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How To Estimate Cost of Structural Steel Fabrication
How To Estimate Cost of Structural Steel Fabrication
ESTIMATE
the COST
O F
S T R U C T U R A L
S T E E L
CONTENTS
1.
2.
INTRODUCTION
7.
8.
3.
4.
5.
6.
Material Pricing
Escalation
Surcharges
Fuel Costs
Value of the Dollar
Lead Times
1. INTRODUCTION
BRIEF DESCRIPTION
A steel framed building is an alternative to a concrete framed
building. The steel framed building is equally a good choice
as a concrete framed building. They each have distinct
building materials, practices and benefits that have to be
carefully weighed, as timing and situation will dictate the
best choice. However, steel is a material that has the highest strength-to-weight ratio and is very ductile. Steel is also
shop fabricated and therefore has a higher quality control as
its produced in a controlled environment. Steel beams and
steel columns are used to structurally frame a building so
that it supports the exterior faade, roof, interior construction, mechanical and electrical systems of the building and
of course the personnel, furnishings and equipment that
will occupy the building. The structural steel framed building also includes components such as steel floor decking,
steel roof decking, steel joists, bolted connections, welded
connections, base plates, slab pour stops, braced framing,
moment connections, and other miscellaneous cold-formed
metals to complete the steel framing system. Again, for the
purposes of this paper I will only focus on a few of these
components.
HEIGHT OF BUILDING
The height of the building will dictate the type of crane to
be used on the project. Smaller projects may be able to use
a mobile wheel-mounted or track-crawler crane. Tall buildings will need a tower crane that will require concrete pad
foundations and electrical power requirements.
SITE CONDITIONS
The site conditions and constraints will also dictate the type
crane that will be utilized. Tight sites in city areas will need
tower cranes versus the ability to use mobile cranes in open
sites assuming heights arent an issue.
CONNECTION DETAILS
A project that utilizes welded connections takes longer to
erect than with bolted connections. In addition, the fieldtesting of welded connections will also add time to the
schedule. Curtainwall support connections will add to the
cost as well as precast panel connections. Therefore, its important to know what the faade of the building will be so
connection detail costs can be accounted for.
MOMENT CONNECTIONS
GEOGRAPHICAL LOCATION
The location of the project may have an influence on cost
due to regional material, labor, and equipment costs based
on availability of resources and manpower. R.S. Means uses
a coefficient factor to adjust for regional differences.
BEAM PENETRATIONS
EQUIPMENT
4. OVERVIEW OF LABOR,
MATERIAL, EQUIPMENT AND
INDIRECT COSTS
The following example is intended to demonstrate a simple
take-off and pricing method for a structural steel frame system including beams, columns, decking, shear studs, bent
plate (pour stop), and connections.
With todays technology many companies perform takeoff using OST and digitizers. OST allows you to take-off
quantities on your computer screen while color coding the
element youre taking off and recording up to three (3) units
of measure for that element at the same time.
However, for the purposes of this paper I will complete
the take-off and pricing sheets on Excel to demonstrate the
method being used.
MATERIAL
Take-off the lengths of each different size beam and column. Next Ill multiply the length of each beam and column by its respective weight. From the sum of all these
beams and columns Ill then calculate the total tonnage.
The shear studs will be counted for each beam and a total tallied. The perimeter of the floor plates will be calculated in order to figure the length of pour stop. The area
of the floors will be calculated to determine the decking quantity. And lastly, the connections will be figured
by calculating percentages of the total steel tonnage.
LABOR
Since the steel is fabricated in the shop the labor portion refers to the erection crew. Generally, its assumed
that for erection a crane can pick between 35 and 60
pieces a day. Assuming the average is 45 picks per day,
and using common sizes of beams and columns that
would probably equate to around 30 tons erected per day.
INDIRECT COSTS
Tower cranes also require concrete pad foundations to be set
on and also require electrical power service. Safety costs for
perimeter cabling needs to be considered along with other
temporary construction costs to provide a secure and safe
working environment.
Other indirect costs to consider are sales tax, payment
and performance bonds and liability insurance.
