midreview - new life for urban manufacturing districts

UMDIUMDI

URBAN MANUFACTURING DISTRICTSNEW LIFE FOR

Northeastern University School of Architecture | Fall 2013

54255 25805 12274 5838 2776 1320 lux

CLERESTORY DIFFUSED SAW TOOTH

Illuminance study conducted at 10:00 AM Illuminance study conducted at 10:00 AM Illuminance study conducted at 10:00 AM

This publication has been prepared as a part of the 2013 Master’s Research Studio in the Northeastern University School of Architecture. All research and content in this publication was produced by the “New Life for Urban Manufacturing Districs” studio research team.

Published byNortheastern University School of Architecture360 Huntington AvenueBoston Massachusetts, 02115

Copyright © 2013 byNortheastern University School of ArchitectureAll rights reserved.

UMDIUMDI

URBAN MANUFACTURING DISTRICTSNEW LIFE FOR

Northeastern University School of Architecture | Fall 2013

Contributors: Tim Love | Elizabeth Decorso | Chris Marciano |

Ryan Matthew | Jonathan Miller | Rachel Mutschler | Nicole

Pandolfo | Matthew Piccirillo | Eric Pereira | Jenna Principi

INTRODUCTIONA Case For Urban ManufacturingA Case For ArchitectsRelevance

FIELD RESEARCH

GEOGRAPHY/LOGISTICSUrban Industrial ParksSuburban Industrial Parks

STANDARDSPallets

Daylighting

TYPOLOGICAL CONSIDERATIONSOrganizational Strategies

Expressing The Contents

Prototypes

1357

9

434559

6971

81

83 85

91

99

INTRODUCTION

A CASE FOR URBAN MANUFACTURING

A CASE FOR THE ARCHITECT

RELEVANCE

The goal of our research initiative was to understand how

architects and urban designers can better impact the

conception, planning, and design of manufacturing facilities

as part of a healthy mixed-use urban neighborhood. Central

to our analysis and speculative thinking are two foundational

questions:

What kinds of manufacturing (still) needs to be located in

cities and why?

Why do architects need to be at the center of the discussion

about the proper program-mix, layout, spatial qualities, and

expressive strategy of these kinds of facilities?

These questions were posed not only to guide our research

priorities, but also because our shared research was

formulated and formatted to launch speculative design

proposals by each of the eleven students on the research

team.

Manufacturing needs to be close to designers and/or engineers because of on-going adjustments and revisions to the design of the product. Examples include small batch prototyping for new medical instruments, “bespoke” fashion and leather goods, and custom architectural components.

Manufacturing needs to be close to parts suppliers for bespoke and small batch production. Examples include the relationship between accessory suppliers (buttons, zippers, fabric, and thread) and manufacturers in the Garment District in New York.

Manufacturing needs to be close to a skilled work force with technical proficiency in all areas of relevant production. Examples include sewers and other specialists in the Garment District in New York and precision metal fabricators that work for defense suppliers in Connecticut.

Manufacturing needs to be close to a targeted consumer group because products are sold on-site in a showroom, testing room, or store. Examples include artisanal food production that appeals to nearby city residents and/or tourists drawn to a district by other destinations.

Manufacturers want to provide directly to retailers (and eliminate third-party distribution from the supply chain). Examples include micro-breweries distributing directly to stores, bars, and restaurants via their own fleet of trucks.

Each of the rationales for urban manufacturing has specific design implications, whether at the interface of people visiting the facility (designers, consumers, and/or potential new employees), the need to receive just-in-time stock for manufacturing, and/or the need to efficiently park a fleet of small trucks – all in a dense urban neighborhood.

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Facing Page:

Men pulling racks of clothing on busy sidewalk in Garment

District, NYC (World Telegram & Sun photo by Al Ravenna)

REASONS WHY MANUFACTURING TAKES PLACE IN NORTH AMERICAN CITIES

A CASE FOR URBAN MANUFACTURINGINTRODUCTION

The company both manufactures and sells products at the same location to highlight the manufacturing process itself as part of the marketing strategy and/or to provide shelf space during the early phases of a product line roll out (before third-party distributors have agreed to carry the product). As a result, the quality and character of the customer experience during tours of the facility and in the showroom are essential to the success of the business.

The company wants to broadcast the business brand by the shape and color of the building, applied graphics, transparency to the functions inside, and/or the character of the architecture itself.

Because of the physical characteristics of the neighborhood context, the exterior planning and architecture of the facility needs to be compatible with adjacent buildings in terms of scale, materiality, and relationship to the sidewalk and larger urban realm.

Because of land values and/or in-place development guidelines, manufacturing functions need or want to be part of a mixed-use building that includes other uses on the ground and/or upper floors.

Because of land values and/or in-place development guidelines, manufacturing functions need to be on multiple floors – thus complicating freight access, ventilation, and structural solutions.

Each of these overlays to the basic function of manufacturing requires an architectural response that balances the need for flexible high bay space with the idiosyncrasies of a specific business communication strategy and local context.

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Facing Page:

Craigieburn Train Maintenance Facility (HBO+EMTB)

FIVE REASONS FOR THE INVOLVEMENT OF AN ARCHITECT

A CASE FOR THE ARCHITECTINTRODUCTION

Every large American city has a dedicated manufacturing and industrial district that was created from scratch in the late 1950s and 1960s to remove industry from the central business districts and to relocate manufacturing companies to the new interstate highway system. Many of the districts, such as Newmarket in Boston, Mill River in New Haven, CT, and Morris Point in the Bronx, still have vital companies, but not at the density that they had at their inception and through the 1970s. The question today is what to do with these districts from an economic development and urban design standpoint. Until recently, “post-industrial” sites were often seen as targets for mixed use residential/commercial/retail development – modeled on the mix of (non-industrial) uses that made up the traditional city. More recently, public policy has highlighted the need to preserve and attract manufacturing jobs to the city, casting these once-forgotten districts in a new light.

This studio will begin by understanding why certain businesses still thrive in 1960s era industrial districts to understand models for densification. We will also look at rapidly gentrifying districts like Red Hook in Brooklyn, NULU in Louisville, and the LA Garment District to learn about new kinds of businesses like micro-breweries, artisanal food producers, and precision fabrication shops that are flourishing in industrial districts located near potential customers. Our goal will be to leverage these lessons to develop a tool-kit for urban design and architectural interventions that can maximize the density of these districts while attracting and maintaining as many manufacturing jobs as possible. The hope is to achieve levels of density that inspire pedestrian activity, resulting in the chance encounters that can create synergies between businesses based on shared technological know-how, transportation needs, and talent.

Facing Page:

Research group at Artisan’s Asylum (Kate Schneider)

DESIGNING HEALTHY MIXED-USE URBAN MANUFACTURING NEIGHBORHOODS

RELEVANCEINTRODUCTION

FIELD RESEARCHIn order to gain an in-depth understanding of urban

manufacturing, our research team has visited and analyzed

a targeted range of local businesses. The goal of these

case studies is to better understand the advantages and

challenges of an urban location and to understand the

logistical and urban design issues that impact specific

manufacturing facilities.

While a wide range of manufacturing occurs in the greater

Boston area, we identified four kinds of businesses that

gravitate towards urban sites: large-scale manufacturing of

consumer goods, “maker” spaces, urban agriculture, and

food/ beverage production. We identified businesses from

each of these categories in order to better understand the

unique parameters of each type. Unfortunately, due to the

heightened security surrounding large-scale facilities that

manufacture consumer products, we were not able to gain

access to or information about these facilities. We were,

however, able to visit and document the remaining

categories of manufacturers by visiting the following

businesses: Bolt, Artisan’s Asylum, Higher Ground Farm,

Harpoon Brewery, Taza Chocolate, and Rad Lab.

Through the analysis of these six local models, our research

team was able to better understand the programmatic and

spatial requirements of urban manufacturing across diverse

scales of production and distribution. By visiting six facilities,

we were able to compare dimensions, spatial adjacencies,

and the flow of product during the production and distribution

process. We also spoke with the business managers of

each company to gain an understanding of the complex

variables that affect their businesses. Through these visits

our research team was able to see and hear firsthand how

each of these businesses operates and learn about the

challenges and advantages of operating a business in the

city. More broadly, our research was guided by these

questions:

Which types and scales of manufacturing currently exist in

the city?

