8

- D

- i APPENDIX 8

- D

. INSTALLATION COST DE TERMINATION FOR BOILERS

TABLE OF CO NTENTS

8

- D.1 INTRODUCTION

................................ ................................ ................................ 8

- D

- 1
8

- D.2 INSTALLATION COST ME THODOLOGY

................................ ...................... 8

- D

- 2
8

- D.2.1 Introduction

................................ ................................ ................................ ........... 8

- D

- 2
8

- D.2.2 New Construction and Repl acement Market Shares.

................................ ........... 8

- D

- 2
8

- D.2.3 Basic Installation Costs

................................ ................................ ......................... 8

- D

- 3
8

- D.2.4 Venting

................................ ................................ ................................ .................. 8

- D

- 3
8

- D.2.4.1 Replacement Installations

................................ ............................. 8

- D

- 5
8

- D.2.4.2 Stainl ess Steel Venting

................................ ................................ . 8

- D

- 8
8

- D.2.4.3 New Construction Installations

................................ ................... 8

- D

- 11
8

- D.2.5 Condensate Removal for Condensing Boilers

................................ .................... 8

- D

- 11
8

- D.3 RS MEANS 2013 REGION AL LABOR COSTS

................................ .............. 8

- D

- 12

LIST OF TABLES

Table 8

- D.1.1 Example Installation Cost Table

................................ ................................ 8

- D

- 1
Table 8

- D.2.1 Boiler Installation Locations

................................ ................................ ...... 8

- D

- 3
Table 8

- D.2.2 Fraction of Existing Masonry Chimney Installations

................................ 8

- D

- 6
Table 8

- D.2.3 Fraction of Commonly Vented Boiler and Water Heater Installations

...... 8

- D

- 6
Table 8

- D.2.4 Non

- Condensing to Non

- Condensing Venting Issues, Fraction Impacted, and Average Installation Cost

................................ ................... 8

- D

- 8
Table 8

- D.2.5 Stainless Steel Venting Installation Fractions by AFUE level

.................. 8

- D

- 9
Table 8

- D.2.6 Fraction of Direct Vent Condensing Boiler Installations

........................ 8

- D

- 10
Table 8

- D.2.7 Non

- Condensing to Condensing Venting Issues

................................ ..... 8

- D

- 11
Table 8

- D.2.8 Installati on Fractions for Condensate Removal

................................ ....... 8

- D

- 12
Table 8

- D.3.1 RS Means 2013 National Average Labor Costs by Crew

........................ 8

- D

- 13
Table 8

- D.3.2 RS Means Labor Costs Markups by Trade (Residential)

........................ 8

- D

- 13
Table 8

- D.3.3 Material and Labor Cost Factors by Geographical Area (for RECS 2009 Sample)

................................ ................................ ........................... 8

- D

- 14
Table 8

- D.3.4 Material and Labor Cost Factors by Census Division (for CBECS 2003 Sample)

................................ ................................ ................................ .... 8

- D

- 15

LIST OF FIGURES

Figure 8

- D.2.1 Masonry Chimney Venting Installation (Non

- Condensing Boiler)

........... 8

- D

- 4 Figure 8

- D.2.2 Metal Venting Installation (Non

- Condensing Boiler)

............................... 8

- D

- 5 Figure 8

- D.2.3 Plastic PVC Installation (Condensing Boiler)

................................ ........... 8

- D

- 58

- D

- 1 APPENDIX 8

- D. INSTALLATION COST DE TERMINATION FOR BOILERS

8

- D.1 IN TRODUCTION

This appendix provides further details about the derivation of installation cost s for
boilers

. The installation cost is the price to the consumer of labor and materials (other than the cost of the actual product) needed to install a boiler product.

The Department of Energy (DOE) estimated installation costs for boil er s based on RS Means, a well

- known and respected construction cost estimation method , as well as
manufacturer literature and info rmation from expert consultants. Table 8

- D.1.1 offers an example of the installation cost calculation. All labor costs are derived using the latest residential

201 3 RS Means labor costs by crew type. 1 Replacement inst allation cost tables include a trip charge

, which is often charged by contractors and calculated to be equal to one half hour of labor per crew member. Labor hours (or person

- hours) are based on RS Means data, expert data, or engineering judgment. Bare c os ts are all the costs without any markups. Material costs are based on RS Means data, expert data, or internet sources. The total includes overhead and profit (O&P), which is calculated using labor and material markups from RS Means. Values reported in
this appendix are based on national average labor costs. The labor costs shown in the tables in this appendix are the national average values. In its analysis, DOE used regional labor costs to more accurately estimate installation costs by region. Section 8

- D.3 describes the derivation of regional labor costs. DOE then applied the appropriate regional labor cost to each RECS sample
household. The total costs include O&P. (Note that the unit “L.F.” in the tables means “linear foot.”)

