COST ESTIMATE FOR 28.

8KM OF 2 LANES ASPHALT ROAD

Road dimensions
Road length in metres 28,800
Road width in m 7.3
Asphalt basecourse thickness in m 0.076
Asphalt wearing course thickness in m 0.051
Equipment
1 Mobile drum-mix asphalt plant located in the middle of the
project of capacity in T/hr of 150
2 Sixty (60) minutes make one (1) hour 60
3 Assume 50 minutes effective hour, 50/60, efficiency is 83 %
Production rate of the asphalt plant in T/hr will be 83% of 150
Haulage trucks to be used will be of capacity in tonnes 20
Haul distance in Km assumed is 15 Average delivery speed in kph is 48 Average
return speed in kph is 56
Effective hour for hauling operation assumed is 45 minutes 75 %

Specifications for Asphalt

Asphalt cement content by weight in % 6%
Coarse aggregate larger than a no 10 sieve 60 %
Fine aggregate and filler 40 %

Losses: Assume as follows:

Asphalt cement 2%
Coarse aggregate 5%
Fine aggregate 10 %
Weight of asphalt in T/m3 is 2.138

Grading and mix composition as in Table

Estimation of quantity of materials

Total road surface area in square metres is 210240
Materials for 76.2mm basecourse in tonnes 34,251.38
Materials for 50mm wearing course in T 22,834.25
Total asphalt materials in Tonnes is 57,085.63

Less 6% asphalt cement 94 %

Effective weight of aggregate in Tonnes is 53,660.49

Material Quantities for costs

Coarse Agg.(60% : 0.6*53,660.49) 32,196.29
Add waste at 5%*53,660.49 1,609.81
Subtotal coarse agg 33,806.11
Fine agg.(40%: 0.4*53,660.49) 21,464.20
Add waste at 10% 2,146.42 Subtotal fine aggr 23,610.62

Asphalt cement (6%) 3,219.63 Waste 2% 64.39

Subtotal asphalt cement 3,284.02

Production time for asphalt plant

production rate for a 50-min effective hour in T/hr 125 Time required to mix the asphalt,
hours 456.69

Production time for hauling HMA

Cycle Time for a truck
Load asphalt: 20T/125T/H 0.16
Haul:15km@ 48 kph 0.31
Dump:12min: 12/60 0.20 Return:15km @ 56kph 0.27
Total cycle time in hours 0.94

Quantity of HMA per trip:

20 T/trip * 1 trip/0.94 hr in T/hr 21.27
For a 45-min effective hour, quantity T/hr is 15.95

Required No of Trucks
Is plant production/truck production: 125/15.95 7.84
Provide no trucks 8
Using 8 trucks, the haul rate will be greater than the plant production rate

Asphalt plant costs chargeable to the project

Delivered plant cost in Naira (First cost) 80600000
Useful life of equipment, no salvage value, years 12
No of hours in 1 day 8 No of days in 1 month 20
No of months in 1 year 12

Plant usage rate per year:45/60 * 8hr-day*20day-month*12 1440

Cost of moving the plant will be charged to this project

Calculation of asphalt plant ownership cost

Interest on money 25 %
Risk addition 5%
Taxes and insurance 7%
Total interest i 37 %
Minimum attractive rate of return MARR is 37 %
Annual ownership cost is discounted first cost less salvage value
Salvage value 0
Annual Ownership Cost (AOC) is CRF * first cost
(1+i)^n is 43.72
(1+i)^n -1 is 42.72
Capital recovery factor (CRF) is 0.38
Annual ownership cost is 30,520,135.38
Hourly ownership cost is cost/1440hr 21,194.54

Asphalt plant operating costs

Annual straight line depreciation cost 6,716,666.67

Maintenance and repairs:10% 466.44

Fuels and hot oils: 315 galls@ N200/gall 63000
Diesel fuel for engines: 50 litres @ N165 8250
Lubricating oil: 2litres @ N750/litres 1500
Other lubricants and greeze 750
Hourly operating costs 73,966.44

