Textile project

Designing of a cotton textile project objectives

1. Industrial building project -Textile Factory
Industry is the production of goods or related services within the economy. It can be defined as
the collective large-scale manufacturing of goods in well-organized plants with a high degree of
automation and specialization. Although this is a common example of industry, it can also
include other commercial activities that provide goods and services such as agriculture,
transportation, hospitality, and many others.
Industrial progress from raw material to a product:
Figure-01
Industry can be divided into three main categories. Recently Tertiary industry has been sub-
divided into a fourth type.
Primary Industries:
Extract raw materials (which are natural products) from the land or sea e.g. oil, iron ore, timber,
fish. Mining, quarrying, fishing, forestry, and farming are all example of primary industries.
Secondary Industries (sometimes referred to as manufacturing industry):
Involve the manufacture of raw materials, into another product by manual labor or machines.
Secondary industries often use assembly lines e.g. a car factory.
Tertiary Industries (sometime referred to as Services industry):
Neither produce a raw material nor make a product, instead they provide services to other
people and industries. Tertiary industries can include doctors, dentists, refuse collection and
banks.
Quaternary Industries:
Involve the use of high tech industries.
People who work for these companies are often highly qualified within their field of work.
Research and development companies are the most common types of businesses in this sector.
All of the companies are linked in one way or another. For example:
The raw material cotton is extracted by primary industries; it may then be turned into an item of
clothing in the secondary industry. Tertiary industries may advertise the goods in magazines and

2. newspapers. The quaternary industry may involve the product being advertised or researched to
check that the item of clothing meets the standards that it claims too.
A factory is an industrial site, usually consisting of buildings and machinery, or more commonly
a complex having several buildings, where workers manufacture goods or
operate machines processing one product into another.
Factories arose with the introduction of machinery during the Industrial Revolution when the
capital and space requirements became too great for cottage industry or workshops. Early
factories that contained small amounts of machinery, such as one or two spinning mules, and
fewer than a dozen workers have been called "glorified workshops".
Most modern factories have large warehouses or warehouse-like facilities that contain
heavy equipment used for assembly line production. Large factories tend to be located with
access to multiple modes of transportation, with some having railed, highway and water loading
and unloading facilities.
Cotton textile manufacturing is a major industry. It is based on the conversion
of cotton into yarn, yarn into fabric. These are then dyed or printed, fabricated into clothes.
There are many variable processes available at the spinning and fabric-forming stages coupled
with the complexities of the finishing and coloration processes to the production of a wide
range of products. There remains a large industry that uses hand techniques to achieve the
same results.
There are five stages of manufacturing cotton into fabric:
1. Cultivating and Harvesting
2. Preparatory Processes
3. Spinning
4. Weaving or Knitting
5. Finishing

 Cultivating and harvesting
Cotton is grown anywhere with long, hot dry summers with plenty of sunshine and low
humidity. The cotton bolls are harvested by stripper harvesters and spindle pickers that remove
the entire boll from the plant.

 Preparatory processes - preparation of yarn
 Ginning, bale-making and transportation.
 Opening and cleaning.

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 spinning is done using Break or Open-end spinning, this is a technique where the staples
are blown by air into a rotating drum, where they attach themselves to the tail of formed yarn
that is continually being drawn out of the chamber.
Checking is the process where each of the bobbins is rewound to give a tighter bobbin.
Folding and twisting Plying is done by pulling yarn from two or more bobbins and twisting it
together, in the opposite direction that in which it was spun. Depending on the weight desired,
the cotton may or may not be plied, and the number of strands twisted together varies.
Gassing is the process of passing yarn, as distinct from fabric very rapidly through a series of
Bunsen gas flames in a gassing frame, in order to burn off the projecting fibers and make the
thread round and smooth and also brighter.
 Weaving-fabric manufacture
The weaving process uses a loom. The length way threads are known as the warp, and the
cross way threads are known as the weft. The warp which must be strong needs to be
presented to loom on a warp beam. The weft passes across the loom in a shuttle, that carries
the yarn on a pin. These pins are automatically changed by the loom. Thus, the yarn needs to
be wrapped onto a beam and onto pins before weaving can commence.
 Finishing- processing of textiles
The woven cotton fabric in its loom-state not only contains impurities, including warp size, but
requires further treatment in order to develop its full textile potential. Furthermore, it may
receive considerable added value by applying one or more finishing processes.
Scouring, is a chemical washing process carried out on cotton fabric to remove natural wax and
non-fibrous
Bleaching, improves whiteness by removing natural coloration and remaining trace impurities
from the cotton; the degree of bleaching necessary is determined by the required whiteness and
absorbency.
Dyeing, cotton is an absorbent fiber which responds readily to coloration processes. Printing, on
the other hand, is the application of color in the form of a paste or ink to the surface of a fabric,
in a predetermined pattern. It may be considered as localized dyeing. Printing designs onto
already dyed fabric is also possible.

