BUILDING SAFETY REVIEW IN PAKISTAN

Structural Stability, Fire & Electrical Safety Assessment Report

Summary of the factory/site

Supplier Company
Address XX
Assessment date XX
Electricity Rules 1937
Pakistan Electric and Telecommunication Code
Building Code of Pakistan – Fire Safety Provisions 2016
Reference Standards Sindh Factories Act 2015
American Standard Testing Material (ASTM)
American Concrete Institute (ACI)
I-way must 1.5 Severe health or Safety hazards
Auditors XX
Supplier participants Compliance Officer and Health & Safety Officer
Site area 201,573 m2
Overall facility of Company comprises of 39 buildings spread across production area,
dormitories, godowns and office blocks with a total staff strength of 6400. Considering the
Assessment
size of the facility, our assessment was conducted over two days. During the first day of
Summary &
our assessment team covered the floor visits for electrical, fire and structural safety while
Limitations
the second day was for documentation review and compiling our preliminary site
observations with management close out meeting.

Summary of Assessment Findings

Severe
Regulatory Non- Above Regulatory
health/safety Remarks
Conformities Non-Conformities
hazards
Electrical Safety - 2 - 3
Fire Safety - - - 6
Structural Safety - 2 - 4
Total - 4 - 13
 1. ELECTRICAL SAFETY ASSESSMENT
Index
1.1 Electrical Safety Management Plan
1.2 Electrical Layout and Installation Drawings
1.3 Electrical Utilities
1.4 Electrical Safety Training
1.5 Thermography Test Results
1.6 Annexure 1 | Electrical Safety – Documents Reviewed
1.7 Annexure 2 | Electrical Safety – Picture References

1.1 Electrical Safety Management Plan - OK

Internal inspection, risk assessment and training plan is present and is being followed.

1.2 Electrical Layout and Installation Drawings

1.2.1 Single Line Diagram – OK
Approved single line diagram exists.

1.2.2 Approved Drawing - OK

Fitness certificate of electrical inspector for generator installation is available.

1.3 Electrical Utilities

1.3.1 Transformer - OK
Transformers were provided with separate earthing connections and available transformers were
segregated from all other apparatus by means of masonry walls and portable fire extinguishers were also
placed in transformer rooms.

1.3.2 DG Room – OK
Generator facility had sufficient working space and generators were properly earthed with separate
controlling mechanism.

1.3.3 Power Distribution System – OK

Presence of electric shock instructions, earthing of wires, junction boxes and distribution panels were
inspected, also electrical supply lines were protected by cut –outs.

1.3.4 Wiring and Cable Installation – NC

Non Conformity: We observed open / loose wiring in bachelor dormitory area in multiple rooms of the
same building. The room size is compact with seven persons in one room with open/ loose wiring visible
that poses a threat of electrical shock to workers. As per Chapter VI, Para 49 (2), (3), (4) of Electricity Rules
1937, all cable connections shall be properly affixed and live parts shall not be exposed for workers’ safety.

Risk Rating: Multiple instances of loose electrical connections were observed in dormitory area and
chances of electrical incidents are likely to happen. Therefore, likelihood is kept at high level. Further,
majority of loose wires were not live and their voltage level was also low, therefore, impact is categorized
as low.
Hence, Risk Rating=3 *1=3 which qualifies it as a medium risk observation.

Remark: In transformer yard, cables were lying on the floor without any protection and wires used for
incoming and outgoing connection of transformers were not properly dressed. This issue was only observed
at one place while other areas of facility were well maintained in terms of cable dressing. It is recommended
that all electrical cables shall be covered with protective materials and cable dressing shall be adequately
done.

1.3.5 Switchgear Protection System – OK

Switchgear and LT panels are installed with three feet space available in front and two feet space at back
of the panels. High pressure electrical supply lines and apparatus were also placed above ground level.

1.3.6 Lighting Protection System – OK

Lighting protection system was installed and it was properly grounded. Insulation test reports were also
reviewed.

1.3.7 Inspection, Maintenance and Test Records – NC

Non Conformity: To provide electrical supply, shift in charge/ engineers are authorized to operate
generators or other allied equipment, however, this procedure for transferring and shifting of load from
generating/ receiving end is not present in documented form. This is not in compliance with Section 9.10
(1-7) of Pakistan Electric and Telecommunication Code. It is required that detailed written switching
procedure shall be formulated which clearly defines the responsibilities for maintenance of record and
issuance/ denial of authorization for specific switching work to be carried out.

