INITIAL STRUCTURAL INTEGRITY ASSESSMENT REPORT (SIAR)

Transcription

1 INITIAL STRUCTURAL INTEGRITY ASSESSMENT REPORT (SIAR) Factory Address: 50, New Chaktai (4th & 5th Floor), Haji Delware Hosen Sowdagar Market, Chittagong Chittagong Chittagong Bangladesh 05 May 2014 The Alliance for Bangladesh Worker Safety Page 1/15

2 05 May 2014 Introduction to the Report The following report contains a site profile and summary of non-conformities identified during an onsite assessment commissioned by the Alliance for Bangladesh Worker Safety (Alliance) and conducted by a third-party Qualified Assessment Firm (QAF). The assessment was conducted 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) for the Bangladesh National Tripartite Plan of Action (NTPA). The goal of the Alliance process is to provide clear and practical technical requirements by which Bangladeshi Ready Made Garment (RMG) Factories producing for Alliance members may be consistently and fairly evaluated for fire, structural, and electrical safety in a non-duplicative manner. Each assessment will prompt action plans that will be used by RMG factories to systematically and sustainably improve safety conditions for garment workers. Beyond tracking and reporting on action steps taken in a transparent manner, the Alliance organization and its members will seek to further support factory improvements through technical assistance, training, implementation support for functional Worker Committees, and in some cases financial assistance and wage support 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 or continued safety against fire, electrical and/or structural integrity issues that may lead to injury or loss of life. The report is designed to provide a non-exhaustive summary of risk issues, based on a limited sampling and duration of time onsite by the named QAF. Neither the QAF nor the 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: The Alliance for Bangladesh Worker Safety Page 2/15

3 05 May 2014 GENERAL INFORMATION General Information Factory Address: Country: Province: City: 50, New Chaktai (4th & 5th Floor), Haji Delware Hosen Sowdagar Market, Chittagong Chittagong Chittagong Bangladesh Bangladesh Chittagong Chittagong Zip Code: Audit Duration: Re-Audit: 1 Days Re-Audit After 0 Months Draft Report Date : July 1, 2014 Final Report Date : September 12, 2014 Are all Action Items From Previous Assessment Completed?: Buildings in Complex : Number of Building Levels (Stories) : Approximate Building Area (SF) : Date of Building Construction : Date of Last Building Renovation/Addition : Is the Building mixed use?: Ancillary Structures in Complex : Number of Ancillary Levels (Stories) : No 1 Main Building 6 (Ground + 5) 8,837 SF 1997 None Yes None NA The Alliance for Bangladesh Worker Safety Page 3/15

4 05 May 2014 Approximate Ancillary Structures Area (SF) : Number of Occupants : Exterior Facade Description : Structural System Description : Issues were not found during the structural integrity assessment that required the Emergency Escalation Protocol (and referral to NTC Review Panel)?: NA 780 Total 5" brick masonry infill wall with standard windows (glass & steel) RCC frame (Column & Beam) structure with monolithic 5" slab and 5" brick wall and telecommunication guy supported tower. No The Alliance for Bangladesh Worker Safety Page 4/15

5 05 May 2014 ASSESSMENT FINDINGS Structural System Design Has evidence of structural integrity been provided using a Preliminary Structural Assessment? High The following are the findings of the Review Panel: Columns of eastern and western grid over-stressed. There are unapproved & undocumented cantilevers at 02 sides (East & West) of the building. There are undocumented and unapproved Cell tow Uploaded Document: Review panel report. Based on the Review Panel investigation, the following recommendations are made by the Panel and should be implemented by the factory: 1. Proper 'Propping' on both Eastern and Western part of the building (areas shown in the attached drawing) up to Reference Alliance Standards Part 8 Section 8.2 Structural Integrity of Existing Factory Buildings Are the available FoS for the columns adequate based on Preliminary calculation? High 42psf Central 1.74 Corner 1.05 Edge psf Central 2.05 Corner 1.15 Edge 0.98 FoS < 1.25 (for both 42 and 20 psf) is a very low value. Limits on loading are required and evacuation must be considered. Subsequent to this asse Uploaded Document: Columns FoS calculations, propping areas. Based on the Review Panel investigation, the following recommendations are made by the Panel and should be implemented by the factory: 1. Proper 'Propping' on both Eastern and Western part of the building (areas shown in the attached drawing) up to Provide results of preliminary calculations in space provided. a) column capacity; FoS > Safe b) column capacity; FoS Needs The Alliance for Bangladesh Worker Safety Page 5/15

