Factory Building
Design, permits, and construction for factories. El-Eman Office provides surveying and contracting for industrial projects.
Choosing the Factory Site
The site is one of the most important project decisions, because it affects transport, utilities and labour costs. When comparing sites, consider proximity to raw materials and sales markets, truck access, the availability of electricity, water and gas, and the possibility of waste disposal. The nature of the activity also affects the choice of area, since some industries must stay away from residential zones.
- Confirm the factory's activity suits the zoning of the industrial area.
- Compare the capacity of available utilities with the needs of the production lines.
- Estimate truck traffic within and around the site.
- Leave space for future expansion.
Site Layout and Production Flow
A good factory is designed around the flow of materials, not the shape of the building. The flow starts with receiving and storing raw materials, then manufacturing and assembly, then inspection, packing, storage and dispatch. The shorter this path and the fewer the crossings between product movement and the movement of workers and vehicles, the higher the efficiency and safety. Worker entrances are kept separate from truck entrances, and space is set aside for manoeuvring and loading.
Building height and column bay widths are also worked out from the dimensions of machines, overhead cranes and racking, because changing them after construction is very costly.
Floors and Industrial Services
The factory floor is among the most heavily stressed elements, carrying heavy equipment, impact and sometimes chemicals. Its design depends on the activity: some floors need a very flat surface for forklifts, others a layer resistant to acids or oils. Industrial drainage and floor falls must be planned from the start.
- Determine machine loads and the positions of their concrete bases.
- Plan electrical, compressed air and water routes before pouring the floor.
- Arrange ventilation and extraction according to the fumes and dust produced.
- Coordinate with the production line supplier on installation requirements.
Surveying is used to set out the bases and align the machine axes, since even a small deviation can hold up installation.
Schedule and Coordination Between Contractors
A factory needs coordination between the civil contractor, the electrical and mechanical contractors and the machine supplier. The most common delay is the delivery of imported machinery, so the programme is planned so that floors and bases are ready when it arrives. It is advisable to set staged handover points between trades and record them in writing, and to avoid closing ceilings and floors before buried networks have been tested.
Frequently asked questions
Should the structure be steel or concrete?
Steel structures are faster to build and span wide bays, and are common for warehouses and some light industry. Concrete suits heavy loads and areas needing higher fire resistance. The structural engineer decides according to the activity and the budget.
When should utilities planning begin?
At the preliminary design stage, before construction, because changing electrical loads or water needs later may require major changes to transformers and supply lines.
Which permits need to be considered?
The authorities involved depend on the activity and usually include industrial development, civil defence, environment and electricity bodies. It is best to contact them early to learn the required documents and avoid delaying start-up.
