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Abstract

The fire incidents significantly influence the textile garments building structure directly or indirectly. Therefore, this article aims to assess the fire incident related to Textile Garments Manufacturing Buildings (TGMBs) in Karachi, Pakistan. Moreover, the questionnaires were filled out by professionals with knowledge and experience of past fire incidents. The literature review, international and national fire incidents in (TGMBs) identified 30 factors contributing to fire incidents in (TGMBs). The Relative Importance Index (RII) was utilized to rank the factors contributing to fire incidents in (TGMBs). This study exposes 81.6% of high-risk fire incidents in TGMBs in Karachi, Pakistan. The identified factors, including the availability of hazardous material on the floor, insufficient firefighting service, and timber structure floor, emerged as the top three contributors to the fire incident (TGMBs). This paper focused on the steps required to provide appropriate strategies to eliminate all 47 contribution factors, which increased the fire incident factor in (TGMBs) in Karachi, Pakistan. The research highlights the urgent consideration of effective fire risk assessment measures and enhancing fire safety in (TGMBs). The findings and recommendations presented in this study can serve as a valuable resource for the textile garments manufacturing sector, industry professionals, policymakers, and stakeholders in Karachi, Pakistan.

Plain Language Summary

Understanding the Causes of Fires in Karachi’s Textile Garment Factories

This study delves into the impact of fire incidents on textile garment manufacturing facilities (TGMFs) in Karachi, Pakistan. Despite numerous fire incidents, there’s been limited research on this sector. The study aimed to understand these incidents by gathering insights from professionals familiar with past incidents. Through a thorough review of international and national incidents, 30 contributing factors to TGMF fires were identified. Using the Relative Importance Index (RII), these factors were ranked, revealing that factors like hazardous material presence, inadequate firefighting services, and timber structure floors are key contributors to TGMF fires. The study uncovered that 81.6% of TGMFs in Karachi are at high risk of fire incidents. It proposes strategies to address all 47 contributing factors and emphasizes the need for effective fire risk assessment and safety measures. The findings and recommendations provided can be valuable for TGMF stakeholders, industry professionals, and policymakers in Karachi, Pakistan, to enhance fire safety in these facilities.

Keywords

fire incidents factors strategies textile garments manufacturing buildings

Introduction

General Background View

A sustainable building structure must be carefully constructed to last more than 60 years to ensure longevity without devastation (Le et al., 2021). In the textile industry, fire incidents have directly or indirectly led to serious injury, fatality, property loss, and destruction of building structures (Tan et al., 2021), and textile workers consider the worst building infrastructure hazardous and dangerous. According to the World Fire Statistics (WFS) report, 45,000 fires resulted in 206 hundred deaths, while 69,500 injured from 48 progressive countries (Brushlinsky, Ahrens, Sokolov, & Wagner, 2016). One developed Nation faced 1.35 million fire incidents, 3,800 deaths, and 1,470,000 injured, including $15.9 billion in property losses (Mahood et al., 2022). Fire incidents are mostly observed within the textile sector compared to other regional sectors. These deviations indicate failures in the textile manufacturing sector to meet fire safety requirements or to take necessary measures to prevent fire incidents (Theuws et al., 2013).

Specific Pakistan View

Pakistan’s industrial sectors have faced various incidents ranging from security attacks to safety risks (Rush et al., 2020). Fire incidents have been recognized as Pakistan’s second most prevalent type of disaster (Ali et al., 2015). Previous reported fire incidents, including Ali Enterprises (2012) and others between 2015 and 2022 (e.g., Mundia Textile, Essa Tex, Rajwani Denim, Lucky One Textile Mill, Star Textile Mill, Afroze Textile Mill, and Artistic Milliners Unit) (Al Jazeera, 2015; Dawn, 2017, 2018, 2019; ECCHR, 2019; Forensic Architecture, 2018; IndustriALL Global Union, 2016; Workers Rights Consortium, 2022 and Campaign, 2013). Based on understanding fire incidents, appropriate research is required to determine the cause of the fire incidents in Pakistan’s garment sector. Mohsin et al. 2016 suggested that textile factory fires in Pakistan have caused significant loss of life and property over the past decade.

On September 11, 2012, a massive textile disaster resulted in 262 worker’s death and seriously 55 injured in a three-story building in Karachi (Dying, 2016). On April 13, 2023, a fire occurred at a six-story building of the Usman & Sons company in New Karachi; four firefighters were killed, and 14 others were injured (F. Khan, 2023). According to the (Soomro, 2021), a fire disaster affected 16 workers’ death in a Karachi garment factory.

Problem Statement, Study Significance, and Objective

Annually, textile buildings fire disasters disrupt Pakistan’s textile sector’s utilization and development procedure (Yasmeen et al., 2022). The statistical value of fire incidents in the Karachi textile buildings from 2015 to 2022 is mentioned in (Figure 1). Proper investigation is essential for assessing the current situation and eliminating future fire risks in textile buildings. Unfortunately, the textile sector was not given attention from the beginning. Therefore, the primary aim is to evaluate the fire risk in (TGMBs), identify the key factors contributing to fire incidents in (TGMBs) and propose effective strategies to reduce fire incident factors.

Figure 1.

Municipal fire department data (2015–2022 December).

It is of greater significance to explore the elements that increase the fire incident of (TGMBs) in Karachi, Pakistan. This topic has not yet been researched because of recent serious fire events, literature, and research gap. This study’s objectives are to assess the factors that increase the fire incident of (TGMBs) in Karachi, Pakistan, and to provide solutions to the issues identified as contributing to the fire incident of TGMBs in Karachi, Pakistan.

