US ETHYLENE COMPLEX CONSTRUCTION

COSTS DATA 2018 – 2020

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Introduction
Petrochemical Update has asked Pathfinder LLC to provide observations and recommendations
for estimating Ethylene Projects in the upcoming 5-year timeframe by evaluating collected
relevant data associated with recent Ethylene projects. The following is Pathfinder’s analysis:
Over the past five years, US Ethylene projects have ridden a wave of new construction spurred
on by US shale gas production and cheap ethane and propane which are ethylene production
feedstocks. Most of the additional capacity is produced for export to Asia (China and India) to
cover plastic (polyethylene) demand. In support of this demand, there has been and dramatic
increase in capital project execution over this same time period. The number of petrochemical
projects constructed simultaneously had significant impact in the marketplace. “Time to market”
was the primary driver for these projects as everyone wanted to capture the early market
opportunity. This resulted in a fast track planning and Construction driven project environment.
This strategy caused many plants to be built with higher cost and schedule delays. Specific
impacts resulted from:
ŸŸ Labor shortages
ŸŸ Raw material shortage (steel, alloys)
ŸŸ Immature design (Weak FEL) with implications in EPC scope and change orders
ŸŸ Poor planning during construction which impacted labor productivity
ŸŸ Competitive labor market to hire skilled workers

During the first two years of the wave, the US petrochemical industry maintained an advantage
with its shale gas price. Plants in Asia and Europe mostly use Naphtha as feedstock which is a
derivative of crude oil. With the decline of crude oil prices in 2014 - 2015, some projects were
delayed or canceled with the changing economics of Naphtha vs Shale Gas. Recent stability of
crude oil pricing coupled with a forecast increase in demand is motivating a new wave of ethylene
and propylene derivatives. Petrochemical producers are confident that the availability of cheap
gas is a long term event. Even though, potential return from new ethylene plants is not as high as
previous periods, there are still market opportunities that can be covered from new US projects.
Even with the above described improved outlook, producers must be aware that factors which
impacted previous project cost are still there and must be considered in planning new projects.
The Construction Industry consistently struggles with an upward trend in cost. The trend results
from multiple contributing factors including those listed above. The trend has driven many Owner
organizations to defer, suspend, or cancel capital projects. In other down periods, reduced activity
has stimulated a “buyers’ market” wherein Suppliers and Contractors react to reduced activity
with competitively priced proposals and willingness to share risk/reward. This does not appear
to be the case during the recent extended period when rather than reducing prices, contractors
have cutback staffing and capabilities to reduce losses until the long term effect of changing
economics becomes more predictable.
In any event, cost impacts can be confusing. Reduced activity in some areas, is being replaced
by new projects associated with the shift toward other more profitable energy sources and

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emerging new opportunities related to the availability of reasonably priced sources of oil and
gas. New projects include multiple Business Sectors. It now appears that the Power and Energy
and Petrochemical Industries are poised to take advantage of currently attractive natural gas
prices with a flurry of new plant construction. While new projects would seemingly be good
news for the industry, the current increase is having the immediate impact of adding to the labor
shortage which in turn adds to project cost and schedule delay.
In 2017, the cost of labor and material escalated both due to short term events, and continuing
longer term impacts like declining or varied capital investment. These impacts have caused craft
labor to seek alternative industries, reducing the labor pool associated with the hydrocarbon
industries, necessitating Owners and Contractors to offer attraction and retention premiums
to secure the levels required to support large to mega-scale capital projects. In addition, while
wage rates have remained reasonably stable, there has been a notable decrease in productivity
leading to the need to spend more hours on both direct and indirect activities.
Foreseeable marketplace and feedstock cost conditions have stimulated particular interest in
sponsorship, investment and construction of large to mega-scale Petrochemical facilities such as
Ethylene Plants. Given the level of interest, this attached cost estimate(s) were prepared by the
Compass Organization to provide a point of reference for participants in Ethylene projects. The
data was prepared by normalizing six recent estimates and should provide insight into how cost
has been impacted by 2017 events and how current trends may impact the future. This research
focuses on evaluating the anticipated cost of constructing a 1.5 M Ton per year Ethylene facility
in either the Gulf Coast or in the North East region of the United States. By definition, this type of
analysis is challenging in that available reference information is subject to variations in plant size,
process design, ultimately selected site conditions, technical standards and other considerations
such as tax abatement incentives, proximity to feedstock supply, customer base/consumers,
logistics, etc. With that said, the team collected relevant data associated with recent Ethylene
projects, to represent the best estimating experience and data of the organizations involved
in the reference projects. The data has been normalized to align construction timing and plant
size to establish a representative base case for a hypothetical 1.5 M Ton facility based on current
market conditions and cost trends.
The above mentioned variations in plant scope and conditions makes it impossible to produce
a highly accurate single point estimate without pinpointing a particular plant configuration.
However, using estimates for clear scope variances and “most common” design information,
the team was able to establish a minimum / maximum cost range for the 1.5 M Ton facility and
subsequently able to condition the cost to fit two distinct geographic locations in the United
States.

