diff --git a/README.md b/README.md index e9444e2..8535ea2 100644 --- a/README.md +++ b/README.md @@ -85,6 +85,12 @@ The detail lives in dedicated documents: control, CCTV, whole-factory HVAC (temperature, humidity, PM), archive and audio protection, fire and life safety, plant monitoring, Thai compliance anchors +- [Overhead crane, workshop and visitor corridor](docs/crane-workshop-tours.md): + a 5 t crane over the whole production floor to move machines in and + out, a crane-served maintenance workshop and machine bay at the ramp + end, and a glazed ground-level corridor for guided tours without noise, + dust or plating chemistry; what each changes in the building and what + it costs - [Process logging and traceability](docs/traceability.md): end-to-end per-order traceability for customers, batch genealogy from audio file to shipment, and the requirements this sets for the factory software @@ -151,6 +157,7 @@ docs/ ├── suppliers/ Supplier contacts, vendor landscape, supplier map ├── biomass.md Biomass fuel strategy and the 60 rai coppice idea ├── boi.md BOI promotion strategy and requirements +├── crane-workshop-tours.md Overhead crane, workshop, visitor corridor ├── digital-factory.md Data platform, NixOS/Clan fleet, acquisition, app ├── facility-security.md Security, HVAC, fire and life safety, compliance ├── process-flow.md Audio file to delivered record, with all checks diff --git a/docs/crane-workshop-tours.md b/docs/crane-workshop-tours.md new file mode 100644 index 0000000..05d9b9b --- /dev/null +++ b/docs/crane-workshop-tours.md @@ -0,0 +1,400 @@ +# Overhead Crane, Maintenance Workshop and Visitor Corridor + +Three additions to the building program, decided in October 2026: + +1. **An overhead crane over the whole factory floor**, so machines can be + moved in, out and around without hiring a mobile crane or dragging + them on skates. +2. **A maintenance workshop** with a crane-served service bay, so a + machine can be lifted out of the line and serviced properly instead of + in place. +3. **A glazed visitor corridor at ground level through the factory**, so + guided tours see the whole process without being exposed to noise, + dust or plating chemistry, and without production having to stop or + escort people across the floor. + +They are planned together because they collide with each other and with +the building: the crane decides where walls may go, the workshop sits +where the crane parks, and the corridor runs under the crane runway. +This page states what each one needs, what it changes in the +[construction RFQ](finance/phase1-construction-rfq.md), the +[zone table](scale.md) and [facility security](facility-security.md), and +what is still open. Every figure without a vendor or contractor behind it +is an estimate. + +## 1. Overhead crane + +### What it has to lift + +| Item | Weight | Source | +|---|---|---| +| Newbilt press (HRP 12) | 1,350 kg | [Newbilt Duplex site requirements](equipment/newbilt/) | +| Newbilt extruder | 660 kg | same | +| Newbilt hydraulic aggregate (250 L tank, 50 L accumulator) | 600 kg | same, plus the [budgetary offer](equipment/newbilt/) | +| Pheenix AD12 automated press | **unknown**, ask Pheenix | not in any document yet | +| Galvanics cells, water-treatment evaporator, Sibert machines | unknown, lifted empty | to be asked with each quote | + +**Planning capacity: 5 t safe working load** (estimate). It covers the +heaviest known lift with its lifting beam and slings at a wide margin and +leaves room for the automated presses until Pheenix states their weight. +If the AD12 turns out under about 2.5 t, price a **3.2 t** crane as the +alternative: lighter runway and frame, and possibly a lighter inspection +regime. Thai cranes fall under the Ministry of Labour's 2021 Ministerial +Regulation on machinery, cranes and boilers (the same regulation that +covers the boiler); a crane-industry summary puts cranes above 3 t on an +engineer inspection every three months. Confirm the intervals against the +regulation text before choosing the capacity. + +The crane does **not** serve the outdoor plant. Boiler, chiller, cooling +tower, transformer and the BESS enclosure sit outside the main building +and are set by mobile crane as normal. + +### What kind of crane + +- **Single-girder electric overhead travelling (EOT) crane** spanning the + building's full 25 m width (about 24 