Manufacturing insights

• Future industrial projects must account for the growing use of IoT and design for scalability to adapt to rapidly evolving technologies and processes.
• Supply chain challenges and the trend toward re-shoring manufacturing to the U.S. are increasing the demand for flexible, modular designs and proactive procurement strategies.

• Jarron Gass, PE, CFPS, Fire Protection Discipline Leader, CDM Smith, Pittsburgh
• Justin Milne, PE, PMP, Senior Engineer, Jensen Hughes, Allen, Texas
• Jonathan Sajdak, PE, Associate Principal / Fire Protection engineering director, Page, Houston
• Michael Whalen, PE, LEED AP BD&C, Project Manager, HDR Engineering, New York

Please explain some of the codes, standards and guidelines you commonly use during the project’s design process. Which codes/standards should engineers be most aware of?

Jarron Gass: In the fire protection discipline, our starting point for prescriptive solutions is primarily based on editions of the International Fire Code (IFC), International Building Code (IBC) or NFPA 1: Fire Code. These codes determine if, when, and what types of fire protection are required for any given occupancy, typically directing compliance with specific standards. Important examples include NFPA 13: Standard for the Installation of Sprinkler Systems and NFPA 72: National Fire Alarm and Signaling Code.

Jonathan Sajdak: It is imperative to coordinate with the authority having jurisdiction at the beginning of a project to ensure all applicable codes and standards are being applied. Additionally, a majority of municipalities have local amendments that need to be adhered to. From the fire protection engineering perspective, there is a wide variety of codes and standards used for the design and construction of industrial and manufacturing facilities. The IBC and IFC contain most of the general project requirements. These codes include references to NFPA codes and standards that apply to the design of certain types of systems or facilities. Loss prevention is also a key consideration for these types of facilities. Some insurance underwriters may provide additional guidelines and requirements to follow. FM Global data sheets are one example of guidelines that are commonly referenced, which can have more stringent requirements than some of the standard building or fire code requirements.

What are some best practices to ensure that such buildings meet and exceed codes and standards?

Jarron Gass: Investing in front-end due diligence can yield significant benefits for a project. With thorough planning, consulting and design incorporated at the outset, engaging all relevant stakeholders with a proposed approach and developing a design scheme with buy-in, at least conceptually, from approving authorities is crucial. When faced with a design challenge that doesn’t fit into a standard prescriptive approach, this type of buy-in at the front end can help keep projects moving forward while maintaining timelines and schedules.

Justin Milne: To ensure buildings meet and exceed these codes and standards, the most important issue is to define the basis of design in the proposal phase of the project, and no later than the initial concept design. Ensuring this is determined in the scoping phases, gives the owner greater flexibility to allocate the appropriate budget to ensure all lawful codes and standards can be successfully incorporated into the final building design.

Jonathan Sajdak: One process that can be used to ensure codes are met is creating a code matrix. This document is best developed at the beginning of a project and will require input from the architect and all engineering disciplines. The goal is to identify each applicable code, standard and guideline on a project and review the associated design requirements or criteria from each of those. This is best illustrated using a tabular format in which rows are specific system requirements and columns include the requirements associated with each code, standard or guideline. By doing this, it is easy to see what the most stringent requirement is and then apply it across the project.

How are codes, standards or guidelines for energy efficiency impacting the design of industrial and manufacturing facilities?

Jarron Gass: Implementing mandates to increase efficiency can lead to unintended consequences, especially for existing facilities undergoing renovations, upgrades or expansions. Improvements in efficiency in one area may necessitate upgrades in other areas, such as adding structural elements to support new photovoltaics. In newer projects, these guidelines can be more easily accounted for and incorporated, often resulting in minimal disruption. However, they may drive increased upfront costs, with an expected return on investment based on savings from the mandated efficiency.

Michael Whalen: Increases in energy efficiency are mandated in most adopted codes now. We are seeing impacts and changes in design specifically related to heat reclamation and water reuse, which have become important when considering equipment technologies in new facilities.