The following table presents a representative base case for constructing a mega-scale Ethylene
production facility on the Gulf Coast of the United States in 2017 dollars.

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1.50 Million Ton per year USA Gulf Coast Ethylene Facility 1/1/2017 to 12/31/2017

Cost Categories Qty UoM Material M-H's M-H Rate Labor Cost Minimum Total Material M-H's M-H Rate Labor Cost Maximum Total

Major Equipment (M.E.)

Columns c/w trays 70 EA 292,388,671 31,850 31.40 1,000,090 293,388,761 380,105,272 41,405 40.82 1,690,152 381,795,424
Drums / Vessels 67 EA 16,536,026 26,850 31.40 843,090 17,379,116 21,496,833 34,905 40.82 1,424,822 22,921,655
Pumps 98 EA 14,586,472 13,800 31.40 433,320 15,019,792 18,962,413 17,940 40.82 732,311 19,694,724
Compressors / Fans / Blowers 25 EA 79,711,416 100,600 31.40 3,158,840 82,870,256 103,624,840 130,780 40.82 5,338,440 108,963,280
Heat Exchangers 91 EA 17,386,317 12,750 31.40 400,350 17,786,667 22,602,212 16,575 40.82 676,592 23,278,803
Tanks 7 EA 12,123,821 2,850 31.40 89,490 12,213,311 15,760,967 3,705 40.82 151,238 15,912,205
Material Handling 4 EA 13,595,999 3,600 31.40 113,040 13,709,039 17,674,799 4,680 40.82 191,038 17,865,836
Water Treatment 10 EA 4,189,213 1,900 31.40 59,660 4,248,873 5,445,977 2,470 40.82 100,825 5,546,802
Miscellaneous Equipment 19 EA 46,584,699 15,350 31.40 481,990 47,066,689 60,560,109 19,955 40.82 814,563 61,374,672
Electrical Equipment 29 EA 12,556,814 5,750 31.40 180,550 12,737,364 16,323,859 7,475 40.82 305,130 16,628,988
Instrumentation Devices
5,400 EA 14,725,360 129,000 31.40 4,050,600 18,775,960 19,142,968 167,700 40.82 6,845,514 25,988,482
(Tagged)
Freight ALLOW 16,003,650 16,003,650 20,804,745 20,804,745
Vendor Assistance ALLOW 1,287,140 1,287,140 1,673,282 1,673,282
Total Major Equipment (M.E.) 541,675,597 344,300 10,811,020 552,486,617 704,178,276 447,590 18,270,624 722,448,900
Removals / Demolition ALLOW 6,524,716 60,000 29.63 1,777,800 8,302,516 8,482,130 78,000 38.52 3,004,482 11,486,612
Site Earthmoving /
1,200,000 CY 25,629,032 600,000 29.63 17,778,000 43,407,032 33,317,742 780,000 38.52 30,044,820 63,362,562
Improvements
Piling 6,000 LF 6,446,014 120,000 29.63 3,555,600 10,001,614 8,379,818 156,000 38.52 6,008,964 14,388,782
Buildings 60,000 SF 6,446,014 180,000 29.63 5,333,400 11,779,414 8,379,818 234,000 38.52 9,013,446 17,393,264
Concrete 84,000 CY 34,486,785 140,000 29.63 4,148,200 38,634,985 44,832,820 182,000 38.52 7,010,458 51,843,278
Refractory / Fireproofing ALLOW 4,680,291 6,000 29.63 177,780 4,858,071 6,084,379 7,800 38.52 300,448 6,384,827
Structural Steel / Platforms 9,000 TON 28,019,649 240,000 29.63 7,111,200 35,130,849 36,425,543 312,000 38.52 12,017,928 48,443,471
Piping systems 780,000 LF 160,018,669 3,000,000 29.63 88,890,000 248,908,669 208,024,270 3,900,000 38.52 150,224,100 358,248,370
Insulation ALLOW 38,776,998 48,000 29.63 1,422,240 40,199,238 50,410,097 62,400 38.52 2,403,586 52,813,683
