A Case Study on Strengthening an Existing Structurally Risky Ready

Made Garments Industrial Building in Dhaka City

1
Subrata Chowdhury, 2Aniruddha Mazumder, 3Mahbub-ul-Alam & 4Farhana
Chowdhury
1,3,4
Assistant Professor, Department of Civil Engineering, Stamford University
Bangladesh
2
Former Student, Department of Civil Engineering, Stamford University Bangladesh

ABSTRACT
The Garments (RMG) sector has emerged as the biggest earner of foreign currency in
Bangladesh. The sector contributes significantly to the GDP. It also provides employment
to around 4.2 million Bangladeshis, mainly women from low income families. Now-a-
days many garment buildings collapse due to fault in design and improper maintenance.
The main reason for the collapse is also frequent change in occupancy of building. In this
study improvement of the faulty building which is at risk due to excess loads, has been
examined. The entire building condition and information have been collected by
feasibility study. Then the analysis of the existing building has been done. After
performing analysis, of the existing structure, it is found that all columns of each floor
resists 125 psf live load but fails at 250 psf live load and lateral loads. So, Improvement
work is necessary for structurally failed columns so that it can resist high industrial
loadings with wind and earthquake considerations. For improvement of column,
reinforced cement concrete column jacketing method have been followed. All the columns
have been improved in terms of size and reinforcement and thus the load bearing capacity
of each column have also been increased. Such type of study can be considered for
historically important but risky structures especially in old Dhaka.

INTRODUCTION

The readymade garment industry has become the lifeline of the Bangladesh economy.
Now-a-days it has turned to be one of the key sources of its development strength. The
Readymade Garment (RMG) industry of Bangladesh tells an impressive story of country
successful transition towards a major export- oriented economy The readymade garment
industry of Bangladesh is the third-biggest exporter of clothes in the world, after China
and Italy. While global market size export of RMG is US$ 400 billion, Bangladesh’s
share is about 5 %. This sector is under a great threat after the undesired structural failure
of an eight-storied commercial building Rana Plaza in Savar. More than eleven hundred
people died in the incident. Before this, with the collapse of the Savar Spectrum Sweater
factory, the Phoenix Fabrics Mill Ltd., the fire at Tazreen Fashions factory, Garib and
Garib garments factory, KTS Fabrics Mills and Chowdhury Knitwear Garments,
industrial compliance and safety issues have been identified as a burning issue in the
RMG sector and lots of pressure have been imposed on industry proprietors as well as on
the government regarding the safety of workers. According to the Bangladesh Institute of
Labour Studies (BILS),t he highest number of workplace accident deaths in Bangladesh
occurred in the transport sector while the readymade garments sector is in the second
position. As an immediate result of these disasters, the RMG industry and government of
Bangladesh, aided by international support - and pressure -, have increased their efforts to
improve the standard of safety in this industry Significant number of garments industries
of our country are at risky condition because of their weak structural stability. A large
number of RMG industries are running their production in the buildings which were not
designed for the purpose of RMG industry. Even the garments owners are not properly
aware of the structural conditions of their industrial buildings. Bangladesh Garment
Manufactures & Exporters Association (BGMEA) has already taken necessary steps to
involve qualified structural engineers for inquiry and inspection of these kinds of
industries. The study is to reveal probable solution options for strengthening existing
industrial building. A feasibility study is to be conducted before conducting a
strengthening project for determination of its suitability in terms of technical, financial,
commercial and socioeconomic issues.

OBJECTIVES OF THE STUDY

The study has been conducted in the Department of Civil Engineering at Stamford
University Bangladesh with the specific objective of determining the present structural
condition of a risky garment factory. The other objectives of the study are to investigate
suitable economic method for improving strength of the structure so that it can resist all
lateral and heavy gravity loads. By considering a series of strengthening methods,
reinforced concrete jacketing method has been adopted for this study. Through the
method, improving load bearing capacity of the existing columns have been examined in
the study.

