Case Study

BAHIR DAR UNIVERSITY
ILU
DEPARTMENT OF
ARCHITECTURE
COORDINATE DESIGN III

CERAMIC FACTORY
GELILA ZELALEM 0600798 22/03/10 E.C

COORDINATE DESIGN III CERAMIC FACTORY
SITE SELECTION REPORT
OBJECTIVE
We have been working on site selection stage of the design process under the urban part
of the coordinated design course.
The objective of this report is I order to to give clear information about the process and
findings in the site selection and how the final site is selected
This report contains all the steps and decisions that led to the final selected site
1
INTRODUCTION
A ceramic is an inorganic, non-metallic, solid
material comprising metal, non-metal or
metalloid atoms primarily held in ionic and
covalent bonds.
Ceramic engineering is the science and

technology of creating objects from inorganic nonmetallic materials. This is done either by
the action of heat or at lower temperature using precipitation reaction from high purity
chemical solutions. It includes the purification of raw materials, the study and production of
the chemical compounds concerned, their formation into components and the study of their
structure, composition and properties
SITE SELECTION CRIETERIA

 Economical
 Social
 Environmental
 Area of the factory
 Shape of the factory
 Orientation of the factory
no Economical factors Social factors Environmental factors

1 Availability of raw material Size of site Soil type
2 Availability of transportation Future expansion Topography
3 Available water supply Distance Existence of greenery
4 Available electric lines disturbance Wind orientation
5 Available sewage utilities Free zone

6 Available nearby markets
2
ECONOMICAL FACTOR
 Availability of raw material – the existence of materials that are the input to the
production of ceramics
0=bad >5km
1=fair 3km-5km
2=good <3km
 Availability of transportation – transportation system for the raw materials and
products
0=bad No existing system
1=fair 100m
2=good Available within the site
 Available water supply
1=fair 50m
 Available electric lines
1=fair 50m
 Available sewage utilities
1=fair 5om
 Available nearby markets – In order to be economical and the factory become
profitable markets play a major role so in the site should be near to the town
market or to the airport for export purpose or else it can be located in a way that
the town market and the airport can access it easily
0=bad >5km
1=fair 3km-5km
2=good <3km
3
SOCIAL LAND USE FACTORS

 Size of site- for the estimated area of the factory is the site area enough with the
additional area for the expansion or not
0=bad 2000m2
1=fair 40000m2
2=good 50000m2
 Future expansion- the existence of free space that the factory can use its future
expansion
0=bad No space
1=fair 5000m2
2=good 10000m2
 Distance - The distance between the living area to the industry

0=bad Near by
1=fair 500m
2=good 700m
 Disturbance - Area which do not disturb the public area like church airport&
hospitals because of the sound and smoke
0=bad Near by
1=fair 500m
2=good 700m
 Free zone - no existing situation residence or agricultural lands
0=bad Used space

1=fair Small and unplanned settlements
2=good Bare land
4
ENVIROMENTAL FACTORS
 Soil type - Stable Soil type with less construction cost
0=bad Black cotton soil
1=fair Loam soil
2=good Red ash soil
 Topography – the elevation deference for cost effective construction
0=bad >15%
1=fair 10%-12%
2=good <10%
 Existence of greenery - Ceramic industries has an emission of carbon dioxide so a
site with greenery is preferable
0=bad No opportunity for afforestation
1=fair Some greenery with the opportunity of afforestation
2=good High green cover
 Wind orientation - according to smoke emission and the wind direction with respect
to the town
0=bad From factory to town
1=fair Any direction but not factory to town
2=good From town to factory
AREA OF THE INDUSTRY

 In Bahirdar the maximum area given for ceramic industry is 50000 and the minimum
is 20000
 From international case study the total area occupied is from 50 to 60 hectares with
the quarry areas
 So 40000- 50000 is estimated area for ceramic industry
5
SHAPE OF THE INDUSTRY

