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Unit Rate Build - Up Concrete 1

This document provides information on unit rates for concrete, including the materials, mixing, placing, and production methods. It discusses the components of concrete, including cement, aggregates, and water. Ready mixed concrete is commonly used in New Zealand due to its quality control. Mix ratios and conversion factors are provided for estimating concrete quantities and weights. The labor involved varies depending on the mixing and placing method used.

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0% found this document useful (0 votes)
369 views36 pages

Unit Rate Build - Up Concrete 1

This document provides information on unit rates for concrete, including the materials, mixing, placing, and production methods. It discusses the components of concrete, including cement, aggregates, and water. Ready mixed concrete is commonly used in New Zealand due to its quality control. Mix ratios and conversion factors are provided for estimating concrete quantities and weights. The labor involved varies depending on the mixing and placing method used.

Uploaded by

tiepblack
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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UNIT RATE BUILD - UP

CONCRETE

BD 5017 Cost Estimation


CONCRETE
CONCRETE
 The CONCRETE is a construction trade which generally divided into two specific areas
such as:
 Concrete
 Formwork
 CONCRETE is a homogenous material made from cement, fine aggregate( Sand),
coarse aggregate and water. The cement, sand and water combine to form a matrix
which binds the coarse aggregate together.
 The concrete trade includes details of
 Components of concrete and grade
 Mixing methods
 Placing methods
 In New Zealand, Ready Mixed Concrete (RMC) is widely used exclusively on building
sites because the quality of mix to reach a desired strength is the most critical aspect
in producing concrete. RMC is charged out at a cost per cubic metre, delivered to
site.
CONCRETE
 MATERIALS
 Cement – Cement is purchased.
 Bulk ex silo (storage) in lots of 2 tonnes and over, and charged per tonne
 Ex store in 40 kg bags, and charged out per bag. A discount is usually given for bulk
purchases.
CONCRETE
 MATERIALS
 Aggregates – These are purchased in cubic metres.
 These materials are suitable for site mixing ordinary grade concrete to comply with NZS
3604. Graded premix with fine and coarse aggregate mixed at the quarry. Graded premix
is often referred to builder’s mix, but traditionally, builder’s mix is unblended natural river
gravel.
 The fine and coarse aggregates will be kept separately in bins adjacent to mixer.
CONCRETE
 MATERIALS
 Water
 Water is usually supplied by the territorial authority to the site via a meter, with the
contractor paying for the consumption.
 The cost of water used in mixing concrete on site is normally included in P & G section.
 For remote locations, water may have to be carted to site through tankers.
CONCRETE
 Unloading
 Unloading cement bags from the delivery truck and carting to the store takes
approximately one labourer hour per tonne.
 Aggregates are usually tipped directly into bins adjacent to the mixer and require no
labour.
CONCRETE
 Ready Mixed Concrete (RMC)
 This is the most common method for obtaining concrete for building projects, and is
purchased at a cost per cubic metre, delivered to site and unloaded.
 Unloading can be
 Directly into the final position from the truck
 Into a skip, bin or barrow
 Into a concrete pump
 On a conveyor (often provided with the truck if required)
CONCRETE
Concrete Production
 The production of concrete is categorized into four grades, with each grade having a
separate set of parameters under which it is produced.
GRADE Achievable strengths Relevant NZS Comments
(mPa) Standards
Low Not applicable None Site mixed or ready mixed. Used for tidy or site
concrete.
Ordinary 17.5 & 20 3108 Site mixed or ready mixed. Used mainly for
structures built under NZS 3604 Timber Framed
buildings. Aggregates may be weigh or volume
batched. Cement must be weight batched.
High 17.5 to 40 3104 Ready mixed. Used in all situations. Aggregates may
be weigh or volume batched. Cement must be weight
batched.
Special 17.5 to 50 3104 As for high grade except aggregates and cement
must be weigh batched.
CONCRETE
 Concrete Production
 The important aspect of concrete produced under ordinary grade is that it requires
more cement than the same strength concrete produced under high or special grade
conditions. This makes the higher grade concrete less expensive, in terms of
materials, to produce. Balancing this saving is the added supervision and batching
costs required to produce the higher grade concrete.
 Ratios of volume to weigh may vary for fine and coarse aggregates used in different
parts of the country. Therefore the estimator should check the source of supply.
CONCRETE
 Concrete Production
 The conversion factors shown in the below table are a guide to average weights
of material
Material Kg/ m3
Cement 1444
Lime 722
Medium Dry sand 1750
Graded aggregate 1670
Concrete unreinforced 2310
Reinforced concrete in:
(i) Walls and floors 2370
(ii) Beams and footings 2420
(iii) Columns up to 3 storeys 2450
(iv) Columns up to 7 storeys 2500
CONCRETE
 Concrete Production
 The below table gives a guide on the specified concrete mixes based on volume of materials
to give 1 cubic metre of concrete.

