Zafar Fabrics New Unit Dec 2021

M/S. ZAFAR FABRICS (PVT.) LTD.
(NEW PROCESSING UNIT)

3-KM Jhumra Road, khurrianwala, Faisalabad
R
I
S
K
S
U
R
V
E
Y
R
E
P
O
R
T
ADAMJEE INSURANCE COMPANY LIMITED
Risk Management Department
ADAMJEE HOUSE 80/A, Block E-1, Main Boulevard, Gulberg-III, Lahore.
☎ (+92) 42 35771245-52
This report is intended for insurance & reinsurance purpose only. This report is based upon conditions and information observed
during survey. Any recommendation(s) for risk improvement contained herein are purely advisory, and the decision and
responsibility for implementation rests with the recipient’s management. This report does not guarantee, assure or warrant that
compliance with any recommendations will eliminate all hazards or accidents, or that the recipient is in compliance with any
laws, statutes, regulations or directives. This report is “issued without prejudice”.
M/s. Zafar Fabrics (Pvt.) Ltd.
Location 3-KM Jhumra Road, khurrianwala, Faisalabad
Reason for Visit Pre Insurance Risk Survey
Report Issued January 10, 2022
Survey Date December 28, 2021
Surveyed By Ahmed Husnain (Joint Manager-RMD)
Accompanied By Syed Zahid Zaidi (DO Faisalabad)
Site Contacts Mr. Idrees Ahmad (GM Processing)
Risk Type Textile Processing
Concerned Branch/Division Circular Road Division/Main Branch, Faisalabad
Type of Cover Building, Machinery & Office Equipment
Sum Insured PKR 710,000,000
Reference Number FSD-2112-21/01
Pre Insurance Risk Survey Report Page 2

1- SCOPE 0F SURVEY
A pre insurance risk survey was carried out by the AICL RMD representative at request of Circular Road
Division/Main Branch, Faisalabad. The purpose of the survey was to find out potential hazards attached with
the risk and to collect related underwriting information. In the aim to improve the level of loss prevention, a
number of recommendations have been included in this report for safety and loss control in general and fire
protection in particular.
Zafar Fabrics (Pvt.) Ltd. (ZFL) is an existing client of AICL. ZFL is going to operate a new processing unit at 3Km
Jhumra road previously known as Jeea Textile (Pvt.) Ltd. The risk was not operational during visit on 28-12-
21. Maintenance work was going on. Risk is expected to be operational within 2 months (Feb.2022).
2- RISK PROFILE
M/s. Zafar Fabrics (Pvt.) Ltd. was established in 1985 as textile weaving unit. Currently, Zafar Fabrics is involved
in spinning, weaving, dyeing/printing/finishing and stitching, having separate units for each process.
Our risk assessment is limited to the new processing unit established in 2021 located at 3Km Jhumra road.
The risk is involved in the business of dyeing & finishing. Average daily production capacity of processed fabric
would be around 8-10 Lac meter.
Total area is around 17 acres while covered area is around 6.5 acres. Total number of hands at risk is around
131 persons including 22 Security guards.
Total Sum Insured:
Description Sum Insured (PKR)
Building & Machinery 700 Million
Office Equipment 10 Million
Total Sum Insured 710 Million

Surrounding Exposure:
The surrounding exposure is as follows;
East : Open Land (Fields)
West : Open Land
North : Open Land (Fields)
South : Chak Jkumra Road (Main Entrance)
Surrounding exposure is termed as Low.
Access: The approach road to the factory is in satisfactory condition.

Parking: The parking of the vehicles is allowed near the main gate/security office. Commercial vehicles have
limited access to loading/unloading areas and are required to depart as soon as their job is completed.
Entrance & Security: There is one entrance into the risk, protected with Iron Gate and guarded by armed
security guards. 07 guards were available at time of visit. CCTV Cameras were also observed at entrance gate
during visit.

Fences/Walls: The premises was bordered by 08 feet high un-plastered brick wall provided with barbed wires.

Aerial View (Google Map)
Coal & Corn Cob Storage
Stiching Halls & Grey Storage Area
70’
Dying Buiding & Offices
Security
Parking
Main Entrance

3- CONSTRUCTION & OCCUPATION
Construction : Mills spread over an area of about 17 acres with the following main occupancies:
 Dyeing Mills Building

 Main Store/Chemical Store
 Grey Storage Halls
 Stitching Halls
 Boiler House
All buildings pertaining to the dyeing mills, main store, Chemical Store and boiler
house are ground floor structures except stitching & Grey fabric storage halls. The
Production building is a 03 story structure (Ground+2). Construction standard of the
building is 1st Class RCC roof structure supported with beams and columns, provided
with 14-16 ft. high plastered burnt bricks plastered walls and cemented floor. 2nd Floor
Stitching hall has Pre Engineered roof structure.






