t] structure weight

- Type : standing 60 ÷ 70 %
hanging 10 ÷ 20 %
cantilever 5 ÷ 10 % m3 x 35,32 = cu ft
platforms floors 5 ÷ 10 % m2 x 10764 = sq ft
- Height : average 10 m
- Rental: average 1 ÷ 2 weeks
109
1.4 EQUIPMENT IN PETROCHEMICAL PLANTS
When estimating the scaffolding for equipment erection one should know who is going to use the
scaffolding. For instance, no scaffolding is required for erection of towers, but it is required for erection of
connection piping, electrical installations, insulation or painting. The best way is to calculate all the
equipment individually for each unit. Similarly, one should also determine the type of scaffolding, its
height, and the rental time.
When the scaffolding is used for the equipment erection only, it could be calculated in the following way:
- Quantity: 0,75 ÷ 1,0 [m3/ton] equipment weight
- Type: standing 90 %
platform floors 10 %
- Height: 10 ÷ 20 m
- Rental: 1 month
2. ESTIMATE OF SCAFFOLDING WHEN DONE BY AN ERECTION COMPANY
This kind of scaffolding erection is used less and less. If used, the scope of scaffolding should be
estimated in the same way as for the first case.
2.1 PIPING IN PLANTS: 2,50 ÷ 3,0 [m3/ton] piping quantity
2.2 PIPING ON PIPERACKS: Option I Pipe rack surface area = [m2] scaffold
Option II 2,0 [m3/ton] piping quantity
2.3 STEEL STRUCTURES: 1,5 ÷ 2,0 [m3/ton] structure quantity
2.4 EQUIPMENT IN PETROCHEMICAL INDUSTRY: 0,75÷1,0 [m3/ton] equipment quantity

(If used for the equipment erection only)
When the scaffolding quantity is calculated in [m3] or [m2], which is more or less the same we
should estimate the material needed for tubular or patent scaffolding.
2.5 TUBULAR SCAFFOLDING
There are sets of tubular scaffolding with a list of material needed such as tubes and clamps for
500 m3 (Iron Works Sisak). If it is expected that the scaffolding will be erected and dismantled several
times during the works execution, the following calculations should be considered:
2.5.1 Tubular scaffold material
3 2
[m ] + [m ]
Total scaffolding: = m3 or m2
5
The scaffolding quantity to round up to hundred (100).
m3 x 35,32 = cu ft
m2 x 10764 = sq ft
110
2.5.2 Planking tops for scaffolding
Scaffold quantity / 100 = m3 planking tops
2.6 SCAFFOLDING LABOUR
Determine the number of scaffolding hours by calculating:

Erection + dismantling = 0,90 [Mhr/m3] or m2 x elevation factor (for average elevation)
(See "Equipment Scaffolding", page 72 - 73)
After that, determine the labour needed for scaffolding and the means of transport.
111
2. ESTIMATE OF WELDING ROD CONSUMPTION AND ADDITIONAL WELDING MATERIAL
1. PIPING
1.1 WELD DEPOSIT [kg/weld]
ø Sch Sch Sch Sch Sch Sch Sch Sch

10 20 30 Std 40 60 XS 80 120 160 XXS
2” 0,009 0,026 0,026 0,043 0,043 0,104 0,213
3” 0,011 0,057 0,057 0,085 0,085 0,255 0,375
4” 0,017 0,086 0,086 0,208 0,208 0,383 0,562 0,835
6” 0,303 0,303 0,558 0,558 0,821 1,215 1,58
8” 0,161 0,39 0,39 0,39 0,717 0,717 0,717 1,565 2,576 2,03
10” 0,186 0,493 0,45 0,45 0,83 0,83 1,215 2,345 3,674 3,27
12” 0,239 0,576 0,576 1,061 1,56 1,061 2,554 3,81 6,776 3,81
14” 0,263 0,393 0,625 0,635 1,17 1,719 1,17 3,0 5,19 8,77
16” 0,3 0,449 0,726 0,726 1,34 2,935 1,338 3,783 5,92 11,59
18” 0,337 0,505 1,501 0,807 1,5 3,28 1,5 5,4 9,58 17,0
20” 0,376 0,907 1,67 0,907 1,22 4,042 1,67 9,743 12,52 19,61
22” 0,413 0,992 1,84 0,998 1,412 5,2 1,84 10,72 15,94 24,56
24” 0,45 1,089 2,255 1,089 3,42 7,2 2,0 12,67 21,42 31,33
26” 0,73 2,172 1,18 2,172
28” 1,27 2,336 3,43 1,27 2,336
30” 1,36 2,506 3,674 1,36 2,504
32” 1,459 2,671 3,92 1,45 4,563 2,671
34” 1,542 2,84 4,164 1,54 4,844 2,84
36” 1,633 3,003 4,409 1,633 6,554 3,003
kg/weld x 2,2046 = lbs/weld
The most difficult job for installation of this type of piping is to estimate welding rod consumption
with regard to the piping weight.
Since this estimate is not used for the welding rod procurement but for calculation of price
only, higher departures than the actual needs are allowed.
1.2.1 If the number of welds is known then they are calculated according to the Table 1.1 with a final
increase of 25 ÷ 35 % (for smaller modifications, repairs, losses, etc.).
1.2.2 If the number of welds is not known and it cannot be determined within a reasonable time, then
the calculation should be done as follows:
Welding rod weight = 0,6 ÷ 1,0 % piping weight or 6,0 ÷ 10,0 [kg/ton]
(Higher percentage is inversely proportionate to the pipe weight in relation to the total weight of piping).
1.2.3 Piping quantity per inchdiameter (ID)

Welding rod weight = 0,06 [kg/ID]
112
1.3 PIPING BETWEEN PLANTS AND PIPING ON PIPERACKS
1.3.1 If the piping quantities are listed according to their diameters then the weld is assumed to come on
average every 6 meters of the piping length. The number of joints estimated to be multiplied by the
values from Table 1.1 and increased by 20 %.
1.3.2 If only the total piping weight is known:
Welding rod weight = 0,5 % of the piping weight or 5,0 [kg/ton]
1.4 PIPING (C.S.) - TOWN NETWORKS
- The best way is to estimate the number of joints and to use the Table 1.1 for the quantity of welding rod,
and to apply the increase of 15 ÷ 25 %.
1.5 PIPELINES
- For this type of pipelines the number of joints on the header line should always be calculated. The
calculation will be done with the weights from Table 1.1 increased by 20 %.
1.6 PIPE SUPPORTS
1.6.1 Support Fabrication
Welding rod weight = 0,8 ÷ 1,0 % support weight or 8,0 ÷ 12,0 [kg/ton]
1.6.2 Support Installation
Welding rod weight = 0,3 ÷ 0,5 % support weight or 3,0 ÷ 5,0 [kg/ton]
2. STEEL STRUCTURES
Fabrication Erection
- Heavy structure 0,6 % or 6,0 [kg/ton] 0,2 % or 2,0 [kg/ton]

- Medium-weight structure 0,75 % or 7,5 [kg/ton] 0,25 % or 2,50 [kg/ton]
- Light structure 0,9 % or 9,0 [kg/ton] 0,3 % or 3,0 [kg/ton]
3. CYLINDRICAL STORAGE TANKS
Welding rod weight = 0,75 ÷ 1,0 % storage tank weight
4. EQUIPMENT IN PETROCHEMICAL INDUSTRY
kg/ton x 2,2046 = lbs/ton

