8-D-i

APPENDIX 8-D. INSTALLATION COST DETERMINATION FOR BOILERS

TABLE OF CONTENTS

8-D.1 INTRODUCTION ................................................................................................ 8-D-1

8-D.2 INSTALLATION COST METHODOLOGY ...................................................... 8-D-2

8-D.2.1 Introduction........................................................................................................... 8-D-2

8-D.2.2 New Construction and Replacement 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 Stainless 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 REGIONAL 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 Installation 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-5
8-D-1

APPENDIX 8-D. INSTALLATION COST DETERMINATION FOR BOILERS

8-D.1 INTRODUCTION

This appendix provides further details about the derivation of installation costs 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 boilers based on RS 

Means, a well-known and respected construction cost estimation method, as well as

manufacturer literature and information 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 

2013 RS Means labor costs by crew type.1 Replacement installation 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 costs 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. 

Material O&P 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 boilers encompass a broad array of product classes, 

installation sizes, and venting configurations, including:

• gas-fired boilers, oil-fired boilers, and electric boilers;

• new and replacement markets;

• single-family, multi-family, and commercial buildings;

• venting systems that are Category I (non-condensing), Category III (stainless vents), and 

Category IV (condensing);

• various vents, such as masonry chimneys, metal vent, stainless steel vents, or plastic 

(polyvinylchloride (PVC));
8-D-2

• single-wall or double-wall vent connectors;

• gas or oil water heaters that are either vented in common with a boiler or isolated; and

• special situations, such as the need to reline a chimney or vent an orphaned water heater.

Applying the RS Means methodology to a boiler installation requires knowledge of its 

details, 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 distribution of values derived from available data; a Crystal Ball Monte 

Carlo simulationa was used to model the resultant costs for each individual household.

8-D.2 INSTALLATION COST METHODOLOGY

8-D.2.1 Introduction

DOE developed installation cost data for boilers using RS Means cost data, DOE 

technical support documents, and consultant reports prepared for this analysis.2,3,4,5,6 The 

installation cost was divided into the following four components:

• basic installation,

• venting,

• condensate removal, 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), for gas-fired hot water boilers, approximately 20% of the market will be new 

construction and 80% will be replacements in 2020.

Boiler Technologies. There are two main boiler designs: non-condensing and 

condensing. Almost all of the non-condensing boilers have an annual fuel utilization efficiency

(AFUE) of 82%, which represents the analysis baseline. Condensing boilers have an AFUE of 

90% or greater. Non-condensing boilers usually use Category I venting systems, while

condensing boilers 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 IV

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 Locations. Table 8-D.2.1 shows the fraction of installations by installation 

location. The installation fractions are derived using RECS 2009 household characteristics 

together 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, then 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 noncondensing 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 venting 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 

vent location, installation type (replacement or new construction), vents (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 that water vapor in the flue gas does not condense; if it does 

condense and does not 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. Typically a small amount of condensate at cold startup is acceptable as long as it dries out 

quickly. More efficient low-temperature condensing boilers condense the water vapor in the 

primary or a secondary heat exchanger, thus increasing boiler efficiency by reducing latent heat 

loss. The condensate is fed to a drain. Because the flue gas temperature is relatively low, 

condensing boilers 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 boilers 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 heater. 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 facade on the exterior

that covers a wooden chase with a flexible metal liner on the interior. (These are faster to build 

compared to brick by brick.) If the water heater is isolatedd

, the common water heater vent 

shown in Figure 8-D.2.1 would not be present.

Figure 8-D.2.1 Masonry Chimney Venting Installation (NonCondensing Boiler)

Metal Vents. Some non-condensing boilers 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 would 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.

Boiler
8-D-5

Figure 8-D.2.2 Metal Venting Installation (Non-Condensing Boiler)

Plastic PVC. All condensing boilers are vented using PVC vents, either horizontal or vertical. 

Figure 8-D.2.3 shows a horizontal side-wall plastic vent. The boiler installation shown below

utilizes a two-plastic-pipe venting system. One of the vents exhausts the flue gases and the other

brings combustion air from the outside to the boiler. Flue gas piping is sloped downward toward 

the boiler so that condensate drips back into the boiler condensate drain. This installation 

includes a gas water heater (analogous to the common vented scenario above), which requires a 

separate flue gas exhaust vent. If the water heater is isolated, this exhaust vent will not be 

present.

Figure 8-D.2.3 Plastic PVC Installation (Condensing Boiler)

8-D.2.4.1 Replacement Installations

For replacements, DOE evaluated two cases. One involves switching from a non 

condensing natural draft boiler (less than 75% AFUE) to a non-condensing fan-assisted boiler

Boiler

Boiler
8-D-6

(82% AFUE) and the other involves switching from a non-condensing (natural draft and fanassisted) to a condensing 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 1994 GRI 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 71.8% 16.4%

Metal Vent 28.2% 83.6%

Table 8-D.2.3 provides the fraction of existing non-condensing installations that are 

commonly vented with gas water heaters, based on the 1991 GTI Water Heater Survey.9

Table 8-D.2.3 Fraction of Commonly Vented Boiler and Water Heater Installations

Common Venting Northeast Midwest South West

Common 78% 68% 22% 65%

Isolated 22% 32% 78% 35%

8-D.2.4.1.2 Non-Condensing 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 surrounded 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 kBtu/hour. This rating is close to 
8-D-7

the representative input capacity for residential boilers assumed in this analysis. Therefore,

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

replacement.

