CHAPTER
ONE
INTRODUCTION
1.1
BACKGROUND TO THE STUDY
Paint Factory or
plant is an industrial site, usually consisting of buildings and machinery, or
more commonly a complex having several buildings, where workers process raw
materials into paint.
Factories arose with
the introduction of machinery during the industrial revolution when the capital
and space requirements became too great for cottage industry and workshops.
Paint is a
subdivision of surface coating. It is a relatively opaque solid coating applied
as thin layer whose films are usually formed by polymerization of
polyunsaturated oil. However, other subdivisions of surface coating include:
varnishes (clear coating), enamels (pigmented varnishes), lacquers (film formed
by evaporation only), printing inks and polishes. Paints generally have very
low thermal conductivity, electrically inert and can be washed and cleaned. The
various raw materials for making paints include pigments, vehicle, alkyd
resins, surfactants, solvents (thinners) and colouring matters.
Paints are classified
into two principal types:
Resin based paints
(Gloss finishes) and Latex based paints (Emulsion paints). The major difference
between the two is only in the types of vehicle used and cost.
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Resin based paints
are used for exterior and interior surfaces and are dry to a lustrous or shinny
finish.
Emulsion (Latex)
paint involves the emulsion of 2-phases one of which is water and any other
phase.
Classically, emulsion
is a suspension of one phase in another. Latex paints have as their major film
forming constituent synthetic resin latex with or without other film forming
constituents added in an oil-water emulsion type system. The continuous phase
consists of an alkali – dispersed hydropholic colloid in water and contains two
more different types of particles in suspension, styrene – butadeux (SBR)
copolymer which was the original quality film former in emulsion paint.
Polyvinyl acetate (PVA), acrylic and PVA acrylics copolymers have largely
replaced SBR as film former.
From these, resins
and latex are made objects with a wide range of colours and texture found in
household wares, building materials, electrical and electronic appliances,
automobile and aeronautics, clothing, building structures etc. in short it s
difficult to imagine contemporary society without painting (colours).
Paints are the
material employed as finishing for other materials. They are used to protect
metals, timber and plastered surface from the effect of weather, heat,
moisture, gases etc., thereby improving their appearance. Paints are classified
into oil, water and cement and bituminom paints. There are also special paints
used for special purpose e.g. heat resisting, fire proofing, chlorinated rubber
paint etc.
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Paint factory is
regarded as an important or essential industry in many country because of it
effect and function in the environment. Finally, this project (paint factory)
will help in improving on the face lift of Makurdi as the capital of Benue
State as well as the job opportunities which our teeming youths desire.
1.2
STATEMENT OF ARCHITECTURAL PROBLEM
In an industrial
building of this nature, it is impossible to solve all architectural problems
involved. However, every building has a general architectural problem that has
to be solved towards the realization of the design. But, there are some
specific problems that are unique to individual projects, for example a paint
factory.
Subsequently, the
core problem this project seek to solve is centered on its purpose; a
compromise between man and machine. And this involves a careful flow in the
synthesis of:
o Efficient work flow
o Making a statement
to the society reflecting the mass production nature of the paint factory.
o Advertising the paint
products to the society as well as creating a welcome impact.
o Expressing
orderliness and aesthetic appeal.
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o Creating openness
in plant to give an impression of attractive working conditions, efficient
production and painstaking devotion to the excellence of paint products.
1.3
OBJECTIVES
The principal
objective of this project is to provide an environment capable of meeting the
needs of the people of Makurdi and Nigeria as a whole by providing them with a
well defined paint factory which is ultra-modern and which will meet their
several needs in terms of seeking a solution for good appearance and packaging
of good products.
Other objectives
include:
To create
versatile, adaptable and flexible form for easy expansion with minimum damage.
To provide a good
production layout with no conflict between raw and finished goods and personnel
in circulation.
To create an ideal
factory architecture and to introduce a level of automation in the proposed
paint factory in Nigeria.
Finally, to help in
the state and Federal Government Programme in rural development and this could
be achieved through industrial development.
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1.4
MOTIVATION
Establishing a house
or a commercial space does not stop at having the edifice erected on a piece of
land. This is since you have to make sure that your structure preserves its
excellent condition so that you can enjoy your investment for a long time.
There are many industrial methods that you can do to keep your home or your
workspace in good condition, but one of the most effective steps that you
should take is to have your walls re-applied with the right paint.
