This document provides information about designing and constructing an industrial textile factory. It discusses the various stages of cotton manufacturing including cultivating, preparatory processes, spinning, weaving/knitting, and finishing. It also outlines the key design requirements for industrial buildings such as promoting connectivity and safety, screening storage areas, and providing adequate parking and loading areas. Specific specifications are provided for constructing a fireproof storehouse on the factory site.

1. Industrial building project -Textile Factory
Industryisthe productionof goodsor relatedserviceswithinthe economy.Itcanbe definedas
the collective large-scalemanufacturingof goodsinwell-organizedplantswithahighdegree of
automationandspecialization.Althoughthisisacommonexample of industry,itcanalso
include othercommercial activitiesthatprovide goodsandservicessuchasagriculture,
transportation,hospitality,andmanyothers.
Industrial progressfromrawmaterial toa product:
Figure-01
Industrycan be dividedintothree maincategories.RecentlyTertiaryindustryhasbeen sub-
dividedinto afourthtype.
Primary Industries:
Extract raw materials(whichare natural products) fromthe landor seae.g.oil,ironore,timber,
fish.Mining,quarrying,fishing,forestry,andfarmingare all example of primaryindustries.
Secondary Industries(sometimesreferredtoas manufacturing industry):
Involve the manufacture of rawmaterials,intoanotherproductbymanual laboror machines.
Secondaryindustriesoftenuse assemblylinese.g.acar factory.
Tertiary Industries(sometime referredtoas Servicesindustry):
Neitherproduce araw material normake a product,insteadtheyprovide servicestoother
people andindustries. Tertiaryindustriescaninclude doctors,dentists,refusecollectionand
banks.
Quaternary Industries:
Involve the use of hightechindustries.
People whoworkforthese companiesare oftenhighlyqualifiedwithintheirfieldof work.
Researchanddevelopmentcompaniesare the mostcommontypes of businessesinthissector.
All of the companiesare linkedinone wayoranother. For example:
The raw material cottonis extractedbyprimaryindustries;itmaythenbe turnedintoan itemof
clothinginthe secondaryindustry.Tertiaryindustriesmayadvertisethe goodsinmagazinesand

2. newspapers.The quaternaryindustrymayinvolve the productbeingadvertisedorresearchedto
checkthat the itemof clothingmeetsthe standardsthatit claimstoo.
A factory is an industrial site,usuallyconsistingof buildingsandmachinery,ormore commonly
a complex havingseveral buildings,whereworkers manufacture goodsor
operate machines processingone productintoanother.
Factoriesarose withthe introductionof machineryduringthe Industrial Revolution whenthe
capital and space requirementsbecame toogreatfor cottage industry or workshops.Early
factoriesthatcontainedsmall amountsof machinery,suchasone or two spinningmules,and
fewerthana dozenworkershave beencalled"glorifiedworkshops".
Most modernfactorieshave large warehousesor warehouse-like facilitiesthatcontain
heavy equipmentusedforassemblylineproduction.Large factoriestendtobe locatedwith
access to multiplemodesof transportation,withsome havingrailed,highwayandwaterloading
and unloadingfacilities.
Cotton textile manufacturingisa majorindustry.Itisbasedon the conversion
of cottonintoyarn, yarnintofabric.These are thendyedorprinted,fabricatedinto clothes.
There are manyvariable processesavailable atthe spinningandfabric-formingstagescoupled
withthe complexitiesof the finishingandcolorationprocessestothe productionof awide
range of products.There remainsalarge industrythatuses hand techniques toachieve the
same results.
There are five stagesof manufacturingcottonintofabric:
1. CultivatingandHarvesting
2. PreparatoryProcesses
3. Spinning
4. WeavingorKnitting
5. Finishing
 Cultivatingand harvesting
Cottonis grownanywhere withlong,hotdrysummerswithplentyof sunshineandlow
humidity.The cottonbolls are harvestedbystripperharvestersandspindle pickersthatremove
the entire boll fromthe plant.
 Preparatory processes - preparation of yarn
 Ginning,bale-makingandtransportation.
 Openingandcleaning.
Cotton mills get the cotton shipped to them in large bales. In order to fluff up the cotton and
remove the vegetable matter, the cotton is sent through a machine known as a picker, and

