*W :«ll^ *bv* star- 'b^ ^ ^ *- G° ♦• • ♦♦*% -$P>- /\ °™* : ** v % «• „/\ o K "W :£K^»' *bf r-^IK- '++ C u ♦ •^o* «5°«* »./ -o/»\ ^ V^\/ V^V V* 8 <*"% WW" «r^ \^/ /\ °-l?# ** v % M; **v ^ » ^°^ W •"• ! 4 \G*" o 'o. T * A <. "-^TT* * "o *o~. 7 * A *bv^ ^ v * ^ v V /•v^.->o /A\ ..-$&. X J*^ •> "oV D >"0 N 'bV" ' * £°* v v s'VL% o W ,0 V \5 *o . » * A -^ .t.o. <% A ^^ ^o A o* >V «*t, <"^ »1*"' » •» ^0« fl5°^ *-P|^too' *0^. >.<^m^ r * Ao ^> l V » v * v v jsi^L.% <^ * A>*% -of 1 .^Ai>/^ a.^ .^-A. .4.9* ..IV- •A, « ^° A ^ v t*lrf4:* ^ aO ^ V , O • „ *<6 ^ , •*. A \ V ^ • UB * ^3 <& r ° " ° ,0 <£ «V L I . *Z* rt\ V* • • • \& °^ ° • » " ,G O *o . » * A, )* e'\L^ *0. ^ < '^c," v\^ ^^. ' . . « ' .6 V o *o . » » .a. <^ C** »^V»l\ ^- A* •' ^cS ' ,4Pv. * • A a 4 ^ «*<^W* % G° S&JffzL* ^ o ^ ^ *^^ Ho* ^ v ... ^ "**" aO 1 <^ **"•• ,G V ^" . *bK «5 Xv ^ **^* a0° ^ **7rV^ ^ °q, -. °^ '".o a0^ V *•'■••"- ^ % aP v .!••*. *> V % *• V*» 'c\ <0 V .' n Bureau of Mines Information Circular/1986 Company Towns Versus Company Camps in Developing Alaska's Mineral Resources By Robert Bottge UNITED STATES DEPARTMENT OF THE INTERIOR tJMMMMIWMMIil llW M t t au ur i fMAmim ivHm m i Hr im m r w r MJtn i wWFl ' m ' J l TJi! ClMfaJtibti*. b*fi»*rf'!M£ Information Circular 9107 // ,r Company Towns Versus Company Camps in Developing Alaska's Mineral Resources By Robert Bottge UNITED STATES DEPARTMENT OF THE INTERIOR Donald Paul Hodel, Secretary BUREAU OF MINES Robert C. Horton, Director i.iiinni—uiinmaili.lllJManra o 1 ^ Library of Congress Cataloging-in-Publication Data Bottge, Robert. Company towns versus company camps in developing Alaska's mineral resources. (Information circular; 9107) Bibliography: p. 5 Supt. of Docs, no.: I 28.27: 9107 1. Miners — Alaska — Housing. 2. Industrial housing — Alaska. 3. Mineral indus- tries — Alaska — Employees — Housing. 4. Company towns — Alaska. I. Title. II. Company camps in developing Alaska's mineral resources. III. Series; Information circular (United States. Bureau of Mines); 9107. TN295.U4 622 s [HD7289.5.M5982U53] [307.7'67'097981 86-600228 CONTENTS Page Abstract 1 Introduction 2 Company towns 2 Company camps 2 The commuting option 2 Economic considerations 3 Hypothetical underground mine example 3 Hypothetical open-pit mine example 4 Page Conclusions 5 References 5 Appendix A. — Capital costs 6 Appendix B. — Operating costs 9 Appendix C. — Estimating the work force size .... 11 ILLUSTRATIONS A-l. Alaska capital cost factors back pocket A-2. Townsite costs versus total employees, 1984 dollars 7 A-3. Campsite costs versus total employees, 1984 dollars 8 C-l. Total employees versus daily tonnage in cut-and-fill mining 12 C-2. Total employees versus daily tonnage in blasthole mining 13 C-3. Total employees versus daily tonnage in open-stope mining 14 C-4. Total employees versus daily tonnage in long-hole mining 15 C-5. Total employees versus daily tonnage in shrinkage-stope mining 16 C-6. Total employees versus daily tonnage in room-and-pillar mining 17 C-7. Total employees versus daily tonnage in open-pit mining 18 TABLES 1. Mine assumptions 3 2. Capital and annual costs and required copper prices by region for a 1,000-st/d underground mine 4 3. Capital and annual costs and required copper prices by region for a 50,000-st/d open-pit mine 4 C-l. Cut-and-fill mining data 12 C-2. Blasthole mining data 13 C-3. Open-stope mining data 14 C-4. Long-hole mining data 15 C-5. Shrinkage-stope mining data 16 C-6. Room-and-pillar mining data 17 C-7. Open-pit mining data 18 C-8. Estimate of mine and mill personnel by type of mining 19 I IW WH I M IH ■•"'-—-"' ■ mlMHMIIIUHMlllMUMIIIll UNIT OF MEASURE ABBREVIATIONS USED IN THIS REPORT d/wk day per week St short ton h hour st/d short ton per day h/d hour per day yr year COMPANY TOWNS VERSUS COMPANY CAMPS IN DEVELOPING ALASKA'S MINERAL RESOURCES By Robert Bottge 1 ABSTRACT When a company develops a mineral property in a remote area of Alaska, it must consider how best to house its personnel. This Bureau of Mines report examines the economics of two options: company towns and company camps. The price required to maintain a 15% discounted-cash-flow rate of return (DCFROR) was derived for hypothetical 1,000-st/d cut-and-fill mines and 50,000-st/d open-pit mines located in three different regions of the State. One set of hypothetical mines utilizes a townsite; the other utilizes a relatively new concept, a fly-in camp or commuting operation, in which two shifts of employees operate the mine and all associated facilities for 1 week before being replaced by a second crew. The study shows that operating costs were higher for mines employing the commuting option than for mines having a company town because of the additional wages paid for overtime hours; however, the price required to obtain a 15% DCFROR for the single-product copper concentrate, f.o.b. the mill site, was significantly lower owing to the lower investment costs for the camp-type operation. The economic advantage for those mines utilizing the camp increases from south to north and from the coast toward the interior. 