DREAM IT - BUILD IT , A FACTORY OWNER'S PLAYBOOK

DREAM IT BUILD IT

FACTORY OWNER’S PLAYBOOK FOR 100% COMPLIANT INDUSTRIAL EXPANSION

India’s Leading Architect With Experience Of 1000+ Govt. Projects

ARCHITECT KANAV KHOSLA

Masters In Urban Design (Oxf. UK) Bachelor Of Architecture

COPYRIGHT©2024 KanavKhosla-AvinashKhosla&Associates

All rights reserved. No part of this publication may be reproduced, distributed, or transmitted in any form or by any means, including photocopying, recording, or other electronic or mechanical methods or by any information storage and retrieval system, without the prior writtenpermissionofthepublisher,bycopyrightlaw.

Forpermissionrequests,writetotheauthor.

Forinformationwritetoaddressasunder :

Architects&Consultants

AvinashKhoslaandAssociates

568-A1,PolicehouseLinkRoad, Civillines,Ludhiana,Punjab(IN) kanavkhosla@gmail.com

Any reference to any events, real people or real places are used factiously,names,charactersandplaces areproductsoftheauthor’s imagination.

FirstPrintingEdition2024

Avinash
Khosla
and
Associates
has
established
itself
as
an
Award-Winning
firm,
featured
in
major
architecture
journals
and
with
a
presence
in
cities
across
India.

Founded
55
years
ago
with
its
headquarters
in
Ludhiana
(PUNJAB),
as
Architecture

Design
Consultants

Avinash
Khosla
and
Associates
has
completed
over
a
1000
Projects
across
15
States
in
India,
with
a
total
cost
exceeding
3000
Crores.

The
participation
in
Industrial
works
ensures
that
the
Methodology
is
transferred
on
to
these
Projects
for
a
seamless
integration
and
solution
delivery.

This
book
encourages
a
proactive
approach
to
factory
setup,
while
stressing
the
importance
of
forward-thinking
in
both
design
and
construction.

THE BOOK

By
emphasizing
the
need
to
establish
a
solid
foundation
today,
we
pave
the
way
for
future
success.
Geared
towards
factory
owners
and
industrialists,
this
guide
speaks
directly
to
those
seeking
to
create
sustainable
and
efficient
manufacturing
facilities.

With
its
comprehensive
coverage,
it
effectively
communicates
the
steps
needed
to
plan
and
execute
a
successful
factory
project.
Readers
will
find
information
to
achieve
their
goals,
drawing
their
attention
to
the
invaluable
insights
and
guidance
within
this
book.

THE START POINT

Are you

buildinganewfactory extendinganexistingunit needwarehousestoragefacility alreadyhaveapieceofland planningtobuyland doyouknowwhattobuild confused about what to build and howtogoaboutstartingit havedecidedaboutthebudget need professional advise about buildingcost

FACTORY BUILDING

What
is
an
Industrial
Building?

Industrial
buildings
are
the
type
of
buildings
serving
the
industrial
production
process
including
types
such
as
factories,
workshops,
warehouses
etc..

Built
and
constructed
out
of
Reinforced
Concrete
as
frame
structures
or
Prefabricated
Steel
these
industrial
buildings
serve
the
purpose
of
housing
production
houses
and
workshops
for
manufacturing
processes.

The
design
of
industrial
buildings
is
always
a
matter
of
great
importance,
in
the
construction
process.
Based
on
the
occupation
and
field
of
operation,
each
organisation
will
have
its
own
requirements
when
designing
its
buildings.
Factory
owners
need
to
clearly
define
the
purpose
of
use
for
each
area
in
particular
and
the
whole
factory
in
general.
This
helps
in
choosing
the

right
design
and
making
a
practical
construction
plan.
Safety
and
meeting
technical
standards
that
are
vital
throughout
the
design
and
construction
phases
to
ensure
the
building
is
durable
and
safe
to
work
in
and
lasts
for
a
long
time.

There
are
different
types
of
industrial
buildings
based
on
what
they're
used
for
and
how
they're
built.
They
can
be
sorted
by
function,
like
factories
or
warehouses
or
by
their
design
features,
such
as
having
columns
inside
or
column
free
spaces.
Also,
depending
on
how
many
floors
they
have,
the
type
of
construction
would
be
different.

DREAM FACTORY

IMAGINE
your
factory
as
a
perfect
space,
where
every
corner
is
optimized
for
maximum
efficiency,
every
machine
meticulously
chosen
for
peak
production
and
every
person
comfortable
and
performing.

