INITIAL FIRE SAFETY ASSESSMENTsfi.fairfactories.org/sfi_dev_files/1/Audit_Files/Color City_Fire.pdfforklift maintenance building, 5) Two story RCC chemical storage building, 6) ETP

INITIAL FIRE SAFETY ASSESSMENT

Factory Name: Color City

Address: Nayapara, Kashimpur Gazipur Gazipur DhakaBangladesh

Assessor: Bureau Veritas

Date: 15 Feb 2015

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The Alliance for Bangladesh Worker Safety Page 1/17

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.


Address: Nayapara, Kashimpur Gazipur Gazipur Dhaka Bangladesh


Date: 15 Feb 2015



GENERAL INFORMATION

General Information



Country: Bangladesh

Province: Dhaka

City: Gazipur

Zip Code:

Audit Duration:

Re-Audit: Re-Audit After 0 Months

Draft Report Date: 02-17-2015

Final Report Date: 03-10-2015

Are all Action ItemsFrom PreviousAssessmentCompleted?:

N/A

Buildings in Complex: There are nine buildings in the factory premises out of which one is main production building and eight areancillary buildings. The buildings are named as: 1) Six story RCC main building (Ground floor partially shed),2) Single story thermal boiler shed with mezzanine floor, 3) Single story generator shed, 4) Single story RCCforklift maintenance building, 5) Two story RCC chemical storage building, 6) ETP area, 7) Two story RCCETP monitoring building, 8) Single story boiler & WTP shed, 9) Three story RCC rain water harvesting building(Under construction).

Is the building(s) ownedor rented by the Factory:

Owned

Number of BuildingLevels (Stories):

1) Six story RCC main building: Building height (Highest occupied floor level): 18.29 m or 60 ft [Height up toroof: 24.39 m or 80 ft], Stories above grade: 6, Stories below grade: 0, Occupied levels: 6, 2) Single storythermal boiler shed: Building height (Highest occupied floor level): 30 cm or 1 ft above grade [Height up toroof: 5.5 m or 18.00 ft], Stories above grade: 1, Stories below grade: 0, Occupied levels: 1, 3) Single storygenerator shed: Building height (Highest occupied floor level): 30 cm or 1 ft above grade [Height up to roof:5.5 m or 18.00 ft], Stories above grade: 1, Stories below grade: 0, Occupied levels: 1, 4) Single story RCCforklift maintenance building: 30 cm or 1 ft above grade [Height up to roof: 5.5 m or 18.00 ft], Stories abovegrade: 1, Stories below grade: 0, Occupied levels: 1, 5) Two story RCC chemical storage building: Buildingheight (Highest occupied floor level): 3.05 m or 10 ft [Height up to roof: 6.10 m or 20 ft], Stories above grade:2, Stories below grade: 0, Occupied levels: 2, 6) ETP area: Building height (Highest occupied floor level): Atfinished grade, Stories above grade: 1, Stories below grade: 0, Occupied levels: 1, 7) Two story RCC ETPmonitoring building: Building height (Highest occupied floor level): 4 m or 13.12 ft [Height up to roof: 7 m or22.96 ft], Stories above grade: 2, Stories below grade: 0, Occupied levels: 2, 8) Single story boiler & WTPshed: Building height (Highest occupied floor level): 30 cm or 1 ft above grade [Height up to roof: 5.5 m or18.00 ft, Stories above grade: 1, Stories below grade: 0, Occupied levels: 1, 9) Three story RCC rain water




Date: 15 Feb 2015



harvesting building: Under Construction.