Welding rod weight = 0,1 ÷ 0,3 % equipment weight
113
3. ESTIMATE OF CONSUMPTION OF TECHNICAL GAS AND GRINDING PLATES
P I P I N G
Piping
between
plants
and Erection Equipment in Cylindr.
In town Pipe of steel petrochemical storage
plants networks Pipelines supports structures plants tanks
Oxygen [kg/ton] 6÷8 3 ÷ 5 2÷3 12 ÷ 15 3÷5 0,7 ÷ 1,0 2÷3
Acetylene [kg/ton] 4÷5 2 ÷ 3 1,5 ÷ 2 7 ÷ 11 2÷3 0,5 ÷ 0,7 1,5 ÷ 2
Argon (2.*) [kg/ton] 10 ÷ 15 0 ÷ 4 - - - 0,3 ÷ 0,5 -
Grinding & [pc/ton] 4÷6 3 ÷ 4 2÷3 5÷8 2÷3 0,25 ÷ 0,33 4÷6
cutting plates
1. The quantities of other technical gas such as hydrogen, nitrogen, and CO2 are negligible and I
leave it up to the estimator to estimate their quantities or not.
2.* The quantity of argon depends on the welding method and use of different types of materials. The above
data of 10 ÷ 15 kg/t is taken into account when there is some 10 % of stainless steel and when the root on
carbon steel is welded by TIG process.
If the quantity of stainless steel is known, than the calculation is done by 17,0 ÷ 22,0 kg/ton.
3. Technical Gas Data:

- Oxygen 40 l bottle, 150 bar = 6 m3 = 8,4 kg
50 l bottle, 200 bar = 10 m3 = 13,27 kg
- Acetylene 40 l bottle, 15 bar = 6,5 m3 = 6,3 kg

50 l bottle, 15 bar = 8,1 m3 = 10 kg
- Argon 40 l bottle, 150 bar = 6,4 m3 = 10,8 kg

40 l bottle, 200 bar = 8,8 m3 = 14,4 kg
50 l bottle, 200 bar = 10 m3 = 18 kg
- CO2 40 l bottle, 60 bar = 6m3 = 30 kg
- Propane small bottle (27,2 l) = 11,5 kg (max.)

large bottle (79 l) = 33,5 kg (max.)
- Butane small bottle (27,2 l) = 13,3 kg (max.)

large bottle (79 l) = 38,7 kg (max.)
- Nitrogen 40 l bottle, 150 bar = 6 m3 = 7,55 kg

50 l bottle, 200 bar = 10 m3 = 12,6 kg
114
4. Calculating the quantities of nitrogen or air required for pressure testing
The quantity of nitrogen or air is calculated by the following formula:
(p2 - p1 ) x V x 100.000
m= [kg] kg x 2,2046 = lbs
TxR
where: m = gas weight [kg]

p2 = final pressure [bar]
p1 = starting pressure [bar]
V = system volume (to be tested) [m3]
T = temperature [K] ( = °C + 273,15)
R = gas constant [J/kgK]
Rair = 287,0 [J/kgK]
Rnitrogen = 296,7 [J/kgK]
EXAMPLE: A 50 m3 system should be tested to 10 bars. The pressure can be increased to 6 bars by air
compressor. Outside temperature is c. 17 °C (290 °K). How much nitrogen and how many bottles do
we need?
(10- 6 ) x 50 x 100.000
m= = 232,44 kg
290 x 296,7
the number of 40 l bottles, 150 bar : 232,44 / 7,55 = 31 bottles
4. ESTIMATE OF ELECTRICITY CONSUMPTION
The client often requires an estimate of electricity consumption it has to provide and the estimator
must fulfil that request. If he finds that the contractor will use its own power sources from generators and
generating sets, then he will estimate only the part of electricity consumption from the power grid. The t o t a l
power requirements should be calculated on the basis of an estimate of the welding rods needed.
1. Piping
1.1 In plants 7,5 [kWh/kg] welding rod quantity

1.2 Piping between plants 5,0 [kWh/kg] welding rod quantity
1.3 Pipelines 3,5 [kWh/kg] welding rod quantity
2. Erection of steel structure 4,0 [kWh/kg] welding rod quantity

3. Equipment erection 9,2 [kWh/kg] welding rod quantity
4. Storage tank erection 7,0 [kWh/kg] welding rod quantity
kWh/kg x 0,4536 = kWh/lbs
115
5. ESTIMATE OF CONSUMPTION OF FUEL AND LUBRICANT
The manufacturer provides the technical data on fuel consumed by the machinery. Such data can
be used only if the motor operates continuously under the load foreseen by the manufacturer. However,
this is not the case in practice because there are stoppages in operation and the machinery operates
under different loads. Below is an estimate of the percentage use of the machinery and the means of
transport that the estimator can evaluate at his discretion.
1. FUEL CONSUMPTION
Machinery/Means Fuel Consumption % use l/day l/month

1. Power Plant
125 kW Diesel oil 30 l/h 50 % 360 9.000
2. Diesel Welding Set
400 A Diesel oil 6 l/h 5 ÷ 60 % 3 ÷ 36 75 ÷ 900
3. Diesel
Compressor
7 m3/min Diesel oil 8 l/h 5 ÷ 50 % 4 ÷ 40 100 ÷ 1.000
4. Pipe Laying Machine Diesel oil 40 l/h 20 % 80 2.000
5. Tractor 53 kW
(72 HP) Diesel oil 8 l/h 20 % 16 400
6. Tractor 88 kW
(120 HP) Diesel oil 12 l/h 20 % 24 600
7. Fork Lift 3 t Diesel oil 12 l/h 10 % 12 300
8. Fork Lift 5 t Diesel oil 18 l/h 10 % 18 450
9. Tank truck Diesel oil 20 l/100 km 15 ÷ 75 km/day 3 ÷ 15 75 ÷ 375
10. Truck 7,5 t Diesel oil 20 l/100 km 25 ÷ 150 km/day 5 ÷ 30 125 ÷ 750
11. Truck 10 t Diesel oil 22 l/100 km 30 ÷ 150 km/day 6 ÷ 33 150 ÷ 825
12. Trailer truck Diesel oil 26 l/100 km 75 - 160 km/day 20 ÷ 40 500 ÷ 1.000
13. Pickup Gasoline 15 l/100 km 50 ÷ 150 km/day 7,5 ÷ 22,5 188 ÷ 560
14. Passenger van 8
+ 1 seat Gasoline 16 l/100 km 60 ÷ 150 km/day 10 ÷ 24 250 ÷ 600
15. Passenger car
Gasoline 10 l/100 km 75 ÷ 150 km/day 7,5 ÷ 15 225 ÷ 450
NOTE: The fuel consumption for other machinery (cranes, shovels, dredgers and the like) is not
calculated because the price of fuel and lubricants is already contained in the rental fee.
2. LUBRICANT CONSUMPTION
Since oil and grease are also used for other purposes at the job site and not only for the
machinery, the price of lubricants can be calculated as 10% of the fuel prices.
l x 0,2642 = U.S. gal
116
6. TOOL COST ESTIMATE AT THE JOB SITE
It is not either possible or necessary to make detailed lists of small tools to be used at the job site.
In practice, only 50% of tools is purchased for a specific job and c. 50% of tools is used from the previous
job sites. It can also be taken into account that c. 60 ÷ 70 % of tools will be left in good condition and reused
(or sold).
For that reason, the cost of tools should be calculated in the following way:
Type of job
1. Piping......................................................................[US$/h] in 2002
1.1 in plants................................................................0,25
1.2 piping between plants..............................................0,20
1.3 pipeline..................................................................0,15
2. Erection of steel structure.......................................... 0,15
3. Equipment erection...................................................0,18
4. Storage tank erection *..............................................0,15
*There are more tools and devices used at erection of storage tanks that are not included in this table.
7. ESTIMATE OF SAFETY AT WORK MEANS
The means for safety at work are:

1. For personal protection 2. For protection at different jobs
- protective clothing - protection masks - welding aprons
- protective shoes - welding masks - welding gloves
- protective gloves - glass - welding clothes
- protective goggles - goggles - belts
- raincoats or overalls - rubber boots - waistcoats
- protective helmets - etc.
The estimator should evaluate the yearly costs per each labourer for maximum number of labourers.
Costs per labourer/year:
- climate similar to Croatia 250,- US$

- climate colder than in Croatia 300,- US$
- climate warmer than in Croatia 200,- US$
8. ESTIMATE OF ERECTION TIME
When the erection time is not mentioned in the call for tenders, the estimator should estimate it. In
the magazine "3 R" of April 1985, there is a formula for calculating the time required for erection of piping:
D = tm0,3
where D = erection time in weeks (50 hour week)

tm = hours required acc. to the calculation
My opinion is that this formula should be used to calculate the erection time only for the works up to
10.000 hours . For the works above 10.000 hours the erection time should be increased by c. 20% in the
following way:
D = tm0,3 x 1,2
117
The table below contains the erection time in weeks (a 50 hour week) for a range from 1.000 to
1.000.000 hours of work.
Total Erection time

Manhours Weeks Months
1.000 8 1,9
1.500 9 2,1
2.500 10 2,3
4.000 12 2,8
6.500 14 3,25
10.000 17 4
15.000 21,5 5
25.000 25 6
40.000 29 6,75
65.000 33,5 7,8
100.000 38,5 9
150.000 43 10
250.000 50,5 11,75
400.000 57,5 13,4
650.000 66 15,3
1.000.000 75,6 17,6
9. SELECTION OF HOISTING MACHINERY (CRANES, FORK LIFTS, ETC.)
When determining manhour rates, the costs of hoisting equipment have a significant impact. It is
therefore very important to make a careful and realistic estimate of the type of crane, number of cranes and
the time of use of the crane, forklift and the like. It is not a problem to determine the type of individual
hoisting machine, the time and the power required for hoisting a given piece of equipment but this job is
much more difficult when it has to be done for the entire project. During all the years of my service, I never
found any trace of that issue. Talking to colleagues of mine I heard different opinions and methods for
making estimates. Some make estimates based on weight and they consider that a crane should lift between
150 and 300 kg/hour. Others take into account the number of labourers and say that one crane should be
sufficient for serving 6 to 20 labourers. There are no tables for any of these methods. I thought something
should be done about it so I tried to describe the way I did it in my calculations and estimates hoping that
younger colleagues would elaborate this better in future.
When selecting the cranes care should be taken of the crane type because of very different rental
costs. As for the operating costs, the cranes can be grouped from the cheapest to the most expensive.
TYPE CAPACITY
OF CRANE 10 t 20 t 30 t 45 t 60 t 80 t 100 t 150 t > 150 t
BUILDING CRANES 4 4 5 5 — — — — —
TOWER
PORTAL 1 1 1 1 1 — — — —
CRANES
MOBILE CRANE 3 3 2 3 3 2 2÷3 2 3
PROJECTION
MOBILE CRANE 2 2 4 4 4 3 2÷3 3 2
trussed boom
CATERPILLAR — — 3 2 2 1 1 1 1
trussed boom
(They are grouped according to "Montage Gerätebuch", Issue 1985)
118
The most suitable trucks for up to 2-ton cargo are those with a hydraulic jack. Forklifts are very
suitable for the cargoes from 2 to 8 tons.
To make an optimum selection of the cranes, it is important to fully familiarize with the project for
which a calculation is made. The estimator should devise a concept of the erection method and possible
erection technique as well as probable work organization. Before selecting the cranes, an average number
of production labourers should be determined.
9.1 SELECTION OF THE LARGEST CRANE
Any erection project should be firstly identified the heaviest equipment and cargoes. Thereupon,
the crane type and capacity are selected (or a combination of two cranes) thus identifying the largest and
the most expensive crane. Care should be taken of the place of erection, elevation, possible access to the
crane, access roads, rental possibilities, lifting technology, working time, etc.
The time for using the largest crane should be estimated by lifting the heaviest pieces of equipment
(above 20 tons if possible). In this case the next largest crane that will stay longer at the job site could be of
smaller capacity (c. 60 ÷ 80 tons) and as a result thereof its monthly rental fee would be lower as well.
9.2.1 PREFABRICATION
The use of a crane is not important during the piping prefabrication. The use of one forklift of 3 ÷ 5
tons could be considered. From time to time, a smaller crane of 8 to 10 tons and HIAB truck could be used of
which 1/3 for prefabrication and 2/3 for erection.
Twenty five labourers should be allocated to one piece of lifting equipment.
9.2.2 ERECTION
At piping erection, the larger the piping diameter the greater need for a crane. The cranes of larger
capacity are required for larger outreach and height otherwise relatively smaller cranes could satisfy the
requirements.
Twenty labourers per crane.

One truck with HIAB for 35 ÷ 40 labourers but only its 2/3.
Crane capacity to be determined as follows:
70 % to 20 t
20 % to 35 t
10 % to 60 t
9.2.3 PREFABRICATION AND ERECTION
For technical calculations, both prefabrication and erection are considered together. This type of
calculation applies when there are not enough data or time to make a calculation, which is the most often
case.
The means for hoisting should be determined in the following way:
- forklift 3 ÷ 5 t 65 labourers per forklift

- truck with "HIAB" 60 labourers per truck
- mobile crane 20 labourers per crane of which
75 % - to 20 t capacity
15 % - to 35 t "
10 % - to 60 t "
119
9.3 PIPING BETWEEN PLANTS
Lower capacity cranes will mostly satisfy the requirements for erection of this kind of piping. The
scope of prefabrication is smaller, and therefore the calculation should be made as follows:
- truck with "HIAB" 45 labourers per truck
- car crane 32 labourers per crane of which
90 % -to 20 t capacity
10 % - to 40 t capacity
9.4 PIPELINES
At pipeline laying special cranes are used for unloading, loading, pipe stringing and performance of
special points. Generally, car crane renting should be avoided whenever a continuous work is not possible.
This refers particularly to the works on right-of-ways where the pipe layers and trucks with HIAB are used.
Consequently, estimator can rely on crane for some activities only, which should be elaborated separately.
All manuals for calculations of pipeline erection provide for special elaboration of each activity from pipe
transport to pressure testing.
9.5 ERECTION OF STEEL STRUCTURES
Erection of steel structures is not actually possible without cranes. The costs of machinery account
for the largest portion of the man-hour rate. The use of truss boom cranes and particularly tower building
cranes is possible. The truss boom cranes are suitable because of lower rental costs and the tower building
cranes for their very high efficiency and outreach.
The cranes should be calculated as follows:

- heavy steel structure 6÷ 7 labourers per crane
- medium-weight steel structure 10 ÷ 12 labourers per crane
- light steel structure 16 ÷ 18 labourers per crane
9.6 INSTALLATION OF PROCESS EQUIPMENT
At installation of process equipment firstly we should identify the largest crane (item 9.1.) and then
decrease the total number of hours and the average number of labourers for the foreseen heavy equipment
respectively.
The cranes for other equipment to be calculated as follows:
1 crane on 12 ÷ 13 labourers of which:

