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Building A Distillery: What is the Process?

The process of building a distillery can be a nebulous concept to wrap one’s mind around. Each licensed design professional (architect/ engineer) has their own process and phases and names for each step. Each project has one-of-a-kind building conditions, site conditions, building and fire regulatory environments. Rather than thinking of this in terms of “Steps 1-5,” it is helpful to think of the project more as a gradient, one step bleeds into the next and into the one after that. This is the first of a 3 part series.

PRE-DESIGN & SITE ANALYSIS PHASE
The Pre-Design & Site Analysis phase includes architectural due diligence, initial site analysis, programming, high-level construction cost analysis, value engineering and project data coordination.

Site Analysis Gather together and obtain all available data, documents and drawings pertinent to the project including prior studies, tests, maintenance records, site surveys, etc. Establish preliminary building and fire code requirements for a tenant distillery in this project.

Programming defines the project needs of the user. Programming includes cataloging the spaces and equipment needed, and functional relationships.

PROGRAMMING OBJECTIVES
Programming defines the needs of the user. That includes defining a project’s functional needs interior and exterior functional requirements including space sizes, contents, activities and spatial relationships. A project program serves as a basis for design and a source of information about a project. The final product of programming is the project program, sometimes referred to as the Detailed Project Program (DPP).

THE PROJECT PROGRAM
The programming process concludes with a clear and orderly statement of the problem. Detailed program information is usually separated from the more general functional data. Project programs establish quality and scope. Quality is often defined abstractly in the project goals and more specifically in the project program. Scope is clearly defined and incorporates the following factors:

The definition of the users and the purpose of the users
The functions of the space and programs of the users
The assigned square feet of the proposed facility
The equipment needed to facilitate the owner’s production plan
Special factors

The Construction Cost Analysis provides a construction budget amount for the capital improvement budget (CIB) and a cost plan to assist in explaining the budget and in guiding project management. This section describes approaches used to establish construction costs for project budgets.

 

SOURCES OF COST INFORMATION
Estimating construction costs typically involves using costs from similar prior projects and applying those costs to the present project, allowing for adjustments in location, scope, construction time period, and other factors.

METHODS OF ESTIMATING COSTS
The following methods are used to estimate construction costs (in order of increasing detail):

Cost per gross square foot. This method uses data about the costs for various building types published by cost information services, or compiled in databases.

Cost by building systems/components. Reference books are available that provide costs on components by building square foot and by square foot of building component.

Cost by building trade or Construction Specifications Institute (CSI) division. This level of estimate is useful at the Construction Documents Phase when enough detail is available on the project to break the various systems into component parts and do an accurate quantity survey similar to that done by contractors who are bidding a project.

Costs based on historical data from Dalkita’s past projects in this and other markets in the U.S.

CONTINGENCIES
Contingencies are normally used with all of the methods of estimating to allow for unknowns. Avoid adding explicit (clearly understood) contingencies on top of implicit (implied) contingencies. The design contingency allows for the fact that projects often contain more elements when they are fully designed than could have been anticipated earlier in the design process. The project contingency is for unknowns during construction. The project contingency allows for unknown factors that could increase construction and related costs beyond the estimate. Project contingency is not the same as the escalation factor – which is the anticipated annual change in percentage for price levels of goods and services.

 

PREPARING THE CONSTRUCTION COST ESTIMATE
Estimating the design cost is done from a written description of what is included in the proposed design. Representative projects can be used as examples. Recommended comparisons are similar projects. By using the list of factors that influence costs and making assumptions about the factors relevant to the proposed project, these factors can be compared to those identified in the examples. A cost for each building component (factor) can be established by adjusting the related cost (e.g., weight of structure and loading) from the representative project to what are the assumed conditions of the proposed project.

COST INDEXING
Projecting historical cost data forward is accomplished by using the index published by Engineering News Record (ENR).

Value Engineering in the pre-design and site analysis phase scrutinizes the program, site selection, and project budget.