6 05 May 2014 Evaluation c) Column capacity; FoS Needs Evaluation d) Column capacity; FoS < Unsafe In case of a critically low FoS (<1.25), consider Immediate Escalation Protocol Are credible structural design documents available for review and kept on site? No structural design documents were available for review (only a photocopy of 1997 CDA approval documents was available). Document Review: No design documents available for review. Have a qualified structural engineer prepare credible as-built documents based on the requirements of Part 8 Section 8.19 of the Alliance Standard. All elements for all buildings must be evaluated and included in drawings. Alliance Standard Part 8 Section 8.19 Required Structural Documentation for New and Existing Factories Can credible structural documentation indicating general conformance with 2006 BNBC or other comparable applicable international model building code be produced? No structural design documents were available for review and therefore conformance with a building code could not be ascertained. Document Review: No design documents available for review. Engage a qualified structural engineer to develop the required documents to confirm compliance with building code. Documents must comply with Alliance Standard Part 8 Section 8.19 and Reference Alliance Standards Part 8 Section 8.2 Structural Integrity of Existing Factory Buildings Can documentation be provided that the building is compliant with the requirements for wind loading and storm surge loadings as detailed in BNBC Part 6 Section 1.5.3? The Alliance for Bangladesh Worker Safety Page 6/15

7 05 May 2014 No structural design documents were available for review and therefore conformance with wind and storm surge loading design requirements could not be ascertained. Document Review: No design documents available for review. Engage a qualified structural engineer to confirm satisfactory structural performance of the buildings under wind loading. Compliance may be waived if the Factory Owner provides satisfactory evidence of a cyclone operations plan that includes full evacuat 2006 BNBC Part 6 Section 1.5. Compliance may be waived if the Factory Owner provides satisfactory evidence of a cyclone operations plan that includes full evacuation of the factory in advance of any approaching cyclone" Is a clear and redundant load path to resist lateral loads provided? At Level 4, the intermediate (center bay) beam is missing throughout the entire center bay. This beam is present at all other floors. Also, the typical beamcolumn joint is eccentrically loaded (beams not centered over both in both directions). There are Photograph: Missing intermediate beams, eccentrically loaded beam-column joint. Have a qualified structural engineer complete further analysis of the structure and the irregular design elements and develop a remediation plan if required. See additional recommendations for Detailed Engineering Assessment found elsewhere. Alliance Standards Part 8 Section 8.17 Design for Lateral Loads and BNBC Part 6 Section 1.5 Results of ferro-scanning for confirmation of steel rebar in the columns of the lowest tier were satisfactory. Scanning indicated 6-20mm in corner and edge columns. This is not considered satisfactory for the expected loading of the factory building. Visual Assessment: Ferro-scanning completed during visual assessment. As noted elsewhere, a Detailed Engineering Assessment should be The Alliance for Bangladesh Worker Safety Page 7/15

8 05 May 2014 conducted. The size and diameter of steel rebar in most of the columns of the two lowest tiers shall be authentically determined which may require removal of the concrete cover in one or two Alliance Standard Part 8 Section 8.3 Preliminary Structural Assessment Have provisions been made in floors or decks for a concentrated load (such as heavy equipment, water tanks, stored materials, etc) applied at a location wherever this load acting upon an otherwise unloaded floor would produce stresses greater than those caused by a uniform load? No evidence was available to indicate that the structural impact of the following observed concentrated loads had been considered: -Rooftop telecommunications towers (6 total). -East and west side RCC water tanks above stairwells at roof level. Photograph: Rooftop telecommunications tower, billboard, and water tanks. Engage a qualified structural engineer to confirm and document that provisions have been made to accommodate these concentrated loads. If provisions have not been made, have a qualified structural engineer develop a remediation plan or it may be necessary Alliance Standard Part 8 Section 8.13 and 8.14 Where density of operations, storage of materials, or equipment weights require live load capacity in excess of 2.0 kn/m2 (42 psf), do the design documents confirm that the required load capacity exists? Or has the load capacity been analytically confirmed and certified by an Alliance-qualified structural engineer? The Alliance for Bangladesh Worker Safety Page 8/15