'Mineral economist, Alaska Field Operations Center, Bureau of Mines, Juneau, AK. INTRODUCTION The development of mineral deposits in Alaska usually involves the need to provide living accommoda- tions for employees. The options range from constructing a camp for which the company provides room and board to building a townsite which is administered by the company with housing for single people as well as those with families. The capital cost of providing housing for personnel in remote areas must be weighed against the operating costs inherent with each option. If the company operates only during the summer, it will likely opt for mobile bunkhouse units. However, if the company mines year-round, it may want to consider a different set of options. This report explores two housing options avail- able for long-term permanent mining operations and analyzes the impact of each on the total cost of two mining ventures in three regions of the State. A computerized costing system was used for develop- ing cost data. The system developed for the Bureau of Mines was designed to estimate capital and operating costs within ± 25% of actual costs for the 48 contiguous States (3). 2 For Alaska, the costs were modified to reflect higher local costs. While the exact values determined by the model should be viewed cautiously, this method seems reasonable for the purpose of comparing the cost of the housing options explored here. For determining the price required to obtain a 15% discounted cash flow rate of return (DCFROR) for each mining scenario, a second computer program developed by the Bureau of Mines was utilized. The Mine Simulation Program (MINSIM8) 3 was capable of handling all data input without modification. COMPANY TOWNS Company towns are those communities in which 75% of the work force serves a single industry and its supporting companies (25). Commonly the towns are associated with resource-based or transportation-related industries involved in mining and smelting ore, cutting and processing trees, processing pulp and paper, or building, maintaining or servicing railroads. Though the resource that motivates their creation will eventually be exhausted, many mine-related towns may be viewed as relatively permanent. However, when the projected mine life is less than 30 yr and the location is remote, the company often is compelled to build apart- ments or homes for its employees which it then rents to them, generally at a nominal fee. It must also provide schools, churches, a community center, streets, sewers, water, electricity, telephones, landscaping, stores, offices, and a hotel. Once the town is built, the company must operate and maintain all these facilities. In addition to running the mine and mill complex, the mine manager or superintendent also assumes final responsibility for the townsite. The newer towns tend to be more isolated, more technologically intensive, and more carefully planned, and to have more government participation in community development (12). Tumbler Ridge, BC, Canada, exem- plifies this new movement in town conception and development. Here, the Province of British Columbia has created an autonomous townsite to serve two new coal mines that are operated by a private company (8). Because an incorporated town might be eligible for government funds for such municipal services as schools, fire protec- tion, hospitals, sewers, and water, the company's financial burden may be lower than if it had to provide these services itself. COMPANY CAMPS Camps differ from townsites in one principal way: while a townsite usually has a mix of single and married people housed in dormitories, apartments, mobile units, houses, and multifamily structures, a camp usually consists of either portable or permanent structures for housing working employees only. Housing facilities in a small company may consist of a bunkhouse for sleeping all employees and another unit for preparing and serving meals; larger companies may provide a number of bedrooms to sleep four to six employees off a central living area. Still larger companies may provide dormitories with a number of bedrooms off a corridor leading to a recreation room, dining room, and laundry. The number of square feet of living space varies with the company and the longevity of the project. THE COMMUTING OPTION Historically, company-run camps were in remote locations. Wages were high to entice employees, usually men, to work there. But turnover was high and the employees left as they accumulated a "nestegg," com- pleted a contracted work tour, found employment closer to their homes, were lonely for their families, or just drifted on. In an attempt to stabilize the workforce in remote locations and lower operating costs, companies operating in northern Canada have introduced a number of 2 Italic numbers in parentheses refer to items in the list of references preceding appendix A. 3 Further information on MINSIM8 may be obtained by contacting the Division of Minerals Availability, Bureau of Mines, Washington, DC. commuting options. Employees are brought to a remote site at company expense, work a relatively short, predetermined work schedule, and