METHODOLOGY

A primary report has been prepared based on the initial discussion with various
stakeholders for outlining the scope of the work and the major information requirement
for the study. Various relevant reports, project documents, existing literature have been
reviewed and consulted. Interviews/discussions have been done with important
stakeholders including owners of structurally risky RMG industries, BGMEA officials,
and the involved Engineers in the industries. A structurally risky industry has been
selected from BGMEA list of risky garments buildings. Practical field observations in the
industry have been made for collection of necessary photographs, data and information.
Preliminary information, architectural and structural drawings of existing structure, soil
report, material specification etc. have been collected for the study. Structural analysis of
the RCC frame structure have been performed by using Etabs software considering 125
psf (light) and 250 psf (Heavy) live loads recommended by American Concrete Institute
(ACI-318) in their minimum design loads for manufacturing buildings. Based on the
analysis results, some conclusions and the recommendations for the strengthening have
been made. The whole process is shown in Figure 1.

Figure 1: Steps for Improvement Work

FEASIBILITY SURVEY OF THE EXISTING STRUCTURE

The study garment industry site is situated at Tejgaon Thana of Dhaka District. The
Latitude and Longitude of the place are 23.7583°N and 90.3917°E. Extensive field
surveys for collection of data and information has been conducted in the project area for
the planning of the project. The general information about existing structure condition,
types of construction materials used, occupational safety features, utility sources etc. have
been collected through survey. Structural improvement work of the selected structure has
been done during study period. Soil and foundation capacity have been determined.
Existing column size, Beam size, slab thickness determined. Preliminary concept for
improvement cost, manpower operation and time duration of this type of project has also
been got.

ANALYSIS OF EXISTING STRUCTURE

At first the existing building has been analyzed with 125 psf light live load and then the
structure has been analyzed with 250psf heavy Live load. In first case wind and
earthquake loads are not considered. The existing layout of the column is shown in Figure
2.

Figure 2: Layout Plan of the Existing Industry

MATERIAL PROPERTIES & LOADINGS

Based on design code/specification of ACI/BNBC, material properties (compressive

strength of concrete, yield stress of steel, unit weight of concrete, brick etc.) and loading
(standard live load, Floor finish, Partition wall etc.) have been selected. The existing
structure has been analyzed twice with two different live loads. Wind and earthquake
loads as per BNBC 2006 have been considered for structural safety.

RESULTS AND DISCUSSIONS

After performing analysis of the existing structure, the obtained results is shown in Table
1

Table 1: Load Carrying Capacity of Columns at Different Loading Conditions

(Considering 125 psf live load and both

(Considering 125 psf live load and

(Considering 250 psf live load and

Existing Load Carrying Capacity

(Considering 125 psf live load and

both gravity and lateral load)

Maximum Load on Column

Maximum Load on Column

Existing Reinforcement

gravity and lateral load)

Existing Column Size

Condition of Column

Condition of Column
gravity load only)
Column Designation

of the Column

gravity load only)

in2 Kips Kips Kips

C1 10"10" 1.76 167 127.60 Safe 210 Fails
C2 12" 12" 3.16 253 248.81 Safe 347 Fails
C3 14" 14" 10 559 449.51 Safe 654 Fails

From the analysis, it is clear that the existing columns of each floor resists self load, dead
load and 125 psf live load (gravity load only) because the existing load bearing capacity
is greater than the maximum calculated load on the column. But, if 250 psf live load with
lateral load (wind and earthquake) are applied in addition to self and dead load, the load
bearing capacity of existing column becomes smaller than the load maximum calculated
load on the columns. So, Improvement work is necessary for the inadequate columns. For
improvement of columns, reinforced cement concrete column jacketing method have
been used.

IMPROVEMENT OF THE EXISTING STRUCTURE

For improvement work of the structure Reinforced Concrete Jacketing method have been
followed. The excess amount of reinforced cement concrete that has been required for
strengthening the structure has been distributed and designed by following ACI Code.
  Match with the concrete of the existing structure.
 Compressive strength greater than that of the existing
Properties of jackets
structures by 5 N/mm2 or at least equal to that of the existing
structure.
 10 cm for concrete cast-in-place.
 If possible, four-sided jacket should be used.
Minimum width of  A monolithic behavior of the composite column should be
jacket assured.
 Narrow gap should be provided to prevent any possible
increase in flexural capacity.
 Spacing should not exceed six times of the width of the
new elements (the jacket in the case) up to the limit of 60 cm.
Minimum area of  Percentage of steel in the jacket with respect to the jacket
longitudinal area should be limited between 0.015and 0.04.
reinforcement  At least, 12 mm bar should be used at every corner for a
four sided jacket.