What non-industrial programs currently inhabit post-

industrial buildings?

What opportunities exist for mixed-use industrial sites?

BOLT

ARTISAN’S ASYLUM

HIGHER GROUND

HARPOON BREWERY

TAZA

RADLAB

Bolt, a short-term intensive program designed to accelerate hardware startups, inhabits part of a 71,000 square foot commercial space in downtown Boston. The beauty of Bolt is in their business model. A team of mentors provides guidance and expertise in everything from design for manufacturing, to funding, to getting the product on the shelf. Bolt’s facility is part machine shop, part office, and part event space. The space opens up to local innovators for weekly idea-sharing events.

“WE BUILD HARDWARE BUSINESSES”

BOLT

Small Batch

LargeBatch

Medium Batch

CustomSpec.

FabricationFabricated

Local NationalRegional

UMD Field Research

Kate Schneider, Workshop

0 300’ 600’ 1200’

NEIGHBORHOOD

Adjacent ZoningAdditional Zoning

SITE

ZoningLand Use

Distance To FreewayDistance to T Station

Lot AreaLoading Docks

Truck TypeParking Spaces

BUILDING

OwnerYear Built

Building areaTotal building height

Total allowable heightNumber of floors

F.A.R.Ceiling Height

Open To Public?

Commercial, Mixed UseN/A

CommercialCommercial0.5 miles0.1 miles*0N/A0

Chauncy Place Corporation19109,796 SF of 71,000 SF****11’-0”Yes

Chauncy Street

Source: Boston Redevelopment AuthoritySiteIndustrial Zoning

MAP KEY

Non-Industrial BuildingIndustrial Building

Loading Dock Truck Access

ZONING & STATISTICSBOLT

4

35

1

6

2

Bolt is a venture capitalist company that helps to grow and build hardware start up companies. One of the features that make Bolt unique is the full time staff that is on hand to help each start-up team build their company and their product. Their full time mentoring staff have backgrounds in mechanical engineering, electrical engineering, and industrial design. The main advantage of being a start up company with Bolt is that the mentoring staff help each design team refine prototypes of their design. This allows each team to figure out glitches in their design with additional expert guidance before sending their product out to manufacture.

Production Space

Open Studio SpaceSmaller Meeting RoomsConference Room

30%5%

10%

40%

15%

Production & Fabrication

Administration Space

Circulation

Studio Space

Storage Space

Kate Schneider, Ground Level Workstations

Ryan Matthew, Basement WorkshopRyan Matthew, Sketches

Ryan Matthew, Tools Ryan Matthew, Breakout Rooms

Artisan’s Asylum, Inc. is a non-profit community craft studio launched in 2010 by robotics engineer Gui Cavalcanti. The organization’s mission is “to support and promote the teaching, learning and practicing of craft of all varieties,” whether that be in fiber arts or electrical fabrication. To support their mission and encourage DIY culture, Artisan’s Asylum offers a range of affordable, publicly-accessible classes taught by local artisans, monthly and daily membership plans, access to industrial-grade equipment for local artists and businesses, and on-site material storage. The 40,000 square foot facility is located in part of the former Ames Safety Envelope plant in Somerville, once a sprawling, multi-block operation over twelve buildings. Today, Artisan’s Asylum operates next door to diverse businesses including a clean energy idea incubator and a rock-climbing facility.

“THE BEST MAKERSPACE IN THE COUNTRY” -CHRIS qUINTERo, BOLT

ARTISAN’S ASYLUM

Small Batch

LargeBatch

Medium Batch

CustomSpec.



UMD Field Research

Kate Schneider. Artisan’s Asylum

0 300 600’ 1200’

SiteIndustrial Zoning

MAP KEY



NEIGHBORHOOD


SITE

ZoningLand Use




BUILDING

OwnerYear Built




Open To Public?

Residential C, Light Industrial, BusinessArts Overlay District

Light IndustrialManufacturing, Warehouse1.7 miles1.0 miles131,816 SF1Semi Truck187 Off-Street

JWF LLC191040,000 SF of 132,041 SF24’-0”50’-0” maximum21.0124’-0”Yes

Source: City of Somerville Assessor’s Online Database

Somerville Ave

Tyler Street

ZONING & STATISTICSARTISAN’S ASYLUM

4

3

2

15

3

2

Artisan’s Asylum is one of the largest and most efficiently run shared maker spaces in the country. They require membership to access and utilize their facilities. Their facility consists of roughly 40,000 square feet of space that is divided up among various tenants and shared production spaces. Their shared production spaces include: a wood shop, machine shop, welding shop, and bike shop. Their facility also has designated areas for hot crafts, electronics, screen-printing, and a chemical booth. In order to use any of the tools within a shop, members must become certified to work with that shop’s particular equipment. This ensures that all people using shop resources are properly trained, ultimately leading to less shop repairs and safer equipment use. All members also have access to the loading dock but must be present to receive their shipment orders. Artisan’s Asylum has a long wait list for open tenant space and not all members have tenant space. Many of the tenants of Artisan’s Asylum operate their small business out of their individual rented space.

Wood ShopMachine ShopWelding ShopBike ShopElectronicsScreen PrintingHot Craft

Individual Tenant Spaces

30%

10%

10%

35%

5%

10%


Loading DockAdministration Space

Circulation

Maker Spaces

Storage Space

Sunday Monday

Bike Shop

Wood Shop

Machine Shop

Welding Shop

Multipurpose Room

Tuesday Wednesday Thursday Friday Saturday

Fiber Arts/ Glass

6:00a

Midnight

6:00p

Noon

Public ProgrammingOpen for Members

DRAWING KEYArtisan’s Asylum opens its doors to the public throughout the day for various classes in its shared workspaces. Members serve as instructors in courses from jewelry making to welding.

PUBLIC PROGRAMMINGARTISAN’S ASYLUM

Kate Schneider, Artisan’s Asylum

Kate Schneider, Workstation Kate Schneider, Toolbox

“We are currently growing greens, tomatoes, and herbs, which we market through Boston restaurants and retailers.”

Currently, the farm provides bicycle deliveries to local restaurants three times a week. Current buyers include the Franklin Cafe, Neptune Oyster, Tavern Road, Ten Tables JP, Tres Gatos, Coppa, Toro, Sweet Cheeks, Anchovies, Giacomo’s, American Provisions, Clio, Teatro, and Bee’s Knees. In the future, farm founders Courtney Hennessey and John Stoddard hope to expand their offerings to include a CSA and a farm stand in the lobby of the Design Center.

BOSTON’S FIRST ROOFTOP FARM...IN AN UNLIKELY PLACE

HIGHER GROUND FARM

Small Batch

LargeBatch

Medium Batch

CustomSpec.



UMD Field Research

Ryan Matthew. Basil Leaves

NEIGHBORHOOD


SITE

ZoningLand Use




BUILDING

OwnerYear Built




Open To Public?

General Industrial, Light Industrial, Mixed UseRestricted Parking District

General IndustrialManufacturing and Processing & Offices0.3 miles1.3 miles160,010 SF1 of 15Box Truck, Semi Truck*

Boston Design Center LLC191940,000 SF of 559,690 SF**83.5N/ANo

Drydock Ave

Northern Ave

0 300 600’ 1200’


MAP KEY



Source: Boston Redevelopment Authority

ZONING & STATISTICSHIGHER GROUND FARM

Kate Schneider, Milk Crate Planters

Ryan Matthew, Tomato VinesRyan Matthew, The Rooftop Farm

Harpoon was an early participant in the major resurgence of local, craft brewing in the U.S. in the late 1980s. At the start, the founders set out to recreate the rich beer culture that they had experienced in their travels and sought to incorporate the brewery into the local community. Today, Harpoon has become famous for their weekend-long events and tours at the facility are often at capacity. While their location on the South Boston waterfront makes them difficult to access by public transportation, the brewery has easy access to interstate 93, an important connector to its Windsor, VT location and suburban distribution center in Woburn.

THE LARGEST CRAFT BREWER IN NEW ENGLAND

HARPOON BREWERY

Small Batch

LargeBatch

Medium Batch

CustomSpec.



