[DETAILS] DESIGN PROCESS AND FACTORY CONSTRUCTION PROCESS 2025

To have a project that meets technical and safety standards according to state regulations, businesses need to clearly understand each step of the factory construction process. Below is the most detailed information to help businesses build quickly and correctly.

1. Factory design process

After receiving information and requirements from customers, the team of engineers will create the most complete and detailed design.

1.1. Survey and propose construction plans

The first step to take is to survey and propose construction plans. The construction unit will come to survey the location, site, and propose design plans. After that, the team of architects and technicians will propose plans for technology and technical infrastructure so that construction can be carried out reasonably.

The construction unit will propose the most reasonable architectural plans for projects with high requirements for design and architecture such as office areas, security areas, etc. After that, the design and construction team will also review and optimize plans for environmental protection and fire prevention according to the regulations of the State, industrial park, or industrial clusters where the factory construction project is being carried out.

Finally, propose plans for the foundation structure to suit the geology in the factory construction area and set out the main standards and regulations applied when designing and constructing the factory.

1.2. Design preliminary drawings for the factory

After surveying and proposing construction plans, architects and engineers will concretize ideas with specific drawings of the entire master plan, floor plan of each item, and 3D perspective of the project. These drawings will help the investor visualize the project more easily and accurately after completion.

Depending on the production field, technology line, and scale of each factory, the floor plan design will also be different. The drawings need to clearly show the items to be built in the project, density, construction boundaries, internal road system, green space density, etc. In addition, drawings for fire prevention and escape systems are also extremely important.

1.3. Create detailed drawings, estimate construction costs

The preliminary drawings will be the basis for the investor and the construction unit to discuss and reach a final agreement on the construction plan. After that, the construction drawings will be completed by the team of engineers and architects.

At this stage, the drawings will specifically represent every construction item, from architectural details to foundation structural plans, pre-engineered steel frame drawings, connection nodes, material specifications, M&E drawings, and fire protection and emergency exit systems for each of the following items:

• Production workshop area
• Warehouse
• Office area
• Dining hall, canteen, and rest area for staff and workers
• Underground tank
• Electrical substation
• Parking lot, security guard house
• Gates, fencing systems, etc.

In parallel with completing the detailed construction drawings, the investor also needs to obtain construction permits and fire safety permits. As for the general contractor, the construction team will prepare a budget estimate, detailing each task and the specific volume of work to be performed for all items. The documentation set, including construction drawings and the cost estimate, will serve as the basis for the acceptance of construction work and the volume of completed work later on.

2. Factory building construction process

After completing the factory design, the construction unit will begin the steps of factory building construction.

2.1. Receiving and storing factory construction materials

Before proceeding with the steps in the factory construction process, the construction unit needs to receive materials according to the quantity and quality requirements of the construction estimate. For example: the quantity of steel, corrugated iron, bricks, cement, etc. Since the amount of materials used for factory construction is very large, it is possible that the handed-over quantity may be inaccurate, or material types may not be uniform, especially for small items like bolts and screws.

In addition to careful inspection upon receipt, the construction unit also needs to ensure that materials are transported to the warehouse and stored carefully. Materials must not be worn, damaged, or rusted before construction. Deteriorating material quality will affect the quality of the entire project.

2.2. Constructing the factory floor

Constructing the factory floor is an indispensable and important step, as the foundation will affect the durability of the entire factory. Therefore, it is necessary to follow the factory construction process through the following steps:

• Step 1: Ground leveling. Depending on the existing ground condition at the construction site, the contractor will implement the leveling phase accordingly.
• Step 2: Positioning the center axis. This is an extremely important task because the center axis position is where the column foundations are constructed based on the drawings.
• Step 3: Excavating fence foundations. Since the factory has a very large area, the surrounding fence system is also very high and long. Therefore, it requires a solid foundation to stand firmly.
• Step 4: Constructing foundations and tie beams. Foundation work and pile driving will be based on the center axis position determined in step 2. Factory foundations are usually made of reinforced concrete with a single foundation or pile foundation design.
• Step 5: Compacting the soil. After completing the foundation, the ground will be leveled and compacted to achieve the density required in the design.
• Step 6: Compacting the stone base for the factory. The thickness and density of the stone layer must also comply with the requirements in the design.
• Step 7: Constructing the factory floor. After completing the 6 steps above, the construction unit will proceed with steel reinforcement and pouring concrete for the factory floor.

