Factory contractor for production buildings and capacity expansion
A factory is not a warehouse with machines in it. The machine layout drives the column grid, and utility capacity is calculated from a real equipment list rather than from floor area.
Overview
We build new plants, line expansions, and capacity relocations for manufacturers across Greater Jakarta, Cikarang, Karawang, and Serang. Scope can be full EPC under one contract, or a construction package where a design already exists. The biggest difference between building a factory and building a warehouse is the order of reasoning: we start from the production flow and the equipment list, then derive the structural module, machine foundations, and utility capacity from it. Reversing that order produces a building that has to be partly demolished when the machines arrive.
The decisions that set the cost
Not the floor area. These six are what make two buildings of identical size cost very differently.
| Column grid | Derived from the machine layout and material flow, not the other way round. A column landing in the middle of a production line is an error that cannot be fixed once the structure is up. |
|---|---|
| Machine foundations | Pits, trenches, and machine bases are designed alongside the building foundations so no floor has to be broken out after the pour. |
| Electrical capacity | Calculated from a real machine load schedule with diversity factors, plus headroom for expansion. Estate capacity is confirmed with the operator before it is locked. |
| Process utilities | Compressed air, steam, cooling water, and gases designed through to the machine tie-in point, with a ring main that leaves room for added lines. |
| Process ventilation and extraction | Process exhaust, dust collection, and heat control are dictated by the process, and are often the line item missing from an early budget. |
| Effluent treatment | Wastewater treatment follows the Environmental Approval discharge standard, and often needs pretreatment before entering the estate central plant. |
What the scope covers
The full scope runs as TCC’s eight-phase work sequence. Partial packages are equally workable.
Read the 8-phase sequence What determines the cost- Feasibility study, land zoning verification, and geotechnical investigation
- Layout concept from the production flow, then detailed design across architecture, structure, and MEP
- Full permitting: PBG, UKL-UPL or AMDAL, traffic impact analysis, fire service clearance
- Long-lead procurement: transformers, generators, chillers, steelwork, overhead cranes
- Civil works, machine foundations, concrete and steel structure
- Building envelope, epoxy floors, area marking, and support spaces
- Complete MEP and process utilities through to the machine tie-in point
- Commissioning, integrated testing alongside production machinery, occupancy certification, statutory inspection, handover
Questions we are asked
- How long does a factory take from empty land?
- The two biggest variables are process utility complexity and how quickly the local authority issues the PBG, so there is no answer that holds generally. Permitting and design run in parallel. We build a phase-by-phase schedule in Phase 01, once the equipment list and site conditions are known.
- Can you work in a plant that is still producing?
- Yes, and it is a frequently requested scope in Cikarang and Karawang. The work sequence is built from your production schedule: night windows, weekends, or a planned shutdown. Every activity touching a live system has a written rollback plan before it starts.
- Is production machinery installation included?
- We provide machine foundations, power points, compressed air, water, and drainage per the machine layout, then coordinate with the vendor’s technicians during installation. The machine installation itself stays with the vendor, because the warranty sits there.
Tell us about the project.
Send the outline: location, approximate area, process type, and target production start. We will come back with the questions that need answering before any number means anything.