8-D-i

APPENDIX 8-D. INSTALLATION, MAINTENANCE, REPAIR COST 

DETERMINATION FOR FURNACE FANS

TABLE OF CONTENTS

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

8-D.2 INSTALLATION COST DETERMINATION .....................................................8-D-1

8-D.2.2 Summary of Furnace Fan Installation Costs..........................................................8-D-3

8-D.3 MAINTENANCE COST FOR FURNACE FANS ...............................................8-D-4

8-D.4 REPAIR COST FOR FURNACE FANS ..............................................................8-D-4

8-D.4.2 Summary of Furnace Fan Repair Costs.................................................................8-D-6

8-D.5 REGIONAL MATERIAL AND LABOR COSTS................................................8-D-7

LIST OF TABLES

Table 8-D.1.1 Example Cost Table...................................................................................8-D-1

Table 8-D.2.1 Additional Installation Cost Calculation for ECM (National Average) ....8-D-2

Table 8-D.2.2 Installation Costs for Furnace Fans Used in HVAC Products Other 

than Hydronic Air Handlers (2011$).........................................................8-D-3

Table 8-D.2.3 Installation Costs for Furnace Fans Used in Hydronic Air Handlers 

(2011$).......................................................................................................8-D-3

Table 8-D.3.1 Maintenance Cost Calculation for Furnace Fans (National Average).......8-D-4

Table 8-D.3.2 Maintenance Fractions based on 2008 American Home Comfort 

Survey ........................................................................................................8-D-4

Table 8-D.4.1 Warranty Period Assumptions...................................................................8-D-5

Table 8-D.4.2 Service Contract Assumptions...................................................................8-D-5

Table 8-D.4.3 Repair Cost Calculation (Labor Only) for Furnace Fans (National 

Average).....................................................................................................8-D-6

Table 8-D.4.4 Annualized Repair Cost for Furnace Fans Used in HVAC Products 

Other than Hydronic Air Handlers (2011$)...............................................8-D-7

Table 8-D.4.5 Annualized Repair Cost for Furnace Fans Used in Hydronic Air 

Handlers (2011$) .......................................................................................8-D-7

Table 8-D.5.1 RS Means 2011 National Average Labor Costs by Crew (Standard 

Union) ........................................................................................................8-D-8

Table 8-D.5.2 RS Means Labor Costs Markups by Trade (Residential) ..........................8-D-8

Table 8-D.5.3 Material and Labor Cost Factors by Geographical Area ...........................8-D-9

LIST OF FIGURES

Figure 8-D.2.1 Additional Installation Labor Hours Distribution for ECMs.....................8-D-2

Figure 8-D.4.1 Furnace Fan Lifetime Distribution in Operating Hours.............................8-D-5
8-D-1

APPENDIX 8-D. INSTALLATION, MAINTENANCE, REPAIR COST 

DETERMINATION FOR FURNACE FANS

8-D.1 INTRODUCTION

This appendix provides further details about the derivation of installation, maintenance 

and repair costs for furnace fans. 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 furnace product. 

The Department of Energy (DOE) estimated installation, maintenance, and repair costs 

for furnaces 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 cost calculation method. All labor costs are derived using the 

latest residential 2012 RS Means labor costs by crew type.1 Replacement installation,

maintenance, and repair 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 personhours) 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.5 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 Cost Table

Description Crew Labor

Hours Unit

Bare Costs (2011$)

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

8-D.2 INSTALLATION COST DETERMINATION

Because the furnace fan is installed in the furnace in the factory, there is generally no 

additional installation cost at the home. However, ECM furnace fan design may require 

additional installation costs. DOE assumed that a fraction of the ECM furnace fan installations 

will require up to an hour of extra labor at startup to check and adjust airflow. DOE believes this 

additional installation cost is above and beyond the regular basic installation cost calculated in 

DOE’s furnace rulemaking for a baseline non-ECM furnace. This cost is only applied to the 

replacement cases, where contractors would be switching from the old PSC motor to the new 

ECM. In the new construction case DOE assumes that the installer would already make any 

required adjustments with no additional cost.
8-D-2

ECMs have a very different airflow curve compared to PSC motors. The ECM airflow 

curve as described in chapter 7 of this TSD is pretty much flat with increasing static pressure 

(ECMs maintain constant airflow in this range). In the meantime PSC motors decrease airflow 

with increasing static pressure. If an ECM is installed in a household with a previous PSC motor 

without checking or adjusting the airflow there is a likelihood that the ECM could operate at 

undesirable operating conditions. Installers familiar with ECMs will take the time to check and 

adjust airflow. Those that don’t often get callbacks, particularly on systems with tight ducts. 