It's
not
merely
about
building
a
structure,
but
about
creating
a
hub
of
productivity.
A
midst
the
excitement
of
turning
dreams
into
reality,
it
is
vital
to
aim
for
an
efficient
design
and
thoughtful
specifications.

Considering
the
life
cycle
of
your
building
is
like
planning
for
its
retirement.
You
want
it
to
age
gracefully,
maintaining
its
strength
and
functionality
over
time.

Aim
high,
dream
big,
but
don't
forget
to
design
smart
and
plan
for
the
long
haul.
Your
success
story
starts
with
a
blueprint,
but
its
legacy
will
be
written
in
its
efficiency,
durability,
and
sustainability.

THINK
LONG
TERM.

CHAPTER 1 ...listing your requirements KEY NEEDS

People
often
begin
expansion
projects
without
thoroughly
assessing
their
needs
or
considering
the
necessary
utilities.

To
plan
effectively
for
a
new
facility,
consider
these
key
questions
as
a
start
point.

01

existing factory space available

What is the current size of the facility?

Knowing this helps plan for expansion.

02 existing machinery size

03 staff on shop floor and administration

What machines are used in production and what are their sizes? This info guides space requirements for layout and height.

How many employees are involved in production?

Workforce size influences space and workflow design.

04

stakeholders and decision makers

Who are the Partners and Associates?

Identify them to plan for faster decision making.

What is the current production capacity?

Knowing this provides insights for growth potential.

How much do you want to expand production?

Defining goals guides space and infrastructure planning.

What storage facilities are needed? Identifying storage needs influences layout and logistics.

vehicular access

What vehicles access the facility and how often? This guides site layout, parking, and traffic management.

09 shifts in operations 10 facility locations

Are there multiple shifts or specific hours for production? This affects lighting, ventilation, and resource allocation.

11 ventilation, lighting and temperature

Are facilities spread out or centralized? This informs consolidation or expansion strategies.

12

mechanical vibration

Are special measures needed for proper lighting, air quality or temperature control? Essential for a safe working environment.

Does a factory involve hammers and gantries for lifting. Addressing this may involve structural considerations in the shed.

CHAPTER 2 ...the art of site selection STRATEGIC LOCATION

During
a
recent
visit
to
a
proposed
site,
it
became
apparent
that
the
owner
had
acquired
a
sizeable
piece
of
land
without
adequately
considering
the
size
and
suitability
of
the
approach
roads.

As
discussions
progressed
regarding
the
requirements
for
the
new
factory
unit,
it
emerged
that
the
owner
envisioned
accommodating
large
40
feet
trailers
for
bringing
in
raw
materials
and
dispatch
of
finished
goods
purposes.
However,
the
existing
approach
to
the
site
was
not
conducive
to
the
smooth
entry
and
exit
of
such
large
vehicles.

This
situation
underscored
the
importance
of
conducting
an
initial
audit
of
the
site
before
finalizing
the
purchase
or
embarking
on
construction
plans.
Such
an
audit
allows
for
a
comprehensive
review
of
factors

like
access
roads,
infrastructure,
and
logistical
requirements.
By
identifying
potential
challenges
early
on,
owners
can
pro-actively
address
them
in
the
planning
phase,
avoiding
costly
modifications
or
delays
later
in
the
process.

Ultimately,
investing
time
and
resources
in
site
evaluation
upfront
not
only
enables
better
planning
but
also
facilitates
cost
savings
in
the
long
run.

1.

ACCESSIBILITY

AND

INFRASTRUCTURE:

Opt
for
a
location
with
good
access
to
transportation
networks,
including
approachable
roads,
railways
and
ports.
Proximity
to
highways
and
airports
can
facilitate
the
movement
of
goods
and
materials,
reducing
transportation
costs
and
improving
logistical
efficiency.
Additionally,
ensure
that
the
site
has
access
to
essential
utilities
such
as
water,
electricity,
disposal
and
communications
infrastructure.

2.

ZONING

AND

REGULATIONS:

Local
zoning
bye-laws
and
regulations
should
ensure
suitability
for
Industrial
use.
Verify
that
the
zoning
permits
factory
construction
and
manufacturing
operations
and
inquire
about
any
restrictions
or
requirements
imposed
by
Local
Authorities.
Compliance
with
local
civil
and
fire
regulations
from
the
outset
can
prevent
costly
delays
and
legal
issues
down
the
line
for
N.O.C.
,
Sanction
and
Approval
process.

3.