m between rail centres), with an + electric wire-rope hoist. This is the default factory crane in the Thai + market, where most bridge cranes are imported from China and installed + by local firms. +- **Inverter drives on hoist and travel** with a slow creep speed, because + the job is setting precision machines on levelling pads, not moving + steel. Radio remote control, so the operator walks beside the load. +- Overload limiter, hoist limit switches, warning horn and light, and + **protected zones** (a standard option on modern crane controls) so the + hook cannot carry a load over the visitor corridor or over enclosed + rooms. +- **Light duty class.** Machine moves are a few a year plus occasional + maintenance lifts, so a light class (around ISO 4301 M3 to M4, estimate) + is enough. +- **Clean running.** The crane travels over a press hall where dust in a + groove is an audible defect: enclosed gearboxes, lubrication-free wheels + and an enclosed conductor rail, and the crane **parks over the + workshop**, not over the presses. + +### What "the whole factory" means in practice + +The runway runs the full length of the **production compartment**, wall +to wall and end to end: press hall, material area, stamper prep, +finishing, the workshop and the machine bay. It stops at the fire wall +that separates production from the finished-goods warehouse +([RFQ §1a](finance/phase1-construction-rfq.md) requires that wall to be +rated EI 60 or EI 120, and a crane cannot run through a fire wall). The +warehouse is forklift territory with no heavy lifts, so nothing is lost. +With a 300 to 500 m² warehouse at the dock end, the runway is roughly 40 +to 48 m of the 60 m building (estimate, set by the warehouse depth). If +the fire strategy ends up without that wall, the runway can run the full +60 m. + +### What it changes in the building + +This is where the cost is, and it has to go into the shell price before +the contractor quotes. The RFQ currently says **"no crane"**. + +1. **Frame designed for crane loads.** Crane brackets or stepped columns, + runway beams and rails along both long walls, end stops, and a frame + sized for the wheel loads and braking forces. In a PEB this is a known + option, but it is a different frame from the one priced so far. +2. **Hook height under the 7.0 m low eave.** The roof falls across the + 25 m width, so the low side governs. With a single-girder hoist the + rail would sit somewhere around 5.5 to 6 m and the hook around 5 m + (estimate; it depends on the haunch depth at the low eave). That is + enough to lift a press and carry it low along a clear aisle, which is + the right way to move a machine anyway, but not to carry it over other + machines or rooms. Ask the contractor for the achievable hook height at + 7.0 m and price **+1.0 m on the low eave as an option**. The option + costs wall cladding and about 10% more conditioned volume, so take it + only if the quoted hook height falls short. +3. **No full-height cross walls inside the crane zone.** A wall across + the building would stop the bridge. Partitions inside the zone stop + below the bridge, and where a load has to pass (press hall to + workshop), the partition has a **full-height opening closed by a + high-speed door**, because the hoist rope comes down from above and + needs a slot all the way up. Separation between zones is then by air + pressure, not by a sealed wall (see the workshop below). +4. **Rooms inside the crane zone are boxes with lids.** Galvanics, stamper + prep and any other enclosed room in the zone are built room-in-room + with their own ceilings below the bridge. Where heavy kit has to go in + (electroforming cells, the water-treatment evaporator), the ceiling + gets a **removable crane hatch**. The bridge passes over the lids; + loads do not (protected zones). +5. **The roof space belongs to the crane first.** HVAC ducts, sprinkler + mains, cable trays and lighting run above the crane envelope or along + the walls, never through the band the bridge travels in. Sprinkler + coverage under the bridge is an item for the fire designer. +6. **Vibration and the cutting room.