3. gets beaten with a beater bar in order to loosen it up. The cotton, aided by fans, then collects
on a screen and gets fed through more rollers till it emerges as a continuous soft fleecy
sheet, known as a lap.
 Spinning - yarn manufacture
Most spinningisdone usingBreakorOpen-endspinning,thisisatechnique where the staples
are blownbyair intoa rotatingdrum, where theyattachthemselvestothe tail of formedyarn
that iscontinuallybeingdrawnoutof the chamber.
Checkingisthe processwhere eachof the bobbinsisrewoundtogive atighterbobbin.
Foldingand twistingPlyingisdone bypullingyarnfromtwoor more bobbinsandtwistingit
together,inthe opposite directionthatinwhichitwasspun.Dependingon the weightdesired,
the cotton mayor maynot be plied,andthe numberof strandstwistedtogethervaries.
Gassingisthe processof passingyarn,as distinctfromfabricveryrapidlythrougha seriesof
Bunsengasflamesina gassingframe,inorderto burn off the projectingfibersandmake the
threadroundand smoothand alsobrighter.
 Weaving-fabricmanufacture
The weavingprocessusesa loom.The length waythreadsare knownasthe warp,and the
cross waythreadsare knownas the weft.The warpwhichmustbe strongneedstobe
presentedtoloomona warp beam.The weftpassesacrossthe loomin a shuttle,thatcarries
the yarn on a pin.These pinsare automaticallychangedbythe loom.Thus,the yarnneedsto
be wrappedontoa beam andonto pinsbefore weavingcancommence.
 Finishing- processingoftextiles
The wovencottonfabricin itsloom-state notonlycontainsimpurities,includingwarpsize,but
requiresfurthertreatmentinordertodevelopitsfull textile potential.Furthermore,itmay
receive considerableaddedvaluebyapplyingone ormore finishingprocesses.
Scouring,is a chemical washingprocesscarriedoutoncotton fabricto remove natural wax and
non-fibrous
Bleaching, improveswhitenessbyremovingnatural colorationandremainingtrace impurities
fromthe cotton;the degree of bleachingnecessaryisdeterminedbythe requiredwhitenessand
absorbency.
Dyeing,cotton isan absorbent fiberwhichrespondsreadilyto coloration processes. Printing,on
the otherhand,is the applicationof colorinthe form of a paste or inkto the surface of a fabric,
ina predeterminedpattern.Itmaybe consideredas localized dyeing.Printingdesignsonto
alreadydyedfabricisalsopossible.

4. Space requirements:
Space requirements dependonthe production rate of manufacturing, thuswe cancalculate numberof
machines required, beside areasof spaces andemployees requirements.
A textile factory must provide these spaces:
Offices
Parkinglots
Circulation area
Storage
Laboratory
Marketingsector
Research centre
Production areas
Warehouse
Service areaforemployees andstaff
Greenareas
Bufferzone
Expansion areasforfuture

5. Textile factory designoutline1:
Second floor plan
First floor plan

6. List of machinery and equipment Human resources requirements
Design requirements for industrial buildings:
Objectives:
 To promote the creationof industrial precinctcharacteranda sense of addressthrough gateway
or entrance statements,includingappropriatelandscape treatments.
 To effectivelyco-ordinatethe redevelopmentof industrialareastominimize the conflicts
betweenindustrialandmore sensitive landusessuchasadjoiningandnearby residential uses.
 To reduce visual impactof on-site storage andgeneral refuse/wastestorage areasfrom street
viewthroughimproved siting,design,landscaping,fencingandotherscreening treatments.
 To improve connectivity,accessandmobilitywithinandbetweenindustrialprecincts and
surroundingareaswhilstnotadverselyimpactingonsurroundingresidentialor publicuses.
 To promote saferareasthroughimprovedbuildingdesignandorientation,andby designingnew
developmenttoensure passive surveillance of openspacesandwithin the industrialareas.