What new or updated code, standard, guideline organization or association do you feel will change the way such projects are designed, bid out or built?

Jarron Gass: It wouldn’t surprise me if some nationally recognized independent testing and regulating agencies began to take a more leading role in the development, listing and approval of new and innovative products. They could help create a more streamlined process for incorporating these approved products into adopted codes and standards. The pathway to acceptance and incorporation often lags behind the rapid development of new products, especially in the tech realm.

What are some of the biggest challenges when considering code compliance and designing or working with existing buildings?

Jarron Gass: Retrofitting new protection into existing spaces is complex and presents various challenges. Old construction styles or methods combined with outdated materials can lead to compatibility issues. In fire protection, particularly in storage areas within older buildings, leveraging new protection criteria intended for taller storage poses challenges. Most listings require a flat ceiling, while many older manufacturing facilities have sloped roof constructions like a middle monitor or sawtooth style, which cannot accommodate some of the current listings. These challenges have spurred additional research into this particular topic.

Justin Milne: One of the most significant challenges when working on existing buildings is clearly defining the scope of work. The International Existing Building Code and NFPA 101: Life Safety Code provide guidance on various types of work in existing buildings, including repair, alteration, changes in occupancy, additions and relocations. These works are addressed under the building code for rehabilitation, renovation, modification, reconstruction and in use or occupancy changes. In complex scenarios where both standards are applicable, the components of the fire and life safety design for a building may differ.

For instance, the building code focuses on compliance from a ‘building safety’ perspective, while the life safety code emphasizes ‘life safety.’ This dual approach can result in the incorporation of structural fire-related provisions from the building code and egress provisions from the life safety code into the designs.

A continental structural plastics manufacturing facility and office. Courtesy: Page

Michael Whalen: Bringing existing buildings up to current codes during a design involving a retrofit or change in occupancy presents challenges as many of the codes, specifically related to fire life safety and energy efficiency, have evolved significantly in the past 20 years. It is a balancing act to design around an existing building without making the design and construction so cumbersome that retrofitting the building is no longer cost effective.

Jarron Gass: It wouldn’t surprise me if some nationally recognized independent testing and regulating agencies began to take a more leading role in the development, listing and approval of new and innovative products. They could help create a more streamlined process for incorporating these approved products into adopted codes and standards. The pathway to acceptance and incorporation often lags behind the rapid development of new products, especially in the tech realm.

What are some of the biggest challenges when considering code compliance and designing or working with existing buildings?

Jarron Gass: Retrofitting new protection into existing spaces is complex and presents various challenges. Old construction styles or methods combined with outdated materials can lead to compatibility issues. In fire protection, particularly in storage areas within older buildings, leveraging new protection criteria intended for taller storage poses challenges. Most listings require a flat ceiling, while many older manufacturing facilities have sloped roof constructions like a middle monitor or sawtooth style, which cannot accommodate some of the current listings. These challenges have spurred additional research into this particular topic.

Justin Milne: One of the most significant challenges when working on existing buildings is clearly defining the scope of work. The International Existing Building Code and NFPA 101: Life Safety Code provide guidance on various types of work in existing buildings, including repair, alteration, changes in occupancy, additions and relocations. These works are addressed under the building code for rehabilitation, renovation, modification, reconstruction and in use or occupancy changes. In complex scenarios where both standards are applicable, the components of the fire and life safety design for a building may differ.

For instance, the building code focuses on compliance from a ‘building safety’ perspective, while the life safety code emphasizes ‘life safety.’ This dual approach can result in the incorporation of structural fire-related provisions from the building code and egress provisions from the life safety code into the designs.

Michael Whalen: Bringing existing buildings up to current codes during a design involving a retrofit or change in occupancy presents challenges as many of the codes, specifically related to fire life safety and energy efficiency, have evolved significantly in the past 20 years. It is a balancing act to design around an existing building without making the design and construction so cumbersome that retrofitting the building is no longer cost effective.

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