60 % - for the second largest crane (c. 40 ÷ 80 t)
20 % - for 30 t cranes
20 % - for 20 t cranes
9.7 ERECTION OF CYLINDRICAL STORAGE TANKS
Special attention should be paid to the selection of a crane for erection of cylindrical storage tanks.
This type of crane cannot be selected according to the number of labourers but according to the type,
diameter, height, arrangement, and the number of storage tanks, etc.
A mobile crane with a truss boom of maximum 20-ton capacity is the most adequate when we install
one storage tank. If there is a group or a series of storage tanks, we should consider using tower cranes of
sufficient reach and on tracks, if possible and necessary.
If there are several storage tanks, we shall need another smaller crane for loading and unloading the
plates and getting them closer. Generally, an adequate erection concept is required and each activity should
be supported with an adequate crane.
On average, 18 ÷ 25 labourers should be allocated per one crane.
When erecting spherical storage tanks (balls) the same measures for crane selection apply.
120
10. UNLOADING, HANDLING AND SORTING OF THE MATERIAL
Almost all manhour rates include the erection activities from withdrawal of the material and
equipment from the investor's store to the completion according to detail design. We shall often come
across a request in tendering documents to offer unloading, handling and sorting of the material. (The
quantity/volume ratio see page 213.)
10.1 MATERIAL FOR PIPING

- Unloading: 0,70 [Mhr/ton]
- Handling and sorting:
Piping in plants 60 % and above 1,20 [Mhr/ton]
Piping between plants 60 % and above 0,80 [Mhr/ton]
Pipeline 60 % and above 0,50 [Mhr/ton]
10.2 STEEL STRUCTURE

Heavy structure (above 60 kg/m) 1,10 [Mhr/ton]
Medium-weight structure (31 ÷ 60 kg/m) 1,50 [Mhr/ton]
Light structure (to 30 kg/m) 2,0 [Mhr/ton]
10.3 PROCESS EQUIPMENT

- Unloading:
Bulk material (packings) 1,20 [Mhr/ton]
Equipment to 5 [t/pc] 1,10 [Mhr/ton]
Equipment 5 ÷ 10 [t/pc] 1,0 [Mhr/ton]
Equipment above 10 [t/pc] 0,80 [Mhr/ton]
Bulk material (packings) 0,60 [Mhr/ton]
Equipment to 5 [t/pc] 0,80 [Mhr/ton]
Equipment 5 ÷ 10 [t/pc] 1,0 [Mhr/ton]
Equipment - Sorting near foundation above 10 [t/pc] 0,30 [Mhr/ton]
Equipment - Sorting at store above 10 [t/pc] 0,90 [Mhr/ton]
10.4 CYLINDRICAL STORAGE TANKS

- Handling and sorting: near foundation 0,40 [Mhr/ton]
- Handling and sorting: in store 0,80 [Mhr/ton]
121
11. TEMPORARY WORKS, SPACE REQUIRED AND CONNECTIONS AT THE SITE
OPTION 1 OPTION 2
1. TEMPORARY WORKS OFFICE BUILDINGS & CONTAINERS
CANOPIES [m²] [pc.]
1.1 MANAGEMENT SITE OFFICES Average number of staff 1 container for 2 office workers
x 1,0 =……….m²
1.2 SITE OFFICES No of foremen 1 container for 3 foremen
x 4 =……….m²
1.3 LOCKER ROOM Maximum number of 1 container for 40 direct
workers x 0,3 = ……….m² labourers
1.4 TOOLS STORE Average number o workers 1 office + 1 cargo container for
x 0,275 =……….m² 90 direct labourers
1.5 ENCLOSED STORE Average number of 1 cargo container for 75
workers x 0,2 =……….m² direct labourers
1.6 SANITARY FACILITIES 1 container for 50 workers
1.7 MESS ROOMS Average number of workers 1 container for 30 workers
x 0,5 =……….m²
1.8 PREFABRICATION HANGAR Average number of workers
x 3 =……….m²
1.9 MAINTENANCE WORKSHOP 8 m² for each maintenance 1 container for 2 maintenance
worker (electrician, mechanic) workers (electrician, mechanic)
1.10 CANOPIES FOR Average number of workers
TECHNICAL GAS x 0,15 =……….m²
1.11 ENCLOSED STORE FOR On principle, the investor is
CAPITAL EQUIPMENT responsible for providing such
store) The store area to be
determined as follows: Total
weight of erection equipment
(piping + steel structure
+ equipment) in tons
x 0,2 m2/ton
122
2. AREA NEEDED METHOD OF CALCULATING THE AREA IN [m²]
2.1 OUTDOOR AREA FOR THE JOB SITE A sum of net area from each item:
MANAGEMENT SITE OFFICE BUILDINGS 1.1 + 1.3 + 1.6 + 1.7
increased 4 times
2.2 OUTDOOR AREA FOR A sum of net area from each item:
WORKSHOPS AND BULKING OF 1.4 + 1.8 + 1.9 + 1.10
EQUIPMENT increased 3 times
2.3 OUTDOOR AREA FOR Double the area of item 2.2

SORTING PREFABRICATED ITEMS
2.4 OUTDOOR STORE AT THE JOB SITE Generally, every job site has a few plants.
On each plant the contractor needs a fenced
area for storing the capital equipment and
consumables. The area for that purpose
would be: 20 ÷ 50 m²
2.5 OUTDOOR AREA FOR Job sites to: 50 direct labourers 750 m²
PARKING MACHINERY 100 direct labourers 1000 m²
above: 100 direct labourers 1200 m²
2.6 OUTDOOR REA FOR STORING 1,5 m² per ton of capital equipment
CAPITAL EQUIPMENT
3. CONNECTIONS NEEDED METHOD OF ESTIMATE
3.1 POWER CONNECTIONS 1 main connection: maximum number of

welding rectifiers x 15 kVA
Connections at the plants: at least 1 off
75 kVA power connection for each plant
3.2 PROCESS WATER CONNECTIONS If there is a hydrant network: determine

the quantity required. If there is no hydrant
network: determine the quantity needed,
storing in water storage tanks or supply by
tank lorries.
3.3 DRINKING WATER CONNECTIONS Quantity: 30 ÷ 40 litre/man/day

Connections: every sanitary facility 1" ÷ 1 1/4"
3.4 SEWERAGE CONNECTIONS 1 connection for each sanitary facility
3.5 TELEPHONE LINES 2 telephone lines at least
123
12. ESTIMATE OF THE NUMBER OF WELDS AND RADIOGRAMS FOR PIPING
Data on the number of welds are not often given in the call for tenders. Of course, this cannot be
calculated without complete detail documentation. To make a technical calculation an estimator needs the
data on the number of welds. If he wants to estimate the quantity of radiograms, he should know only the
quantity of butt welds and if he wants to calculate precisely the quantity of welding rods and electric power,
he should know the quantity of all types of welds. The estimate of the quantity of other types of welds such
as nozzle welds and socket welds, the estimator can base on the butt welds quantity.
The quantity of butt welds can be estimated in several ways:
1. ESTIMATE OF BUTT WELDS BASED ON A LIST OF MATERIAL

- PIPES, FITTINGS AND FLANGES
1.1. Piping in plants
- Pipe 1 weld/24 m
- Bends 1,8 weld/piece
- Tees 2,5 weld/piece
- Pipe caps 1 weld/piece
- Reducers 1,5 weld/piece
- Weldolets 1 weld/piece
- Neck flanges 1 weld/piece
1.2. Piping between plants piperacks and sleeper ways
- pipes to 3" 1 weld/5,0 m