UMD Field Research

Ryan Matthew. Brewery Tour

0 300 600’ 1200’

NEIGHBORHOOD


SITE

ZoningLand Use




BUILDING

OwnerYear Built




Open To Public?

IndustrialN/A

Industrial, Economic DevelopmentManufacturing, Retail0.4 miles1.4 miles50,000 SF2Semi Truck51

Economic Dvlpmnt. & Industrial Corp. of Boston192045,000 square feet43’-7”N/A20.928’-0”Yes

Drydock Ave

Northern Ave


MAP KEY



Source: Boston Redevelopment Authority, Boston Assessing Dept.

ZONING & STATISTICSHARPOON BREWERY

3

1

6

2

7

45

8

99

Beer Hall & Retail Space

Brewing

Grain & Hops StoragePost-packaging Storage

Selling Space10%

25%

15%

15%

15%

5%

15%



Circulation

Bottling & Packaging

Storage Space

Harpoon Brewery is all about the beer experience and bringing Europe’s rich beer culture to the United States. The founders of Harpoon have always aspired to have a beer hall that emulated the models found throughout their European travels. Recently they were able to make this dream a reality. They have a large beer hall which also doubles as rentable event space. The beer hall looks out onto the second story of their custom beer bottling machine. This allows customers to be directly connected to the manufacturing process, allowing them to watch part of the beer making process while drinking their favorite Harpoon Ale. Harpoon also offers daily tours which leave from the beer hall and take customers on a catwalk over the brewery, where customers can learn about the brewing process.

Ryan Matthew, Harpoon Brewery Beer Hall

Ryan Matthew, Pedestrian Catwalk Ryan Matthew, Vintage Cans

Ryan Matthew, Northern Avenue GatesRyan Matthew, Packaging

Two years ago, Taza Chocolate opened its Factory Store and began offering public tours. Since then, Taza has become known for its many food-culture events and for its holiday celebrations. This focus on in-factory programming has resulted in an increased demand for its products in grocery stores regionally. Despite these public programs, Taza struggles with finding its place in a continuously evolving neighborhood. While the factory is located in an industrial enclave that is experiencing an uptick in activity, it feels separated from the larger demographic forces that are making Somerville a center for entrepreneurial activity. Currently, the area is accessible by car, but the location is off the beaten track for pedestrians. With the extension of the Green Line to nearby Union Square, the neighborhood between Taza and Union Square is likely to be filled in with additional retail, entertainment venues, maker spaces, and arts-related organizations; thus improving Taza’s visibility and impact.

STONE GROUND CHOCOLATE

TAZA CHOCOLATE

Small Batch

LargeBatch

Medium Batch

CustomSpec.



UMD Field Research

Kate Schneider, Equipment Repair

0 300 600’ 1200’

NEIGHBORHOOD


SITE

ZoningLand Use




BUILDING

OwnerYear Built




Open To Public?

Residential, CommercialArts Overlay District

Transit Oriented Development 135Industrial Warehouse1.3 miles1.0 miles27,481 SF1Semi Truck*

Millers River Realty Trust192083,224 SF65’-0”*53.012’-0”Yes

Windsor Pl

Cambridge Street

Webster Ave

Source: City of Somerville Assessor’s Online Database

ZONING & STATISTICSTAZA CHOCOLATE

43

57

8

9

10

11

6 12

2

1 12

Taza Chocolate has sought to bring the rich tradition of Mexican chocolate to the United States. The company utilizes the same methods that have been used to make chocolate in Mexico for centuries. They even utilize hand carved granite millstones in the production process, which are carved using the same techniques used by traditional Oaxacan chocolatiers. Alex Whitmore, one of the company’s co-founders, still carefully carves each millstone and has only revealed the carving technique to one other Taza employee. This technique is very important because it is precisely this milling process that gives Taza chocolate its distinctive texture and bright distinctive flavor.

Roasting RoomHot Room & MoldingCold RoomDemolding Room

Staff SpaceOf�ce Space

Automated & Hand PackagingShipping

Selling Space5%

20%

25%

10%

15%

5%

20%



Circulation

Packaging & Shipping

Storage Space

Kate Schneider, Entry Kate Schneider, Chocolate Machine

Ryan Matthew, Loading Dock Kate Schneider, Chocolate Beans

Kate Schneider, Chocalate Sample

During co-founder Matt Trimble’s education at MIT, he was intrigued by his classmates’ innovative use of scripting as an integrated part of the design process. Through the use of tools like the laser cutter, 3D printer, and CNC router, Trimble “began to see a range of potential commercial applications for ‘design computing’ (modeling, scripting, programming, animating, rendering). These applications included architecture, but were not limited to architecture.”

At RadLab, Trimble and his small team of industrial designers and programmers work as consultants for architects, product designers, and entrepreneurs. The office has recently completed work across scales: from a retail interiors scheme to high-volume production of tactile braille graphics.

A MULTIDISCIPLINARY DESIGN & FABRICATION FIRM

RADLAB

Small Batch

LargeBatch

Medium Batch

CustomSpec.



UMD Field Research

Kate Schneider, Crafted Wood

0 300’ 600’ 1200’

NEIGHBORHOOD


SITE

ZoningLand Use




BUILDING

OwnerYear Built




Open To Public?

Residential C, Institutional, Mixed UseN/A

IndustrialManufacturing0.1 miles0.1 miles11,615 SF1Box Truck5

Spice Street LLC*3,000 SF of 29,548 SF*N/A*2.520’-0”No

Spice Street

Source: Boston Redevelopment AuthoritySiteIndustrial Zoning

MAP KEY



ZONING & STATISTICSRADLAB

Kate Schneider, Lobby

Kate Schneider, Workstation

Kate Schneider, Wood Paddles

GEOGRAPHY/LOGISTICS

INTRODUCTION

URBAN INDUSTRIAL PARKS

SUBURBAN INDUSTRIAL PARKS

Although manufacturing centers first developed within

dense urban centers to be near ports and rail terminals,

industrial districts were moved out to the suburbs in the

mid to late twentieth century because of the implementation

of the essential components of the interstate highway

system. This shift was compelled by not only a shift to truck

transport, but also because of relatively low property values

and government action that included urban renewal and

new regulations that aimed to remove noxious

manufacturing from the central city.

This chapter will analyze five different manufacturing

centers in Massachusetts, four of which still exist in dense,

urban contexts. Through these case studies, we hope to

better understand the larger distribution networks that have

developed as a result of this shift to suburban industrial

parks. as well as the role urban manufacturing centers play

in this network. In addition, by studying one of these

suburban industrial parks, we hope to uncover the perceived

and actual benefits of shifting manufacturing industries out

of city centers.

BOSTON

PROVIDENCE

WORCESTER

FALLRIVER

NEWBEDFORD

WOBURN

REVERE

CHELSEA

NEWTON

WALPOLE

NORWOOD

BOSTON

QUINCY

I-93

RT 1

I-95

I-95I-93

RT 3

I-90

URBAN INDUSTRIAL PARKS

The circumferential system of highways that surround greater Boston, known as the Route 128 Loop and now an amalgam of linked segments of MA 128, I-95, and I-93, serves as the spine of a regional truck transportation network. Industrial parks and districts along and within this loop together constitute a co-dependent eco-system of manufacturing and goods distribution. Land value, delivery times, and cost of transportation, among other financial and spatial factors, influence the mix of businesses, rents, and relative economic health of each of the industrial areas within the network.

Against this regional system, Newmarket, the Boston Marine Industrial Park, and the industrial area along the Cambridge/Somerville boundary were studied to understand the particular issues of urban industrial areas in terms of logistics and urban design. Although these areas host a variety of industries at a wide range of scales, they are all historically rooted in rail-dependent manufacturing. Municipal and state leaders are currently looking for ways to preserve these industrial districts by allowing for a wider bandwidth of compatible uses while keeping out residential and commercial development that can drive up land values.

GEOGRAPHY/LOGISTICS

THE GREATER BOSTON AREA

Cambridge has a long history of manufacturing and was one of the main industrial cities of New England in the 1920s. From Carter’s Ink Company to the New England Glass Company, Cambridge hosted many major manufacturers at the time. After World War II, however, most of the industrial base left and Cambridge began its transition to an intellectual center of Boston. It was not until the 1980s that Cambridge brought in high-technology startups to reinvigorate its urban manufacturing heritage.