Table 8

- D.1.1 Example Installation Cost Table

Description Crew Labor

Hours Unit Bare Costs ( 2009$ ) Quantity Total
incl.

O&P Material Labor Total

Trip Charge CREW1 0.5

- 0.00 23.00 23.00 1 35.00
Description of Installation Item CREW1 0.5 Ea. 15.00 23.00 48.00 1 51.50

Total 1.0 15.00 46.00 71.00 86.50

The installation cost calculations for boiler s encompass a broad array of product classes, installation sizes, and venting configurations , including :

• gas

- fired boiler s, oil

- fired boilers, and electric boilers ;

• n ew and replacement markets ;

• s ingle

- family

, multi

- family , and commercial buildings ;

• v enting systems that are C ategor y I (non

- condensing), Category III (stainless vents), and Category IV (condensing) ;

• various v ents , such as m asonry chimneys , metal vent

, stainless steel vents, or plastic ( polyvinylchloride ( PVC ) ) ;8

- D

- 2 • s ingle

- wall or double

- wall vent connectors;

• g as or o il w ater h eater s that are either v ented in common w ith a boiler or isolated ; and

• s pecia l situations , such as the need to reline a c himney or vent an orphaned water heater

.

Applying the RS Means methodology to a boiler i nstallation requires knowledge of its
detail s , including the vent length, venting material, vent type, diameter, number of elbows, etc. To estimate these quantities, DOE reviewed relevant literature, data, and installation manuals.
Each estimate was a dist ribution of values derived from available data ; a Crystal Ball Monte
Carlo simulation a was used to model the resultant costs for each individual household

.

8

- D.2 INSTALLATION COST ME THODOLOGY

8

- D.2.1 Introduction

DOE developed i nstallation cost data for boiler s using RS Means cost data , DOE

te chnical support documents, and consultant report s prepared for this analysis. 2, 3

, 4,5,6 The
installation cost wa s divided into the following four components:

• b asic i nstallation

,

• v enting

,

• c ondensate r emoval , and

The following information about market shares

, technologies, and installation location helped to shape the installation cost calculations.

8

- D.2.2 New Construction and Replacement Market Shares.

As determined in the shipment analysis portion of the national impact analysis ( NIA ) (see Chapter 9), f or gas

- fired hot water boiler s , approximately 2 0 % of the market will be new construction and 80 % will be replacement s in 20 20

.

Boiler Technologies. There are two main boiler designs : non

- condensing and condensing. Almost all of the non

- condensing boiler s have an annual fuel u tili zation e fficiency ( AFUE ) of 8 2 % , which represents the analysis baseline. Condensing boiler s have a n AFUE of

90 % or greater. N on

- condensing boiler s usually use Category I venting system s, while condensing boiler s are vented using Category IV venting systems. A Category I venting system
relies on negative pressure and uses either a masonry chimney or a metal vent. A Category I V venting system uses positive pressure and a plastic (PVC) vent.

a See Chapter 8 for a description of the Monte Carlo simulation methodology.8

- D

- 3 Installation Location s. Table 8

- D.2.1 shows the fraction of installations by installation
location. The installation fractions are derived using RECS 2009 household characteristics
toge ther with the following assumptions: 7

1) If a household has a basement

, b then the boiler is installed in the basement

. 2) If the household has a garage , then the boiler is installed in the garage. 3) If the household has neither a basement nor garage, the n it is assumed that the boiler is
installed in a location classified as “other”. c

Table 8

- D.2.1 Boiler Installation Locations

Boiler Location Gas Boilers Oil Boilers Basement (Conditioned) 35% 40% Basement (Unconditioned) 27% 49% Garage 8% 4%
Other Locations 30% 7%

For residential boilers installed in commercial buildings, DOE assumed that 40 percent of the time they would be installed in a basement, 20 percent in an indoor location, and 40 percent in an equipment room.

8

- D.2.3 Basic Installation Costs

For gas

- fired boilers , DOE estimated basic installation costs that are applicable to both replacement and new home installations. These costs, which apply to both condensing and non

condensing gas boilers , include putting in place and setting up the boiler , gas piping, water piping, electrical hookup for the thermostat, permit, and removal or disposal fees.