Site/ Project Data/ Coordination in this phase provides a framework for gathering the needed distillery information and compiling it for use in later phases. This could include a Short Interval Production Schedule, a Distiller’s Process Description, cut sheets on equipment and furnishings, electrical/ plumbing/ hvac needs etc., compilation of CAD files from outside sources.

Geotechnical Engineering uses principles of soil mechanics and rock mechanics to investigate subsurface conditions and materials; determine the relevant physical/mechanical and chemical properties of these materials; evaluate stability of natural slopes and man-made soil deposits; assess risks posed by site conditions; design earthworks and structure foundations; and monitor site conditions, earthwork and foundation construction.

Land Surveys/ Survey Updates If needed, we will assist in obtaining site boundary, existing physical features (i.e. structures, utilities, rock outcroppings, water courses, trees) and topographical survey, utilities, right-of-ways, property lines, easements, and other tests as required.

Investigation/Confirmation of Existing Site Conditions will be based upon on-site observations and data/information obtained from existing topographical surveys and other available documents. Site parameters deemed noteworthy include boundaries, access and egress routes, traffic/circulation considerations, pedestrian and vehicular conflicts, archeological findings, solar/wind/ geothermal characteristics, utilities, known environmental hazards, setbacks, zoning restrictions and features of site that would impact development costs.

Deliverables from the Pre-Design & Site Analysis phase may include:

  • Organize/restructure CAD files from previous projects to prepare for new project
  • Digital compilation of all relevant survey and historical data for the property relevant to the proposed scope of work
  • Preliminary Code Analysis Document for Tenant Distillery in this building and revisions to Building’s Code Analysis
  • Comprehensive list of technical data/reports that should be conducted or updated
  • Recommendations, negotiation of technical consultants new work or updates
  • Draft of Project Program establishing quality and scope of project
  • Draft of Equipment and Use Requirements
  • Draft of Distiller’s Process Description
  • High-level Construction Cost Analysis
  • Options for potential cost savings on overall project

Building A Distillery: What is the Process? (Part 1)

The process of building a distillery can be a nebulous concept to wrap one’s mind around. Each licensed design professional (architect/ engineer) has their own process and phases and names for each step. Each project has one-of-a-kind building conditions, site conditions, building and fire regulatory environments. Rather than thinking of this in terms of “Steps 1-5,” it is helpful to think of the project more as a gradient, one step bleeds into the next and into the one after that. This is the first of a 4 part series.

PRE-DESIGN & SITE ANALYSIS PHASE

The Pre-Design & Site Analysis phase includes architectural due diligence, initial site analysis, programming, high-level construction cost analysis, value engineering and project data coordination.

Site Analysis Gather together and obtain all available data, documents and drawings pertinent to the project including prior studies, tests, maintenance records, site surveys, etc. Establish preliminary building and fire code requirements for a tenant distillery in this project.

Programming defines the project needs of the user. Programming includes cataloging the spaces and equipment needed, and functional relationships.

A. PROGRAMMING OBJECTIVES
Programming defines the needs of the user. That includes defining a project’s functional needs interior and exterior functional requirements including space sizes, contents, activities and spatial relationships. A project program serves as a basis for design and a source of information about a project. The final product of programming is the project program, sometimes referred to as the Detailed Project Program (DPP).

B. THE PROJECT PROGRAM 
The programming process concludes with a clear and orderly statement of the problem. Detailed program information is usually separated from the more general functional data. Project programs establish quality and scope. Quality is often defined abstractly in the project goals and more specifically in the project program. Scope is clearly defined and incorporates the following factors:

– The definition of the users and the purpose of the users
– The functions of the space and programs of the users
– The assigned square feet of the proposed facility
– The equipment needed to facilitate the owner’s production plan
– Special factors

C. CONSTRUCTION COST ANALYSIS
The Construction Cost Analysis provides a construction budget amount for the capital improvement budget (CIB) and a cost plan to assist in explaining the budget and in guiding project management. This section describes approaches used to establish construction costs for project budgets.