“INTELLECTUAL CENTER WITH INDUSTRIAL ROOTS”

“Boston, Massachusetts.” Map. Google Maps. Google, 25 October 2013.

CAMBRIDGE /SOMERVILLE

UMD Geography+Logistics

The industrially zoned regions in Cambridge and Somerville demonstrate a palimpsest of historical manufacturing roots, a progression to repurposed initiatives in the late 20th century, and a resurgence of manufacturing sentiments today. In Cambridge specifically, there is a clear divide between intellectual urban property, what Cambridge is most known for today, and a smattering of light manufacturing and technology companies promoting fabrication, prototyping, and production. Somerville contains similar disjointed elements of largely residential areas broken only briefly by industrially purposed manufacturing buildings and workshops.

0 1000 2000 4000

ZONING ANALYSIS

Waterfront IndustrialIndustrial AIndustrial BMixed UseResidential AResidential BResidential C

ZONING MAP KEY

2828

3

FABRICATION

Bolt Beraneck & Newman Inc

Boston Precision Parts CO

Brankamp Process Automation, Inc

Cambridge Electric Motor Service

Cambridge Keys & Security

China Fair

Ck Estores LLC

International Service Conslnts

L Singer Fire Alarm Line

Massachusetts Foundry Inc

Mass Gas & Electric Of Boston Inc

Norel Service CO Inc

Nuclead Inc

Patricio Sandoval Oil�eld Supply

Alien Industries

Bayard Industries Inc

Precibio Medical Devices, LLC

Soy Soul Candles

Accumet Corp

IDTechEx

5 College Storage

AAA Warehousing & Dstrbtn

Academy Movers

All Star Storage & Moving CO

Intelligent Medical Devices, Inc

Spiroll International Corp

Hold Everything

Joseph Barrell Plbg & Htg

Ligon Discovery

Lyman Real Estate Trust

1087systems Incorporated

2nd Gear, Inc

Abcam

Adaptive Optics Associates Inc

Airgas East

am Dutch Distribution Products

Amplitude Laser Inc

Best Mold Removal Of Cambridge

Bio-Rad Laboratories, Inc

Biospace Lab Usa

Bmr Rogers St LLC Fire / Elevator Lines

Boston Biochem

Brankamp Process Automation

Cambridge Brands Inc

Candy Cupboard Confectionery Co

Christinas Spice & Specialty Foods

Savenor Supply Company

Siegel Egg Co Inc

Superior Nut Company Inc

Holleran Daily Grind

Medisense Inc

Opteon Corp

Oscomp Systems Inc

Perkinelmer, Inc

Perkinelmer Inc

Harvard Observatory Model Shop

President Fllows Hrvard Cllege

Pro Line Printing Ink Of New Eng

Pvi (America) Inc

Quaker Case Licsw

Sed Physics

Senior Spring Productions

24%DISTRIBUTION

SUPPLY

FOOD PROCESSING/WHOLESALE

SERVICE/OTHER

6%

45%

15%

10%

0 1000 2000 4000

BUILDING USE ANALYSISCAMBRIDGE/SOMERVILLE

4. CAMBRIDGE BRANDS INC - TOOTSIE ROLLSAREA: 12,000 SFFLOORS: 6USE: FOOD/WHOLESALE

1. CAMBRIDGE BREWING COMPANYAREA: 12,500 SFFLOORS: 6USE: MANUFACTURING

2. GOLDEN CANOLLI SHELLS CO.AREA: 2,500FLOORS: 2USE: MANUFACTURING

3. FLANN MICROWAVE CO.AREA: 25,000FLOORS: 12USE: FABRICATION

5. WAAV INC + RIVE TECHNOLOGYAREA: 150,000 SFFLOORS: 6USE: FABRICATION

0 250 500 1000

The Boston Marine Industrial Park is a 191-acre industrial area located on the eastern end of South Boston waterfront on the site of former South Boston Naval Annex, a military base that was decommissioned in 1974. The district is primarily known for its seafood processing and wholesale companies. Under Mayor Thomas Menino’s initiative to reinvigorate and enhance business growth in the area, the Marine Industrial Park has been attracting new businesses that use innovative new manufacturing processes.

“MANUFACTURING ON THE WATERFRONT”


“Boston Marine Industrial Park, Massachusetts.” Map. Google Maps. Google, 15 October 2013.

BOSTON MARINE INDUSTRIAL PARK


The City of Boston has decided that manufacturing in this location provides a diversity of jobs and provides important cultural returns. The Boston Redevelopment Authority, because it controls the parcels and buildings in the district, has been able to attract and retain businesses through targeted marketing and rents that are geared to manufacturing businesses.

0 500 1000 2000 4000

ZONING ANALYSIS


ZONING MAP KEY

24

25

30%

30%

5%

Adcotron EMS Inc.

Bitwise International Tech.

Matt J. McDonald Co. Inc.

Loki Custom Furniture

Fort Point Cabinet Makers15%

FABRICATION

Lumenpulse

Re�ex Lighting Group

Coastal Cement

Design Communications

Amramp

SUPPLY

Calvin Fabrics

Koplow Games

Discover Tile

Again Faster Equipment

Commercial Lobster

F.J. O’Hare

Fresh Water Fish Co.

Globe Fish Co.

North Coast Seafood

P.J. Lobster

John Nagle Co.

Sousa Seafood Inc.

Sunny’s Seafood

B& M Fish Company

Atlantic Coast Seafood Inc.

Beau’s Seafood Inc.

Puritan Fish Co.

Stavis Seafod

Ideal Seafood Inc.

Frasher Fish Ltd.

Jonh Mantia & Sons Co.

Red’s Best

Sea Jem Imports Inc.

Pangea Shell�sh


Allegra Print and Imaging

Blanchard Press

Copy Cop

Seaport Graphics

Sir Speedy

Waterfront Printing

Recycles Printing Co.

Francine Zaslow Photography

John Holt Studio

Boston Art

Casewell Framing

DISTRIBUTION

10%

Genalco

Grainger

HADCO

Megellan Distribuition

Wagner Solar

Back Stage Hardware

SERVICE/OTHER

Computer Science Corp.

Tide Street Tech Center

R & R Builders

Bachtel

First Call Trucking

Boston Buffalo Express

Portside Truck Repair

Baker Design Group

Philips Design Group

Silverman Trykowski Design

Peter King Design Co.0 500 1000 2000 4000

BUILDING USE ANALYSISBOSTON MARINE INDUSTRIAL PARK

12

3

4

5 6

1. THE BRONSTEIN BUILDINGAREA: 400,000 SFFLOORS: 8 USE: Multiple Services

2. 88 BLACK FLACON AVEAREA: 200,000 SFFLOORS: 3 USE: Multiple Services

3. NORTH COAST SEAFOODAREA: 140,000 SFFLOORS: 2 USE: Seafood Distribution

4. FISHING PIERAREA: 270,000 SFFLOORS: 3 USE: Seafood Distribution

5. HARPOON BREWERYAREA: 112,000 SFFLOORS: 2 USE: Beer Manufacturing

and Distribution

6. NEW BOSTON SEAFOOD CENTERAREA: 80,000 SFFLOORS: 1 USE: Seafood Distribution

0 500 1000 2000

In the 1950s, Newmarket Square was built as a modern new home for the meatpacking and food processing companies that were being relocated from Faneuil Hall and Haymarket to allow for redevelopment of the area for retail, restaurants and office space. After the establishment of Newmarket, manufacturing and distribution continued to locate in the area, resulting in the establishment of the Newmarket Business Association in 1976. The organization was charged with maintaining continued business growth, encouraging collaboration between businesses, and advocating policies that would improve the economic health of the district. Today, Newmarket has grown substantially and though it now hosts a diversity of businesses, it still remains true to its core as a historically manufacturing-based district. Most food processing companies that were relocated in the late 50s are still alive and flourishing.