 Shape mainly depends on the machines and the product levels that means the
industry product is low, medium or high level production.
 The shape of factories in most factories is rectangular since the machine layouts are
placed in linearly
 Rectangle is a shape for maximum space usage and simple to place the machines
since the machines are mostly rectangular in shape
(1.5- 2.5) W
ORIENTATION
 In terms of effects of wind, a ceramic industry should orient besides the direction of
the wind with respect to the living environment
 In terms of the sun orientation industries should orient to the west direction to the
living environment because workers can leave the sun behind while going to work in
the morning and also leave the sun behind in the afternoon returning back home
 Longest side facing north- south for a better ventilation
 The emission of co2 should not be towards the city or the town and should orient to
the greenery
6
INCOMPATABLE LAND USES

 Hospital because of the emission of co2 from the industry hospitals are not
incompatible
 Church and mosque in terms of sound should be located mostly 500m far from
industrial zone
 Residence
 Public space and recreational areas
 School and educational areas and administrative activities (≥200m).
 Grave yards 300m away
 Advisable if it is adjacent to forest land use
BASE MAP
7
SITE SELECTION CRIETERIA RANKING

no Selection criteria’s Criteria in Justification
percent
1 Availability of raw material 18 Resource is the main thing in
the industry process so
selecting a site where there is
available raw material is
necessary. It minimizes the
transportation cost
2 Wind direction 15 Because of smoke and dust
emission of ceramics the wind
direction plays a big role in
selecting a site
3 Availability of transportation 13 Ceramic products are fragile
transportation road should be
safe and comfortable and
must be wide enough for the
raw material excavating
machines
4 Availability of Infrastructure 12 Infrastructures are mandatory
for the industry to work
5 Proximity living area, church.. 10 The distance between the

incompatible land uses should
be as far as possible from the
selected factory
6 Slope 9 Since machines should be
placed or fixed in linearly the
elevation difference should
not exceed the estimated
slope
7 Soil type 8 Industries are big construction
sites so the construction cost
should be considered which
depends on the soil type
8 Existence of greenery 6 If there is a green area it is

an opportunity for the
respiratory system (plants
8
take carbon dioxide from the

factory and gives off oxygen
to the environment)
9 Free zone 5 Free from any existing
buildings
10 Size of site 4 Size of the site should be
compatible with the estimated
area plus has an extra space
for future expansion
Total 100
CRIETERIA MAP
9
10
11
12
13
#1. List of possible outdoor activities inside the industry (your project) and adjacent to the compound
Outdoor activities in the industry(ceramics)
 Parking
 Loading
 Unloading space
 Outdoor siting areas
 Pedestrian movement
 Vehicle circulation
 Shopping
Outdoor spaces adjacent to the compound
 Sport activities
 Farming
 Manufacturing
#2. Prepare compatibility matrix of these activities
Parkin loading unloading Pedestrian Outdoor Vehicle Sport Farming shoppin manufacturing
movement activity g
g siting circulation
areas
Parking x linked connected x x linked x x linked x

loading linked x linked x x x x linked x linked
unloading linked linked x linked x linked x x linked linked
Pedestrian x x x x linked linked linked x X linked
movement
Outdoor x x x linked x linked linked linked X x
siting areas
Vehicle linked linked linked linked linked x x x X linked

circulation
Sport x x x linked x x x x X x
activity
Farming x linked x x x x x x X x
shopping linked x linked linked x x x x X linked
manufacturi x linked linked linked x linked x x linked

