Industrial Cost Calculator - WordPress Plugin

A comprehensive B2B cost calculator plugin for WordPress, specifically designed for industrial projects including tables, staircases, piping, and electrical calculations.

Features

• Multiple Calculator Types: Table calculator (with support for additional calculators)
• Complex Cost Calculations: Automatically calculates materials, consumables, execution costs, overhead, and profit margins
• Dual Range Pricing: Provides both lower and higher cost estimates
• Material Database: Comprehensive database of materials with prices
• Drag-and-Drop Form Builder: (Future feature) Create custom calculators easily
• PDF Export: Generate professional PDF quotes
• Email Notifications: Automatic emails to customers and admins
• User Access Control: Only logged-in users can access calculators
• Calculation History: Track all calculations
• Shortcode Support: Embed calculators anywhere on your site

Installation

Method 1: Manual Installation

1. Download the plugin folder industrial-calculator-plugin
2. Upload to /wp-content/plugins/ directory
3. Activate the plugin through the 'Plugins' menu in WordPress
4. The plugin will automatically create necessary database tables

Method 2: ZIP Installation

1. Compress the industrial-calculator-plugin folder into a ZIP file
2. In WordPress admin, go to Plugins > Add New > Upload Plugin
3. Choose the ZIP file and click Install Now
4. Activate the plugin

Initial Setup

1. Populate Materials Database

After activation, you need to add material pricing. Go to Cost Calculator > Materials in the WordPress admin.

You can also run this SQL directly in your database (adjust table prefix if different from wp_):

-- Square Tube Grade 316 Prices
INSERT INTO wp_icc_materials (calculator_id, material_type, grade, size, finish, price) VALUES
(1, 'Square Tube', 'Grade 316', '15x15x1', NULL, 100),
(1, 'Square Tube', 'Grade 316', '15x15x1.5', NULL, 100),
(1, 'Square Tube', 'Grade 316', '15x15x2', NULL, 100),
(1, 'Square Tube', 'Grade 316', '20x20x1.5', NULL, 100),
(1, 'Square Tube', 'Grade 316', '20x20x2', NULL, 150),
(1, 'Square Tube', 'Grade 316', '20x20x2.5', NULL, 100),
(1, 'Square Tube', 'Grade 316', '25x25x2', NULL, 170),
(1, 'Square Tube', 'Grade 316', '25x25x2.5', NULL, 100),
(1, 'Square Tube', 'Grade 316', '25x25x3', NULL, 100),
(1, 'Square Tube', 'Grade 316', '30x30x2', NULL, 245),
(1, 'Square Tube', 'Grade 316', '30x30x2.5', NULL, 100),
(1, 'Square Tube', 'Grade 316', '30x30x3', NULL, 100),
(1, 'Square Tube', 'Grade 316', '40x40x2', NULL, 320),
(1, 'Square Tube', 'Grade 316', '40x40x2.5', NULL, 100),
(1, 'Square Tube', 'Grade 316', '40x40x3', NULL, 435),
(1, 'Square Tube', 'Grade 316', '40x40x4', NULL, 100),
(1, 'Square Tube', 'Grade 316', '40x40x5', NULL, 100),
(1, 'Square Tube', 'Grade 316', '50x50x2', NULL, 100);

-- Plain Sheet Grade 316 Prices
INSERT INTO wp_icc_materials (calculator_id, material_type, grade, size, finish, price) VALUES
(1, 'Plain Sheet', 'Grade 316', '1220x2400x0.5', 'Mirror', 250),
(1, 'Plain Sheet', 'Grade 316', '1220x2400x0.5', 'Brush', 270),
(1, 'Plain Sheet', 'Grade 316', '1220x2400x1', 'Mirror', 250),
(1, 'Plain Sheet', 'Grade 316', '1220x2400x1', 'Brush', 550),
(1, 'Plain Sheet', 'Grade 316', '1220x2400x1.2', 'Mirror', 250),
(1, 'Plain Sheet', 'Grade 316', '1220x2400x1.2', 'Brush', 675),
(1, 'Plain Sheet', 'Grade 316', '1220x2400x1.5', 'Mirror', 250),
(1, 'Plain Sheet', 'Grade 316', '1220x2400x1.5', 'Brush', 775),
(1, 'Plain Sheet', 'Grade 316', '1220x2400x2', 'Mirror', 250),
(1, 'Plain Sheet', 'Grade 316', '1220x2400x2', 'Brush', 830),
(1, 'Plain Sheet', 'Grade 316', '1220x2400x2.5', 'Mirror', 250),
(1, 'Plain Sheet', 'Grade 316', '1220x2400x2.5', 'Brush', 250);

-- Add Grade 304 and MS materials with same sizes
-- (You can copy the above and change 'Grade 316' to 'Grade 304' and 'MS')

2. Configure Labour Settings

Go to Cost Calculator > Labour to adjust:

• Team size
• Cost per day (lower and higher ranges)
• Welding inches per day (lower and higher ranges)

3. Configure Consumables

Go to Cost Calculator > Consumables to adjust prices for:

• Argon Gas
• Grinding Disc
• Cutting Disc
• Buffing Disc
• Wire Brush

Usage

Embedding the Calculator

Use the shortcode in any page or post:

[icc_table_calculator]

Or specify a calculator by ID:

[icc_table_calculator id="1"]

Form Fields

The table calculator includes these fields:

1. Frame Style: Square Tube, Rectangular Tube, C-Channel, L-Angle, Round Pipe
2. Grade: Grade 316, Grade 304, MS
3. Size: Various dimensions (e.g., 15x15x1, 20x20x2)
4. Material Finish: Brush, Mirror, Painted, Galvanized
5. Footing Type: Base plate, Wheels, Rubber Caps, Height adjustable rubber base
6. Marine Ply: With/Without
7. Load (KG): Expected weight capacity
8. Load Description: Details about the load
9. Installation Required: Yes/No
10. Dimensions: Length, Width, Height (in meters)
11. Quantity: Number of tables needed

Calculation Output

Users receive:

1. Materials Summary: List of materials needed (without prices)
2. Consumables Summary: Quantities of consumables used (without prices)
3. Execution Details: Days required and team size
4. Magic Numbers: Two cost estimates
   • Lower Range: Conservative pricing with 6% overhead
   • Higher Range: Premium pricing with 9% overhead

PDF Export

After calculation, users can download a comprehensive PDF report with all details.

Email Notifications

• Customer Email: Contains cost estimates and specifications
• Admin Email: Contains all form data and calculation results

Admin Features

Manage Calculators

• View All: See all created calculators
• Add New: Create new calculator configurations
• Edit: Modify existing calculators
• Duplicate: Copy calculators for variations
• Delete: Remove unused calculators

Materials Management

• Add/edit/delete materials
• Set prices for different grades and sizes
• Organize by calculator type

Consumables Management

• Adjust consumable prices
• Modify usage rates
• Add new consumables

Labour Settings

• Configure team size
• Set daily costs
• Adjust welding rates

Calculation History

View all calculations made by users including:

• User details
• Date/time
• Form data submitted
• Calculated results
• PDF links

Calculation Logic

Material Calculation

Square Tube Requirements:

Total Meters = (Length × 2) + (Width × 2) + (Height × 4) + ((Length × 2 - 1) × Width)
Tubes Needed = Total Meters ÷ 6 (standard tube length)

Top Sheet Requirements:

Thickness = Load (KG) ÷ 200 (rounded to nearest 0.5mm)
Sheets Needed = ceil(Length ÷ 1.22) × ceil(Width ÷ 2.4)

Welding Calculation

Seven welding steps calculated based on table dimensions and tube size:

1. Top Frame Corner
2. Top Frame Middle Bar
3. Table Legs
4. Bottom Frame
5. Sheet Corner
6. Sheet Outer & Inner
7. Sheet to Middle Bar

Total inches with 10% wastage for higher range.

Consumables Calculation

• Argon Gas: 10 inches per kg
• Discs: 41 inches per disc (<4mm), 20.5 inches (≥4mm)
• Wire Brush: 1 per 200 inches
• Misc: 15% of total consumables

Execution Calculation

Days Required:

Days = Total Welding Inches ÷ Welding Inches Per Day

Days Rounding:

• ≤ 1.2 days → 1 day
• 1.2 to 1.7 days → 1.5 days

• 1.7 days → Rounded up

Final Cost Calculation

Lower Range:

Subtotal = Materials + Consumables + Execution
Overhead = Subtotal × 6%
Total Before Profit = Subtotal + Overhead
Profit = Total Before Profit × Profit %
Final = Total Before Profit + Profit

Higher Range:

Same as above but with 9% overhead and higher profit percentages

Profit Percentages: | Total Cost Range | Lower Profit | Higher Profit | |-----------------|--------------|---------------| | 1,000 - 35,000 | 25% | 40% | | 35,001 - 500,000 | 20% | 35% | | 500,001+ | 15% | 30% |

Customization

Adding New Calculator Types

1. Create new calculator class in /includes/calculators/
2. Extend base calculator functionality
3. Add calculator type to admin interface
4. Create corresponding frontend form

Modifying Formulas

All calculation formulas are in the calculator class files. Modify the methods:

• calculate_materials()
• calculate_welding_inches()
• calculate_consumables()
• calculate_execution()
• calculate_final_costs()

Styling

• Admin CSS: /admin/css/admin-style.css
• Frontend CSS: /frontend/css/frontend-style.css

Email Templates

Modify email templates in:

• /includes/class-icc-email.php

PDF Templates

Modify PDF layout in:

• /includes/class-icc-pdf.php

Requirements

• WordPress 5.0 or higher
• PHP 7.4 or higher
• MySQL 5.6 or higher
• TCPDF library (for PDF generation)

Installing TCPDF

Via Composer:

cd /path/to/plugin
composer require tecnickcom/tcpdf

Manual:

1. Download TCPDF from https://tcpdf.org/
2. Extract to /includes/tcpdf/
3. Include in main plugin file

Security

• User authentication required
• AJAX nonce verification
• Data sanitization and validation
• Capability checks for admin functions
• SQL injection prevention via prepared statements

Future Enhancements

• [ ] Drag-and-drop form builder
• [ ] Staircase calculator
• [ ] Piping calculator
• [ ] Electrical calculator
• [ ] Multi-currency support
• [ ] Quote versioning
• [ ] Customer portal
• [ ] Advanced reporting
• [ ] Integration with accounting software

Support

For support, please contact: support@yourcompany.com

License

This plugin is proprietary software. All rights reserved.

Changelog

Version 1.0.0

• Initial release
• Table calculator functionality
• Material database
• PDF generation
• Email notifications
• Admin interface
• Calculation history

Credits

Developed by: M Hamza Raees