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DESIGN APPROACH OF ENERGY EFFICIENT READY MADE GARMENTS FACTORY

IN VIEW OF THERMAL COMFORT

Conference Paper · January 2011

DOI: 10.13140/RG.2.1.2858.2002

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DESIGN APPROACH OF ENERGY EFFICIENT READY MADE GARMENTS

FACTORY IN VIEW OF THERMAL COMFORT

Sajal Chowdhury* and Md. Rabiul Alam

Department of Architecture, Chittagong University of Engineering and Technology, Chittagong, Bangladesh

* Corresponding author ([email protected])

ABSTRACT: In Bangladesh Garments Factories are playing a vital role in the field of economical development but over
the last 32 years these factories have been highly criticized for the hazardous working environment in the production floor
in which high thermal gains from the artificial lighting, poor natural lighting system, excessive heat from the upper metal
roofing system are common phenomenon. Most of our Garments Factories do not consider building depth, building height,
volume, equipments and number of storey which factors are very essential to make factory energy efficient. This paper
identifies the cause of poor and unhealthy working condition of Garments Factories in Dhaka and detail analysis in view of
Thermal Comfort level to make garment factory energy efficient by a design approach with the help of building simulation
tools such as Radiance, Eco-tech, Dia-Lux etc.

Keywords: Thermal Comfort, Energy Efficient Design Approach, Ready Made Garments Factory

1. INTRODUCTION demonstrate that energy reduction can be achieved in

The Ready-Made Garment (RMG) industry of Bangladesh Garments Factory Buildings in view of Thermal Comfort.
started in the late 1970s and became a prominent player in Design approach, building envelope, planning and building
the economy within a short period of time. The industry services are all considered with respect to comfort level in
has contributed to export earnings, foreign exchange RMG sectors. The key factors associated with the
earnings, employment creation, poverty alleviation and the successful achievement of low energy RMG factory design
empowerment of women. But Like many other developing have been identified and formulated into a methodology to
countries, occupational health is still a neglected area in provide a guide for designers.
Bangladesh. Very little industrial management is concerned
to the work place environment and health of the workers.
2. CLIMATE OF DHAKA CITY
As a result, the industrial management does not provide
Dhaka city has mainly three different seasons. These are:
any attention to the work place injuries, sickness and
1. The hot dry season (March-May)
environment.
2. The hot humid season (June- November)
The workers bear the sole responsibility to their health and
3. The cool dry season (December- February)
safety. But to ensure sustainable economic and social
development, the industry owners and management must April is considered as hottest month and is considered
take responsibility. Any development will be meaningless average temperature is available as 30.3 – 34.8 deg c
if the poor workers do not have any share of it. January is considered as coldest month and is considered
The objective of this work is to investigate the energy average temperature is available as 9 – 15.2 deg c
efficient strategies that can be employed within RMG
factories and demonstrate the role of modeling and
simulation in the designing of low energy RMG sector in Type Hot Warm Humid Cool Total
of Dry Dry Day
Bangladesh.
Sky Pre- Monsoon Post- Dec-
The purpose of evaluating these case studies is to Feb

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Mons June- Monsoon efficient design considerations and building energy

on Sept Oct-Nov
Marc simulation software was used to get the final design criteria
h- considering thermal comfort level for the Ready Made
May
Garments Factory in Bangladesh.
Clear 62 38 39 77 215
Sky
4. ENERGY EFFICIENCY AND THERMAL
Overc 30 84 22 14 150
COMFORT
ast
Sky
Total 92 122 61 90 365
Days

Table: 1 Sky condition with respect to cloud cover for year

(Joarder, AR, 2007.)