Fix proportions
Quantities for 1 m3 concrete
(approx)
Max. Size Agg (mm) Mpa Coarse
Cement: Sand:
Fine aggregat
Aggregate
Added Water Cement aggregate e (Sand)
(litre or kg) (Bags) (Sand) (m3) (m3)
14 1:3.5:4.8 140 6 0.65 0.9
20 1:2.8:4.3 140 7 0.6 0.9
40
25 1:2.5:3.8 140 7.5 0.6 0.9
30 1:2.2:3.3 140 8.5 0.55 0.9
15 1:3.2:3.3 170 7 0.7 0.7
20 1:2.7:3.0 170 8 0.65 0.7
20
25 1:2.3:2.7 170 9 0.65 0.7
30 1:2.0:2.3 170 10 0.6 0.7
15 1:3.2:2.3 180 8 0.75 0.6
20 1:2.7:2.2 190 9 0.7 0.6
10
25 1:2.3:1.8 190 10 0.7 0.6
30 1:2.0:1.7 190 11 0.65 0.6
CONCRETE
 Concrete Production
 The below table gives a guide on the specified concrete mixes based on weight of materials to
give 1 cubic metre of concrete.
Cement Fine Coarse
Water
Max. Size Agg (mm) Mpa aggregate aggregate Coarse aggregate
(Ltr or kg)
Bags Kg (Sand) (kg) (Sand) (kg) quantities
15 140 6 240 790 1200 660 kg (55%) - 40mm
20 140 7 280 760 1200 330 kg (28%) - 20mm
40 25 140 7.5 300 730 1200 210 kg (17%) - 10mm
30 140 8.5 340 700 1200
40 150 10 400 650 1200 1200 kg (100%)
50 150 12 480 580 1200
15 170 7 280 860 1000 700 kg (70%) - 40mm
20 170 8 320 830 1000 300 kg (30%) - 40mm
20 25 170 9 360 790 1000
30 170 10 400 760 1000
40 170 12 480 680 1000 1000 kg (100%)
50 180 14 560 610 1000
15 180 8 320 940 800
20 190 9 360 900 800
25 190 10 400 870 800
10 30 190 11 440 840 800
40 190 13 520 770 800
50 190 15 600 690 800
CONCRETE
 Labour
 The cost of labour will vary depending on the method selected to supply the concrete.
 The labour involved for the supply of three methods are :
 Hand mixed – very high labour contents
 Machine mixed – considerably reduced labour content
 Ready mix – no labour content
 There is a considerable reduction in the labour required for placing and finishing for ready
mixed concrete than other type concretes. This is because it comes in large quantities and the
method if placing is not labour intensive ( conveyor. Off truck, by pump or from crane).
 For hand and machine mix concrete, the estimator need to calculate the size of gang to be
used. A typical gang for a 0.12 m3 mixer on foundation work would be four people involved in
mixing, transporting and placing concrete.
 For RMC, the concrete can either be placed by the formwork subcontractor’s gang or
sometimes a specialist concrete place and finish subcontractor is used, particularly on a large
project.
 Some of the variables that will affect the size of the gang to be used are
 Quantity of work at a time
 Continuity of work
 Method of transportation of concrete (crane / hoist or barrow)
CONCRETE
 Plant
 Concrete mixers
 Machine mixing is more economical than hand mixing and it gives more consistent
results.
 From the various sizes and types of concrete mixers in the market, the estimator need to
select the correct one on which to base the pricing. It must have the capacity to
accommodate the peak outputs required by the contract programme but must not be so
big as to be idle for most of its time.

