initial structural safety assessmentsfi.fairfactories.org/sfi_dev_files/1/audit_files/britannia...

INITIAL STRUCTURAL SAFETY ASSESSMENT -EXPANSION

Factory Name: Britannia Label (BD) Ltd. (PKG)

Address: Jaigir, Dholla Bazar, Singair, Manikganj ManikganjDhaka Bangladesh

Assessor: Bureau Veritas

Date: 04 May 2015

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The Alliance for Bangladesh Worker Safety /12

Introduction to the Report

The following report contains a site profile and summary of non-conformities identified during an onsite assessment commissioned by theAlliance for Bangladesh Worker Safety (Alliance) and conducted by a third-party Qualified Assessment Firm (QAF). The assessment wasconducted against the Alliance for Bangladesh Worker Safety Assessment Protocols (APs) and Fire Safety and Structural Integrity Standard,which is harmonized with the factory assessment guidelines developed by Bangladesh University of Engineering and Technology (BUET) forthe Bangladesh National Tripartite Plan of Action (NTPA). The goal of the Alliance process is to provide clear and practical technicalrequirements by which Bangladeshi Ready Made Garment (RMG) Factories producing for Alliance members may be consistently and fairlyevaluated for fire, structural, and electrical safety in a non-duplicative manner. Each assessment will prompt action plans that will be used byRMG factories to systematically and sustainably improve safety conditions for garment workers. Beyond tracking and reporting on actionsteps taken in a transparent manner, the Alliance organization and its members will seek to further support factory improvements throughtechnical assistance, training, implementation support for functional Worker Committees, and in some cases financial assistance and wagesupport for workers if factories are closed for remediation.

The contents of the report do not constitute a guarantee of compliance with the applicable laws, the Alliance Standard or the absolute orcontinued safety against fire, electrical and/or structural integrity issues that may lead to injury or loss of life. The report is designed to providea non-exhaustive summary of risk issues, based on a limited sampling and duration of time onsite by the named QAF. Neither the QAF northe Alliance can certify or guarantee the quality, outcome, or effectiveness of actions taken in response to the report.

For more information and report feedback please go to: www.bangladeshworkersafety.org.

FactoryName:

Britannia Label (BD) Ltd. (PKG)

Address: Jaigir, Dholla Bazar, Singair, Manikganj Manikganj Dhaka Bangladesh


Date: 04 May 2015



GENERAL INFORMATION

General Information

Factory Name: Britannia Label (BD) Ltd. (PKG)


Country: Bangladesh

Province: Dhaka

City: Manikganj

Zip Code:

Audit Duration: 7.45 Hours

Re-Audit: Re-Audit After 0 Months

Draft Report Date : 5-May-2015

Final Report Date : 29-June-2015

Are all Action ItemsFrom PreviousAssessmentCompleted?:

N/A

Buildings in Complex : In factory premises there are nine buildings among which two are main production buildings and seven areancillary buildings. Following buildings were in audit scope: 1) Two storied RCC woven label building, & 2)Single storied RCC utility building with occupied roof.

Number of BuildingLevels (Stories) :

1) RCC woven label building: [Storied above grade: 2, stories below grade: 0]; 2) RCC utility building withoccupied roof: [Storied above grade: 2 (G+Occupied roof), stories below grade: 0];

Approximate BuildingArea (SF) :

Total area of building under audit scope: 10807.00 sft; Floor-wise breakdown as follows: 1) Two storied RCCwoven label building: 7497.00 sft, [ Ground floor: 2499.00 sft, First floor: 2499.00 sft, Roof: 2499.00 sft], 2)Single storied RCC utility building with occupied roof: 3310.00 sft, [ Ground floor: 1655.00 sft, Roof: 1655.00sft].

Date of BuildingConstruction :

As per the statement provided by the factory legislative bodies, construction of RCC woven label buildingextended portion of utility were started in September, 2013 and finished in February, 2015.

Date of Last BuildingRenovation/Addition :

Expansion of utility building was done in Feb, 2015;

Is the Building mixeduse?:

No

Ancillary Structures inComplex :

There are seven ancillary buildings in factory premises among which following one was in audit scope: 1)Single storied utility building with occupied roof.