“DEDICATED MANUFACTURING AND CONTINUED GROWTH”

NEWMARKET INDUSTRIAL DISTRICT



The arrangement of industrially zoned regions in Newmarket display two key points in understanding manufacturing in an urban context: the arrangement, and the location. The arrangement is reminiscent of a historically dedicated manufacturing district that has steadily grown since its original founding. This is evident as the zones are still largely contiguous, and less scattered as is evident in other urban areas that had at some point severed from their industrial history. Furthermore, the location of industrial zones is largely connected to arteries, projecting out and around the intersection of the two major automotive arteries.

0 500 1000 2000

ZONING ANALYSIS


ZONING MAP KEY

18

16

30%

30%

5%

Atel

O’Bass Electronic5%

FABRICATION

Harry Miller Company

The Harvard Common Press

SUPPLY

New England Wood Floor

Capitol Wood Floor Supply Inc.

Maxwell Box Company

The Waldwin Group

Atlantic Seacove Inc.

Foley Fish Company

Slade Gorton Co.

Steve Connolly Seafood Company

Boston Briske Co.

Boston Lamb and Veal Co.

J & D Imports

J. Carter Veal Co.

Metropolitan Meat

Katsiroubas Bros.

Chinese Spaghetti Factory

City Packing Company

Costa Provision

Dancing Deer Bakery

Mutual Beef

Boston Salads & Provision

Lun Fat Produce


Eagle Elevator

Morgan Linen & Uniform Service

Guigliano Corp

Suffolk Construction

Alternate Concepts Inc.

Paul Revere Transportation

Boston Freightliners

C & L Auto

First Call Trucking

Boston Veterinarian

Salami’s Truck Center

United Waste

DISTRIBUTION

20%

Accurate Fasteners Inc.

Harrison Supply

R & R Sales

Waldo Bros Co.

Whitney Building Products

P.J. O’Donnel Co.

Portland Pine & Fitting Co.

Royal Fire Door Company Inc.

The Waterproo�ng Company

Chester Brown Wholesale Florist

SERVICE/OTHER

Boston Body Work

Dorchester Tire Company

Middlesex Truck & Coach

American Ice Co.

Peninsula of Boston Inc.

Castle Self Storage Inc.

Planet Self Storage

Howard Storage

New England Storage Warehouse

Public Storage

Patriot Self Storage

0 500 1000 2000

BUILDING USE ANALYSISNEWMARKET INDUSTRIAL DISTRICT

1

2

3

4

5

6

1. KATSIROUBAS PRODUCEAREA: 15,000 SFFLOORS: 2USE: WHOLESALE

4. CHESTER BROWNAREA: 80,000 SFFLOORS: 1 USE: DISTRIBUTION

2. SLADE GORTON & CO.AREA: 50,000 SFFLOORS: 2USE: WHOLESALE

6. BOSTON FOOD TERMINALAREA: 100,000 SFFLOORS: 1USE: WHOLESALE

5. STEVE CONNOLY SEAFOODAREA: 20,000 SFFLOORS: 1USE: WHOLESALE

3. BOSTON LAMB AND VEAL CO.AREA: 50,000 SFFLOORS: 2USE: WHOLESALE

0 200 1000600

BOSTON

PROVIDENCE

WORCESTER

FALLRIVER

NEWBEDFORD

TAUNTON

MIDDLEBOROUGH

BROCKTONRT 24

I-495

I-495

RT 140

RT 24

I-195

I-195

RT 140

NEWBEDFORD

FALLRIVER

TAUNTON

SUBURBAN INDUSTRIAL PARKS

Fall River and New Bedford are two cities that developed working waterfronts adjacent to protected natural harbors that were well-located for whaling and the global trade network of the early 19th century. With the establishment of an extensive regional and national rail network in the late nineteenth century, both cities shifted focused to the textile industry. At the same time that industrial areas were moving from urban centers to suburban areas to be more accessible to the interstate system, both cities experienced a decline in industrial production due to larger market forces. To address this trend, both Fall River and New Bedford developed suburban industrial parks along either Route 24 or Route 140, which connect the cities to Boston and Providence.

Although some industrial production still occurs along the waterfront in Fall River, most of its historic mill structures have been adapted to new uses, in particular retail and residential. As a result, the historic industrial zone of the city has been re-zoned for mixed use and has developed into the city’s downtown. Unlike Fall River, New Bedford’s waterfront is still primarily zoned for industrial uses given the continuing strength of maritime industries including fishing, although there has been some introduction of mixed use zoning and a few cases of adaptive reuse of its historic mill structures.

The following pages will analyze both the urban industrial area along New Bedford’s waterfront and its suburban industrial park along Route 140. It is our hope that through this analysis we can understand the limitations of urban industrial areas and the actual and perceived benefits of suburban industrial “parks.” With this analysis, we hope to be able to propose benefits and strategies for maintaining an industrial presence along the urban waterfront instead of rezoning the area for retail and residential as was done in Fall River.

GEOGRAPHY/LOGISTICS

FALL RIVER, NEW BEDFORD, ROUTE 24, ROUTE 140 LOOP

New Bedford’s waterfront is an industrial area that has grown organically over time. Its early industrial development was centered on whaling; however, when the industry began declining in the 1880’s, New Bedford shifted its focus towards to cotton textile production, which had already established itself in places such as Lowell and Pawtucket. By the end of the 19th century, New Bedford was one of the largest producers of cotton yarns and textiles in the country. Over the last century, industry in the area has shifted to electronic circuitry production, needle trade, and other types of manufacturing. In addition, some of the historic mill buildings in the area have been adapted to other uses such as light manufacturing, small businesses, professional offices, and residential use.

“THE WHALING CAPITAL OF THE WORLD”

NEW BEDFORD WATERFRONT

“New Bedford, Massachusetts.” Map. Google Maps. Google, 15 October 2013.


ZONING ANALYSIS

While historic mill buildings still define the northern half of the New Bedford’s industrial area, a large quantity of Butler buildings have been constructed in the southern end of the district because urban renewal removed most of the historic industrial buildings in the oldest part of the port. These Butler buildings primarily house seafood wholesale and distribution companies, the predominate business type in the district.

The industrial zones in the area exist along the waterfront, reflecting the industry’s historic connection to the water. These industrial areas are separated from adjacent residential zones by the JFK Memorial Highway (Route 18). A pocket of mixed use zoning defines New Bedford’s “downtown” at the intersection of the JFK Memorial Highway and Route 6. This mixed-use zoning has begun to spread as some of the historic mill buildings are repurposed for other uses such as residential and business.

15

16

0 1000 2000 4000


ZONING MAP KEY

15

16

21%

11%

15%

32%

21%

ABCO Electric Inc.

Bobby T. Machine Co.

Continental Plastics Inc.

CL Machining

Crystal Ice Co.

Evergreen Sheet Metal

Marine Hydraulics Inc.

Mass Fabricating & Welding

Oberon Co. (safety equipment)

Revere Copper Inc.

Whaling City Iron Co.

FABRICATION

American Pride Seafood

Big G Seafood

Eastern Fisheries

Hygrade Ocean Products

Kylers Seafood Market

Marder Trawling Inc.

Mariner

Mar-Lees Seafood

M&B Sea Products

Northern Pelagic Group

Pier Fish Company

Saraiva Enterprises (wine/beer)

Sea Trade International

Skip's Marine Seafood Packaging

Sea Watch International

Tichon Seafood

Top Quality Seafood Inc.


Bruce's Splicing & Rigging

Crystal Ice Company

New Bedford Ice & Cold Storage

NGN Transport

Packaging Products Corporation

West Terminal Cold Storage

DISTRIBUTION

CAT Marine Equipment

Global Co-Op Warf (oil & fuel)

Lighthouse Marine Supply

Luzo Fishing Gear

Marine Enterprises

New Bedford Ship Supply Co.