7.  To ensure the protectionof sensitive environmental areasandpublicopenspace from
encroachmentfrominappropriateindustrial activities.
Buildingform and interface:
 The external appearance of buildingsmustbe attractivelydesigned.New industrial buildings
mustmake a positive designcontributiontothe streetscape,particularly where thesebuildings
are visible frommainorsecondaryroads.Blankwallswithno visual reliefmustbe avoidedif
these are visible frompublicareas.
 Developmentadjacenttoopenspace areas,waterwaysorsensitive usessuchas residentialland
use shouldbe of a complimentary/transitional scale andappearance to the adjoiningenvirons.
The designof newbuildingsinindustrial areasshould:
 Be consistentinscale withnearbybuildings.
 Encourage highqualitycontemporarybuildingformsandpresentationtostreet frontagesand
otherkeyinterfaces.
 Provide clearentrances,interestingfacadesanddetailing.
 Emphasize the importance of “landmark”andgatewaysites.
 Incorporate facadesthataddressbothstreetsoncorner buildings.
 Locate office componentstothe frontof the building.
 Have no advertisingsignsprojectingabove the buildingline.
 Screenplantand equipmentfromstreetview.
 Integrate orconceal exteriorelementsof services,plumbing,andheatingandventilation
systems intothe building.Roof topservicesshouldbe locatedoutof sightfromthe street.
Streetscape Amenityand Landscaping:
 Landscapingshouldbe designedasanintegral part of any developmentandassistin creatinga
unifiedappearancewithinanindustrial areaandinimprovingthe environmentalqualityof the
area.
 The provisionof a landscape bufferincorporatinglandscapingandplantingshouldbe provided
alongstreetfrontagestosoftenthe visual impactof the builtformandimprove the amenityof
the area. Landscape areaswhichare narrow and provide maintenance challengesshouldbe
avoided.
 The landscapingtheme adoptedforadevelopmentshouldbe simple andincludeuse of semi-
mature treesand where possible,the retentionof existingmature trees.
Frontage Car parking and Vehicle Loading
 Car parks and car parkingwithinfrontboundarysetbacksshouldbe avoidedwiththe exception
of a limitedproportionof visitorparking.
 Large car parksshall include landscapedtrafficislandstoallow additional canopytree andunder
storeyplanting.Plantspeciesshall be selectedtoallow clearsightlinesfor freightmovements,
pedestrians,cyclistsandmotorists.
 The visual impactof parkedvehiclesshouldbe minimizedbythe use of appropriate contouring
and landscapingtreatments while maintainingoverall safetyandsightlines.
 All cars shouldbe able toenterand leave frontage car parkingina forwarddirection.
 All truckloadingandservicingshall occurwithinthe site.Noloadingorservicingis permittedin
the frontage car parkingor on publicroads.

8.  Loadingand servicesbaysshouldbe separatedfromprivatevehicle,pedestrianand bicycle
routes.
 Frontage car parkingand othercar parksare not to be usedfor temporarystorage of goodsor
for servicingorloading.
 Truck parkingshall notbe locatedwithindesignatedfrontage car parkingareasor landscape
setbacks.If truck parkingisrequired,designatedtruckparkingspacesare to be provided.On-
streetparkingof trucks will notbe permitted.
General Refuse/Waste Storage
 General refuse/waste storage areasshouldbe confinedtothe rear/side of the lotwhere the
side setbackisnota streetfrontage orabuttinga sensitiveorresidential landuse.If thisisnot
possible,the general refuse/waste storage areashouldbe screenedby landscapingand/or
fencingtoavoidvisual impacttothe street.
 Anyareas intendedforthe exteriorstorage of goodsormachineryshouldbe screened fromany
streetor neighboringproperty.
 Where possible,storage areasshouldbe anintegral partof the designof buildings. Outside
storage areas shouldbe designedtopreventthe proliferationof litterandother material within
and beyondthe site.
 The informal storage of goodsor material aroundbuildingsshouldbe avoidedand landscape
and/orscreeningshouldbe providedtoensure the visual amenityof the streetscape and
adjoiningproperties.
 Streetsetbacksshouldnotbe usedtostore goods,materialsorwaste.
Access and Circulation:
 Newdevelopmentshouldprovideimprovedcirculationto promote walkingand cycling.
 Newdevelopmentshouldprovidesecure bicyclestorage lockersandshowersforstaff and
employees.
 Newdevelopmentshouldavoidcreatingaccessconflictswithresidentsandotherland users
accessingtheirhomesorfacilities andvehiclesaccessingthe industrial precinct.