4. Space requirements:
Space requirements depend on the production rate of manufacturing, thus we can calculate number of
machines required, beside areas of spaces and employees requirements.



A textile factory must provide these spaces:
Offices
Parking lots
Circulation area
Storage
Laboratory
Marketing sector
Research centre
Production areas
Warehouse
Service area for employees and staff
Green areas
Buffer zone
Expansion areas for future

5. Textile factory design outline1:

Second floor plan




First floor plan

6. List of machinery and equipment Human resources requirements





Design requirements for industrial buildings:

Objectives:
 To promote the creation of industrial precinct character and a sense of address through gateway
or entrance statements, including appropriate landscape treatments.

 To effectively co-ordinate the redevelopment of industrial areas to minimize the conflicts
between industrial and more sensitive land uses such as adjoining and nearby residential uses.

 To reduce visual impact of on-site storage and general refuse/waste storage areas from street
view through improved siting, design, landscaping, fencing and other screening treatments.

 To improve connectivity, access and mobility within and between industrial precincts and
surrounding areas whilst not adversely impacting on surrounding residential or public uses.

 To promote safer areas through improved building design and orientation, and by designing new
development to ensure passive surveillance of open spaces and within the industrial areas.

7.  To ensure the protection of sensitive environmental areas and public open space from
encroachment from inappropriate industrial activities.

Building form and interface:
 The external appearance of buildings must be attractively designed. New industrial buildings
must make a positive design contribution to the streetscape, particularly where these buildings
are visible from main or secondary roads. Blank walls with no visual relief must be avoided if
these are visible from public areas.

 Development adjacent to open space areas, waterways or sensitive uses such as residential land
use should be of a complimentary/transitional scale and appearance to the adjoining environs.

The design of new buildings in industrial areas should:
 Be consistent in scale with nearby buildings.
 Encourage high quality contemporary building forms and presentation to street frontages and
other key interfaces.
 Provide clear entrances, interesting facades and detailing.
 Emphasize the importance of “landmark” and gateway sites.
 Incorporate facades that address both streets on corner buildings.
 Locate office components to the front of the building.
 Have no advertising signs projecting above the building line.
 Screen plant and equipment from street view.
 Integrate or conceal exterior elements of services, plumbing, and heating and ventilation
systems into the building. Roof top services should be located out of sight from the street.

Streetscape Amenity and Landscaping:
 Landscaping should be designed as an integral part of any development and assist in creating a
unified appearance within an industrial area and in improving the environmental quality of the
area.
 The provision of a landscape buffer incorporating landscaping and planting should be provided
along street frontages to soften the visual impact of the built form and improve the amenity of
the area. Landscape areas which are narrow and provide maintenance challenges should be
avoided.
 The landscaping theme adopted for a development should be simple and include use of semi-
mature trees and where possible, the retention of existing mature trees.

Frontage Car parking and Vehicle Loading
 Car parks and car parking within front boundary setbacks should be avoided with the exception
of a limited proportion of visitor parking.
 Large car parks shall include landscaped traffic islands to allow additional canopy tree and under
storey planting. Plant species shall be selected to allow clear sightlines for freight movements,
pedestrians, cyclists and motorists.
 The visual impact of parked vehicles should be minimized by the use of appropriate contouring
and landscaping treatments while maintaining overall safety and sightlines.
 All cars should be able to enter and leave frontage car parking in a forward direction.
 All truck loading and servicing shall occur within the site. No loading or servicing is permitted in
the frontage car parking or on public roads.

8.  Loading and services bays should be separated from private vehicle, pedestrian and bicycle
routes.
 Frontage car parking and other car parks are not to be used for temporary storage of goods or
for servicing or loading.
 Truck parking shall not be located within designated frontage car parking areas or landscape
setbacks. If truck parking is required, designated truck parking spaces are to be provided. On-
street parking of trucks will not be permitted.


General Refuse/Waste Storage
 General refuse/waste storage areas should be confined to the rear/side of the lot where the
side setback is not a street frontage or abutting a sensitive or residential land use. If this is not
possible, the general refuse/waste storage area should be screened by landscaping and/or
fencing to avoid visual impact to the street.
 Any areas intended for the exterior storage of goods or machinery should be screened from any
street or neighboring property.
 Where possible, storage areas should be an integral part of the design of buildings. Outside
storage areas should be designed to prevent the proliferation of litter and other material within
and beyond the site.
 The informal storage of goods or material around buildings should be avoided and landscape
and/or screening should be provided to ensure the visual amenity of the streetscape and
adjoining properties.
 Street setbacks should not be used to store goods, materials or waste.