ng
14
CASE STUDY
INTRODUCTION
The term ‘ceramics’ (ceramic products) is used for inorganic materials (with possibly some organic content),
made up of non-metallic compounds and made permanent by a firing process. In addition to clay based
materials, today ceramics include a multitude of products with a small fraction of clay or none at all.
Ceramics can be glazed or unglazed, porous or vitrified.
Firing of ceramic bodies induces time-temperature transformation of the constituent minerals, usually into
a mixture of new minerals and glassy phases. Characteristic properties of ceramic products include high
strength, wear resistance, long service life, chemical inertness and nontoxicity, resistance to heat and fire,
(usually) electrical resistance and sometimes also a specific porosity.
Ceramic tiles are thin slabs made from clays and/or other inorganic materials, generally used as
coverings for floors and walls. Ceramic tiles are usually shaped by extrusion or dust pressing at room
temperature, then dried and subsequently fired at temperatures sufficient to develop the required
properties. The most common tile shapes are squares and rectangles, but other polygonal shapes
(hexagons, octagons, etc.) are also available. As for size, tile sides range from only a few centimeters
(mosaics) to slabs with 60 – 100 cm sides. Thickness ranges from around 5 mm for wall tiles to over 25
mm for some extruded tiles. There are several types of ceramic tiles available on the market: shaped
through dust pressing or extrusion; with porous, compact or vitrified bodies; with white (whitish) or colored
(reddish) bodies; unglazed or glazed.
15
CASE STUDY ON KARABEN CERAMICS
Address: Ctra Valencia - Barcelona,Castellón, Spain
Keraben specializes in the design, manufacture and sale of floor and wall ceramic tiles. It has become the
image of a philosophy which has strengthened the company and which marks the difference: the effort to
offer optimum quality, innovative solutions and the latest trends in ceramic decoration. Keraben boasts
one of the largest ranges of ceramic products, adapted to the tastes and needs of the modern consumer.
Its ceramic products include wall and floor tiles of red and white paste, sophisticated polishing and
rectifying wall tiles, technical and glazed porcelains of high technical quality. The company’s modern
facilities are located in one of the main traditional ceramics industry areas, and are equipped with
cutting-edge technology that guarantees the quality and novelty of its products and designs.
The process for manufacturing the tiles takes place at the KERABEN, S.A. factory in Nules (Castellón) and
generally includes the following successive stages:
- Dispensation and wet mixing of the raw materials that will make up the ceramic tile support.
- Atomization of the grinding products to shape the wet powder.
- Pressing to shape the tile support to which the decoration can be applied.
- Decoration (enamel, silkscreen printing).
- Firing.
- Machining (grinding) and resistance test.
- Classification.
- Machining (scraping and meshing).
- Packaging and storage before shipment.
16
The main steps in the manufacture of ceramic products are largely independent of the materials used and
the final product. The following figure schematically shows the typical process and possible or necessary
supply and disposal facilities. The process is made up of the steps: mining/quarrying of raw materials
and transport to the ceramic plant (neither of these two steps is covered in this document), storage of raw
materials, preparation of raw materials, shaping, drying, surface treatment, firing and subsequent
treatment.
17
HOW CERAMIC TILE IS MADE?

At the beginning the clay mixture will be
unloaded, This clay mixture contains just
enough moisture to allow it to keep its shape
after compaction.
Once the clay has been set in place, around

10,000 tons of compression comes down and
forms the actual tile. The bottom die lifts
up and an arm gently pushes all 6 green ware
tiles (green ware = non-fired tile) to the
conveyor heading off to the glazing lines. In
order to keep the delicate green ware tiles
from having to be handled much, the entire
production line moves the tiles in a straight line
from beginning to end.
The first glazing step for all quality tiles is

an engobe coating delivered by a bell or
waterfall application (this is essentially a
primer coat of glaze). Functioning just like a
primer paint, engobe glazes give a clean
white surface that is easy for the more finicky
finishing glazes to adhere.
18
Next it was time to actually decorate the

surface of the tile. For this collection
Keraben uses the Roto-color glaze delivery
system with multiple glaze rollers creating
nearly limitless variation in their stone
reproduction.
As the tiles pass beneath the rollers, each

one gets a different segment of seven
different screens which creates a
very realistic reproduction of natural
stone. Depending on the number of rollers
in the production line, an almost infinite
amount of variation can occur.
Here’s a good look at one of the drums

actually applying the glaze. The lighter
colored stripe in the center of the drum is
the screen, which is in constant motion so
that each tile gets a different segment of
the drum in different areas of the tile.
19
In the bottom right hand of this picture, you can see a

bucket of glaze. Each one of these rollers applied a
different color and screen of glaze creating a deeply
varied pattern on the tile. To keep the frits and
minerals from settling in the glaze, each glaze bucket
is kept in constant motion by a rotating arm (seen
attached to the side of the bucket).
After the tiles have received their glaze, the sides of

the tile are gently brushed to ensure grouts can adhere
to the body of the tile during installation.
In this picture, the tile passes under high-heat lamps to

help dry off the excess water from the glaze before it
gets absorbed into the bisque. This step is so that the
tiles don’t deform or explode in the high heat of the
kiln.
Ones the tile makes it through the glazing lines they