Interior Chimneys. The NFGC mandates 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, for example. Water heater 

vents are typically 3 inches in diameter, so an interior masonry chimney cannot exceed 49 square 

inches, corresponding to an 8 x 8 nominal chimney liner size. DOE assumed that all interior 

chimneys would need to be relined, if built before 1995 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 2009 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 installations shown in Table 8-D.2.3, DOE determined if the household had a chimney 

installation. To determine if a household had an unlined chimney, DOE used the following two 

criteria:

1) Boiler exhaust gases are vented through a chimney.

2) The existing boiler was installed before 1995 when building codes requiring the relining 

of chimneys were not yet in place.

Based on these criteria, DOE calculated that about one-quarter of households in the 

RECS 2009 sample had an unlined chimney. DOE determined that half of these would be relined 

already by 2020, based on boiler equipment retirements from 2009 to 2020. (By 2020 the

existing boilers that would require relining would be 25 years old or older). Therefore, the 

analysis resulted in 10% of the stock needing to be relined in 2020.

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 common). There are three main types 

of vent connectors: Type B double wall, single-wall galvanized 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. The air gap in between the tubes provides insulation, which 

reduces the likelihood of condensation in the vent connector. A single-wall galvanized steel vent 

is simply a zinc-coated steel tube vent. Aluminum single-wall vent connectors are similar to 

galvanized steel single-wall vents and are found in some regions. Condensing boilers do not 

require metal vent connectors.
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 connector 

diameter will be less 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 82% or greater for gas-fired hot water boilers) replaces a natural 

draft non-condensing boiler (an AFUE of less than 75%). Although fan-assisted boilers 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 boilers, based on RECS 2009 equipment 

age.

Table 8-D.2.4 summarizes the three different venting issues associated with noncondensing boilers.

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 venting cost associated with stainless steel venting for a 

fraction of installations between 82% AFUE and 86% 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 installations 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 2020, a growing number of replacement installations

would be from non-condensing to condensing boilers. The next four sections explain the changes 

to the venting systems that would be required when installing condensing boilers and provide 

information about the fractions of impacted installations. The sections address the following four 

installation issues:

• condensing flue vent (PVC);

• combustion air vent;

• concealing vents in indoor installations; and

• installation with orphaned 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 household in 

RECS 2009 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 determines the cost of penetrating the wall.
8-D-10

Combustion Air Vent (PVC)

A fraction of the condensing boiler installations are direct-vent installations, which uses 

combustion air supplied from the outdoor air. For each household in the RECS 2005 sample

DOE considered the following factors when calculating the installation cost of the combustion 

air vent for condensing boilers in the replacement market:

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

• vent installation fraction, which depends on the installation location.

Table 8-D.2.6 shows the fraction of direct vent installations by installation location, 

based on the consultant report in section 8-D.6. As shown in the table, nationally about 62.1% of 

the condensing boiler installations are direct vent. The fractions of direct-vent condensing 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 pipes—putting in place structures to mask vents that pass through the living space. DOE 

assumed that half of the indoor horizontally vented 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. Such requirements include upgrading the vent connector, resizing metal 

vents, or masonry chimney relining. 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 40% 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 draft 
8-D-11

boiler. DOE also assumed that 20% of the venting systems with existing fan assisted noncondensing 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 such 

replacement installations. 

Table 8-D.2.7 Non-Condensing to Condensing Venting Issues

Existing NonCondensing BoilerReplacement 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 installations 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 installation costs of commonly 

vented boilers (together with a water heater). When installing a condensing boiler in new 

construction, 100% of the 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 vented 

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

while in the condensing boiler installations with orphaned water heaters DOE added half of the 

venting system installation cost of the orphaned water heater.

8-D.2.5 Condensate Removal for Condensing Boilers

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 boilers, 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 exists to remove the condensate from the air conditioner 

during the cooling season. DOE assumes that a condensate pump is required for half of 

the installations without a central air conditioner.

• Condensate Freeze Protection: If the condensate is exposed to freezing temperatures,

then heat tape and pipe insulation is required. DOE assumes that heat protection is 

required in all unconditioned attics.

• Drip Pan: Some codes require a drip pan. DOE assumed that a drip is required for all 

attic installations or boilers installed in a 2nd 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 associated with condensing 

boilers.

Table 8-D.2.8 Installation Fractions 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 electricity 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 chapter 7).

8-D.3 RS MEANS 2013 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 labor 
8-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 2013 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 for cost associated with 

fire suppression, plumbing, 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 0.88
8-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 0.79
8-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 & Repair 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. 

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Kingston, MA.

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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 - Appendices, 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. Report 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.