Risk Rating: As per current practice, a shift engineer is the only person responsible for transferring load
from one end to another. Therefore, likelihood is kept at low level. Since energizing/ de-energizing is a vital
process that involves 400 volts of electric supply from generation panels to distribution panels. Therefore,
impact is categorized as high.
Hence, Risk Rating=1*3=3 which qualifies it as a medium risk observation

Remark: A detailed cable schedule was present containing information of individual cable size/ length,
however, cable layout drawing was not in place. As per better practice, an overhead and underground cable
layout drawing shall be formulated to ensure tracing of cables is made easy for users.

Remark: Performa for preventive maintenance of allied equipment of power house generation is in place,
however, preventive maintenance is not being carried out on required intervals and documented records of
preventive maintenance are also not available. It is recommended that preventive maintenance shall be
carried out as documented for all electrical equipment and relevant records shall be maintained to ensure
that equipment breakdowns are minimized and needs of any potential repairs are highlighted on a timely
basis.

1.4 Electrical Safety Training – OK

Training manual regarding electrical safety was available and records related to refresher trainings for
electrical safety were also available and maintained.

1.5 Thermography Test Results – OK

Thermographic tests were performed on multiple switchgear panels and temperature was found normal.
1.6 Annexure 1 | Electrical Safety – Documents Reviewed

S.No. Document Name Reviewed Remarks/ Comments

1 Approved electrical installation Drawing Yes -
Approval or inspection certificate from electrical inspector
2 for installation of Generator set and Transformers (in Yes -
case any)
Cable layout drawing
3 Cable Schedule Yes
was not available
Electrical Panel wiring diagram with ferruling
4 Yes SLD available
details(Single line Diagram)
Inspection, Maintenance and testing records for
5 Lightening Protection, Switchgear Transformer, Yes -
Generator and Earthing
External risk
assessment report was
Previous THERMOGRAPHIC IMAGING STUDY
6 Yes reviewed in which
REPORTS for Electrical Distribution System.
thermography results
were present

1.7 Annexure 2 | Electrical Safety – Picture References

1.3.4 Evidences of loose electrical wiring - NC

1.3.4 Improper cable dressing in transformer yard - Remark

 2. FIRE SAFETY ASSESSMENT
Index

2.1 Fire safety management plan

2.2 Means of egress
2.3 Fire safety construction
2.4 Structure and finishes
2.5 Fire safety systems
2.6 Provisions for fire fighting
2.7 Maintenance and housekeeping
2.8 Maintenance records
2.9 Emergency preparedness
2.10 Annexure 3 | Fire safety – Documents Reviewed
2.11 Annexure 4 | Fire safety – Picture References

2.1 Fire safety management plan – OK

Internal audits of fire safety were carried out regularly and formal system of fire incidents reporting,
investigation and root cause analysis was also in place. System of regular trainings for newly hired
workers and refresher trainings was also evident from available training records.

2.2 Means of egress

2.2.1 Floor Exits – OK

Floor exits were marked, illuminated and were made free of obstruction whereas two floor exits were
available in areas of facility. Further, workers interviewed at production facility were aware of floor exits
and immediate action to be taken in case of an emergency.

2.2.2 Escape paths – OK

Buildings of Company with high human occupancy were provided with illuminated exits that can be used
in case of an emergency.

Remark: Dormitory building A for workers has two emergency exits to allow safe evacuation of workers in
case of emergency. However, another spiral stair is also available in this building .This stair case is not
marked as an emergency exit, also the width of stair case was under 5 feet, however, there is a possibility
that workers can use it as an emergency exit. It is recommended that width of the spiral stairs shall be
increased up to 1.5 meter (5 feet) or replaced with other suitable ladder so the stair case can be used in a
safe manner.

2.2.3 Exit signage – OK

Exit signage were placed at exit gates along with directional arrows in different locations across the
facility to provide guidance to workers for safe evacuation in case of an emergency.

2.2.4 Exit doors – OK

Exit doors were marked and emergency lighting was also provided. Further, exit doors had outward
openings with no obstruction.

