APPENDIX 8-E. MAINTENANCE AND REPAIR COST DETERMINATION FOR 

COMMERCIAL PACKAGED BOILERS

TABLE OF CONTENTS

8-E.1 INTRODUCTION ................................................................................................. 8-E-1

8-E.2 MAINTENANCE COST FOR COMMERCIAL PACKAGED BOILERS.......... 8-E-1

8-E.3 REPAIR COST FOR COMMERCIAL PACKAGED BOILERS......................... 8-E-4

8-E.4 REGIONAL MATERIAL AND LABOR COSTS................................................ 8-E-5

LIST OF TABLES

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

Table 8-E.2.1 Example Maintenance Tasks and Costs of 120-500 kBtu/h Hot Water 

Boiler Based on 2013 RS Means Data....................................................... 8-E-3

Table 8-E.2.2 Annualized Maintenance Costs Based on 2013 RS Means Data............... 8-E-4

Table 8-E.3.1 Boiler Repair Rates.................................................................................... 8-E-5

Table 8-E.3.2 Boiler Repair Costs and Labor Hours........................................................ 8-E-5

Table 8-E.4.1 RS Means 2013 National Average Labor Costs by Crew.......................... 8-E-5

Table 8-E.4.2 RS Means Labor Costs Markups by Trade ................................................ 8-E-6

8-E-i
APPENDIX 8-E. MAINTENANCE AND REPAIR COST DETERMINATION FOR 

COMMERCIAL PACKAGED BOILERS

8-E.1 INTRODUCTION

This appendix provides further details about the derivation of maintenance and repair 

costs for commercial packaged boilers. 

The U.S. Department of Energy (DOE) estimates maintenance and repair costs for boilers 

based on RS Means, a construction estimation database that is used by professional estimators 

for up to date labor, materials and overhead costs for specific project types and locations, as well 

as manufacturer literature and information from expert consultants. Table 8-E.1.1 offers an 

example of the cost calculation method using RS Means data. The cost calculation consists of 

first estimating the material and labor costs, and then applying appropriate markups and 

summing the two quantities to get a final cost value. All labor costs are derived using the latest 

commercial 2013 RS Means labor costs by crew type.1 Maintenance and repair cost tables 

sometimes include a trip charge, which is often charged by contractors and estimated to be equal 

to one half hour of labor per crew. Labor hours (or person-hours) are based on RS Means data, 

expert consultant information, or engineering judgment. Bare costs include all costs without any 

markups. Material costs are based on RS Means data, expert data, or other sources. The subtotal 

column is the sum of the material and labor costs without markups. The final total column 

includes overhead and profit (O&P). To clarify, the labor costs shown in the tables in this 

appendix are the national average values, in its analysis, DOE uses regional labor and material 

markups to more accurately estimate installation costs by region. Section 8-D.3 describes the 

derivation of regional labor costs. DOE then applies the appropriate regional labor cost to each 

Commercial Building Energy Consumption Survey (CBECS) sample building.

Table 8-E.1.1 Example Cost Table

Description Crew Labor

Hours Unit

Bare Costs (2012$)

Quantity

Total 

incl. 

Material O&P Labor Subtotal

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-E.2 MAINTENANCE COST FOR COMMERCIAL PACKAGED BOILERS

The maintenance cost is the routine cost to the commercial consumer of general 

maintenance for equipment operation. DOE estimates the labor hours and costs for each 

maintenance task from 2013 RS Means Facilities Maintenance and Repair Cost Data.

1 The 

maintenance cost depends on boiler capacity and heating medium (hot water or steam). Within 

8-E-1
an equipment class, DOE assumes that the maintenance cost is the same at all non-condensing 

efficiency levels, and that the maintenance cost at condensing efficiency levels is slightly higher,

due to an added cost for a condensate neutralizer. Table 8-E.2.1 presents an example of the 

considered maintenance costs for a 120-500 kBtu/h hot water boiler. Each maintenance task has 

an associated crew type, number of labor hours, and frequency of occurrence. RS Means does 

not itemize material costs by task, but presents them as a total annualized value. 8-E-4

8-E-2
Table 8-E.2.1 Example Maintenance Tasks and Costs of 120-500 kBtu/h Hot Water 

Boiler Based on 2013 RS Means Data

Task

ID Task Description Labor Hours

Material

Cost

Frequency

(times per 

year)

1 Check combustion chamber for air or gas leaks. 0.077 - 1

2 Inspect and clean oil burner gun and ignition 

assembly where applicable. 0.835 - 1

3 Inspect fuel system for leaks and change fuel filter 

element, where applicable. 0.125 - 1

4 Check fuel lines and connections for damage. 0.023 - 12

5 Check for proper operational response of burner to 

thermostat controls. 0.169 - 4

6 Check and lubricate burner and blower motors. 0.099 - 4

7 Check main flame failure protection and main flame 

detection scanner on boiler equipped with spark 

ignition (oil burner).

0.155 - 12

8 Check electrical wiring to burner controls and 

blower. 0.100 - 1

9 Clean firebox (sweep and vacuum). 0.793 - 1

10 Check operation of mercury control switches (i.e., 

steam pressure, hot water temperature limit, 

atomizing or combustion air proving, etc.).

0.185 - 12

11 Check operation and condition of safety pressure 

relief valve. 0.038 - 12

12 Check operation of boiler low water cut off devices. 0.070 - 12

13 Check hot water pressure gauges. 0.073 - 12

14 Inspect and clean water column sight glass (or 

replace). 0.160 - 12

15 Clean fire side of water jacket. 0.433 - 1

16 Check condition of flue pipe, damper and exhaust 

stack. 0.183 - 4

17 Check boiler operation through complete cycle, up 

to 30 minutes. 0.806 - 1

18 Check fuel level with gauge pole, add as required. 0.046 - 12

19 Clean area around boiler. 0.137 - 12

20 Fill out maintenance checklist and report 

deficiencies. 0.022 - 12

Total 15.881 $101

Reference: 2013 RS Means Maintenance and Repair Cost Data, Page 413, D3025 130 2950.