9 05 May 2014 Several areas a high storage loads were observed including the Level 5 fabric store, accessories storage in stair area, and accessories store. No design documents or load plans were available to confirm the required load capacity exists in these areas. Photograph: Large storage loads. Have a qualified structural engineer confirm that capacity to support the load is available. Load Plans complying with Alliance Standard Part 8 Section should also be developed. Alliance Standards Part 8 Section 8.15 Minimum Floor Design Loads Are Certificates of Occupancy available for review? Low No credible occupancy certificates were available for review. Document Review: Documents reviewed on-site. Provide Certificates of Occupancy for review. Alliance Standard Part 8 Section 8.3 Preliminary Structural Assessment Structural System Construction Is the structural system free of settlement cracking, excessive perimeter separations, and unlevel floors attributable to foundation settlements? High The available soil test report recommends a shallow foundation system for a building up to 4 stories (along with provisions for soil improvement) and a castin-place end-bearing pile foundation system for a building over 4 stories. This building contains Document Review: Soil report recommendations. The foundation system should be evaluated by a qualified structural engineering team. Results should be compared to existing (or revised) soil test and geotechnical recommendations. Recommendations for retrofitting or otherwise strengthening the foundatio The Alliance for Bangladesh Worker Safety Page 9/15

10 05 May 2014 Reference Alliance Standards Part 8 Structural Design Section 8.2 Structural Integrity of Existing Factory Buildings Are the performance of key structural elements such as columns, slender columns, flat plates and transfer structures satisfactory? High Non-Compliance Level: 2 As noted elsewhere, beam crack repairs were observed in several beams. Beam-column joints are eccentrically loaded, the intermediate (center bay) beam is missing throughout the entire center bay at Level 4, and the cantilevers at the front and back (east Photograph: Beam cracking repairs. Engage a qualified structural engineer to confirm structural performance of the structure, particularly regarding the stress on the beams. This should be conducted as part of detailed engineering assessment noted elsewhere. Alliance Standard Part 8 Section Is the structural system free of distress, separations, or cracking that indicates lack of performance or overstress of the lateral load-carrying system? High Non-Compliance Level: 2 Cracking observed on the west side exterior facade in the vicinity of the cantilever slab is potentially indicative of overstress potentially caused by the cantilever slab load. The east and west cantilever slabs are not noted on the available structural Photograph: Cracking on west side exterior at cantilever. Engage a qualified structural engineer to provide additional investigation into the cracking at the cantilever slabs and provide a remediation plan if required. Alliance Standard Part 8 Section The Alliance for Bangladesh Worker Safety Page 10/15

11 05 May 2014 Is the structural system free of distress, settlement, shifting, or cracking in columns or walls? High Non-Compliance Level: 1 Hairline cracks were observed at the east side stair landing. These cracks are not expected to be structural in nature (likely due to poor construction practices), but the cause of the cracking is unknown and warrants additional investigation. Photograph: Cracking at stair landing. Have a qualified structural engineer provide analysis of the identified cracks to determine the cause of the cracking. Repair as deemed necessary. Alliance Standard Part 8 Section If yes, have the structural members constructed with MCAC been investigated by an appropriate program of in-situ testing and representative destructive testing or core samples? No documentation of in-situ testing and representative destructive testing or core samples of MCAC was available. Document Review: No documentation of testing available. As part of the detailed engineering assessment outlined elsewhere, the compressive strength of structural elements constructed using MCAC shall be investigated by an appropriate program of in-situ testing and representative destructive testing of core sam Reference Alliance Standards Part 7 Building Materials Section 7.2 Masonrychip aggregate concrete (MCAC) Are any structural elements constructed with MCAC exposed to rainfall or other sources of water sealed with a protective coating to prevent water intrusion? Exposed reinforcing and column concrete was observed in certain locations at the roof level. The elements were not completely sealed from water intrusion The Alliance for Bangladesh Worker Safety Page 11/15

