30,000 sq ft shop build

[stewie97]

Building a new 30,000 sq ft shop for our Manufacturing business - follow along for the process!

Currently the foundation is poured - and it took forever. With the record rain we have gotten in Iowa this year we are about a month behind schedule on everything and the tentative move in date will be June 1 2019

Some shop details

30,000 total sq ft all free span - approx 1500 sq ft of that is office space

Dims are 320' x 100 ' - a portion of the building bumps in for the semi dock

1 x dock door for semi loading
3 x doors for fork truck travel in and out of the building. The largest being 26' wide

Here is a view of the dock walls - let me know what else you want to see

 

[stewie97]

And a pic of the lighting for the shop/office

 

[el monte slim]

Thanks for posting, as this might be something I will need to do in the future as well. Did the foundation require any special work to accommodate heavy machinery or equipment, and what will you be manufacturing in the building?

 

[stewie97]

Thanks for posting, as this might be something I will need to do in the future as well. Did the foundation require any special work to accommodate heavy machinery or equipment, and what will you be manufacturing in the building?

We have one large press that will require a special pad, but that will be added later when we figure out exactly where it is going to be place.

We have a large cnc bridge mill with a 60x120 table, but it does not require a special pad.

The equipment going in the building will be

1 x bridge mill
1 x 325 ton press
1 x 4000 ellis band saw
1 x pirhana iron worker
1 x 5x10 plasma table (unknown at this time)

We manufacture non-penetrating roof mounts for satellite dishes, microwave, cameras, and anything else you can mount on a pole.

https://www.bairdmounts.com/

 

[MacTexas]

Looks like a good construction project to follow.

 

[protegeV]

This is very cool. Not your typical GJ build.

 

[stewie97]

Looks like a good construction project to follow.

This is very cool. Not your typical GJ build.

Thanks for the interest - let me know if there is anything specific you guys want to see. I have daily photos from the beginning of the project - but the don's show much other than the foundation.

There won't be any AC in the building other than the office. We are using two Cambridge heaters to heat the shop.

https://www.cambridge-eng.com/

And here is a neat lean video of their facility

 

[LXCam]

Congratulations on the new facility. Will this be a tilt up or red iron structure?

 

[stewie97]

Here is a tentative equipment layout. Currently undecided where the Plasma table will go.
We were able to spec the spacing of the support columns to accommodate the pallet racking with very little wasted space.

 

[stewie97]

Congratulations on the new facility. Will this be a tilt up or red iron structure?

Thanks!

it will be a Butler building - not a tilt up

https://www.butlermfg.com/how-we-build/

 

[LXCam]

Thanks!

it will be a Butler building - not a tilt up

https://www.butlermfg.com/how-we-build/

Very nice and I'm VERY familiar with them. I've played my roll in the construction of a couple million square feet of their product In my lifetime and they have always been great to deal with.

 

[stewie97]

Very nice and I'm VERY familiar with them. I've played my roll in the construction of a couple million square feet of their product In my lifetime and they have always been great to deal with.

It's the only building our builder will sell - and for very good reason from the sound of it.

 

[LXCam]

It's the only building our builder will sell - and for very good reason from the sound of it.

I can't say that on any of those projects there was ever an issue with the building or maintaining the schedule. Hell I was the Forman on all three of new manufacturing buildings in San Bernardino 35yrs ago. The first two where built just to manufacture the structure for Library Tower in downtown LA which was for many years the tallest building in la. It was cheaper for them to construct ~200ksqft facility then it was to ship everything back n forth from Sacramento since the raw extrusions where forged about ten miles away.

 

[stewie97]

I can't say that on any of those projects there was ever an issue with the building or maintaining the schedule. Hell I was the Forman on all three of new manufacturing buildings in San Bernardino 35yrs ago. The first two where built just to manufacture the structure for Library Tower in downtown LA which was for many years the tallest building in la. It was cheaper for them to construct ~200ksqft facility then it was to ship everything back n forth from Sacramento since the raw extrusions where forged about ten miles away.

Awesome!

And no problem with the schedule - the building is currently sitting on site waiting for the crew to start building it.

The shear amount of Rain we had in sept and oct put the foundation behind. Once the foundation crew had good weather they really made hay.

 

[jeepxj]

Here is a tentative equipment layout. Currently undecided where the Plasma table will go.
We were able to spec the spacing of the support columns to accommodate the pallet racking with very little wasted space.

are you going to divide the warehouse space from the manufacturing space?

What kind of workflow analysis have you done with this layout? I'd highly suggest building a model of the building with your machines so you can move it around and get a feel for how it works given your workflows.

 

[sjvicker]

are you going to divide the warehouse space from the manufacturing space?

What kind of workflow analysis have you done with this layout? I'd highly suggest building a model of the building with your machines so you can move it around and get a feel for how it works given your workflows.