8

- D.2.4 Venting

Estimating v enting costs is complex

, because there are a large variety of installation
scenarios that are possible. DOE calculated venting costs for each household in the RECS boiler sample. To determine venting costs for both new construction and replacement installations,
DOE used a number of parameters that have an impact on the venting installation cost , including

v ent location, installation type (replacement or new construction) , vent s (metal or plastic)

, vent
connectors, and chimney type

.

Non

- condensing boilers exhaust high

- temperature flue gas, which heats the inside of the vent above the dew point to ensure tha t water vapor in the flue gas does not condense; if it does
condense and does n o t re

- evaporate quickly during the boiler firing cycle, it could corrode the

b DOE intends to distinguish between conditioned and unconditioned basements when deriving the annual energy use of a particular household.

c “Other” locations include indoor closets, utility rooms, and exterior closets.8

- D

- 4 ent

, the boiler heat exchanger, or both, thus reducing the lifetime of the vent system or the boiler
itself

. T ypically a small amount of condensate at cold startup is acceptable as long as it dries out quickly. More efficient low

- temperature condensing boiler s condense the water vapor in the primary or a secondary heat exchanger, thus increasing boiler e fficiency by reducing latent heat
loss. The condensate is fed to a drain. Because t he flue gas temperature is relatively low, condensing boiler s can be vented through PVC piping.

Masonry chimneys, metal vents, and PVC piping are the most common venting
assemblies . Details of these types of installation follow.

Masonry Chimney

. Some non

- condensing boiler s are vented using masonry chimneys

, either lined or unlined. Figure 8

- D .2.1 shows a lined masonry chimney venting a non

- condensing boiler
and a water he ater. For unlined chimneys, the flexible liner shown is not present, and a clay tile
liner is used instead

. Since the 1970s chimney construction techniques have changed. For newer chimneys, the chimney and clay tile liner is usually replaced by a masonry f acade on the exterior
that covers a wooden chase with a flexible metal liner on the interior

. ( T hese are faster to build compared to brick by brick

. ) If the water heater is isolated d , the common water heater vent
shown in Figure 8

- D .2.1 would not be presen t.

Figure 8

- D.2.1 Masonry Chimney Venting Installation (Non

Condensing Boiler )

Metal Vents

. Some non

- condensing boiler s are vented using metal vents

, either single wall or Type B double wall. Figure 8

- D .2.2 shows a Type B double

- wall metal vent. The combination of wall thimbles, storm collar, and flashing replace the chimney. Most metal vents go straight through the roof. If the water heater is isolated, the common water heater vent shown w ould not be present.

d There are a number of water heater types that would not be vented in common with a boiler. These include electric, gas direct side

- vented, and gas power

- vented water heaters. In this appendix, the term “isolated” water heater is defined to include all of these possibilities, but only the most prevalent (more than 90%) option

– electric water
heaters

– is modeled. Boiler8

- D

- 5 Figure 8

- D.2.2 Metal Venting Installation (Non

- Condensing Boiler )

Plastic PVC

. All condensing boiler s are vented using PVC vents

, either horizontal or vertical. Figure 8

- D .2.3 shows a horizontal side

- wall plastic vent. T he boiler installation shown below
utilizes a two

- plastic

- pipe venting system. One of the v ents exhaust s the flue gases and the other brings combustion air from the outside to th e boiler

. Flue gas piping is sloped downward toward
the boiler so that condensate drips back into the boiler condensate drain. T his installation
includes a gas water heater (analogous to the common vented scenario above), which requires a separate flue gas exhaus t vent

. If the water heater is isolated , this exhaust vent will not be
present.

Figure 8

- D.2.3 Plastic PVC Installation (C ondensing Boiler )

8

- D.2.4.1 Replacement Installations

For replacements

, DOE eval uated two cases

. One involves switching from a non

c ond ensing natural draft boiler ( less than 75% AFUE) to a n on

- condensing fan

- assisted boiler Boiler

Boiler8

- D

- 6 ( 8 2 % AFUE) and the other involves switching from a non

- c ond ensing ( natural draft and fan

assisted) to a c ond ensing boiler (90% or greater AFUE)

.

Table 8

- D .2. 2 provides the fraction of existing masonry chimneys and metal vent installations by region used in the analysis , based on the 199 4 GR I Furnace Survey

. 8 DOE assumes that this data these fractions are applicable to boilers.