LAND

SIZE

AND

TOPOGRAPHY:

Evaluate
the
size
and
topography
of
the
land
to
ensure
it
can
accommodate
the
planned
factory
facility
and
future
expansion
needs.
Consider
factors
such
as
terrain,
elevation,
drainage
and
soil
stability,
which
can
affect
construction
costs
and
feasibility.
Choose
a
site
with
ample
space
for
building
construction,
parking,
storage

and
other
operational
requirements.

4.

ENVIRONMENTAL

CONSIDERATIONS:

Assess
the
environmental
suitability
of
the
site,
taking
into
account
factors
such
as
air
and
water
quality,
soil
conditions
and
potential
hazards.

5.

SURROUNDING

AREA
AND

COMMUNITY:

Consider
the
surrounding
area
when
selecting
a
site
for
the
factory.
Assess
factors
such
as
proximity
to
other
industrial
areas,
commercial
developments
and
potential
sources
of

noise

pollution
and
vibration.

6.

PLANNING


FRAMEWORK

:

It
will
be
appropriate
to
look
at
the
existing
planning
framework
/
Master
Plans
/
Development
Plans
/
Zonal
Plans,
evolved
for
the
city
and
identify
the
permissible
zone
in
which
the
land
use
of
the
project
is
permissible.
Site
must
be
identified
in
the
permissible
land-use
zones
defined
in
the
planning
framework
of
the
city,
failing
which
it
will
create
numerous
problems
in
getting
statutory
approvals
like
change
of
land
use
and
getting
building
permit
for
starting
the
construction
etc.,
which
may
inordinately
delay
the
project
and
may
even
require
selection
of
an
alternate
site
in
the
relevant
zones.
In
case
of
projects
having
large
land
requirement,
it
will
be
desirable
that
before
selecting
/
locating
the
precise
site,
it
is
essential
to
understand
/
analyse
the
context
of
the
planning
framework
of
the
city,
for
which
services
of
the
professionals
must
be
made
use
of.

If
the
site
is
being
sourced
in
the
planned
area,
developed
by
a
Parastatal
agency
/
Development
Authority
/
Urban
Local
Bodies
/
Improvement
Trusts
/
Private
Builders
/
Developers;

then

in
such
cases,
the
approved
layout
plan
of
the
area
in
which
site
falls;
the
availability
and
positioning

of
supportive
infrastructure
etc.
must
be
looked
at
.

7.

INVOLVING

TECHNOLOGY

:

Make
use
of
available
technology
for
zeroing
on
the
site.
Google
maps
can
be
a
handy
tool
to
provide
the
overall
profile
of
the
area
including
mapping

physiography;
understanding
topography
and
contours
of
the
area;
existing
road
network;
connectivity
with
roads-
both
main
and
sub-roads;
position
of
the
railway
lines;
location
of

major
transport
nodes
including
railway
station,
Bus
Terminals,
Airport
;
distance
from
major
landmarks
of
city
water
bodies,
canals,
rivers,
electric
lines-
both
Low
/High
Tension
Lines,
service
network,
forests,
low
lying
areas
etc

Advanced
technologies
like
Total
Station
Surveys,
DGPS,
Lidar
Survey
and
Drone
Based
Aerial
Survey
etc
using
photogrammery
software
can
create
geo
referenced
orthomosaics,
elevation
models
and
3d
model
of
the
project
are
in
case
of
major
topographoical
variations.
These
are
highly
accurate
methods
that
reduce
time
and
require
less
manpower.

CHAPTER 3 ...material and technology BUILDING BLOCKS

01 standard r.c.c. construction technology using common and reliable methods for building. think of it as using tools and techniques that are tried and true, like building with bricks or concrete.

02 prefabricated shed design

industrial buildings use steel fabrication where parts of the structure are made in a factory and then assembled on-site making construction faster and more efficient

03 master planning

master planning means carefully thinking and deciding how the entire construction project will look and function in totality even if building in phases integration with specialized systems

04 integrating specialized systems like HVAC, electrical, plumbing, automation, and environmental controls as part of the building as per norms

Industrial
buildings
are
increasingly
incorporating
automation
and
robotics
technologies
to
streamline
manufacturing
processes
and
improve
productivity.

The
adoption
of
advanced
building
technologies
in
Industrial
and
Factory
Buildings
is
driven
by
the
need
for
efficiency,
sustainability,
and
competitiveness
in
the
Global
Market.