- pipes 4"- 6" 1 weld/6,0 m
- pipes 8"-10" 1 weld/7,5 m
- pipes 12"-14" 1 weld/9,0 m
- pipes above 16" 1 weld/10,0 m
- fittings and flanges: as for the piping in a plant (item 1.1.)
1.3. Combined piping (in plants and between the plants)
If there are no separate lists of materials for piping in the plant and for the piping between the plants,
but we know there are both of them, the quantity of butt welds should be calculated as follows:
Pipes: calculate 1 weld to the lengths that are twice the length of the piping between the plants (item 1.2.).
If the estimator can estimate proportional relations of two kinds of piping then he can make the
calculation with other piping lengths as well.
- Fittings and flanges: As for the piping in plants (item 1.1)
2. ESTIMATE OF BUTT WELDS BASED ON A LIST OF MATERIAL

- FITTINGS AND FLANGES ONLY
- Bends 2 weld/piece
- Tees 3 weld/piece
- Pipe caps 1 weld/piece
- Reducers 2 weld/piece
- Weldolets 1 weld/piece
- Neck flanges 1 weld/piece
The pipe-to-pipe welds are not considered because it is deemed that the quantity of such welds
is deemed to be similar to the number of fitting-to-fitting welds.
This is the most widely used method for estimating the butt welds. I know from experience that this
method is not a reliable one. If applied, it should be calculated in the following way:
- Piping in the plant: decrease the weld number by c. 10 ÷ 12%

- Combined piping (in plants and between the plants): increase by c. 8 ÷ 12%
124
3. ESTIMATE OF BUTT WELDS BASED ON THE PIPING LENGTHS
- MEASURED ON THE LINE AXIS
1 butt weld/length [m]

Diameter Plant Line Combined Town network
to 1 1/2" 4,50* 4,50 4,50 3,00
2" 0,80 4,70 1,20 3,20
3" 0,85 5,00 1,25 3,30
4" 0,90 5,30 1,30 3,50
6" 0,95 6,00 1,35 4,00
8" 1,00 6,80 1,40 4,80
10" 1,05 7,50 1,45 5,60
12" 1,10 8,20 1,50 6,80
14" 1,15 9,00 1,55 7,80
16" 1,20 9,60 1,60 8,50
18" 1,30 9,90 1,65 8,80
20" 1,35 10,00 1,70 9,00
24" 1,50 10,00 1,85 9,20
28" 1,60 10,00 1,95 9,40
30" 1,70 10,00 2,00 9,50
32" 1,75 10,00 2,10 9,50
above 34" 1,80 10,00 2,20 9,50
*In the case of to 11/2" piping, the fittings are mostly with the socket welds and therefore there are fewer butt welds.
m x 3,2281 = ft
4. ESTIMATE OF TOTAL WELDS (ALL TYPES)
This estimate can be used for calculation of welding rod consumption (item 2, page 112) and the
power consumption costs (item 4, page 115).
Once the quantity of butt welds is calculated by any of previously described methods, the quantity of
other welds can be calculated as well. This is done in such a way that the quantity of butt welds is increased
by the following percentage:
- Piping in plants: 30 ÷ 35%

- Piping between plants (piperacks and sleeper ways): 10 ÷ 15%
- Combined piping: 20 ÷ 25%
- Town networks: 3 ÷ 5%
5. ESTIMATE OF RADIOGRAMS ON THE PIPING
The number of radiograms depends on the media, working pressure, working temperature,
materials and special safety regulations. Generally, the estimator i.e. the process engineer determines
the percentage of radiographic tests and include them in the piping line list. The percentages are
different and can vary from 5% to almost 200%. (200% is in special cases when highly alloyed
materials are used and the radiography is required before and after thermal treatment of the weld).
125
The following table is mostly used to determine the percentage of radiographic inspection.
WORKING
TYPE OF TEMPERATURE Class 3 Class 2 Class 1
STEEL [°C] 125 lb 150 lb 150 lb 300 lb 600 lb >900 lb
CARBON - 20 ÷ 100 0% 5% 5% 5% 10% 100%
STEEL 101 ÷ 300 0% 5% 5% 10% 30% 100%
301 ÷ 400 10% 30% 30% 100%
C - STEEL
LOW - 45 ÷ - 21 — — 5% 10% 30% 100%
TEMPERATURE
- 20 ÷ 300 — — 5% 10% 30% 100%
Mo - STEEL 301 ÷ 450 — — 10% 30% 100% 100%
- 20 ÷ 450 — — 30% 30% 100% 100%

CrMo - STEEL 451 ÷ 580 — — 30% 100% 100% 100%
AUSTENITE - 99 ÷ 500 0% 5% 10% 30% 30% 100%

STEEL 501 ÷ 700 — — 30% 30% 100% 100%
(STAINLESS) - 196 ÷ - 100 — — 30% 100% 100% 100%
Source: Code for Pressure Piping, Petroleum Refinery Section ANSI B31.3, Chapter VI
If we know the quantity of butt welds according to their diameter, material and class, then it will
not be difficult to determine the number of welds to be tested. In most cases, however this information
is not available and cannot be determined within the scheduled time. Because of that the estimator will
monitor and develop statistics of the projects executed, he will ask for professional opinions of more
experienced colleagues, and decide for an average percentage of radiography. When the estimator
determines the percentage, he will calculate the number of radiograms according to the table below.
The number of radiograms and lengths of films according to API - STD.1104

("ZIT" - Institute for Welding, Testing and Technology - Zagreb)
Outside Number of Film

diameter radiograms size
to 1 1/2" (40 mm) 2 (ellipse) 10 X 12 cm
2"- 3 1/2" (50-90 mm) 2 (ellipse) 10 X 16 cm
4" - 5" (100-140 mm) 3 10 X 16 cm
6" - 7" (150-190 mm) 3 10 X 24 cm
8" - 11" (200-280 mm) 3 10 X 32 cm
12" - 13" (300-360 mm) 3 10 X 40 cm
14" - 18" (360-450 mm) 3 10 X 48 cm
20" (500 mm) and more: Number of films depends on diameter 10 X 48 cm
20" - 22" (500-550 mm) 4 10 X 48 cm
24" - 28" (600-700 mm) 5 10 X 48 cm
30" - 34" (750-850 mm) 6 10 X 48 cm
36" - 40" (900-1000 mm) 7 10 X 48 cm
42" - 46" (1050-1150 mm) 8 10 X 48 cm
48" - 52" (1200-1300 mm) 9 10 X 48 cm
When the quantity of radiograms is calculated, it should be increased by:
4-5% for weld repair