Story Production building (Ground + 2)

 Ground floor is occupied as dyeing, printing, finishing & packing department
and storage of finished goods (RCC Structure)
 First floor: Grey Storage Hall & Stitching hall (RCC Structure)
 Second Floor: Stitching Section (Pre Engineered roof Structure)

Stiching Hall
Grey Storage Hall
Separation All sections in production building are separated by steel doors and partition wall of
9” & 13” thickness. Grey Fabric Storage & Stitching building is 70 feet away from dying
building.
Age : About 10 years
Plinth Level : Plinth level of the building is about 1 feet above the road level.
Condition : Satisfactory
4- STORAGE
Storage : Raw Material: Raw material is grey fabric, Accessories & Chemicals etc.
Condition
Finished Goods: Finished goods of the risk is dyed/processed fabric. There was not finished
stock available as unit was not operational.
Main Store/Chemical Store: Main store was attached inside dyeing mills building. The
main store contains accessories and spare parts as well as chemical stock. Chemicals were
stored in drums, bags and bottles according to their nature.
Coal & Corn Cob Storage: Coal (800 tons) & Corn Cob (1000 tons) storage for boilers was
stored in an open yard located near the boiler house.
LPG Storage: Two bowsers were available for the storage of LPG. The capacity of the
bowsers was 5 tons each. The bowsers were surrounded by iron mesh and located at a
distance of 50 feet from the main production building.

Caustic Soda Storage: Four Caustic soda tanks were also available with total capacity of 80
tons.
Overall storage condition of raw material including chemicals, accessories etc. was noted
satisfactory. Stocks details of Chemicals were shared by the Client.
Chemicals Storage

Accessories Storage


Chemicals Stock

LPG Storage Tanks

Coal & Cotton Cob Storage

Caustic Soda Recovery System

Caustic Soda Storage Tanks
5- MACHINERY
: At the time of visit, the mills was found not operational. Machinery is around 10 years
old. Machinery is mix of local and imported machines. Machinery includes dying,
printing, folding, stitching machines, fork lifter, Boilers, Thermo oil heaters etc. Overall
condition of plant and machinery was satisfactory. New machinery for dying process
is also installed. List of machinery details was not provided by the Client.


Printing Machine

Machines Maintenance Workshop
Boiler


Thermo oil Heaters

Boilers Maintenance Certificate
6- HOUSEKEEPING & UTILITIES
Waste : Overall housekeeping condition was found satisfactory. “No Smoking” signs were also
Management displayed. Area has also been designated for smoking.
Electrical : Ducted wiring was provided inside the building. Cables are properly laid in cable trays.
Wiring
Utilities Water: Main source of water was through bored pumps. Two turbines of unknown
capacity were available at the premises. There was one overhead water storage tank
having capacity of 60,000 gallons. One underground water storage tank having
capacity of around 100,000 gallons was also available.

Reverese Osmosis (RO) plant is being used to purify hard water. This water is being
used for drinking as well as in processing.
Overhead Water Storage Tank
Underground Water Storage Tank
RO Plant

Electricity: Main Electrical source is from WAPDA (3500 kVA). New Electrical Panel was
just procured from the WAPDA for the premises. Generators were not available at
time of visit as they were in process of procurement.
Boilers: 20 Tons/hour (8 million Kilo Callories) steam Boiler is also being used at risk
for various operations including washing & pressing. Total 02 boilers (1 is Coal fired &
1 is Gas fired) were available at premises. Coal fired boiler is used primarily with gas
fired boiler as backup. 03 Thermo oil heaters were also available.

7- FIRE PROTECTION & SECURITY
Fire : Adequate number of fire extinguishers & buckets were available at risk. Further, fire
Extinguishers safety equipment was in process of procurement.
& Fire Buckets
Fire Hydrant : Available. It was observed near LPG Storage tanks. Further, water pipeline for fire
System / Fire hydrant/hose reel at grey storage hall had been laid by Heaven Engineering (Third
Party). Renovation work was in process. 08 fire hose reel points was provided at grey
Hose reel
storage hall. Layout is given below.

Hydrant Line inside Gray storage Hall

Emergency Available.
Exits
Fire Brigade : Nearest fire brigade station is located at Khurrianwala with an estimated response
time of around 15 minutes.
Fire Alarms : Push button Fire Alarms are available.

Smoke : Not Available.

Detectors
Water Not Available.
Sprinklers
Staff Training :
Concerned staff seems to be trained in elementary firefighting procedures.
Smoking : No Smoking signs were not observed during visit.
Prohibition
Security : At time of visit, 07 armed security guards were available at the premises. It was
informed that total 22 company owned security guards are available to perform their
Guards and
duties in 03 shifts. 08 Security guards are dedicated for night shift.
CCTV Cameras Barbed fence wire was also provided along the boundary wall to ensure effective
security arrangements.
CCTV cameras were provided at various locations covering the whole premises from
inside and outside. The monitoring of the cameras was done from security and admin
office.
Emergency numbers were not posted at security check post.