** The crane runs on the building + frame. Keep the mastering and cutting room outside the crane zone (it + belongs at the quiet front of the building with the offices and + archive anyway), on a slab isolated from the frame columns, and do not + run the crane during a cutting session. + +### Machine door: how machines get in and out + +The vehicle ramp in the RFQ (10.5 m at 1:10, 4.5 m wide) already sits at +the far end of the building, opposite the loading docks. That end gets +the **machine door** and the **machine bay**: + +- An insulated sectional door of about **4.5 m wide × 5.0 m high** + (estimate) with full seals. It opens only for machine moves, a few + times a year, so it does not undermine the airtight envelope the HVAC + and the burning-season PM design depend on; schedule moves outside + February to April where possible. +- The crane runway runs right up to the inside face of the door. +- **Method:** a rigid truck reverses up the ramp and through the door + into the machine bay, and the crane lifts the machine off the bed + inside the building. Three checks for the contractor: the ramp + transitions against the truck's ground clearance, door headroom for the + truck, and the machine-bay slab rated for **truck wheel loads**, which + are point loads and not covered by the 30 kN/m² distributed rating. +- **Fallback:** a truck-mounted crane sets the machine on skates at the + door threshold and the overhead crane takes it from there. + +### Rough cost (estimate) + +| Item | THB | USD | +|---|---|---| +| 5 t × ~24 m single-girder EOT crane, supplied and installed | 1.0M – 2.5M | 30k – 76k | +| Runway beams, rails, end stops, conductor rail, ~2 × 45 m | 0.8M – 1.6M | 24k – 48k | +| Frame premium for crane loads (brackets, heavier columns) | 1.0M – 2.5M | 30k – 76k | +| Machine door and truck-rated slab in the machine bay | 0.4M – 0.9M | 12k – 27k | +| **Crane total** | **~3.2M – 7.5M** | **~97k – 227k** | + +## 2. Maintenance workshop and machine bay + +### Where + +At the ramp end, inside the crane zone, between the machine door and the +press hall. One space does two jobs: + +- **Machine bay**: new machines land here, are unpacked, inspected and + documented before they go to the floor; machines leaving for vendor + repair are crated here. +- **Workshop**: a machine is disconnected, lifted out of the line with + the crane, set down on the service bay and worked on properly, with + tools, light and space around it. + +The crane's parking position is above it, which keeps the idle crane off +the press hall. + +### What is in it + +| Area | Contents | Size (estimate) | +|---|---|---| +| Service bay | Clear crane-served floor for one press-sized machine with about 1.5 m working space all round (a Newbilt press stands on under 1 m², an AD12 on about 3.25 m²); bunded drip-tray floor; 400 V three-phase and 230 V outlets; compressed air drop; task lighting | ~60 m² | +| Bench area | Workbenches and vices, pillar drill, hydraulic hose crimper (the press hydraulics run at 180 to 200 bar and hoses are a routine spare), closed-loop parts washer, mould and platen bench, optionally a small lathe and mill for brackets and one-off parts | ~40 m² | +| Spares store | Lockable, shelved; every part tracked in the factory application (stock, minimum level, which machine it fits) | ~20 – 30 m² | +| Hot-work corner | Welding screen and fume extractor; hot-work permit, because paper, cartons and hydraulic oil share the building | ~10 m² | +| **Total** | | **~100 – 150 m²** | + +**Spares are the uptime lever.** Newbilt service comes from Germany and +Pheenix from Sweden; the northern-dispatch service question in the +[supplier map](suppliers/equipment-suppliers.md) only partly closes that +gap. A press down for a seal or a heater should be back the same day from +the shelf, not after a courier. + +### Keeping the workshop's dirt out of the press hall + +Grinding dust, welding fume and oil mist must not reach the presses. Since +the crane zone rules out a sealed full-height wall (section 1), the +workshop is held at **negative pressure** to the press hall: local +extraction at the welding and grinding positions, an exhaust that keeps +air flowing from the hall into the workshop over the top of the partition +and through the high-speed door, never the other way. The HVAC zoning in +[facility security](facility-security.md) gains the workshop as a zone +below the press hall in the pressure cascade. + +### Oil, waste and water + +- Hydraulic oil drums on spill pallets, spill kits at the service bay, + used oil and oily rags collected by a licensed waste contractor under + DIW manifests. +- **No floor drain.