then are returned to a home location. A number of scenarios have been im- plemented, including seven 12-h days at the work site and seven days at home (called seven on-seven off or seven-twelves), 20 days on and 10 days off, 30 days on and 14 days off, and 6 weeks on, 2 weeks off (13). The results of the various programs indicate that the shorter the work period, the lower the turnover rate (13). In Alaska, the oil industry in Cook Inlet has long worked its platform employees 12-h days, 7 days on and 7 off. The same work schedule has been followed for the oil-related activities on the North Slope and the Trans- Alaska pipeline pump stations. At the Polaris Mine on Little Cornwallis Island, NT, Canada, "southerns" work 10 weeks on and 2 weeks off while the Native Inuit work either that schedule or 6 weeks on and 4 weeks off (20). In other Canadian mines, the system of seven on-seven off is often employed (4, 9, 14). Chenard said the seven on-seven off system seemed the most suitable for everybody involved (6). Cominco, Ltd., is planning to implement a commuting program for its employees at the Red Dog Mine in northwestern Alaska during the projected 50-yr life of the mine (2). ECONOMIC CONSIDERATIONS Labor is a major cost in any mining venture, and labor turnover reduces efficiency and raises operating costs. While the fly-in or commuting option is not a panacea for all remote mining ventures, it does provide some benefits for the company and for its personnel. Employees receive large paychecks and large blocks of time off to spend with their families or for other activities. The company tends to attract more mature, family- oriented people who give the company stability, good performance, fewer accidents, less absenteeism and lower turnover. (3). The company's capital costs for the venture are lower because it does not have to build, manage, and maintain a remote townsite. To measure the impact of each housing option on the total economic picture for a mining venture, two types of mines are proposed in three geographically different parts of Alaska: Southeast, South-Central, and North-Central. An underground cut-and-fill operation producing 1,000 st/d and a 50,000-st/d open-pit mine are examined with the fly-in or commuting option and with the townsite option. HYPOTHETICAL UNDERGROUND MINE EXAMPLE The assumptions for the three cut-and-fill mining scenarios were essentially the same (table 1). Major cost differences occurred with the different regional locations. Capital and operating costs for the mines, concentrators, and town or camp sites increased from south to north and from coastal to interior locations. Regional capital and operating costs are discussed in some detail in appendixes A and B. Major differences in capital and operating costs occurred with the choice of a town or camp site. For the townsite scenario, 428 people were required to fill the 102 positions in the mine (358 employees) and the concentra- tor (70 employees) for the three 8-h shifts each day. Appendix C discusses the number of employees likely to be employed in six types of underground mines and in open-pit mining. A commuter campsite required 204 people for each week's crew (171 in the mine and 33 at the concentrator). Because each crew worked 1 week and was off 1 week, a total of 408 people was required. The difference in the total of 428 people for a townsite and 408 for a campsite was due to the number of hours worked; townsite employees worked 8 h/d, 5 d/wk, and campsite employees worked 12 h/d, 7 d/wk. Both the mine and the concentrator in the townsite and campsite operations were assumed to run 7 d/wk. The town would have to be large enough to house a pool of additional employees equal to 20% of the work force to fill in for those people on annual and sick leave, or in training, or for those who had quit. For the camp option, the towns and villages surrounding the point of embarkation would house the excess people for the mine and concentrator. The townsite not only had more employees, but each employee could be expected to add anywhere from 0.7 to 1.8 additional people to the townsite, depending upon how strongly the company encouraged families to live there. In January and February 1982, the town of Faro, YT, Canada, had 2,128 people when the Anvil Mining Co. had 767 direct employees, a ratio of 2.77:1 (11). In 1973, the town of Clinton Creek, YT, Canada, had 515 people living TABLE 1 . — Mine assumptions Underground Open-pit Assumptions cut-and-fill mine mine Town Camp Town Camp Total employees, mine . . . 358 171 428 204 Total employees, concentrator 70 33 378 180 Work tours, hours per week 40 84 40 84 Type of ore deposit Copper Copper Reserves st . . 5,20C.'X>: 345.iJ0u.0Cii! Ore grade % . . 5 0.5 Mining rate, ore . . st/d . . 1,000 35,000 Mining rate, waste st/d . . 15,000 Mine life yr . . 15 30 Mine-mill operating efficiency % . . 90 90 Ore recovery % . . 