Revision : Issue 1 Date: 18 March 2014 ASHULIA APPARELS LTD Samad Mansion, Sec # 6, Block # kha, Road No# 1, Plot #14, Shenpara Parbata, Mirpur, Dhaka (23.8065N,90.3683E) 4th March 2014 Client Summary Report Observations & Actions Authors: Sean Barrett, Erick Karla Reviewed by: Dan Moran Approved by: Aidan Madden Category Amber Category Red if actions on page 2 are not addressed and construction above level 6 does not cease immediately 1
Executive summary On Tuesday 4th March 2014 Seán Barrett and Erick Karla carried out a visual structural survey of Ashulia Apparels Limited at the address and coordinates given on the cover page of this report. We met with Mr. Moftahus Sattar Hillol, Managing Director & Mrs. Sadia Afrin, compliance officer and we were provided access to most parts of the building for inspection, with the exception of some areas of ground, level 1 (approx 30% accessible) and level 2 (approx 50% accessible) which were not occupied by Ashulia apparels. The extent of testing carried out was limited to 3 test locations at 1st floor for the same reason. We have important and urgent concerns in relation to the adequacy of the structural support columns for the Building. We also have concerns that the existing load bearing elements have insufficient capacity to safely support additional load which will be imposed by the weight of the current construction of additional floors. Based on this and following our review of the building we raised concern with the factory management in relation to the new construction works. We informed Factory Management that building works should cease. A Detail Engineering Assessment should be carried out and this needs to be addressed immediately. In addition, the column in the north east corner of the building (toilet block area) is highly stressed and the floor build up and walls in this area should be removed or adequately designed propping should be installed. If the above actions are not carried out immediately this report will become Category Red. 2
Executive Summary (Continued) The factory comprises of a single 6 storey building and contains general garment production floors on levels 3, 4 & 5 with retail and office units on ground, level 1 and level 2. Ashulia Apparels has approximately 300 staff and fully occupies the 3 factory floors. Their operations include sewing, cutting & finishing. We understand that the building was constructed as a two storey structure in 1999 and in 2003 the structure was extended to the 4 th floor. Between 2003 and 2013 the 5 th floor was added and gave the building its current height. At the time of inspection construction work had commenced above roof level (6) for a new level 7 floor with columns complete and propped formwork in place for a new concrete floor. In addition we were informed that an 8 th floor is permitted by Rajuk and works will commence shortly. We were presented with copies of Architectural & Engineering drawings for the Building which were not dated. The drawings indicated an 8 storey building. Structural drawings are not consistent with the actual arrangement of the structure. Discrepancies in column reinforcement details were also noted from ferromagnetic scanning at level 1. We were also provided with a copy of a soil investigation report dated 2014 which was prepared for the new vertical extension currently under construction. 3
Executive Summary (Continued) A high level and non exhaustive list of other key concerns are: Toilet Area - High Structural Loading Loading from Water tanks on Roof Drawings not matching existing structure Structural Damage due to water ingress No edge protection at Roof Level At this point we see no reason to suspend operations in the facility due to these concerns, subject to immediate responses to the required actions noted at the end of this report and that no further construction works are carried out which could increase the load on the structure. Further actions with associated priorities and timeframes are given at the end of this report. Please note that these actions should be completed as soon as practically possible and certainly within the timeframe noted. We have reviewed the property from an outline seismic perspective and would consider that the building along with many others in the Dhaka region to have a significant risk in a major Seismic event. Our Limitations and Assumptions are also noted at the end of this report. 4
5 Building Extents
N 5 Storey Garment Factory W E S South Elevation Aerial View 6 Building Extents North Elevation
N S Garments building (6 storeys including Market in ground floor, and offices on level 1 and level 2) 7 Building Extents
It appears that the building was constructed to 3 storeys (to level 3) and then extended in 2003 to 5 Storeys (to level 5) with a further extension to level 6 added since 2003. Construction of a new 7th floor has commenced and we understand that it is intended that an 8th floor will also be constructed. Structural drawings are not consistent with the actual arrangement of the structure 2003-2013 2003 1999 6 5 4 3 2 1 G Planned Future Construction Under Construction Ashulia Apparels Offices & Retail Market Building Extents
9 Structural System
Structural System: R.C. Beam and column frame with a 2- way spanning solid slab Moment frame stability system Pad foundations Column grid 6.48 x 3.9m (varies) Column size 360 x 300 mm (typical) Beam size: 300x610 mm (incl slab) 250x430mm (incl Slab) Slab thickness incl Finish 190 mm Concrete columns contain brick aggregate Floor to floor height 3.05 m Structural system
11 Observations
12 Vertical extension
Construction of new level 7 slab in progress. Outline calculations indicate that column size at lower levels of the building appear to be smaller than required by code for the applied dead and live load, assuming typical concrete strength. To avoid risk of overloading columns, building work on new floor slab should cease immediately and temporary propping and formwork removed immediately. Vertical extension 13
14 Column stresses
Column at lower levels appear to be highly stressed and smaller than required by Design Codes for the applied loading and in excess of safe limits. 1 st floor column exposedconcrete contains brick aggregate Building Engineer to carry out Detail Engineering Assessment including calculations and concrete tests to prove column size and (if required) : Reduce loads further by preparation of allowable floor loading plans Carry out strengthening works Scope of Detail Engineering Assessment to include consideration of 2 scenarios: the existing structure without additional floors Additional Stresses due to the construction of additional floors Column stresses
16 Factory storage and occupancy loads throughout should be limited to maximum of 2.0kN/m2 until a Detail Engineering Assessment and calculated loading plans for the building have been completed (see below) and actively managed to prevent any future overloading Column stresses
17 Structure in Toilet Area North East Corner
Approximately 280mm buildup with masonry wall cubicles in toilet area in Northeast corner observed on levels 3, 4 & 5 (access to Level 1,2 was not possible) Calculations indicate the corner column in this area is highly stressed due to the weight of the floor build-up and walls over 3 levels 18 Structure in Toilet Area North East Corner Toilet area floor buildup and walls to be removed and area to be cordoned off to prevent further loading. Alternatively adequate propping designed by a competent engineer to be installed immediately from level 5 to ground level. Building Engineer to verify the structural capacity of the supporting structure and implement Loading Plans as part of the Detailed Engineering Assessment (see below).