2-3% for incorrectly issued orders
1-2% or undefined needs and samples
0,5-1% for certifying processes and welders
7,5-11% Total
126
XV. APPENDIX
1. ISO R7 DIN 2448/2458 SUMMARY OF PIPE SCHEDULED SIZES, WALL THICKNESS AND UNIT MASS [kg/m]
Dn-mm OD-mm Wall thick. Std|Ext 2 2,3 2,6 2,9 3,2 3,6 4 4,5 5 5,6 6,3 7,1 8 8,8 10 11 12,5
15 21,3 2\2 0,95 1,08 1,2 1,32 1,43 1,57 1,71 1,86 2,01
20 26,9 2\2,3 1,23 1,4 1,56 1,72 1,87 2,07 2,26 2,49 2,7 2,94 3,2
25 33,4 2\2,6 1,55 1,76 1,97 2,18 2,38 2,65 2,9 3,21 3,5 3,84 4,21 4,61
32 42,4 2\2,6 1,99 2,27 2,55 2,82 3,09 3,44 3,79 4,21 4,61 5,08 5,61
40 48,3 2,3\2,6 2,28 2,61 2,93 3,25 3,56 3,97 4,37 4,86 5,34 5,9 6,53 7,21 7,95 8,57 9,45 10,1 11
50 60,3 2,3\2,9 2,88 3,29 3,7 4,11 4,51 5,03 5,55 6,19 6,82 7,55 8,39 9,32 10,3 11,2 12,4 13,4 14,7
65 73 2,6\2,9 3,5 4,01 4,51 5,01 5,51 6,16 6,81 7,6 8,38 9,31 10,4 11,5 12,8 13,9 15,5 16,8 18,7
65 76,1 2,6\2,9 3,65 4,19 4,71 5,24 5,75 6,44 7,11 7,95 8,77 9,74 10,8 12,1 13,4
80 88,9 2,9\3,2 4,29 4,91 5,53 6,15 6,76 7,57 8,38 9,37 10,3 11,5 12,8 14,3 16 17,4 19,5 21,1 23,6
100 114,3 3,2\3,6 5,54 6,35 7,16 7,97 8,77 9,83 10,9 12,2 13,5 15 16,8 18,8 21 22,9 25,7 28 31,4
125 139,7 3,6\4 8,79 9,78 10,8 12,1 13,4 15 16,6 18,5 20,7 23,2 26 28,4 32 34,9 39,2
150 168,3 4\4,5 11,8 13 14,6 16,2 18,2 20,1 22,5 25,2 28,2 31,6 34,6 39 42,7 48
200 219,1 4,5\6,3 17 19,1 21,2 23,8 26,4 29,5 33,1 37,1 41,6 45,6 51,6 56,5 63,7
250 273 5\6,3 21,3 23,9 26,5 29,8 33 36,9 41,4 46,6 52,3 57,3 64,9 71,1 80,3
233
300 323,9 5,6\7,1 25,3 28,4 31,6 35,4 39,3 44 49,3 55,5 62,3 68,4 77,4 84,9 96
350 355,6 5,6\8 27,8 31,3 34,7 39 43,2 48,3 54,3 61 68,6 75,3 85,2 93,5 106
400 406,4 6,3\8,8 35,8 39,7 44,6 49,5 55,4 62,2 69,9 78,6 86,3 97,8 107 121
450 457 6,3\10 40,3 44,7 50,2 55,7 62,3 70 78,8 88,6 97,3 110 121 137
500 508 6,3\11 44,8 49,7 55,9 62 69,4 77,9 87,7 98,6 108 123 135 153
550 559 6,3\12,5 61,5 68,3 76,4 85,9 96,6 109 119 135 149 168
600 610 6,3\12,5 67,2 74,6 83,5 93,8 106 119 130 148 162 184
650 660 7,1\14,2 80,8 90,4 102 114 129 141 160 176 200
700 711 7,1 87,1 97,4 109 123 139 152 173 190 215
750 762 8 104 117 132 149 163 185 204 231
800 813 8 99,6 112 125 141 159 175 198 218 247
850 864 8,8 133 150 169 186 211 231 262
900 914 10 112 125 141 159 179 196 223 245 278
Dn-mm OD-mm Wall thick. Std|Ext 2 2,3 2,6 2,9 3,2 3,6 4 4,5 5 5,6 6,3 7,1 8 8,8 10 11 12,5
Above weights are for carbon and alloy steel pipe only. For austenitic stainless steel multiply by 1.02.
For ferritic stainless multiply by 0.95. kg/m x 0. 67197 = lbs/ft
(CONTINUATION ISO R7 DIN 2448/2458 PIPES)
Dn-mm OD-mm Wall thick. Std|Ext 14,2 16 17,5 20 22,2 25 28 30 32 36 40 45 50 55 60 65 70
15 21,3 2\2
20 26,9 2\2,3
25 33,7 2\2,6
32 42,4 2\2,6
40 48,3 2,3\2,6
50 60,3 2,3\2,9 16,1
65 73 2,6\2,9 20,6
65 76,1 2,6\2,9
80 88,9 2,9\3,2 26,2 28,8
100 114,3 3,2\3,6 35,1 38,8 41,8
125 139,7 3,6\4 43,9
150 168,3 4\4,5 54 60,1 65,1 73,1 80
200 219,1 4,5\6,3 71,8 80,1 87 98,2 108 120 132
250 273 5\6,3 90,6 101 110 125 137 153 169
234
300 323,9 5,6\7,1 108 121 132 150 165 184 204 217 230
350 355,6 5,6\8 120 134 146 166 183 204 226 241 255 284
400 406,4 6,3\8,8 137 154 168 191 210 235 261 278 295 329 361
450 457 6,3\10 155 174 190 216 238 266 296 316 335 374 411 457
500 508 6,3\11 173 194 212 241 266 298 331 354 376 419 462 514 565
550 559 6,3\12,5 191 214 234 266 294 329 367 391 416 464 512 570 628 684
600 610 6,3\12,5 209 234 256 291 322 361 402 429 456 510 562 627 691 753 814
650 660 7,1\14,2 226 254 277 316 349
700 711 7,1 244 274 299 341
750 762 8 262 294 321 366
800 813 8 280 314 343 391 433
850 864 8,8 298 335 365 416
900 914 10 315 354 387 441 488
Dn-mm OD-mm Wall thick. Std|Ext 14,2 16 17,5 20 22,2 25 28 30 32 36 40 45 50 55 60 65 70
Above weights are for carbon and alloy steel pipe only. For austenitic stainless steel multiply by 1.02.
kg/m x 0. 67197 = lbs/ft
For ferritic stainless multiply by 0.95.
235
3. DIMENSIONS - TABLE MANUAL ANSI B 36.10 SUMMARY OF PIPE SCHEDULED SIZE - WALL THICKNESS [mm]
DN OD Schedule STD Schedule XS Schedule XXS
[inch] d and and
[mm] 5S 10S 10 20 30 40S 40 60 80S 80 100 120 140 160
ELBOW 90° - 180°
1/2" 21,3 1,65 2.11 2,77 3,73 4,78 7,47
R = 1,5 d ELBOW 60°
R = 1,5 d 3/4" 26,7 1.65 2.11 2.87 3,91 5,56 7,82
ELBOW 45°
K R = 1,5 d ELBOW 30° 1" 33,4 1.65 2.77 3.38 4,55 6,35 9,09
R = 1,5 d 1 1/4" 42,2 1.65 2.77 3.56 4,85 6,35 9,70
F
B
1 1/2" 48,3 1.65 2.77 3.68 5,08 7,14 10,16

C
H
d
A
2" 60,3 1.65 2.77 3.91 5,54 8,74 11,07

K
H
A 2 1/2" 73,0 2.11 3.05 5.16 7,01 9,52 14,02
J
G
l
E d d d
3" 88,9 2.11 3.05 5.49 7,62 11,13 15,24
4" 114,3 2.11 3.05 6.02 8,56 11,13 13,49 17,12
d 5" 141,3 2.77 3.40 6.55 9,52 12,70 15,88 19,05
0 max d 6" 168,3 2.77 3.40 7.11 10,97 14,27 18,26 21,95
d
O 8" 219,1 2.77 3.76 6.35 7,04 8.18 10,31 12,70 15,09 18,26 20,62 23,01 22,22
0 min
Y
N
10" 273,0 3.40 4.19 6.35 7,80 9.27 12,70 12,70 15,09 18,26 21,44 25,40 28,58 25,40
d
0 max 12" 323,8 3.96 4.57 6.35 8,38 9.52 10.31 14,27 12,70 17,47 21,44 25,40 28,58 33,34 25,40
d
S
N N 14" 355,6 3.96 4.78 6.35 7.92 9,52 9.52 11.13 15,09 12,70 19,05 23,82 27,79 31,75 35,71
0 min WELDING NECK
M 16" 406,4 4.19 4.78 6.35 7.92 9,52 9.52 12.70 16,64 12,70 21,44 26,19 30,96 36,52 40,49
TEE-PIECE FLANGE
REDUCER STRAIGHT R. F. ANSI B. 16-5 18" 457,2 4.19 4.78 6.35 7.92 11,13 9.52 14.27 19,05 12,70 23,82 29,36 34,92 39,67 45,24
236
20" 508,0 4.78 5.54 6.35 9.52 12,70 9.52 15.09 20,62 12,70 26,19 32,54 38,10 44,45 50,01
24" 609,6 5.54 6.35 6.35 9.52 14,27 9.52 17.48 24,61 12,70 30,96 38,89 46,02 52,37 59,54
DN OD ø ø O O S S Y Y GASKET GASKET NR. OF NR. OF STUD STUD