are grouped together and arranged and placed in
massive drying cubes. This is to ensure that as much
moisture as possible is drawn out of the biscuits prior to
firing.
20
Before the kilns is a massive amount of these pre-dried tiles waiting to be fired. The kiln is the most
sensitive and expensive to run, piece of equipment in the factory. They don’t want it to ever have to shut
down or run empty. The recalibration time and resource expense is horrible so a factory will always have
a platoons of tile ready to fire to ensure this doesn’t happen… these cubes-o-tile are moved around the
facility by robotic forklifts.
Finally, the tiles make it to the roller kiln, a massive natural gas powered furnace that bakes the tiles at
temperatures up to 2200 degrees Fahrenheit (1200 degrees Celsius) the white tubes you see there are
industrial porcelain rollers from which the kiln gets its name. They are virtually the same material as is
used to clad the space shuttles as it is the only thing that will withstand prolonged exposure to the white-
hot heat of the kilns.
21
This was most people’s favorite part of the tour because it was the only part that had even a little heat to
it. Even though it looks like you’re staring into the depths of hell there, the amount of heat given off is so
minimal- a testament to the efficiency of a good ceramic kiln. Any heat-loss is wasted energy and
Spanish ceramic production prides itself on its efficiency and environmental responsibility.
This is the sintering point of the kiln, where the feldspar fuses with the sand and clay creating an inert and
immutable ceramic tile. Even at this hottest point in production you can touch the ceramic rollers and they
are merely warm to the touch… usually.
22
PARAMETERS OF STUDY
 Packaging, transport, storage and handling
 Ventilation
 Waste management
 Key environmental issues
 Applied processes and techniques
 Emissions and consumptions
 Reduction of energy consumption (energy efficiency)
 Emissions of dust (particulate matter)
 Process waste water
 General considerations concerning noise
CASE ANALYSIS
PACKAGING, TRANSPORT, STORAGE AND HANDLING
The tiles are distributed on wooden pallets, strapped in packs of no more than 3 units with several points
of adhesive between each one to prevent rubbing. During palletization, 2 blocks must be formed with
cardboard separators between both blocks. Finally, the pallet must be perfectly strapped and
packaged.
The tiles must be placed in the middle of the transport so that they do not move in order to avoid
damage during transport.
The material must be unloaded as near as possible to the place of use in order to avoid unnecessary
carrying. To prevent the deterioration of the surface from rubbing with sharp particles, the tiles must not
be slid along on top of each other, but rather lifted one by one.
The materials must not be knocked about during the loading process or during handling and they must not
be dropped.
Gloves must be worn when handling the tiles during transport and installation.
23
VENTILATION
Regardless of the position of the building front and the type of seals, the ventilation of the front is
guaranteed by the air inlet opening at the bottom of the cladding, lintels and the outlets at the window
sills and finishes at roof level. The amount of the opening for ventilation must be based on the height of
the building:
- minimum: 20 cm2 /ml.
- height h ≤ 3 m: 50 cm2 /ml.
- height 3 < h ≤ 6 m: 65 cm2 /ml.
- height 6 < h ≤ 10 m: 80 cm2 /ml.
- height 10 < h ≤ 18 m: 100 cm2 /ml.
WASTE MANAGMENT
For the intents and purposes of waste management, the tiles will be considered as "inert waste". The
aluminum of the sections must be recycled, including the parts rejected during the 14 set-up and when the
ventilated front system is disassembled.
KEY ENVIRONMENTAL ISSUES
Depending on the specific production processes, plants manufacturing ceramic products cause emissions to
be released into air, water and land (waste). Additionally, the environment can be affected by noise and
unpleasant smells. The type and quantity of air pollution, wastes and waste water depend on different
parameters. These parameters are, e.g. the raw materials used, the auxiliary agents employed, the fuels
used and the production methods:
 emissions to air: particulate matter/dust, soot, gaseous emissions (carbon oxides, nitrogen oxides,
Sulphur oxides, inorganic fluorine and chlorine compounds, organic compounds and heavy metals)
can arise from the manufacture of ceramic products