Remark: Two instances were noted where access to emergency exit doors was partially obstructed (gas
turbine room and Jenbacher power house). It is required that all pathways of all emergency exits and
emergency exit doors shall be free from any sort of obstruction.
2.2.5 Exit stairs – OK
Exit stairs were present in good condition and emergency lighting was also provided. Random operational
check of emergency lighting was carried out and it was found operational.

2.2.6 Final exit (corridors and passageways) – OK

Battery operated emergency lighting was provided at final exits that were in operational condition.

2.3 Fire Safety Construction

2.3.1 Protection of openings – OK

Internal and external stair cases were constructed from non-combustible material and openings of walls
(except for one described below) were protected from fire resistant material.

Remark: Cables crossing from the wall of power generation room were not adequately secured from fire/
smoke spread. This finding was observed at power generation room only. It is recommended that cables
passing through a wall shall be protected by a fire stop system or device. Hence, it is necessary that all
openings shall be sealed with fire resistant material (expandable foam, plaster, grout etc.) so that fire and
smoke cannot penetrate through openings.

2.3.2 Separation of occupancies – OK

Buildings have their own ventilation system that are not interlinked with each other. Only production
department (cotton mill room, spinning, ring and weaving) shared common ventilation system.

2.3.3 Storage area - OK

Fuel storage facility was found inside factory area with separation with bund wall and firefighting
arrangements were also in place.

2.3.4 Other high risk areas – OK

Powerhouse and boiler rooms were far away from other buildings and were well maintained. Further, no
combustible material was stored inside the power house.

Remark: We noted that combustible material was placed beneath the waste heat recovery boiler that was
located in open area beside new power house and fluff was also evident in gas turbine room. Both
instances were found only once during our visit. It is recommended that accumulations of combustible
waste material, dust, and debris shall be removed from the structure and its immediate vicinity for safe
operations. Although waste management system is in place but adherence to such system shall also be
ensured by designated persons and waste shall be removed daily or more frequently as necessary.

2.4 Structure and Finishes – OK

Structure and wall ceilings were made of fire resisting material.

2.5 Fire Safety System

2.5.1 Fire Detection System – OK

Smoke detectors were installed in production department that were in working condition and they were
interlinked with a factory fire alarm system.

Remark: Only two smoke detectors of spinning department were switched off because fluff was present
in air that was causing false alarm as informed by supplier’s fire team. It is recommended that smoke
detectors shall be replaced with heat detectors in spinning department to ensure fire detection system
remains intact and concern of false fire alarm is mitigated.

2.5.2 Fire sprinkler – OK

No manual or automatic fire sprinkler system was installed at the facility but additional measures (smoke
detectors linked with fire alarms) for fire detection and firefighting were available at the facility.
2.5.3 Fire alarm system – OK
Electrical and manual fire alarm system was installed throughout the factory that contained both sound
and flash light system for high noise areas. Further, one fire call point was checked in spinning
department that was found in operational condition.

2.5.4 Emergency lighting – OK

Emergency lighting is provided at staircases, lobbies and exit doors and these emergency lights also had
backup of batteries. Random checking of emergency lights was carried out and they were found in
operational condition.

2.6 Provisions for Fire Fighting

2.6.1 Water supply - OK

Dedicated water storage is available for firefighting purpose, also additional water can also be used from
normal utility tanks for firefighting as needed. Two separate fire water pumps were available with electrical
driven motors and diesel engine as well.

2.6.2 Firefighting system – OK

Wet riser system was available that covers factory area. Dedicated firefighting team was available round
the clock. Operational check of one fire hydrant was carried out and it was found in operational condition.
Fire hose reel system was also provided inside the production area. Portable firefighting extinguishers
were available in the factory that were well maintained and placed at correct height (less than 5 feet from
ground).

2.6.3 Access for fire fighting vehicles - OK

Sufficient width (13 feet 6 inch) available at the entrance and throughout the factory area and no
obstruction/hinder was found for vehicle movement around the building.

2.7 Maintenance and Housekeeping

2.7.1 Legal documents (Fire NOC) - OK

Fire NOC from civil defence department was available and reviewed.

2.7.2 Other fire authority documentation – OK

Regular evacuation drills were conducted in factory and related record was also available.