Table 8

- D.2.2 Fraction of Existing Masonry Chimney Installations

Venting Type North South

Masonry 7 1.8 % 1 6.4 %

Metal Vent 28 .2 % 8 3.6 %

Table 8

- D .2. 3 provides the fraction of existing non

- condensing installations that are commonly vented with gas water heaters, based on the 199 1 GTI Water Heater Survey. 9

Table 8

- D.2.3 Fraction of Commonly Vented Boiler and Water Heater Installations

Common Venting Northeast Midwest South W est

Common 78% 68% 22% 65%

Isolated 22% 32% 78% 35%

8

-

D.2.4.1.2 Non

- Cond ensing to Non

- Condensing Boiler Installations

Many non

- condensing to non

- condensing boiler replacement installations require venting modifications to meet current safety requirements

. There are two main issues that can arise when replacing a non

- condensing boiler with a more efficient non

- condensing boiler : relining an unlined chimney and resizing an existing venting system.

Chimney Relining

There are two types of masonry chimney

— interior and exterior. Exterior chimneys are usually exposed on three sides; they are less insulated by the structure, lowering the internal temperature and making it more likely that exhaust gases will condense inside

. Interior chimneys

are s urrou nded by the heated building ; the temperature in the chimney tends to be higher , making
flue gases less likely to condense. Because of these different insulating properties, the National Fuel Gas Code (NFGC) 10 has different lining requirements for interior and exterior chimneys

. These requirements are important

, because the cost of chimney relining is a major component of

a boiler installation cost.

Exterior Chimneys

. In Table 13.11 of the Code, 10 the minimum allowable input rating for appliances that are vented in exterior masonry chimneys is 150 kB t u /hour

. This rating is close to8

- D

- 7 the representative input capacity for residential boiler s assumed in this analysis . Therefore,

DOE ’s analysis assumes that all exterior lined chimneys will require a re

- lining upon replacement.

Interior Chimneys . T he NFGC mandate s that all interior chimneys be relined when the

boiler is isolated from the water heater (NFGC Tables 13.3 and 13.4)

. 10 When a boiler is vented

in common with a water heater

, the vertical vent upsizing / 7X rule applies. This rule specifies that the flow area of the vertical vent shall not exceed seven times (7X) the flow area of the
smallest vent connector

— the vent connector for the water heater , fo r example

. Water heater vents are typically 3 inches in diameter, so an interior masonry chimney cannot exceed 49 square inches, corresponding to a n 8 x 8 nominal chimney liner size. DOE assumed that all interior chimneys would need to be relined

, if built before 199 5 and if the existing boiler is a natural
draft boiler

.

DOE determined which boiler installations of the entire boiler sample would require chimney relining

, based on RECS 200 9 equipment age data and the fraction of chimney installations (see Table 8

- D .2.3)

. For each bin DOE assigned an equipment installation year using a uniform distribution with the ranges shown in the table. Finally, using the fraction of chimney installation s shown in Table 8

- D .2.3, DOE determined if the household had a chi mney installation. To determine if a household had a n unlined chimney

, DOE used the following two criteria:

1) Boiler exhaust gases are vented through a chimney

. 2) The e xisting boiler was installed before 199 5 when building codes requiring the relining of chimneys w ere not yet in place

.

Based on these criteria, DOE calculated that about one

- quarter of households in the

RECS 2009 sample had a n unlined chimney. DOE determined that half of these would be relined already by 20 20 , based on boiler equipment retirements from 200 9 to 20 20

. ( B y 20 20 the existing boiler s that would require relining would be 2 5 years old or older). Therefore, t he analysis resulted in 10 % of the stock need ing to be relined in 20 20

.

Vent Resizing

Vent resizing occurs when the existing vent diameter is too large for the new gas boiler or for the commonly vented boiler and gas water heater. Two solutions are possible: 1) vent connector resizing (most common) or 2) vent resizing (less commo n). There are three main types
of vent connectors: Type B double wall, single

- wall gal vanized steel, and single

- wall aluminum.
A double

- wall vent uses a galvanized steel outer tube to surround an aluminum inner tube and is sold in multiple section lengths

. T he air gap in between the tubes provides insulation , which
reduces the likelihood of condensation in the vent connector. A s ingle

- wall galvanized steel vent is simply a zinc

- coated steel tube vent. Aluminum single

- wall vent connectors are similar to galv anized steel single

- wall vent s and are found in some regions. C ondensing boiler s do not require metal vent connector s

.8

- D

- 8 The vent connector portion of the vent is the horizontal part of the masonry and metal
vent systems shown in Figure 8

- D .2.1 and Figure 8

- D .2.2, respectively

. In each figure there are
two vent connectors shown: one for the water heater, and one for the boiler

. As water heater capacity is typically less than boiler capacity, in many cases the water heater vent conn ector diameter will be les s than the boiler vent connector diameter. DOE assumes that the boiler
diameter is 4 inches on average, while the water heater vent connector is 3 inches on average.