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Date: 04 May 2015



Number of AncillaryLevels (Stories) :

1) RCC utility building with occupied roof: [Storied above grade: 2 (G+Occupied roof), stories below grade: 0];

Approximate AncillaryStructures Area (SF) :

1) Single storied RCC utility building with occupied roof: 3310.00 sft, [ Ground floor: 1655.00 sft, Roof:1655.00 sft].

Number of Occupants : Total number of occupants in buildings under audit scope: 42. Building wise breakdown as follows: 1) Twostoried woven label building: 40 (Ground floor: 10, 1st floor: 30), 2) Single storied RCC generator building withoccupied roof: 02.

Exterior FacadeDescription :

The perimeter facade of the woven label building consists of brick masonry wall. Windows are sliding glass inaluminium frame and main door is open type. Roof is fenced with 3'-6'' long parapet. Two steel stairs havebeen attached with exterior face of this building. Perimeter facade of the utility building also consists of brickmasonry wall. Main door is metallic swinging type.

Structural SystemDescription :

Woven label building is a two storied RCC moment resisting frame structural with monolithic beams and slabs.As per structural drawing, foundation of the building is on "pile foundation". On the other hand, structuralsystem of utility building is same as woven label building. Foundation type of the extended portion is unknown.

Issues were not foundduring the structuralintegrity assessment thatrequired the EmergencyEscalation Protocol (andreferral to NTC ReviewPanel)?:

Yes

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Date: 04 May 2015



ASSESSMENT FINDINGS

Expansion Details

Question: Provide details on the changes and/or expansions that have taken place in thebuilding(s) since the initial inspection. Report new construction, updatednumbers of floors or buildings, etc.

Priority Level:

Non-Compliance Level:

Description: During previous inspection, the building was under construction. As per thestatement provided by the factory legislative bodies, construction of thebuilding was started in Sep, 2013 and finished in Feb, 2015. The building is atwo storied RCC structure named woven label building. By reviewing thestructural design document it has been noted that, the building has beendesigned as five storied RCC building. But, the factory Managing Director hasstated that, so far he has no intention to expand the building in future. Comingto the utility building, it should be mentioned that, 50% of this building wasconstructed before (date of construction is unknown). Then the building wasextended in Feb, 2015. The extended part is connected with the the twostoried woven label building by external stairs.

Source of Findings:

Suggested Plan ofAction:

Suggested DeadlineDate:

Standard:

Structural System Design

Question: Are credible structural design documents available for review and kept on site?

Priority Level: Medium

Non-Compliance Level: 3

Description: 1) Woven Label Building: Approval plan issued from PWD is available on-site.A set of structural drawing is available for review but they are no longer validas the building is constructed by not keeping pace with design documents (i.eexisting column layout, grid No. is not matching with design documents). Nodetail of two external steel stairs and cantilever at south direction are available.These mismatches occurred because the building was constructed beyond theway the building was designed. Design calculation report is available but thisreport is no more valid as the building is constructed beyond its designconsideration. Also, the report is not prepared as per Alliance Standard andBNBC 2006 section 1.9; As-built architectural drawing is available butorientation of toilets at 1st floor (gym room), and window schedule are notmatching with existing condition. 2) Utility building: No structural documents

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Date: 04 May 2015



are available for the extended part of the building.

Source of Findings: Document Review: Documents reviewed on-site


Have a qualified structural engineer prepare credible as-built documentsreinforced by design report based on the requirements of Part 8 Section 8.19of the Alliance Standard.


15 Aug 2015

Standard: Alliance Standard Part 8 Section 8.19 Required Structural Documentation forNew and Existing Factories

Question: Can credible structural documentation indicating general conformance with2006 BNBC or other comparable applicable international model building codebe produced?



Description: Structural general notes indicating code conformance (i.e BNBC 1993, ACI1995 & UBC 1997) are available. But, this statement could not be acceptedwithout design report.



Engage a qualified structural engineer to develop the required documents toconfirm the structural integrity of the buildings. Documents must comply withAlliance Standard Part 8 Section 8.19 and 8.20


15 Aug 2015

Standard: Reference Alliance Standards Part 8 Section 8.2 Structural Integrity of ExistingFactory Buildings

Question: If built after 2006, can documented compliance with the seismic and windrequirements of the 2006 BNBC be provided?