 emissions to water: process waste water mainly contains mineral components (insoluble particulate
matter) and also further inorganic materials, small quantities of numerous organic materials as
well as some heavy metals
 process losses/waste: process losses originating from the manufacture of ceramic products, mainly
consist of different kinds of sludge, broken ware, used plaster moulds, used sorption agents, solid
residues (dust, ashes) and packaging waste
 energy consumption/CO2 emissions: all sectors of the ceramic industry are energy intensive, as a
key part of the process involves drying followed by firing to temperatures of between 800 and
2000 ºC.
24
APPLIED PROCESSES AND TECHNIQUES
The manufacture of ceramic products takes place in different types of kilns, with a wide range of raw
materials and in numerous shapes, sizes and colors. The general process of manufacturing ceramic
products, however, is rather uniform, besides the fact that for the manufacture of wall and floor tiles,
household ceramics, sanitary ware and technical ceramics often a multiple stage firing process is used.
In general, raw materials are mixed and cast, pressed or extruded into shape. Water is regularly used
for a thorough mixing and shaping. This water is evaporated in dryers and the products are either
placed by hand in the kiln – especially in the case of periodically operated shuttle kilns – or placed onto
carriages that are transferred through continuously operated tunnel or roller hearth kilns. For the
manufacture of expanded clay aggregates, rotary kilns are used.
During firing a very accurate temperature gradient is necessary to ensure that the products obtain the
right treatment. Afterwards controlled cooling is necessary, so that the products release their heat
gradually and preserve their ceramic structure. Then the products are packaged and stored for delivery.
EMISSIONS AND CONSUMPTIONS
Emissions
The processing of clays and other ceramic raw materials inevitably leads to dust formation – especially in
the case of dry materials. Drying, (including spray drying), comminution (grinding, milling), screening,
mixing and conveying can all result in a release of fine dust. Some dust also forms during the decorating
and firing of the ware, and during the machining or finishing operations on the fired ware. Dust emissions
are not only derived from the raw materials as described above, but also the fuels contribute to these
emissions to air.
The gaseous compounds released during drying and firing are mainly derived from the raw materials,
but fuels also contribute gaseous pollutants. In particular, these are SOX, NOX, HF, HCl, VOC and heavy
metals.
Process waste water is generated mainly when clay materials are flushed out and suspended in flowing
water during the manufacturing process and equipment cleaning, but emissions to water also occur during
the operation of wet off-gas scrubbers. The water added directly to ceramic body mixes is subsequently
evaporated into the air during the drying and firing stages.
Process losses can often be recycled and re-used within the plant due to product specifications or process
requirements. Materials, which cannot be recycled internally, leave the plant to be used in other industries
or to be supplied to external waste recycling or waste disposal facilities.
25
Consumptions
The primary energy use in ceramic manufacturing is for kiln firing and, in many processes, drying of
intermediates or shaped ware is also energy intensive.
Water is used in virtually all ceramic processes and good quality water is essential for the preparation
of clays and glaze slips, clay bodies for extrusion, ‘muds’ for molding, preparation of spray dried
powders, wet grinding/milling and washing or cleaning operations.
A vast range of raw materials is consumed by the ceramic industry. These include the main body forming
materials, involving high tonnages, and various additives, binders and decorative surface-applied
materials which are used on a lesser scale.
REDUCTION OF ENERGY CONSUMPTION (ENERGY EFFICIENCY)
The choices of energy source, firing technique and heat recovery method are central to the design of the
kiln and are also some of the most important factors affecting the environmental performance and
energy efficiency of the manufacturing process. The main techniques for reducing energy usage, which
can be applied individually or in combination, are listed below
 improved design of kilns and dryers