Electrical / Instrumentation 4,200,000 LF 10,079,971 1,200,000 29.63 35,556,000 45,635,971 13,103,963 1,560,000 38.52 60,089,640 73,193,603
Painting / Coatings ALLOW 2,583,365 72,000 29.63 2,133,360 4,716,725 3,358,375 93,600 38.52 3,605,378 6,963,753
Other Miscl Costs ALLOW 13,418,642 120,000 29.63 3,555,600 16,974,242 17,444,234 156,000 38.52 6,008,964 23,453,198
Bulk Material Costs 337,110,145 5,786,000 171,439,180 508,549,325 438,243,188 7,521,800 289,732,214 727,975,402
Fringe Benefits / Payroll Burdens 50,817,185 50,817,185 66,062,341 66,062,341
Consumables / Small Tools 19,448,880 19,448,880 25,283,544 25,283,544
Field Supervision & Expenses 1,215,000 37.81 45,939,150 45,939,150 1,579,500 49.15 59,720,895 59,720,895
Field Establish't (Trailers, Toilets) 7,768,910 240,000 29.16 6,998,400 14,767,310 10,099,583 312,000 37.91 11,827,296 21,926,879
Support Labor (logistics /
1,293,045 600,000 30.24 18,145,620 19,438,665 1,680,959 780,000 39.32 30,666,098 32,347,056
clean up)
Construction Equipt Rental /
77,795,525 175,000 30.24 5,292,473 83,087,998 101,134,183 227,500 39.32 8,944,279 110,078,461
Fuel
Heavy Lift Cranes 6,491,830 6,000 30.24 181,456 6,673,287 8,439,380 7,800 39.32 306,661 8,746,040
Scaffolding 649,185 300,000 29.16 8,746,980 9,396,165 843,941 390,000 37.90 14,782,396 15,626,337
Temporary field utilities 6,491,830 6,491,830 8,439,380 8,439,380
Taxes on Plant Hire consumables 6,491,830 6,491,830 8,439,380 8,439,380
H O Construction Support 120,000 81.02 9,722,400 9,722,400 156,000 105.33 12,639,120 12,639,120
Contractor Fee 64,652,235 64,652,235 84,047,906 84,047,906
Overtime - Shiftwork 12,930,445 12,930,445 16,809,579 16,809,579
BAR Insurance & Performance
19,422,275 19,422,275 25,248,957 25,248,957
Bonds
Other Costs 6,491,830 6,491,830 8,439,379 8,439,379
Freight (Bulk Materials) 9,045,990 9,045,990 11,759,787 11,759,787
Contingency 128,405,630 128,405,630 166,927,319 166,927,319
Indirect Costs 93,998,495 2,656,000 419,224,611 513,223,106 122,198,044 3,452,800 560,344,316 682,542,360
Total Construction Cost 972,784,237 8,786,300 601,474,811 1,574,259,048 1,264,619,508 11,422,190 868,347,154 2,132,966,662
Detail Design / Engineering M-H's 1,200,000 195,432,850 195,432,850 1,560,000 254,062,705 254,062,705
Project Management & Controls M-H's 100,000 19,543,285 19,543,285 130,000 25,406,270 25,406,270
Procurement - Subcontracts &
M-H's 100,000 19,543,285 19,543,285 130,000 25,406,270 25,406,270
P.O.'s
EPC Warranty 12,921,180 12,921,180 16,797,534 16,797,534
EP Fee 65,144,285 65,144,285 84,687,570 84,687,570
S/T 1,400,000 312,584,885 312,584,886 1,820,000 406,360,349 406,360,349
Total Project Cost 972,784,237 10,186,300 914,059,695 1,886,843,933 1,264,619,508 13,242,190 1,274,707,503 2,539,327,011
EPC Cost per Ton $1,258 $1,693
Cost per Major Equipment
$4,492,486 $6,046,017
420 Items
Cost per Major Equipment
5,820 Tagged Items (includes $324,200 $436,310
Instrumentation Devices).