** A dry workshop keeps the zero contaminated water + commitment in [sustainability](sustainability.md) simple: spills are + absorbed and collected, never washed down. + +### Safety + +- **Isolation before lifting.** Before a machine is disconnected: + electrical lockout, steam isolated and vented, and the hydraulics + depressurised, including the aggregate's 50 L gas-loaded accumulator, + which holds pressure after the pump stops. Written lockout/tagout per + machine. +- **A lift plan for every machine move**, a trained crane operator and a + trained slinger, and nobody under the load. +- **Warranty.** Newbilt's offer requires every installation to be + commissioned by an engineer trained on Newbilt machinery, the first one + by Newbilt itself, and ties warranty claims to that. Ask Newbilt in + writing whether lifting a press into the workshop and back counts as a + re-installation during the warranty period. + +### Rough cost (estimate) + +Workshop fit-out (benches, hand and power tools, hose crimper, parts +washer, welding set and fume extractor, shelving, spill equipment, small +machine tools if wanted): **1.0M to 2.5M THB (~30k to 76k USD)**. The +first spares stock sits in the existing working-capital line in +[total investment](finance/total-investment.md). + +## 3. Visitor corridor + +### What it is for + +Guided tours for artists, labels, investors, schools and the public that +show the whole chain from lacquer to packed record, while visitors: + +- hear nothing louder than conversation, so no hearing protection; +- breathe the corridor's own filtered air, never press hall or galvanics + air; +- need **no PPE** at all, which turns a tour from an escorted, kitted-out + floor walk into something that can run several times a day; +- cannot touch anything, distract an operator or bring dust onto the + floor. The glass protects production as much as it protects visitors. + +### Route + +At ground level along **one long wall, the car-park elevation**, which is +where the RFQ already places the main entrance and a second exit at the +far end of the same wall ([RFQ §1b](finance/phase1-construction-rfq.md)). +The tour starts at reception and leaves by the far exit, or loops back. + +Along a wall rather than down the middle, for three reasons: + +- it does not cut the production floor in two, so forklift routes and + crane moves never cross it; +- the strip under the crane runway is where the hook reaches least well + anyway, so the corridor uses the least valuable floor; +- both ends already have exits. + +**Stations follow the process order**, which means the process layout has +to run along the corridor: + +1. Mastering and cutting (window into the cutting room) +2. Galvanics (fixed, sealed window in the clean room wall; no opening, no + shared air) +3. Stamper prep +4. Material lab and PVC handling +5. **Press hall**, the long glazed stretch and the centre of the tour +6. Trimming and 100% optical inspection +7. QC and listening, with a headphone listening point +8. Finishing and packaging, where the records leave production + +Finished goods sit behind the fire wall and are shown from a fire-rated +window or not at all. The concept drawing +[facility-layout.drawio](facility-layout.drawio) predates this corridor +and the detached utility yard and does not yet follow this order; it +needs redrawing at the next layout pass. + +### How it is built + +- **Room-in-room**: a glazed wall on the production side, a solid roof at + about 3.0 m (an acoustic lid and protection from anything dropped), + floor on the slab. +- **Clear width about 2.4 m** (estimate): a group of about 15 with a guide, + and room for a wheelchair to pass. +- **Length about 45 to 55 m**, so roughly **110 to 130 m²** of floor and + **~150 m²** of glazing (estimate). +- **Acoustics.** Press halls typically run 80 to 90 dB(A) near the + presses (to be measured on this plant). Laminated acoustic double + glazing in the Rw 40 to 45 dB class (estimate) brings that down to + roughly 40 to 50 dB(A), so a guide can talk without a headset system. + Seals, penetrations and door gaskets decide whether that is achieved, + more than the glass does. +- **Air.** Its own HVAC zone with filtered supply at slight positive + pressure to the press hall, so any leak runs from the corridor into the + hall. It is the cleanest-air space a visitor enters, which matters in + burning season. +- **Glass safety.