Asphalt plant total hourly

ownership and operating cost 95,160.97

Cost Data Asphalt materials

Coarse aggregate in Naira/tonne 4,500
Fine aggregate in Naira/Tonne 700
Asphalt cement in Naira/tonne 130,000
Material Costs:

Coarse aggregates: 152,127,485.37

Fine Aggregates 16,527,430.51
Asphalt cement 426,922,847.82
Total cost 595,577,763.70

Cost Data of Equipment in Naira/day

Front end loader 120,000
Portable conveyor 80,000
20 T Haul trucks 40000
Asphalt paver 100,000
Asphalt distributor truck 40,000
Smooth wheel roller 40,000
Pneumatic tyre roller 60,000
Sweeper 10,000
Utility vehicle 15,000
Water tanker 30,000
Mobilization and set up of asphalt plant (PS) 2,500,000
Equipment at mixing plant
Asphalt plant: 43,458,590.19
Moving to job and setting up, lump sum 2,500,000.00
Front end loader: 456.69 hr@ 120,000/8 6,850,275.15
Portable conveyor: 456.69 hr @ 80,000/8 4,566,850.10
Total cost 57,375,715.44

Labour at Mixing Plant

Asphalt plant operator wage/day 11,250
Loader operator wage/day 10,000
Mechanic 8,000
Foreman/paving inspector 12,500
Paver operator 11,500
Roller operator 8,000
Truck driver 8,000
Utility vehicle driver 4,000
Flat bed transport per equipment retrun 80,000
Superintendence costs/day 6,000
Rakers 2,500
Labourers 2,000

Labour at Mixing Plant

Loader operator: 456.69 hr @ 570,856.26
Batch plant operator: 456.69 hr 642,213.30
Mechanic 456,685.01
Foreman 713,570.33
Total cost 2,383,324.90

Equipment Hauling HMA

Trucks:456.69 hr 18,267,400.40

Labour Hauling HMA

Truck drivers: 456.69 hr * 4 no 3,653,480.08

Equipment Placing Pavement

Aspalt paver 5,708,562.62
Asphalt distributor truck 2,283,425.05
Smooth wheel roller 2,283,425.05
Pneumatic roller 3,425,137.57
 Total cost 13,700,550.30
Labour Placing HMA
Aspalt paver operator 656,484.70
Asphalt distributor truck driver 456,685.01
Smooth wheel roller operator 456,685.01
Pneumatic roller operator 456,685.01
Rakers: 4 No 570,856.26
Labourers: 5 No 570,856.26
Total cost 3,168,252.26

Other Direct Costs

asphalt plant land site rental 1,000,000
Plant and road tools 300000
Service trucks: 456.69 hr *2No 1,712,568.79
Barricades, signs and signals 350000
Superintendence 456.69 hr 342,513.76
Flat bed transport: 3 Plants 240000
Total costs 3,945,083

Summary of direct costs

Bulk Materials 595,577,763.70

Plant equipment 57,375,715.44
Plant labour 2,383,324.90
Equipment hauling HMA 18,267,400.40
Labour Hauling HMA 3,653,480.08
Paving equipment 13,700,550.30
Labour paving 3,168,252.26
Other direct costs 3,945,082.54
Total direct costs 698,071,569.61
With holding tax @ 10% 69,807,156.96
G&A overheads @10% 69,807,156.96
Total dc + WHT+ G&A overheads 837,685,883.53
Profit of 25% 209,421,470.88
Estimated total cost 1,047,107,354.42

Bid price per tonne, N 18,342.75

Bid price per square metres, N 4,980.53

125
ACCURATE PRODUCTION COST ESTIMATES, INCLUDING
DEBT SERVICE AND DEPRECIATION
ALL OTHER FIXED AND VARIABLE PLANT OPERATING COSTS

