A practical problem in factory building design and construction

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K. J. KOCH

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Koch, R. J.

A practical problem in
factory building design and

For Us3 in Lirary Only

A PRACTICAL PROBLEM

IN Factory Building --h
Design and Construction

A THESIS

PRESENTED BY

Raymond J. Koch

TO THE

PRESIDENT AND FACULTY

OF

ARMOUR INSTITUTE OF TECHNOLOGY

FOR THE DEGREE OF

CIVIL ENGINEER

MAY 27, 1920

APPROVED

^jWOjS INSTITUTE OF TKHNOLOGY /y

P^UL V. GALVIN LIBRARY '-^--^;,- y

35 WEST 33RD STREET
CHICAGO, IL 60616

Dean ot Ifingineerlng Studies

Dean of Cultural Studies

Digitized by the Internet Archive

in 2009 with funding from

CARL!: Consortium of Academic and Research Libraries in Illinois

http://www.archive.org/details/practicalproblemOOkoch

A PRACTICAL PROBLEM IN"

FACTORY BUILDING

DESIGN

AND

CONSTRUCTION

BY
Raymond J. Koch

^912S

A PRACTICAL PROBLEM IN FACTORY BUILDING, DESIGN AND
CONSTRUCTION.

PROBLEM:

The writer was appointed by the Ilg Electric
Ventilating Co. of Chicago to look after their interests
and to make a study of the type of huildlng which would be
best suited to their needs, both industrially and struc-
turally. Subsequently the writer also acted as super-
intendent for the owner during the 'construction of the
plant.

The plat of survey marked Exhibit No.l, shows the
site which had been selected for the erection of the
Company's new plant. The site is bounded by George St. on
the north, Crawford Ave. on the east, and the main line of
the Chicago Milwaiikee & St. Paul Railway Co. on the west.
A switch track was to serve this property, but its loca-
tion was to be determined after the building was settled.

The points that had to be settled were: what shape
of building was best suited for present needs and lended
Itself most easily for future expansion, what height
building should be erected, should the building be built
of reinforced concrete, structural steel or heavy timber.

METHOD OF ATTACK:

In order to proceed intelligently on this problem
the first thing that required attention was the product
manufactured, the processes in the manufacturing, the pres
ent floor area alloted to various processes and depart-
ments, and the co-relation between various departments.

PRODUCT MANUFACTURE:

The particular output of the Company is electrical
ventilating equipment. This consists of fans and blowers
made up of castings and sheet metal on which electric
motors are mounted as a source of propulsion.

PROCESS OF MANUFACTURE:

By dividing up the various finished products into
their pieces and tracing back their parts to their origin
it was possible to make a chart of the various departments
through which the individual parts pass until the" final
assembly of the article is completed for shipment. Exhibit

(2)

No. 2 gives the department chart referred to above. In
this chart the numbers refer to the departments as listed
below:

1. Raw Stock department

2a Punch Press and Forge departments

2b Machine department

2c Commercial Blower Fabricating department

3 Motor V/inding department

4 Motor Assembly department
5a Fan Y^eel department

5b Fan Frame department

6 Blower Assembly department

7 Sheet Metal department

8 Painting department

9 Testing department

10 Finishing department

11 Semi Finished stock department

12 Shipping department

For instance, if we take a small blower which con-
sists of a cast iron housing, sheet metal wheel and a
motor and refer to the chart we find that a casting is
drawn from the Raw Stock (#1) and goes to the Fan Frame
dept. (5b) where it is machined, ground and finished into
a blower housing. The housing then proceeds to the Blower
Assembly dept, (#6) where it meets the wheel which has been
built vfhile passing through the Raw Stock room (#l),Fan
V/heel dept. (#5a) and Painting dept. (#8). In the Blower
Assembly dept. the vfheel is placed in the housing, the
unit painted in the Paint shop (#8) and then is placed in
the Semi Finished stock room (#11). Upon an order the
blov;er is drawn from the semi finished rooms, returns to
the BlOT/er Assembly dept. (#6) where motor is attached and
then goes on test in (#9). Upon passing a satisfactory
test the set goes to the Shipping dept. (#12) and thus
leaves the plant.