Access and Circulation:
 New development should provide improved circulation to promote walking and cycling.
 New development should provide secure bicycle storage lockers and showers for staff and
employees.
 New development should avoid creating access conflicts with residents and other land users
accessing their homes or facilities and vehicles accessing the industrial precinct.

9.  Loading and service areas shall be integrated with the built form and landscape treatments for
each lot.
Loading bays should:
 allow delivery vehicles to enter and leave the site in a forward direction (generally on larger
sites), unless it can be demonstrated that no substantial traffic hazard is likely to occur; and
 be located to the side (if not a street frontage) or rear of the site (generally for larger sites); or
be located internally within buildings or screened from street view.

Security/Safety:
 Buildings should be orientated and glazing provided where possible to provide passive
surveillance to the street and other adjoining public areas.
 Pedestrian and cyclist circulation should be separated from vehicular movements wherever
possible/appropriate.
 Clear sightlines should be maintained at all vehicular crossovers.
 External lighting should be provided for security, safety and amenity for all exterior areas
including car parks, pedestrian paths and storage areas without causing light spill into adjoining
properties or neighboring areas.


Building Height

Building heights should be not be out of scale with existing or planned development.
Standards and Guidelines:
A. The height of new development should be compatible with and transition from the height of
adjacent development.
B. The maximum building height is 40.0-feet to the top of the building parapet and 50.0-feet for
architectural projections.
C. Building height may exceed the 40.0-foot height limit up to 50.0-feet, when authorized through the
PUD process for buildings/users that require specialized equipment.

The store house shall be constructed according to the following specification:
1. The walls shall be constructed of brick, stone, concrete or other non-inflammable material, the
floor of concrete or other impervious material and the roof of re-enforced concrete or other
non-inflammable material.
2. The store shall be provided with a well-fitted metal sliding door, or a metal door opening
outwards of not less than 3.5mm thick, carried on an iron door frame. Such door shall have an
all-round over-lap of not less than 50mm and shall be fitted with a substantial lock.
3. The window frames shall be constructed of metal and fitted with fire resisting glass panes or
metal sheets.
4. Every store shall be constructed in such manner or surrounded by walls not less than 150mm in
height forming a well of such character that the inflammable liquid contained therein cannot
escape there from.
5. Low and high level means of ventilation shall be provided in the store.
6. The openings shall be protected by non-corrodible wire gauze of not less than 0.9mm.
7. A store shall not be situated in such a position that will impede the escape of any person from
the premises, or endanger any room, building, or premises in the case of fire.
8. Any store with a floor area in excess of 10m2 shall be provided with at least two doors.

10. Fireproof construction
Cotton mills are huge fire risks; cotton fibers in the air could form an explosive mixture in their gas-lit
interiors. The first mills using fireproof construction were built in Shropshire and Derbyshire in the 1790s
and Philips & Lee's mill built in Salford in 1801.
2. Fireproofing took the form of cast iron columns and beams from which sprang jack arches that were
filled with ash or sand and covered with stone flags or floorboards.
Cotton is sensitive to temperature and humidity. Heating systems used wrought iron pipes suspended
at a height of 7 feet (2.1 m) to carry steam under pressure. In summer the system was barely used but in
winter the boilers would be fired up two hours before the shift started to warm up the mill. As heat was
applied the humidity dropped and system of humidifiers, either atomizer which played an air jet against
a jet of water or ones that injected a stream/air mixture into the room.
Early fire fighting systems used sprinklers supplied by water captured on flat roofs in shallow tanks.
Later mills had a water tank at the top of the stair tower. Water pressure of the sprinklers need to be
above 7 psi, and the header tank at least 15 feet (4.6 m) above the highest sprinkler.

Treatment of Cotton and Woolen Textile Mill Waste :
The pollution load of the waste is dealt with in the operations like segregation, equalization,
neutralization, chemical precipitation , chemical oxidation and biological oxidation. Several chemicals
are used to 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, when free from toxic substances may be treated as efficiently as domestic
sewage, as most of the textile mill wastes contain sufficient nutrients like nitrogen and phosphorus.
Trickling filters, Activated Sludge Process , Waste Stabilization ponds, all these types of biological
treatment have been tried for the treatment of textile mill wastes and all of them are found to be
very effective. Excellent results were also obtained with Extended Aeration in treating a strong waste,
even without any equalization and pre-treatment; this method eliminates the necessity of sludge
digestion as well.

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