For this analysis, DOE assumed that vent resizing occurs only when a non

- condensing
fan

- assisted boiler ( an AFUE of 8 2 % or greater for gas

- fired hot water boilers ) replaces a natural
draft non

- condensing boiler ( an AFUE of less than 7 5%). Although fan

- assisted boiler s have been the only installed non

- condensing designs since the early 1990s, there is still a fraction of
the stock that includes natural draft non

- condensing boiler s , b ased on RECS 2009 equipment

age

.

Table 8

- D .2. 4 summarizes the three different venting issues associated with non

condensing boiler s

.

Table 8

- D.2.4 Non

- Condensing to Non

- Condensing Venting Issues, Fraction Impacted
, and Average Installation Cost

Existing
Boiler Replacement
Boiler Installation Requirement Frequency

Chimney
installed
before 1990 82% AFUE Relining all unlined chimneys 100%

Natural
Draft 80 % AFUE Installing New Vent

Connectors (Converting from single

- wall to Type B
double

- wall) 75%

Natural
Draft 80% AFUE Resizing Vent System 10%

8

- D.2.4.2 Stainless Steel Venting

DOE considered the additional v enting cost associated with stainless steel venting for a
f rac tion of installations between 82 % AFUE and 8 6 % AFUE based on the fraction of models
with inducer or forced draft fans. Based on manufacturer installation manuals some of these boilers can be installed using stainless steel venting . DOE assumes that 50 percent of these models will be installed using stainless steel venting. Table 8

- D .2.5 shows the fractions used in the analysis . For the fraction of i nstallations at 82 % to 86% AFUE that are already part of the base case, DOE assumed that no stainless steel vent is required.8

- D

- 9 Table 8

- D.2.5 Stainless Steel Venting Installation Fractions by AFUE level

Efficiency,
AFUE Gas

- fired Hot
Water Boiler Gas

- fired Steam
Boiler Oil

- fired Hot
Water Boiler Oil

- fired Steam
Boiler

82% 11 % 3% NA 9%

83% 18 % 6% NA NA

84% 18 % NA 15% 9%

85% 32 % NA 26% 11%

86% NA NA 32% 11%

8

-

D.2.4.2.2 Non

- Condensing to Condensing

The standard cases that DOE considered in the analysis represent condensing boiler designs at 90% AFUE or greater

. DOE’s analysis assumes that the venting requirements would
be the same when replacing an existing condensing boiler with another condensing boiler

.

DOE estimated that nationally in 20 20

, a growing number of replace ment installation s would be from non

- condensing to condensing boiler s

. T he next four sections explain the changes to the venting systems that would be required when installing condensing boiler s and provide
information about the frac tions of impacted installations. The sections address the following four
installation issues :

• condensing flue vent (PVC) ;

• combustion air vent;

• concealing vents in indoor installations ; and

• i nstallation with o rphaned water heaters

.

Condensing Flue Vent (PVC)

When replacing an existing non

- condensing boiler with a condensing boiler , the existing metal vent is replaced with a plastic (PVC) flue vent. The installation cost of the condensing
boiler flue vent takes into account the following:

• boiler location;

• house ceiling height and number of floors (determined for each boiler househ old in
RECS 200 9 sample ) ;

• boiler distance from wall or roof , and whether to install a vertical vent (through the roof)

or a horizontal vent (through the wall) ; and

• wall type , which determine s the cost of penetrati n g the wall.8

- D

- 10 Combustion Air Vent (PVC)

A fraction of the condensing boiler installations are direct

- vent installations, which uses

c ombustion air s upp lied from the outdoor air

. F or each household in the RECS 2005 sample

DOE considered the following factors when calculat ing the installation cost of the combustion air vent for condensing boiler s in the replacement market:

• vent length , which is the same as flue pipe length ; and

• vent installation fraction , which depen ds on the installation location

.

Table 8

- D .2. 6 shows the fraction of direct vent installations by installation location,
based on the consultant r eport in section 8

- D .6. As show n in the table

, nationally about 6 2.1 % of the condensing boiler installations are d irect vent

. The fraction s of direct

- vent con densing boiler
installations for the North and South regions are also shown in the table.