Etimate Basis & Remarks:

Exclusions & Qualifications

Owner Costs (Engineering, Oversight & 3rd party Inspection)
Spare Parts
Initial Start Up Materials
Soil Testing
Based on 45 hour workweek
Above costs reflect 4th Q 2017 values

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This cost model assumes that the plant is being built on the Gulf Coast of the United States using nonunion
labor. Industry experience demonstrates that building the same facility at other locations will impact the cost
and differences must be evaluated on a case by case basis. For example, building the plant in the North East
United States using union labor will result in higher wage rates, and additional work hours associated with
work rules, variations in craft productivity, etc. But with the poorer productivity mow being experienced in the
Gulf Coast these tend to even themselves out.
The selection of the US Gulf Coast for the base case is consistent with industry trends. Typically, the Gulf Coast
is used for this type of modeling with the intent of applying variations in craft productivity, wage rates and
other factors associated with large scale construction. This practice/trend is based on the assumption that
the Gulf Coast offers good weather conditions, ability to attract a qualified work force and an adequate level
of Construction support and logistical access. In simple terms, the Gulf Coast offers a standard case that can
be contrasted with other locations to identify the impact of less desirable conditions. Compass International
has produced the following tables that can be used to tailor an estimate to a particular location, work force
makeup and projected productivity based on a composite of industries, including heavy and light industrial,
pharmaceutical, commercial buildings.

State / City Open Shop / Non-Union Workers Union Workers

Louisiana 1.00 1.10 – 1.15

Ohio (Cleveland) 1.05 – 1.10 1.15 – 1.20
Ohio 1.05 1.10 - 1.15
Pennsylvania (Philadelphia / Pittsburgh) 1.10 - 1.15 1.20 – 1.30
Pennsylvania 1.05 - 1.10 1.10 - 1.20
Texas (Dallas / Houston) 1.05 - 1.10 1.10 - 1.20

Texas (Gulf Coast) - Base Case this includes

Gulfport, Baton Rouge, New Iberia, Lake
Charles, Beaumont, Port Arthur, Baytown,
1.10 – 1.15 (typically all work is
Texas City and Victoria: (Note: in certain 1.00
completed on open shop basis)
cases i.e. large projects with a lot of repeat
/ similar work activities: productivity could
be 0.90 – 1.00 say an average of 0.95)

West Virginia 1.00 - 1.05 1.00 - 1.15

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Average Open Shop Wage Rates US Gulf Coast): 3rd Q 2017:

Abbreviations
FB/H = Fringe Benefits - Holidays
WCI = Workers Compensation Insurance Average
F&S / FICA = Federal & State Unemployment / FICA
ST&C = Small Tools & Consumables
SS = Safety Supplies
ST = Sub Total
HO & S & P = Home Office Support & Profit
THR (W/O per Diem)* = Total Hourly Rate without per diem
per Diem)

Trade / Skill Base FB/HWP WCI F&S / FICA ST&C SS 2.5% ST HOS & P THR (W/O)*
Hourly Average Average Average $3.85 15% per diem)
Rate 3.25% 16.50% 15%

Carpenter
1 28.82 0.94 4.76 4.32 3.85 0.72 43.41 6.51 49.92
(Journeyman)
Mason / Bricklayer
2 28.66 0.93 4.73 4.30 3.85 0.72 43.19 6.48 49.66
(Journeyman)
3 Concrete Finisher 21.90 0.71 3.61 3.29 3.85 0.55 33.91 5.09 38.99
Equipment
4 Operator (Heavy 29.19 0.95 4.82 4.38 3.85 0.73 43.91 6.59 50.50
Crawlers / Cranes)
Electrician
5 32.12 1.04 5.30 4.82 3.85 0.80 47.93 7.19 55.12
(Journeyman))
Instrumentation
6 Installer 32.12 1.04 5.30 4.82 0.80 44.08 6.61 50.70
(Journeyman)
Insulator
7 27.39 0.89 4.52 4.11 3.85 0.68 41.44 6.22 47.66
(Journeyman)
Ironworker
8 29.14 0.95 4.81 4.37 3.85 0.73 43.84 6.58 50.42
(Journeyman)
9 Laborer 19.57 0.64 3.23 2.94 3.85 0.49 30.71 4.61 35.32
Millwright
10 31.33 1.02 5.17 4.70 3.85 0.78 46.85 7.03 53.88
(Journeyman)
Oiler / Mechanic
11 29.40 0.96 4.85 4.41 3.85 0.74 44.20 6.63 50.83
(Journeyman)
Pipefitter
12 31.37 1.02 5.18 4.71 3.85 0.78 46.91 7.04 53.94
(Journeyman)
13 Painter 24.37 0.79 4.02 3.66 3.85 0.61 37.30 5.59 42.89
Refractory
14 28.90 0.94 4.77 4.34 3.85 0.72 43.52 6.53 50.04
(Journeyman)
15 Rebar Installer 28.53 0.93 4.71 4.28 3.85 0.71 43.01 6.45 49.46
16 Scaffolder 24.03 0.78 3.96 3.60 3.85 0.60 36.83 5.52 42.36
Truck Driver / JLG
17 21.83 0.71 3.60 3.27 3.85 0.55 33.81 5.07 38.88
Lift
Welder
18 31.42 1.02 5.18 4.71 3.85 0.79 46.97 7.05 54.02
(Journeyman)