** Toughened laminated glass; a kerb or steel barrier on + the production side wherever forklifts run; the crane's protected zone + over the whole corridor. +- **Fire and escape.** The corridor is an escape route with exits at both + ends. Where it runs along a fire compartment wall or the galvanics room, + that stretch of glazing must be fire-rated (EI), which costs several + times standard glazing, so keep those stretches short. +- **Viewing.** Light the production side brighter than the corridor and + use low-reflection glass, or the visitors mostly see themselves. + +### Step-free access is now required + +The building floor sits at **+1.2 m** and the RFQ's only ramp is the 1:10 +vehicle ramp, which it notes is not an accessible gradient and asked to +be told now if a step-free entrance is wanted. Public tours make it a +requirement: a **1:12 ramp at the main entrance**, about 14.4 m of run +for the 1.2 m rise plus intermediate landings, with handrails both sides. + +### Running tours + +- **Visitor screens** at the stations showing live, non-confidential + plant data: a read-only visitor view of the factory application in the + style of the [plant operation page](plant-operation.html), on kiosk + displays wired like the station kiosks. The visitors' own phones stay + on the guest Wi-Fi, which reaches the internet only (VLAN plan in + [digital factory](digital-factory.md)). +- **Confidentiality.** Unreleased artwork and labels are visible on the + floor, and some clients will not want that. Options: schedule tours + around confidential runs, a no-photography rule, or switchable privacy + glass at the label and packaging stations (extra cost, estimate on + request). +- **CCTV notice** at the corridor entrance; footage of visitors falls + under PDPA like staff footage. +- **The tour ends where people can buy records.** A small shop or + pick-up counter at the exit fits the + [artist platform](artist-platform.md) idea of fans collecting their + copy at the plant. +- **Access control.** The corridor is its own zone. No door leads from it + onto the production floor except, if the fire strategy needs one, an + access-controlled staff door. + +### Rough cost (estimate) + +| Item | THB | USD | +|---|---|---| +| Acoustic laminated glazing, ~150 m² at 6,000 – 15,000 THB/m² | 0.9M – 2.3M | 27k – 70k | +| Structure, roof, finishes, HVAC zone, lighting, screens | 1.0M – 2.0M | 30k – 61k | +| 1:12 accessible entrance ramp with landings and handrails | 0.3M – 0.6M | 9k – 18k | +| **Corridor total** | **~2.2M – 4.9M** | **~67k – 148k** | + +## What the three add up to + +| | Area | THB | USD | +|---|---|---|---| +| Overhead crane and machine door | (in the shell) | 3.2M – 7.5M | 97k – 227k | +| Workshop and machine bay | 100 – 150 m² | 1.0M – 2.5M | 30k – 76k | +| Visitor corridor and accessible entrance | 110 – 130 m² | 2.2M – 4.9M | 67k – 148k | +| **Total** | **~210 – 280 m²** | **~6.4M – 14.9M** | **~195k – 450k** | + +All estimates, not yet in the roll-up in +[total investment](finance/total-investment.md); that page lists them as +added scope until the next re-base. + +**On area**: the 1,500 m² phase 1 footprint was already tight for the +zone table in [scale](scale.md). Moving the boiler and chiller into the +detached utility yard freed about 126 m² there, and scale.md left open +whether to shrink the building or grow the program into it. These +additions answer that: the program grows into it. At the lower half of +the zone table everything still fits; at the upper half it does not, and +the release valve is the one scale.md already names, moving finished +goods into the phase 2 building. + +## Changes made elsewhere + +- [Construction RFQ](finance/phase1-construction-rfq.md): frame type + changed from "no crane" to crane-ready, a new section for the crane and + the machine door, the accessible entrance ramp made a requirement. +- [Scale](scale.md): workshop and corridor added to the zone table. +- [Facility security](facility-security.md): visitor management and + access zones updated for corridor tours. +- [Worker safety](worker-safety.md): lifting operations and the workshop. +- [Roadmap](roadmap.md): item 15 (building fit-out). + +## Open decisions + +1. **Crane capacity**: 5 t or 3.2 t, once Pheenix states the AD12 weight + and the inspection intervals are confirmed. +2. **Low eave**: keep 7.0 m or raise to 8.0 m, once the contractor states + the achievable hook height. +3. **Runway length**: stop at the warehouse fire wall (recommended) or run + the full 60 m if the fire strategy drops the wall. +4. **Process layout along the corridor**: the stations above need the + layout redrawn in process order along the car-park elevation. +5. **Fire-rated glazing extent**, from the fire strategy. +6. **Tour policy**: who tours, how often, and the confidentiality rule + for client work on the floor. diff --git a/docs/facility-security.md b/docs/facility-security.md index a30d2a9..9dd0e97 100644 --- a/docs/facility-security.md +++ b/docs/facility-security.md @@ -38,15 +38,20 @@ option per room. - **Access control**: zoned, not just at the gate. Minimum zones: general production, galvanics clean room (controlled access is already a safety requirement), chemical storage, master/stamper archive, server/IT room, - finished goods and shipping. Badge or biometric, with logs. + finished goods and shipping, and the visitor corridor. Badge or + biometric, with logs. - **CCTV**: entrances, perimeter, loading dock, production floor, chemical storage, archive. Retention policy to be defined; Thai PDPA (personal data protection) applies to camera footage of staff and visitors. - **Intrusion alarm** with monitoring, covering off-hours. - **Perimeter and lighting**: fencing appropriate to the site, lit approaches and parking. -- **Visitor management**: sign-in, escort rules, PPE issue at entry, no - unaccompanied access to production or galvanics. +- **Visitor management**: sign-in, escort rules, no unaccompanied access to + production or galvanics. Tours run through the glazed visitor corridor + ([crane, workshop and tours](crane-workshop-tours.md)), which keeps + visitors out of noise, dust and plating air and so needs no PPE; anyone + who goes onto the floor itself is escorted and issued PPE at entry as + before. ## Protecting the irreplaceable diff --git a/docs/finance/phase1-construction-rfq.md b/docs/finance/phase1-construction-rfq.md index 0c16d93..3b35cd3 100644 --- a/docs/finance/phase1-construction-rfq.md +++ b/docs/finance/phase1-construction-rfq.md @@ -14,7 +14,7 @@ zoning is unverified, so this is a budget number, not a bid. | Item | Spec | |---|---| -| Type | Single-storey steel portal frame (PEB), no mezzanine, no crane | +| Type | Single-storey steel portal frame (PEB), no mezzanine, **crane-ready: one 5 t EOT crane runway over the production compartment** (see §1c) | | Footprint | **60 × 25 m = 1,500 m²** | | Roof | Monopitch, **10° pitch**, roof plane **1,523 m²**, low eave **7.0 m**, high side **~11.4 m** (both above finished floor) | | Roof load | Carries a rooftop PV array (~425 modules, ~247 kWp): add **~20 kg/m²** dead load plus wind uplift on racking; PV mounts on the purlins | @@ -22,7 +22,7 @@ zoning is unverified, so this is a budget number, not a bid. | Wall quantities | Masonry/precast dado **170 m perimeter × 2.5 m = 425 m²** (impact, security, washdown), internally insulated so the envelope stays continuous; **sandwich panel above dado ~1,140 m²** | | Floor | **200 mm** ground-bearing slab rated **30 kN/m² UDL**, provision for machine plinths, power-floated finish | | Finished floor level | **+1.2 m above surrounding ground** — see §1b | -| Doors | 2 loading doors (insulated sectional) as **sealed dock positions**: dock shelters/seals plus dock levelers, so the docked trailer acts as the airlock and doors never open to outside air. Personnel entrances with vestibule; fire exits per code | +| Doors | 2 loading doors (insulated sectional) as **sealed dock positions**: dock shelters/seals plus dock levelers, so the docked trailer acts as the airlock and doors never open to outside air. **1 machine door** (~4.5 × 5.0 m insulated sectional, fully sealed) at the ramp end, see §1c. Personnel entrances with vestibule; fire exits per code | | Interior | **Shell only — no internal fit-out** in this price (clean room, offices etc. priced later) | On the slab spec: 30 kN/m² (3 t/m²) is the standard industrial warehouse @@ -93,13 +93,37 @@ Two things deliberately not in the model, to be priced anyway: **handrails** to both sides of every flight and to the ramp, and **door thresholds**. The ramp is 1:10, which suits forklifts and vans