95 100 Mine locations were remote from major cities Yes Yes Ground transportation connected mine to supply sources Yes Yes All price determinations were at the mine site before smelter and refining charges and transportation costs . . . Yes Yes 15%DCFRORon investment was assumed Yes Yes Straight-line depreciation was used on all items . Yes Yes Standard State and Federal taxes were assumed Yes Yes iwtTw i nn i mm mmwiii ii i i wii i nii«MiwiMffi« « «i^^ at the site of the Clinton Mine Division of Cassiar Asbestos Corp., Ltd., which had 296 direct employees, a ratio of 1.74:1 (5). In this report a ratio of 2.66:1 was arbitrarily chosen, which meant that the townsite contained 1,150 people. A ratio of 2.66:1 indicated that the company's policy was to encourage workers with families to settle in the town and stabilize the work force. A townsite for 1,150 people cost considerably more than a campsite for 204, not only because of the physical size of the town, but also because of the need for larger diesel electric generators, domestic water facilities, fire protection, shopping and recreational areas, etc. On the other hand, the campsite cost more to operate. The difference was in the salaries. Personnel in the town worked five 8-h days per week; camp employees worked seven 12-h days, which included 44 h of overtime per week. Table 2 summarizes capital and annual costs for a 1,000-st/d underground mining venture for three regions of Alaska utilizing a campsite or a townsite. Total initial capital costs are given for each venture, including the initial housing and electrical costs. Because housing and electrical costs are the major components being varied in the study, they are also shown separately in the second column. Direct annual operating costs, without deprecia- tion, are given to show the impact of the greater wages in the camp situation. The required price (revenue) per short ton of copper metal and per short ton of ore mined are also given for each scenario. In both cases, the required price assumes a 15% DCFROR on the respective investment. The table indicates that the combination of relatively lower capital costs and relatively higher annual operating costs in the mining scenario utilizing a campsite produced a cheaper copper price f.o.b. the mill than a mining situation utilizing a townsite. Further, as capital and annual costs increase from south to north, the choice of a campsite becomes more advantageous. HYPOTHETICAL OPEN-PIT MINE EXAMPLE To check the validity of the calculations made in the first example, a second one was constructed. An open-pit mine moving 35,000 st/d of ore and 15,000 st/d of waste was proposed. All assumptions made for the underground mine applied to the open-pit example except those regarding total personnel and the ore deposit (table 1). The method and cost factors for determining capital and operating costs for the open-pit mine were the same as those employed for the underground mine, with one exception: the open pit miners were paid less than the underground miners. Table 3 summarizes capital and annual costs and required concentrate prices for a 50,000-st/d open pit mine in three regions of Alaska. The table 3 data indicate that TABLE 2.— Capital and annual costs and required copper prices by region for 1,000-st/d underground mine 1 £?.;!! housing and I°' a ' Required Required n«„i„„ ™£ electrical JSISSL revenue revenue Re9 ' on S££? capital °S3 g per st per st ore costs ' costs costs ' coDDer 4 mined 5 millions m°l?ons millions PP Southeast Alaska: Camp $93.7 $21.5 $32.2 $1,514 $196 Town 162.2 86.1 27.4 2,025 262 South-Central Alaska: Camp 123.2 27.9 33.5 1,733 224 Town 205.5 112.0 31.1 2,490 322 North-Central Alaska: Camp ■ 1 50.5 34.9 37.8 2,001 258 Town 261.4 140.0 35.8 3,020 390 'Required price is the price to maintain a 15% DCFROR on investment. includes environmental impact statement, exploration, access, mining, beneficiation, housing, and electrical costs; the latter 2 categories are also shown separately in the next column. ^Direct operating costs including mining, beneficiation, administration, transportation, housing, and electrical costs. "Total revenues over the life of the project (including depreciation and amortization costs) divided by total short tons of recovered copper. 5 Total revenues over the life of the project (including depreciation and amortization costs) divided by the total ore mined. TABLE 3. — Capital and annual costs and required copper prices by region for 50,000-st/d open-pit mine 1 To . ta ] housing and J^L Required Required Dq „™ f i electrical „„"".' revenue revenue 9 ° cos P s ca P ital S" 9 P erst P erst ° re c °f ts ' costs, co ,f ts ' copper 4 mined 5 mllllons millions milhons _ Southeast Alaska: Camp $774.3 $58.2 $96.8 $1 ,800 $28 Town 893.8 172.1 89.0 2,022 31 South-Central Alaska: Camp 1,020.7 75.6 102.7 2,265 35 Town 1,175.6 223.7 97.0 2,580 40 North-Central Alaska: Camp 1,239.0 94.5 113.9 2,693 42 Town 1,433.6 279.6 109.7 3,104 48 'Required price is the price to maintain a 15% DCFROR on investment. includes environmental impact statement, exploration, access, mining, beneficiation, housing, and electrical costs; the latter 2 categories are also shown separately in the next column. ^Direct operating costs including mining, beneficiation, administration, transportation, housing, and electrical costs. "Total revenues over the life of the project (including depreciation and amortization costs) divided by total short tons of recovered copper. 