SOURCES OF COST INFORMATION
Estimating construction costs typically involves using costs from similar prior projects and applying those costs to the present project, allowing for adjustments in location, scope, construction time period, and other factors.

METHODS OF ESTIMATING COSTS 
The following methods are used to estimate construction costs (in order of increasing detail):

Cost per gross square foot. This method uses data about the costs for various building types published by cost information services, or compiled in databases.

Cost by building systems/components. Reference books are available that provide costs on components by building square foot and by square foot of building component.

Cost by building trade or Construction Specifications Institute (CSI) division. This level of estimate is useful at the Construction Documents Phase when enough detail is available on the project to break the various systems into component parts and do an accurate quantity survey similar to that done by contractors who are bidding a project.

Costs based on historical data from Dalkita’s past projects in Denver and other markets in the U.S.

CONTINGENCIES
Contingencies are normally used with all of the methods of estimating to allow for unknowns. Avoid adding explicit (clearly understood) contingencies on top of implicit (implied) contingencies. The design contingency allows for the fact that projects often contain more elements when they are fully designed than could have been anticipated earlier in the design process. The project contingency is for unknowns during construction. The project contingency allows for unknown factors that could increase construction and related costs beyond the estimate. Project contingency is not the same as the escalation factor – which is the anticipated annual change in percentage for price levels of goods and services.

PREPARING THE CONSTRUCTION COST ESTIMATE
Estimating the design cost is done from a written description of what is included in the proposed design. Representative projects can be used as examples. Recommended comparisons are similar projects. By using the list of factors that influence costs and making assumptions about the factors relevant to the proposed project, these factors can be compared to those identified in the examples. A cost for each building component (factor) can be established by adjusting the related cost (e.g., weight of structure and loading) from the representative project to what are the assumed conditions of the proposed project.

COST INDEXING
Projecting historical cost data forward is accomplished by using the index published by Engineering News Record (ENR).

D. Value Engineering in the pre-design and site analysis phase scrutinizes the program, site selection, and project budget.

E. Site/ Project Data/ Coordination in this phase provides a framework for gathering the needed distillery information and compiling it for use in later phases. This could include a Short Interval Production Schedule, a Distiller’s Process Description, cut sheets on equipment and furnishings, electrical/ plumbing/ hvac needs etc., compilation of CAD files from outside sources.

F. Geotechnical Engineering uses principles of soil mechanics and rock mechanics to investigate subsurface conditions and materials; determine the relevant physical/mechanical and chemical properties of these materials; evaluate stability of natural slopes and man-made soil deposits; assess risks posed by site conditions; design earthworks and structure foundations; and monitor site conditions, earthwork and foundation construction.

G. Land Surveys/ Survey Updates If needed, we will assist in obtaining site boundary, existing physical features (i.e. structures, utilities, rock outcroppings, water courses, trees) and topographical survey, utilities, right-of-ways, property lines, easements, and other tests as required.

Investigation/Confirmation of Existing Site Conditions will be based upon on-site observations and data/information obtained from existing topographical surveys and other available documents. Site parameters deemed noteworthy include boundaries, access and egress routes, traffic/circulation considerations, pedestrian and vehicular conflicts, archeological findings, solar/wind/ geothermal characteristics, utilities, known environmental hazards, setbacks, zoning restrictions and features of site that would impact development costs.

Deliverables from the Pre-Design & Site Analysis phase may include:

  • Organize/restructure CAD files from previous projects to prepare for new project
  • Digital compilation of all relevant survey and historical data for the property relevant to the proposed scope of work
  • Preliminary Code Analysis Document for Tenant Distillery in this building and revisions to Building’s Code Analysis
  • Comprehensive list of technical data/reports that should be conducted or updated
  • Recommendations, negotiation of technical consultants new work or updates
  • Draft of Project Program establishing quality and scope of project
  • Draft of Equipment and Use Requirements
  • Draft of Distiller’s Process Description
  • High-level Construction Cost Analysis
  • Options for potential cost savings on overall project

Egress!