New Bedford Welding Supply

NStar Power Plant

SUPPLY

Dockside Repairs

Fishermen's Pier Visitor Center

Goyette Auto Part Recycling

Knuckle Head Bar & Grill

LECH Auto Body

Mill Stores Factory Outlet

New Bedford Glass Museum

Ryder Transportation Services

Shuster Machine Engineers

State Pier & Ferry Terminal

Warf Tavern

SERVICE/OTHER

BUILDING USE ANALYSIS

0 1000 2000 4000

NEW BEDFORD WATERFRONT

5. SKIP’S MARINE SEAFOOD PCKGAREA: 43,346 SFFLOORS: 1USE: WHOLESALE/DISTRIBUTION

1. OBERON SAFETY EQUIPMENTAREA: 42,532 SFFLOORS: 1USE: MANUFACTURING

2. CL MANUFACTURINGAREA: 190,514FLOORS: 4USE: BUSINESS/LIGHT MFG.

4. FISHERMAN’S PIERAREA: 32,160FLOORS: 1USE: BUSINESS/DISTRIBUTION

3. SEA WATCH INTERNATIONALAREA: 28,252 SFFLOORS: 1USE: WHOLESALE/DISTRIBUTION

6. HYGRADE OCEAN PRODUCTSAREA: 46,677 SFFLOORS: 1USE: WHOLESALE/DISTRIBUTION

4

5

6

3

2

1

0 250 500 1000

The New Bedford Business Park is comprised of 150 acres of industrially zoned land. The area currently employs over 2,500 employees and accounts for approximately $650 million in sales revenue. The New Bedford Business Park advertises itself as “New England’s most cost effective location” thus demonstrating the trend of moving industrial centers out of cities with high property values to the more affordable suburbs. The park is located adjacent to Route 140 and is located 40 miles from Boston and 25 Miles from Providence. In addition the park has access to three airports within an hour’s commute time.

“NEW ENGLAND’S MOST COST EFFECTIVE LOCATION”

NEW BEDFORD BUSINESS PARK

“New Bedford, Massachusetts.” Map. Google Maps. Google, 15 October 2013.


ABCO Electric Inc.



CL Machining

Crystal Ice Co.





Revere Copper Inc.


FABRICATION

Route 140

7

0 1500 3000 4500

The New Bedford Business Park, adjacent to undeveloped greenfield sites, is zoned exclusively for industrial uses. The Park is also adjacent to a small mixed use zone near the Route 140 interchange. Unlike many organically grown urban industrial areas, this area is a result of planned development and is run by a separately established management company, the Greater New Bedford Industrial Foundation. As a result, it is constantly undergoing infrastructure improvements and provides it employees many services within the park including a daycare, restaurants, and a career center for job recruiting.

ZONING ANALYSIS


ZONING MAP KEY

ABCO Electric Inc.



CL Machining

Crystal Ice Co.





Revere Copper Inc.


FABRICATION

Route 140

7

FABRICATION

Titleist Ball Plants 2 & 3

Morgan Technical Ceramics

Symmetry Medical New Bedford

Massachusetts State Lottery

HighTech Manufacturing

New England Plastics

Five Star Companies

Aerovox

DISTRIBUTION

Lighthouse Masonry

Symmetry Medical

Edson

ASSEMBLY

Better Image Apparel

Nameplates for Industry

SUPPLY

Butler Architectural Woodworking

Maximum Weather Instruments

FOOD PROCESSING / DISTRIBUTION

Reinhart Food Service

16%

23%

45%

13%

3%

C.P. Bourg

Polyneer

Poyant Signs

GEC Durham

Zapp Precision Strip

A & R Machining

AFC Cable Systems

Milhench Supply

Schaefer Marine

Horacio’s Welding & Sheet Metal

Epec Engineered Technologies

Vectrix/Gold Peak Industries

Imtra Marine Products

Ahead Inc.

0 1500 3000 4500

BUILDING USE ANALYSISNEW BEDFORD BUSINESS PARK

2. MASSACHUSETTS STATE LOTTERY AREA: 100,000 FT2 FLOORS: 1 USE:MANUFACTURING

3. TITLEIST AREA: 100,000 FT2 FLOORS: 2 USE: MANUFACTURING

1. AMERICAN CABLE SYSTEMS AREA:100,000 FT2 FLOORS:1 DOCKS: 7 USE: MANUFACTURING

4. NEW ENGLAND PLASTICS AREA: 40,000 FT2 FLOORS: 1 USE: MANUFACTURING

6. AEROVOX AREA: 60,000 FT2 FLOORS:1 USE: MANUFACTURER

5. IMTRA MAXIMUM AREA: 30,000 FT2 FLOORS:1 USE: MANUFACTURER

6

4 5

31

2

0 500 100 1500

STANDARDSThe dimensional logic of modern manufacturing and

distribution buildings is built up from the dimensions of a

standard pallet: 40 by 48 inches, The pallet is the driving

metric for the entire shipping and manufacturing industry

since 80% of all US trade is carried on pallets. The metrics

of pallets influence four elements: Pallet Transportation,

Pallet Entry (into the building), Pallet Lifts, and Pallet

Stacking. Each one of these categories, the stacked pallets

of materials define spatial volumes and the logistics of truck

transport and forklift operations. As a result, the architect

must fully understand these systems in order to design

buildings that meet the needs of the contemporary global

distribution network.

PALLETS

DAYLIGHTING

48”40”

UMD Standards

PALLETS

The standard pallet size used in the US is 40” x 48”

The Service Duty of a palette is understood using the following weight categories: Light-Duty (1000 pounds); Medium-Duty (2000 pounds); Heavy-Duty (3000 pounds). For ‘Heavy-Duty’, stacking no more than 60” is allowable.

Once the pallets are assembled, it is a matter of determining which truck type is best suited for the delivery. The truck chosen influences which manufacturing buildings are accessible and which are not.

The storage of pallets is governed by the Pallet Lift. These range from 15.5 to 42’ of vertical reach. The lower-end of the scale is most common, and this becomes the parameter for racking. A tri-level racking is possible when using a 15.5’ Lift.

A DRIVING METRIC FOR MANUFACTURING

254855

62”

CITYLOW BOY

CONTAINERSEMI

62”

PALLET TRANSPORTATIONPALLETS

The transportation of pallets into and out of the building occurs via the truck. The type of truck that is most likely to be servicing the building brings with it a unique set of constraints that must be anticipated when designing the building.

The maximum legal truck width (without a special permit) is 8’6”, and the maximum trailer height is 13’6”. The width of the truck is critical to consider in determining the width of a truck bay. The necessary response is to create a 9’0“ bay. This makes the unloading of pallets manageable and allows for a greater leniency in terms of truck alignment when backing into a designated bay.

Pictured to the right are four primary truck types used for shipping:

LOW BOY

The Low Boy has a bed height of 25”.

CITY

The City has a bed height of 48”.

SEMI

The Semi has a bed height of 55”.

CONTAINER

The Container has a bed height of 62”.

Porter, W. (2013). Loading dock design. Retrieved from http://loadingdocksupply.com/

CANTILEVER OPEN

FLUSH ENCLOSED

*

PALLETS

PALLET ENTRYThe entry of pallets into the building occurs at the loading dock. An Exterior strategy (of which there are three options) is the most common due to its cost effectiveness. When an exterior arrangement is created, it is preferable to have an 1-2% incline in the tarmac leasing up to the dock. Although this is difficult to achieve in urban environments, it is considered ideal due to its water mitigation capabilities.

Pictured to the left are the four ways in which the actual threshold itself may be handled:

CANTILEVER

In this scenario, the dock face projects past the exterior wall of the building. This is desirable because it helps to protect the building itself in the case that the bumper fails.*

OPEN

The Open loading dock is preferred by the USPS, and its implementation is less cumbersome as compared to the Cantilever. The issue is there is little in terms of drainage.

FLUSH

The Flush scenario is the most common, as it is the most cost effective; relying solely on the bumper. It is necessary that this bumper projects a minimum of 4.5” from the wall.

ENCLOSED

The Enclosed condition is widely used by package handlers and those exchanging sensitive materials. In this case, special care must be given to how the space is ventilated.

Porter, W. (2013). Loading dock design. Retrieved from http://loadingdocksupply.com/

TURRET TRUCK4.5’-5.5’ AISLE

COUNTERBALANCED12’ AISLE

ORDER PICKER4’-5’ AISLE

DEEP REACH9’ AISLE

42’ Lift*

PALLET LIFTSPALLETS

The vertical storage of pallets is governed by the Pallet Lift. These machines tend to have a maximum vertical reach of 42’, with a lift capacity that ranges from 2,500 to 36,000 pounds. This then becomes the parameter for racking height and speed of storage.