5 Total revenues over the life of the project (including depreciation and amortization costs) divided by the total ore mined. the open-pit mines having campsites were cheaper to construct than those having townsites. The operating cost for the campsite facility was greater than that utilizing a townsite. Over the life of the mine, the price required to maintain a 15% DCFROR was less for those facilities having a campsite. As with the examples using under- ground mines, the cost advantage for an operation using a campsite became greater from south to north and from coastal areas toward the interior. CONCLUSIONS In developing a remote site, a mining company must decide whether to place its personnel at the mine site or at a distant site from which they commute. Which option is chosen is based in part on company philosophy, but economics can play a big role in making the final decision. As seen from the hypothetical mine examples presented here, mine operations having fly-in or commuter camp- sites are cheaper to build and require fewer people at the site than those employing a town; therefore, initial investment costs are less. However, if a commuter or fly-in type campsite is used, operating costs are higher, primarily owing to higher personnel costs. From the standpoint of regional economics, about the same number of people are employed with either option; however, each employee earns considerably more money working 84 h every other week at a campsite than he would working 40 h each week at a townsite. But while wage costs are higher with a fly-in or commuter option, turnover, sickness, and absenteeism are relatively lower (3). The price required to obtain a 15% DCFROR for the single-product copper concentrate, f.o.b. the mill site, was significantly lower. The economic advantage for mines utilizing the camp increases from south to north and from the coast toward the interior. REFERENCES 1. Alaska Department of Labor, Research and Analysis Division. Unpublished data for March 1984, obtained from staff economist on June 6, 1984; available upon request from R. Bottge, Juneau, AK. 2. Alaska Office of Mineral Development (Dep Commerce and Econ Dev.) Red Dog Project Analysis. Feb. 1984, 300 pp. 3. Beveridge, J. The Rabbit Lake Commuting Operation: A Case for Mutual Adaptation? Paper in Proceedings: Conference on Commuting and Northern Development (Saskatoon, Sas- katchewan, Feb. 15-16, 1979). Inst, for Northern Studies, Univ. Saskatchewan, 1979, pp. 110-162. 4. Canadian Mining Journal. Key Lake Pit Development a Formidable Design Challenge, v. 105, No. 6, 1984, pp. 26-27. 5. Cassiar Asbestos Corp., Ltd. Cassiar Asbestos Corporation, Ltd., Welcomes You to the Clinton Mine Operation. Company handout, May 1973, 7 pp. 6. Chenard, P. Native Workers' Experience. Paper in Proceed- ings: Conference on Commuting and Northern Development (Saskatoon, Saskatchewan, Feb. 15-16, 1979). Inst, for Northern Studies, Univ. Saskatchewan, 1979, pp. 98-100. 7. Clement, G. K., Jr., R. L. Miller, P. A. Seibert, L. Avery, and H. Bennett. Capital and Operating Cost Estimating System Manual for Mining and Beneficiation of Metallic and Nonmetal- lic Minerals Except Fossil Fuels in the United States and Canada. BuMines Spec. Publ., 1981, 149 pp. 8. Compressed Air. Canada's Largest Mining Scheme, v. 89, No. 5, 1984, pp. 24-27. 9. Envers, P. Cullaton Lake: Worst Over as Second Mine Starts Up. v. 105, No. 6, 1984, pp. 56-58. 10. Godfrey, R. S. (ed.). Building Construction Cost Data 1984. Robert Snow Means Co., Inc., Kingston, MA, 1984, 434 pp. 11. Gunther, P. E. Cypress Anvil — Impact on the Yukon. Informetrica, Ltd., Ottawa, undated, 67 pp. 12. Himelfarb, A. The Social Characteristics of One-Industry Towns in Canada, A Background Report. Study No. 30. Royal Commission on Corporate Concentration, Ottawa, 1977, 43 pp. 13. Hobart, C. W. Commuting Work in the Canadian North: Some Effects on Native People. Paper in Proceedings: Conference on Commuting and Northern Development (Saskatoon, Sas- katchewan, Feb. 15-16, 1979). Inst. For Northern Studies, Univ. Saskatchewan, 1979, pp. 1-37. 14. Knoll, K. Beating the Clock and Budget of Canada's Largest Gold Mines. Can. Min. J., v. 105, No. 5, 1984, pp. 63, 65-66, 69. 15. Lucas, R. A. Minetown, Milltown, Railtown: Life in Canadian Communities of Single Industry. Univ. Toronto Press, 1971, 387 pp. 16. Mamen, C. (ed.). Canadian Mining Manual 1969. Natl. Business Publications Ltd., Gardenvale, Quebec, 1969, 222 pp. 17. Canadian Mining Manual 1970. Natl. Business Publications Ltd., Gardenvale, Quebec, 1970, 212 pp. 18. Canadian Mining Manual 1971. Natl. Business Publications Ltd., Gardenvale, Quebec, 1971, 212 pp. 19. O'Hara, T. A. Quick Guides to the Evaluation of Ore Bodies. CIM Bull., v. 73, No. 814, 1980, pp. 87-99. 20. Scales, M. High Arctic Wizardry: Polaris Mine on Stream. Can. Min. J., v. 103, No. 7, 1982, pp. 24-41. 