Related Studies

Understanding Fire Outburst Behavior in Buildings

A thorough reading of fire behavior is optimal for monitoring and forecasting actual fire scenes (Meskéoulé Vondou et al., 2020). The combustion process involves the chemical reaction between oxygen and a fuel source, resulting in an emission of heat energy and the destruction of a particular substance (Winchell et al., 2021). The combusting substances produce temperature alteration and color variation flame during a real fire scene. The flame color of the “Rame” material transitions from red to yellow as the temperature decreases. As the temperature increases, the flames become white, manifesting white fire (Wang et al., 2017). The dynamic form of fire can be identified as a result of the air currents generated by wind.

In contrast, the composition of the smoke emanating from fires is contingent upon the nature of the combustible material involved (Toptaş & Hanbay, 2020). Moreover, the concept is clarified that eliminating a single variable will result in fire extinction by disrupting the fire triangle. Any one factor must be prohibited from combining with the remaining two variables to prevent the starting point of a fire. Subsequently, the traditional triangular framework was questioned by contemporary research, which proposed the addition of a fourth variable (Hasofer et al., 2006). According to the study, a chemical chain reaction acts as a reaction chain that accelerates the combustion process (Hasofer et al., 2006). C.-H. Chang and Huang (2005) have addressed the fire growth rate based and fire expansion impact on burning materials. Accordingly, (Čolić & Pečur, 2020) have demonstrated that fire can move vertically and horizontally throughout a building.

Fire Incidents in Textile Manufacturing Buildings

Fire risk is a universal concern observed in all countries. Textile developing countries such as India and Bangladesh have faced the highest yearly fire deaths (10,000–25,000; Bruslinskiy et al., 2019). The Asian region is the second-highest non-compliance rate with fire safety regulations (Rathnayake, Sridarran, & Abeynayake, 2020). Over the years, Karachi textile buildings have encountered numerous significant fire incidents (The Nation, 2012). Additionally, fire occurrences have been ranked as Pakistan’s second-highest catastrophe category (NDMA, 2007; Saif-ul-Islam et al., 2019). When examining fire-related incidents across various sectors, it becomes evident that the textile manufacturing sector has the highest reported non-conformities compared to other sectors in Pakistan (A. F. Khan & Ahmad, 2022). In 2012, there was a massive fire disaster in Tazreen Garments, Bangladesh, with approximately 112 workers’ deaths (Mahood et al., 2022). In 2013, eight people died in a fire incident at the Tung Hai T.M.B. in Mirpur, Dhaka (Naoshin et al., 2020; Wadud et al., 2014). According to (Rush et al., 2020), a fire disaster killed 13 textile workers in a New Delhi garments building. In the past decades, horrible fire incidents have been identified in the textile garment sector, namely the Ali Enterprises garment factory (Bugti, 2020; Raza et al., 2018). For example, Khalid et al. (2020) investigated smoke extraction efficiency in immersed tunnel fires using large eddy simulations, highlighting the critical influence of vent geometry and heat release rates on smoke movement and control. The dynamic form of fire can also be influenced by air currents generated by wind, which shape flame behavior and spread.

The massive building destruction observed ineffective fire alarm systems, locked emergency doors, windows covered with iron grills, blocked escape routes, and clothing bails (combustible material) stored on the main floor. Several textile buildings reported massive fire incidents in Karachi, Pakistan, such as M/S Rajwani Denim, Al-Awal Garment, and Essa Tex (Pvt) Ltd (Shaik et al., 2019). Bajaj (2012) mentioned that fire explosions and incidents frequently influence Karachi’s garments manufacturing industry.

Causal Factors to Building Fire Incidents

According to (Liu et al., 2012), ignoring the causes of fire occurrences reduces the effectiveness of the building’s existing fire safety measures. Unfortunately, there are an average of five to six fire-related fatalities in the UK daily. This statistic is regrettably representative of many other nations throughout the world. The Inadequate fire safety system and design characteristics errors are the main factors for insufficient fire safety in the buildings (Park et al., 2014).

Delft University, Crowne Plaza Hotel, Bradford building, and King’s Cross Station were recognized as significant fire disasters due to poor design features (Lottman et al., 2013). The building consisted of horizontal windows and a mezzanine floor that provided direction for relaxation and intimacy. The investigation revealed that fire occurrence severity worsened because these building structures accelerated fire spread vertically (Park et al., 2014). The Bradford City building and King’s Cross station fire incidents were the major causes of ancient buildings and wooden structures (Cheng et al., 2001). The investigation indicated bad signs in the fireman’s elevator, and the door’s color matching the adjacent walls made it challenging to recognize the entrance (Gatheeshgar et al., 2020).

A fire incident occurred at a Hong Kong high-rise building. The building design and construction require fire safety concerns during the renovation process (Li, Ng, & Skitmore, 2017; Wong & Lau, 2007). The doors were removed, and plywood panels were not permanently sealed during the renovation work in the lift shaft. The vertical gaps allowed the fire to spread quickly in the building (Wong & Lau, 2007). Moreover, the identified combustible material supported the fire’s quick spread (Lavigne et al., 2014). Most building fire causes electric spark during welding (J. I. Chang & Lin, 2006). A fire occurrence in Hong Kong was linked to deviating from the building’s original architectural function (Times, 2023). A fire brigade’s slow response would have increased the number of fire accidents in Karachi (Dawn, 2009). The construction workers involved irresponsible in using cigarettes during the working project (Wong & Lau, 2007). Shaikh et al. (2023) recent advances in fire modeling in Pakistan have also focused on forensic analysis of real building fires.