Mixer size in m3 Output per hour m3 Labourers required to operate


0.06 0.6 1
0.12 1.20 2
0.14 1.40 2
CONCRETE
 Plant
 Concrete Pumps
 Concrete pumps are capable of pumping large quantities of concrete per hour and thus are suited to
large projects.
 Maximum output may be as high as 1 m3 per minute but an average of 20m3 per hour is more
reasonable. This is because the pumps require feeding and the concrete requires working into final
position.
 Feeding concrete into position by pumps will reduce labour costs for handling and placing concrete. The
cost of hiring should be compared against labour and time saving.
 When pumped concrete is used, a reduction in the labour constant must be made to allow for the
reduction of handling concrete prior to final placing and vibrating.
 Hire charges of concrete pumps are usually built-up from 3 factors.
 Set up cost
 Hourly hire rate of the pump
 Pumping charges per cubic metre
 There may be a minimum hire time, for example, 3 hours minimum before mid – day.
CONCRETE
 Plant
 Concrete Pumps
 Example
 Calculate approximate cost per m3 using hire rates of a boom pump assuming a 3 hour hire time is
acceptable.
 Assume the following
Set up cost = $ 120.00
Hire rate per hour= $ 135.00
Pumping @ $ 5.50 / m3
Output per hour - 20 m3
CONCRETE
 Plant
 Concrete Pumps
 Example
 Calculate approximate cost per m3 using hire rates of a boom pump assuming a 3 hour hire time is
acceptable.
 Hourly cost ($)

Set up cost = 120$ / 3 hours = 40.00


Hire rate per hour = 135.00
Pumping @ $ 5.50 / m3 x 20 (output / hour) = 110.00
Rate per 20 m3 = $285.00

Rate / m3 = $14.25
CONCRETE
 Plant
 Concrete Pumps
 Example
 Let us assume the same example but assume pump can only be used for 1 hour but minimum hire is for 3
hours.
 Assume the following
Set up cost = 120.00
Hire rate per hour @ $135.00
Pumping @ $ 5.50 / m3
Output per hour - 20 m3
CONCRETE
 Plant
 Concrete Pumps
 Example
 Let us assume the same example but assume pump can only be used for 1 hour
 Hourly cost ($)

Set up cost = 120.00


Hire rate minimum 3 hours @ 135 = 405.00
Pumping @ $ 5.50 / m3 x 20 (output / hour) = 110.00
Rate per 20 m3 = $635.00