Table 8

- D.2.6 Fraction of Direct Vent Condensing Boiler Installations

ID Installation Location Fraction of
Direct Vent
Installations

1 Basement (Conditioned) 50 %

4 Garage 90 %

5 Indoor (Closet, Alcove, Utility Room) 60 %

Concealing Vent Pipes

For a fraction of indoor installations, DOE added an installation cost to conceal the PVC
vent p ipes

— putting in place structures to mask vents that pass through the living space . DOE
assumed that half of the indoor horizontally ven ted condensing boiler installations would require
such modifications

.

Orphaned Water Heaters

– Chimney Relining and Vent Resizing

When a condensing boiler replaces an existing non

- condensing gas boiler that is commonly vented with a gas water heater , the water heater after the installation becomes “orphaned”. Many of these “orphaned water heaters” require venting modifications to meet safety requirements . S uch requirements include upgrading the ve nt connector, resizing m etal
vents, or m ason ry chimney relin ing

. DOE assumed that 100 % of the venting systems with existing natural draft boiler would need to have the vent connectors replaced for the orphaned
water heater , while an additional 4 0 % would need to have the entire venting system of the orphaned water heater resized or upgraded

. DOE assumed that all orphaned water heater chimneys would need to be relined if built before 1990 and if the existing boiler is a natural draft8

- D

- 11 boiler . DOE also assume d that 20 % of the venting systems with existing fan assisted non

condensing boiler would need to have the entire vent of the orphaned water heater resized or upgraded

.

Table 8

- D .2. 7 summarizes the four different scenarios that might be encountered in suc h replacement installations.

Table 8

- D.2.7 Non

- Condensing to Condensing Venting Issues

Existing Non

Condensing Boiler Replacement Installation Requirement Frequency of applying requirements

Natural Draft Condensing Convert Water Heater from single wall to B Type vent
Connector 100%

Natural Draft Condensing Resizing Orphaned Water Heater Chimney or upgrading Metal Vent 40%

Natural Draft Condensing Reline all unlined chimneys for Orphaned Water Heater 100%

Fan Assisted Condensing Resizing Orphaned Water Heater Chimney or upgrading Metal Vent 20%

8

- D.2.4.3 New Construction Installations

For boilers installation s in new construction, DOE accounted for the installation cost of a new venting system for both non

- condensing boilers (80% AFUE, baseline) and condensing
boilers (AFUE of 90% and greater , standard cases).

In the new construction cases, DOE also accounted for the install ation costs of commonly
vented boiler s (together with a water heater). When installing a condensing boiler in new
construction

, 100% of th e cost of the venting system is assigned to the orphaned water heater installation. When a commonly vented non

- condensing boiler and water heater are installed, then the venting cost is equally divided between the two appliances. Therefore, for commonly ve nted

non

- condensing boiler installations, DOE subtracted half of the venting system installation cost

, while in the condensing boiler installations with orphaned water heater s DOE added half of the

ven ting system installation cost of the orphaned water hea ter

.

8

- D.2.5 Conden sate R emoval for Condensing Boiler s

Condensate removal is required for all condensing boiler installations in both replacement and new construction cases

. DOE considered the following when assessing the cost
of condensate removal :8

- D

- 12 • Condensate Pipe: For condensing boiler s, excess condensate must be deposited in a
drain. Therefore, for all installations DOE applied the cost of adding condensate pipe (on average 15 feet)

.

• Condensate Pump : If a drain is not near, then the condensate must be pumped to a remote drain. If a central air

- conditioner is present

, then DOE assumes that already there is either a drain nearby or a pump already exis ts to remove the condensate from the air conditioner during the cooling season. DOE assumes that a condensate pum p is required for half of
the installations without a central air conditioner.

• Condensate Freeze Protection: If the condensate is exposed t o freezing temperatures

, then heat tape and pipe insulation is required

. DOE assumes that heat protection is required in all unconditioned attics.

• Drip Pan : S ome codes require a drip pan. DOE assumed that a drip is required for all
attic installations or boiler s installed in a 2 nd floor or above.

• Additional Electrical Outlet : DOE assumed that half of installations requiring a
condensate pump or heat tape would also require an additional electricity outlet. DOE
included this additional cost

.

Table 8

- D .2. 8 summarizes the condensate removal adders assoc iated with condensing
boiler s.

Table 8

- D.2.8 Installation F ractions for Condensate Removal

Installation Cost Description Criteria Frequency of applying
criteria

Pipe All installations 100%

Drip Pans Attics or higher floor
installations 0 %

Pump Installations without AC 25 %

Heat Tape and
Insulation Installations in
Unconditioned Attic 0 %

Electrical Outlet (additional) Installations requiring a Pump or Heat Tape 25 %

In addition to the installation costs, the e lectricity use of the pump and heat tape is taken into account (45 watts for Heat Tape and 60 watts for the condensate pump) in the energy use calculations (see c hapter 7).