21. U.S. Army Corps of Engineers. Cost Engineering. EIRS Bull. 82-02, 1984, 25 pp. 22. Walsh, P., G Paget, and R. A. Rabnett. Tumbler Ridge: A New Approach to Resource Community Development. CIM Bull., v. 76, No. 853, 1983, pp. 33-38. 23. Wohlford, J. Engine and Turbine-Powered Generating Plants. Ch. in Society of Mining Engineers Handbook, ed. by I. A. Given. Soc. Min. Eng. AIME, 1973, pp. 23-21 to 23-23. I MMtMJIJHHUBftWMdmWiHBi BH B^ APPENDIX A.— CAPITAL COSTS Certainly a major consideration in the choice of a town or a camp is cost. While precise costs may be closely estimated once the go-ahead is given on a project, most economic evaluations require only order of magnitude estimates. Deriving order of magnitude cost estimates is difficult owing to the dearth of precise data available. While the literature often contains cost estimates for new projects, closer scrutiny reveals a lack of precision on what components are included. At least two publications can be used to estimate construction costs in Alaska: "Building Construction Cost Data" (10Y and the Corps of Engineers booklet "Cost Engineering" (21). The former publication lists average construction cost indexes for typical "average" building construction projects for 162 cities in the United States and Canada. The latter publication lists location factors to apply to the construction of repetitive-type facilities for all 50 States and at military locations within each State. A comparison of cost factors for Anchorage versus Washington, DC, in reference 10 shows a factor difference of 1.41; reference 21 shows a factor difference of 1.90 between Elmendorf Air Force Base (which borders Anchorage) and Washington, DC. A comparison of con- struction indexes for cities in other States often shows differences of less than 5%. It is interesting, then, that the difference in the two Anchorage estimates is nearly 35%. If two sources differ so widely on a construction site where extensive experience exists, one must wonder how accurately construction costs away from that area can be estimated. ESTIMATING CONSTRUCTION COSTS IN ALASKA In an attempt to estimate capital costs for Alaskan projects in a consistent manner, a map showing escalation factors for each part of the State was developed (fig. A-l — in pocket). The escalation factors are based on the Corps of Engineers booklet, "Cost Engineering" (21) with subjective modifications based upon the collection of cost data and estimates by the author over the last 12 yr. The escalation factors assume that a road system will be built to exploit a major property and that the company will not be required to pay for that road. Therefore, the factors will not apply until some form of ground transportation exists. In general, the escalation factors are lowest along the coast and increase in mountainous areas and in higher latitudes. The area north of the Brooks Range is the most expensive area in which to construct any facility. The factors shown on figure A-l represent multiples of a cost to construct a similar facility in Washington, DC (or Seattle, which is 1.01). In a sense, facilities are costed-out in Seattle and "moved" to the location in Alaska using the appropriate escalation factor. The factors given on figure A-l assume that facilities will be permitted in the area. The factors include lands that are designated wilderness, wildlife preserves, and national parks. Because of political factors, however, these areas are not likely to be exploited. The factors do not consider the politics of development, only the physical aspects and their impact on costs. For the study discussed in the main body of the report, non-specific sites were chosen in three parts of the State, or regions. The region and the escalation factors follow: southeast, 2.00; south-central, 2.60; north-central, 3.25. Although there may be a number of escalation factors within each area of the State, for this report one factor has been chosen to represent each region. The Southeast region is defined as that part of Alaska east of 141° longitude (fig. A-l). The South-Central region is defined here as that part of Alaska south of 64° north latitude. The North-Central region is defined as that part of Alaska north of 64° and south of 68° north latitude. To obtain the total capital costs for the facilities in each part of the State, the cost for underground and open-pit mines developed by O'Hara (19) was computed, updated from 1978 to 1984 using the Bureau's cost- estimating system (CES) program (7), and multiplied by the appropriate escalation factor. The various capital cost components in the CES program were adjusted until that total matched the total estimate using O'Hara's equations times the escalation factor. Two components in the CES program were not used: electrical and town and campsite costs. CES assumed power would be provided by a power company, but in Alaska, it would be diesel generated. Electrical capital costs were based upon Wohlford (23) updated to 1984. CES provided no estimates for townsite costs or for the total installed cost for large camps. The author estimated these costs from published data (2, 19, 22) and discussions with mining people during the past 12 yr. Figures A-2 and A-3 show curves and equations for calculating the 1984 cost to design and completely install either a town or a campsite. 