 recovery of excess heat from kilns
 cogeneration/combined heat and power plants
 substitution of heavy fuel oil and solid fuels by low emission fuels
 modification of ceramic bodies.
EMISSIONS OF DUST (PARTICULATE MATTER)
To prevent diffuse and channeled dust emissions, several different measures are presented here, which
can be applied individually or in combination:
 enclosure of dusty operations, such as grinding, screening and mixing

 the use of covered and vented trough or pan mixers
 filtration of air displaced whilst charging mixers or dosing equipment
 storage silos with adequate capacity, level indicators with cut out switches and with filters to deal
with dust-bearing air displaced during filling operations
 covered conveyor belts for potentially dusty raw materials
 a circulation process is favored for pneumatic conveying systems
 material handling in closed systems maintained under negative pressure and de-dusting of the
suction air
 reduction of air leakage and spillage points, completion of installation.
26
Gaseous compounds
To prevent emissions of gaseous air pollutants (in particular SOXx, NOXx, HF, HCl, VOC), primary and
secondary measures/techniques are described, which can be applied individually or in combination.
These are:
 reduction of pollutant precursor input

 addition of calcium rich additives
 process optimization
 sorption plants (absorbers, absorbers)
 afterburning.
PROCESS WASTE WATER
Minimizing water consumption is fundamental, and to achieve this reduction, the following process
optimization measures can be implemented:
 acting on the water circuit, installing automatic valves that prevent leaks of water when it is no
longer needed
 installation of a high pressure system in the plant for cleaning purposes (or high pressure cleaning
equipment)
 switching from wet off-gas cleaning systems to alternative, non-water consuming systems
 installation of ‘in-situ’ waste glaze collection systems
 installation of slip conveying piping systems
 separate collection of process waste water streams from different process steps
 re-use of process waste water in the same process step, in particular repeated re-use of the
cleaning water after suitable treatment.
GENERAL CONSIDERATIONS CONCERNING NOISE
 enclosure of units
 vibration insulation of units
 using silencers and slow rotating fans
 situating windows, gates and noisy units away from neighbors
 sound insulation of windows and walls
 closing windows and gates
 carrying out noisy (outdoor) activities only during the day
 good maintenance of the plant.
27
CONCLUSION
Basic features in a Ceramic industry-are store, spaces for Preparation of raw

material, shaping, drying, Surface treatment, firing, packaging, store and Electric
power station. In addition to spaces Packaging, transport, storage and handling,
Ventilation systems, Waste management systems, Key environmental issues and
considerations, applied processes and techniques for the Emissions and
consumptions, Process waste water, General considerations concerning noise and
consideration for Emissions of dust (particulate matter) and measures for this issues
should be considered.
28
REFERENCE
www.wikipedia.com
www.archdaily.com
www.cer_bref_0807.pdf
www.lifeofanarchitect.com
29
PROGRAM OF ACCOMODATION
General classifications
 Outdoor
 Manufacturing
 Administration
 Residence
 Other facilities
NO Main Purpose/function Standard or Quantity Total Floor Remark

activities of space estimated Area( m2)
value /
vehicle or
person
OUTDOOR
1 Entrance Vehicle 2.5 m/ vehicle 2 For all 35%
program circulation
Pedestrian > 2m/person 2 truck
2 Security Bath room 1.2m*2m 2 4.8
Shower 1.2m*1m 2 2.4
case team 3*3 1 9
shift leader 3*3 1 9
patrolling tower 3*2 8 48
3 Vehicle Loading & 35*4 4 560
activity unloading
Service parking 24*4 10 960
automobile 8.5*2.3 50 1000
parking
Truck parking 38*4 10 1520
Weight 22*4 1 88
measurement
car washing 22*4 2 176
4 Recreation Foot ball 90*73 1 6570
Basket ball 22*44 1 960
Swimming pool 25*17 1 425
Sitting area 1.20*0.6 0.72
5 Green area shade 40%of the
total site =
buffer zone 3000
road side
TOTAL AREA 15332.92+4316.5=
19650
30
MANUFACTURING
1 Store raw material 50*50 1 2500
2 Preparation of 1 80
raw material Mixer 4*10
crusher 6*15 1 90
3 Underground Slurry mix is 20*20 1 400
storage tank stored
4 shaping High 12*4 1 48

pressure
hydraulics
press
machine
5 drying Atomizer 10*4 1 40
machine
5 Storage of 10*10 1 100

Storage bins unfinished
ceramic tiles
6 Glaze 4*9 36
Surface preparation
treatment Glazing and 12*3 1 36
screening
machine
7 Giving the 5*6 1 30
brushing sides an
edge
8 High heat Extract 3*8 1 24
lamp drying moisture
9 12*10 1 120
Drying cubes
10 Firing final 15*6 1 90