8

- D.3 RS MEANS 201 3 REGIONAL LABOR COSTS

DOE used regional material and labor costs to more accurately estimate installation, maintenance, and repair costs by region. RS Means provides average national labor costs for different trade groups as shown in Table 8

- D.3.1

. Bare costs are given in RS Means, while labor8

- D

- 13 costs including overhead and profit (O&P) are the bare costs multiplied by the RS Means markups by trade shown in Table 8

- D.3.2

.

Table 8

- D.3.1 RS Means 20 13 National Average Labor Costs by Crew

Crew Type Crew Description Laborers per Crew Cost per Labor

- Hour

Bare Costs Incl. O&P*

Residential Labors Costs Q1 1 Plumber, 1 Plumber Apprentice 2 $ 42.65 $64.23

Q9 1 sheet metal worker, 1 sheet metal worker apprentice 2 $ 40.73 $62.11

Q10 2 sheet metal worker, 1 sheet metal worker apprentice 3 $ 44.92 $68.50

1 Plum 1 Plumbers 1 $ 55.80 $84.03 1 Plum Apprentice 1 Plumber Apprentice 1 $ 29.50 $44.43

1 Elec 1 Electrician 1 $ 52.40 $78.39

1 Sheet 1 Sheet metal worker 1 $ 53.30 $81.28 1 Sheet Apprentice 1 Sheet metal worker apprentice 1 $ 28.15 $42.93 1 Carp 1 Carpenter 1 $31.45 $ 52.84 Commercial Labors Costs (Standard Union) Q1 1 Plumber, 1 Plumber Apprentice 2 $42.65 $64.23

Q9 1 sheet metal worker, 1 sheet metal worker apprentice 2 $40.73 $62.11

Q10 2 sheet metal worker, 1 sheet metal worker apprentice 3 $44.92 $68.50

1 Plum 1 Plumbers 1 $55.80 $84.03 1 Plum Apprentice 1 Plumber Apprentice 1 $29.50 $44.43

1 Elec 1 Electrician 1 $52.40 $78.39

1 Sheet 1 Sheet metal worker 1 $53.30 $81.28 1 Sheet Apprentice 1 Sheet metal worker apprentice 1 $28.15 $42.93 1 Carp 1 Carpenter 1 $44.90 $69.15

* Q&P includes markups in Table 8

- A.8 .2

Table 8

- D.3.2 RS Means Labor Costs Markups by Trade (Residential)

Trade Workers Comp. Aver Fixed

Overhead Overhead Profit Total

Plumber 6.7% 17.9% 30.0% 10.0% 6.7%

Electrician 5.7% 17.9% 30.0% 10.0% 5.7%

Sheet Metal 8.6% 17.9% 30.0% 10.0% 8.6% Carpenter 15.1% 17.9% 25.0% 10.0% 15.1%

RS Means also provides material and labor cost factors for 295 cities and towns in the

U.S. To derive average labor cost values by state, DOE weighted the price factors by 2008

- 2012 boiler shipments by state . DOE used the material and labor cost factors fo r cost associated with fire suppression, p lumbing , and HVAC

. Table 8

- D.3.3 shows the final regional material and labor price factors used in the analysis by geographical area and Table 8

- D.3.4 by census
division

.8

- D

- 14 Table 8

- D.3.3 Material and Labor Cost Factors by Geographical Area (for RECS 2009 Sample)

Geographical Area Plumbing, HVAC Electrical Weighted Average

Material Labor Material Labor Material Labor Connecticut, Maine, New Hampshire, Rhode Island, Vermont 0.99 0.90 1.01 0.90 1.00 0.95

Massachusetts 1.00 1.19 1.02 1.16 1.01 1.27

New York 1.00 1.61 1.02 1.68 1.03 1.60
New Jersey 1.00 1.25 1.02 1.37 1.00 1.24
Pennsylvania 0.98 1.14 0.96 1.25 0.98 1.16

Illinois 0.99 1.28 0.95 1.27 0.99 1.32
Indiana, Ohio 0.99 0.89 0.98 0.90 0.98 0.90

Michigan 1.00 1.01 0.97 0.99 0.96 1.01

Wisconsin 0.99 0.95 1.02 0.95 1.00 1.01
Iowa, Minnesota, North Dakota, South Dakota 0.99 0.97 1.01 0.94 1.00 1.00
Kansas, Nebraska 0.99 0.74 0.99 0.77 0.99 0.74

