# Industrial and Warehouse Design

## Building Types

### Classification
| Type | Description | Clear Height |
|------|-------------|--------------|
| Bulk warehouse | Storage, distribution | 28'-40' |
| Distribution center | High-volume throughput | 32'-40' |
| Fulfillment center | E-commerce, order picking | 36'-45' |
| Cold storage | Refrigerated/frozen | 30'-40' |
| Manufacturing | Production | 20'-35' |
| Flex/R&D | Office + light industrial | 16'-24' |
| Data center | Computing | 12'-16' |

### Size Classifications
| Class | Size Range | Use |
|-------|------------|-----|
| Small | 10,000-50,000 SF | Local distribution |
| Medium | 50,000-250,000 SF | Regional distribution |
| Large | 250,000-500,000 SF | National distribution |
| Mega | 500,000-1,000,000+ SF | E-commerce, 3PL |

---

## Site Design

### Yard Dimensions
| Element | Dimension |
|---------|-----------|
| Truck court (standard) | 120'-130' |
| Truck court (deep) | 135'-185' |
| Trailer parking | 12' × 53' per space |
| Auto parking | 9' × 18' per space |
| Drive lane (1-way) | 24' |
| Drive lane (2-way) | 35'-40' |

### Dock Configuration
| Type | Spacing |
|------|---------|
| 45° angled | 12'-0" per door |
| 90° perpendicular | 10'-0" per door |
| Drive-through | Per use |

### Parking Ratios
| Use | Ratio |
|-----|-------|
| Warehouse | 1 per 2,000-3,000 SF |
| Distribution | 1 per 1,000-2,000 SF |
| Manufacturing | 1 per 500-1,000 SF |
| Office (within) | 1 per 250-350 SF |

### Truck Turning
| Vehicle | Turning Radius |
|---------|----------------|
| Box truck (40') | 40' outside |
| Semi (48') | 45' outside |
| Semi (53') | 50' outside |
| Fire truck | 50' outside |

---

## Structural Systems

### Clear Heights
| Use | Clear Height |
|-----|--------------|
| Light manufacturing | 18'-24' |
| General warehouse | 24'-32' |
| Distribution | 32'-36' |
| Mega warehouse | 36'-40' |
| High-bay | 40'-50' |

### Column Spacing
| Type | Bay Size |
|------|----------|
| Light industrial | 40' × 40' |
| Standard warehouse | 50' × 40' |
| Distribution | 52' × 40' or 56' × 50' |
| Mega warehouse | 60' × 50' or 70' × 56' |

### Floor Loading
| Use | Live Load |
|-----|-----------|
| Office area | 50-80 PSF |
| Light storage | 125-150 PSF |
| General warehouse | 250 PSF |
| Heavy industrial | 300-500 PSF |
| Forklift rated | Per axle load |

### Floor Flatness
| Classification | FF/FL |
|----------------|-------|
| Conventional | 25/20 |
| Moderately flat | 35/25 |
| Flat | 45/35 |
| Very flat (VNA) | 50/40 |
| Super flat | 100/50 |

---

## Loading Docks

### Dock Door Sizes
| Type | Width | Height |
|------|-------|--------|
| Standard | 8'-0" | 9'-0" |
| Wide | 9'-0" | 10'-0" |
| Drive-in | 12'-0" | 14'-0" |
| Overhead | 10'-0" | 12'-0" |

### Dock Heights
| Type | Height |
|------|--------|
| Standard trailer | 48"-52" |
| Container | 48"-52" |
| Van | 24"-30" |
| Grade level | 0" |

### Dock Equipment
| Equipment | Capacity |
|-----------|----------|
| Mechanical leveler | 25,000-35,000 lb |
| Hydraulic leveler | 35,000-80,000 lb |
| Edge-of-dock | 30,000 lb |
| Dock lift | 4,000-10,000 lb |

### Dock Ratio
| Use | Doors per SF |
|-----|--------------|
| Bulk storage | 1 per 10,000-15,000 SF |
| Distribution | 1 per 5,000-8,000 SF |
| Cross-dock | 1 per 2,500-5,000 SF |
| E-commerce | 1 per 3,000-5,000 SF |

---

## Office Areas

### Typical Ratios
| Building Type | Office % |
|---------------|----------|
| Warehouse | 2-5% |
| Distribution | 3-8% |
| Manufacturing | 5-15% |
| R&D/flex | 20-50% |

### Office Space
| Space | Size |
|-------|------|
| Reception | 150-300 SF |
| Private office | 120-180 SF |
| Open office | 100-150 SF/person |
| Conference | 20-25 SF/person |
| Break room | 15-20 SF/person |
| Restroom | Per code |

### Separation
| Feature | Requirement |
|---------|-------------|
| Fire separation | 1-2 hour (check code) |
| Sound | STC 45-50 |
| HVAC | Separate system |
| Finishes | Commercial grade |

---

## HVAC Systems

### Warehouse Heating
| System | Application |
|--------|-------------|
| Unit heaters | General areas |
| Radiant | High-bay, spot heating |
| Make-up air | Loading areas |
| RTU | Small warehouses |