Since the motor continues to deliver rated airflow, it generates objectionable noise and often 

noticeable additions to power consumption, thus requiring a callback to reduce airflow and 

reassure the customer all is well. DOE assumes that X13 motors don’t require much extra time 

to set up, although some will require additional adjustment over a PSC due to the steeper fan 

curve delivering more air at high static. Therefore, DOE assumed that for X13 motors the 

additional installation cost is one fourth that of the ECM.

The additional labor hours required for an ECM are calculated using a triangular 

distribution with a range from 0 hours to 1 hour and a most likely value of 0 hours (See Figure 8-

D.2.1). The average value from this distribution is 0.33 hours.

Figure 8-D.2.1 Additional Installation Labor Hours Distribution 

for ECMs

Table 8-D.2.1 shows the installation costs using RS Means. 

Table 8-D.2.1 Additional Installation Cost Calculation for ECM (National Average)

Description Crew Labor

Hours Unit

Bare Costs (2011$) Total

incl.

Material O&P Labor Total

Check blower airflow for ECM Q1 0.33 Ea. $0.00 $10.51 $10.51 $17.16
8-D-3

8-D.2.2 Summary of Furnace Fan Installation Costs

Table 8-D.2.2 and Table 8-D.2.3 show the average total installation costs used in the 

analysis. 

Table 8-D.2.2 Installation Costs for Furnace Fans Used in HVAC Products Other than 

Hydronic Air Handlers (2011$)

Key Product Class 0 1 2 3 4 5

Baseline 

PSC

Improved 

PSC

PSC w/ 

Controls

X13 ECM ECM + 

Backward

-curved 

Impeller

Non-weatherized, Noncondensing Gas Furnace 

Fan

$0 $0 $0 $3 $10 $10

Non-weatherized, 

Condensing Gas Furnace 

Fan

$0 $0 $0 $3 $13 $13

Weatherized Gas Furnace 

Fan

$0 $0 $0 $2 $10 $10

Oil Furnace Fan $0 $0 $0 $4 $17 $17

Electric Furnace / Modular 

Blower Fan

$0 $0 $0 $2 $9 $9

Manufactured Home Nonweatherized, Noncondensing Gas Furnace 

Fan

$0 $0 $0 $2 $6 $6

Manufactured Home Nonweatherized, Condensing 

Gas Furnace Fan

$0 $0 $0 $2 $8 $8

Manufactured Home 

Electric Furnace / Modular 

Blower Fan

$0 $0 $0 $1 $6 $6

Table 8-D.2.3 Installation Costs for Furnace Fans Used in Hydronic Air Handlers

(2011$)

Key Product 

Class

0 1 2 3 4 5 6 7

Baselin

e PSC

Improve

d PSC

PSC w/ 

Controls

X13 ECM ECM + 

Backwar

d-curved 

Impeller

Switching 

Mode 

Power 

Supply

Toroidal 

Transformer

Hydronic Air 

Handler Fan 

(Heat/Cool)

$0 $0 $0 $3 $12 $12 $12 $12
8-D-4

8-D.3 MAINTENANCE COST FOR FURNACE FANS

The maintenance cost is the routine annual cost to the consumer of maintaining 

equipment operation. It is the cost associated with general maintenance. The regular furnace 

maintenance generally includes checking the furnace fan. DOE assumes that this maintenance 

cost is the same at all efficiency levels.

DOE estimated labor hours and costs for annual maintenance was estimated using RS 

Means data (See Table 8-D.3.1). 

Table 8-D.3.1 Maintenance Cost Calculation for Furnace Fans (National Average)

Description Crew Labor

Hours Unit

Bare Costs (2011$) Total

incl.

Material O&P Labor Total

Check blower Q1 0.042 Ea. $0.00 $1.34 $1.34 $2.10

The frequency with which the maintenance occurs was derived from a 2008 consumer 

survey

2 on the frequency with which owners of different types of furnaces perform maintenance. 