Missouri 0.99 0.96 1.01 0.95 0.99 0.98
Virginia 0.99 0.66 0.97 0.71 1.01 0.69
Delaware, District of Columbia, Maryland 0.98 0.84 0.98 0.95 0.99 0.84
Georgia 0.99 0.66 0.99 0.69 0.97 0.67
North Carolina, South Carolina 1.00 0.36 0.97 0.44 0.99 0.48

Florida 1.00 0.69 0.99 0.68 1.00 0.73
Alabama, Kentucky, Mississippi 0.99 0.75 0.99 0.78 0.97 0.80

Tennessee 1.00 0.71 1.00 0.63 0.98 0.68
Arkansas, Louisiana, Oklahoma 1.00 0.59 1.02 0.65 0.99 0.62

Texas 0.99 0.56 0.95 0.61 0.98 0.61

Colorado 0.99 0.79 1.01 0.84 1.01 0.82
Idaho, Montana, Utah, Wyoming 1.00 0.70 0.98 0.70 1.01 0.71

Arizona 1.00 0.80 0.98 0.66 0.97 0.74
Nevada, New Mexico 1.00 0.76 0.91 0.80 0.99 0.80

California 0.99 1.21 1.00 1.21 1.01 1.19
Oregon, Washington 1.00 1.04 1.02 0.97 1.02 0.98

Alaska 1.00 1.05 1.34 1.17 1.24 1.14

Hawaii 1.00 1.10 1.06 1.27 1.12 1.21
West Virginia 0.98 0.85 0.96 0.90 0.99 0.888

- D

- 15 Table 8

- D.3.4 Material and Labor Cost Factors by Census Division (for CBECS 2003 Sample)

Census Division Plumbing, HVAC Electrical Weighted Average

Material Labor Material Labor Material Labor

New England 0.99 1.02 1.01 1.01 1.00 1.08

Middle Atlantic 0.99 1.43 1.01 1.51 1.01 1.42

East North Central 0.99 1.06 0.98 1.05 0.98 1.09

West North Central 0.99 0.96 1.01 0.93 1.00 0.99

South Atlantic 0.98 0.79 0.97 0.88 0.99 0.80

East South Central 1.00 0.73 0.99 0.70 0.97 0.74

West South Central 1.00 0.58 0.99 0.63 0.99 0.62

Mountain 1.00 0.76 0.99 0.79 1.01 0.798

- D

- 16 REFERENCES

1. RS Means Company Inc., RS Means Residential Cost Data . 29th Annual Edition ed. 2010: Kingston, MA

2. U.S. Department of Energy

- Energy Efficiency & Renewable Energy, Technical Support Document: Energy Efficiency Standards for Consumer Products: Residential Furnaces
and Boilers , 2007. Washington, DC.

3. RS Means Company Inc., Facilities Maintenance & Re pair Cost Data 2005 . 2004. Kingston, MA.

4. U.S. Department of Energy

- Energy Efficiency & Renewable Energy, Technical Support Document: Energy Efficiency Standards for Consumer Products: Residential Water

Heaters , 2001. Washington, DC.

5. Smith, D. C.

, Consultant Report

- Water Heater Installation Costs , 2008. Florence, SC.

6. RS Means Company Inc., 2008 Mechanical Cost Data

- 31st Annual Edition . 2007. Kingston, MA.

7. U.S. Department of Energy: Energy Information Administration, Residential Energy Consumption Survey: 2005 Public Use Data Files . 2008: Washington, DC. http://www.eia.doe.gov/emeu/recs/recspubuse05/pubuse05.html

8. Jakob, F. E., J. J. Crisafulli, J. R. Menkedick , R. D. Fischer, D. B. Philips, R. L. Osbone, J. C. Cross, G. R. Whitacre, J. G. Murray, W. J. Sheppard, D. W. DeWirth, and W. H. Thrasher, Assessment of Technology for Improving the Efficiency of Residential Gas Furnaces and Boilers, Volume I and II

- App endices, September, 1994. Gas Research Institute. AGA Laboratories, Chicago, IL. Report No. GRI

- 94/0175.

9. D.D. Paul et al., Assessment of Technology for Improving the Efficiency of Residential Gas Water Heaters, December, 1991. Battelle. Columbus. Repo rt No. GRI

- 91/0298. GRI/GATC Water Heater NAECA Analysis.

10. National Fire Protection Association, National Fuel Gas Code

- 2002 Edition , 2002. 1 Batterymarch Park, P.O. Box 9101, Quincy MA.