Approximate BuildingArea (SF):

Total area of all buildings in the factory premises: 591,854 sft. Building wise breakdown as follows: 1) Six storyRCC main building: 452994 sft (Ground floor: 196300 sft, 1st floor: 65913 sft, 2nd floor: 56624 sft, 3rd floor:38522 sft, 4th floor: 38522 sft, 5th floor: 57113 sft), 2) Single story thermal boiler shed: 16740 sft, 3) Singlestory generator shed: 9750 sft, 4) Single story RCC forklift maintenance building: 5100 sft, 5) Two story RCCchemical storage building: 19270 sft (Ground Floor: 9635 sft, 1st Floor: 9635 sft), 6) ETP area: 64000 sft, 7)Two story RCC ETP monitoring building: 8400 sft (Ground floor: 4200 sft, 1st floor: 4200 sft), 8) Single storyboiler & WTP shed: 15600 sft, 9) Three story RCC rain water harvesting building: Under construction.

Date of BuildingConstruction:

Factory personnel informed the date of construction as follows: Started in 2011 and finished in 2014 (ExceptRain water harvesting building which was under construction during audit).

Date of Last BuildingRenovation/Addition:

Factory personnel informed the date of last building renovation as follows: 1) Single story thermal boiler shed:Renovation running during audit, 2) Three story RCC rain water harvesting building: Under construction. Norecord for date of renovation or addition was found for rest of the buildings from factory personnel.

Ancillary Structures inComplex:

1) Single story thermal boiler shed with mezzanine floor, 2) Single story generator shed, 3) Single story RCCforklift maintenance building, 4) Two story RCC chemical storage building, 5) ETP area, 6) Two story RCCETP monitoring building, 7) Single story boiler & WTP shed, 8) Three story RCC rain water harvesting building(Under construction).

Approximate AncillaryStructures Area (SF):

1) Single story thermal boiler shed: 16740 sft, 2) Single story generator shed: 9750 sft, 3) Single story RCCforklift maintenance building: 5100 sft, 4) Two story RCC chemical storage building: 19270 sft (Ground Floor:9635 sft, 1st Floor: 9635 sft), 5) ETP area: 64000 sft, 6) Two story RCC ETP monitoring building: 8400 sft(Ground floor: 4200 sft, 1st floor: 4200 sft), 7) Single story boiler & WTP shed: 15600 sft, 8) Three story RCCrain water harvesting building: Under construction.

Number of Occupants: Total number of occupants: 660. 1) Six story RCC main building: 624 (Ground floor: 384, 1st floor: 88, 2ndfloor: 58, 3rd floor: 64, 4th floor: 30, 5th floor: 0), 2) Single story thermal boiler shed: 7, 3) Single storygenerator shed: 5, 4) Single story RCC forklift maintenance building: 3, 5) Two story RCC chemical storagebuilding: 10 (Ground Floor: 8, 1st Floor: 2), 6) ETP area: 0, 7) Two story RCC ETP monitoring building: 6(Ground floor: 6, 1st floor: 0), 8) Single story boiler & WTP shed: 5, 9) Three story RCC rain water harvestingbuilding: 0.

Number of AncillaryLevels (Stories):

1) Single story thermal boiler shed: Building height (Highest occupied floor level): 30 cm or 1 ft above grade[Height up to roof: 5.5 m or 18.00 ft], Stories above grade: 1, Stories below grade: 0, Occupied levels: 1, 2)Single story generator shed: Building height (Highest occupied floor level): 30 cm or 1 ft above grade [Heightup to roof: 5.5 m or 18.00 ft], Stories above grade: 1, Stories below grade: 0, Occupied levels: 1, 3) Singlestory RCC forklift maintenance building: 30 cm or 1 ft above grade [Height up to roof: 5.5 m or 18.00 ft],Stories above grade: 1, Stories below grade: 0, Occupied levels: 1, 4) Two story RCC chemical storagebuilding: Building height (Highest occupied floor level): 3.05 m or 10 ft [Height up to roof: 6.10 m or 20 ft],Stories above grade: 2, Stories below grade: 0, Occupied levels: 2, 5) ETP area: Building height (Highestoccupied floor level): At finished grade, Stories above grade: 1, Stories below grade: 0, Occupied levels: 1, 6)Two story RCC ETP monitoring building: Building height (Highest occupied floor level): 4 m or 13.12 ft [Heightup to roof: 7 m or 22.96 ft], Stories above grade: 2, Stories below grade: 0, Occupied levels: 2, 7) Single storyboiler & WTP shed: Building height (Highest occupied floor level): 30 cm or 1 ft above grade [Height up toroof: 5.5 m or 18.00 ft, Stories above grade: 1, Stories below grade: 0, Occupied levels: 1, 8) Three story RCCrain water harvesting building: Under Construction.