Final kiln moisture
extraction
11 Tag and 6*4 1 24

packaging branding
31
12 Product 50*50 1 2500

store store
13 6*8 1 48
Laboratory
14 5*4 1 20
Design group
15 AC 15*12 1 180
16 Electric power generator 15* 20 1 300

station
transformer 6*10 1 60
TOTAL AREA 6726+2354=9080
ADMINISTRATION
1 Office reception 3*4 1 12
and
waiting
manager 4*5 1 20
assistant 3*5 1 15
manager
finance 5*6 1 30
support
human 5*6 1 30
resource
record and 6*8 1 48
file
public r/n 5*6 1 30
head
marketing 5*6 1 20
conference 10*6 60
toilet 1.2*2 4 9.6
2 Manufacturing case team 3*4 1 12
office
shift 3*4 1 12
controller
mechanical 3*4 1 12
electrical 3*4 1 12
toilet 1.2*2 2 4.8
32
3 Training room Training 15*30 1 450

workers
4 clinic reception 3*4 1 12

waiting 5*6 1 30
room
doctor 3*4 2 24
consult
examination 3*4 2 24
emergency 3*4 2 12
laboratory 3*4 1 12
bedroom 3*3 3 27
5 Lounge cafeteria 2.4*2.4/4p 250 360

erson
kitchen 5*6 1 30
store 5*4 1 20
bath room 90*250cm 6 13.5
Shop 3*3 1 9
6 Changing locker 0.5 400-500 200-250
room
shower 1.2*1 10 12
7 toilet men 10 flush 2 54

10 urinal
3 basin
Total=27m2
women 10 flush 2 50
3 basin
Total=25m2
TOTAL AREA 1717+600=2317
RESIDENCE
1 apartment 3 bed 110 20 2200
2 bed 90 30 2700
1 bed 78 40 3120
studio 40 30 1200
2 recreation Green area
33
Infant day 10*10 1 100

care
Kindergarte 15*10 1 150
n
Library 15*10 1 150
Meeting 20*15 1 300
space
Game room 8*10 1 80
Library 8*10 1 80
3 shops Super 8*12 1 96
market
Beauty salon 4*5 1 20
Cafeteria 5*8 1 40
Gymnasium 10*10 1 100
TOTAL AREA 10336+3617=13953

OTHER FACILITIES
1 Facilities of Napping 6*8 2 96
rest
Relaxing 6*8 1 48
2 Fire Emergency 12*8 1 96

extinguisher fire control
and control Store 8*10 1 80
room
3 Water supply Incoming 20*20 1 400
water tanker
Pumping 4*4 1 16
house
Water 12*20 1 240
treatment
Tape water 20*20 1 400
tanker
4 Waste Septic tank 40*40 1 1600
disposal
Sewer line
system
Controlling 3*4 12
unit
Solid disposal Trash can 100m
distance
Temporary 3*5 15
store
5 Generator Backup 20*20 1 400

rooms and generators
34
power supply Power 5*6 1 30

tools controlling
unit
6 General store Spare part 15*20 1 300
chemical 15*10 1 150