2.3. Constructing the factory steel frame

The steel frame is an extremely important part, considered the backbone of the factory. This is one of the most important steps in the factory construction process. Therefore, the contractor must ensure the stability, accuracy, and load-bearing capacity of the steel frame. To increase accuracy during steel frame installation, construction units will need to use modern measuring equipment such as theodolites, laser levels, etc.

The factory steel frame consists of 2 main parts:

• Installing iron frames and steel columns: Iron frames and steel columns will be pre-fabricated at the factory and then transported to the construction site. Depending on the site, the construction unit will proceed to install the frames and columns from the middle towards the two gables or from one gable inwards.
• Installing purlins and bracing: After the iron frame and steel columns are installed, the construction team will proceed to install the bracing system to ensure stability outside the frame plane and the purlin system to increase the stability of the steel frame and support the roof panels. This entire system needs to ensure accuracy and must not be shifted so that subsequent stages can be implemented correctly.

2.4. Constructing the factory roof

After the steel frame is assembled, the construction unit will proceed to construct the factory roof. Like the steel frame system, installing the first corrugated iron sheet requires extremely high accuracy because it is the reference point for subsequent sheets. After completing the roof, the sheets must meet the requirements: the overlapping joints of the sheets must always lie on a straight line and be perpendicular to the purlins.

In addition to precise installation, the contractor also needs to calculate heat insulation solutions for the factory roof. To prevent heat, the roof will be covered with an additional layer of thermal insulation, helping to limit hot and cold air from the outside environment from entering the production area. The insulation layer also needs to ensure straight joints, without folds or shrinkage, and a flat, smooth underside without wrinkles.

2.5. Constructing surrounding walls and interior partitions

The exterior walls and interior partitions of the factory can be built with materials such as corrugated iron, bricks, etc. This stage needs to ensure alignment with the design and compatibility with the steel frame core in the factory construction process.

Although it does not require the same high level of precision as installing the roof, the construction of exterior walls and interior partitions must account for safety measures: fire resistance, wind resistance, dust protection, etc., in the best way possible. Partitions can be made from fire-resistant and heat-insulating materials such as Smartboard panels, Gywall plasterboard, etc.

After erecting the partitions and walls, the construction unit will proceed to install doors, windows, ventilation openings, etc. Upon completion, the technical team needs to re-check the tightened bolts, connection points between the sheets, and gaps at the window frames to avoid leaks or water ingress later when it rains.

2.6. Constructing factory infrastructure

Constructing the infrastructure system around the factory includes: drainage systems, access roads, yards, warehouses, storage areas, etc. These infrastructure items are intended to ensure that the transportation of goods and production and work activities at the factory take place most conveniently.

2.7. Construction of factory technical systems

In the next step of the factory construction process, the construction unit will install technical systems for the factory such as: electrical systems, water supply, drainage systems, waste treatment systems, fire protection systems, communication systems, etc. These technical systems will ensure the factory operates as smoothly and efficiently as possible.

2.8. Factory completion and equipment installation

Next is the stage of completing the factory and installing equipment, machinery, and final items. The technical team will also re-check all joints, bolts, and screws in the factory to ensure there are no issues. Once everything is installed accurately, the construction unit will place the equipment and production lines in the exact positions as per the design drawings.

2.9. Cleaning and commissioning

After completing the above stages, the construction team will clean the entire factory area one last time before putting it into operation. After ensuring everything is installed correctly and there are no technical errors, the construction unit will hand over the project to the investor.

In addition to cleaning and inspection upon completion, the contractor must also perform regular warranty, maintenance, and upkeep tasks for the project. This will ensure the project operates most efficiently and durably over time.

3. Hai Long Construction – A leading general contractor for factory construction today

Hai Long Construction is a leading factory design and construction consulting unit today. With 25 years of experience, Hai Long Construction has executed many projects, following standard factory construction processes and ensuring all requirements are met when carrying out construction projects like the above.

Investors and business owners in need of factory construction should contact Hai Long Construction immediately for detailed consultation and to receive a specific quotation upon request.

• HAI LONG CONSTRUCTION JSC – MEMBER OF TAIYO GROUP
• Address: Taiyo Building, 97 Bach Dang, Ha Ly Ward, Hong Bang District, Hai Phong City, Vietnam.
• Hotline: 084 6625 888
• Email: info@hailongjsc.vn