Description: There is no clear indication on design document to clearly understand theconsideration on wind and seismic loading. It should be mentioned that, theavailable structural design documents are no longer valid as the building isconstructed by not keeping pace with design documents (i.e existing columnlayout, grid No. is not matching with design documents).



Have a qualified structural engineer document compliance with the seismicand wind requirements stated in the 2006 BNBC.

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Date: 04 May 2015




15 Aug 2015

Standard: Alliance Standards Part 8 Section 8.17 Design for Lateral Loads and 2006BNBC Part 6 Section 1.5

Question: Can documentation be provided that the building is compliant with therequirements for wind loading and storm surge loadings as detailed in BNBCPart 6 Section 1.5.3?



Description: There is no clear indication on design document to clearly understand theconsideration on wind and seismic loading.



Engage a qualified structural engineer to confirm satisfactory structuralperformance of the buildings under wind loading.


15 Aug 2015

Standard: 2006 BNBC Part 6 Section 1.5. Compliance may be waived if the FactoryOwner provides satisfactory evidence of a cyclone operations plan thatincludes full evacuation of the factory in advance of any approaching cyclone"

Question: If the structure has been previously expanded, was the structural impact onthe entire structure analytically evaluated and confirmed by a qualifiedstructural engineer.



Description: 4'-2'' long cantilever was constructed at south side of the building. Thiscantilever was constructed beyond original construction.

Source of Findings: Document Review: Documents reviewed on-site, Visual Assessment: Visuallyconfirmed


Have a qualified structural engineer complete an analytical evaluation of thestructural impact of the addition.


15 Aug 2015

Standard: Reference Alliance Standards Part 8 Section 8.1 Applicability of BuildingCode.

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Date: 04 May 2015



Question: Have provisions been made in floors or decks for a concentrated load (such asheavy equipment, water tanks, stored materials, etc) applied at a locationwherever this load acting upon an otherwise unloaded floor would producestresses greater than those caused by a uniform load?



Description: Four plastic water tanks having a total capacity of 22000L(10000X2+1000X2)L placed on roof of woven label building. No provisionshave been made for these water tanks. Also, there is a mobile tower placed onroof of utility building. No provisions have been made for this tower also.

Source of Findings: Visual Assessment: Visually confirmed


Engage a qualified structural engineer to confirm and document that provisionshave been made to accommodate concentrated loads. If provisions have notbeen made, have a qualified structural engineer develop a remediation plan.


15 Aug 2015

Standard: Alliance Standard Part 8 Section 8.13 and 8.14

Structural System Construction

Question: Is the structural system free of distress, settlement, shifting, or cracking incolumns or walls?

Priority Level: High


Description: Masonry crack has been observed on wall (east side) at 1st floor of the wovenlabel building.



Have a qualified structural engineer provide further testing and analysis ofcracking in walls and provide a remediation plan to correct noted issues.


15 Aug 2015

Standard: Alliance Standard Part 8 Section 8.3.3

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Date: 04 May 2015



Question: Are all non-structural elements suspended from, attached to, or resting atopthe structure adequately anchored and braced to resist earthquake forces?



Description: 1) Four plastic water tanks having a total capacity of 22000L(10000X2+1000X2)L placed on roof of woven label building. 2) Storage racksat ground floor of woven label building. Mentioned non-structural elements doneed to be braced and anchored.



Adequately anchor and brace all non-structural elements to resist earthquakeforces to comply with the BNBC and Alliance Standard.


15 Aug 2015

Standard: Alliance Standards Part 8 Section 8.18 Seismic Bracing of Key Non-StructuralElements and 2006 BNBC Part 6

Question: Have all areas of needed maintenance, including areas with efflorescence,dampness, standing water on rooftops, and corrosion been addressed.



Description: 1) Standing water has been observed on roof of utility building, 2) Corrosionhas been noted on exposed rebar of roof and on steel angles at stair case(roof level) of woven label building.



