How to design a production hall?

Production halls have for years been recognised as one of the more ergonomic, modern and functional structures. This is due to the fact that they are custom-designed (individual customer/company order) taking into account, among other things, the specific needs of the investor, the type of business conducted and the size/area of the facility. Not surprisingly, the entire project should be planned down to the smallest detail.

Table of contents:

1. Factors to consider when designing production halls
2. Production hall – step-by-step design process
3. Why is it so important to develop/prepare the design of the production hall in advance?

Any production hall that has been designed in the right way offers the opportunity to have a modern plant at a reasonable cost. It is then characterised not only by durability and high quality workmanship, but also by a very short construction time, which, as we know, is of key importance for many investors. With this type of facility, they gain adequate space for employees and the production lines (machinery and equipment) used in their operations.

Facilities of this type are usually constructed on the basis of steel structures that have been adapted for modification. In this way, virtually any production hall can be extended or modified at any time according to the current needs of the company in question, which can have a significant impact on the development of the business and becoming more competitive in the market.

Factors to consider when designing production halls

In order for the client to be able to count on a building that meets his or her requirements and is therefore fully usable, a number of different factors must be taken into account during the design process. Only in this way will it be possible to create a structure with the specified parameters that fully satisfies the client.

Due to the fact that this type of facility can vary greatly, a number of very important issues must be taken into consideration, such as the purpose of the hall, the type of machines or production lines used, the delimitation of individual zones, i.e. the office space, the back office and the storage area, the type of lighting and heating used for the hall.

Production hall – step-by-step design process

The initiation of activities in the design of production halls can be divided into several steps, viz:

1. Architectural and construction plan – i.e. tailor-made (bespoke) design

The creation of an architectural plan of the facility, which in this case is a production hall, should take place even before the moment of purchasing the plot of land. The development of this concept, taking into account the spatial development, will provide a complete (approximate) picture of the facility to be built. In this way we will check whether we are able to estimate whether the planned size of the hall (investment) will fit into the specified area.

It is important that such a design is tailored not only to the needs, but also to the capabilities of the company, the type of business and the machinery and technology used in the production process. This will avoid many unnecessary costs during both the construction itself and the subsequent operation of the facility.

At this stage, it is quite often necessary to carry out a geotechnical study of the ground. The design should then be adapted to the results obtained, which will allow both the appropriate foundations and the hall structure to be designed.

2. Location of the investment – so where to build?

A very important issue that must not be forgotten, when starting to design structures such as production halls, is their location. The location of such facilities is of great importance in the daily operation of many businesses. This is why it is so important for the design to take into account not only the geological conditions, but also other issues related to, among other things, the neighbourhood of the future production facility.

3. Hall construction technology – or how?

Production halls should also be designed with a view to the type of future construction and, more specifically, the choice of construction technology. The said decision largely depends on such issues as:

• the intended use of the hall,
• the type of terrain and environment in which it will operate,
• possible future expansion of the facility,
• the type of products to be manufactured,
• the degree of fire load.

By taking these factors into account, the optimum type of structure can be selected, including appropriate insulation, lighting, ventilation and heating systems.

Due to the lightness of the structure itself and the speed of construction, steel-framed production halls are the most popular. Some investors, due to the specific nature of their business and the need to meet increased fire protection requirements, opt for hybrid (mixed) structures. These combine steel and reinforced concrete elements.

4. Timing of the construction of the hall – in other words, when?

The time of year in which the process related to the construction of a steel production hall takes place is of little importance when it comes to the durability of the structure being created. The situation is different when we decide to invest in masonry halls, where it is not possible to carry out certain (so-called wet) works in low temperatures.

Why is it so important to develop/prepare the design of the production hall in advance?

The development of a suitable concept for a production hall, in accordance with the investor’s requirements outlined earlier, plays a very important role for two reasons, viz:

• Firstly, it allows for proper planning of the upcoming construction work.
• Secondly, it gives the investor the opportunity to open up a potential avenue for possible modernisation or expansion of the hall in the future.

It is therefore not surprising that the investment project for a production hall, prepared by professional companies, consists of several, reliably developed construction projects, viz:

• structural – takes into account the production processes carried out in the hall and includes information on the elements making up the facility and the materials from which it will be built,
• architectural – defines the form of the facility, taking into account all the guidelines set out by building regulations in this area, provides knowledge on technical solutions and the type of materials to be used during construction,
• land development – focuses on proper planning of the space/area around the hall, determines potential environmental hazards of the investment, compiles data on the specifics of the building object,
• internal installations and external networks – presents the conditions for the distribution of networks, connection of utilities and installations to the key locations of the facility, takes into account the planned safety, distribution and control equipment,
• and technology related to the production process – it is created on the basis of serial production of products, their type and complexity, as well as the volume and rationalisation of production.

Each of the above-mentioned projects takes into account issues related to the function of the facility and the type of activities carried out in it by the investor. The preparation of such studies, is necessary in order to be able to complete and then apply for a building permit.