Pictured to the right are four common types of Pallet Lifts:

DEEP REACH AISLE

The Deep Reach Lift requires that the aisles between pallet racks must be a minimum of 9’ in width. The vertical reach of this type of lift is 42’.*

COUNTERBALANCED

The Counterbalanced Lift requires that the aisles between pallet racks must be a minimum of 12’ in width. The vertical reach of this type of lift is 15.5’.

ORDER PICKER

The Order Picker Lift requires that the aisles between pallet racks must be a minimum of 4’ in width. The vertical reach of this type of lift is 30.5’.

TURRET TRUCK

The Turret Truck Lift requires that the aisles between pallet racks must be a minimum of 4.5’ in width. The vertical reach of this type of lift is 41’.

Gandall, D. (2013). Pallet rack estimator. Retrieved from http://webtools.cisco-eagle.com/rack/

18’-0”

28’-0”

42”

6’-0”

5’-0”

PALLETS

In the design of a contemporary factory building, the ideal ceiling height is 28’. This very specific ceiling height is due (in part) to the parameters set by the Pallet Lift. The most common lift, for economical reasons, is the Counterbalanced Lift. With this machine limited at 15.5’ in vertical reach, a tri-level racking system is ideal. The total height of such a system is 18‘, with each individual segment being 6’ tall. This, in turn, leaves 9’8” of space for decking, lighting, and refrigeration. The critical dimension to consider for the refrigeration unit is its height; 4’8”. Not every warehouse facility requires such an apparatus, but this parameter then leaves 5’ of clear space between the top-most filled pallet and the underside of the refrigeration unit. This specific relationship can be seen illustrated in the diagram to the left.


PALLET RACKING

SEMI

CONTAINER

FLAT BED

LOW BOY

CITY

Length

60’ Overall, 53’ Trailer

Height (bed)45”-55”

Length60’ Overall, 53’ Trailer


Length60’ Overall




Length40’ Overall



SEMI

CONTAINER

FLAT BED

LOW BOY

CITY

Length

60’ Overall, 53’ Trailer




Length60’ Overall




Length40’ Overall

Height (bed)45”-48” 90’

130’

130’

130’

130’

PALLETS

When designing a manufacturing building, the Apron Space is the area immediately outside of the loading docks that must be provided so that the trucks can successfully maneuver into their designated bay.

The rule of thumb for predicting this distance is through the following formula: 2(LENGTH OF TRUCK + TRAILER) + 10’

SEMI

The Semi truck has an overall length of 60’, thus the apron space required is 130’ = 2(7’ + 53’) + 10’

CONTAINER

The Container truck has an overall length of 60’, thus the apron space required is 130’ = 2(7’ + 53’) + 10’

FLAT BED

The Flat Bed truck has an overall length of 60’, thus the apron space required is 130’ = 2(60’) + 10’

LOW BOY

The Low Boy truck has an overall length of 60’, thus the apron space required is 130’ = 2(7’ + 53’) + 10’

CITY

The City truck has an overall length of 40‘, thus the apron space required is 90’ = 2(40’) + 10’. The City truck is an ideal means of shipping for tight urban conditions. Certain scales of manufacturing, however, will require servicing via a Semi.

APRON SPACE

62,500 SF

40,000 SF

22,500 SF

10,000 SF

2,500 SF

25 BAYS50’X50’

16 BAYS50’X50’

9 BAYS50’X50’

4 BAYS50’X50’

1 BAYS50’X50’

Pallet Racks784

Pallets4704

Pallet Racks484

Pallets2904

Pallet Racks256

Pallets1536

Pallet Racks90

Pallets540

Pallet Racks15

Pallets90


In a Semi Truck, one can �t 52 pallets (double stacked). In a 62,500 sf facility, it would take 91 Semi Trucks to �ll that amount of storage space.





62,500 SF

40,000 SF

22,500 SF

10,000 SF

2,500 SF

25 BAYS50’X50’

16 BAYS50’X50’

9 BAYS50’X50’

4 BAYS50’X50’

1 BAYS50’X50’

Pallet Racks784

Pallets4704

Pallet Racks484

Pallets2904

Pallet Racks256

Pallets1536

Pallet Racks90

Pallets540

Pallet Racks15

Pallets90

PALLETS

The 50’ x 50’ column grid is ideal in a manufacturing setting. Beyond the reasons of structural justification, the ideal nature of this number comes from the dimensional constraints of the singular pallet. A 50’ x 50’ grid works in such a way that 90 pallets can be stored (assuming 2,000 pounds/pallet and a tri-level racking system. A total of 15 pallet racks can fit into that amount of space, while leaving the obligatory clear space in the aisles for the Pallet Lift to maneuver. In this arrangement, the weight per beam level would be 4,000 pounds, and the price of the racking system would be approximately $115.42 per pallet.

The matrix to the left displays the capacities of varying warehouse square footages. The figure, which illustrates the number of semi trucks needed to fill the space, is assuming a double-stacking of the pallets within the semi. It is important to note that while the truck bay doors typically come in heights of 8, 9, and 10’, only the 10’ height is capable of properly servicing a double-stacked semi.

STORAGE SPACE

54255 25805 12274 5838 2776 1320 lux



DAYLIGHTING STRATEGIESThe concept of passive daylighting strategies is not a new idea for the manufacturing industry. Factories from the first half of the 20th century can be useful for determining daylighting strategies for the future of manufacturing. The following 3 examples represent ideas worth considering:

STRATEGY 1: CLERESTORY

The clerestory is an ideal response to alternating bay heights.

STRATEGY 2: DIFFUSED LIGHT

Diffused light allows for visual privacy from the exterior.

STRATEGY: SAW TOOTH ROOF

Saw tooths (or monitors) can be used for capturing north-light. This is ideal for precision manufacturing.

54255 25805 12274 5838 2776 1320 lux



TYPOLOGICAL CONSIDERATIONS

ORGANIZATIONAL STRATEGIES

EXPRESSING THE CONTENTS

PROTOTYPES

Like modern housing and office buildings, manufacturing

facilities have both essential program components and

time-tested circulation armatures that both provide access

to and organize the relationship between the parts. When

considered through a completely pragmatic lens, the

determinants of space organization in factories are more

complex than other building types because circulation

patterns and space arrangement needs to suit the needs of

both personnel and product movement. In addition, most

manufacturing spaces need to account for spaces that can

handle the machinery process as well as storage for stock

items and completed goods before they are shipped.

These competing demands on the layout of a factory need

to be balanced with the desire for flexibility to allow for

changes in manufacturing processes because of

technology and/or changes in production runs. As a result, a

natural tension exists between the desire for universal

space, on the one hand, and specialized spaces of specific

tasks, on the other. Given these pragmatic and efficiency-

driven parameters, factory design has recently been the

purview of industrial engineers and not architects. The goal

of our analysis is to take a half a step back to understand

whether an architectural framework can point in innovative

new directions.

UMD Typological Considerations

The arrangement of high and low-bay spaces provides the essential organizational structure of industrial buildings. High-bay spaces are designed to accommodate a flexible area for both industrial production and the efficient warehousing of stock materials and finished goods for distribution. These spaces are directly linked to the larger supply chain by loading docks that determine the dimensional rhythm of the building elevation. Contrasting the high-bay space are the low-bay spaces that contain support functions such as office suites, research labs, and service areas. The arrangement of high-bay and low-bay spaces establishes the basic organization schema of an industrial building.

ANALYZING BUILDING ARRANGEMENT TECHNIQUES THROUGH PRECEDENT STUDIES AND PROTOTYPICAL DIAGRAMMING.


The Life & Style Kameha Grand Bonn Hotel (Karl-Heinz Schommer)

Gira Giersiepen GmbH (Ingenhoven Overdiek Architekten)

Short SideThe admininistrative program is arranged along one side of the manufacturing

DetachedThe admininistrative program is physically disconnected from the the manufacturing

AbsentThe admininistrative program is removed

Long SideThe admininistrative program is arranged along one side of the manufacturing

EmbeddedThe admininistrative program is centrally located, dividing the manufacturing space

‘Sandwich’The admininistrative program is arranged along two sides of the manufacturing

1

2

3

4

5

6 7

8

Taking into consideration the importance of the loading dock as the foremost factor in determining the layout of factory space, a variety of low spaces were placed around an adjacent high bay space to understand the effects these programs have on both the scale and use of an industrial building. The effective use of low bay space allows for a more efficient use of manufacturing space.