As the roof of the building is constructed with MCAC, provide protectivecoating or else provide 2% slope to prevent accumulation of water. In case ofrebar corrosion, provide appropriate anti corrosive coating to avoid futurecorrosion.


15 Aug 2015

Standard: Alliance Standard Part 8 Section 8.26 Durability and Maintenance

Question: Are any structural elements constructed with MCAC exposed to rainfall orother sources of water sealed with a protective coating to prevent waterintrusion?



Description: Roof of both buildings are of MCAC. But no protective sealing is available on

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Date: 04 May 2015



roof surface.



Provide a protective coating at the structural elements constructed with MCACexposed to rainfall or other sources of water. Have protective coatingapproved by the Alliance or a qualified structural engineer.


15 Aug 2015

Standard: Alliance Standards Part 7 Building Materials Section 7.2 Masonry-chipaggregate concrete (MCAC).

Question: Are structural steel members free of corrosion, physical damage or other typesof deterioration?



Description: Corrosion has been noted on steel angles of stair case (roof level) of wovenlabel building.



Complete further testing on areas of deterioration and have a qualifiedstructural engineer develop a remediation plan.


15 Aug 2015

Standard: Alliance Standard Part 8 Section 8.26

Structural Safety Programs

Question: Is a program in place to ensure that the live loads for which a floor or roof is orhas been designed will not be exceeded?



Description: No such program is available.

Source of Findings: Document Review: Confirmed by reviewing the documents


Develop a program to ensure that all live loads for which a floor or roof hasbeen designed for will not be exceeded. The designated Load Manager shalloversee this program and ensure it is enforced.


15 Aug 2015

Standard: Alliance Standard Part 13 Section 13.7 and Part 8 Section 8.9.

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Date: 04 May 2015



Question: Have Load Plans been prepared for each floor documenting the actualmaximum operational loading that is intended and/or allowable on each floor.

Priority Level: Low


Description: No Load Plan is available.

Source of Findings: Document Review: Confirmed by reviewing the documents


Have a qualified structural engineer develop Floor Loading Plans per therequirements of Part 8 Section 8.20.5.3


15 Aug 2015

Standard: Alliance Standard Part 8 Section 8.10 Floor Loading Plans (Load Plans)

Question: Are Floor Load Plans posted as required?

Priority Level: Low


Description: No Load Plan is available.



Have a qualified structural engineer prepare load plans including theinformation required in Section 8.20 of the Alliance Standard. Once prepared,do post the Load Plans in each floor of the building.


15 Aug 2015

Standard: Alliance Standard Part 8 Section 8.20.5.3

Question: Are areas used for storage of work materials and work products, clearlymarked to indicate the acceptable loading limits as described in the Load Planfor that floor?

Priority Level: Low


Description: Neither Load plan available, nor the areas of storage are marked.

Source of Findings: Document Review: Load Plans Unavailable, Visual Assessment: Visuallyconfirmed


Provide signage or the appropriate markings at all areas used for storage toindicate the acceptable loading limits detailed in the Load Plan.


15 Aug 2015

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Standard: Alliance Standard Part 8 Section 8.11 Floor Load Markings

Question: Is a designated representative (Factory Load Manager), who is onsite full time,trained regarding the structural floor capacity, and serves as an ongoingvendor resource and monitor of operational factory floor loadings?

Priority Level: Low


Description: "Mr. Golam Sohan" is the labeled Load Manager. A certificate (to whom it mayconcern) is available, whereas no appointment letter isavailable. Also, notraining certificate is available which will confirm that the person in trained onLoad Management.

Source of Findings: Document Review: Certificate (To Whom it May Concern) is reviewed on-site


Designate a representative as the Factory Load Manager. The Factory Ownershall ensure that at least one individual, the Factory Load Manager who islocated onsite full time at the factory, is trained in calculating operational loadcharacteristics of the specific factory. The Factory Load Manager shall serveas an ongoing resource to RMG vendors and be responsible to ensure that thefactory operational loads do not at any time exceed the factory floor loadinglimits as described on the Floor Loading Plans.


15 Aug 2015

Standard: Alliance Standards Part 8 Section 8.9 Factory Load Manager

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Date: 04 May 2015

