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Design and construction process of prefabricated factory

Prefabricated factories are becoming a popular construction trend in industrial factories. With a large and small scale, appearing in many provinces and cities, why do prefabricated factories receive so much attention?

1. What is a prefab factory?

Prefabricated factory is simply defined, is a type of house built with a pillar frame made of steel materials, forming plates and many other basic components, installed according to architectural design drawings and techniques are available.

The entire steel structure can be produced synchronously and then brought to the erection site with the forming plate to complete the work in a relatively short time.

A complete prefabricated factory is created in 3 stages:

  • Firstly, design.
  • Second, processing components.
  • Third, rebuild the building.

Prefabricated factories are one of the optimal solutions for projects in the field of industrial and civil construction such as factories, warehouses, shopping centers, offices, hospitals, schools, etc.

2. What is the structure of the prefabricated factory?

The pre-engineered steel frame factory has the main structure including:

Basic structure of the prefabricated factory

2.1 Foundation structure system

The steel frame house has a reinforced concrete foundation structure, the foundation system has the effect of transmitting the load above to the hard ground below. The foundation used in the steel frame workshop can be single foundation, ice foundation, raft foundation or pile foundation depending on the construction geology and technical load of the building.

Before concrete is poured, the anchor bolts are properly and firmly connected to the foundation steel system. Installing bolts is an important step and requires high accuracy, to ensure that the installation of steel columns and trusses is more accurate and easier to build.

2.2 Factory background

The prefabricated factory floor is usually poured with concrete under the base layer and compacted sand. The thickness of concrete foundation depends on the load of machines and vehicles moving in the workshop according to the needs of each unit. The floor is usually polished with cement or epoxy paint to ensure a smooth, clean surface during use.

2.3 Main structural frame system

The main structural frame system of the steel frame prefabricated factory is columns, beams, and steel trusses.

The main structural frame system of the steel frame prefabricated factory is columns, beams, and steel trusses

Steel columns, steel trusses are the main structure of  the pre-engineered factory , columns and trusses are designed to be able to bear the load and to exceed large spans that can be up to 100m according to the requirements of the design workshop. Steel columns and trusses are designed in the form of H-shaped steel to change the cross-section, or a truss structure to ensure bearing. The connection between the column and the truss is usually coded and connected with high-strength bolts.

2.4 Canopy’s skylight and roof

The skylight is usually placed on the top of the factory, has a ventilation effect to help the factory breathe during the operation of the factory.

Canopy roof is a roof system that has the effect of shading the sun and rain at the doors and windows of the factory. Canopy roof can be designed from materials such as steel, corrugated iron, glass roof, polycarbonate sheet, Canopy aluminum roof, depending on the investment needs of each workshop.

2.5 Purlins and roof bracing, column bracing, purlin bracing

Purlins used for steel frame factories are galvanized steel purlins, usually in the form of C, Z, … The purlin distance from 1m to 1.5m is linked with the main frame to support the side corrugated iron roof system. above.

The roof and column bracing system, although not occupying much volume, is an indispensable part of the prefabricated factory structure. The bracing system has the effect of increasing the stability of the main structural frame system during erection and use. Many factory structural systems are deformed because of the subjectivity of this bracing system.

2.6 Roofing and insulation materials

Currently, there are 3 common types of corrugated iron, which are 3-layer heat-insulating corrugated iron, 1-layer ordinary corrugated iron and light-weighted corrugated iron. Roofing corrugated iron is usually used with 1-layer color-plated corrugated iron, increasing aesthetics and avoiding environmental corrosion. However, with the hot weather in our country, the corrugated iron roof is often constructed with an extra layer of insulation by means of air bags or a layer of glass wool that has the effect of preventing heat and noise for the factory.

2.7 Cover sheet, shaping the factory

After having the main frame and roof, the wall covering is one of the important structures of a beautiful prefabricated house. To ensure certainty, in the past, traditional bricks were used to make walls and partitions for the entire building. However, bricks are made from clay that is exploited from nature and undergoes a burning process, which consumes more materials. This greatly affects the protection of the environment and natural resources. Therefore, nowadays, people often use existing cement panels to replace this traditional fired brick. Cement board – lighter weight compared to other materials helps reduce load pressure in all aspects on the building.

3. Why should you choose a prefabricated factory?

One of the reasons that are considered as advantages for the appearance of a series of large-scale projects in all provinces and cities is:

3.1 Investment cost savings

Compared with traditional construction methods such as reinforced concrete foundations, concrete pillars, brick walls, and tiled roofs, steel frame factories have 25% lower investment costs per m2. Since then, the problem of low investment has always been an attractive number for many businesses.

3.2 Fast construction

With simplicity, no fuss, all steel structures of the factory are manufactured in the factory and erected by bolt links at the construction site. Therefore, the construction and erection process is quick and simple with compact construction equipment. Save time to complete and put into production; save labor.

3.3 Quality assurance

Steel structures are designed and manufactured at the factory, with a strict quality control process, continuously from the time of production until the erection site. Prefabricated factory with fast production and construction time, but still ensure structural quality and longevity.

3.4 Flexible in use

The steel-framed factory is designed with steel-framed components, so it is easy and flexible to expand or shrink. Easy to dismantle, install at another location, ensure low cost and make full use of the designed technical structure.

3.5 Energy Solutions

Pre-engineered steel buildings are considered a green solution for the industry. Pre-engineered steel buildings are said to be a beneficial model for the industrial environment by minimizing the amount of CO2 emitted, saving energy and effectively recycling, thus reducing the high risk of industrial environmental pollution.

4. Construction steps of prefabricated factories

The construction will depend on each project, there will be different construction stages. Basically, the construction of  pre-engineered factories  will follow the following 4-step process:

4.1 Construction of the factory foundation

After receiving the handover of the site, the contractor carries out the construction of the foundation according to the construction technical design drawings. Before pouring concrete foundation, it is necessary to connect with the laying of foundation bolts, to connect with the steel column system of the factory. After pouring concrete foundation, proceed to pour the soil and compact the ground according to the requirements of the drawing, prepare the ground for the work of gathering and erecting the steel structure afterwards.

4.2 Producing steel structures at the factory

The steel structure production phase at the factory will be carried out in parallel with the foundation construction phase. So that as soon as the foundation is completed with sufficient strength, it is possible to transport the manufactured steel frame according to the design drawings to erect and erect, speeding up the construction progress.

4.3 Construction and erection of steel frames

After the steel frame components are transported from the factory to the construction site, the erection will be carried out according to the previous technical drawings of the factory design.

4.4 Complete construction of related items

After completing the erection of the steel frame, the related items will be completed such as construction of the wall, installation of the wall covering, roofing, floor polishing, etc.

Thus,  prefabricated factories  with the advantages of construction time, low investment costs, high applicability, are favored by industrial construction. For detailed advice on factory projects, please contact Hasacon directly.

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