ANALYZING PLAN ARRANGEMENTS USING HIGH AND LOW BAY SPACES.

PLAN ARCHETYPESORGANIZATIONAL STRATEGIES

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25 26

27

28

29 30

31

32 33

34

36

35

Hung WithinThe low-bay program is located within the high-bay space as a mezzanine.

AboveThe low-bay program is located above the high-bay program.

DetachedThe low-bay program is separated from the high-bay program.

Stacked AdjacentThe low-bay program is stacked adjacent to the high-bay program.

AbsentThere is no low-bay program.

Section archetypes analyze a productive use of vertical space. Issues such as pallet stacking, and machine processing are impacted by both sectional arrangement and overall building height. Sectional strategies may also generate spatial efficiencies that can reduce a building’s footprint. Five typical section arrangements emerged out of a study of high bay and low bay section relationships.

ANALYZING SECTIONAL ARRANGEMENTS USING HIGH AND LOW BAY SPACES.

SECTION ARCHETYPES

10

5

18

20

29

8

19

36


9

26

16

30

11

12

22 23

2

25

24

28

27



Expressive strategies help convey either a message about the company or the product they manufacture, and are often conceived as part of a broader branding strategy. Companies can use a wide range of strategies, from painting an exterior wall the company color to including large expanses of glass to expose the production process to people passing by. Many companies choose to express the company brand through the architecture but wish to conceal, for various reasons, actual production. An example of this can be seen in a printing press with large letters wrapping around its facade. For other companies, the plant tour is a central part of the marketing strategy. Often, the architects for these buildings have included special viewing areas such as elevated mezzanines and catwalks.

Understanding this range of expressive strategies equips the architect and client with a shared framework to make decisions about the design of a building for a specific company and site.

STRATEGIES FOR EXPRESSING THE MANUFACTURING PROCESS AND THE COMPANY BRAND

Printworks Veenman (Neutelings Riedijk)

Graphic Skin Expression

Expressive Building Shape

Using both building shape and graphic representation on the building skin, this type of building contains a publice image, but does not actually reveal what happens inside. This is often a tactic to only convey a specific message, or is due to a necessity of privacy or safety for the specific program of the building. As a tool, this type of image strategy can be useful to both maintain an amount of necessary privacy while still addressing the public.

DECORATED SHED/DUCK


VEENMAN PRINTING PRESS

This building for a printing press company uses their facade material to hint at what is happening inside. The use of letters on the facade creates a public message or theme for the building without actually exposing the machinery within.

METALSA

This building for automotive manufacturer Metalsa has a saw-toothed roo�ine that is reminiscent of old industrial buildings and the nearby mountains. Designed to create an impression, it easily does so with its entirely metal facade.

DHC ENERGY PRODUCTION

This energy production plant takes a unique approach to public relations. Due to the types of processes taking place within, it cannot expose its interior spaces. Instead, it places a large LED screen on its exterior that shows the type of energy production happening inside at the moment, as well as how much energy has been produced that day.

Transparent Skin

Using transparency as a tool for literally exposing the contencts of a manufacturing space can be an interesting way to engage the public. In an era advocating for business and political transparency, as well as a strong environmental movement, exposing a clean manufacturing process can go a long way to boost public approval and actively engage consumers.

TRANSPARENCY


BIOMASS PLANT

This biomass plant attempts to be as transparent as possible. The main building is entirely made of glass, exposing all spaces, including both administrative as well as production. A wood screen wraps around the top portion of the building, providing very little privacy, but leaving the bottom most portion totally open, where the manufacturing actually occurs.

MORS DISTRIBUTION CENTER

This project for Mors Distribution is built as an exposed entrance and show-area being revealed from within the larger structure. The exposed area includes a showroom with machinery used by Mors as well as an entrance lobby and o�ce spaces.

THE DAILY JOURNAL

This o�-set printing press was built in the paper’s beginning stage, and was also to act as a publicity buliding for the new paper. The building was wrapped in glass, and had brightly painted printing presses to be seen from the road.

Designed Viewing Area

This type of project takes expression one step further. It creates and environment inside the manufacturing space that allows for the public to enter into it and experience the production. Regardless of how the exterior addresses the public, this strategy allows for an extensive interactive relationship between the consumer and the product.

VIEWING THE PROCESS


HARPOON BREWERY

With the inclusion of a Beer Hall with their main Brewery in Boston, MA, a large part of Harpoon’s business plan includes customer interaction. The Beer Hall opens up to the production line with a large interior window. Several tours a day take place, weaving through the production area on catwalks built to expose visitors to the brewing process.

BMW FACTORY

This BMW Factory, by Zaha Hadid, takes a di�erent approach to both building layout and experience. The vehicles move through the o�ce spaces while partially completed to di�erent areas of production on raised tracks, bringing employees closer to the actual production process.

TAZA CHOCOLATE

Taza chocolate has a local buisness model, and their on-site store brings in much of their business. Two large windows show the most interesting piece of the chocolate production: the melting and mixing machine, which includes piping to move the melted chocolate through the room. A guided tour takes visitors through the production line.


After analyzing a wide range of manufacturing facilities to uncover common organizational and expressive strategies, a series of prototypes were developed that synthesized the analysis. The three basic design elements analyzed earlier in this chapter - the relationship of the high-bay to low-bay space, the roofline, and the façade strategy – were recombined in a variety of configurations. These prototypes are not conceived to be off-the-shelf solutions, but rather a starting point for an iterative design process that takes into account the specific demands of the site, manufacturing process, logistics, and brand of the business.

A COMPREHENSIVE SET OF PROTOTYPICAL BUILDINGDESIGNS.

PROTOTYPES

Wallen Forestry Center (Samyn and Partners)

1. EMBEDDED ABOVE DECORATED DUCK

2. EMBEDDED ABOVE TRANSPARENT BOX

3. EMBEDDED WITHIN DECORATED DUCK

4. EMBEDDED WITHIN TRANSPARENT BOX

5. EMBEDDED STACKED DECORATED DUCK

6. EMBEDDED STACKED TRANSPARENT BOX

7. SHORT-SIDE ABOVE DECORATED DUCK

8. SHORT-SIDE ABOVE TRANSPARENT BOX

9. SHORT-SIDE STACKED DECORATED DUCK

10. SHORT-SIDE STACKED TRANSPARENT BOX

11. SHORT-SIDE WITHIN DECORATED DUCK

12. SHORT-SIDE WITHIN TRANSPARENT BOX

13. SHORT-SIDE DETACHED DECORATED DUCK

14. SHORT-SIDE DETACHED TRANSPARENT BOX

15. LONG-SIDE ABOVE DECORATED DUCK

16. LONG-SIDE ABOVE TRANSPARENT BOX

17. LONG-SIDE STACKED DECORATED DUCK

18. LONG-SIDE STACKED TRANSPARENT BOX

13. SHORT-SIDE DETACHED DECORATED DUCK

19. LONG-SIDE WITHIN DECORATED DUCK

20. LONG-SIDE WITHIN TRANSPARENT BOX

21. LONG-SIDE DETACHED DECORATED DUCK

22. LONG-SIDE DETACHED TRANSPARENT BOX

23. SANDWICH ABOVE DECORATED DUCK

24. SANDWICH ABOVE TRANSPARENT BOX

25. SANDWICH STACKED DECORATED DUCK

26. SANDWICH STACKED TRANSPARENT BOX

27. SANDWICH WITHIN DECORATED DUCK

28. SANDWICH WITHIN TRANSPARENT BOX

29. SANDWICH DETACHED DECORATED DUCK

30. SANDWICH DETACHED TRANSPARENT BOX

31. DETACHED STACKED DECORATED DUCK

32. DETACHED STACKED TRANSPARENT BOX

33. ABSENT ABOVE DECORATED DUCK

34. ABSENT ABOVE TRANSPARENT BOX

35. ABSENT ABSENT DECORATED DUCK

36. ABSENT ABSENT TRANSPARENT BOX

midreview - new life for urban manufacturing districts

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