9.  Loadingand service areasshall be integratedwiththe builtformandlandscape treatmentsfor
each lot.
Loadingbaysshould:
 allowdeliveryvehiclestoenterandleave the site inaforwarddirection(generallyonlarger
sites),unlessitcanbe demonstratedthatnosubstantial traffichazardis likelytooccur;and
 be locatedto the side (if nota streetfrontage) orrear of the site (generallyforlarger sites);or
be locatedinternallywithinbuildingsor screenedfromstreetview.
Security/Safety:
 Buildingsshouldbe orientatedandglazingprovidedwhere possibletoprovide passive
surveillance tothe streetandotheradjoiningpublicareas.
 Pedestrianandcyclistcirculationshouldbe separatedfrom vehicularmovements wherever
possible/appropriate.
 Clearsightlinesshouldbe maintainedatall vehicularcrossovers.
 External lightingshouldbe providedforsecurity,safetyandamenityforall exterior areas
includingcarparks,pedestrianpathsandstorage areaswithoutcausinglightspill intoadjoining
propertiesorneighboringareas.
BuildingHeight
Buildingheightsshouldbe notbe outof scale with existingorplanneddevelopment.
Standards and Guidelines:
A. The heightof newdevelopment shouldbe compatible withandtransitionfromthe heightof
adjacentdevelopment.
B. The maximumbuildingheightis40.0-feettothe topof the buildingparapetand50.0-feetfor
architectural projections.
C. Buildingheightmayexceedthe 40.0-footheightlimitupto50.0-feet,whenauthorized throughthe
PUD processfor buildings/users thatrequire specializedequipment.
The store house shall be constructed according to the followingspecification:
1. The wallsshall be constructedof brick,stone, concrete orothernon-inflammable material,the
floorof concrete or otherimperviousmaterialandthe roof of re-enforcedconcrete orother
non-inflammable material.
2. The store shall be providedwithawell-fittedmetal slidingdoor,ora metal dooropening
outwardsof not lessthan3.5mm thick,carriedon an iron doorframe.Such doorshall have an
all-roundover-lapof notlessthan50mm and shall be fittedwithasubstantial lock.
3. The windowframesshall be constructedof metal andfittedwithfire resistingglasspanesor
metal sheets.
4. Everystore shall be constructedinsuch manneror surroundedbywallsnotlessthan150mm in
heightformingawell of suchcharacter that the inflammableliquidcontainedthereincannot
escape there from.
5. Low andhighlevel meansof ventilationshall be providedinthe store.
6. The openingsshall be protectedbynon-corrodible wire gauze of notlessthan0.9mm.
7. A store shall notbe situatedinsuch a positionthatwill impede the escape of anypersonfrom
the premises,orendangeranyroom, building,orpremisesinthe case of fire.
8. Anystore witha floorareain excessof 10m2 shall be providedwithatleasttwodoors.