Building codes are essential to provide building protection and fire safety design. The legislation covers minimum safety regulations for building investors (Li, Zlatanova, & Fabbri, 2007). Several construction structures significantly influenced fire safety, while others may have a lesser impact. Moreover, architects show frustration over restrictive building codes hindering their performance from incorporating old building concepts (Li, Zlatanova, & Fabbri, 2007). In addition, international fire codes and standards recognized Pakistan as having a poorly organized Fire Brigade (Kodur et al., 2020). However, ineffective safety laws lead to ineffective safety measures (Stollard, 2014). Fire policies and actual scenarios have generated contradictions between previous fire incident investigations. During fire incidents, the occupant chooses the unfamiliar exit routes rather than the nearest emergency exit (Stollard, 2014).

The Ali Enterprises fire was significantly worsened by insufficient firefighting services and a lack of appropriate equipment (Siddique & Hussain, 2020), Emergency lighting (Ahmad et al., 2020), and Fire alarm system (Paś & Klimczak, 2019). For instance, Pakistan lacked firefighting vehicles like the Sky Lifter. Only about 15 Sky Lifters are in the country, and half are concentrated in the capital, resulting in insufficient firefighting resources. Increased fire dangers are also a result of the location of existing firefighting services (Anadolu, 2022). In addition, (Paul et al., 2022) emphasized the Delhi fire service difficulties in India, including a staff and equipment shortfall. Along with these flaws, the lack of emergency exits, poor safety signage, inaccessible stairs, inadequate ventilation, and a lack of emergency lighting all contributed to a considerable increase in casualties during various fire occurrences (Tazmul et al., 2018). Accordingly, Table 1 summarizes the factors contributing to the fire risk of (TGMBs).

Table 1.

Factors Contribute to Fire Incidents of (TGMBs).

Factor	Sources
Availability of hazardous material on the floor	Chavan (2001), Gursoy-Haksevenler et al. (2022)
Insufficient firefighting service	Siddique and Hussain (2020)
Timber structure floor	Cheng et al. (2001), Vijay and Gadde (2021)
Negligence of architects in fire safety	Kobes et al. (2010)
Explosions of boiler	Kim (2017), Tazmul et al. (2018)
Building materials/features designed which enhance fire spread	Park et al. (2014)
Errors in building design	Mehrbod et al. (2020)
Smoking	Sanders et al. (2020)
Differences between policy considerations and findings from actual fire incidents	Stollard (2014)
Inadequate fire detection system	Chow and Wong (1998)
Inadequate fire protection system	Briet (2001)
Poor maintenance of electrical wiring and connections	Hassanain et al. (2016)
HVAC system fire risk	Rathnayake, Sridarran, and Abeynayake (2022)
Ineffective renovation	Gatheeshgar et al. (2020), Li et al. (2017), Wong and Lau (2007)
Insufficient firefighting service	Siddique and Hussain (2020)
Design/architecture and fire safety integration errors	Park et al. (2014)
The fire brigade delayed response	Dawn (2009)
Insufficient firefighting staff	Jacobsson et al. (2015), Paul et al. (2022)
Insufficient utilization of fire-resistant materials	Rafikov et al. (2022)
Structures with a lot of continuous horizontal and vertical openings	Lottman et al. (2013)
The geographic distribution of present firefighting services	Anadolu (2022)
Using the building not for its original design	McMullan (2017)
The fire brigade is inadequately equipped	Kodur et al. (2020), Masood Rafi et al. (2012)
Inadequate maintenance of electrical equipment	Electronic Library of Construction Occupational Safety and Health (2001)
The process of welding involves the generation of electrical sparks	Mäkinen (2013)
Iron burglar windows	Tulchinsky (2016)
Exit door locked	Ahmed and Hossain (2009)
Emergency lighting	Ahmad et al. (2020)
Fire hose reel	Azmi et al. (2009)
Fire alarm system	Paś and Klimczak (2019)

Materials and Methods

This research combines exploratory and qualitative methods based on various data. The secondary data using an inclusive literature review, Articles from Science Direct, Google Scholar, JSTOR, and online sources following the availability criteria, validity, relevancy, and quality was selected to gain in-depth knowledge and causes contributing to the fire incidents in the (TGMBs). The primary data was collected through questionnaires, semi-structured interviews, and emphasizing three previous fire incident cases. Professionals with extensive knowledge about previous fire incidents were selected to complete the questionnaire. A total of 21 professionals with in-depth expertise in fire safety management within the three fire cases were selected in semi-structured in-depth interviews from the 75 questionnaires. Table 2 illustrates the respondent’s interview summary.

Table 2.

Interviewers’ Profiles.

Case	Respondent code	Position title	Working experienced
Ali enterprises	AH1	Director of compliance	12
	AH2	Manager I, environmental, health, and safety (EHS)	6
	AJ1	Construction engineer	9
	AJ2	Project director	6
	AA1	Chief operating officer	13
	AA2	Operations manager	9
	ATI	Maintenance officer	11
Rajwani Denim	BH1	Technical director	9
	BH2	Occupational health and safety administration	8
	BJ1	Machine operator	11
	BJ2	Civil-engineer in chief	10
	BA1	Facility planning manager	8
	BA2	Sustainability and energy management executive	9
	BT1	Complain, officer	6
Usman and Sons Company	CH1	Internal control auditor	9
	CH2	Operations and compliance director	7
	CJ1	Project supervisor	12
	CJ2	Architectural designer	7
	CA1	Executive	18
	CA2	Environmental sustainability officer	10
	CT1	Safety officer	5

In this research, a non-probability sampling approach was employed due to the absence of probability associations with the population units, with the researcher’s judgment being the basis for selection (Rowley, 2014). A purposive sampling technique was deemed the most appropriate for identifying interviewees within the non-probability sampling framework (Rowley, 2014).