Sky condition with respect to cloud cover for year is shown

in Table 1. It is seen that April is the hottest month with
average temperature of 32 deg C and January is the coldest Fig. 2 Components of Energy Efficiency
month having temperature 15 deg C.
From Fig. 2 it is shown that eight components are co-
3. METHODOLOGY OF ANALYSIS related with the Energy Efficiency, among them passive
design features are discussed to achieve thermal comfort
Theoretical study Field Survey Secondary Data
level in this paper. Thermal comfort is one of the main
elements of passive design features. Standard Thermal
Concept of Object
Energy Efficiency Development Concept of comfort level has not been yet introduce for the working
Thermal Comfort
Consider Local (production) area of the Ready Made Garments Factory in
Data Analysis Climate
Bangladesh which is very important to make a factory
green and energy efficient. Thermal comfort is affected by
Findings
heat conduction, convection, radiation and evaporative heat
Design
loss. Thermal comfort is maintained when the heat
Consideration generated by human metabolism is allowed to dissipate
Actionable thus maintaining thermal equilibrium with the
Ideas
surroundings. Any heat gain or loss beyond this generates a
Idea sensation of discomfort. It has been long recognized that
Testing
the sensation of feeling hot or cold is not just dependent on
Proposal air temperature alone. Factors determining thermal comfort
Formation
include: (i) Air temperature (ii) Mean radiant temperature
Fig. 1 Structure of the Research (iii) Air movement / velocity (iv) Relative humidity (v)
From Fig. 1 it is seen that there are difference strategies Isolative clothing (vi) Activity levels. The concept of
and steps to identify the design approach of energy thermal comfort is closely related to thermal stress.
efficient Garments Factory in view of Thermal Comfort
level under the consideration of Dhaka Local Climate, 4. FINDINGS FROM FIELD SURVEY

Bangladesh to make sure of energy demand and generation From the field survey it is seen that the following gaps are

in all the RMG sectors. In this paper after gathering the generally occurred in local RMG factory, Bangladesh

National and International theoretical Knowledge about the which has the great impact of thermal comfort level in the

RMG sectors, data have been collected from practical field production space.

survey. After the data analysis, with the help of energy

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Most of our RMG factories are constructed by steel 18.3 Cold/Cough 15.6
structure in the upper portion and brick plaster in the lower 11.3 Chest pain 12.2
portion which is found from field survey. RMG factories 9.9 Diarrhea/stomach 5.5
have no consideration about protect or restore open habitat
Dysentery
and pest management, erosion control and landscape
management plan in Bangladesh. From the physical survey Table: 2 Type of diseases or illness of workers for bad
it is noticed that most of Ready Made Garments factories working environment (Paul, Majumder, 2003)
have no reflection about the ratio of open space and built In finishing and sewing section thermal level is high and
space. Many of the factories have less than 30-40% open perfect monitoring system is not found most of factories.
green space and no consideration about the future Noise level control is another problem. Most of factories
expansion. There no found of non-fossil fueling facility for want to maintain 22-26 degree Celsius temperature for
vehicles and lack of green consideration about soft paving. indoor environment but for our climatic consideration what
According to field survey it is noticed that most of Ready is the standard temperature, we don't know even now. Heat
Made Garments factories have less reflection about the generate from machine in the dyeing section of RMG
water conservation and water efficiency strategy. Most of factory. Now days many of our factories take the initiatives
the factories have no efficient indoor plumbing fixture and against Environmental tobacco Smoke and dust Control by
water harvesting system. There is less use of water that using sensor and highly performance machineries. The
comes from ETP and no consideration about water efficient single largest operating cost of industrial buildings in the
landscaping. By now, the building envelope serves multiple Bangladesh is lighting. Lighting systems represent one-
roles. It protects the occupants from changing weather third or more of the total electrical energy costs of a
conditions and it plays a key part in meeting the occupants’ commercial building. They also introduce heat into the
comfort needs. In Bangladesh even now there is no space and increase building cooling loads. Because lighting
consideration about sustainable ventilation, lighting, systems significantly impact a building’s operating cost
building envelope etc. From the field survey, we have and energy performance, evaluate options for the lighting
noticed that most of the occupants who sit beside the systems before considering strategies for a low-energy
evaporative cooler often suffer from various healths HVAC system. Also, take advantage of day lighting
hazardous. In many factories are using LED in sewing opportunities whenever possible. Most of our RMG
section for effective lighting. But here some problems are factories use artificial lighting for whole day long. But they
created. This machine LED light generally creates contrast have a lot of opportunities to use natural day light. And
between work plane and surroundings to occupants and final result is they have to need provide more electricity
this happen serious problem in eye in future. which is our main problem. The sustainable placement of
exhaust fan and evaporative cooler are not considered
Workers General Diseases Average Duration while designing a factory. As a result thermal comfort level

Percentage of Sufferings (in is high at the middle part of the factory.