[mm] d A B C E F G H J K L M max min N 150# 300# 150# 300# 150# 300# 150# 300# BORE BORE BOLTS BOLTS
150# 300# 150# 300#
1/2" 21,3 38 48 29 76 16 15 10 10 22 - - - - 25 16 16 60,3 66,7 47,6 52,4 48x21 54x21 4 4 12x65 12x70
3/4" 26,7 29 43 22 57 11 11 8 8 17 15 38 1/2" 3/8" 29 16 20 69,9 82,5 52,4 57,1 57x27 67x27 4 4 12x65 16x75
1" 33,4 38 56 29 76 22 15 10 10 22 20 51 3/4" 3/8" 38 16 20 79,4 88,9 55,6 61,9 67x33 73x33 4 4 12x70 16x85
1 1/4" 42,2 48 70 37 95 25 19 - 13 - 25 51 1" 1/2" 48 16 20 88,9 98,4 57,1 65,1 76x42 83x42 4 4 12x70 16x85
1 1/2" 48,3 57 83 44 114 29 22 15 15 33 30 63 1 1/4" 1/2" 57 16 23 98,4 114,3 61,9 68,3 86x49 95x49 4 4 12x75 20x95
2" 60,3 76 106 58 152 35 30 20 20 44 39 76 1 1/2" 3/4" 64 20 20 120,6 127 63,5 69,8 105x60 111x60 4 8 16x85 16x90
2 1/2" 73,0 95 132 73 191 44 37 - 25 - 49 89 2" 1" 76 20 23 139,7 149,2 69,8 76,2 124x73 130x73 4 8 16x90 20x100
3" 88,9 114 159 87 229 51 44 32 30 66 59 89 2 1/2" 1 1/4" 86 20 23 152,4 168,3 69,8 79,4 137x89 149x89 4 8 16x95 20x110
4" 114,3 152 210 116 305 64 59 41 40 88 79 102 3" 1 1/2" 105 20 23 190,5 200 76,2 85,7 175x114 181x114 8 8 16x95 20x115
5" 141,3 190 262 145 381 79 74 - 50 - 98 127 4" 2" 124 23 23 215,9 234,9 88,9 98,4 197x141 216x141 8 8 20x100 20x120
6" 168,3 229 313 175 457 95 89 61 60 132 119 140 5" 2 1/2" 143 23 23 241,3 269,9 88,9 98,4 222x168 251x168 8 12 20x100 20x125
8" 219,1 305 414 233 610 127 119 82 80 176 158 152 6" 4" 178 23 26 298,4 330,2 101,6 111,1 279x219 308x219 8 12 20x110 22x140
10" 273,0 381 518 292 762 159 149 102 99 220 197 178 8" 4" 216 26 29 361,9 387,3 101,6 117,5 340x273 362x273 12 16 22x120 24x160
12" 323,8 457 619 350 914 190 178 123 119 264 237 203 10" 5" 254 26 32 431,8 450,8 114,3 130,2 410x324 422x324 12 16 22x120 30x170
14" 355,6 533 711 408 1067 222 208 143 139 308 276 330 12" 6" 279 29 32 476,2 514,3 127 142,9 451x356 486x356 12 20 24x135 30x180
16" 406,4 610 813 467 1219 254 238 163 159 352 316 356 14" 8" 305 29 35 539,7 571,5 127 146 515x406 540x406 16 20 24x140 33x190
18" 457,2 686 914 525 1372 286 268 183 179 396 355 381 16" 10" 343 32 35 577,8 628,5 139,7 158,7 550x457 595x457 16 24 30x150 33x195
20" 508,0 762 1016 583 1524 318 297 204 199 440 394 508 18" 12" 381 32 35 635 685,8 144,5 161,9 605x508 655x508 20 24 30x160 33x210
24" 609,6 914 1219 700 1829 381 357 245 239 528 473 508 22" 16" 432 35 42 749,3 812,8 152,4 168,3 720x610 775x610 20 24 33x180 39x235
237
5. CONVERSIONS BETWEEN ENGLISH AND (SI) STANDARD UNITS
QUANTITY
Length millimeter (mm) inch (in) 1 inch = 25.4 mm
Pressure* bar (bar g, or bar a) pounds/sq. in. (psig or psial) 1 bar = 14.5 psi
Pressure** mm or mercury (mm Hg) inches of mercury (in Hg) 1 in.Hg = 25.4 mm Hg
Flow*** liters per minute (l/min) U.S. gallons per minute (U.S. GPM) 1 U.S. GPM = 3.79 l/min
Flow+ cubic decimeters/sec (dm3/sec) cubic feet per minute (cfm) 1 dm3/sec = 2.12 cfm
Force Newton (N) pound (f) or lb (f) (force) 1 lb (f) = 4.44 N
Mass kilogram (Kg) pound (m) or lb (m) (mass) 1 Kg = 2.2 lb (m)
Time second (sec) second (sec) -
Volume*** liter (l) gallon (U.S. gal) 1 U.S. gal = 3.79 l
Temperature degrees Celsius (°C) degrees Fahrenheit (°F) °C = 5/9 (°F -32)
Torque Newton-meters (Nm) pounds (f) inches [lbs(f)-in] 1 Nm = 8.88 lb (f)-in
Power kilowatt (kw) horsepower (HP) 1 kw = 1.34 HP
Shaft speed revolutions per minute (rpm) revolutions per minute (rpm) -
Frequency Hertz (Hz) cycles per second (cps) 1 Hz = 1 cps
Displacement millimeters/revolution (ml/rev) cubic inches per revolution
(cipr) or (cir) 1 ml/rev = 0.061 cipr
Kinematic viscosity centistokes (cSt) Saybolt Universal Seconds
(SUS or SSU) cSt = (4.635) (SSU)++
Velocity meter per second (m/s) feet per second (fps) 1 m/s = 3.28 fps
NOTES:
*Pressure above atmospheric. **Pressure below atmospheric. ***Liquid. +Gas. ++@38°C; Factor is
4.667@99°C
LENGTH
mm x 0.03937 = inches x 25.4 = mm
cm x 0.3937 = inches x 2.54 = cm
meters x 39.37 = inches x 0.254 = cm
meters x 3.281 = feet x 0.3048 = meters
meters x 1.0936 = yards x 0.9144 = meters
Km x 3280.8 = feet x 0.0003048 = Km
Km x 1093.6 = yards x 0.0009144 = Km
Km x 0.6214 = miles x 1.609 = Km
Km x 0.5397 = sea miles x 1.853 = Km
AREA
sq mm x 0.00155 = sq inches x 645.2 = sq mm
sq cm x 0.155 = sq inches x 6.452 = sq cm
sq meters x 10.764 = sq feet x 0.0929 = sq met.
sq meters x 1.196 = sq yards x 0.8361 = sq met.
sq Km x 0.3861 = sq milesyardsx 2.59 = sq Km
hectares x 2.471 = acres x 0.4047 = hectares
VOLUME
cu cm x 0.061023 = cu inches x 16.387 = cu cm
cu cm x 0.3381 = fl ounces x 29.57 = cu cm
liters x 61.023 = cu inches x 0.016387 = liters
liters x 0.03531 = cu feet x 28.317 = liters
liters x 0.2642 = U.S. gal x 3.785 = liters
liters x 0.22 = Imperial gal x 4.544 = liters
cu meters x 35.314 = cu feet x 0.02832 = cu met.
cu meters x 6.3226 = barrel (oil) x 0.158162 = cu met.
cu meters x 6.1104 = barrel (Eng.) x 0.163656 = cu met.
238
MASS (WEIGHT)
grams x 15.432 = grains x 0.0648 = grams
grams x 0.0353 = oz. avoir-dupois x 28.35 = grams
Kg x 35.27 = oz. avoir-dupois x 0.02835 = Kg
Kg x 2.2046 = lbs x 0.4536 = Kg
Kg x 0.001102 = U.S. tons x 907.2 = Kg
Kg x 0.000984 = long tons x 1016.048 = Kg
tons (metric) x 19.684 = cwt (Eng.) x 0.0508 = tons (metric)
tons (metric) x 22.046 = cwt (US) x 0.04536 = tons (metric)
PRESSURE
gr/sq cm x 0.01422 = p.s.i. (lb/sq in) x 70.31 = gr/sq cm
Kg/sq cm x 14.22 = p.s.i. (lb/sq in) x 0.07031 = Kg/sq cm
Atmosphere x 14.70 = p.s.i. (lb/sq in) x 0.06804 = Atmosphere
Atu x 14.22 = p.s.i. (lb/sq in) x 0.07031 = Atu
bar x 14.5 = p.s.i. (lb/sq in) x 0.069 = bar
UNIT VOLUME
liters/min x 0.2642 = U.S. gpm x 3.785 = liters/min
liters/min x 0.03531 = cfm x 28.317 = liters/min
liters/hr x 0.0044 = U.S. gpm x 227.1 = liters/hr
cu m/min x 35.314 = cfm x 0.02832 = cu m/min
cu m/hr x 0.5886 = cfm x 1.6992 = cu m/hr
cu m/hr x 4.4028 = U.S. gpm x 0.2271 = cu m/hr
POWER
Watts x 0.00134 = hp x 745.7 = Watts
Kw x 1.3410 = hp x 0.7457 = Kw
Kw x 0.948 = Btu/sec x 1.05486 = Kw
Kw x 0.5272 = Ctu/sec x 1.8967 = Kw
cheval vap. x 0.9863 = hp x 1.0139 = cheval vap.
WORK/TORQUE
mkp (mkg) x 7.233 = ft lbs x 0.1383 = mkp (mkg)
mkp (mkg) x 86.80 = inch - lbs x 0.0115 = mkp (mkg)
cmkp (cmkg) x 0.868 = inch - lbs x 1.15 = cmkp (cmkg)
Kw/hr x 0.000293 = Btu x 3413 = Kw/hr
Kw/hr x 0.0001628 = Ctu x 6143 = Kw/hr
MISCELLANEOUS
Circumference of cyrcle = 3.1416 x dia = 6.2832 x radius
Area of Circle = 0.7854 x (dia) 2 = 3.1416 x (radius) 2
Area Sphere = 3.1416 x (dia) 2
Volume of Sphere = 0.5236 x (dia) 2
1 lb per sq in is equivalent to 0.06804 atmospheres
239