Additionally, the study analyzed the quantitative data using the Relative Importance Index (RII) technique. According to (Gündüz et al., 2013), priorities identification and rank attributes in the (RII). In this context, the results derived from the five-point Likert scale were transformed using RII to ascertain the relative importance of different factors. The RII calculation was performed using Equation 1:

RII = \frac{\sum w}{AxN}

(1)

Where w = weighting determined by each respondent’s factor on the Likert scale.

A = most substantial weight on the scale.

N = overall response rate.

Ethical Considerations

Formal ethics approval was not required for this type of research in accordance with local legislation and institutional requirements. To minimize potential risks to participants, the study avoided the collection of sensitive personal information, ensured anonymity by assigning respondent codes, and stored raw data securely. Only aggregated findings are reported. The potential benefits of this research informing policy and improving fire safety in the textile garment manufacturing sector were considered to outweigh the minimal risk of participation. Written informed consent was obtained from all participants after explaining the study objectives, procedures, confidentiality protections, and voluntary nature of involvement.

Results and Discussion

Fire Risk Factors in Karachi Textile Garment Manufacturing Buildings

Below are the findings of Karachi’s three textile garment buildings that have gone through fire accidents presented separately as case studies.

Case Study 1

On September 12, 2012, a three-story textile garment factory in Karachi, Pakistan, occurred at 6:00 PM, killing 262 workers and seriously injuring 55; the factory fire scene images are shown in (Figure 2). The basement floor, ground floor, mezzanine floor, first floor, and second floor comprised the three stories of the building. The clothing bail was present on the ground floor. According to investigation reports, the fire was allegedly initiated on the ground floor using kerosene oil, where clothing bales wrapped in polyethylene plastic acted as fuel, contributing to the rapid spread throughout the building (Figure 3).

Figure 2.

Factory scene inside.

Figure 3.

Factory scene outside.

Case Study 2

At around 2.36 PM on March 10, 2017, an enormous fire erupted in a three-story building in Karachi due to an electrical short circuit. The fire broke out on Friday afternoon, taking 2 days to contain. The firefighters said the electrical wiring was outdated. Early on, the fire spread to the upper stories and nearby floors. Smoke and heat from a fire can enter the upper floors through the staircase or the building’s outside. Unfortunately, the absence of sprinkler systems in the building contributed to the fire’s rapid spread. The fire department lacked the necessary tools and fire tenders. There was only one snorkel actively putting out the flames. Poor firefighter gear encourages financial losses. Figure 4 shows the industry’s image before the fire, Figure 5 shows the industry’s image while it was burning, and Figure 6 represents the industry’s image 2 days following the fire.

Figure 4.

Factory scene outside.

Figure 5.

Factory scene outside.

Figure 6.

Fire after 2 days.

Case Study 3

On April 13, 2023, a bedsheet factory’s multi-story building suffered a massive fire in the southern port city of Karachi, Pakistan. Four firefighters died, and nearly a dozen others were injured. Figure 7 illustrates the factory image from the outside after the fire.

Figure 7.

Factory scene outside.

The survey results indicate a high probability of fire incidents in Textile Manufacturing Garments Buildings (TMGBs) in Karachi, Pakistan, with 81.6% of respondents attributing a high fire risk to TMBs and 18.4% attributing a moderate fire risk.

A comprehensive literature review identified 30 factors associated with fire risk factors in textile buildings. A questionnaire was conducted among professionals with knowledge and experience regarding past fire incidents in the three selected cases to investigate factors. The survey utilized a Likert scale ranging from 1 to 5, allowing participants to assess their opinion on the importance of each. The collected responses from the questionnaire were then analyzed to determine the relevance of these identified factors in the context of fire incidents in (TGMBs) in Karachi, Pakistan. It is important to note that all respondents provided their answers based on their opinions and experiences. The Relative Importance Index (RII) values were computed as indicated in the analysis method to evaluate and rank the responses. All responses were evaluated and ranked using RII values, as shown in Table 3.

Table 3.

Ranked Factors Based on RII Value.

Variables parameters	RII value	Rank
Availability of hazardous material on the floor	1	1
Insufficient firefighting service	.9999	2
Timber structure floor	.9888	3
Electric wiring and poor maintenance	.9888	4
Electric sparks during the welding process	.9777	5
The location of the firefighting department	.9666	6
Building design features	.9555	7
Delayed response time of the fire brigade	.9333	8
Smoking	.9111	9
Inadequate maintenance of electrical equipment	.9	10
Inadequate fire detection system	.8999	11
Inadequate fire protection system	.8777	12
Negligence of architects in fire safety	.8666	13
Explosion of boiler	.8333	14
Design/architecture and fire safety integration errors	.8222	15
Insufficient utilization of fire-resistant materials	.8	16
Lack of sufficient firefighting service	.7999	17
Structures with a lot of continuous horizontal and vertical openings	.7666	18
Errors in building design	.7555	19
Using the building not for its original design	.7111	20
Differences between policy considerations and findings from actual fire incidents	.7	21
The fire brigade is inadequately equipped	.6888	22
Insufficient staff in firefighting organizations	.6777	23
HVAC system fire risk	.6555	24
Ineffective renovation	.6222	25
Iron burglar windows	.6111	26
Exit door locked	.6	27
Emergency lighting	.5999	28
Fire hose reel	.5777	29
Fire alarm system	.5555	30

Table 3, illustrates the highest relevance (RII value of 1) of the availability of “hazardous material on the floor.” The RII value is .9999, followed by “Insufficient firefighting service” with an RII value of .9888. The “Timber structure floor” factor was rated third, indicating a substantial relationship to fire incidents in textile manufacturing buildings (TGMBs). The fourth and fifth most important, significant factors are “Electric wiring and poor maintenance” and “Electric sparks during the welding process.”