Occupancy Type:

Construction Type:

Height of HighestOccupied Floor LevelAbove Grade:




Date: 15 Feb 2015






Date: 15 Feb 2015



ASSESSMENT FINDINGS

Fire Protection Construction

Question: Are openings and penetrations through rated walls and/or assembliesprotected?

Priority Level: High

Non-Compliance Level: 2

Description: The wall separating chemical dosing plant from production area hasunprotected windows.

Source of Findings: Photograph: Windows in chemical dosing plant.

Suggested Plan ofAction:

Either seal the unprotected openings mentioned above or protect theunprotected openings with fire rated assemblies.

Suggested DeadlineDate:

Standard: Includes doors, windows, ducts, piping, etc. Reference Alliance Standards Part4 Section 4.6 Opening Protectives and Section 4.7 Penetrations

Fire Protection Systems

Question: Are sprinklers spaced and installed at the required heights in order to providedrequired coverage and protection?



Description: No approved hydraulic design confirming the spacing and installation height ofsprinklers is available. The spacing of the installed sprinklers was found 10 ftand the installation height is 10'-3".

Source of Findings: Visual Assessment: Height and spacing were measured during audit.


Get the hydraulic calculation from the designer of the installed sprinkler systemand obtain approval from Alliance.


Standard: Reference NFPA 13




Date: 15 Feb 2015



Question: Are storage racks and shelves compliant based on class of commoditystorage?



Description: No approved hydraulic design confirming the commodity class of storedmaterials is available. Stored materials are stacked in racks.

Source of Findings: Photograph: Stored materials on rack.




Standard: Reference NFPA 13 Chapter 13, 14, 15, 16, or 17

Question: Does the building have a Standpipe System?



Description: Highest occupied floor level of main building is 60 ft. Therefore Class-IIIstandpipe system is required for the main building. Class-II hose connectionsalong with hose reel and variable nozzle are available in floors and stairwellsof main building. But class-I hose connection installation is under process andalready installed in some required stairwells. Capacity of water reservoir wasfound 90,000 gallon. No approved hydraulic design for the installed system isavailable. Highest occupied floor level of other structures is less than 10 m,therefore standpipe system is not required for those structures.

Source of Findings: Photograph: Hose cabinet.


Complete the installation of class-I standpipe system at required stairwellsalong with class-II standpipe system in floors designed by a qualified fireprotection engineer. The system is to be compliant with the requirements ofNFPA 14. Installation o


Standard: Does the building have a standpipe system installed where required. AllianceStandard Part 5 Section 5.4.2




Date: 15 Feb 2015



Question: Does the building have a fire pump?



Description: An electric pump of 125 hp capacity dedicated for fire fighting is available inthe factory premises. Hydraulic calculation of the installed standpipe andsprinkler system is unavailable. Therefore, required capacity of fire pump is notknown. A jockey pump of 15 HP capacity is available for the pump and thepump is also connected with generator. Hose pressure at most remote pointwas found approximately 4.5 bar.

Source of Findings: Photograph: Fire Pump, Hose Pressure


Get the hydraulic calculation of the installed standpipe and sprinkler systemand verify the capacity of the installed fire pump. Also obtain approval fromAlliance regarding the installation of fire pump.


Standard: Alliance Standard Part 5 Fire Protection Systems

Question: Are hangers, bracing, and restraints properly installed and supporting thesystem piping?