12 05 May 2014 by a well maintained protective coating. Visual Assessment: Exposed MCAC roof elements. The top surface of the framing must be completely sealed from water intrusion by a well maintained protective coating. Alternatively, create a positive drainage slope of at least 2% and provide drains with downspouts at low points to prevent water ponding Alliance Standards Part 7 Building Materials Section 7.2 Masonry-chip aggregate concrete (MCAC). Have all areas of needed maintenance, including areas with efflorescence, dampness, standing water on rooftops, and corrosion been addressed. Non-Compliance Level: 2 Water ponding was observed at the roof level due to water pipe leakage. There was also exposed reinforcing at the roof level in which the reinforcing can come into direct contact with rainwater and corrode. Photograph: Rooftop water ponding, exposed reinforcing. Repair water pipe leakage and clean/clear roof of ponded water and debris. Evaluate the condition of any existing slab coating. Re-coat as necessary or alternatively create a positive drainage slope of at least 2% with drains containing downspouts at low Alliance Standard Part 8 Section 8.26 Durability and Maintenance Are structural steel members free of corrosion, physical damage or other types of deterioration? Non-Compliance Level: 2 As described elsewhere, exposed reinforcing at the roof level (for future expansions) shows corrosion due to exposure to weather. Photograph: Corroded exposed reinforcing. As noted elsewhere, rebar should be covered by temporary concrete or other appropriate protection (e.g. epoxy coating) immediately to protect from weathering or other degradation. Prior to any expansion (lateral or horizontal), approval regarding the cond The Alliance for Bangladesh Worker Safety Page 12/15

13 05 May 2014 Alliance Standard Part 8 Section 8.26 Are all non-structural elements suspended from, attached to, or resting atop the structure adequately anchored and braced to resist earthquake forces? Non-Compliance Level: 2 Accessory storage racks at Level 5 were noted not not contain adequate anchorage or bracing to resist earthquake forces. Photograph: Unanchored storage racks. Adequately anchor and brace all non-structural elements such as the rack systems to resist earthquake forces to comply with the BNBC and Alliance Standard. Alliance Standards Part 8 Section 8.18 Seismic Bracing of Key Non-Structural Elements and 2006 BNBC Part 6 The exterior façade is free of cracking. Low Non-Compliance Level: 2 As noted elsewhere, cracking observed on the west side exterior facade in the vicinity of the cantilever slab is potentially indicative of overstress potentially caused by the cantilever slab load. The east and west cantilever slabs are not noted on the a Photograph: Cracking on west side exterior at cantilever. Have a qualified structural engineer provide further analysis of the identified cracks to determine the appropriate course of corrective action. Alliance Standard Part 8 Section 8.2 Structural Safety Programs Is a program in place to ensure that the live loads for which a floor or roof is or has been designed will not be exceeded? The Alliance for Bangladesh Worker Safety Page 13/15

14 05 May 2014 No program is in place to ensure that the live loads for which a floor or roof is or has been designed will not be exceeded. Document Review: No load management program documented. Develop a program to ensure that all live loads for which a floor or roof has been designed for will not be exceeded. The designated Load Manager shall oversee this program and ensure it is enforced. Alliance Standard Part 13 Section 13.7 and Part 8 Section 8.9. Have Load Plans been prepared for each floor documenting the actual maximum operational loading that is intended and/or allowable on each floor. Low Load Plans have not been prepared for each floor documenting the actual maximum operational loading that is intended and/or allowable on each floor. Document Review: No load plans available for review. Have a qualified structural engineer develop Floor Loading Plans per the requirements of Part 8 Section Alliance Standard Part 8 Section 8.10 Floor Loading Plans (Load Plans) Are Floor Load Plans posted as required? Low No floor load plans are posted as required. Document Review: No posted load plans observed. Have a qualified structural engineer prepare load plans including the information required in Section 8.20 of the Alliance Standard. Floor load plans should be visibly posted on all levels of the building. Alliance Standard Part 8 Section Are areas used for storage of work materials and work products, clearly marked to indicate the acceptable loading limits as described in the Load Plan for that floor? The Alliance for Bangladesh Worker Safety Page 14/15

15 05 May 2014 Low Areas used for storage of work materials and work products are not clearly marked to indicate the acceptable loading limits. Visual Assessment: No marked loading limits observed. Provide signage or the appropriate markings at all areas used for storage to indicate the acceptable loading limits detailed in the Load Plan (noted elsewhere). Alliance Standard Part 8 Section 8.11 Floor Load Markings Is a designated representative (Factory Load Manager), who is onsite full time, trained regarding the structural floor capacity, and serves as an ongoing vendor resource and monitor of operational factory floor loadings? Low No factory load manager has been designated. Worker Interviews: Management confirms no Load Manager appointed. Designate a representative as the Factory Load Manager. The Factory Owner shall ensure that at least one individual, the Factory Load Manager who is located onsite full time at the factory, is trained in calculating operational load characteristics of the Alliance Standards Part 8 Section 8.9 Factory Load Manager The Alliance for Bangladesh Worker Safety Page 15/15