### Temperature Zones
| Zone | Temperature |
|------|-------------|
| Ambient warehouse | 50-90°F (varies) |
| Cooler | 35-40°F |
| Freezer | -10 to 0°F |
| Deep freeze | -20°F or colder |
| Office | 68-76°F |

### Ventilation
| Area | CFM/SF |
|------|--------|
| Warehouse | 0.05-0.15 |
| Loading dock | 0.25-0.50 |
| Manufacturing | Per process |
| Office | 0.15-0.20 |

---

## Fire Protection

### Sprinkler Classifications
| Hazard | Use |
|--------|-----|
| Ordinary Group 1 | General storage < 12' |
| Ordinary Group 2 | Warehouse < 20' |
| Extra Hazard | Flammable/combustible |
| High-piled storage | Storage > 12' high |

### High-Piled Storage
| Commodity | Requirements |
|-----------|--------------|
| Class I-IV | ESFR or in-rack |
| Plastic | Enhanced protection |
| Aerosols | Special requirements |
| Flammable | FM/NFPA Chapter |

### Sprinkler Types
| Type | Application |
|------|-------------|
| ESFR | Open warehouse, no rack |
| In-rack | High-bay racking |
| CMDA | High challenge |

### Fire Separation
| Occupancy | Separation |
|-----------|------------|
| Office to warehouse | 1 hour |
| Manufacturing | 2 hour |
| Hazardous | Per code |

---

## Lighting

### Light Levels
| Area | Foot-candles |
|------|--------------|
| Warehouse (general) | 10-20 |
| Distribution | 20-30 |
| Manufacturing | 30-75 |
| Inspection | 75-100 |
| Office | 30-50 |
| Loading dock | 20-30 |
| Parking | 1-5 |

### Fixture Types
| Type | Application |
|------|-------------|
| High bay LED | > 20' mounting |
| Low bay LED | 12'-20' mounting |
| Linear LED | Lower ceilings |
| Emergency | Egress, safety |

### Controls
| Control | Energy Savings |
|---------|----------------|
| Occupancy sensors | 20-40% |
| Daylight harvesting | 15-30% |
| Scheduling | 10-20% |
| High/low switching | 10-20% |

---

## Mezzanines

### Structural
| Capacity | Use |
|----------|-----|
| 125 PSF | Light storage |
| 250 PSF | General storage |
| 500 PSF | Heavy industrial |

### Dimensions
| Element | Requirement |
|---------|-------------|
| Clear height (above) | 7'-0" minimum |
| Clear height (below) | Per use |
| Stair width | 44" minimum |
| Guardrail height | 42" |
| Kick plate | 4" |

### Access
| Type | Use |
|------|-----|
| Stairs | Personnel |
| Lift | Materials |
| VRC | Vehicles |

---

## Cold Storage

### Insulation Values
| Zone | R-Value |
|------|---------|
| Cooler walls | R-25 to R-32 |
| Cooler ceiling | R-32 to R-40 |
| Freezer walls | R-40 to R-50 |
| Freezer ceiling | R-50 to R-60 |
| Freezer floor | R-25 to R-35 + heat |

### Floor Heating
| Requirement | Description |
|-------------|-------------|
| Glycol system | Prevent frost heave |
| Under-slab heating | Electric or hydronic |
| Vapor barrier | Above insulation |

### Door Types
| Type | Use |
|------|-----|
| High-speed | Frequent access |
| Strip curtain | Forklift traffic |
| Insulated sliding | Dock access |
| Air curtain | Temperature barrier |

---

## Material Handling

### Forklift Types
| Type | Aisle Width |
|------|-------------|
| Counterbalance | 12'-15' |
| Reach truck | 8'-10' |
| Turret/VNA | 5'-6' |
| Order picker | 8'-10' |

### Racking
| Type | Application |
|------|-------------|
| Selective | General access |
| Double-deep | High density |
| Drive-in | LIFO storage |
| Push-back | LIFO, fast moving |
| Pallet flow | FIFO, high volume |
| Cantilever | Long goods |

### Racking Dimensions
| Element | Typical |
|---------|---------|
| Pallet width | 42"-48" |
| Beam depth | 42"-48" |
| Bay width | 96"-108" |
| Frame depth | 36"-48" |

---

## Electrical

### Power Density
| Use | W/SF |
|-----|------|
| Warehouse | 2-5 |
| Distribution | 3-8 |
| Manufacturing | 10-30 |
| Cold storage | 15-25 |

### Motor Loads
| Equipment | Typical HP |
|-----------|-----------|
| Dock leveler | 1-3 HP |
| Overhead door | 1/2-1 HP |
| Conveyor | 1-10 HP |
| Compressor (small) | 5-25 HP |
| Compressor (large) | 50-500 HP |

### EV Charging
| Type | Power |
|------|-------|
| Level 2 (fleet) | 7-19 kW |
| DC fast (trucks) | 50-350 kW |