P[ANT OPERATING COSTS INCLUDES

CAPITAL COST OF EQUIPMENT AND INSTALLATION
LAND ACQUISITION
PERSONNEL COSTS
EMPLOYER FIXED COSTS
MATERIALS
TRANSPORTATION
UTILITY COSTS
COSTS OF ENVIRONMENTAL AND SAFETY STANDARDS COMPLIANCE

BATCH PLANTS
MIX ASPHALT IN BATCHES
4000# PLAN

ASPHALT PLANT COSTS

CAPACITY COST USED PRICE
30T/H 150,000 20T/H 75000
325 1,350,000 100-199 160,000
500 4,000,000 200-299 280,000 300 375,000

A 300T/H PLANT USES 17.4T/H OF OIL

A 30,000 GALLS TANK HOLDS APPROX 116.7 TONS OF OIL AT 7.78 PPG
COST ESTIMATE FOR 1 KM 2-LANE ASPHALT ROAD USING READY MIX ASPHALT
#########
cost of ready mixed asphalt (HMA) per tonne in Naira 22,000.00

Road Data
Length of road, m 1,000.00
Paved width, m 7.30
Asphalt basecourse thickness, m -
Asphalt wearing course thickness,m 0.04

Resources
Dump trucks of capacity in tonnes 30
Dump trucks of 30 tonnes/day rental in Naira 40,000
distributor truck of 30 tonnes 40,000
asphalt paver rental /day in naira 100,000
Steel wheel roller, rental/day in Naira 60,000
Pneumatic tyre roller -do- 90,000
Utility vehicle rate per day 15,000
Road tools (barrow, rakes, shovels) -do- 10,000
Barricades, signs and signals -do- 6,000
Paving inspector rate/day 12,000
Paver operrator rate/day 10,000
Roller operator rate/day 10,000
Rakers rate/day 2,500
Labourers rate/day 2,000
Supervisor/foreman 5,000

Cycle time for delivering asphalt/hr 1

Quantity of HMA delivered per trip is
equal to 30 T/trip *1trip/1.0hr in T/hr 30
For a 45-minutes effective hour the quantity
delivered becomes 30*45/60 in T/hr 22.5
Required number of 30 t trucks is either
plant production/truck production, or
estimated day paving/truck production

Materials quantity
Area of paving in M2: 1,000*7.3 7,300
Volume of HMA,m3: 7,300*0.04 292.00
 Assume weight of HMA in T/m3 is 2.3
HMA required in tonnes is 671.60
Add waste, 5% 33.58
Allow for shrinkage, 30% 201.48
Total HMA required for billing purposes, T 906.66
Number of trucks required: 906.66T/22.5T/h 40.30
round off to no of trucks 41

COST ESTIMATE
Asphalt (HMA): 906.6 T*N22,000 19,946,520.00
Trucks delivering HMA: 41 No * N40,000 1,640,000.00
Paver for 1 day:8hrs* N100,000/8 100,000.00
Steel wheel roller: 8hrs*N60,000/8 60,000.00
Tyre Roller:8 hrs*N90000 90,000.00
Oil for paver and rollers: 200litres*3*N165 99,000.00
Paver operator: 8hrs* N10,000/8 10,000.00
roller Operator: 8Hrs*2*N10,000/8 20,000.00
Utility vehicle: 8Hrs *N15000/8 15,000.00
Rakers: 4no* 10,000.00
Labourers:4No 8,000.00
Foreman 5,000.00
Paving inspector 12,000.00
Road tools 10000
Barricades, signs and signals 6000
Total direct costs of HMA installed, Naira 22,031,520.00

Add WHT 10% 2,203,152.00

Add G&A overheads 10% 2,203,152.00

Total base costs + WHT + OHs, Naira 26,437,824.00

Profit, 25% 6,609,456.00
Estimated total bid price for 671.6t, N 33,047,280.00

Bid price per tonne, N 49,206.79

Bid price/m2 4,527.02

Bid price/m3 113,175.62

NOTE All prices are those prevailing in Nigeria in 2013.