Structure
Floor
SOG
SOMD
SOMD
SOMD
1st Floor
2nd Floor
3rd Floor
4th Floor
L
Length (lf)
W
Width (lf)
90
90
90
90
90
90
90
90
360
360
360
360
Floor
90
90
360
360
360
360
360
Unit Wt.
LF
LF
LF
LF
Un
18.00
18.00
18.00
18.00
Total Wt.
PLF
PLF
PLF
PLF
6,480
6,480
6,480
6,480
Total Weight:
32,400
Roof
Perimeter Un
8,100
8,100
8,100
8,100
P
A
Perimeter (lf) Area (sf)
Un
Total Wt.
LB
LB
LB
LB
Un
3.24
3.24
3.24
3.24
25,920 LB
TN
TN
TN
TN
12.96 TN
8,100
# of Col. Size
2nd Floor
3rd Floor
4th Floor
Roof
16
16
16
16
Max. %
2.00%
4.00%
4.00%
160.07 TN
Min. Wt. Un Max. Wt. Un
3.00%
5.00%
5.00%
3.20 TN
6.40 TN
6.40 TN
Total Weight:
Floor
Min. %
W14x82
W14x61
W14x61
W14x53
82
61
61
53
12
12
12
12
192
192
192
192
Total Weight:
Total Wt.
15,744
11,712
11,712
10,176
Un
LB
LB
LB
LB
49,344 LB
Total Wt.
Un
4.80 TN
8.00 TN
8.00 TN
9,604 LB
16,007 LB
16,007 LB
20.81 TN
41,618 LB
Total Wt. Un
7.87
5.86
5.86
5.09
TN
TN
TN
TN
24.67 TN
Steel Deck
Floor
L
Length (lf)
2nd Floor
3rd Floor
4th Floor
W
Width (lf)
90.00
90.00
90.00
A
Area (sf)
90.00
90.00
90.00
Waste (10%)
8,100
8,100
8,100
Total SF
810
810
810
8,910
8,910
8,910
26,730 SF
Roof
90.00
90.00
8,100
810
8,910
8,910 SF
Ste e l Be a m s Ta ke -Off
35,640 SF
2nd floor
Qty
Size
8
4
8
8
22
W24x55
W36x135
W21x44
W8x10
W16x31
Le ngth
30
30
30
10
30
Unit Wt.
55
135
44
10
31
GSF
6.60
8.10
5.28
0.40
10.23
Ite m
De scription
Qty
Un
61,220
30.61
Ma t Tota l
La b Un Pr
La b Tot
32,400
147.11 tons
2,200.00
323,642
900.00
132,399
$ 29,422.00
485,463
14.98
12.96
20.81
5,124
26,730
$
$
$
$
2,200.00
3,350.00
2.68
2.18
$
$
$
$
28,512
69,714
13,732
58,271
$
$
$
$
1,100.00
1,650.00
1.32
1.07
$
$
$
$
14,256
34,337
6,764
28,601
$
$
$
$
$
$
$
$
$
$
$
$
42,768
104,050
20,496
86,873
$
$
$
$
1.32
3.21
0.63
2.68
2.01
17,909
0.99
8,821
26,730
0.83
511,780
225,177
766,380
23.65
6.
tons
tons
each
sf
8,910 sf
20.00%
200.00
$/SF
1.
2.
3.
4.
5.
Subtota l We ight:
Ma t Un Pr
29,422
153,276
4.73
919,655
28.38
3rd floor
Qty
Size
8
4
8
8
22
W24x55
W36x135
W21x44
W8x10
W16x31
Le ngth
30
30
30
10
30
Unit Wt.
55
135
44
10
31
Subtota l We ight:
6.60
8.10
5.28
0.40
10.23
61,220
30.61
4th floor
Qty
Size
8
4
8
8
22
W24x55
W36x135
W21x44
W8x10
W16x31
Le ngth
30
30
30
10
30
Unit Wt.
55
135
44
10
31
Subtota l We ight:
6.60
8.10
5.28
0.40
10.23
61,220
30.61
Roof
Qty
Size
8
4
8
8
22
W24x55
W36x135
W21x44
W8x10
W16x31
Subtota l We ight:
Tota l We ight:
Le ngth
30
30
30
10
30
Unit Wt.