Rate / m3 = $31.75
CONCRETE
 Plant
 Concrete Pumps
 From these examples, it is easy to understand that how important is to evaluate the actual
cost against possible savings in labour and time.
 Possible extra allowances to make, if using a concrete pump are as follows:
 Often a small amount of very fine concrete slurry is pumped through the pipe to line the sides of it to
make it smooth. Therefore the estimator need to allow for this ( often 0.4 m3 used) every time the
pump is used.
 On a large project such as multi-storey building, a pump can be set up on a permanent basis and
sections of steel pipes are added as each floor proceeds. For this allow costs such as erect and
dismantle of pipe, hire of pipe sections and cost of fixings for holding in position.
 If a pump is the main source of delivering the concrete to its position, it may mean that a pump is
hired on a weekly / monthly basis. This means that the estimator need to allow a location on the site.
And if it is an inner city office tower project, then this may mean paying for parking spaces on the
street for the duration. Also need to include the cost of getting the pump to and from site.
CONCRETE
 Plant
 Hoists and tower cranes
 In pricing for multi storey structures, the cost of tower cranes and hoists for lifting the concrete is
generally included in P & G section.
 The crane is usually used to lift many different materials, and it serves little purpose to allocate crane time
to each item. The total cost of hoisting equipment is therefore calculated and included in P & G as lump
sum.
 Vibrators
 In pricing reinforced concrete, the estimator must make allowance for the cost of needle vibrator to obtain
full consolidation of the concrete. There is no additional labour cost in that the placers operate as
vibrators as part of their duties. The cost of vibrators usually included in your rate build – up as a hire
charge.
CONCRETE
 Following items must be considered by an estimator before preparing the unit rate
of Concrete. These are the principal items that can affect unit rates for mixing and
placing concrete
 For site-mixed concrete
 The position of the mixing plant, or plants, in relation to the areas and quantities of concrete
to be placed. This will determine the distance that the mixed concrete has to be carted. This is
best done by plotting the mixing plant on the site layout, taking into account the access on to
the site, the transporting of the material to the mixing plant, and the transportation of the
mixed concrete.
 The type and size of mixer to be used. Mixers can be loaded mechanically, by hand or by
means of overhead hoppers and gravity feed. The size of the mixer will depend largely upon
the output required.
 The method of transporting the mixed concrete over the site. If the concrete has to be carted
long distances, trucks or dumpers should be used, taking care when setting up the mixing
plant to ensure that the mixer will discharge into the truck or dumper. Where short distances
are involved and open trenches have to be crossed, barrows are often cheaper.
CONCRETE
 For site-mixed concrete (contd…)
 Whether bag or bulk cement is to be used. On smaller concreting jobs, cement in bags is
more convenient than bulk cement and a silo. It is, however, more expensive than bulk
cement, and it needs to be unloaded by hand and carefully stored. Bulk cement is stored on
the site in cement silos, which are usually placed next to the concrete mixer. Silos have their
own weigh batcher, which means that the cement can be weighed out to the amount
required and discharged straight into the loading hopper of the mixer.
 The percentage allowances for voids in the aggregates. The fine aggregate and cement are
mixed together to form the matrix, which fills the voids in the coarse aggregate and binds it
together. The percentage of voids in concrete varies with the different sizes and types of
aggregate, and tests must be done to find the percentage required for any particular
aggregate and mix. Concrete that has been thoroughly vibrated when placed has less voids in
it than concrete that has not been so well vibrated. The percentage addition for voids to be
added to normal concrete mixes varies between 40% and 55%. It is usual to allow 50% for
voids. With cement and builder's mix, allow 33.33 % unless the specified mixes allow for voids
and the quantities given are for 1 cubic metre of wet concrete
CONCRETE
 For ready-mixed concrete
 Estimator should compare the cost of ready-mixed concrete versus site-mixed concrete.
Quality control of site-mixed concrete is a significant factor in any comparison. Availability,
location, site layout and conditions, grade of concrete produced by ready mix plant, and
programme restrictions of volume within certain time limits, may also have a bearing on
whether to use ready-mixed concrete.
 Pumped concrete uses smaller, round (or uncrushed) aggregate and higher cement ratio and
additives to reduce the chance of pump blockage. This special mix is slightly more expensive
than standard ready mix.
 As ready-mixed concrete is delivered in loads by the loose cubic metre, allowance has to be
made for consolidation, shrinkage, waste and spillage.
 Ready-mix concrete has a minimum order delivery of around 0.4 m3, and also, under another
value (around 1 m3), they may also apply a small load charge. Pricing unit rates for small
quantities will need to reflect this.
CONCRETE
 For site – mixed and ready-mixed concrete
 The method of hoisting or pumping, placing and compacting the concrete. Multi-storey,
reinforced concrete buildings are suited to hoisting and placing of concrete by means of a
tower crane, a mobile crane, or a concrete pump. The mixer or concrete truck must be sited
where it can discharge directly into a skip or concrete pump. Compacting of concrete is
usually done with immersion vibrators.
 Use of a concrete pump is an efficient and quick method of dealing with large quantities of
concrete, especially where the finished work is not easily accessible with wheelbarrows or
skips. Concrete pump hire arrangements include the costs of skilled operators.
 Estimator need to allow a small percentage for waste. For site-mixed concrete, this covers loss
of aggregates in mixing and for both site and ready-mixed concrete in penetrations and
spillage. Also for consideration is what the concrete is being poured against (for example,
formwork or natural ground), formwork tolerances and deflection, testing and samples. These
waste factors are offset to a degree by non-deductible voids and reinforcing steel
displacement.
CONCRETE
 Common waste factors for ready-mixed concrete are
 against ground 5-10%
 slabs 2 ½ -5%
 columns and beams 2 ½ %
 For site-mixed concrete, allow up to 2 ½ % more to each.
 The cost of any precautions that have to be taken such as protection and curing of the placed
concrete. The curing process can involve keeping the concrete continuously damp for days.
 On large inner city projects, there may also be the cost of a cleaning down station so the
concrete trucks leaving the site do not make a mess on the road.
 In extreme hot or cold weather, the concrete needs protection or additives to help prevent
over drying or freezing before setting.
 The cleaning of surfaces splattered by concrete, particularly when a skip is used, may also be
a cost factor.
CONCRETE
 The following three calculations show the supply cost of 15 MPa concrete mixed by
the three different methods.
 Hand-mixed 15 MPa, 20 mm aggregate mix
 Consider the Volume table
 Material
 Cement rate per bag (40kg) - $10.50
 Delivery rate @ $12.00 per tonne
 Unloading rate - $16.50 per hour ( 1 hour per tonne)
 Coarse Aggregate - @ $22.00 / m3
 Fine aggregate -@ 31.00/ m3
 Delivery of aggregates @ $8.00/ m3
 Waste 5%
 Labour
 Labour required 5 hrs/m3
 Labour rate - $20.00/h
 Plant
Shovel nominal allowance @$0.50
CONCRETE
 The following three calculations show the supply cost of 15 MPa concrete mixed by the three different
methods.
 Hand-mixed 15 MPa, 20 mm aggregate mix
Materials
Cement 7 bags (40 kg) @ 10.50 73.50
Delivery 280 kg @ 12.00/t 3.36
Unloading 280 kg @ 1 hour/t @ 16.50 4.62