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Average Union Wage Rates (Pennsylvania): 3rd Q 2017:

Abbreviations
FB/H = Fringe Benefits - Holidays
WCI = Workers Compensation Insurance Average
EA = Each
LF = Lineal Feet
F&S / FICA = Federal & State Unemployment / FICA
M-H = Man Hours
ST&C = Small Tools & Consumables
SS = Safety Supplies
ST = Sub Total
HO & S & P = Home Office Support & Profit
**THR (W/O per Diem) = Total Hourly Rate without per diem
per Diem)

Trade / Skill Base FB/HWP WCI F&S / FICA ST&C SS 2.5% ST HOS & P THR
Hourly Average Average Average $4.35 15% (W/O)**
Rate 4.25% 16.50% 15% per diem)

Carpenter
1 35.30 1.50 5.83 5.30 4.35 0.88 53.16 7.97 61.13
(Journeyman)
Mason / Bricklayer
2 35.15 1.49 5.80 5.27 4.35 0.88 52.94 7.94 60.88
(Journeyman)
3 Concrete Finisher 26.83 1.14 4.43 4.02 4.35 0.67 41.44 6.22 47.65
Equipment
4 Operator (Heavy 35.76 1.52 5.90 5.36 4.35 0.89 53.79 8.07 61.85
Crawlers / Cranes)
Electrician
5 39.35 1.67 6.49 5.90 4.35 0.98 58.75 8.81 67.56
(Journeyman))
Instrumentation
6 Installer 39.35 1.67 6.49 5.90 4.35 0.98 58.75 8.81 67.56
(Journeyman)
Insulator
7 33.45 1.42 5.52 5.02 4.35 0.84 50.60 7.59 58.19
(Journeyman)
Ironworker
8 35.80 1.52 5.91 5.37 4.35 0.89 53.84 8.08 61.91
(Journeyman)
9 Laborer 23.99 1.02 3.96 3.60 4.35 0.60 37.52 5.63 43.15
Millwright
10 38.44 1.63 6.34 5.77 4.35 0.96 57.49 8.62 66.12
(Journeyman)
Oiler / Mechanic
11 36.06 1.53 5.95 5.41 4.35 0.90 54.20 8.13 62.33
(Journeyman)
Pipefitter
12 38.43 1.63 6.34 5.76 4.35 0.96 57.48 8.62 66.10
(Journeyman)
13 Painter 29.85 1.27 4.93 4.48 4.35 0.75 45.62 6.84 52.47
Refractory
14 35.40 1.50 5.84 5.31 4.35 0.89 53.29 7.99 61.29
(Journeyman)
15 Rebar Installer 34.95 1.49 5.77 5.24 4.35 0.87 52.67 7.90 60.57
16 Scaffolder 29.48 1.25 4.86 4.42 4.35 0.74 45.10 6.77 51.87
Truck Driver / JLG
17 26.94 1.15 4.45 4.04 4.35 0.67 41.60 6.24 47.84
Lift
Welder
18 38.47 1.63 6.35 5.77 4.35 0.96 57.53 8.63 66.16
(Journeyman)

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1.50 Million Ton per year USA North East Ethylene Facility 1/1/2017 to 12/31/2017

Cost Categories Qty UoM Material M-H's M-H Rate Labor Cost Minimum Total Material M-H's M-H Rate Labor Cost Maximum Total

Major Equipment (M.E.)