Respectively, RII values of the Iron burglar windows “.6111,” Exit door locked “.6” Emergency lighting “.5999” Fire hose reel “.5777” and the Fire alarm system “.5555” were regarded as the least significant. These findings suggest that these factors contribute to fire accidents in (TGMBs) Karachi, Pakistan. Availability of hazardous material on the floor received the highest RII score of all the variables and was consistently given a weight of five by all respondents. Respondents AH1, AH2, CJ1, and BA1 agree with this conclusion. In response, AH2 said:

[…] Hazardous material on the floor causes fires in (TGMBs). During the fire of Ali Enterprises, clothing bails were stored on the main ground floor, frequently blocking the escape route. However, clothing bails are wrapped in polyethene plastic, the predominant fuel for the fire.

Furthermore, respondent CJ1 addresses that:

[…] Insufficient firefighting service may cause fire incidents.

Respondent AA1 stated that evaluate the existing firefighting service to determine its strengths and weaknesses. Identify areas where improvements are needed, such as response time, equipment, training, or personnel.

Respondent AH1 illustrated that “timber structure floor” may cause fire incidents in (TGMBs). AA1 respondents agreed with timber structures on the mezzanine floor in Ali Enterprises. Karachi Building Regulation Authority (KBRA) states that all steel and other metal structural elements shall be protected with non-combustible materials to provide the required fire resistance. The above statement shows that the factory was not adopting international standards and regulations.

Respondent AH2 stated that

[…] Faulty electric wiring and poor maintenance cause fire incidents in TGMBs.

Furthermore, respondent CJ1 indicated that:

[…] The old building’s electric wiring structure cannot support the new electric system; the wires loosen and strung, which possibly causes breakdown and fire.

Respondent AA1 mentioned that welding fire generates hot slag, torch flames, and sparks which may reach temperatures about 2,000 degrees Fahrenheit, and the ability to move horizontally for up to 10 m when they fall.

Respondent CA2 mentioned the importance of the “Location of the firefighting department.”

[…] Most firefighting department’s located far away from the TGMBs. Respondent (AH2) stated developing a mechanism to get help from neighboring industries during the emergency.

The most significant causes of textile fires are “improper refurbishment and Heating, ventilation, and air conditioning (HVAC) systems.” Respondent CJ2 indicated that opening or removing lift shaft doors due to incorrect restoration was uncommon compared to other variables, supporting these findings. Additionally, the availability of built-in fire safety measures, such as closed fire dampers and smoke detectors in the duct system, can be credited for the lower ranking of “fire risk in HVAC systems.”

Through interviews and questionnaire surveys, 20 factors contributing to fire events were identified in addition to those mentioned in the literature. The “worn-out electrical sockets and grounding issues” and “high installation and repair costs of fire systems” were cited by respondent AH1 as major causes. According to respondent CH2, “improper chemical storage” raises the fire risk in TGMBs. Respondent BA2 emphasized that “Sudden breakdowns” can still happen even with thorough testing and monitoring of fire protection devices, increasing the severity of fire accidents. According to respondent BH2 and survey participants, “Penetration through fire-rated barriers” is a problem. The questionnaire survey’s respondents and respondent AH2 mentioned issues like “deficiencies in commanding at fire scenes,”“lack of fire training and awareness among employees,”“lack of technical knowledge regarding fire safety,” and “lack of competent and educated fire protection engineers in Karachi, Pakistan. Respondent AJ2 focused on “starting fire safety practices in the middle of business operations” and “lack of safety culture and attitudes in Pakistan.”

Respondent AA1 emphasized that:

[…] Due to the industry’s nature and the workforce’s diversity, garment companies often experience high worker turnover. This might result in a shortage of staff that is properly educated in fire safety since new hires might not have the necessary background or education to deal with fire situations. Additionally, the frequent turnover may bring a lack of knowledge of firefighting and evacuation protocols among the staff members.

“The existence of high-heat-generating equipment, such as heat sealers, boilers, thermal printers, and high-heat dyeing machines, was mentioned as contributing to the fire risk by respondent BH1.” Respondent BH2 underlined the need to follow standard operating procedures and highlighted placement difficulties linked to operational activities, such as locating chemical storage near the cooking or smoking area or storing chemicals near the trash yard. Respondent CA1 continued declaring:

[…] Due to a lack of passion and knowledge of fire training, department supervisors sometimes choose their least productive workers to participate in fire drills and training, increasing the fire risk.

Furthermore, Respondent AT1 claims to have one fire alarm in the main gate building. Another fire around 8 months earlier similarly failed the alarm system. Despite the incident, the fire alarm had not been repaired. Respondent AJ2 mentioned that the factory had five escape routes. Unfortunately, these doors could not open during the fire incident. Respondent AH2 mentioned the unavailability of a “fire hose reel” on the industry premises. The fire hose reel is fire safety equipment most significant for fire incidents (Stevens & Eijsink, 1994). Respondent CT1 disagreed about the practices of the “Emergency lighting” measures in the factory. A factory must install sufficient emergency lighting on particular points where emergency light functions automatically in case of emergency or electricity breakdown in the passages or workroom. According to respondent AH1, “Iron burglar windows” cause fire disasters. During the fire incident Ali Enterprises; windows were covered with iron burglar windows.