Coarse aggregate 0.7 m3 @ $22.00 / m3 15.40


Fine aggregate 0.7 m3 @ 31.00/ m3 21.70
Delivery of aggregates 1.4 m3 @ $8.00/ m3 11.20
129.78
Waste 5% 6.49
136.27
Labour
5 hrs/m3@ $20.00/h 100.00
Plant
Shovel nominal allowance 0.50
Cost / m3 $236.77
CONCRETE
 Machine-mixed 15 MPa, a 20 mm aggregate mix. (Using 0.14 m3 mixer, 2 labourers in attendance )
Materials
From previous example 136.27
Labour
2 people attending produce 1.4 m3 /h
Labour rate per person @ $20.00/hr
Plant
Mixer per day @$46.00
Fuel per day @$8.00
Shovels per day @$0.50
Delivery and collection $10
Assume 5 days
What is the Cost / m3 of concrete?
CONCRETE
 Machine-mixed 15 MPa, a 20 mm aggregate mix. (Using 0.14 m3 mixer, 2 labourers in attendance )
Materials
From previous example 136.27
Labour
2 people attending produce 1.4 m3 /h
2/1.4 hrs / m3 @ $20.00/hr 28.57
Plant
Mixer per day 46.00
Fuel per day 8.00
Shovels per day 0.50
Delivery and collection $10
Assume 5 days, use -10/5 2.00
56.50/day
Output per 7 hour day = 7 x 1.4 m3 / day = 9.8 m3 / day
Therefore, $56.50/9.8 = 5.77

