1. October 2004 Through September 2005
Order of Magnitude Scope and Cost Estimate for a Design-Build Contract Package for the Braidwood Theta 13 Experiment
October 2004
Through
September 2005

2. Background
Proposed as an engineering scope needed to prepare a Design-Build bid package for tender in the Fall of ‘05
Order of magnitude estimate based on:
Regional geologic data sets (no site-specific data)
An allowance for Electrical/Mechanical finish-out
Excludes studies of detector hoisting/transportation needs
Excludes cost for additional site investigation work
The overall process outlined is consistent with principles-of-practice set-out for Design-Build Contracting:
US Design & Build Institute and
US Guidebook “Design-Build Subsurface Projects”
Redpath Engineering Handbook

3. Braidwood Design-Build Design Scope
Underground Design Scope
2 Vertical Shafts
2 Sump Chambers
2 Detector Chambers and connector tunnels
Surface Design Scope
Utility Runs
Fenced/Gated Platforms
Industrial Assembly Buildings
Note: Under Design-Build Delivery Format
Layout, Requirements & “Baseline Design” by Owner-Designer
Final Design-Build by Contractor

4. Why Design-Build? Faster and potentially cheaper. However,
Key that owner requirements be defined early in process:
Owner commitment needed to avoid after-bid scope growth (build margin into scope to cover scope creep / experiment uncertainties)
Early focus on development of a well-defined set of requirements that gives bidding contractors maximum design flexibility….
Leave detailed design and construction to Contractor
Contractor knows best how to manage/use local labor, methods, means and materials most cost-effectively
Additional Onus on Owner to select a good contractor and oversee the work (design reviews/approvals, QA inspections etc..)
Greater potential for owner and contractor to work together (longer-term, less adversarial relationship with fewer intermediaries) but great reliance on contractor competence

5. Proposed Activities
Rough timeline for accomplishment of the main engineering and procurement tasks:
October - February
Selection/Tasking of Design Contractor(s)
Fix Experimental Design Requirements for D-B Contract
Start Engineering and Procurement Tasks…
January - June
Engineering Activities: Geology/Geotechnical, Civil/ Structural, Electrical, Mechanical (Budget/Schedule Input)
Budget/Schedule Baseline Developed
Procurement Activities: Pre-Qualification, Bid Package Preparations

6. Geology & Geotechnical Engineering Tasks ~ $75k
Geologic/Geotechnical Characterization of:
Ground units
Ground water tables and unit permeabilities
Viable options identified, baseline design developed
Excavation Methods
Rock Support Systems (Bolts, Shotcrete..)
Water Control Systems (Grouting, Drain Systems..)
Layout Optimization
Develop Outline Specifications
Meetings, reporting, reviews, contract documentation etc..

7. Civil/Structural Engineering ~ $50k
Surface Platform Requirements and Baseline Design
Work Platforms & Buildings
Utility Runs and Access Roads
Etc..
Underground
Shaft Lining Requirements and baseline Design
Soil and Rock Units
Equipment Mountings..
Invert/Floor Requirements and baseline Design
Drains, Rails, Equipment Mountings..
Outline Specifications
Meetings, reporting, reviews, contract documentation etc..

8. Electrical Engineering ~ $25k
Power and Communications
Electrical services
Enclosure normal/emergency lighting, outlets, cable trays, sump systems, grounding, include technical space needs for electronics (DAQ)
Distribution system requirements (transformers, distribution panels, underground ducts, grounding, and raceways)
Fire detection systems
Emergency generator system(s)
Outline specifications
Meetings, reporting, reviews, contract documentation etc..

9. Mechanical Engineering ~ $25k
HVAC
Load calculations
Fire Protection
code review, system parameter selection and associated diagrams
Groundwater Pumping
Drain, sump, pump system layouts and associated diagrams
Other Utilities
water, gas, sanitary, as required
Spatial layout of (equipment/ducting/piping..)
Outline Specifications
Meetings, reporting, reviews, contract documentation etc..

10. Drafting ~ $75k
General Design Criteria (scale-approximate “schematics”)
Title Sheet, Location Plan, Notes and Legend
Design Criteria (Near & Far Sites)
Surface Layout and, Shaft, Tunnels and Chambers
Design Drawings (scale-accurate)
General
Existing conditions and road/utility runs for Near Site & Far Site
Underground
Space Envelopes and Elec/Mech Finish-Out
Surface
Platform/Road Footprints, Utility runs, Building Envelopes and Elec/Mech Finish-Out
Electrical/Mechanical Drawings (line diagrams)
HVAC and electrical systems
Meetings, reporting, reviews, contract documentation etc..

11. Schedule/Cost ~ $25k
To Support the Construction Proposal and Project Planning
Cost Estimate Methodology
Cost Estimate/Schedule
Quantity Take-Offs
Equipment Selection
Crew Sizes/Make-ups
Production Rates
Schedule
Risk Analysis
Etc..
Contingency Setting

12. Other Costs ~ $50k Environmental Safety and Health Land Survey
Initial evaluation and findings/recommendations
Contract ES&H requirements and permitting
Contractual ES&H instruments to ensure compliance
Additional site investigation needs and monitoring
Land Survey
Site layout
Access routes
Meetings, reporting, reviews, contract documentation etc..

13. Project Management & Contract Administration ~ $75k
Inter-Agency Coordination
Plant Owner, Funding agency(ies), Owner’s Representative
Management agreement(s)
Coordination of Engineering Reviews
Constructability and Value Engineering Reviews
Work-in-Progress and Proposal Reviews
Contract Administration
Procurement & Execution Plans (ref. other projects, DBI format)
Contract Development/Formatting/Assembly
Contractor Selection - Pre-qualification
Project Controls Establishment (Cost, Schedule, Risk.. Tracking)
Meetings, reporting, reviews, contract documentation etc..

14. Cost Summary ~ $500k (with 25% Contingency)
$25k increments - don’t want to give the impression that this is anything but an order of magnitude estimate ($25k represents ~1 senior engineering-month, or ~2 junior engineering-months)
$75k Geology/Geotechnical
$50k Civil/Structural
$25k Electrical
$25k Mechanical
$75k Drafting
$25k Schedule/Cost
$50k Other Costs
$75k Management/Administration/Bid Package Preparation
(Design shown in basis of estimate is straightforward - there should be design duplication between near/far site so costs could go down but at this point in time think the above numbers provide a reasonable starting point)
Contingency ~ 25%

15. Summary
It is assumed that the work will get us to a point where the contract can be approved and bid:
Adequate up-front engineering ($500k ~ a 25% design level)
Ensure that bidding contractors know what is required
Support funding decisions
Upfront engineering by a “design contractor” with firsthand tunneling experience (builder-led with access to PE/SE).
Design progress should be documented/reviewed by other qualified bidders so that “design contractor” does not get a bidding advantage.
Final permit/design work will be done by Design-Build Contractor.
Additional tasks may be required to comply with agency requirements (e.g. added documentation, planning and/or review cycles etc..).
The budget may need significant adjustment depending on the disposition of partners. Suggest that we discuss internally and with our partners before writing a formal proposal.