Crack observed in cantilever beam and slab soffit on Level 6 Plaster to be removed for further investigation by Building Engineer. Structure in Toilet Area North East Corner Building Engineer to check cracks in slabs/beam and define a repair system, if required. 19
Unmanaged steam pipes causing corrosion to façade and structure. Northeast Corner Column Location Leaking water from toilet blocks and pipes also visible 20 Structure in Toilet Area North East Corner
21 Water tanks at Level 06 (roof)
2 plastic tanks and one concrete tank mounted on concrete roof slab (level 6). Building Engineer to verify that the support structure (slab, beams, columns) have sufficient capacity to support the applied loads. 22 Water tanks loading
23 As built structure does not match engineering drawings
3 bars each side, 20mm diameter observed by Ferromagnetic scan, 6 bars in total. Design drawing indicates 12 bars. 24 Reinforcement as built does not appear to match Engineers drawings
6.48 2.77 6.43 Additional concrete columns in ground floor and first floor, not indicated on drawings 3.81 3.81 3.56 1.80 3.53 3.94 3.86 25
26 Water ingress and leaking with potential to cause corrosion and lasting damage to roof slab (level 6)
Unmanaged leaking water from the roof causing corrosion to façade and structure in 5 th floor. Moisture Damage 27
28 No edge protection at Roof Level Safety Concern
Unsafe unprotected edge to level 6 roof slab with access to construction and factory staff. Adequate edge protection to be installed on all 4 sides of building level 6 29 Level 6 Edge Protection
30 Priority Actions
Problems Observed 1. High Column Stresses & Vertical Extension 2. Structure in North East Corner (Toilet Area) 3. Loading From Water Tanks at Level 6 4. Drawings not matching Existing 5. Water ingress and leaking with potential to cause corrosion and lasting damage to roof slab (level 6) 6. No edge protection at level 6 31
Item 1 and actions High Column Stresses Priority 1 (Immediate - Now) Priority 2 (within 6-weeks) Priority 3 (within 6-months) Cease all Construction Works above Level 6 Roof Slab immediately Remove all temporary construction propping and formwork All loads to be maintained at or limited to maximum of 2kN/m2 (unless noted otherwise see Item 2) Building Engineer to verify the design, loads and columns stresses at all levels Verify insitu concrete strength either by cores or existing cylinder strength data A Detail Engineering Assessment of Factory to be commenced, see attached Scope Produce and actively manage a loading plan for all floor plates within the factory giving consideration to floor capacity and column capacity. Detail Engineering Assessment to be completed None required. 32
Detail Engineering Assessment This Schedule develops a minimum level of information, Analysis and testing expected as part of a Detail Engineering Assessment. The Building(s) have been visually assessed and it is deemed necessary that a detailed engineering assessment be carried out by a competent Engineering Team employed by the factory Owner. This Request should be read in conjunction with the BUET developed Tripartite Guideline document for Assessment of Structural Integrity of Existing RMG Factory Buildings in Bangladesh (Tripartite Document), the latest version of this document should be referenced. T his document also gives guidance on required competency of Engineering Team. We expect that the following will be carried out: 1. Development of Full Engineering As-Built Drawings showing Structure, loading, elements, dimensions, levels, foundations and framing on Plan, Section and Elevational drawings. 2. The Engineering team are to carry out supporting calculations with a model based design check to assess the safety and serviceability of the building against loading as set out in BNBC-2006, Lower rate provisions can be applied in accordance with the Tripartite Guidelines following international engineering practice, justification for these lower rate provisions must be made. 3. A geotechnical Report describing ground conditions and commenting on foundation systems used/proposed. 4. A report on Engineering tests carried out to justify material strengths and reinforcement content in all key elements studied. 5. Detailed load plans shall be prepared for each level showing current and potential future loading with all key equipment items shown with associated loads. 6. The Engineering team will prepare an assessment report that covers the following: As-Built drawings including Plans at each level calling up and dimensioning all structural components Cross sectional drawings showing structural beams, slabs, floor to floor heights, roof build-ups and Basic design information of the structure Highlight any variation between As-built compared to the designed structure Results of testing for strength and materials Results of geotechnical assessment and testing/investigation Details of loading, inputs and results of computer modelling Commentary on adequacy/inadequacy of elements of the structure Schedule of any required retrofitting required for safety or performance of Structure Any proposals for Retrofitting to follow guidance developed in the Tripartite Document 33