Columns c/w trays 70 EA 292,388,671 38,220 34.26 1,309,325 293,697,996 380,105,272 49,686 44.53 2,212,760 382,318,032
Drums / Vessels 67 EA 16,536,026 32,220 34.26 1,103,780 17,639,805 21,496,833 41,886 44.53 1,865,388 23,362,221
Pumps 98 EA 14,586,472 16,560 34.26 567,306 15,153,778 18,962,413 21,528 44.53 958,747 19,921,160
Compressors / Fans / Blowers 25 EA 79,711,416 120,720 34.26 4,135,577 83,846,993 103,624,840 156,936 44.53 6,989,126 110,613,966
Heat Exchangers 91 EA 17,386,317 15,300 34.26 524,141 17,910,458 22,602,212 19,890 44.53 885,799 23,488,011
Tanks 7 EA 12,123,821 3,420 34.26 117,161 12,240,982 15,760,967 4,446 44.53 198,002 15,958,969
Material Handling 4 EA 13,595,999 4,320 34.26 147,993 13,743,992 17,674,799 5,616 44.53 250,108 17,924,907
Water Treatment 10 EA 4,189,213 2,280 34.26 78,107 4,267,320 5,445,977 2,964 44.53 132,001 5,577,978
Miscellaneous Equipment 19 EA 46,584,699 18,420 34.26 631,025 47,215,724 60,560,109 23,946 44.53 1,066,432 61,626,541
Electrical Equipment 29 EA 12,556,814 6,900 34.26 236,377 12,793,192 16,323,859 8,970 44.53 399,478 16,723,337
Instrumentation Devices
5,400 EA 14,725,360 154,800 34.26 5,303,076 20,028,436 19,142,968 201,240 44.53 8,962,199 28,105,167
(Tagged)
Freight ALLOW 16,003,650 16,003,650 20,804,745 20,804,745
Vendor Assistance ALLOW 1,287,140 1,287,140 1,673,282 1,673,282
Total Major Equipment (M.E.) 541,675,597 413,160 14,153,870 555,829,467 704,178,276 537,108 23,920,040 728,098,316
Removals / Demolition ALLOW 6,720,457 72,000 31.92 2,298,218 9,018,675 8,736,594 93,600 41.50 3,883,989 12,620,583
Site Earthmoving /
1,200,000 CY 26,397,903 720,000 31.92 22,982,184 49,380,087 34,317,274 936,000 41.50 38,839,891 73,157,165
Improvements
Piling 6,000 LF 6,639,394 144,000 31.92 4,596,437 11,235,831 8,631,212 187,200 41.50 7,767,978 16,399,190
Buildings 60,000 SF 6,639,394 216,000 31.92 6,894,655 13,534,049 8,631,212 280,800 41.50 11,651,967 20,283,179
Concrete 84,000 CY 35,521,388 168,000 31.92 5,362,510 40,883,898 46,177,805 218,400 41.50 9,062,641 55,240,446
Refractory / Fireproofing ALLOW 4,820,700 7,200 31.92 229,822 5,050,522 6,266,910 9,360 41.50 388,399 6,655,309
Structural Steel / Platforms 9,000 TON 28,860,238 288,000 33.90 9,762,422 38,622,661 37,518,310 374,400 44.07 16,498,494 54,016,804
Piping systems 780,000 LF 164,819,229 3,600,000 33.90 122,030,280 286,849,509 214,264,998 4,680,000 44.07 206,231,173 420,496,171
Insulation ALLOW 39,940,308 57,600 31.92 1,838,575 41,778,883 51,922,400 74,880 41.50 3,107,191 55,029,592
Electrical / Instrumentation 4,200,000 LF 10,382,370 1,440,000 33.90 48,812,112 59,194,482 13,497,081 1,872,000 44.07 82,492,469 95,989,551
Painting / Coatings ALLOW 2,660,866 86,400 31.92 2,757,862 5,418,728 3,459,126 112,320 41.50 4,660,787 8,119,913