Priority Level: Medium


Description: Hydraulic design confirming the adequacy of hangers, bracing or restraints isnot available. But visually the hangers or restraints supporting the sprinklersystem piping seems sufficient.

Source of Findings: Photograph: Sprinkler system piping hangers.




Standard: Reference NFPA 13 Chapter 9 Hanging, Bracing, and Restraint of SystemPiping.

Question: All valves controlling the automatic sprinkler systems are electricallysupervised by a listed fire alarm system control unit.



Description: Valves controlling the automatic sprinkler systems are not electrically




Date: 15 Feb 2015



supervised, which is required by Alliance Standard.

Source of Findings: Visual Assessment: Valves controlling the automatic sprinkler systems werenot electrically supervised.


Provide electrically supervised devices on the valves controlling the automaticsprinkler systems. Devices are to be supervised by a listed fire alarm systemcontrol unit.


Standard: Reference Alliance Standard Part 5 Section 5.3.5 Supervision and Alarms.

Question: Aisles in storage areas are free of storage based on design criteria used forthe sprinkler system.



Description: No approved hydraulic design was available. However, aisles were foundstorage free.

Source of Findings: Photograph: Aisles free of storage.




Standard: Alliance Standard Part 5 Section 5.3.6.3

Question: Are portable fire extinguishers installed throughout the building at requiredlocations and mounted at the correct height?



Description: Fire extinguishers were installed within 100 ft travel distance. But not mountedat the required height and kept on floor in some places.




Date: 15 Feb 2015



Source of Findings: Photograph: Fire Extinguisher not mounted at required height


Fire extinguishers having a gross weight not exceeding 18.14 kg (40 lb) shallbe installed so that the top of the fire extinguisher is not more than 1.53 m (5ft) above the floor (NFPA 10 6.1.3.8) as mentioned in clause 5.6.2.1. Fireextinguishers h


Standard: BNBC Part 4 Section 4.10 and NFPA 10

Question: Fire extinguishers are inspected, tested, and maintained as required.



Description: Extinguishers are inspected monthly by factory's concerned people. But nodocument containing the policy of annual maintenance of extinguishers by aservicing agent and annual testing of nozzle of CO2 extinguisher is available.These are required as per NFPA 10.

Source of Findings: Photograph: Extinguisher maintenance record.


Fire extinguishers are to be inspected, tested, and maintained in accordancewith NFPA 10 Chapter 7 as demanded in Alliance Standard Part 13 Section13.10.3. And also provide and maintain proper documentation.


Standard: NFPA 10 Chapter 7

Question: Are inspection, maintenance, and testing procedures of the sprinkler systemdocumented and up to date?

Priority Level: Low


Description: Documents regarding the inspection, testing and maintenance procedure ofthe sprinkler system is not available.

Source of Findings: Document Review: No document regarding inspection, maintenance andtesting procedure of sprinkler system was found.


Establish maintenance program that includes the requirements established inNFPA 25.





Date: 15 Feb 2015



Standard: Reference NFPA 25 Chapter 5 Sprinkler Systems Table 5.1.1.2

Question: Does the automatic sprinkler system have an approved audible deviceactivated by waterflow equal to the flow of one sprinkler?

Priority Level: Low


Description: Approved audible device that is supposed to be activated by water flow is notavailable, which is required by Alliance Standard Part 5 Section 5.3.5.2.

Source of Findings: Visual Assessment: During site tour such audible device was not found.


Install an approved audible device connected to every automatic sprinklersystem and activated by water flow equal to the flow of one sprinkler. Where afire alarm system is installed, activation of the water flow shall activate the firealarm system.


Standard: Reference Alliance Standards Part 5 Section 5.3.5.2 Alarms.

Question: Is signage for the standpipe system installed at required locations and onrequired components?

Priority Level: Low


Description: The available signage for the installed standpipe system does not comply withthe requirements of NFPA 14.