Table 8-D.3.2 Maintenance Fractions based on 2008 American Home Comfort Survey

Frequency of Maintenance Assumed 

Frequency 

for Analysis

Fraction of Households

Oil Furnaces Other Furnaces

Last maintenance within a year Annual 71% 53%

Last maintenance within two years Biannual 17% 17%

Last maintenance over 2 years Every 5 years 7% 15%

Never Never 5% 14%

8-D.4 REPAIR COST FOR FURNACE FANS

The repair cost is the cost to the consumer for replacing or repairing components in the

furnace fan that have failed. 

DOE included motor replacement as a repair cost for a fraction of furnace fans. To 

estimate rates of fan failure, DOE developed a distribution of fan motor lifetime (expressed in 

operating hours) by motor size using data from DOE’s analysis for small electric motors.

a

Figure 8-D.4.1

See 

for the furnace motor Weibull distribution, which indicates 30,000 hours as the 

mean operating hours. DOE then paired these data with the calculated number of annual 

operating hours for each sample furnace. 

 

a http://www1.eere.energy.gov/buildings/appliance_standards/commercial/sem_finalrule_tsd.html
8-D-5

Figure 8-D.4.1 Furnace Fan Lifetime Distribution in Operating 

Hours

Motor costs were based on costs developed in the engineering analysis and marked up 

using the replacement markups developed in the markup analysis. DOE assumed that the motor 

cost does not apply if motor failure occurs during the furnace warranty period or if a service 

contract covers parts. Table 8-D.4.1 shows the warranty period assumptions based on 

manufacturer product literature. Table 8-D.4.2 shows the service contract assumptions based on 

a 2008 consumer survey.2

Table 8-D.4.1 Warranty Period Assumptions

Warranty Period Fraction of 

Households

One year Labor and Parts 100%

5 years parts only 90%

10 year parts only 10%

Table 8-D.4.2 Service Contract Assumptions

Service Contract Types Fraction of Households

Oil Furnaces Other Furnaces

Total Package (Labor and Parts) 27% 15%

Annual Cleaning 11% 6%

None 62% 79%
8-D-6

DOE estimated repair costs at each considered level, based on 2012 RS Means Facility 

Repair and Maintenance Data.

3 DOE accounts for regional differences in labor costs. DOE 

estimated labor hours and costs for annual maintenance using RS Means data (See Table 8-

D.4.3). DOE assumed that the labor cost does not apply if motor failure occurs during the 

furnace warranty periods first year or if a service contract covers labor.

Table 8-D.4.3 Repair Cost Calculation (Labor Only) for Furnace Fans (National 

Average)

Description Crew Labor

Hours Unit

Bare Costs (2011$) Total

incl.

Material O&P Labor Total

Check blower Q-1 1 Ea. $0.00 $31.85 $31.85 $52.01 

Remove fan motor Q-1 0.976 Ea. $0.00 $31.09 $31.09 $50.76 

Replace fan motor Q-1 1.951 Ea. $0.00 $62.14 $62.14 $101.47 

Total $204.25 

8-D.4.2 Summary of Furnace Fan Repair Costs

Table 8-D.4.4 and Table 8-D.4.5 show the average annualized repair costs used in the 

analysis. 
8-D-7

Table 8-D.4.4 Annualized Repair Cost for Furnace Fans Used in HVAC Products Other 

than Hydronic Air Handlers (2011$)

Key Product Class 0 1 2 3 4 5

Baseline 

PSC

Improved 

PSC

PSC w/ 

Controls

X13 ECM ECM + 

Backward

-curved 

Impeller

Non-weatherized, Noncondensing Gas Furnace 

Fan

$13 $13 $14 $14 $18 $19

Non-weatherized, 

Condensing Gas Furnace 

Fan

$13 $14 $14 $15 $18 $19

Weatherized Gas Furnace 

Fan

$15 $15 $16 $17 $21 $23

Oil Furnace Fan $14 $14 $14 $15 $18 $19

Electric Furnace / Modular 

Blower Fan

$14 $14 $15 $16 $19 $21

Manufactured Home Nonweatherized, Noncondensing Gas Furnace 

Fan

$12 $12 $13 $14 $17 $18

Manufactured Home Nonweatherized, Condensing 

Gas Furnace Fan

$13 $13 $14 $15 $17 $18

Manufactured Home 

Electric Furnace / Modular 

Blower Fan

$13 $13 $14 $15 $19 $21

Table 8-D.4.5 Annualized Repair Cost for Furnace Fans Used in Hydronic Air 

Handlers (2011$)

