Factory design is not merely about constructing a production space; it also requires a harmonious integration of many important factors such as overall planning, architectural design, structural considerations, technical infrastructure, fire protection systems, and various other elements. If these components are not closely integrated from the outset, conflicts can easily arise, affecting both operational efficiency and the safety of the factory.
An optimal design not only helps businesses save on initial investment costs but also enhances production efficiency, minimizes risks, and ensures compliance with labor safety regulations. In the article below, BIC will share 7 important principles that any business should keep in mind when factory design.
Master planning is a core element in factory design, directly impacting production efficiency, operational costs, and future scalability. Depending on the industry, production processes, technological requirements, and raw materials, the layout of the factory space will vary. However, there are general principles that must be followed to ensure rationality and optimization in design:
- Logical arrangement of functional areas: Areas that are closely related, such as raw material storage and finished goods storage, should be located near each other to optimize movement flow, minimizing internal transportation time and costs.
- Environmental impact control: Production areas that generate smoke, dust, or odors should be placed downwind to limit their impact on other parts of the factory, helping to maintain a clean working environment.
- Separation of areas by activity type: Production areas with different characteristics should be arranged separately to avoid mutual interference. For example, wet and dry production areas, clean rooms and dusty areas, high-noise zones and office spaces.
In addition to ensuring a logical layout, compliance with construction standards is also an important requirement that investors need to pay attention to:
- Maximum building density: Should not exceed 70% for regular land lots.
- Factories over 5 stories: If the factory has more than 5 stories for production, the maximum building density is reduced to 60%.
- Green space area: Must account for at least 20% of the total land area, contributing to environmental improvement and creating a cool working space.
A well-planned master layout not only enhances production efficiency but also ensures sustainability and compliance with construction regulations, laying a solid foundation for the long-term development of the factory.
Architecture not only contributes to the aesthetic appearance of industrial buildings but also directly affects durability, operational efficiency, and maintenance costs throughout the lifecycle of the structure. Therefore, when designing industrial facilities, investors need to balance aesthetic factors with practicality to ensure that the building operates effectively, safely, and sustainably over time.
Some impressive architectural designs on paper, such as natural light roofs, skylights, or stylized roofs, can make industrial buildings look more modern. However, if not carefully calculated, these designs can lead to various issues in practice:
- Excessive heat absorption, causing internal temperatures to rise, which affects the working environment and consumes a lot of energy for cooling systems.
- The risk of leaks due to inadequate waterproofing systems, especially in rainy weather conditions.
- Difficulties in maintenance, leading to increased costs and time when repairing or replacing components.
In addition to reasonable architectural design, choosing appropriate building materials also plays a crucial role in optimizing the operation and maintenance of industrial facilities. Investors should prioritize using high-durability materials that can withstand harsh weather conditions, such as heat-resistant paint, stainless steel, and green materials, which help extend the lifespan of the structure and minimize repair costs.
When designing architecture, instead of solely focusing on aesthetic factors, investors need to prioritize operational efficiency, maintenance, and durability of the structure. A smart industrial design, combined with quality materials, not only helps optimize long-term costs but also ensures that the facility operates steadily and efficiently for many years to come.
One of the major challenges in designing industrial buildings is ensuring close coordination between architecture, structure, and mechanical, electrical, and plumbing (MEP) systems. This requires stakeholders to work synchronously from the initial design phase to create integrated drawings that optimize space and ensure feasibility in construction, operation, and maintenance of the facility.
Architects and design engineers need to ensure:
- Accurate identification of the location and elevation of each system, allowing structural, electrical, plumbing, HVAC, ventilation, and fire protection components to operate harmoniously without interfering with one another.
- Full compliance with technical requirements while maintaining the aesthetics and functionality of the facility.
If this coordination is not effectively managed from the outset, it can lead to serious issues such as overlaps between pipes, electrical wiring, and load-bearing structures, hindering construction and impacting the integrity of the building. This results in additional costs for adjustments or rework, delays in construction timelines, and waste of resources.
During the design process of industrial buildings, the load-bearing capacity of the structure is always a factor that needs careful calculation. To avoid conflicts with beams, columns, and load-bearing walls, the design team should:
- Reasonably adjust the positions of pipes, electrical wiring, and HVAC equipment to ensure they do not affect the main structure.
- Flexibly address mandatory cases, such as when pipes must pass through beams or load-bearing structures, requiring calculations of load-bearing capacity and the addition of appropriate reinforcement measures.
Early detection and resolution of conflicts between architecture, structure, and MEP systems not only help optimize space and functionality but also minimize the risk of cost overruns, ensuring a smooth and efficient construction process.
The electrical system plays a crucial role in the operation of factories, directly affecting production efficiency and the safety level of the plant. Therefore, from the design phase of the factory, the design unit needs to closely collaborate with the investor to fully understand the operational capacity of the plant, the characteristics of the production line, and the related technical requirements. Accurate load calculation helps the electrical system meet usage demands, minimizing the risk of overload that can damage equipment or disrupt production activities.