Cost / m3 $170.61
CONCRETE
 15 MPa Ready – mixed concrete delivered to site per m3 $150.00
 Waste 2.5% $3.75
Cost / m3 $153.75

 Hand – mixed concrete $ 236.77


 Machine – mixed concrete $ 170.61
 Ready – mixed concrete $ 153.75

(all prices are excluding placing the concrete)


CONCRETE
 The following is an example of fully worked pricing for calculating unit rate of supply and placing of hand-
mixed concrete.
 25 MPa concrete in reinforced 100mm suspended slab 120 m3
Assume that we are mixing the concrete on site using a 0.14 m3 mixer with an output of 1.4 m3 per hour and barrowing the concrete into position. Assume a 9
hour day with 8 hours production and 1 hour cleaning up. For this operation, six workers are likely to be required. The specification calls for weight batching of
materials using 20 mm maximum aggregate. Weight proportions are taken from the Table shown before.
Materials
Cement bag (40 kg) @ $10.50
Delivery @ $12.00/t
Unloading 1 hour/t @ $16.50
Coarse aggregate @ $25.00 / m3
Fine aggregate @ $35.00 / m3
Delivery of aggregates @ $8.00/ m3
Waste 5%
Labour
Mixing concrete — 2 labourers @$20.00/hr
Place — 3.0 hrs/m3 @$20.00/hr
Finish - power float 0.15 hrs/m2 @$20.00/hr
Cleaning @$20.00/hr
Plant
Mixer per day @$46.00
Fuel per day @$8.00
Shovels and barrows per day @$3.50
Vibrator @$50.00
Delivery and collection @$10 (Assume 5 days)
CONCRETE
 The following is an example of fully worked pricing for calculating unit rate of supply and
placing of hand-mixed concrete.
 25 MPa concrete in reinforced 100mm suspended slab 120 m3
Assume that we are mixing the concrete on site using a 0.14 m3 mixer with an output of 1.4 m3 per hour and
barrowing the concrete into position. Assume a 9 hour day with 8 hours production and 1 hour cleaning up. For this
operation, six workers are likely to be required. The specification calls for weight batching of materials using 20 mm
maximum aggregate. Weight proportions are taken from the Table shown before.
Materials
Cement 9 bags (40 kg) @ 10.50 94.50
Delivery 360 kg @ 12.00/t 4.32
Unloading 360 kg @ 1 hour/t @ 16.50 5.94
Coarse aggregate 1000 kg @ 1670 kg/ m3
0.60 m3 @ $25.00 / m3 15.00
Fine aggregate 790 kg@ 1750 kg/ m3
0.45 m3 @ $35.00 / m3 15.75
Delivery of aggregates 1.05 m3 @ $8.00/ m3 8.40
143.91
Waste 5% 7.20
151.11
CONCRETE
Labour
Mix concrete — 2 labourers x 8 hrs x $20.00/hr 28.57
11.20 /day
Place — 3.0 hrs/m3 $20.00 60.00
Finish - power float 0.15 hrs/m2
(100 mm thick slab = 10 m2/m3)
0.15 x 10 x $20.00/hr 30.00
Cleaning @$20.00 per day 1.78
120.35
Plant
Mixer per day 46.00
Fuel per day 8.00
Shovels and barrows per day 3.50
Vibrator 50.00
Delivery and collection $10
Assume 5 days, use -10/5 2.00
109.50/day
Output per 8 hour day = 8 x 1.4 m3 / day = 11.2 m3 / day
Therefore, $109.5/11.2 plant cost per m3 = 9.77

Cost / m3 $281.23
THANKS!!!

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