2 The curves reflect the data in references 2, 19 and 22 adjusted to 1984. Calculations for the camps turn out to be approx- imately double the direct cost of living space plus community center space estimated by CES (7). In addition to the basic units, a campsite requires roads, walkways, utilities, a sewer system, landscaping, and outdoor recreation facilities. As the campsite becomes larger, the community center grows. As the campsite grows from 20 to 200 people, the space per person increases as more amenities are added for the workers' convenience. Beyond 200 employees, the space per employee diminishes because all of the amenities have been provided and the increase in the unit space per person is less than one unit per person. A 200-plus-employee camp includes space for kitchen and dining rooms, lounge and recreation rooms, laundry, infirmary, gymnasium, hobby rooms, commis- sary, library, post office, maintenance, and storage. italic numbers in parentheses refer to items in the list of references preceding this appendix. ^he curves and equations shown on each figure estimate housing facility costs (y-axis) given employees (x-axis). < o o uu on Y= $ I30,900( 500 sX <2,50 x) 0.92 employees IU J 100 ipoo EMPLOYEES 10,000 FIGURE A-2. — Townsite costs versus total employees, 1984 dollars. II II II I II I I I I I I III I iMlirfimin ■«— mm— ■■■■« I WBUMAM* JFMl V r a mM * Pft MBn ^UiJJlAMJIIJU n UMMmilUUM^ uu — 1 U ~ 1 = *90,I00(X) - 805 00 UJ Ul Q 4001- u 5c 300 200- 100 Y= 54.4 + 0.09665 X Correlation coefficient = 0.957 Standard error of estimate =±34 standard deviation unit ipoo 2000 3000 DAILY TONNAGE 4000 5000 FIGURE C-3. — Total employees versus daily tonnage in open-stope mining. 15 TABLE C-4. — Long-hole mining data Year Company Mineral concentrates Other types of mining 1 Tonnage, ore + waste Mine Mill Surface plant Office staff Total Salaried staff Hourly workers Salaried staff Hourly workers Salaried staff Hourly workers employees 3 22 10 26 3 24 12 100 12 121 7 38 4 84 23 289 46 325 37 203 51 193 77 2 932 6 62 3 25 2 18 11 127 13 72 5 19 7 26 18 160 14 93 8 29 5 3 50 15 214 7 53 4 25 1 16 11 117 30 199 6 29 5 24 35 328 12 98 5 21 3 21 16 176 18 110 11 42 11 42 20 254 1971 Consolidated Canadian Faraday 1971 Kam Kotia Mines 1970 Brunswick Mine & Smelting 1970 Camflo Mines 1970 Consolidated Canadian Faraday 1970 Consolidated Rambler 1970 Dresser Minerals 1970 East Malartic Mines 1970 Giant Mascot Mines 1970 Manitou Barvue Mines 1970 St. Lawrence Columbium and Metals Corp. 1 969 Barnat Mines 1969 Dresser Minerals Ni, Cu, PGM . CF, SL 320 Cu, Zn, Au, Ag 2,395 Pb, Zn, Cu . . . OS 5,200 Au SH 1,146 Ni, Cu, PGM . CF 650 Cu, Au, Ag . . . Ba, Ag, Pb, Cu Au SL 1 ,200 CF 860 SH 1,653 Ni, Cu SH 1,600 Ag, Cu, Zn, Au, Asbestos Pyrochlorite SH 1 ,080 1,475 1969 Wilroy Mines Au, Ag CF 625 12 Ag, Pb, Cu, CF 1,120 7 Zn, Ba Cu, Zn, Pb, 645 9 Au, Ag 70 80 48 115 3 10 31 3 15 23 26 21 13 22 56 17 7 14 28 156 128 118 251 1 Certain mines using long-hole mining also reported other types of mining as follows: CF — cut and fill; OS — open stope; SH — shrinkage stope; SL — sublevel caving, included in calculations, not plotted in figure C-4. 3 Estimate based upon the average percent the work group comprises of the total for all of the companies. ruu 7 S " / s s 600 - //^ 500 V) 4 / ' // / UJ Ul >- q 400 / y / a. / / / 2 / / / Ul /-, / / < 300 o K ' / .// Y= 3.7+0. I6359X 200 Correlation coefficient = 0.93I Standard error of estimate =±75 I00 " I ipoo 2pOO 3000 DAILY TONNAGE 4.000 5.000 FIGURE C-4. — Total employees versus daily tonnage in long-hole mining. 16 TABLE C-5. — Shrinkage-stope mining data Year Company Mineral concentrates Other types of mining 1 Tonnage, _ ore + Salaried waste s t a tf Mine Surface plant Hourly workers Salaried staff Hourly workers Salaried staff Hourly workers Office staff Total employees 1971 1971 1970 1970 1970 1970 1970 1970 1970 1969 1969 1969 1969 OS BH CF Echo Bay Mines Ag, Au Sisco Mines Ag, Co Anglo-Rouyn Mines Cu ... Canadian Jamieson Mines . Cu, Zn Deer Horn Mines Ag, Co Dickenson Mines Au, Ag Preissac Molybdenite Mo, Bi . LH, OS Renabie Mines Au BH ... Sisco Mines Ag, Co Agnico Mines Au, Co, Cu Anglo Rouyn Cu Echo Bay Mines Ag, Cu Wasamac Mines . Au, Ag 200 182 1,001 590 55 537 1,150 508 170 300 1,150 150 1,130 8 20 9 5 18 17 13 8 6 18 6 19 34 51 135 65 18 133 165 89 60 35 103 36 127 15 11 22 32 12 29 36 18 11 16 18 14 28 31 6 45 20 1 39 39 20 58 18 44 36 42 17 8 20 9 4 18 2 22 12 9 10 28 17 2 19 'Certain shrinkage-stope mines also reported other types of mining as follows: BH — blasthole; CF — cut and fill; LH — long hole; OS — open stope. 2 Estimate based upon the average percent the work group comprises of the total for all of the companies. 114 87 252 146 44 244 286 157 157 89 219 115 246 700 600 - 500 *- • I i IPOO 2P00 DAILY TONNAGE 3OO0 FIGURE C-5. — Total employees versus daily tonnage in shrinkage-stope mining. 