CHAPTER 4 ...follow rules and norms GUIDING PRINCIPLES

As
an
Industry
owner
planning
on
building
a
new
factory
unit,
it
is
important
to
follow
certain
rules
and
guidelines.
These
rules
cover
things
like
getting
permission
to
build
your
factory,
making
sure
the
building
is
strong
and
safe
and
taking
steps
to
protect
the
environment.
You
also
need
to
think
about
fire
safety
and
providing
basic
facilities
like
clean
drinking
water
and
washrooms
for
your
workers.
Following
these
rules
not
only
keeps
your
workers
safe
but
also
shows
that
you're
running
your
industry
responsibly
and
caring
for
the
environment.

The
quality
of
the
industrial
factory
has
a
significant
impact
on
the
operation
and
production
productivity
of
the
enterprise.

Waste
treatment
system,
water
supply
and
drainage
system
must
be
controlled,
ensuring
safety
when
using.
Sewage,
garbage
etc
should
be
treated
so
as
not
to
pollute
the
surroundings.

The
Design
and
Construction
process
must
ensure
the
best
standards
and
quality.

1.

LOCAL

BYE-LAWS:

Adhere
to
local
bye-laws
governing
land
use,
zoning
regulations,
and
building
codes
specific
to
Industrial
zones.

Establishment
of
Industrial
units
within
designated
Industrial
Zones
or
Industrial
Estates
approved
by
the
State
Government
or
Local
Authorities.

Compliance
with
Master
Plans
and
Development
Regulations
governing
Industrial
Zones
to
ensure
orderly
development
and
infrastructure
provision.

2.

BUILDING

PLAN

APPROVAL:

Obtain
approval
from
the
Local
Municipal
Corporation
or
Industrial
Development
Authority
for
the
construction
of
factory
buildings.

Submit
proposal
for
Sanctioning
of
detailed
building
plans,
structural
drawings
and
specifications
for
approval
by
the
Department
of
Industries
as
per
applicable
norms.

Design
should
comply
with
regulations
related
to
setbacks,
maximum
floor
area
ratio
(FAR),
building
height
restrictions
and
other
site-specific
requirements.

CHAPTER

5

Factory
owners
often
rely
on
the
advice
of
their
longtime
contractor,
like
seeking
wisdom
from
an
old
friend.

Sometimes
they
are
given
a
cost
estimate
without
much
reasoning
behind
it.
This
estimate
then
becomes
the
cornerstone
of
their
budgeting,
only
to
reveal
later
that
the
cost
has
exceeded
beyond
a
reasonable
limit
hampering
construction.

Similarly
a
well-defined,
practical
timeline
ensures
that
procurement
of
plant
and
machinery
aligns
seamlessly
with
the
construction
progress.
Having
a
clear
timeline
allows
for
efficient
coordination
between
suppliers
and
construction
teams,
minimizing
delays
and
ensuring
that
the
factory
is
up
and
running
on
schedule.
This
not
only
helps
in
coordinating
the
procurement
of
plant
and
machinery
but
also
ensures
that
deadlines
are
met.

By
leveraging
lessons
from
your
existing
facilities
and
observing
infrastructure
around,
you
can
develop
innovative
and
effective
solutions
that
address
the
unique
challenges
of
your
upcoming
projects
while
delivering
value
.

02 compliance with regulations

01 expertise in design principles trained in spatial design to optimise the layout for efficient workflow, machinery placement and comfortable employee workspace familiar with building codes and regulations, ensuring design meets legal requirements, safety standards and environmental regulations

03 customise for industry needs

04 create an infrastructure that is not only efficient but also visually appealing and contributes to a positive work environment can tailor the design as per industry specific needs, accommodate unique production processes and equipment requirements aesthetics and functional integration

An
Architect
as
a
professional
steps
into
your
shoes
to
serve
you
and
get
the
desired
results.
Hiring
an
Architect
for
design
and
coordination
of
an
Industrial
Project
ensures
a
holistic
and
professional
approach
to
factory
design.
He
address
not
only
the
technical
and
operational
aspects
but
also
the
aesthetic,
environmental
and
humancentric
considerations
crucial
for
a
successful
Industrial
facility.

Every
factory
construction
invariably
suffers
from
the
same
issues
during
the
design
and
construction
process
if
not
given
enough
thought.

As
an
Architectural
Practice
it
is
our
job
to
give
every
project
the
best
possible
suggestions
in
terms
of
the
space
available
and
the
kind
of
infrastructure
that
can
be
created
as
part
of
an
Industrial
setup.

As
part
of
our
Consultancy,
we
share
suggestions
incorporate
good
building
construction
practices
and
healthy
work
environment.

As
an
active
reader
of
this
book
who
desires
a
safe
and
maintenance
free
campus,
we
offer
our
suggestions
and
guidance
to
take
you
forward
with
the
process.