Also find a good way to vent around the plasma table

Sent from my Nexus 9 using The Garage Journal mobile app

 

[jeepxj]

Also find a good way to vent around the plasma table

Sent from my Nexus 9 using The Garage Journal mobile app

downdraft table or a hood over the water table that lowers during cutting.


But having metal working sharing air space with your inventory is asking for a bunch of inventory cleaning days.

 

[stewie97]

are you going to divide the warehouse space from the manufacturing space?

What kind of workflow analysis have you done with this layout? I'd highly suggest building a model of the building with your machines so you can move it around and get a feel for how it works given your workflows.

Oh yeah - this is version #87 of the shop layout . I watched NYCCNC's video on 3d printing equipment - that would be fun.

We started the process on a white board, then modeled everything in solidworks and moved it around in there.

As far as venting goes - we will have two airmaids above the welding area and one above the plasma table. I haven't decided if we are going to do a water table or a down draft table - either way we will filter as much out as possible.

We are trying to do with without the use of overhead cranes. If possible I'd like to use gantry cranes above the saw and iron worker for items we cant load by hand or with the fork truck. I prefer loading the conveyor with the truck myself, but I'm not the operator so I'd like to give them options.

 

[jeepxj]

How does material flow through your space? it looks like it crosses over a bunch. With all the equipment on that one wall so close together won't it be crowded? genuinely curious what kind of process flow you have.

 

[stewie97]

How does material flow through your space? it looks like it crosses over a bunch. With all the equipment on that one wall so close together won't it be crowded? genuinely curious what kind of process flow you have.

Material comes in through the 26 ft door and is staged at the cantilever - unless it is precut then it goes straight to welding.

If we do have to process it in house it typically will flow from one machine to the next - iron worker to the press or CNC, or saw to CNC.

Once it it processed it goes to weld then to hot dip, or straight to hot dip.

Very minimal criss crossing, and we don't want weld cells close to the machines.

The boxes we have around the machines are better described as their "area of influence" - not even close to being crowded honestly.

 

[stewie97]

How does material flow through your space? it looks like it crosses over a bunch. With all the equipment on that one wall so close together won't it be crowded? genuinely curious what kind of process flow you have.

Take for instance the press - it has a 12' bed, but we are allowing close to 27' for it's area. The largest part we punch on it Is 6.5' long - so plenty of room to stage material around the machine. It is the one piece of equipment we can't move without spending a fortune to do so, so it will be locked into place. The cnc would cost $ to move, but not nearly as much as the Press. The saws, iron worker, and future plasma can all be moved with a fork truck, so no issues there.

 

[jeepxj]

Ahh got it. "largest part we press is 6.5' long" I bet in 5 years its a medium size part lol.

 

[stewie97]

Ahh got it. "largest part we press is 6.5' long" I bet in 5 years its a medium size part lol.

Lol! Anything longer we get laser cut. The larger parts we don’t do in any kind of volume to punch.

 

[jeepxj]

Lol! Anything longer we get laser cut. The larger parts we don’t do in any kind of volume to punch.

where you going to be putting your laser table? 10x40' cutting bed?

 

[stewie97]

where you going to be putting your laser table? 10x40' cutting bed?

We outsource the laser cut parts - we have one main supplier for flat cut, and a couple different suppliers for laser cut tube and angle

 

[jeepxj]

We outsource the laser cut parts - we have one main supplier for flat cut, and a couple different suppliers for laser cut tube and angle

few more years and you will be building "laser cutting building 2"

 

[stewie97]

few more years and you will be building "laser cutting building 2"

That would be nice, we could cut 99% of our parts on a tube laser. I come from a laser shop background, and one of the owners was the president of a laser shop.

However with one of the best laser shops in the Midwest less than a half mile away there isn’t any reason to start our own.

 

[stewie97]

Small update - the lifts are on site. The crew is supposed to start erecting the steel Monday or Tuesday after the holiday.

 

[jblnut]

Oh boy what a building !!

I could put everything I own in a 320'x100' structure. I've been in a 300'x150'x26' farm shop a fair few times and it is kind of boggling how much space is in there. They still grumble about not building it big enough

 

[stewie97]

Oh boy what a building !!

I could put everything I own in a 320'x100' structure. I've been in a 300'x150'x26' farm shop a fair few times and it is kind of boggling how much space is in there. They still grumble about not building it big enough

Our current shop is around 40k under roof, but it is terribly partioned and multi level. Not a great layout for manufacturing but we have been successful with it so far.

 

[stewie97]

The back wall uprights are going up - I don't envy the guys putting this thing up in the cold. I'm not even going to get out of the truck to take pics!

 

[stewie97]

Its way past time for an update - the roof is on and 2/4 garage doors are up. Small snafu with the 26' wide door. It was supposed to be 14' tall, not 16'