In addition to the previously mentioned factors, respondents highlighted issues in regulations and guidelines regarding fire safety. Respondents CH1, CH2, and questionnaire survey respondents identified the absence of specific fire regulations for the garments sector in Karachi and issues with existing fire regulations as contributing factors—furthermore, differences in the interpretation of Pakistan’s fire regulations and standards. Respondent BH2 explained the inadequacy of a proper monitoring mechanism for fire regulations and guidelines in Pakistan. Unclear definitions of fire regulations and redundant manufacturing ordinances plague fire safety rules in Pakistan’s garment business. Overall, a total of 47 factors contributing to textile building fire incidents were recognized through the study.

Fire Incidents Controlling Strategies in Karachi Pakistani TGMBs

Ever since the independence of Pakistan till today, Karachi textile industries have faced a considerable fire incident. Therefore, some strategies may become useful to decrease the fire incident in TGMBs, as mentioned in Table 4.

Table 4.

Strategies to Overcome Identified Factors Contribute to Fire Incidents of TMBs in Karachi, Pakistan.

No.	Factor	Strategies	Source
1	Availability of hazardous material on the floor	Follow safety protocols Clean up and remove the hazardous material Implement preventive measures Conduct regular inspections	AH1, AH2, CJ1, and BA1
2	Insufficient firefighting service	Collaborate with fire department officials Advocate for increased funding: Expand recruitment efforts Enhance training programs Upgrade equipment and technology Regularly review and update procedures	CJ1, AA1
3	Timber structure floor	Use of metal structural elements Use concrete fire protection on steel columns Implement Karachi Building Regulation Wood with a fire-resistant coating Avoid constructing with wood in high tropical climates	AH1, AA1
4	Electric wiring and poor maintenance	Engage qualified electricians that possess the appropriate skills It recommended performing “Merger” testing every three years Constantly utilize a wire screw or other authorized connector when making electrical connections rather than tapping the wires	AH2, CJ1
5	Electric spark during the welding process	Issue work permits for each building where hot work started Utilize prefabricated parts Set flash-back detectors for the welders	AA1
6	The location of the firefighting department	Develop a mechanism to request help from nearby businesses during emergencies They are getting help from the military, the police, and the Department of Civil Security	CA2, AH2
7	Building design features	Fire professionals should be consulted before any construction materials or equipment are selected	AH2, CH2
8	Delayed response time of the fire brigade	Improve the fire safety system in your building’s Perform mock exercises often to discover their true capabilities Make arrangements to get assistance from nearby businesses	AH1, AJ2
9	Careless smoking	Adopt a strict “no smoking” policy	AH1, AH2, BH2, CH1, CH2
10	Inadequate maintenance of electrical equipment	Conduct proper maintenance and inspection Develop a procedure for electrical safety Keep an eye on electrical equipment and label it to indicate its condition	AH1, AH2, CA2
11	Inadequate fire detection system	Maintenance and inspections performed properly Fire safety must undergo an internal assessment Incorporate modern equipment Qualified staff conducting inspections	AH1, AH2
12	Inadequate fire protection system	Periodic inspections and maintenance are essential Perform a fire safety audit within the building Fire safety equipment must be properly licensed and submitted to regular testing Using the equipment with the latest technology	AH1, AH2, BH2
13	Negligence of architects in fire safety	Fire safety experts review the building design Provide training for builders on fire prevention measures and regulations	CH1, CH2, AJ2
14	Explosion of boiler	Maintaining a safe environment requires regular inspections of all equipment Identify qualified boiler operators and hire them	BJ2
15	Design/architecture and fire safety integration errors	Fire safety experts and building designers should be consulted Involved facilitation supervisor commissioning and conducting testing before building occupying Examine the building’s continuing construction concerning fire safety	AH1, AH2, AA2, CH1
16	Insufficient utilization of fire-resistant materials	Use financially effective and fire-resistant materials Instruct those who need to know about the advantages of fire-resistant materials Buildings with a higher risk of fire should be equipped with resistant materials	AH1, CH1, BJ2
17	Lack of sufficient firefighting service	Develop qualified internal employees who have to recognize fire safety Let the government know that its current service providers are inadequate	AH2, Respondent questionnaire survey
18	Structures with a lot of continuous horizontal and vertical openings	Reduce the use of materials that contribute to fires Compartmentation Install a customized fire safety system to the specific design install fire-resistant glass	AH1, BA2, CJ1
19	Errors in building design	Observe appropriate design standards, construction codes, and regulations Higher building professionals and experts in the design process	AH1, AH2, BH1
20	Using the building not for its original design	A proper examination by a certificate of conformity Appropriate to the current company operation, take the essential fire safety procedures Make the necessary changes	AJ2, BJ1, BJ2