Other Miscl Costs ALLOW 13,821,201 144,000 31.92 4,596,437 18,417,638 17,967,561 187,200 41.50 7,767,978 25,735,539
Bulk Material Costs 347,223,449 6,943,200 232,161,514 579,384,963 451,390,484 9,026,160 392,352,958 843,743,442
Fringe Benefits / Payroll Burdens 52,595,786 52,595,786 68,374,522 68,374,522
Consumables / Small Tools 20,129,591 20,129,591 26,168,468 26,168,468
Field Supervision & Expenses 1,458,000 42.21 61,538,243 56,410,056 1,895,400 54.87 79,999,716 73,333,073
Field Establish't (Trailers, Toilets) 8,040,822 288,000 32.30 9,303,077 17,343,899 10,453,068 374,400 41.99 15,722,200 26,175,268
Support Labor (logistics /
1,338,302 720,000 34.08 24,539,436 25,877,738 1,739,792 936,000 44.31 41,471,647 43,211,439
clean up)
Construction Equipt Rental /
80,518,368 210,000 34.08 7,157,336 87,675,704 104,673,879 273,000 44.31 12,095,897 116,769,776
Fuel
Heavy Lift Cranes 6,719,044 7,200 34.08 245,394 6,964,439 8,734,758 9,360 44.31 414,716 9,149,474
Scaffolding 671,906 360,000 32.30 11,628,846 12,300,752 873,478 468,000 41.99 19,652,750 20,526,228
Temporary field utilities 6,719,044 6,719,044 8,734,758 8,734,758
Taxes on Plant Hire consumables 6,719,044 6,719,044 8,734,758 8,734,758
H O Construction Support 144,000 81.19 11,690,698 11,690,698 187,200 105.54 15,197,907 15,197,907
Contractor Fee 66,915,064 66,915,064 86,989,583 86,989,583
Overtime - Shiftwork 13,383,011 13,383,011 17,397,914 17,397,914
BAR Insurance & Performance
20,102,055 20,102,055 26,132,671 26,132,671
Bonds
Other Costs 6,719,044 6,719,044 8,734,757 8,734,757
Freight (Bulk Materials) 9,362,600 9,362,600 12,171,380 12,171,380
Contingency 132,899,827 132,899,827 172,769,775 172,769,775
Indirect Costs 97,288,443 3,187,200 461,648,096 553,808,352 126,474,976 4,143,360 620,763,420 740,571,752
Total Construction Cost 986,187,489 10,543,560 707,963,480 1,689,022,782 1,282,043,735 13,706,628 1,037,036,418 2,312,413,511
Detail Design / Engineering M-H's 1,200,000 204,227,330 204,227,330 1,560,000 265,495,528 265,495,528
Project Management & Controls M-H's 100,000 20,422,735 20,422,735 130,000 26,549,555 26,549,555
Procurement - Subcontracts &
M-H's 100,000 20,422,735 20,422,735 130,000 26,549,555 26,549,555
P.O.'s
EPC Warranty 13,502,635 13,502,635 17,553,425 17,553,425
EP Fee 68,075,780 68,075,780 88,498,514 88,498,514
S/T 1,400,000 326,651,213 326,651,213 1,820,000 424,646,577 424,646,577
Total Project Cost
986,187,489 11,943,560 2,015,673,995 1,282,043,735 15,526,628 1,461,682,996 2,737,060,088
1,034,614,693
EPC Cost per Ton $1,344 $1,825
Cost per Major Equipment
$4,799,224 $6,516,810
420 Items
Cost per Major Equipment
5,820 Tagged Items (includes $346,336 $470,285
Instrumentation Devices).