Remark: Upon review of documents we noted that 18 disable workers were present at the factory,
however, neither written procedure nor practical equipment for emergency rescue was available for
evacuation of disabled workers. It is recommend that a comprehensive SOP shall be formulated for
disabled persons that includes necessary guidelines for evacuation of disabled workers and necessary
emergency rescue equipment for disabled workers be arranged separately.

2.8 Maintenance Records – OK

We checked the maintenance record of fire detectors, fire alarm, fire pump, fire hose, fire extinguishers
and emergency lighting that were updated and readily available.

2.9 Emergency Preparedness- Fire Emergency Plan - OK

Documented emergency plan is available that covers possible emergency scenarios. Emergency layout
plan is affixed at different locations as well as at the exit gates of Company’s facility. Upon random
interview with workers, it was noted that workers were aware of evacuation route and the assembly area
in case of an emergency.
2.10 Annexure 3 | Fire safety – Documents Reviewed

S.No. Document Name Reviewed Remarks/ Comments

1 Fire License/No Objection Certificate (In case any) Yes -
2 Fire Safety Annual Inspection Reports Yes -
3 Fire Suppression systems Maintenance records Yes -
Water intake report
4 Municipal water supply from Mains Yes
reviewed
5 Advise on water storage supply facilities for premises Yes Water storage is sufficient
6 Advise on backup power supply for emergency system Yes Battery backup is available
7 Nearest Fire Station & expected response time for Fire Brigade Yes
8 Emergency Evacuation Drill(Tracking of Findings) Yes Checked and found correct
9 Any Fuel Storage areas in the building Yes
Automatic Fire Alarm System inspection and maintenance
10 Yes Checked and found correct
records

2.11 Annexure 4 | Fire safety – Documents Reviewed

2.2.2 Width of stair case is less than 5 feet - 2.2.4 Emergency exits are partially blocked -
Remark Remark

2.3.1 Cables passing through a wall are not 2.3.4 Presence of fluff and garbage beneath boiler
protected – Remark - Remark
 3. STRUCTURAL SAFETY ASSESSMENT
Index
3.1 Vertical Structural System (Gravity Loads)
3.2 Lateral Structural System (Wind and Seismic Loads)
3.3 Key Elements
3.4 Foundation Performance
3.5 Visible Stress in Structural Members
3.6 Visible Stress in Non-Structural Members
3.7 Performance of Extensions/Additions
3.8 Structural documentation
3.9 Annexure 5 | Structural – Documents Reviewed
3.10 Annexure 6 | Structural – Picture References

3.1 Vertical Structural System (Gravity Loads) – OK

Vertical support system along with roof and floor structural systems were apparent and logical. Further,
design evaluation team was carrying out verification of roof and floor structural systems that comprise of
two way spanning slabs.

3.2 Lateral Structural System (Wind Seismic Loads)

3.2.1 Steel Buildings - OK
Seismic load was catered for steel structures that were added in past five years at Company’s facility and
it was also verified from typical steel design available.

3.2.2 Concrete Buildings - OK

Lateral stability system was provided with moment frame (columns and beams) and movement joint were
also provided at junctions.

3.3 Key Elements

3.3.1 Column – NC
Non Conformity: Schmidt Hammer Testing (SHT) was conducted on columns of Jacquard building on
random basis to examine Pound per Square Inch (PSI) strength designed by structural designer at the
time of construction. As communicated verbally by civil team, design strength of Jacquard building is
3000 PSI and it differs from current strength of 1500 PSI after converting into cylindrical strength as
tested. This is in non-compliance with standard number C39 of ASTM and ACI 318 (Section 5.1.1). Since
no design or structural drawings are available and SHT was conducted on sampled columns, it is advised
that independent assessment from structural designer shall be carried out to examine and verify the
current PSI strength of the building for all columns.

Risk Rating: Since this observation is based on SHT on sample basis, therefore, the likelihood is kept at
medium level. The impact is also medium because the building has extensive number of columns and
load can be sustained according to original loading plan.

Hence, Risk Rating= 2*2=4 which qualifies it as a medium risk observation.

Remark: We performed Ferro Scanning Testing (FST) on columns on random basis to examine
uniformity of the steel placement as designed by structural designer at the time of construction. We
concluded that during construction steel uniformity has been displaced in Jacquard Building. It is
recommended that all rebar (steel) placements shall be reassessed for the same building by structural
designer and corrective actions are taken in accordance with the guidance provided by structural
designer
3.3.2 Beam – OK
The design check on cantilever was completed. However, loading plan and mechanism control of loading
is to be proposed and implemented.