Source of Findings: Photograph: Available signage for the standpipe system


Install required identification signs at the noted locations. Signage mustcomply with NFPA 14 Chapter 6.


Standard: Reference NFPA 14 Chapter 6

Question: Are inspection, maintenance, and testing procedures of the fire pumpdocumented and up to date?

Priority Level: Low


Description: Available maintenance record does not comply with the requirements of NFPA25.

Source of Findings: Photograph: Available maintenance record.




Date: 15 Feb 2015




Establish an inspection, maintenance and testing procedure for fire pump inaccordance with the requirements of NFPA 25.


Standard: Reference NFPA 25 Chapter 8 Fire Pumps

Question: Are identification signs for the sprinkler system installed at the requiredlocations?

Priority Level: Low


Description: Identification sign for the sprinkler system was found at some locations but notas per NFPA 13 Section 6.7.4.

Source of Findings: Visual Assessment: Identification sign.


Install identification signage at the required locations. The five basic types ofidentification signs are as follows: Type A- Control Valve Sign Type B- Multi-Purpose Text Signs Type D- Fire Alarm Sign Type E- Hydraulic CalculationSign Re


Standard: Reference NFPA 13

Means of Egress

Question: Travel distance to reach an exit does not exceed the maximum distanceallowed by Occupancy Type.



Description: Travel distance on ground floor of extended prefabricated shed from the mostremote point was measured 210 ft. Since the installed standpipe system is notcompliant with Alliance Standard, travel distance fails to meet therequirements stated in Section 6.13.1 of Alliance Standard.

Source of Findings: Visual Assessment: Travel distance was measured on sample basis.


Provide additional exits to keep the travel distance within 45 m or ensure thecompliance of the installed standpipe system and keep the travel distancewithin 60m.


Standard: Alliance Standard Part 6 Section 13 Travel Distance and BNBC Part 4 Section3.15.1




Date: 15 Feb 2015



Question: Exit access corridors serving an occupant load exceeding 30 are separated bywalls having a fire-resistance rating of 1 hr.



Description: Production area on ground floor and store containing combustibles on 4th floorof 6 story main building are located beside the exit access corridors and thewalls separating the corridors have non rated openings.

Source of Findings: Photograph: Exit access corridor


Provide fire-resistive rated assemblies at the required exit access corridors orclose those non rated openings or install automatic sprinkler system at thenoted locations.


Standard: Alliance Standard Part 6 Section 6.3 and Part 4 Section 4.5. Does not apply ifan automatic sprinkler system is installed throughout the building.

Question: Doors are not locked in the direction of egress under any conditions. All hasps,locks, slide bolts, and other locking devices have been removed whererequired.



Description: There are collapsible, sliding steel doors provided with locking arrangementsavailable in the buildings.

Source of Findings: Photograph: Locking arrangements


Remove all hasps, locks, slide bolts or other locking devices at the notedlocations.


Standard: Alliance Standards Part 6 Section 6.8 Doors and Gates




Date: 15 Feb 2015



Question: All doors in a means of egress are of the side-hinged swinging type.



Description: Exits are provided with steel sliding, collapsible, rolling type doors. Though thefactory authority has already started installation of side hinged swinging typefire rated doors at exits.

Source of Findings: Photograph: Non side hinged swinging type doors.


Replace non-compliant doors and frames in the means of egress with side-swinging doors. Replacement doors shall be a minimum width of 0.8 m (32 in),and are listed, approved, self-closing, fire rated doors assemblies (door andframe) with latching panic h



Question: Emergency power for means of egress illumination is verified at least once peryear. If battery operated lights are used, these lights are tested on a monthlybasis. Functional testing of battery powered lights is provided for a minimum90 min once per year.



Description: Maintenance checklist containing monthly testing emergency power for meansof egress illumination is available. But no policy regarding annual functionaltesting of battery powered lights was available among the documentsreviewed.