21	Differences between policy considerations and findings from actual fire incidents	Policy review and periodic policy review following fire events	CH1
22	The fire brigade is inadequately equipped	advanced interior suppression systems for fires Inform the government and the fire safety agency about the problem Regularly perform mock exercises to become familiar with their capabilities Develop a system for requesting help from nearby organizations	AH1, CH1
23	Insufficient staff in firefighting organizations	Advanced interior suppression systems for fires Inform the government and the fire safety agency about the problem Develop a system for requesting help from nearby organizations	AH1, CH1
24	HVAC system fire risk	Cut off the intake of fresh air Install smoke-control devices	AH1
25	Ineffective renovation	Even while renovating, consider fire risk into consideration present work permits Involve fire spectators	CH2, CA1
26	Iron burglar windows	Engaging with fire safety professionals and adhering to local fire safety codes and regulations will help ensure that the strategies implemented are appropriate and effective in improving the safety of iron burglar windows	AH1
27	Exit door locked	The primary purpose of exit doors is to provide a safe means of egress during emergencies While security measures are important, they should not impede or delay the evacuation process It’s crucial to strike the right balance between security and life safety considerations to protect the occupants of the building	AJ2
28	Emergency lighting	It’s crucial to regularly review emergency lighting strategies and adapt them based on feedback. Consulting with lighting experts and fire safety professionals can provide valuable insights for improving emergency lighting systems in your building or environment	CT1
29	Fire hose reel	Implementing these strategies will help ensure that the fire hose reel system is ready for emergencies and that building occupants are trained and equipped to utilize it effectively	AH2
30	Fire alarm system	It’s important to note that fire alarm systems should be designed, installed, and maintained by qualified professionals with expertise in fire safety and building codes	AT1
31	The Pakistan garment sector lacks specific fire regulations, and there are concerns regarding the adequacy of existing policies and regulatory framework	It is recommended to seek guidance and notify the appropriate local fire authorities to establish fire regulations specific to the garment sector Develop in-house fire policies after comprehensively assessing applicable rules and standards Integrate a reporting system for accidents and near misses into existing infrastructure Renew out-of-date rules	BH1, CH1, CH2, and respondent questionnaire survey
32	High-temperature generators are easily accessible	Install customized fire protection system in all machine Division of heat-producing machinery	AA1
33	Imperfections commanding during the fire scene	Fire drills and training sessions should be conducted more frequently	AH2 respondent questionnaire survey
34	Highly cost installation and maintenance of fire protection equipment	To find appropriate service providers, you should first get funding from management	AH1
35	Employee turnover intention	Increase the number of training sessions and create incentive schemes for the most experienced firefighters Promote a positive image of the fire staff within the company	AA1
36	Improperly stored chemicals	Put in place appropriate fire precautions Examine for chemical reactions To electrically connect combustible chemical containers, bonding cables must be used	CH2
37	Insufficiency of trained and qualified fire safety workers	Provide opportunities for those with expertise in fire safety in the job market Arranged skilled training programmers	AH2 and respondent questionnaire survey
38	Lack of awareness and fire training	Instruct the workers about firefighting techniques and the causes and effects of fire in the workplace	AH2 respondent questionnaire survey
39	Lack of interest in and indifference toward fire drills and other kinds of fire training	Monthly fire department employees meeting to express their ideas and receive feedback	CA1
40	Negative safety norms and perspectives	Train workers in firefighting skills and the causes and effects of fire in our workplace The organizing of a “best practices sharing forum“	AJ2
41	Inadequate understanding of fire safety measures	Participate in fire safety training programs with your employees The organizing of a “best practices sharing forum“	AH2
42	Standard operation procedures (SOPs) not properly adhere	Increasing consciousness of standard operating procedures Publish SOPs in the appropriate languages near each workstation Change standard operating procedures as needed	BH2
43	Barrier breaking in the direction of a fire	Fire barriers should be inspected and reinstalled if necessary	BH2 and respondent questionnaire survey
44	Multiple operational functions have placement issues	Consider the risk assessment and where you would like each function to go according to how dangerous it is Use fire-resistant materials, barricades, etc., as required	BH2
45	Incorporate fire safety measures into everyday operations	Communicate early on the value of investing in a reliable fire safety system	AJ2
46	Unexpected failures and breakdown	Maintain a routine of checking, cleaning, and fixing Keep your essential systems’ backup up to date	BA2
47	Problems with grounding and worn-out plug sockets	Check the foundations and modify them according to the requirements Replace old plugs with new ones	AH1