but is **not** an -accessible gradient. If a step-free staff entrance is required, that is a -separate 1:12 ramp with intermediate landings — flag it now if wanted. +accessible gradient. **A step-free visitor entrance is now required**: the +plant will run public tours through a glazed visitor corridor (see +[crane, workshop and tours](../crane-workshop-tours.md)). Price a **1:12 +ramp at the main entrance**, about 14.4 m of run for the 1.2 m rise plus +intermediate landings, with handrails both sides. Exit positions are provisional: they are placed for reasonable escape distances on a 60 × 25 m footprint, but final numbers and locations follow the fire strategy and the racking layout, neither of which is fixed. +### 1c. Overhead crane and machine door + +The building must carry an overhead crane for moving machines in, out and +to the maintenance workshop. Background and the reasoning behind each +figure: [crane, workshop and tours](../crane-workshop-tours.md). + +| Item | Spec | +|---|---| +| Crane | Single-girder EOT, **5 t SWL** (3.2 t as an alternative price), span the full building width (~24 m between rail centres), electric wire-rope hoist with inverter drives, radio remote, light duty class | +| Runway | Both long walls, over the **production compartment only**: from the ramp-end wall to the production/warehouse fire wall, **~40 to 48 m** (estimate, set by the warehouse depth). Brackets or stepped columns, runway beams, rails, end stops, enclosed conductor rail | +| Frame | Designed for crane wheel loads and braking forces from day one | +| Hook height | **State the achievable hook height under the 7.0 m low eave.** Price **+1.0 m on the low eave** as an option | +| Machine door | ~**4.5 m wide × 5.0 m high** insulated sectional, fully sealed, at the ramp end; the runway reaches its inside face | +| Machine bay slab | The bay inside the machine door rated for a rigid truck reversing in: **wheel point loads**, not only the 30 kN/m² distributed rating | +| Ramp | Confirm the 10.5 m × 4.5 m 1:10 ramp and its transitions take a rigid truck reversing up to the machine door | + +The crane itself may be quoted by a specialist sub; the runway, frame +premium and machine door belong in the shell price. Inside the crane zone +no wall may run full height across the building; internal partitions are +fit-out and are not in this price. + ## 2. Detached utility yard Simple industrial enclosures beside the main building. @@ -179,6 +203,9 @@ transformer (PEA), and land works beyond normal grading. way. - **Racking height** in the warehouse zone: undecided; drives the fire design, not the shell, but they may ask. +- **Crane**: achievable hook height at the 7.0 m eave, the frame premium + for crane loads, and whether they supply the crane or price a + specialist sub (§1c). - **Permits**: ask whether the price includes permit drawings by a licensed engineer for the building permit and Ror.Ngor. 4 factory license — rough shell prices usually don't. @@ -189,6 +216,8 @@ transformer (PEA), and land works beyond normal grading. above — not the bare-shed spec - Separate rates for **heavy-duty** and **general** paving - A separate rate for **mineral-wool core** panel +- The **crane package** separately: runway and frame premium, machine + door, the crane itself, and the hook height they achieve - A lump figure for the rest of the site works - The foundation/geotech assumption behind all of it diff --git a/docs/finance/total-investment.md b/docs/finance/total-investment.md index dbec7a5..047eea8 100644 --- a/docs/finance/total-investment.md +++ b/docs/finance/total-investment.md @@ -33,6 +33,19 @@ July 2026; the underlying THB estimates are unchanged, because EUR/THB at | Contingency 15% | ~0.6M – 1.2M | ~20M – 38M | | | **Total, full vision** | **~4.7M – 8.9M USD** | **~155M – 294M THB** | | +### Added scope, not yet in the roll-up + +Decided after the roll-up above was compiled; carried here as estimates +until the next re-base folds them into the blocks (the building and +software lines, and the contingency on top). + +| Block | USD | THB | Basis | +|---|---|---|---| +| Overhead crane, runway, frame premium, machine door | 97k – 227k | 3.2M – 7.5M | estimate, [crane, workshop and tours](../crane-workshop-tours.md) | +| Maintenance workshop and machine bay fit-out | 30k – 76k | 1.0M – 2.5M | estimate, same | +| Visitor