- Determine load requirements for each area, ensuring that each workshop, production line, and auxiliary system is provided with stable electricity that matches operational capacity.
- Provide safety capacity, especially for equipment with high power consumption or continuous operation, to reduce the risk of overload or voltage drop.
- Build a flexible electrical system capable of accommodating future production expansion without requiring significant changes to the electrical structure.
In addition to ensuring stable operation of the electrical system in the initial phase, consideration must be given to the potential for future plant expansion. Some flexible design measures include:
- Reserving space and infrastructure for upgrading the electrical system when necessary.
- Choosing equipment and materials that allow for expansion, facilitating a quick upgrade process that saves time and costs.
- Constructing a rational power grid that enables effective electricity distribution even when usage capacity increases.
Thorough calculations from the outset not only ensure the electrical system operates stably and safely but also optimize long-term costs for the investor, ensuring the plant can develop sustainably in the future.
The HVAC system (Heating, Ventilation, and Air Conditioning) in factory design plays a crucial role in maintaining a stable air environment within the facility, contributing to product quality, improving working conditions, and increasing production efficiency. However, each industry has different requirements for the HVAC system, necessitating a flexible design to suit each field and production area.
- Pharmaceutical and Food Industry: Strict control of temperature and humidity is required to prevent the growth of bacteria and mold, ensuring product quality. HVAC systems in these areas typically include HEPA filters, deep cooling systems, and precise humidity control capabilities.
- Electronics Industry: A clean environment, static control, and stable temperature maintenance are essential to protect sensitive components. The HVAC system needs to integrate air filters, dehumidification systems, and precise cooling technology.
- Metalworking and Metallurgy Industry: A robust ventilation system is necessary to reduce heat, control smoke and dust, and ensure good air circulation.
- Heat Load Calculation: Determine the amount of heat generated by machinery, people, and the external environment to select an appropriate air conditioning system.
- Equipment Layout Strategy: The installation positions of air conditioners, fans, and ductwork need to be arranged logically to ensure even air distribution and avoid temperature discrepancies between areas.
- Energy Efficiency: Utilize HVAC systems with smart sensors that automatically adjust the temperature based on actual heat loads to reduce electricity consumption and optimize operating costs.
- Support for Building Structure: Ensure that the floors and ceilings can bear the load for installing fans, air vents, and duct systems without compromising the overall structure.
Choosing the right HVAC system not only improves production conditions and the working environment but also optimizes long-term operating and maintenance costs, contributing to enhanced operational efficiency of the factory.
The fire protection system (FPS) plays a crucial role in ensuring safety for factories, helping to minimize the risk of fire and explosions while protecting both people and property. When designing the FPS, the design unit must comply with QCVN 06:2021/BXD and Circular 02:2021/TT-BXD, while also adjusting the fire protection plan to suit each production area to ensure maximum effectiveness.
Building the FPS according to factory characteristics
Each area in the factory has different fire and explosion risks, so it is necessary to choose an appropriate firefighting system:
- Chemical, petroleum, and flammable solvent manufacturing plants
+ Use foam, powder, or CO₂/FM200 firefighting systems to quickly control fires without spreading hazardous chemicals.
+ Equip specialized smoke extraction and ventilation systems to minimize the risk of flammable vapor accumulation.
- Electrical rooms, server rooms, data centers
+ Do not use water spray systems as they may damage equipment.
+ Prioritize CO₂, FM200, or nitrogen firefighting systems to extinguish fires quickly without affecting electronic components.
- Food processing and seafood processing plants with high humidity
+ The fire risk is lower, so fire protection requirements are generally less stringent.
+ However, it is essential to ensure that the fire alarm system and heat sensors operate reliably to promptly detect incidents.
Factors to Ensure When Designing Fire Protection Systems
- The layout of emergency exits in the factory design must be reasonable, ensuring that every area in the factory has a safe exit according to standards.
- The automatic fire alarm system must have high sensitivity, especially in areas with a high risk of fire and explosion.
- The water supply and pressure for firefighting must be strong enough to meet immediate firefighting requirements.
- Training employees on fire protection helps enhance their ability to handle situations when incidents occur.
A fire protection system designed according to standards and suitable for each production area not only helps protect the factory from fire risks but also ensures compliance with legal regulations, creating a safe and sustainable working environment.
Each production industry has its own emission characteristics, from exhaust gases, wastewater to solid waste, requiring the environmental treatment system to be designed appropriately to meet environmental protection standards and comply with legal regulations. The factory design company needs to work closely with the investor to gather detailed information about the production process, types of waste, and discharge flow to propose effective treatment solutions.
Investing in an environmental treatment system not only helps the factory comply with legal regulations and avoid the risk of penalties for violations but also demonstrates the company's social responsibility, contributing to sustainable development.
Factory design must adhere to 7 core principles that help businesses optimize space, ensure smooth production processes, and meet safety and environmental standards. If you are looking for an optimal factory design solution, please contact BIC for consultation and detailed planning, helping you achieve a modern, safe, and efficient production space!