3.4 Foundation Performance – OK

No evidence of foundation settlement was present and no physical distress and any differential
movement was found in building structures. Further, no differential movement is found.

3.5 Visible Stress in Structural Members – NC

Non Conformity: We observed cracks in the slabs which are causing deterioration and leading to
damages which are not recommended for concrete structure stability. Following are the locations where
cracks were identified:
 Old Power Generation
 Local Processing
 Finish Folding
This is in non-compliance with ACI 562-16. It is advised that independent assessment from structural
designer shall be carried out to examine and verify the current PSI strength of all columns for
aforementioned buildings.

Risk Rating: Since this observation is based on visible stress and cracks, the likelihood is kept at
medium level. The impact of this observation is high because the building has considerable human
occupancy and regular usage.
Hence, Risk Rating= 2* 3 =6 which qualifies it as a high risk observation.

3.6 Visible Stress in Non-Structural Members – OK

There was neither façade cracking nor structural deterioration found.

Remark: We observed visible cracks in the block masonry due to seepage in R-60 spinning and Finish
Folding units of Company facility. The cracks were non repetitive and they were observed in
abovementioned units only. As per chapter 21 of International Building Code, it is recommended that all
cracks of block masonry shall be repaired and rectified to ensure long term safety of buildings.

3.7 Performance of Extensions/ Additions

There were neither signs of previous structure demolition nor addition of non-engineered (temporary)
structures.

3.8 Structural Documentation – OK

Structural stability certificate of facility was available along with latest material test reports and soil test
reports.

Remark: As-built drawings of only two buildings were made available out of 39 buildings of Company’s
overall facility. As communicated by civil team, preparation of as built drawings of remaining buildings was
under process. It is recommended that as built drawings of buildings shall be formulated at the earliest so
that amendments in original design of buildings is available in documented form which can also lead to
implementation of structural maintenance plan.

Remark: Upon review of documents, we noted that allowable loading plans for floors and accessible roof
areas were not available. It is recommended that loading plans for separate buildings indicating allowable
load on each floor shall be formulated to ensure that complete documentation is maintained for structural
safety.
3.9 Annexure 5 | Structural – Documents Reviewed
Remarks/
S.No. Document Name Reviewed
Comments
Architect As-Built Drawings # 2 No copies at full scale or
1 Yes -
A3 (1 copy for the assessment team to take away
As built drawings of
Structural & Electrical As built Drawings # 2 No copies at
only two buildings
2 full scale or A3 (1 copy for the assessment team to take No
out of 39 were
away
made available
Site/Building Layout Plans # (2 No copies at full scale or
3 Yes -
A3)
Factory Registration
Certificate, Building
Approval Plan,
All Relevant Permits including Occupancy Certificate- 1 No Building Stability
4 Yes Certificate,
copy of each permit.
Approval of
Environmental
Management Plan

Material Test Certificates (Concrete Cube Tests,

Available material
Reinforcing Steel Tests, Structural Steel Material
5 Yes certificates were
Certificate, Weld Testing Certificate etc.) - 1 No copy at A4
reviewed.
or A3.
6 Soil Test Report Yes -
Declaration of Building Safety/ Loading Certificate(Signed
7 Yes -
by the building engineer)
Certificate from a registered structural design consultant on
8 Yes -
building stability
Initial loading plan
Structural/Sketches/ Calculations indicating allowable load
9 No needs to be
on each floor(Load Plans)
developed
All areas of loading heavier than workshop, sewing, cutting
and general operative activities e.g. material storage, pre-
10 No -
order delivery storage areas, temporary and permanent
water tanks, generators, boilers etc.
Initial loading plan
Please advice on how floor loading is controlled. By limiting
11 No needs to be
height or load zones?
developed
Available Inspection
12 Previous Building Inspection Reports Yes Reports were
reviewed
3.10 Annexure 6 | Structural – Picture References
3.3.1 SHT | Current PSI strength is less than
3.5 FST | Displacement of steel uniformity – Remark
design PSI strength – NC

3.5 Cracks in slabs – NC

Finish Folding Local Processing Power Generation Room

3.6 Cracks in block masonry - Remark

Finish Folding R 60 Spinning