(%) days) per Month

57 Headache 14.4
21.9 Muscular-skeleton 21.8
pain
42.4 Weakness 19.8 a) b)
Fig. 3 a) Worker besides the Evaporative cooler; b)
20.3 Eye pain 10.7
artificial lighting during day time
3.2 Ear pain 12.8

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From Fig. 3 it is shown the internal hazardous condition of be seen that many of the factory buildings have no
a local RMG factory. From the field investigation it is observation about the wall and window area ratio. It is
noticed that there are many water bodies besides the observed that for 550 sqm floor areas, it has only average
factories. But no more consideration and proper design 21% opening which is not sufficient for natural cross
initiatives about natural disasters and risk management. ventilation system.
Geographically specific environmental priorities may cause
5. SIMULATION MODELING PROCEDURE
flood and serious problem at any time because lack of
The study is performed in a simple rectangular shape for
management consideration about efficient water treatment.
the benefit of comparison of thermal condition and comfort
Sustainable orientation is another key point for the factory
level of the workers. Factory size is considered as 80m by
building. Many of our factories should not compromise
25m (depth) and ceiling height is considered as 3.00m to
about sustainable orientation. As a result excessive heat
12m and windows area is considered as 15% to 80% (total
and light come through windows from outer environment.
wall openings). Room is considered to be constructed by
Density is one of the vital issues for poor indoor air quality.
brick, metal, concrete and cleared glass construction
In maximum RMG factories have no adequate movement
(average U value for cleared glass construction 5.100
place for worker and production space. Therefore, it creates
w/m2k). In all cases all windows are located .76m above
lack of fresh air in production area. As a result indoor air
the floor level and are made with 25.4mm aluminum frame.
temperature becomes high.
Impact of exterior surface has not considered on the
Very Good interior surface. It is assumed that 150-200 workers work
Ventilation 27.1% Workers
Ventilation
in this single production space model from 9.0 AM to
Moderately Good 7.0PM in a day. All analysis is based on the local climate
46.2% Workers
Ventilation
of Dhaka, Bangladesh. Eco-Tect and Radiance building
Bad/ Very Bad environmental simulation software are used to predict the
26.7% Workers
Ventilation
circumstances.

Density Not Congested 33.3% Workers 5. DESIGN CONSIDERATION

Moderately Workspace Protected from Sun Heat

29.9% Workers
Congested

Introduce Production Method without Heat

Very Congested 36.8% Workers Generation

Condition for a
Cleanliness Very Clean 22.8% Workers Standard Workplace Insulating Heat Generating Parts
Temperature

Having the Heat Absorbed and Diverted from

Moderately Clean 35.6% Workers
Original Source

Not Clean 41.6% Workers At least 10 Cubic Meter Workspace per Worker

Fig. 5 Nature of physical working condition and health

condition of the RMG factories Individual Fresh Air Tunnel for every Worker

From 15 factory buildings survey it is shown about 50 Fig. 6 Condition for standard workplace temperature
percent garments workers have moderate ventilation According to the international labor law and WHO Fig. 6 is
system. As a result mechanical ventilation system is shown that six requirements are very essential for a factory
required to improve the indoor air temperature and it costs building to achieve the good working environment and
extra energy per month. From the field survey it can also indoor air quality.