 Designed and spaced as per earthquake design practice.

Minimum area of  Minimum bar diameter used for ties is not less than 10
transverse mm or 1/3 of the diameter of the biggest longitudinal bar.
reinforcement  The ties should have 135-degree hooks with 10bar
diameter anchorage.

 Provide adequate shear transfer mechanism to assured

monolithic behavior.
 A relative movement between both concrete interfaces
(between the jacket and the existing element) should be
Shear stress in the prevented.
interface  Chipping the concrete cover of the original member and
roughening its surface may improve the bond between the old
and the new concrete.
 For four-sided jacket, the ties should be used to confine
and for shear reinforcement to the composite element.
 Connectors should be anchored in both the concrete such
that it may develop at least 80% of their yielding stress.
 Distributed uniformly around the interface, avoiding
Connectors concentration in specific locations.
 It is better to use reinforced bars (rebar) anchored with
epoxy resins of grouts.

The conditions after strengthening of columns through jacketing is shown in Table 2

 Table 2: Columns after Strengthening

Improved Additional Improved Load Condition of Column

Column Reinforcement Bearing Capacity of
Size(After (in2) Column(KIP)
Jacketing)
18"×18" 3.16 576 Safe
20"×20" 3.16 829 Safe
22"×22" 1.76 993 Safe

After improvement, the additional concrete and steel almost doubled the load bearing
capacity of columns. So, after improvement, the structure can resist high loadings with
wind and earthquake effects. The reinforcement layout of existing columns and the
columns after strengthening is shown in Figure 3. Figure 4 shows comparison between
load carrying capacity of existing column and column after strengthening Figure 5 shows
comparison between gross area of existing column and column after strengthening. Figure
6 shows comparison between reinforcement of existing column and column after
strengthening. Photo 1 to Photo 8 show different view of the construction works during
strengthening of the column in the site.
Designation
Column

Existing Column Columns after Jacketing

(4 nos.)
C1
(20 nos.)
C2
(25nos.)
C2

Figure 3: Reinforcement Layout of Columns

Load Carrying Capacity (Kips)

Reinforcemnet (Sq. inch)

500

Column Area (Sq. inch)

100 0 450

400
900
800 350 10
300
700 250
600 200
500 150

400 100

300 50 5
0
200
100 C1 C2 C3
0 Existi ng Column Area (Sq. inch)
After Improvemen t Column Area (S q. inch)
C1 C2 C3 0
Existing Load Carrying Capacity (Kips) C1 C2 C3
After Improvement Load Carrying Capacity (Kip)
Existing Reinforcement Area (sq. inch)

After Improvement Reinforcement Area (Sq.

inch)

Figure 4: Load Carrying Figure 5: Gross Area of Figure 6: Reinforcement of

Capacity of Existing Existing Column and Existing Column and Column
Column and Column after Column after Strengthening after Strengthening
Strengthening

Photo 1: Existing Photo 2: Additional Photo 3: Chipping of

Reinforcement is Pulling Reinforcement Bars are Concrete from Column
Out from Pedestal being Entered through
Column Slab
 Photo 4: A Finished Photo 5: Closed View of a Photo 6: Existing
Interior Column of Finished Column after Column Grade Beam
Ground Floor after Jacketing Joint
Jacketing

Photo 7: Supporting the Floor Beam Photo 8: A View of Re-Casting of

During Strenthening of Column Columns for Strengthening

RECOMMENDATIONS

Based on the objectives, scopes and limitation of the study and the obtained results, few
recommendations can be proposed for further studies. Jacketing is conventional method
for improving existing structure. Sprayed up Fiber Reinforced Polymer Strengthening is
an updated method of improvement. Though Sprayed up FRP Strengthening method is an
expensive method but its construction process is easier compared to Reinforced Concrete
Jacketing Method. From ETABS Analysis it is found that some of the beams and slab
panels also been failed due to 250 psf live load. So, improvement of these inadequate
beams and slab panels is also recommended. Soil condition and bearing capacity of soil is
an important factor for improvement work. So, detail soil investigation is also
recommended for further improvement study. Same study can be conducted considering
other structures instead of industrial one. Such type of study can be taken for historically
important but risky structures especially in old Dhaka.

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