Discussion

In this part, we concentrate on the fire risk of textile manufacturing buildings (TGMBs) in Karachi, Pakistan, and thoroughly analyze the studies and pertinent literature findings. We look at how the data gathered throughout the study process compares to the conclusions from previous literature and how they differ. The main study results are thoroughly explored, including justifications and insights into the data’s analysis. This section thoroughly explains the fire risk variables particular to (TGMBs) in Karachi, Pakistan, by comparing and contrasting the research results with the actual data.

Fire Incident of Textile Garments Manufacturing Buildings in Karachi

The fire incident is a major cause that directly or indirectly impacts the durability of buildings’ performance (Shokouhi et al., 2019). The fire statistics reported as the Asian region is considered the second-highest region with non-compliance in fire safety. The textile garments manufacturing sector has the highest number of fire incidents among all the other sectors (Islam et al., 2022). Moreover, fire incidents have been identified as the second-highest disaster topology in Pakistan. This study supported recognizing the fire incident in (TGMBs) Karachi, Pakistan. However, the level of fire incidents varied according to the responses and explanations of study respondents. The high fire risk of (TGMBs) in Pakistan was recognized by 81.6% of respondents, and 18.4% of respondents mentioned it as a moderate fire risk.

Factors Contributing to ﬁre Risk of Textile Manufacturing Buildings in Karachi

According to (Tan & Moinuddin, 2019), factors contributing to fire incidents lead to the underperformance of existing building fire safety systems. Furthermore, a deep investigation is required to identify the factors contributing to the fire incident of (TGMBs) in Karachi, Pakistan. The 30 factors were identified in the literature findings. They were ranked with the responses from the questionnaire survey to recognize the relevance of fire incidents (TGMBs) in the Karachi, Pakistan context. The hazardous material on the floor, insufficient firefighting service, timber structure floor, faulty wiring, welding work with electric sparks, and building design features are recognized factors contributing to fire incidents in (TGMBs). The significance emphasizes determining the causes of building fire events and understanding the critical situation of the precise elements that increase the fire incident in Karachi Textile Garment Manufacturing Buildings. Thirty such indicators were found in the literature, and their importance to the fire incident of (TGMBs) in Karachi, Pakistan, was evaluated by ranking them based on survey answers. The top six contributing factors to the fire incident in Karachi Textile Garment Manufacturing Buildings were the availability of hazardous material on the floor, insufficient firefighting service, timber structure floor, electric wiring and poor maintenance, electric spark during the welding process, and location of firefighting department. These contributing factors become the reason to spread the fire quickly. The analysis found that floor storage of hazardous materials was a common cause of building fires (Electronic Library of Construction Occupational Safety and Health, 2001; Mikalsen et al., 2021).

Furthermore, insufficient firefighting service is another frequent cause of building fires (Kamau, 2007; Omar et al., 2007). The building design feature is blamed for a large fire in a high-rise building in Hong Kong (Wong & Lau, 2007). There are only 25 firefighting services in Pakistan. The Daily News (2019) mentioned that the mezzanine floor was fully covered with a timber structure, and the location of the firefighting department was also far away from the fire scene Ali Enterprises. Park et al. (2014) explained building design errors and difficulties integrating design features into the fire protection system. Poor building design characteristics lead to the notable fire incidents at Delf University, King’s Cross Station, Bradford City Building, and Crown Plaza Hotel.

Limitations and Future Research

This study is subject to several limitations. First, the sample size was relatively small (21 professionals) and purposively selected, which may limit the generalizability of the findings beyond the textile garment manufacturing sector in Karachi. Second, the research focused on three major fire incident cases, which, while representative of severe events, may not capture the full spectrum of fire risk scenarios in the region. Third, data collection relied on self-reported perceptions from professionals, which may be influenced by recall bias or personal interpretation. Future research could employ larger, more diverse samples, include additional geographic locations for comparative analysis, and integrate quantitative fire risk modeling or simulation approaches. Longitudinal studies could also examine the effectiveness of implemented safety strategies over time.

Conclusion

The literature findings validate the research results and examples from real-world situations, emphasizing the need to address these underlying causes to successfully reduce the fire incident in Karachi Textile Garment Manufacturing Buildings. The Karachi fire incidents posed a significant threat, as evidenced by the findings regarding the (TGMBs). The building fires behavior, locally and globally, and relevant literature on the subject further emphasized the dangers associated with such incidents. 81.6% of survey participants agreed that Karachi Textile Garment Manufacturing Buildings pose a significant fire risk. The research found 30 factors that increase the fire incidence in (TGMBs). Using RII values, we graded the importance of factors identified in the literature study to Pakistan’s garment industry. Mostly, (TGMBs) six factors cause a fire incident; availability of hazardous material on the floor, insufficient firefighting service, timber structure floor, faulty electric wiring, poor maintenance, welding work with electric sparks, and firefighting department location spread the fire quickly. Seventeen additional contributor factors to fire risk were identified via interviews and a questionnaire survey, in addition to those documented in the literature. Some of the recently identified factors are the lack of specific fire regulations for the textile garments sector in Karachi, the deficiencies of commanding at fire scenes, the high cost of installing and maintaining a fire safety system, the availability of high heat-generating machines, and improper chemical storages.

Furthermore, this research has identified 47 factors contributing to fire incidents in Karachi Textile Garment Manufacturing Buildings. In addition, this research has suggested many strategies and solutions to prevent fire incidents in textile garment manufacturing buildings (TGMBs) in Karachi, Pakistan. The findings and recommendations presented in this study can serve as a valuable resource for the textile garments manufacturing sector, industry professionals, policymakers, and stakeholders in Karachi, Pakistan.

Footnotes

ORCID iDs

Mohsin Ali Shaikh

Muhammad Kashan Surahio

Ethical Considerations

Consent to Participate

Written informed consent was obtained from all participants after explaining the study objectives, procedures, confidentiality protections, and voluntary nature of involvement.

Funding

The authors received no financial support for the research, authorship, and/or publication of this article.

Declaration of Conflicting Interests

The authors declared no potential conflicts of interest with respect to the research, authorship, and/or publication of this article.

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Examining the Causes of Fire Incidents in Textile Garment Manufacturing Buildings in Karachi,Pakistan

Abstract

Plain Language Summary

Keywords

Introduction

General Background View

Specific Pakistan View

Problem Statement, Study Significance, and Objective

Related Studies

Understanding Fire Outburst Behavior in Buildings

Fire Incidents in Textile Manufacturing Buildings

Causal Factors to Building Fire Incidents

Materials and Methods

Ethical Considerations

Results and Discussion

Fire Risk Factors in Karachi Textile Garment Manufacturing Buildings

Case Study 1

Case Study 2

Case Study 3

Fire Incidents Controlling Strategies in Karachi Pakistani TGMBs

Discussion

Fire Incident of Textile Garments Manufacturing Buildings in Karachi

Factors Contributing to ﬁre Risk of Textile Manufacturing Buildings in Karachi

Limitations and Future Research

Conclusion

Footnotes

ORCID iDs

Ethical Considerations

Consent to Participate

Funding

Declaration of Conflicting Interests

References