For decades now, net
and sprays have been the only effective methods for controlling the mosquitoes
that causes malaria and dengue. I think by introducing the factory, it will lay
more emphasize on protection by inventing a way of embedding pesticide in
microcapsule stirred into house paints. And this insecticide will be realized
slowly from the paint and will remain effective for two to four years, while
spray will be typically re-applied at least every 6 months. The paint will act
like a vaccine for houses and buildings.
The minute amount of
pesticides released from the paint won’t be harmful to people but will be
devastating to insect.
The introduction or
provision of paint factory in Makurdi will help to increase the effectiveness
of other producing industries around e.g.
Most industries
producing steel and aluminum building cladding.
For yatch, small
boats and craft, fishing fleets manufacturers.
For all furniture
and plywood industries
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For most petrochemical
plants-protective coating
For all kinds of
vessels that visit Nigeria port.
For manufacturers
of refrigeration, bicycles, other household articles, drums and industrial
components – powder paints.
For building
industries etc
Therefore, one should
realize that this material is utilized in many industries and that such service
industry should be established for the propagation of other.
Finally, I intend to
increase the awareness of this service industry in Nigeria, and that’s what
prompted my motivation towards proposing this project.
1.5
AIMS
The ultimate aim of
this project is to create, functional, simple, pleasing, economical, orderly,
flexible, safe and convenient industrial building – paint factory.
And to satisfy the
key words of the aims, the following are inevitable:
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To achieve an
effective and efficient design for a factory with a serious view to
flexibility, adaptability and versatility of the building structures. Therefore,
the aim is to realize a purely functional planning with a specific purpose of
smooth and maximum efficient working of the different machineries, the
administration of the complex and the overall production.
To create a system
that will allow personnel; operational and administrative to enjoy efficient
and pleasant working environment.
To provide
efficient circulation system between the individual units of the factory and
within the layout as a whole thereby facilitating easy movement and assemblage
of raw materials and distribution of finished products.
To enhance the
psychology of workers towards efficiency by creating an aesthetical industrial
architecture.
To reflect the use
to which the factory is to be put into which will be in form of an
advertisement for the products.
There will be a
deviation from the old idea which emphasizes much on mass to a modern approach
which gives emphasis on lines and planes (volume).
1.6
SCOPE OF WORK
The factory will
undertake on mass production basis, the manufacture of paints and other paint
products. It will also consist of four major paints of an industrial building;
Research
Manufacturing
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Administration and
Welfare.
The research includes
laboratory and library to investigate and recommend possible way of producing
better products and raw materials.
The manufacturing
section, according to the manufacturing process, include: dispersion, mixing,
sieving and canning.
The administration
comprises of offices, personnel and sales while
The welfare section
includes the factory cline and staff canteen.
Other components
include the maintenance block, staff and visitor’s parking spaces, warehouse
for raw materials and finished products, delivery bays and yards etc.
1.7
RESEARCH METHODOLOGY
To really collect
important information towards the realization of this project and to make an
important contribution to Architecture, some research activities had been carried
out and data collected through;
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Visits to existing
paint factories site of the projects to determine their production processes,
organizational chart and determine the requirement and conditions to be
fulfilled in the setting up of such factory.
Use of libraries,
research institute, books, journals and unpublished manuscript of thesis
reports.
Visits to relevant
Government establishment like the ministry of commerce and industry, for
collection of data, byelaws, history and other important information.
Personal interview
of some people.
Internet.
1.8
LIMITATION OF RESEARCH
Due to the limitation
of standard paint factories in Nigeria, one is limited to researching with only
the small scale private paint factories.
In researching with
the private factories it was discovered that the factories were over protective
of their setting. They feared that their competitors might get hold of
information given out for the research and have a hold over them. Some of them
that co-operated discourage photographs.
Also the fact that
the country is not in peace due to the Boko Haram and other threats, the
factories are conscious and at the same time trying to protect their life and
properties.
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Materials on paint
factories are not much available in libraries, research institutes, records and
documents on paint factories in Nigeria.
1.9
IMPORTANCE OF THE PROJECT
The importance or the
breaks through this project hope to achieve are:
To provide a
comprehensive setting for paint industry in Nigeria in order to help improve
the economy attains technology and industrial independence.
To create job
opportunities for the increasing labour forces.
It will help in
saving foreign exchange by providing goods which would have been purchased
abroad.
1.10
HISTORICAL DEVELOPMENT OF FACTORY
The factory began
with the shop-connected residence as in Ancient Egypt, then the open air
workshops and the home the home industry as in Greece. Then, some specialized
craft and trades like metal smiting, carpentry, pottery, shoe making were home
industry; therefore, operation were in dwelling houses.