Item 2 and actions Structure in North East Corner (Toilet Area) Priority 1 (Immediate - Now) Priority 2 (within 6-weeks) Priority 3 (within 6-months) Remove all temporary construction works and all loading on level 6 in Northeast corner of building Remove Raised floor and masonry walls from toilet blocks on levels 3, 4 & 5 and cordon off area to restrict loading to 0.5kN/m 2 (50kg/m2) Capacity of corner column to be verified as part of the Detailed Engineering Assessment (Item 1) for loading from floor structure, raised toilet area and partition walls Sections of plaster finish to beams to be removed to investigate if cracks are structurally significant or penetrate the building structure. Building Engineer to prepare Allowable Floor Loading Plans to ensure that the applied loading is actively managed. Building Engineer to issue details of repair works to be completed on the cracked structures. 34
Item 3 and actions Loading From Water Tanks at Level 6 Priority 1 (Immediate - Now) Priority 2 (within 6-weeks) Priority 3 (within 6-months) None Required Verify that slab has sufficient capacity to support fully filled water tanks, if not relocate tanks to areas advised by the Building Engineer following the preparation of the Allowable Floor Loading Plans. None Required 35
Item 4 and actions Structural drawings do not match current arrangement of the structure. Priority 1 (Immediate - Now) Priority 2 (within 6-weeks) Priority 3 (within 6-months) None required Building engineer to check, collect information and produce accurate and complete as-built documentation as part of the detailed engineering assessment (Item 1 above). None required 36
Item 5 and actions Water ingress and leaking with potential to cause corrosion and lasting damage to roof slab. Priority 1 (Immediate - Now) Priority 2 (within 6-weeks) Priority 3 (within 6-months) None required. None required. Engineer to inspect water damaged structure including the exterior and propose and implement a suitable repair. Roof drainage system to be installed. 37
Item 6 and actions No edge protection at level 6 Priority 1 (Immediate - Now) Priority 2 (within 6-weeks) Priority 3 (within 6-months) Install adequate edge protection Barrier, or restrict access to these areas None Required None Required 38
Survey Limitations and Assumptions This report is for the private and confidential use of Accord for whom it was prepared together with their professional advisors as appropriate. It should not be reproduced in whole or in part or relied upon by third parties for any use without the express written permission of Arup. This report can be used in discussion with the supplier or factory owner as a means to rectify or address any observations made. The report is not comprehensive and is limited to what could be observed during a visual inspection of the building. This Report is not intended to be treated as a generalised inspection and does not cover the deterioration of structural members through dampness, fungal or insect attack, nor does it deal with problems and defects of a non-structural nature. Other non structural aspects of the building such as fire safety have not been assessed in this survey. Except as otherwise noted, drains and other services were not viewed or tested during our inspection and are therefore similarly excluded from this Report. We have not inspected any parts of the structure which are covered, unexposed or inaccessible and we are therefore unable to report that any such part of the property is free from defect. External inspection of the façade walls has generally been carried out from ground level only by visual sighting. No opening up works were carried out (except as noted) and we rely on the Architects and Engineers drawings provided to us for our views on concealed parts of the structure and in particular foundations. Strengths of materials and components are untested and we recommend that the factory owners Building Engineer carries out insitu testing over and above those suggested to satisfy themselves with the material strengths and component details. Recommendations, where given, are for the purpose of providing indicative advice only, are not exhaustive, relate solely to identifying key and obvious structural defects as identified in this presentation, and do not take the form of or constitute a specification for works. We take no responsibility for the works as constructed. This report does not interfere with the factory owners Building Engineers responsibility for the structural performance of this building, The Building Engineer remains fully responsible for the structural adequacy of the building. This report does not comment in detail on the future seismic performance of the building and only highlights the fact that the building may experience significant damage or collapse in a seismic event along with many others in the Dhaka region. The observations in this report are based on the Engineering Judgement of the lead surveyor/engineer at the time of the survey. We assume in making these observations that no covering up of faults defects, filling or plastering over cracking or significant repair work has been carried out by the building owner. Any future alteration or additional work by the building owner will void this report. 39