FLOOR AREAS:

At the time that it was decided that a new plant
was required the floor area of the Company's old plant was
58,000 sq.ft. To provide for expansion for a period of
from three to five years it is necessary to provide for
approximately 100,000 sq.ft. of space in their new plant.
The following table therefore, was gotten up showing the
present area allotted to each department together with the
new area. In determining the new area required in each
department, due consideration was given to the fact that
some departments were more crowded than others and con-
sequently in order to even up operating conditions, a
cramped department was allotted a little more than the nom-
inal percentage of increase in the new layout. The fol-

(3)

lowing table gives the present and adjusted areas

Present

I Raw Stock dept. 6500
2a Punch Press and Forge depts. 2440
2b Machine dept. 5100
2c Coimnercial Blower Fabricating dept. 2050

3 Motor Winding dept. 3V10

4 Motor Assembly dept. 770
5a Pan Wheel dept. 1800
5b Fan Frame dept. 500

6 Blower Assembly dept, 1030

7 Sheet Metal dept. 4480

8 Painting dept. 500

9 Testing dept. 3580

10 Finishing dept. 640

II Semi Finished stock dept. 10070
12 Shipping dept. 2050

TYPE OF BUILDING:

Adjusted
7600
4000
9600
3600
6000
1600
2000
1600
2400
5600
2000
4200
1200
12600
6000

Upon making a study of Exhibit Wo. 2 we get the co-
relation of the various departments. The problem then re-
solves itself into arranging the departments and their re-
spective floor areas in such a way as to result in a pro-
gressive means of manufacturing. In order to determine the
exact shape of building which best suited the Company's
needs, a number of different types were considered. First
of all the question of a single story or multi-story
building presented itself. From the nature of the Company's
product it is easily seen that a large amount of ground
floor area was required in order to eliminate the consump-
tion of a great deal of horse power on account of raising
heavy castings to a second or third floor. Upon further
consideration, however, it was seen that while a great deal
of ground floor space vias necessary the Company could at
the same time very nicely locate certain departments on a
second floor without increasing the manufacturing costs
an appreciable amount. It was also seen that it would not
be practical to consider a building more than two stories
in height, and consequently all efforts so far as depart-
m.ent layout, were confined to the one and two story build-
ings.

The one storj-- layout Exhibit ITo.3 shows v;hat was
finally arrived upon as the ideal departm.ent layout for
this type building. The objections presented against a one
story building were, the large percentage of the available
ground area such a building required, the far greater cost
per square foot involved in the construction of such a type
building, due not only to the expense of a sawtooth roof,
but also on account of sprinkler mains, gas mains and the
like. Another item which operated against this type of

(4)

building was the additional heat required in the V?lnter
due to the very large roof area and also the large amount
of ventilation required to keep the building comfortable
during the hot months. Roof insulation, of course, would
help this condition considerably, but neverthless these
two points would always be important factors. Another ob-
jection is that when future expansion is considered it is
easily seen that it would be necessary to move every de-
partment in order to increase the floor area. This, of
course, would cause a great deal of disturbance in the man
ufacturing processes at the time of future expansion, in-
asmuch as all departments would be affected.

Having disposed of the single story building the
next arrangement that would naturally suggest itself was
the two story building. Layouts of a U, E and 0 shape
building were all considered and were discarded for one
reason or another. For instance in the U type, the wings
were too long for proper routing of materials and the
problem of future expansion was rendered very difficult.
While in the E shape building future expansion was simple,
the departments did not group themselves well. In the 0
shape building the present layout of departments was near-
ly ideal, but future expansion was practically impossible
without a complete rearrangement of all departm.ents.

Finally an H shape building was decided upon as
most nearly fulfilling all the requirements of the present
and future. Exhibit No. 4 shovJS the layout upon which all
calculations were based. Exhibit No.5 shows how easily
this layout lended itself to a 50^ expansion. In this
layout the departments handling the heavy castings and
heavy finished product were kept on the first floor and
the lighter manufacturing departments were placed on the
second floor. This layout also pointed out that a three
story building was not practical.

ELEVATION OP FLOOR:

Having decided on a two story building with the
first floor at ground level, it was necessary to establish
the grade of the first floor. The survey showed that the
natural ground level was approximately 15" below the es-
tablished grade of the curb. To reduce the amount of fill
required in the building to a minimum there, of course, was
only one elevation at which to establish the first floor
line. Other factors, however, were to be considered among
them the grade of the switch track, the approach grade to
the shipping platform and the proper height of the floor
above sidewalk to prevent water from melting snow to find
its way on to the floor.

(5)

A grade of 25 feet above city datura was established
for the first floor line. This brought the sidewalk about
15 inches below the first floor level and required a cut
of about 3 feet for the switch track. It also required a
4^ grade to the shipping platform. The various driveway
grades considered are shown in Exhibit No. 6, The 4% grade
was finally determined upon in order that horse drawn
trucks would be able to leave the platform with a full
load. 6% grades are in use in Chicago at bridge approaches
but they are not desirable as records of horse fallings
show.