55
135
44
10
31
6.60
8.10
5.28
0.40
10.23
61,220
30.61
244,880
122.44
MATERIAL COST
The cost of structural steel is increasing, as theres a huge
global appetite for steel currently underway. Contributing
to this escalation is also the fact that steelmakers are paying large premiums for raw materials from mining companies and passing this cost onto the consumer. Raw material costs have recently contributed to 50% of the steel
cost where a short time ago they traditionally accounted
for roughly 15% of the steel material cost. Steelmakers
are now trying to acquire mines to provide raw materials
for their own companies in order to be more self-sufficient.
ESCALATION
Escalation is a significant cost factor when putting a steel
bid together. Your project may not require the steel to be
on-site for many months to a year, if not longer. Many steel
contractors will not even try to guess what steel prices may
be at that time because of price volatility. In order to level
the playing field for the steel contractors during a bid you
may have to forecast as best you can the projected future
steel cost and carry an escalation allowance. This strategy
should be discussed should be discussed with the Owner.
SURCHARGES
Surcharges are added to the steel material costs because
the material cost is volatile and it gives the steel supplier
more flexibility to lower and raise his price. This practice
eliminates the need to constantly adjust a fixed price so that
you can appear to remain competitive.
FUEL/ENERGY COSTS
The cost of a barrel of oil is hovering around $140/barrel
and the average cost of gasoline in the U.S. right now is
about $4.00/gallon. Fuel and energy costs are making steel
more expensive to produce and ship steel.
will take the total steel tonnage and divide by the total
building square footage (assuming the ground is a slab-ongrade) and expect to get a unit weight of between 11 psf and
15 psf. If my tonnage is not in this range I will investigate
further to determine why the structure is seemingly light or
heavy. Having a structure with inadequate steel strength is
one issue and having a structure with excessive weight may
be inefficiency in beam usage leading to an unnecessarily
higher cost.
In regards to shear studs I would also divide the total
building square footage by the total quantity of shear studs
and expect this number to be in the range of 6-8 sf per stud
(or 0.13 0.17 studs per sf). If not, Ill make adjustments to
make sure that I carry enough shear studs in the estimate.
The following logic chart below is a sample calculation used
to check the validity of the estimate. I have shown how to
complete a logic check on the structural steel beams, columns, bent plate, and connections to see if the unit weight
of the structural steel system is in the projected range. I
have also shown how to complete a logic check on the shear
studs to make sure there are enough for the composite slabon-deck system. I have performed a quick check on the
structural steel erection cost to see if it is in-line with my
estimate. As you will the erection estimate at $161,821 is
close to what I calculated in the estimate at $176,077. This
again is a logic check to make sure that the numbers in the
estimate are a reasonable cost for the scope of work.
Weight
Columns
Beams
Bent Plate
Connections
49,344
244,880
25,920
41,619
Total Weight
361,763 LB
Building (SF)
32,400 SF
LB
LB
LB
LB
11.2 PSF
Shear Studs
Building (SF)
Square Feet Per Stud
5,124 EA
32,400 SF
6.3 SF
GLOSSARY
Item
Qty
Steel Columns
Un
48 Each
Steel Beams
200 Each
248 Each
147.11 Tons
0.59 Tons
51 Pieces
5 Days
1,100.00
33,000
161,821
176,077
REFERENCES
Means Estimating Handbook
AISC Manual of Steel Construction
7. MISCELLANEOUS
PERTINENT INFORMATION
Recently, in order to evaluate the construction sequencing
of erecting structural steel BIM modeling has been utilized.
BIM stands for Building Information Modeling and is used
to create a computer model of the building from the design
drawings. This computer model is capable of detecting dimensional busts as well clashes with other building elements. It
also has shown weaknesses in erection sequencing that can
lead to a more efficient construction schedule. Another interesting development is the use of barcodes that are placed
on the fabricated steel in the shop, scanned when shipped,
scanned when delivered to the site, and scanned when
erected in place. This real-time scanning process allows the
BIM model to show the Construction Manager and Client
when the steel has been fabricated, shipped, delivered to
the site and erected. The computer model then displays that
actual to-date work put in place showing a time sequence.