store
Old 15*20 1 300

materials
7 Recycling Water 30*30 1 900
processing
Sludge 30*40 1 1200
processing
TOTAL AREA 6283+2200=8482
TOTAL AREA 8482+13953+2317+9080+19650=53482
8482+13953+2317+9080+19650=53482
35
CONCEPT DEVELOPMENT
Ceramic tile is one of the oldest building materials. Its production is probably one of the most
interesting transformations of a natural material into a dynamic building material. Starting out as a
powdery substance, as it gets exposed and moved to different conditions within the
manufacturing process, it becomes a solid product.
This is the essence of the design for the Ceramic Tiles. A story about a solid product and its
manufacturing process told in a visual exhibition through abstractions of various tile installations and
techniques.
To achieve optimal view of the use of ceramic tile on the floor, the design introduces a sloping surface,
where the floor becomes a hybrid floor-wall, that leverages two important things: The ceramic floor
tiles can be viewed as one walks through the tramway approaching the pavilion. The inclined surface
gives an instant snapshot of the tile instead of having to stand directly above the tile to view it. It
also leads the eye to the information desk directly behind it. It serves as a way to showcase the
Ceramic Tiles of Italy logo through visual layering. The logo is “experienced” rather than “viewed”
because as one approaches the pavilion, the casual observer’s eyes are directed from the series of red
square tiles that seemingly move. At the center of the incline is a square hole that when viewed from
the tramway, produces a red square from the wall behind it. The whole sloping installation
then becomes a unique and eye-catching exhibit piece that expresses the abstraction of the
“movement of tile” during a manufacturing process. The underside of the slope is expressed, exposing
the concept of the “clip tile” installation. The idea of “movement in the tile manufacturing process” is
then continued on the west side of the pavilion through the introduction of a visually connected flow
of tiles from the floor that extend to the wall. This wall will showcase a segment of a ventilated facade
system. It can also be.viewed by people while waiting in line at the food serving area.
36
The restaurant/cafe food service area allows for the continues flow of people forming separate lines
for food service and another line for coffee service. The walls forming this area will be clad in tiles
that have been image-printed with pictures showing the tile manufacturing process of member
companies within Ceramic Tiles of Italy. It becomes a retrospective in itself, that is meant to be viewed
and become conversational pieces while people wait in line at the food/coffee service area during peak
hours. Each element in the space then ties in with the bigger picture of the pavilion showing vignettes
of a story on how the tile came to be.
37

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BAHIR DAR UNIVERSITY

COORDINATE DESIGN III

GELILA ZELALEM 0600798 22/03/10 E.C

SITE SELECTION REPORT

Ceramic engineering is the science and

SITE SELECTION CRIETERIA

no Economical factors Social factors Environmental factors

2 Availability of transportation Future expansion Topography

3 Available water supply Distance Existence of greenery

4 Available electric lines disturbance Wind orientation

5 Available sewage utilities Free zone

SOCIAL LAND USE FACTORS

 Distance - The distance between the living area to the industry

0=bad Used space

AREA OF THE INDUSTRY

SHAPE OF THE INDUSTRY

INCOMPATABLE LAND USES

SITE SELECTION CRIETERIA RANKING

5 Proximity living area, church.. 10 The distance between the

8 Existence of greenery 6 If there is a green area it is

take carbon dioxide from the

#2. Prepare compatibility matrix of these activities

Parking x linked connected x x linked x x linked x

Vehicle linked linked linked linked linked x x x X linked

shopping linked x linked linked x x x x X linked

manufacturi x linked linked linked x linked x x linked

CASE STUDY ON KARABEN CERAMICS

Address: Ctra Valencia - Barcelona,Castellón, Spain

HOW CERAMIC TILE IS MADE?

Once the clay has been set in place, around

The first glazing step for all quality tiles is

Next it was time to actually decorate the

As the tiles pass beneath the rollers, each

Here’s a good look at one of the drums

In the bottom right hand of this picture, you can see a

After the tiles have received their glaze, the sides of

In this picture, the tile passes under high-heat lamps to

Ones the tile makes it through the glazing lines they

 Key environmental issues

 Applied processes and techniques

 Emissions and consumptions

 Reduction of energy consumption (energy efficiency)

 Emissions of dust (particulate matter)

 Process waste water

 General considerations concerning noise

KEY ENVIRONMENTAL ISSUES

APPLIED PROCESSES AND TECHNIQUES

EMISSIONS AND CONSUMPTIONS

REDUCTION OF ENERGY CONSUMPTION (ENERGY EFFICIENCY)

 improved design of kilns and dryers

EMISSIONS OF DUST (PARTICULATE MATTER)

 enclosure of dusty operations, such as grinding, screening and mixing

 reduction of pollutant precursor input

PROCESS WASTE WATER

GENERAL CONSIDERATIONS CONCERNING NOISE

Basic features in a Ceramic industry-are store, spaces for Preparation of raw

NO Main Purpose/function Standard or Quantity Total Floor Remark

4 shaping High 12*4 1 48

5 Storage of 10*10 1 100

10 Firing final 15*6 1 90

11 Tag and 6*4 1 24

12 Product 50*50 1 2500

16 Electric power generator 15* 20 1 300