Are Large-Span Factories Truly Better? Understand It Right to Invest Effectively

When designing modern factories, many businesses tend to choose large spans to create spacious, flexible areas that facilitate production operations. However, a larger span does not always guarantee greater efficiency.

So, is a large span truly better? The following article will help you understand the nature of large spans in factory design and how to invest wisely.

1. What Is a Large Span in Factory Construction?

The span of a factory refers to the distance between two main load-bearing columns, measured horizontally across the structure. In construction, typical spans range from 12 to 24 meters. When the span exceeds 30 meters, the building is considered to have a large span.

Some specialized factories, such as logistics warehouses, exhibition centers, heavy mechanical workshops, or sports halls, can have spans ranging from 36 to 60 meters, requiring advanced structural solutions to ensure safety and cost-effectiveness.

2. Advantages of Large-Span Factories

Large spans offer several significant benefits when applied appropriately:

2.1 Unobstructed Open Space

Large spans create seamless, column-free spaces, ideal for:

• Long production lines and the arrangement of large machinery

• Warehouses storing large volumes of goods

• Easy indoor movement of forklifts and container trucks

2.2 Greater Flexibility in Functional Layout

By eliminating interior columns, the factory space can be easily reconfigured to adapt to changes in production sectors or scale expansion.

2.3 Meeting Modern Industrial Standards

Many large factories require heavy-duty cranes or effective natural lighting and ventilation systems—features that are easier to incorporate with large-span designs.

Learn more: What Is Factory Span? Interesting Facts About Span in Construction

3. Limitations of Large Spans You Should Know

Despite their benefits, large spans also come with several challenges and increased costs, such as:

3.1 Higher Material and Structural Costs

The larger the span, the stronger and more robust the structure needs to be, requiring more high-quality steel and larger quantities overall.
This increases the cost of fabrication, transportation, and installation of large components like trusses and roof beams.

3.2 Higher Technical Requirements

Large-span structures demand experienced design and construction teams with in-depth knowledge of steel structures and accurate load calculations.

3.3 Potential Structural Risks if Not Properly Designed

Poorly optimized large-span designs can result in structural deformation, beam deflection, foundation settlement, or high maintenance costs in the future.

4. When Should You Choose a Large Span for Your Factory?

Not all factories require a large span. The choice should depend on your industry, budget, and usage needs. For example:

• Small parts production and packaging: 12m–18m

• Warehousing and logistics: 24m–30m or more

• Mechanical or automotive assembly plants: 30m–40m

• Exhibition or convention centers: 36m–60m

5. Structural Solutions for Large-Span Factories

To ensure safety and cost-efficiency in large-span designs, engineers often apply modern structural solutions such as:

• Zamil frames or built-up steel trusses: Provide high load-bearing capacity while being lighter than traditional structures

• Space frame roofs: Efficiently distribute loads and reduce roof weight

• High-grade steel materials with high-quality welded and bolted connections

• Properly designed roof and wall bracing systems to ensure overall stability

These solutions must be calculated by professional structural engineers and executed following proper procedures to ensure long-term safety.

6. Conclusion

Large-span factory designs provide flexible space and are well-suited to modern industrial demands. However, applying large spans requires careful planning to avoid waste and structural risks. With the right approach and expert implementation, large-span structures can become a smart, strategic investment for your business.

Learn more: Latest Cost Estimates for Pre-Engineered Buildings

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