corridor and accessible entrance | 67k – 148k | 2.2M – 4.9M | estimate, same | +| **Added so far** | **~195k – 450k** | **~6.4M – 14.9M** | about 5 to 6% on the full-vision subtotal | + ## Phased entry A credible launch phase is far smaller, roughly **1.7M to 2.9M USD diff --git a/docs/roadmap.md b/docs/roadmap.md index cc207a4..650699f 100644 --- a/docs/roadmap.md +++ b/docs/roadmap.md @@ -50,8 +50,10 @@ These three run in parallel and gate everything downstream: 9. **Site selection**: candidate buildings/plots in Lamphun and Lampang (Northern Region Industrial Estate first for its shared effluent treatment and licensing simplicity), screened against the - [scale requirements](scale.md): 6 to 8 rai, 1,200 to 1,700 m² single - story, multiple tons per m² slab, 500 to 1,000 kVA connection + [scale requirements](scale.md): 6 to 8 rai, 1,400 to 2,000 m² single + story (including the workshop and visitor corridor), multiple tons per + m² slab, 500 to 1,000 kVA connection, and a frame able to carry an + overhead crane ## Phase 2: Commit (after BOI certificate and validated pricing) @@ -71,7 +73,11 @@ These three run in parallel and gate everything downstream: 15. Building fit-out: slab verification, HVAC, clean zones, utilities, solar and BESS installation, security systems per - [facility-security.md](facility-security.md) + [facility-security.md](facility-security.md), and the overhead crane, + maintenance workshop and visitor corridor per + [crane-workshop-tours.md](crane-workshop-tours.md) (the crane-ready + frame itself is in the construction RFQ, so it is decided before the + shell is ordered) 16. Machinery installation and vendor commissioning (Newbilt on-site commissioning is mandatory for warranty; budget per the service rate card) diff --git a/docs/scale.md b/docs/scale.md index 5c40ac0..46f85c1 100644 --- a/docs/scale.md +++ b/docs/scale.md @@ -54,13 +54,24 @@ running the same machine. | Packaging + finished goods warehouse | ~300 to 500 m² | | Utility rooms (boiler, compressor, chiller, electrical) | ~100 to 150 m² | | Offices, QC/listening, archive, IT, entrance | ~150 to 200 m² | +| Maintenance workshop and machine bay (crane-served) | ~100 to 150 m² | +| Visitor corridor (glazed, ground level) | ~110 to 130 m² | | Circulation, walls, misc | ~150 to 250 m² | -| **Total under roof** | **~1,200 to 1,700 m²** | +| **Total under roof** | **~1,400 to 2,000 m²** | The HVAC budget in the utilities CSV already assumes ~1,500 m² conditioned. Single story throughout: all heavy equipment needs ground-slab floor loading (multiple tons per m²). +The workshop and the visitor corridor were added in October 2026, together +with an overhead crane over the production compartment; what they need and +what they change in the shell is in +[crane, workshop and tours](crane-workshop-tours.md). They add ~210 to +280 m² to a program that already filled the 60 × 25 m footprint, which +settles the open question below in favour of growing the program into the +floor the utility yard frees: at the lower half of the table everything +fits; at the upper half, finished goods move to the phase 2 building. + ### Detached utility yard, parking, and what that moves The massing model puts the boiler and chiller in a **detached utility yard** diff --git a/docs/worker-safety.md b/docs/worker-safety.md index f7acddc..6cdb4d7 100644 --- a/docs/worker-safety.md +++ b/docs/worker-safety.md @@ -16,6 +16,15 @@ commitments: goggles, and process-specific protection) is mandatory per work area, in line with the equipment vendor's site requirements (exhaust work benches, fire protection) and local regulations. +- **Lifting and machine service**: the overhead crane needs trained + operators and slingers, a lift plan for every machine move, and the + periodic engineer inspections Thai law sets for cranes. A machine is + only disconnected and lifted after lockout: electrical isolation, steam + vented, hydraulics depressurised including the accumulator. Welding and + grinding stay in the workshop's hot-work corner under a permit. Detail + in [crane, workshop and tours](crane-workshop-tours.md). +- **Visitors** never share the floor's hazards: tours run in a glazed + corridor with its own air and no PPE requirement. Safety infrastructure (training program, clean-room specification, decontamination workflow) will be planned alongside the equipment, not after