Egress is defined as “the action of going out of or leaving a place”. 

Egress is a major component of safety features in the building, and has an entire chapter devoted to it in the IBC (International Building Code).

This post will cover some of the main concepts that the code uses to ensure a safe way for occupants to exit a building in case of an emergency, fire, etc…

Occupant Loads

You’ve probably seen a sign posted in some rooms/ buildings saying something like ” no more than 155 persons in the space”. This isn’t an arbitrary number. The code has calculated “occupant load factors” (OLF) for different uses of spaces. Table 1004.1.2 is the place this is found.

For instance, if a space is used as an office, that is calculated at a rate of 100 sf per person. So If you have 1,000 sf office room, the occupant load would be 10 people (1,000/100=10). 

A 1,000 sf room used for a concert type setting with standing room only would be calculated at a different rate of 5 sf per person. That would result in a much higher occupant load of 200 people (1,000/5=200)

Egress Sizing

We use the number of occupants serving a stair or hall to size how wide it needs to be. Stairs use the multiplier or .3 inches per occupant. All other egress components, such as halls and doorways use the multiplier .2 inches per occupant. 

So, for instance, if you have 300 occupants, a total door width of 60″ (300x.2=60) would be required. A space serving this many occupants would certainly need to have at least 2 doors, so (2) 36″ doors would meet the requirement. 

In most cases, a 36″ wide door minimum is required. A 36″ wide stair is the code minimum in most cases. A 36″ wide corridor is the code minimum, but 42″ is more often required for various reasons. 

Number of exits & exiting configuration

The column in the above chart called “maximum occupant load of space” tells use the number of occupants that trigger the need to have more than 1 exit to a space. So, for instance, if you have 48 occupants in an office room, 1 exit is ok. If there’s 52 occupants, you must have 2 separate exits. 

When 2 exits are required from a space, room, or building, they must be separated by 1/3 the diagonal distance of the space, room, or building being served (in a sprinklered building). In an unsprinklered building, they must be separated by 1/2 the diagonal distance of the space, room or building being served. Please see the diagram below. 

http://buildingcodenyc.com/sketches/distance-between-exit-doors/

The Maximum Common Path Of Egress Travel (CPET) is another complex yet important concept. The CPET is the distance that one must travel before reaching a point that they have 2 separate options of paths to take to egress the building. 

So, even if an office room is 40 occupants, but from the most remote corner of the room to the door is over 100′, this one door will not suffice, and a second separate exit must be provided. 

Doors & Everything Else

The code has egress requirements for doors. In many cases, doors must swing in the direction of travel, but in some cases (usually under 50 occupants & depending on occpancy) the doors may swing in. You will usually see inswinging doors into smaller rooms within buildings, but main exterior doors or doors into stairwells will often swing out. 

Emergency egress lighting that turns on during a power loss must be provided along the egress path. These are often attached to exit signs, or also separate. 

Exit signs are an important feature to building egress. They are required in may situations, but there are several exceptions, the main one being that they are not required for rooms or areas needing only 1 exit. 

Theres several other concepts of egress that may apply to your building. Accessibility within the IBC & ADA should also be considered. If there are differences between the 2, the more stringent rule will prevail.  If you’d like to know more, please consult chapter 10 of the IBC, or seek help from a design professional. 

Thanks!

What is the LFL & What does it mean to you?

What is the LFL?

The LFL (Lower Flammable Limit) is a concept related to flammability & fire safety. 

The LFL is defined as :

Usually expressed in volume per cent, is the lower end of the concentration range over which a flammable mixture of gas or vapour in air can be ignited at a given temperature and pressure. The flammability range is delineated by the upper and lower flammability limits. Outside this range of air/vapor mixtures, the mixture can not be ignited…

https://en.wikipedia.org/wiki/Lower_flammable_limit

For ethanol, aka alcohol, the LFL is 3.3% by volume. Meaning, if ratio of ethanol vapor to air is less than 3.3%, the vapor can not ignite. 