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simulation result it is seen horizontal window with the

Area Space Ratio Suggested Hours/Day shading device has achieved the good quality comfort
Name Design Occupied range of temperature and the minimum percentage of
Temperature openings should be 25-35% to achieve the standard
Sewing-S S=X 26-28 deg C 12 thermal comfort level for production space. The floor plate
Cutting-C S:1=X:2X 26-28 deg C 12 of a factory building should be no longer deeper than 25-
Irining-I S:1=X:2X 26-28 deg C 12 30m to assist cross ventilation opportunities. It is measured
that production floor area should be come from the
Table: 3 Space ratios of production areas following equation: 15 x no of production line x no of
From Table: 3 it can be shown that sewing section is two
times longer than the cutting and ironing section to achieve machine x sft per machine + circulation. This equation
the great impact from the environment. gives the optimum comfort level for the production area.
In Bangladesh, most of the RMG factories have no
consideration about the building finishes and external-
internal color scheme which is very important to make a
factory green and cost effectives.

Option Elements Materials degC

Fig. 7 Factory height analysis by Eco Tect and Radiance
Model 1 Roof Corrugated metal sheet 29.21
The floor plates and height of a RMG factory can be varied
Wall Brick plaster
depending on the thermal levels required, occupancy and
Floor Concrete slab
activity requirements. Based on the internal heat gain,
space layout can be adjusted. From Fig. 6 it can be seen Model 2 Roof Corrugated metal sheet 25.81

that if the height of the factory building is 6m to 8m, it will Wall Concrete block plaster

give the maximum comfort level for the production area in Floor Concrete slab
which 150-200 workers work at a time in a single space Model 3 Corrugated metal sheet 25.32
Roof
from 9.0 AM to 7.0PM. Double brick cavity plaster
Wall
Floor
Concrete slab

Model 4 Roof Corrugated metal sheet 24.8

Wall Double brick solid plaster

Floor
Concrete slab

Model 5 Roof Corrugated metal sheet 24.75

Wall Brick concrete block plaster

Floor Concrete slab
Table: 4 Factory building materials analysis

Fig. 8 Windows opening analysis by Eco-Tect and From this Table it can be shown from the analysis, if the
Radiance factory wall is constructed by brick plaster only, it creates
According to the thermal comfort factors, production space high temperature for the indoor space than others. Standard
temperature and comfort level are calculated with the help comfort level can be achieved when the factory building’s
of Eco-Tect and Radiance software (Building Performance wall is constructed by cavity or solid block because it
Software) for all types of windows openings. From the creates heat barrier from outdoor to indoor.

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design solutions will require supervisory level control

algorithms by which designers would be able to balance
the visual and thermal aspects to accomplish energy
efficiency. A methodology has been developed for the
combined thermal and human comfort of RMG factory
buildings and applied to existing RMG factory in support
of design guidelines in Bangladesh under the consideration
of local climate.

REFERENCES
Fig. 9 Opening shape and window patterns analysis by
[1] Marsh, A., Eco-Tect, (2010), conceptual design
Eco-Tect and Radiance
analysis tool, San Rafael, USA.
From Fig. 9 it is shown that windows with horizontal and
[2] Majumder, Pratima Paul and Begum Anwara,(January
vertical blind cannot penetrate daylight properly but it
2006), Engendering Garment Industry : The Bangladesh
creates more comfort inside the indoors and makes the
Context, The University, Press Limited, Dhaka Bangladesh.
direct sunlight diffuse which is good for work efficiency. It
[3] Mauritius, C. Bhurtun, N. Kistamah and J. Chummun :
is also seen that when day light penetrates high level into
Energy Saving Strategies In Textile Industry
the inner side of the production space, it creates more
[4] Auliciems A and S Szokolay (1997) Thermal Comfort,
discomfort level. As a result the temperature becomes high
PLEA Note 2, Passive and Low Energy Architecture
and work efficiency goes down lower gradually.

Fig. 10 Heat control strategies in workplace

Finally it can be stated that for the heat control in a
production space of RMG factory four techniques can be
taken which is indicated in Fig. 10.

7. CONCLUSION
In this study, it has been observed that enhanced daylight,
color, building height and depth, material selection
windows performance have often resulted in reduced
thermal performance in a production space. Effective

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