SWITCH TRACK:

The layout of the building showed that the switch
track to serve the Company should be located along the
south end of the building. Exhibit No. 7 shows the layout
of the industry tracks serving both the Ilg and Seng
Companies. The main switch track was an extension of an
existing siding of the railway. Immediately upon leaving
the railway property the Seng track branches from the main
industry track. The tracks swing into the property on
about a 9f degree curve and a .6% down grade until elevation
of 19.5 city datum was reached for the top of rail. This
grade was then maintained to the end of the track. As
stated before, the elevation of this track entailed a cut
of 3 feet. Approximately 5500 cubic yards of material had
to be removed. The top 9" was loam and the remainder clay •
The loam was scraped off with scrapers and saved for grading
around the front of the building. Where a cut was not over
18" in depth the excavating was done with scrapers and for
greater depths a steam shovel working in conjunction with
wagons was used. The material was spoiled in a more or
less even manner over an area of about 100 feet each side
of the track. By handling this excavating as a separate
contract 35^ per sq.yd. was saved over the Railroad
Company's figure.

BUILDING DETAILS:

After a survey of the machinery which will be located
on the second floor and also a study of the floor loadings
in possible stock rooms, it was decided that the second
floor should be designed for a load of 250 lbs. per sq.ft.
The boiler room of the building being located in the basement
with the Punch Press department immediately above, required
a floor loading of 300 lbs. per sq.ft. for the boiler room
ceiling.

In order to eliminate as many posts as possible a
20 foot bay was established as standard. This meant that
the wings of the building should be either 60 or 80 feet.

(6)

Using high ceilings, 16 feet' on the first floor on account
of manufacturing operations and 12 feet on the second floor
sufficient light viould reach the interior of an 80 foot
wing, consequently the design was made for 80 foot wings.

A preliminary design both in reinforced concrete
and heavy timber construction vras made and prices on both
layouts secTired, By this time the structural steel market
was in such condition that the question of using
structural steel for the general construction of the build-
ing was given up. On account of the extremely high price
of lumber at the time that our estimates were completed
it showed that a concrete building could be built for about
5% more than a heavy timber constructed building. Con-
sequently final plans were made for a reinforced concrete
building.

The building was laid out as a flat slab with 7 ft.
drop panels over the coliimn caps. The column cap was 4 ft.
6 inches in diameter at the top and sloped down on a
45 degree angle to the column proper which in most cases
was 20 Inches in diameter for the second floor columns and
22 inches in diameter for the first floor columns. The
spandrel beams were left exposed and came about 14 inches
below the ceiling line. The spandrel beam acted as lintel
over the steel sash. Brick curtain walls were built up
3 feet 6 inches above the floor line and were capped off
with stone sills.

Concrete slotted inserts were provided at 4 foot
centers in both directions in both the roof and second floor
slabs in order to permit the hanging of line shafting and
motors at any point. Two rings of inserts were also pro-
vided on every interior column at 6 and 9 foot heights re-
spectively in order that platforms could be built on any
column to carry motors or other machinery required.

The inserts in all cases were large enough to take a
3/4" bolt.

In order to eliminate excessive chopping of the con-
crete slabs which always entails the cutting of reinforcing
bars when the hole is placed near the colums 4" sleeves were
placed on every fifth column in order to provide for any
future piping which it may be necessary to run from one
floor to another.

Special features involved in the design of Ithls
plant consisted in the driving of a 300 ft. well for drink-
ing T/ater, the installation of oil burners for heating, and
the use of automatic house telephones. By means of the
well it will be possible to get all the drinking water re-

(7)

quired at a year around temperature of 52 degrees. This not
only lends to health of the employes due to a perfectly
pure clear water, but also on account of a uniform temper-
ature, cool enough to be refreshing but not as cold as iced
water. By connecting up the three 75 Horse Power boilers
with which the plant is being equipped, with oil burners
the Company has eliminated the soot and dirt which always
accompany the combustion of coal and have also eliminated
the trouble of proper disposition of ashes. Furthermore,
it will be possible to get up steam in a far shorter time
than had chain grates been used and coal burnt.

