❄️ Module 1: HVAC Estimating Fundamentals

Core principles for estimating HVAC in new construction and retrofit projects — structured for estimators, HVAC techs, apprentices, and PMs entering mechanical takeoffs and bidding.

🎯 Course Goals

• Understand HVAC system types/components and how design choices drive cost.
• Develop a consistent method for ductwork, piping, and equipment takeoffs.
• Read mechanical plans/schedules accurately and cross-reference specs.
• Apply labor units and material pricing with realistic productivity factors.
• Assemble competitive bids with clear inclusions, exclusions, and assumptions.

🗂 Course Modules

1) HVAC System Basics

• System types: Split/heat pump, RTU, VRF/VRV, WSHP, Chiller/Boiler plant, DOAS, ERV/HRV.
• Key components: AHUs/RTUs, fans, coils, condensers, chillers/boilers, terminal units (VAV/FPB), ductwork & fittings, grilles/diffusers/Registers (G/D/R), dampers, controls.
• Zoning & loads: what drives tonnage/CFM (envelope, occupancy, ventilation, process loads), and how zoning impacts duct/pipe quantities, controls points, and TAB.
• Cost levers: static pressure, duct sizes/gauges, equipment selections, routing/access, code-driven ventilation, and control strategy (standalone vs. BAS).

2) Plan Reading for Estimators

• Navigating M, A, S, P, E sheets; use architectural for elevations/ceilings and structural for penetrations/supports.
• Symbols & tags: duct/pipe arrows, size/gauge tags, diffuser/return tags, equipment keys, controls points.
• Schedules: AHU/RTU/VAV, diffuser schedules, valve schedules, control device lists; cross-check against notes and details.
• Addenda & bulletins: how to cloud differences and maintain a revision log (see template below).

3) Ductwork Takeoffs

• Measure LF of mains/branches; classify by width/height and pressure class/gauge.
• Count fittings: 90°/45° elbows, transitions, reducers, offsets, tees/wyes, volume fire/smoke dampers.
• Support/hangers: spacing by code/spec; allow for trapezes, threaded rod, seismic bracing where required.
• Waste/overage: typical 5–10% by shop standard and project complexity (document your rationale).

4) Piping & Condensate Takeoffs

• Identify systems: refrigerant piping (suction/liquid), hydronic (CHWS/R, HHWS/R), condensate drains, condensate pumps.
• Quantify pipe sizes by system; fittings per standard takeoff (elbows, tees, couplings, unions, valves).
• Add insulation thickness/type by spec, hangers/strut, anchors/guides, sleeves and firestopping at penetrations.
• Roof/floor penetrations: curb/roof jack allowances; coordinate flashing with roofing spec.

5) Equipment & Controls

• Locate equipment; record CFM/tonnage/voltage/weight/dimensions for rigging and power coordination.
• Controls scope: packaged vs. DDC/BAS; points list, network cabling, sensors, actuators, safeties; tie-ins to fire alarm.
• Startup/commissioning/TAB: include factory startup line items and TAB by system; capture test ports and balancing dampers.

6) Labor & Cost Calculations

• Use shop labor tables (e.g., per fitting or per LF) as a baseline; adjust with project conditions (height, access, congestion, occupied).
• Price materials: sheet metal by area & gauge, flex length, pipe by size/schedule, valves, insulation, supports, specialty items.
• Don’t forget: permits/fees, lifts/cranes, demo/haul-off, temp protection, badging, O&M manuals, training time.
• Stack pricing in order: Direct Cost → Contingency → Overhead → Profit (margin).

7) Final Estimate & Bid Package

• Summary sheets & breakouts by system (Airside, Hydronic, Refrigerant, Controls).
• Professional scope letter with inclusions/exclusions/assumptions, alternates, unit prices.
• QA/QC pass: math audit, spec alignment, vendor quote log, long-lead notes, schedule constraints.

📋 Sample Takeoff Templates

Ductwork Takeoff (Rectangular)

Piping/Hydronic Takeoff

🧮 Mini Tools

🧠 Controls, Startup & Commissioning — What to Include

• DDC/BAS points list, network topology, panels/power, sensors/actuators, safeties, integration to FA.
• Factory/startup visits (qty of trips, hours), TAB scope (who furnishes instruments?), trend logs, sequences testing.
• Owner training hours & manuals; as-builts/OM submittals and closeout documentation.

🧪 QA/QC & Common Pitfalls

• Verify diffuser counts by room schedule; reconcile against plan symbols.
• Confirm duct pressure classes/gauges match spec table by size and system (supply/return/exhaust).
• Check roof penetrations/curbs against architectural/roofing notes; coordinate flashing responsibility.
• Don’t miss seismic requirements, condensate routing, access panels/clearances, or controls wiring ownership.
• Long-lead equipment (RTU/chiller/VAV) → call out schedule risk and quote validity.

📂 Standards — Folders, Naming & Logs

• File names: YYYY-MM-DD_QTO_Duct_.csv, YYYY-MM-DD_QTO_Pipe_.csv, Estimate__V##.xlsx
• Revision log: Addendum #, date, sheets affected, summary, who updated, export filename.

📝 Scope Letter (Copy/Paste)

🧠 Practice & Exit Ticket

1. Count supply/return diffusers for one floor and reconcile to the schedule.
2. Takeoff one main duct run with fittings and compute surface area (use tool above).
3. Quantify 150 LF of CHWS/R (2") with standard fittings and insulation thickness per spec.
4. Apply labor factors (height + congestion) to a 40-hour base and report adjusted hours.
5. Build a mini bid stack: DC $85k, Cont 5%, OH 10%, Margin 12% → compute price.