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When the need for
expansion began, separate work shed from homes was realized. However, this did
not survive for too long, for with the collapse of the Roman Empire, the
industry reverted to its original dwelling-house status – the gradual
detachment from home only started again with the emergence of the guild system
between the 12th and 15th centuries.
By this period, the
trades men were engaged in producing stained glass, pottery, tapestries and
metal work in great quantities – all operations being carried out in small
shops.
This stage was
followed by the beginning of the 15th century, by the emergence of large city
workshop; derived from the strong influence of the monasteries, and the
basomial manors.
Then came the modern
factory system during the 2nd half of the 18th century. This stage in the factory
evolution was made possible by certain technological inventions like the
Spinning Jenny, Samuel Cromptoris mule in 1779, Edmund Cartwrights power loom
in 1785 and James Watts steam engine, also in 1785. Manufacturing at this stage
developed to much a high level that the whole of Europe was ploughed into the
great industrial Revolution.
The industrial
Revolution with the use of capitation ushered in such keen completion among
early industrialists that some old buildings and other available large spaces
were acquired for loom shops and other industries. This was the period for
birth of industrial architecture from the period of birth to the present day,
Industrial Building Types or Industrial Designs has passed through three main
stages;
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Period of
construction in wood and stone with water power.
Period of
construction in bricks and metal (cast and wrought iron at first, steel later)
with steam power.
And period of
modern construction in reinforced concrete with electricity as a source of
power.
By 1925, this last
phase experienced a new architecture creation – INTERNATIONAL STYLE – which was
first noticed in the industrial designs of Peter Behrens in Germany and Auguste
Perret in France between 1911 and 1924.
These works and most
other modern examples revealed the design philosophy of almost all today’s
meritorious industrial building as an emphasis on lines and planes instead of
mass. Standard design became:
A long rectangular
multi-window structure with a central cupolar or furnace itself.
Large monitors for
interior day lighting.
A possible massing
of all units of an industrial building into one imposing single structure
depending, however on the sizes of the individual units of the complex
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1.11
HISTORY OF PAINT MANUFACTURE
Paint is a thin
protective or decorative coat or a subdivision of surface coating. Painting,
the art of laying colour on a surface, therefore necessitated the development
of paint.
Paint was first
developed in the prehistoric times when the early men recorded most of their
activities in colours on the walls of their caves. These crude paints consisted
of coloured earth or clays suspended in water. However, the use of paint dated
as far back as 1500 B.C. when the earliest paint works discovered in caves of Lascaux,
France, Attemira and Spain were believed to have been done.
The Egyptians artist,
during the early civilization was a paint formulator. He devised his paint
mostly from natural pigments from resins, chalk, tale, clay etc. this could be
regarded as mixture. However, by 1500 B.C. they imported such dies as indigo
and madder to make blue and red pigments. By 1000 B.C. they had developed a
varnish from the gum of Arcacis tree (gum Arabic) which contributed to the
performance of their arts.
Coloured crayon
pigments and clay binder were used in Asia, while before 600 B.C. calcined
mixtures and organic pigments were developed.
Vehicles were
prepared from gum Arabic, eggulute, gelatin and bees max. In our local
traditional architecture, ‘Uri’, ‘Nzu’, cowdung etc. were used to prepare
paints.
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During the medieval
and classical period more specialized form of paint was developed. This is
known as oil paint. The substrate is generally canvas although other surfaces
may be used. The colour consists of concentrated pure pigments ground to a
thixotropic paste in refined or bleached vegetable oil, generally linseed. The
pigments have an influence on the drying rate uniform. This is done by making
the vehicle of a fast-drying colour more saturated oil such as popyseed, and
adding a small fraction or cobalt soap to the blacks and other slow drivers.
The discovery of oil
paints brought a great improvement in the art of painting. The 15th Century
brought with it the knowledge of perspective in which objects could be
represented in three dimensions. In this period, however, and to a more partial
extent even is the earlier classical epoch, efforts were being made to widen
the horizon of painting and to embrace with it the scope of its representations
not only solid objects in themselves, but much objects as a whole in space, in
due relation to each other and to the universe at large.
It was reserved,
however, for the masters of 17th century perfectly to realize this ideal art,
and in their hands painting as an art of representation is widened out of its
fullest possible limits and the whole of nature in all its aspects becomes for
the first time the subject of the picture. The development of painting since
the 17th century gave rise to the modern and more specialized method of paint
production.