Etimate Basis & Remarks:

Exclusions & Qualifications

Owner Costs (Engineering, Oversight & 3rd party Inspection)
Spare Parts
Initial Start Up Materials
Soil Testing
Based on 45 hour workweek
Above costs reflect 4th Q 2017 values

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Application of the appropriate location specific factors, provides a reasonable assessment of how costs will
differ. In reviewing the resultant estimate, it is important to note that achieving a reasonable level of estimate
accuracy will require not only consideration of high level adjustments, such as wage rates and estimated
productivity, but also consideration of review of project specific conditions that can significantly impact
cost. Perhaps the most significant factor to be considered is the availability of a qualified work force. In 2017,
resource availability was a point of discussion for virtually any new project. Locating a new plant in an area
already identifying labor shortages creates a multifaceted risk of cost increase including per diem cost, bonus
wages, lost productivity, excess overtime, etc. This should all reflected in the Project Execution Plan (PEP) which
is also an integral aspects of the estimate. The scope of work and supporting data outlined above provides the
“what” will be built, but the PEP provides the “how” and in today’s marketplace it is equally as important as the
“what”.
As the team analyzed the 2017 data, it was clear that a notable impact, (particularly on the Gulf Coast), is recent
extreme weather resulting in both a shortage of qualified labor and an increased level of construction activity
associated with repair work. While this impact can be viewed as temporary, a recent Compass International
report estimates that the impact over the next six months will range from 5% to 10% for construction support
equipment and other indirect costs, and 3.5% to 6.5% increase for craft labor. While the North East United
States is not expected to see this level of increased labor cost, it is clear that there will be impact relative to bulk
materials resulting from increased repair activity on a national basis. This impact is expected to range from 2.5
% to 5% for all projects, including those in the North East.
The team calculated equipment and material escalation rates for the project over 2017. For 2017 the escalation
rates for major equipment were 3.5% for materials and 4.5% for labor, giving an average of rate of 4%. The
escalation rates for bulk materials for 2017 were 3.5%, with a 0.7% increase in Q1, 0.7% for Q2, 0.7% for Q3 and
1.4% for Q4. Freight and vendor assistance both experienced escalation rates of 3% increase for all of 2017, with
a 0.5% Q1 increase, 0.5% Q2 increase, 0.5% Q3 increase and 1.5% for Q4. The team established a look ahead
escalation table that can be used to model potential escalation for calendar years 2018, 2019, and 2020.

2018, 2019 & 2020 Escalation Forecast

1st 2nd 3rd 4th Total 1st 2nd 3rd 4th Total 1st 2nd 3rd 4th Total
Q Q Q Q for Q Q Q Q for Q Q Q Q for
2018 2018 2018 2018 2018 2019 2019 2019 2019 2019 2020 2020 2020 2020 2020
US Gulf Coast
Materials 1.50 1.50 1.25 1.00 5.25 1.00 1.00 1.00 1.00 4.00 0.90 0.90 0.90 0.80 3.50
Labor 1.50 1.50 1.25 1.25 5.50 1.25 1.00 1.00 1.00 4.25 0.90 0.90 0.90 0.80 3.50
US North East
Materials 1.25 1.00 1.00 1.00 4.25 1.00 1.00 1.00 1.00 4.00 0.80 0.80 0.80 0.80 3.20
Labor 1.25 1.00 1.00 1.00 4.25 1.00 1.00 1.00 1.00 4.00 0.80 0.80 0.80 0.80 3.20

While the level for the Gulf Coast is slightly higher than that in the North East, reflecting the more direct
impact of recent weather events, both geographic locations reflect a level of increase that represents further
challenges for the industry. It is clear that that the seemingly endless escalation of Construction costs is not
limited to a single event or short term impacts but also includes potentially more significant circumstances
such as a diminishing pool of experienced/qualified work force, the industry’s failure to anticipate and
accommodate cyclical marketplace conditions and a failure to apply innovation and technology in an effective
manner. These topics have a negative influence on industry participants that manifests itself as a continual
deterioration in construction productivity, performance and associated cost effects.

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While the overall prognosis is somewhat disconcerting, given decades of deteriorating, or, at best unchanged
performance, it is becoming clear to industry leadership that focus on improvement and innovative solutions
is appropriate. Owners, Contractors and Industry Associations are all actively involved in initiatives that are
starting to show results. Unfortunately, long term solutions such as technology advancement and revised
Construction processes, will take time and are unlikely to have any material impact on the current generation
of Ethylene projects. A look at current conditions leads to the conclusion that the rate of escalation will slow
or at least stabilize as the impact of recent weather events is fully absorbed and the three year outlook is
expected to be as presented in exhibit 7.
In any event, while the analysis presented in this article may be utilized as a basis/input to development
of Ethylene Project Cost Estimates, there is no substitute for thorough marketplace and labor availability
assessments, realistic consideration of project specific risk factors and effective application of Risk Analyses,
such as Monte Carlo Simulation based techniques to arrive at a reasonable level of Cost Estimate accuracy and
predictability upon which alternatives can be analyzed and informed business decisions can be made.

JANUARY 2018 US ETHYLENE COMPLEX CONSTRUCTION COSTS DATA 2018 – 2020 | 11