8- PERIL ASSESSMENT
Fire : Considering the nature of the risk the peril of fire is termed as High.
Explosion : High
Windstorm : Low
Rainfall : Low – plinth level of the building is about 1 ft. above the road level.
Hailstorm High (CatNet Report)
Flood : Low
Escape of Water : The likelihood of any significant damage by an escape of water is low but cannot
be ruled out in case of firefighting by fire brigade.
Impact : The likelihood of any significant impact damage is low.
Aircraft : Low
Earthquake : High (CatNet Report)
Subsidence/ : There were no visible sign of any ground movement.

landslip
Lightning : High (CatNet Report)
Riot or Civil : Low

Commotion
Theft/Burglary : Low
Terrorism : Low

9- SWISS RE CATNET RISK ASSESSMENT REPORT

10- RISK RATING
Risk Criteria Range Rated Risk Rating Risk Rating Rated

Storage Condition 1-5 3 Average Unacceptable 1
Housekeeping 1-5 3 Average Below Average 2

(room for improvement)
Construction 1-5 3 Average Average 3
Fire Protection 1-5 3 Average Good 4
Security 1-5 3 Average Excellent 5
Note for Underwriter
As risk was not operational during visit and renovation works was going on therefore, Resurvey of risk is
recommended after 2 months (March 2022), when risk will be fully operational. Further, machinery was old,
maintenance work was also being done for various machinery at risk. List of machinery was not provided by
the Client.
11- RISK IMPROVEMENT RECOMMENDATIONS
RIR # 01/2022: No Smoking & Signs & Emergency numbers
“No Smoking” signs & Emergency numbers was not displayed at security room near entrance.
Best Practice: It is recommended that smoking should be strictly banned inside the premises and “No
Smoking” signs should be displayed at various locations. Moreover, Emergency numbers should also be
displayed near security entrance.

Zafar Fabrics New Unit Dec 2021

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Zafar Fabrics New Unit Dec 2021

Uploaded by

Copyright:

Available Formats

M/S. ZAFAR FABRICS (PVT.) LTD.

(NEW PROCESSING UNIT)

Location 3-KM Jhumra Road, khurrianwala, Faisalabad

Reason for Visit Pre Insurance Risk Survey

Report Issued January 10, 2022

Survey Date December 28, 2021

Surveyed By Ahmed Husnain (Joint Manager-RMD)

Accompanied By Syed Zahid Zaidi (DO Faisalabad)

Site Contacts Mr. Idrees Ahmad (GM Processing)

Risk Type Textile Processing

Concerned Branch/Division Circular Road Division/Main Branch, Faisalabad

Type of Cover Building, Machinery & Office Equipment

Sum Insured PKR 710,000,000

Reference Number FSD-2112-21/01

Pre Insurance Risk Survey Report Page 2

Total Sum Insured:

Description Sum Insured (PKR)

Building & Machinery 700 Million

Office Equipment 10 Million

Total Sum Insured 710 Million

Pre Insurance Risk Survey Report Page 3

The surrounding exposure is as follows;

East : Open Land (Fields)

West : Open Land

North : Open Land (Fields)

South : Chak Jkumra Road (Main Entrance)

Surrounding exposure is termed as Low.

Access: The approach road to the factory is in satisfactory condition.

Pre Insurance Risk Survey Report Page 4

Pre Insurance Risk Survey Report Page 5

Pre Insurance Risk Survey Report Page 6

Aerial View (Google Map)

Coal & Corn Cob Storage

Stiching Halls & Grey Storage Area

Dying Buiding & Offices

Pre Insurance Risk Survey Report Page 7

3- CONSTRUCTION & OCCUPATION

 Dyeing Mills Building

Pre Insurance Risk Survey Report Page 8

Pre Insurance Risk Survey Report Page 9

Pre Insurance Risk Survey Report Page 10

Pre Insurance Risk Survey Report Page 11

Pre Insurance Risk Survey Report Page 12

Pre Insurance Risk Survey Report Page 13

Story Production building (Ground + 2)

Pre Insurance Risk Survey Report Page 14

Grey Storage Hall

Pre Insurance Risk Survey Report Page 15

Pre Insurance Risk Survey Report Page 16

Pre Insurance Risk Survey Report Page 17

Pre Insurance Risk Survey Report Page 18

Pre Insurance Risk Survey Report Page 19

LPG Storage Tanks

Pre Insurance Risk Survey Report Page 20

Coal & Cotton Cob Storage

Pre Insurance Risk Survey Report Page 21

Caustic Soda Recovery System

Pre Insurance Risk Survey Report Page 22

Caustic Soda Storage Tanks

Pre Insurance Risk Survey Report Page 23

Pre Insurance Risk Survey Report Page 24

Pre Insurance Risk Survey Report Page 25

Machines Maintenance Workshop

Pre Insurance Risk Survey Report Page 26