10. Fireproof construction
Cottonmillsare huge fire risks;cottonfibersinthe aircouldform an explosive mixtureintheirgas-lit
interiors. The firstmillsusingfireproof constructionwere builtinShropshire andDerbyshire inthe 1790s
and Philips&Lee'smill builtinSalfordin1801.
2. Fireproofingtookthe formof cast iron columnsandbeamsfrom whichsprang jack archesthat were
filledwithashorsandand coveredwithstone flags orfloorboards.
Cottonissensitive totemperature andhumidity.Heatingsystemsusedwroughtironpipessuspended
at a heightof 7 feet(2.1 m) to carry steamunderpressure.Insummerthe systemwasbarelyusedbutin
winterthe boilerswouldbe fireduptwohoursbefore the shiftstartedtowarmup the mill.Asheatwas
appliedthe humiditydroppedandsystemof humidifiers,eitheratomizerwhichplayedanairjetagainst
a jetof wateror onesthat injectedastream/airmixture intothe room.
Early fire fightingsystemsusedsprinklerssuppliedbywatercapturedonflatroofsinshallow tanks.
Later millshada watertank at the top of the stairtower.Waterpressure of the sprinklersneed tobe
above 7 psi,and the headertankat least15 feet(4.6m) above the highestsprinkler.
Treatment of Cotton and WoolenTextile Mill Waste :
The pollution load of the waste is dealt with in the operations like segregation, equalization,
neutralization,chemical precipitation,chemical oxidationandbiological oxidation.Severalchemicals
are usedto reduce the BOD by chemical coagulation. These are alum, ferrous sulfate, ferric sulfate,
ferric chloride etc., lime or sulfuric acid is used to adjust the pH in this process. Calcium chloride is
found to be effective in treating wool-scouring waste.
The dye wastes may be treated economically by biological methods, with prior equalization,
neutralization and chemical oxidation for certain wastes.
A composite waste,whenfree fromtoxicsubstancesmaybe treatedasefficientlyasdomestic
sewage,asmostof the textile mill wastescontainsufficientnutrientslike nitrogenandphosphorus.
Tricklingfilters,ActivatedSludgeProcess,Waste Stabilizationponds,all these typesof biological
treatmenthave beentriedforthe treatmentof textile mill wastesandall of themare foundtobe
veryeffective.Excellentresultswere alsoobtainedwithExtendedAerationintreatingastrongwaste,
evenwithoutanyequalizationandpre-treatment;thismethodeliminatesthe necessityof sludge
digestionaswell.

11. Example:
Ipekyol Textile Factory Turkey - by EAA-Emre Arolat Architects
The Ipekyol factory, a custom-designed facility for a manufacturer of high-quality textiles,
represents a successful collaboration between a client and an architect in developing a spatial
strategy that integrates production goals with the well-being of employees. Key design
objectives focused on a single U-shaped volume that makes full use of the site as well as the
use of local materials, reduced energy use, and enhanced thermal performance. The architect
responded with a single, large structure where administration and production spaces were
integrated under one roof, breaking down hierarchies between front- and backof-house
functions. The form of the building conveys its function, its U-shape responding to the demands
of the production line, from inception to the packaging and dispatch of the garments. The glazed
southern facade, five internal courtyards, as well as gardens and light wells give each user
access to natural light and views of nature, and the spaces also provide recreational areas for
the workers.

12. Ground floor plan
Site plan
Elevations

13. References:
Investopedia
NEPA elearning On-line catalog
http://www.lookingatbuildings.org.uk/cities/manchester/topics-and-themes/fireproof-construction.html
http://textilelearner.blogspot.com/2013/07/safety-layout-plan-of-garment-factory.html#ixzz4TwDT32VM
Small-Scale Weaving(WEP, ILO;1983;144 pages)
http://www.wikiwand.com/en/Cotton_mill

14. DESIGN STUDIO-SPININNG & TEXTILE FACTORY
FACULTY OF ARCHITECTURE
NAMARIQ IMAD ISMAIL
SUPERVISORS:
MR. MOHAMMED NAJEEB
MR. AMMAR OSMAN
MR. YAHIA ABDULHAI