17 TABLE C-6. — Room-and-pillar mining data Year Company Mineral concentrates Tonnage, _ ce + Salaried waste sta ff Mine Surface plant Hourly workers Salaried staff Hourly workers Salaried staff Hourly workers Office staff Total employees 1971 Canadian Exploration W0 3 1,000 12 53 15 19 5 39 24 167 1971 Tantalum Mining Ta 2 5 600 3 20 4 10 5 22 13 77 1970 Canadian Exploration Pb, Zn 1,633 16 91 10 21 5 62 30 235 1970 Denison Mines U, Y 4,700 68 385 25 107 19 153 103 1 860 1970 Gaspe Copper Mines Cu, Mo, Au, Ag .. 3,550 34 172 11 73 76 292 99 1 757 1970 Tantalum Mining Ta 2 5 427 4 25 3 9 5 27 14 87 'Included in calculations, not plotted in figure C-6. 700 600 500 CD id UJ O400 Q. UJ 300 200 1 00 I standard deviation unit / / / / / ' / / ' / / / ' ' // / / /# Y= -29.I+O.I95083X / / s Correlation coeff icient = 0.989 Standard error of estimate = ±47 IpOO 2000 3000 4000 DAILY TONNAGE FIGURE C-6. — Total employees versus daily tonnage in room-and-pillar mining. 18 TABLE C-7 — Open-pit mining data Year Company Mineral concentrates Mine' Mill Surface plant Tonnage, Salaried Hourly Salaried Hourly Salaried Hourly waste staff workers staff workers staff workers Office staff Total employees 1971 1971 1971 1971 1971 1971 1971 1971 1971 1971 1970 1970 1970 1970 1970 1970 1970 1970 1970 1970 1970 1969 1969 1969 1969 Advocate Mines Brenda Mines Cassiar Asbestos Mines — Clinton Creek Div. Endako Mines Granisle Copper Jones & Laughlin Mining Lake Asbestos of Quebec National Steel Corp. of Canada . . New Imperial Mines Wesfrob Mines Bethlehem Copper Corp British Columbia Molybdenum Endako Mines Granby Mining Granisle Copper Iron Ore Co. of Canada — Scheffer Div. Jones & Laughlin Mining National Steel Corp. of Canada . . New Imperial Mines Pickends, Mather & Co Steep Rock Iron Mines Bethlehem Copper Corp Granby Mining Hilton Mines Indusmin Nepheline Syenite Asbestos 41,000 Cu. Mo 48,000 Asbestos 46,000 Mo 50,000 Cu 10,400 Fe 22,000 Asbestos 45,000 Fe 10.500 Cu 12,500 Fe, Cu 18,000 Cu 45,000 Mo 22,500 Mo 36,000 Cu 19,100 Cu 16,100 Fe 90,000 Fe 20,000 Fe 10,800 Cu 12,500 Fe 21,000 Fe 33,300 Cu 33,500 Cu 17,200 Fe 19,500 Syenite 1 ,400 119 10 167 21 133 53 503 83 18 73 17 104 49 344 54 17 81 26 127 79 384 102 27 89 32 150 172 572 43 10 40 6 38 20 157 86 20 132 18 112 42 410 200 11 2 88 19 155 27 500 76 16 74 14 49 21 250 40 9 30 8 35 20 142 35 13 52 13 70 23 206 129 19 105 17 169 41 480 67 19 44 26 70 36 262 112 27 87 30 155 70 481 66 6 38 5 41 18 174 40 10 42 5 39 18 154 280 2 43 2 200 70 290 224 1,107 84 14 105 18 43 50 314 68 16 84 21 108 21 318 40 9 30 8 83 20 190 108 16 71 19 128 30 372 142 2 18 2 79 35 120 53 447 162 13 54 18 61 43 351 60 3 43 4 26 17 153 113 16 77 17 122 33 378 10 7 36 3 21 11 88 'Salaried staff positions are included with mine hourly personnel. 2 Estimate based upon the average percent the work group comprises of the total for all of the companies. 1,200, 1,000- 800 2 600- 2 o 400- 200 Y=68.0+0.0I0I8X Correlation coefficient = 0.905 Standard error of eetlmote = ±89 I standard deviotion unit 30 40 50 60 THOUSAND SHORT TONS PER DAY 100 FIGURE C-7. — Total employees versus daily tonnage in open-pit mining. 19 TABLE C-8. — Estimates of mine and mill personnel by type of mining' Underground mining at rate of 500 st/d 1.000 st/d 1,500 st/d 2,000 st/d 3,000 st/d 4,000 st/d 5,000 st/d Underground mining at rate of 500 st/d 1.000 st/d 1,500 st/d 2,000 st/d 3,000 st/d 4,000 std 5,000 st'd Blasthole: Mine Mill 2 110 35 140 50 175 60 215 70 295 85 375 100 460 110 Room and pillar: Mine Mill 35 35 115 50 205 60 290 70 470 85 650 100 835 110 Total Shrinkage stope: Mine Mill Total Total 145 190 235 285 380 475 570 70 165 265 360 555 750 945 Cut and fill: Mine Mill 200 35 255 50 315 60 375 70 500 85 620 100 NC NC NC 120 35 185 50 250 60 NC NC NC NC NC NC NC NC NC NC NC Total 235 305 375 445 585 720 155 235 310 NC Long hole: Mine 50 35 115 50 190 60 260 70 410 85 560 100 710 110 Open-pit mining at rate of 10,000 20,000 30,000 40,000 50,000 60,000 st/d st/d st/d st/d st/d st/d 70,000 st/d Mill Mine Mill Total 50 120 100 170 160 210 230 240 305 270 380 295 455 Total 85 165 250 330 495 660 825 320 Open stope: Mine Mill 65 35 100 50 140 60 175 70 260 85 340 100 NC NC NC 170 270 370 470 575 675 775 Total 100 150 200 245 345 440 NC Not calculated; beyond the limits of the data. 'All numbers are rounded to the nearest unit of 5. 2 Position shifts per 24-h day, 8 h per shift INT.-BU.0F MINES,PGH.,PA. 28393 wwmmjmummmwufMMmm w ,.ijl» j hi m tttsm iE8 B agflB M afl SBCB eB ^ »M I UWMI!M4mtW i MBlflMM^^ mm ^ +* % ,0* ^ /.. s> + ^V V^V V^V \W/ * V< v.-.-.v-"^ vt, " •> ° i U C v A <* V -^ ^ *W* A: \/ .• A= %,♦♦ .». \/ .**«*•. %. o V :•- \^ t A ■o 4' «* » * -^ -.« s! ° "'"• ^ / ^X /.^-^ /-^^ c0<--- V-'^ < •' v,^ -,\ <\ ^ vf 7X *6* o. .6** "*- ♦♦*% A •* /\ °-?W-' •/% 'OSS? ^V : .IS|: .**V -., \ & •«k\Va° ^ ** ** ^^ . mHMammim n ■■ ■ M in i >^wm>wjiMww^iMBffifftfyfflBiWtiwrwrrtrrrr i w tmd LEGEND Region boundaries Roads 10 Escalation factors Note: Escalation (actors are shown as dotted lines of equal cost and as centers ot cells that extend half-way to adjoining cells. o o FIGURE A-1.— Alaska capital cost factors.