Key Product 

Class

0 1 2 3 4 5 6 7

Baseline 

PSC

Improved 

PSC

PSC w/ 

Controls

X13 ECM ECM + 

Backward

-curved 

Impeller

Switching 

Mode 

Power 

Supply

Toroidal 

Transformer

Hydronic Air 

Handler Fan 

(Heat/Cool)

$16 $16 $17 $18 $21 $23 $23 $24

8-D.5 REGIONAL MATERIAL AND 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.5.1. Bare costs are given in RS Means, while labor
8-D-8

costs including overhead and profit (O&P) are the bare costs multiplied by the RS Means 

markups by trade shown in Table 8-D.5.2.

Table 8-D.5.1 RS Means 2011 National Average Labor Costs by Crew (Standard 

Union)

Crew Type Crew Description Laborers 

per Crew

Cost per Labor-Hour

Bare Costs Incl. O&P*

1 Plum 1 Plumber 2 $35.40 $57.81

1 Elec 1 Electrician 1 $33.70 $54.63

Q1 1 Plumber, 1 Plumber Apprentice 2 $31.85 $52.01

1 Carp 1 Carpenter 1 $30.15 $50.47

* Q&P includes markups in Table 8-A.8.2

Table 8-D.5.2 RS Means Labor Costs Markups by Trade (Residential)

Trade Workers 

Comp.

Aver 

Fixed 

Overhead

Overhead Profit Total

Plumber 7.0% 16.3% 30.0% 10.0% 63.3%

Electrician 5.8% 16.3% 30.0% 10.0% 62.1%

Carpenter 16.1% 16.3% 25.0% 10.0% 67.4%

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 city or 

town population size using 2009 census data. DOE used the material and labor cost factors for 

cost associated with fire suppression, plumbing, and HVAC. Table 8-D.5.3 shows the final 

regional material and labor price factors used in the analysis by geographical area. The 

distribution of each RECS 2005 product class sample is different, so the average labor cost 

weighted by RECS 2005 sample weights is different from the RS Means national average (i.e., 

labor cost factor of 1.00).
8-D-9

Table 8-D.5.3 Material and Labor Cost Factors by Geographical Area

Geographical Area Material Labor

Connecticut, Maine, New Hampshire, Rhode Island, Vermont 0.99 0.94

Massachusetts 1.00 1.18

New York 1.00 1.57

New Jersey 1.00 1.21

Pennsylvania 0.98 1.12

Illinois 1.00 1.26

Indiana, Ohio 0.99 0.88

Michigan 1.00 1.00

Wisconsin 0.99 0.93

Iowa, Minnesota, North Dakota, South Dakota 0.99 0.90

Kansas, Nebraska 0.99 0.72

Missouri 0.99 0.95

Virginia 0.99 0.69

Delaware, District of Columbia, Maryland, West Virginia 0.99 0.88

Georgia 0.99 0.68

North Carolina, South Carolina 0.99 0.41

Florida 1.00 0.63

Alabama, Kentucky, Mississippi 0.99 0.63

Tennessee 1.00 0.65

Arkansas, Louisiana, Oklahoma 0.99 0.58

Texas 1.03 0.56

Colorado 0.99 0.79

Idaho, Montana, Utah, Wyoming 1.00 0.69

Arizona 1.00 0.73

Nevada, New Mexico 1.00 0.90

California 0.99 1.20

Oregon, Washington 1.00 1.00

Alaska 1.00 1.03

Hawaii 1.02 0.60

 
8-D-10

REFERENCES

1. RS Means Company Inc., RS Means Residential Cost Data. 31st Annual Edition ed. 

2012: Kingston, MA

2. Decision Analysts, 2008 American Home Comfort Study: Online Database Tool, 2009. 

Arlington, Texas. <http://www.decisionanalyst.com/Syndicated/HomeComfort.dai>

3. RS Means Company Inc., Means Facilities Maintenance & Repair Cost Data. 2012. 

Kingston, MA.