Source of Findings: Document Review: No document for annual functional testing of batterypowered lights was available., Photograph, Document Review: No documentfor annual functional testing of battery powered lights was available.,Photograph


Functional testing of battery powered lights shall be provided for a minimum of30 min once per year.


Standard: Alliance Standards Part 10 Section 10.12 Illumination of Exit Signs and MeansOf Escape Lighting




Date: 15 Feb 2015



Question: Emergency power for exit signs is tested at least once per year. If batteryoperated, these lights are tested on a monthly basis. Functional testing ofbattery powered signs is provided for a minimum 90 min once per year.



Description: Maintenance checklist containing monthly testing emergency power for exitsigns is available. But no policy regarding annual functional testing of batterypowered signs was available among the documents reviewed.

Source of Findings: Photograph: Maintenance checklist


Functional testing of battery powered signs shall be provided for a minimum of90 min once per year.


Standard: Alliance Standard Part 10 Section 10.12 Illumination of Exit Signs and MeansOf Escape.

Question: Handrails are provided on both sides of each stairway. Intermediate handrailsare provided when the stair width exceeds 2.2 m (87 in.). Handrails are notmounted lower than 760 mm (30 in.) or higher than 1100 mm (44 in.).



Description: Handrail is provided on both side of stairways in main building. But handrail isprovided only on one side of the stairway in Thermal Boiler Building and inETP Monitoring Building.

Source of Findings: Photograph: Only one side handrails.


Provide handrails on both side of each stairway. Provide intermediate handrailwhen the stair width exceeds 2.2m (87 inch). Provide handrail of heightbetween the range 865 mm (34 in.) and 965 mm (38 in.).


Standard: Alliance Standard Part 6 Section 6.9 Stairs and 6.12 Handrails and Guards

Question: Every door in a stair enclosure serving more than 5 stories is provided with re-entry unless it meets the requirements of Alliance Standards Part 6 Section6.8.3.1.



Description: Main building is six storied. Re-entry provision in stair enclosure shall be




Date: 15 Feb 2015



provided for this building. Doors are open now. Door installation work is underprocess.

Source of Findings: Visual Assessment: Door installation work was found to be ongoing duringassessment.


Every door in a stair enclosure serving more than 5 stories shall be providedwith re-entry unless it meets the following requirements. Stair doors may bepermitted to be locked from the stair (ingress) side that prevents re-entry to thefloor provided



Question: Ramps do not have a running slope greater than 1 in 8 (12.5 percent) andhave handrails on both sides of the ramp.



Description: The ramp used in ETP monitoring building has a running slope less than 1 in 8(12.5 percent) but do not have handrails on both side. The ramps used instenter section of main building have handrails on both side.

Source of Findings: Photograph: Handrails in ramp.


Provide handrail on both sides of the ramp.


Standard: Alliance Standard Part 6 Section 10 Ramps

Fire Safety Programs

Question: Are the required number of people trained and certified in fire fighting, first aid,and rescue training by the appropriate authority.



Description: As per the verbal information and documents from factory personnel, 118workers are trained in fire fighting, first aid, and rescue but certificate not yetissued. Applied to BGMEA and FSCD for more worker training.

Source of Findings: Document Review: 118 workers trained but certificate was not available.


Get at least 25 percent worker (165 of 660) trained and certified in fire fighting,first aid and rescue training by the proper authority.

Suggested Deadline




Date: 15 Feb 2015



Date:

Standard: Alliance Standard Part 13 Human Element Programs

Question: Emergency egress maps are posted at the entrance to each exit stair or mainpoint of egress.



Description: Emergency egress maps are not posted at the entrance to each exit ofancillary buildings. But egress maps were found at exits of main building.

Source of Findings: Photograph: Egress map at main building


Post emergency egress maps/fire evacuation maps at the entrance to eachexit stair or main point of egress.


Standard: Alliance Standards Part 13 Section 13.4 Evacuation Plan




Date: 15 Feb 2015

