| Cost Elements | Metric | Units | English | Units |
| Mass of three shell components (new CAD weight values) | 2.69E+06 | kg | 5.92E+06 | lb |
| Mass including 5% wastage | 2.82E+06 | kg | 6.21E+06 | lb |
| Deposition rate per head | 0.50 | kg/s | 1.10 | lb/s |
| Number of spray heads, operational | 4 | 4 | ||
| Deposition rate, 4 heads | 2.00 | kg/s | 4.40 | lb/s |
| Elapsed time | 35.96 | d | ||
| Setup time | 120.00 | h | ||
| Build labor time at 50% effcny, 1 operator + 1 assct or inspector | 1569.17 | h | ||
| Inspection and rework | 400.00 | h | ||
| Total labor hours | 2089.17 | h | ||
| Fabrication cost @ $150/h include site premium and overtime | $313,375 | $ | ||
| Material unit cost ($0.60/lb + $0.25/lb for alloying & shipping) | $1.87 | $/kg | $0.85 | $/lb |
| Material cost, aluminum | $5,281,815 | |||
| Coolant tubes, SS | $50,000 | |||
| Energy cost, natural gas for furnaces + pump electrical | $800 | $/d | ||
| Energy cost for pumps | $240 | $/d | ||
| Energy cost total | $37,398 | $ | ||
| Assume construction within Reactor Building | See Act 21.02 | |||
| Furnaces located in temporary buildings | See Act 91 | |||
| Melting Furnace, 90,000 lb capacity, nat. gas | $750,000 | Secondary use possible | ||
| Installation of Melting Furnace | $800,000 | |||
| Holding Furnace, 60,000 lb capacity, nat. gas | $600,000 | Secondary use possible | ||
| Installation of Holding Furnace | $500,000 | |||
| Furnace cost data provided by Al Reinhart, SECO/WARWICK, Meadville, PA | ||||
| T-bar handling system | $25,000 | |||
| Transfer pumps, 4 @ $16k each + 1 spare | $80,000 | |||
| Heated transfer piping | $100,000 | |||
| Spray robots, 4 @ $100k each | $400,000 | Secondary use possible | ||
| Atomizing heads with high pressure pumps, 4 @$100k each | $400,000 | Secondary use possible | ||
| Spare parts, robots and atomizing heads (10% factor) | $80,000 | |||
| Argon shields, 4 | $24,000 | |||
| Argon supply and recovery system | $20,000 | |||
| Robot rail system | $100,000 | |||
| Spray casting computer and installation | $50,000 | |||
| Shell handling fixtures | $100,000 | |||
| Hardware costs | $4,029,000 | |||
| Subtotal | $9,711,588 | |||
| Contingency (20%) | $1,942,318 | |||
| Prime contractor fee | $1,398,469 | |||
| Total | $13,052,375 | |||
| Unit Cost | $4.85 | $/kg |