Technical Calculation and Estimator's Man-Hour Manual

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TECHNICAL CALCULATION

TECHNICAL CALCULATION AND ESTIMATOR'S

ERECTION OF PROCESS OR CHEMICAL PLANTS

I. PIPING ABOVE GROUND

All right reserved.

1. COMPLETE MANUAL (239 pages) US$ 600 US$ 1000

I PIPING ABOVE GROUND - 36 pages + 20* US$ 180 US$ 300

3. A PERSONALISED ANALOGUE VERSION OF THE MANUAL COULD BE ORDERED AS WELL.

Zagreb Croatia, 2003

CHAPTER II. PIPELINES...................................................................................................50

CHAPTER IV. ERECTION OF EQUIPMENT IN PETROCHEMICAL INDUSTRY....................67

CHAPTER V. STORAGE TANKS - CYLINDRICAL AND SPHEROIDAL.................................74

CHAPTER VI. WELDING AND FLAME CUTTING................................................................85

CHAPTER VII. CORROSION PROTECTION......................................................................103

CHAPTER VIII. THERMAL INSULATION..........................................................................106

CHAPTER XI. WEIGHT FACTORS.....................................................................................203

CHAPTER XII. TECHNICAL CALCULATION MANNER OF DATA COMPILING..................210

CHAPTER XIII. MAN HOURS FOR OVERHAULS IN PETROCHEMICAL PLANTS..............214

CHAPTER XV. APPENDIX..................................................................................................233

The standard ranges of productivity efficiency percentages are:

1. PIPING ABOVE GROUND IN PLANTS

PEP = high average 80%

PEP = high average 75%

PEP = high average 80%

1.4 Calculation based on man hours for units of operation

PEP = very good 85 %

PEP = high average 75 %

PEP = high average 75 %

4. PROCESS EQUIPMENT IN PLANTS

PEP = average 70%

5. CYLINDRICAL STORAGE TANKS

PEP = very good 85 %

6. WELDING AND CUTTING

PEP = high average 80 %

PEP = very good 85 %

1. Project Management and Supervision

4. Machinery and Equipment

PEP = Productivity efficiency percentage

CARBON STEEL - NONWRAPPED - ABOVE GROUND STAINLESS STEEL

Man hour included next activities : Materials: k

CARBON STEEL - NONWRAPPED STAINLESS STEEL

Man hour include the next activities: Materials: k

CARBON STEEL STAINLESS STEEL

2.2 CAPS [Mhr/ea] x 0,50 Materials: f f

CARBON STEEL STAINLESS STEEL

2.3.2 REDUCED TEE [Mhr/ea] x 0,95 Materials: f f

CARBON STEEL STAINLESS STEEL

Man hour include next activities: Materials: f f

CARBON STEEL - NONWRAPPED - ABOVE GROUND - WALL THICKNESS 2 - 12,5 mm

CARBON STEEL - NONWRAPPED - ABOVE GROUND - WALL THICKNESS 14,2 - 60 mm

CARBON STEEL - NONINSULATED - WALL THICKNESS - 2 mm - 12,5 mm

Man hour include next activities: Materials: k

CARBON STEEL - NONINSULATED - WALL THICKNESS 14,2 - 60 mm

Man hour include next activities: Materials: k

CARBON STEEL - WALL THICKNESS 2 - 7,1 mm

1.4 INSTRUMENT AND CONTROL PIPING

CARBON STEEL - WALL THICKNESS 2 - 12,5 mm

2.2 CAPS [Mhr/ea] x 0,50 Materials: f

CARBON STEEL - WALL THICKNESS 14,2 - 60 mm

2.2 CAPS [Mhr/ea] x 0,50 Materials: f Stainless steel 1,25

2.3.2 REDUCED TEE [Mhr/ea] x 0,95 Materials: f - Stainless steel 1,25

CARBON STEEL - WALL THICKNESS 14,2 - 60 mm

2.3.2 REDUCED TEE [Mhr/ea] x 0,95 Materials: f - Stainless steel 1,25