Exhibit No. 8 shows a floor plan together with the
overall dimensions of the building as it is actually being
built. The photograph immediately proceeding the exhibits
gives a birdseye drawing of the building. This building
calls for a first floor area of 48,000 sq.ft. and a second
floor area of 42,000 sq.ft. The area of the two extra
floors in the tower is 560 sq.ft. each. In the top of the
tower is located a 60,000 gallon sprinkler tank. The tank
is carried on a concrete floor which frames into the con-
crete columns at a point 73 feet above the sidewalk. The
tank which is of steel construction is to be set on cement
grout so as to bring it to an even bearing.

CONSTRUCTION:

Construction on the building was started in October
1919 and was greatly hampered through failure of the Railway
Company to lay the industry track as per their agreement.
Another delay was caused by a strike of the sewer diggers.
The result of these two delays was that approximately 6000
cu.yds. of concrete was poured during freezing weather.
Approximately 550 yards of this were poured when the ther-
mometer did not rise above the 10 degree mark. Due to the
extreme care taken when placing the concrete none was
affected by the frost. All water, sand and stone was
heated before going into the mixer and a steam jet con-
tinually played into the mixer. Immediately before plac-
ing concrete any ice adhering to the reinforcing steel
form work was melted with a blow torch and the forms heated
with a steam jet. The space beneath the floor which was
being poured was protected with tarplins and heated with
salEimanders . Immediately upon completion of a pouring the
concrete was protected with hay.

On account of the first floor being on the ground
the contractor had intended pouring the first floor slab
first so as to keep uniform lengths on the struts used to
carry the second floor form work. However, on account of
the inability of the sewer contractor to complete his un-
derground work this method had to be abandoned, and the

(8)

.contractor placed mad sills on which to carry his struts.
At this point the contractor made a grave mistake inasmuch
as he insisted on placing 48,000 sq.ft. of form work before
doing any concreting. No amount of persuasion on the part
of the writer to have the contractor complete both floors
of a small section of the building and then proceed to an-
other section could divert him from his original idea of
finishing all of the form work involved on one floor. As
a consequence of his method of erecting this building, he
found that his lumber bill was extremely high and that in
order to start pouring the roof slab it was necessary for
him to buy additional Itimber inasmuch as he could not re-
move the form work from the second floor slab, until after
the roof had been poured. The result of the whole arrange-
ment was that the contractor has only used his foiTn lumber
twice whereas he should have used it four time in order to
reduce expenses and also that the building was delayed
fully a month and a half through this procedure. The princi-
ples of progressive manufacturing and the lesson learned on
this building would indicate that it is not advisable to
take a large area and expect to complete the form work on
the entire area before proceeding to the next floor. It
would be far better to take an area say 100 x 200 sq.ft.
and after completing the form work pour the concrete, while
pouring the concrete start erection of forms for the next
section. Then as soon as the concrete has set proceed with
the roof framing and while doing this pour the concrete on
the first floor of the second section.

Another point which was brought home much to the
financial regret of the contractor was the failure to take
advantage of the frozen ground arotmd the boiler room ex-
cavation. As stated before the soil at the building site
was clay and as soon as the excavation was completed for
the boiler room there was practically no end to the amount
of water which flowed into the cut. By constant pumping
the contractor had been able to place his footings and side-
walls so as to proceed with the rest of the structure. Cold
weather set in at this point freezing the sides of the ex-
cavation and preventing the inflow of any water. The con-
tractor could not be persuaded to take advantage of this
condition and waited until Spring to place his boiler room
floor. As a consequence he has found that up to date it
has been impossible to keep the boiler room dry enough to
warrant the placing of the concrete floor at this time.
Pumps have been operated practically continuously night and
day without making much of an impression upon the inflow of
water.

In the erection of a building of any size the value
of progress photographs should not be overlooked. By tak-
ing photographs at a regular interval it has been possible
not only to keep the directors of the Ilg Company posted

(9)

on the progress of the building, but it has also enabled
the writer to check up on some details which he could not
have done had it been necessary to make a trip to the build-
ing site. One small item which the writer recalls is that
he noticed that the form work on one particular column had
been built without providing a bracket for a future beam*
The mistake was easily remedied inasmuch as it was only
necessary to inform the carpenter foreman and have him
make the necessary corrections. By studying the photo-
graphs made at various intervals the engineer is assisted
in estimating the probable amount of work which will be
done in a certain time to come.

Another point which was borne out on this job is
the advisability of building the form work and concreting
towers strong enough to take care of severe winds. During
the time that the form work on this building was being
erected we had winds of 45 miles an hour on three occasions
and at no time was any of the form work destroyed. We
did, however, after every storm run levels in order to
check the form elevations, but found that in no case were
they off more than l/8 of an inch. This slight variation,
of course, was easily taken care of.

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