Have
a
piece
and
land
or
planning
to
invest
in
one,
but
don't
know
how
to
go
about
building
it,
contact
us
at
the
mobile
number
and
email
mentioned
below
and
we
shall
help
you
move
forward
in
the
right
direction. We
offer
visit
of
the
premise
to
help
you
audit
and
understand
your
requirements
and
map
the
way
forward.

FIRM’S PROFILE

AVINASH
KHOSLA
AND
ASSOCIATES
is
an

ARCHITECTURE
AND
PROJECT
MANAGEMENT

CONSULTANCY
Firm
established
in
India
for
the
past
5

DECADES
with
Ar.
Avinash
Khosla
as
the
Principal

Founder.
The
firm
provides
a
comprehensive
range
of
Architectural
Design,
Interior
design,
Planning,
Urban
Design,
Engineering
&
Project
Management
Consultancy
services,
having
complete
in-house
facilities,
infrastructure
&
organizational
set
up
to
provide
all
the
necessary
Design
Solutions
under
one
roof
&
is
one
of
the
Multi-Disciplinary
Architectural
Practices
in
India.

Our
practice
profile
encompasses
a
variety
of
areas
including
Industrial,
Commercial,
Residential,
Housing,
Offices,
Interiors
&
allied
services
such
as
Air
Conditioning,
Public
Health,
Electrical,
Water
&
Waste
Management,
Fire
Fighting
&
Development
works.

Established
since
1968,
we
have
an
experience
of
more
than
50
years
in
this
field.
We
are
registered
with
The

Council
of
Architecture,
New
Delhi
&
The
Indian
Institute
of
Architects,
Bombay.
Since
its
inception,
the
Firm
has
taken
holistic
approach
to
Architectural
Design
and
Construction
services
combining
the
abilities
of
a
variety
of
Professionals
and
Specialists
into
a
Coordinated
Team.

Grounded
in
Modern
Building
construction
technologies,
the
Firm
possesses
expertise
in
producing
architecture
reflective
of
the
distinctive
Contemporary
Architecture.

The
Pre-eminent
goal
of
the
Practice
is
one
of
providing
solutions
for
the
functional
needs
created
by
human
activity
and
environmental
requirements.
We
believe
in
focusing
on
the
requirements
and
desires
of
the
clients
through
continuous
collaboration
and
interaction.

The
office
has
a
reputation
for
producing
buildings
of
the
highest
architectural
quality
to
satisfy
the
requirements
of
the
Clients
Brief
and
respond
to
the
opportunities
and
context
of
site.

Our
Genre
Of
Projects
Includes:

AVIATION
-
Airport
Terminal
Buildings,
Railway
Stations

INDUSTRIAL
ESTATES
-
Plants,
Factories,
Large
Godowns
,
Sheds.

SPORTS
-
Stadiums
(
Indoor
&
Outdoor
)
,
Sports
Infrastructure.

COMMERCIAL
-
Commercial
Centre,
Corporate
&
Private
offices,

RESIDENTIAL
-
Group
Housing
,
Apartments,
Townships,
Row
Houses

PUBLIC
BUILDINGS
-
Government
Administrative
Buildings,

RETAIL
-
Mega
Malls,
Agro
Marketing
Centres,
Showrooms

EDUCATION
–
University
Campus,
Educational
Institutes.

HEALTH
CARE
-
Hospitals
,
Health
Centres,
Nursing
homes.

Avinash
Khosla
and
Associates
are
dedicated
to
finding
creative
answers
to
complex
architectural
problems.
With
Us
each
project
is
approached
afresh
and
without
any
pre-conceptions.
We
offer
well
designed
cost
effective
solutions
for
buildings
that
exceed
expectations.
In
a
nut-shell,
Ours
is
a
technically
sound
self
sufficient
organization
providing
accurate
services
within
a
time
bound
schedule.

KEY TEAM

Ar. Avinash Khosla

B. Arch, Specialised in Industrial Architecture

M.C.A, F.I.I.A,

Ar. Kanav Khosla

Masters In Urban Design (Oxf. UK)

B. Arch, Specialised In Facade Design

M.C.A, F.I.I.A, A.I.I.I.D.

Ar. Ramesh Nagpal

B. Arch, Specialisation in Industrial Architecture

M.C.A, A.I.I.A.

Ar. Shweta Khosla

B. Arch, Specialisation in Interiors

M.C.A, A.I.I.A, A.I.I.I.D.

INDUSTRIAL

SPORTS

EDUCATION

HEALTHCARE

HOUSING