8-E-3
Table 8-E.2.2 shows the annualized maintenance costs for representative commercial 

packaged boilers.

Table 8-E.2.2 Annualized Maintenance Costs Based on 2013 RS Means Data

Description Crew

Labor Hours Material Cost

Steam Hot Water Steam Hot Water

Maintenance (Small boilers) 1 STPI 20.70 17.38 $196 $108

Maintenance (Large boilers) 1 STPI 27.72 26.66 $332 $164

DOE assumes that all steam boilers and oil-fired boilers are maintained regularly by onsite maintenance staff, and that the maintenance tasks occur at the frequency specified in RS 

Means. DOE assumes that gas-fired hot water boilers may or may not be maintained regularly. 

The CBECS and Residential Energy Consumption Survey (RECS) survey data provides

information on whether building owners maintain their equipment regularly. For gas-fired hot 

water boilers, if the building owner reported that the site maintenance staff did not maintain the

building’s equipment regularly, then DOE assumes maintenance occurred one third as often as 

specified in RS Means. If the building owner reported regular equipment maintenance, then DOE 

assumes maintenance occurred at the frequency specified in RS Means.

DOE investigated the effects of recent low-sulfur fuel oil requirements on oil boiler 

maintenance. DOE assumed that all fuel oil boilers, regardless of fuel oil sulfur content, will be 

maintained with the same frequency. Therefore, the maintenance costs between boilers using 

regular and low-sulfur fuel oil are assumed to be the same.

8-E.3 REPAIR COST FOR COMMERCIAL PACKAGED BOILERS

The repair cost is the cost to the commercial consumer for replacing or repairing 

components in the boiler that have failed. DOE estimates repair costs at each considered 

efficiency level using a variety of sources, including 2013 RS Means Facility Maintenance and 

Repair Cost Data,

1 manufacturer literature, and information from expert consultants. Heat 

exchanger replacement costs are assumed to be 1/3 of the total boiler replacement cost. DOE 

accounts for regional differences in labor costs, as is discussed in appendix 8-D.

Table 8-E.3.1 and Table 8-E.3.2 show repair rate and cost assumptions used in the 

analysis. The failure year distribution is assumed to be a Weibull function for each component. 

The mean failure years for the ignition, controls, mechanical vent damper, and power vent were 

based on RS Means. The heat exchanger mean failure year is based on a report from the Gas 

Research Institute (GRI).

2 DOE assumes that all boilers have a one-year warranty for parts and 

labor and a ten-year warranty on the heat exchanger. If any component of a boiler fails in one 

year or less, then the cost of the repair is presumed free for the owner. If the heat exchanger fails

between 1 and 10 years, it is presumed that there is no material cost to the owner, but there is still 

a labor cost.

8-E-4
Table 8-E.3.1 Boiler Repair Rates

Repair Description Mean Failure Year Repair Rate

Ignition, Controls 7.0 50%

Mechanical Vent Damper or Power Vent Blower 15.0 35%

Heat Exchanger 20.0 17%

Table 8-E.3.2 Boiler Repair Costs and Labor Hours

Repair Description

Bare Material Cost (2013$)* Total Labor Hours

Gas Oil Gas Oil

Large Small Large Small Large Small Large Small

Ignition, Controls, Gas 

Valve, Automatic 

Means (Baseline)

$4072 $1668 $395 $389 15 6 4 4

Ignition, Controls, Gas 

Valve, Automatic 

Means (Condensing)

$4072 $1668 $395 $389 15 6 4 4

Mechanical Vent 

Damper $59 $56 $59 $56 7 7 7 7

Power Vent Blower $236 $223 $236 $223 7 7 7 7

*Does not include sales tax or markups.

8-E.4 REGIONAL MATERIAL AND LABOR COSTS

DOE uses 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-E.4.1. Bare costs are given in RS Means, while labor 

costs including O&P are the bare costs multiplied by the RS Means markups by trade shown in 

Table 8-E.4.2.

Table 8-E.4.1 RS Means 2013 National Average Labor Costs by Crew

Crew 

No. Crew Description No. of Laborers

Cost per Labor-Hour

Bare Costs Incl. O&P

Q1 1 Plumber, 1 Plumber Apprentice 2 50.23 $78.15

1 STPI 1 Steamfitter or Pipefitter 1 56.65 $88.15

Q5 1 Steamfitter, 1 Steamfitter Apprentice 2 50.98 $79.32

Q7 1 Steamfitter Foreman, 2 Steamfitters, 1 

Steamfitter Apprentice 4 53.94 $83.93

* O&P includes markups in Table 8-E.4.2

8-E-5
Table 8-E.4.2 RS Means Labor Costs Markups by Trade

Trade Workers 

Comp.

Average Fixed 

Overhead Overhead Profit Total

Plumber, Steamfitter, and 

Pipefitter (Repair/ Remodel) 6.7% 17.9% 16.0% 15.0% 55.6%

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 weights the price factors by city or town 

population size using 2012 census data. DOE uses the material and labor cost factors for cost 

associated with fire suppression, plumbing, and heating, ventilating, and air conditioning. See 

appendix 8-D for more details.

8-E-6
REFERENCES

1. RS Means Company Inc., RS Means Facilities Maintenance & Repair Cost Data. 2013. 

Kingston, MA.

2. 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, 1994. Gas 

Research Institute. AGA Laboratories, Chicago, IL. Report No. GRI-94/0175. 

8-E-7