This diagram below demonstrates the limits of the LFL of ethanol, as well as the UFL (Upper Flammable Limit). 

Why Does This Matter?

Knowing what the LFL is, and ensuring that flammable vapors, such as ethanol vapors, remain under this limit is a commonly used, well established, and reliable method of ensuring a safe, fire free environment. 

In order to have an alcohol fire, you need:

  1. The Fuel (Alcohol)
  2. Oxygen
  3. Ignition Source (Spark, Heat)

Take away one of these elements, and you can avoid a fire! In this case, we commonly remove the fuel, at least most of the fuel to stay under the LFL!

How do we stay under the LFL?

I’ll get right to it…VENTILATION.
This is the key in keeping under the LFL and keeping safe. If you exhaust out more ethanol vapors than can ever be accumulated and you’ve ensured that the flammable range can never be reached. For most requirements in the codes using the LFL to avoid fires, it usually requires 25% of the (3.3%) LFL. So, for ethanol that would be .825% ethanol vapor in the air. This is essentially a factor of safety.

As shown in the photo below, exhaust is usually achieved via duct, brought to 12″ above the floor, because ethanol vapor is heavier than air, and will settle near the floor. These exhaust ducts may be near any potential ethanol vapor leak, such as near a still (for a possible breach), near tanks, and near barrels. Exhaust is normally powered by an exhaust fan on the roof, and there must be an intake make up air vent to replace the exhausted air. 

 

 

Keeping under the LFL is a very important safety feature in a distillery. It takes a preventative approach of avoiding  a fire in the first place, rather than mitigating a fire after it has occurred. 

Written By:

Matthew Taylor-Rennert

How Many Toilets Are Required In a Building

The IBC (International Building Code) and the IPC (International Plumbing Code) provide prescriptive requirements to calculating the minimum number of plumbing facilities needed in a building, including toilets, sinks, & drinking fountains. 

Calculate Occupant Load

First you need to calculate the number of occupants for a space. The occupant load table in chapter 10 of the building code show the square feet per occupant based on the function of the space. Please see the table below:

So, let go through an example of a bar/ tasting room that is 1,000 SF.

If there is loose, non-fixed furniture, we would use the occupant load factor above of 15 net sf.

The difference between net & gross is that net sf does not include unusable areas such as wall depths, hallways, etc…whereas gross sf includes all areas of the building. If you have a fixed bar in your tasting room, that area can be discounted from the net sf. 

1,000 / 15 = 67 occupants. Simple as that! Of course, these calculations can get much more involved when you begin to have multiple functions of space, etc. Hint… the back of the bar where customers do not go can actually be counted as a business occupancy, which is a different factor of 100 sf per person!

Calculate Minimum Number of Plumbing Fixtures

Now we have determined that we have 67 people. Lets figure out how many bathrooms that equates to. 

We go to Table 2902.1 in the IBC (or Table 403.1 in the IPC) to resolve the minimum plumbing fixtures required. The table takes into consideration the occupancy, and a more descriptive use of the space for these purposes. Check out the chart below:

For a bar, we would simply go with the A-2, Bar category. The Water Closets (Toilets) are required to be 1 fixture per 40 people, of each sex. So, We have 33.5 Males, and 33.5 Females. 33.5/40 is .84, so we are required to have 1 toilet for each sex. In most cases, you are required to have separate facilities for each sex (i.e. a separate mens room and womens room), but there are a few exceptions. If there are less than 15 occupants, a shared bathroom can be used. 

The lavatories (sinks) would be 33.5/75= .45, which would also just round up to 1 sink for each sex. 

The occupant loads and bathrooms can be a critical consideration when designing or remodeling a facility. If you are on the cusp of going over 1 toilet for each sex, that could mean totally different and larger bathrooms. About 80 occupants (40 male and 40 female) would be the threshold to stay under to keep it at 1 toilet for each sex. That translates to approximately 12oo sf for a tasting room area. 

Written By:

Matthew Taylor-Rennert