Fire Risk Assessment - 
Factories and Warehouses

LESH Consulting Ltd provides this in-depth technical expansion of the fire risk assessment (FRA) process, specifically tailored for the complexities of industrial environments. For factory owners, this section is critical as it moves beyond basic concepts into specific preventative measures, equipment standards, and legal management obligations.

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Section 1: Fire Risks and Preventative Measures

The foundation of factory safety is the separation of flammable materials from ignition sources.

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Housekeeping and Storage Effective housekeeping is a primary defence against fire. Factory owners must ensure that combustible waste does not accumulate; it should be kept in suitable containers and removed regularly. Outside, wheeled bins should be secured in a compound to prevent arsonists from moving them against the building. Skips should be placed at least 6 metres away from any part of the premises.

Storage management is particularly vital for factories. High-racked storage presents a major hazard; experimental tests show that fires in 10-metre high racking can reach the top within two minutes. To mitigate this, owners should:

• Maintain a 1-metre clear space between the top of stacks and the ceiling or lighting.

• Ensure aisles are at least 2.5 metres wide to restrict lateral fire spread.

• Keep a 0.5-metre gap between goods and internal walls to allow firefighter access.

• Never store combustible materials in voids (like roof spaces).

 

Dangerous Substances If your factory uses flammable liquids (e.g., paints or solvents), only a daily supply—up to 50 litres—should be kept in the workroom, and it must be stored in a fire-resisting cabinet or bin. Larger quantities must be in a dedicated, separate store. LPG cylinders should be kept to a minimum, with a maximum of 70kg stored inside in a secure, well-ventilated area away from exits.

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Equipment and Machinery Machinery is a frequent cause of industrial fires due to friction, overheating, or electrical faults. Key preventative measures include:

• Lubrication and cleaning: Ensure drive belts are not loose and lubrication is sufficient to prevent friction.

• Ventilation: Do not allow dust or debris to clog equipment ventilation points.

• Forklift Trucks: Charging points are high-risk areas due to the production of explosive hydrogen gas. These should be in well-ventilated areas, preferably against a fire-resisting wall.

• Cooking Processes: If the factory has a canteen, deep fat fryers and ducts must be cleaned regularly to prevent grease fires.

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Insulated Core Panels Many modern factories, especially in the food industry, use insulated core panels. These can be dangerous as the core (often polystyrene or polyurethane) can melt or burn, producing dense toxic smoke and leading to early structural collapse. Owners must ensure heating appliances are not installed against these panels and that any damage to the outer metal skin is repaired immediately to prevent the core from being exposed to fire.

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Section 2: Fire Detection and Warning Systems

In a factory setting, a simple shout of "fire" is rarely sufficient.

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System Requirements Most factories require an electrical fire warning system with manual call points (break-glass boxes). If the factory has noisy areas, the audible alarm must be supplemented by visual alarms (flashing beacons).

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Automatic Fire Detection (AFD) AFD is necessary if:

• A fire could develop unobserved (e.g., in storerooms).

• There are lone workers or people in remote areas who might not hear a manual alarm.

• It is used as a "compensating feature" for extended escape distances.

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False Alarms Complacency is a danger; frequent false alarms may lead staff to ignore a real emergency. Owners should investigate all false alarms and take remedial action, such as fitting protective covers over call points in areas where they are frequently knocked by moving goods.

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Section 3: Firefighting Equipment and Facilities

Portable Extinguishers For standard (Class A) risks, provide one water-based extinguisher for every 200m² of floor space, with at least two per floor. They should be sited on escape routes, near exits, and ideally no one should have to travel more than 30 metres to reach one. This is reduced to 10m if flammable substances are stored / used in the area.

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Fixed Systems

• Hose Reels: These are effective but should only be used by trained staff. Note: Do not use them on aerosol fires.

• Sprinklers: These are highly effective for asset protection and life safety. Owners must ensure that storage heights do not obstruct sprinkler heads. Sprinklers should not be used over salt baths or metal melt pans due to the risk of an explosive reaction with water.

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Facilities for Firefighters Owners have a legal duty to maintain facilities provided for the Fire and Rescue Service, such as dry rising mains, firefighting lifts, and access roads. Access roads and "inlet boxes" for rising mains must be kept clear of parked vehicles at all times.

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Section 4: Escape Routes

Design Principles The primary goal is for everyone to reach a place of total safety unaided. Escape routes must be:

• Adequate for the number of people (750mm width for up to 100 people in normal risk areas).

• Free from obstructions and well-lit.

• Ideally, leading to at least two independent directions of travel.

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Travel Distances The maximum distance staff should have to walk to an exit depends on the risk level:

• Higher risk areas: 25m (more than one route) or 12m (single route).

• Normal risk areas: 45m (more than one route) or 25m (single route).

• Lower risk areas: 60m (more than one route) or 45m (single route).

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Inner Rooms In factory offices, "inner rooms" (where the only escape is through another room) are common. These require a vision panel or an automatic smoke detector in the outer room to ensure the occupant of the inner room is warned of a fire.

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Stairways and Basements Protected stairways must be kept entirely free of combustible materials. Basements are higher risk; they should ideally be separated from the ground floor by two fire doors to prevent smoke from a basement fire from compromising the ground floor escape routes.

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Section 5: Emergency Escape Lighting

Factory owners must provide emergency lighting if the premises are used during hours of darkness or have windowless areas. In large open-plan factories or warehouses, self-contained spotlights are often the most efficient method of illumination.

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Emergency lighting should illuminate:

• Every exit door and intersections of corridors.

• Changes in floor level and stairways.

• Firefighting equipment and alarm call points.

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Maintenance is mandatory: carry out a monthly function test and an annual full discharge test.

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Section 6: Signs and Notices

Signs help people unfamiliar with the layout, such as contractors or visitors. All signs must be pictograms; text-only signs are not compliant.

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• Fire exit signs should be positioned so that the next sign is always in sight during an escape.

• Fire doors must be labelled "Fire door - keep shut".

• Fire action notices should be posted in prominent locations, like canteens or locker rooms, detailing what to do in an emergency.

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Section 7: Management, Training, and Recording

Record Keeping If you employ five or more people, you must legally record the significant findings of your FRA. This includes the hazards identified, the protective measures taken, and the emergency plan.

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Emergency Plans A written plan should cover:

• How people will be warned.

• Evacuation procedures and assembly points.

• The duties of staff with specific roles (e.g., Fire Marshals).

• Procedures for stopping dangerous machinery or isolating power supplies.

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Staff Training All staff must receive induction training when they start and periodic refreshers. Training must include:

• How to raise the alarm.

• The location of escape routes.

• How to stop machines and isolate power.

• The importance of keeping fire doors closed.

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Fire Marshals For complex factories, you should appoint Fire Marshals who receive advanced training in searching the premises, using firefighting equipment, and liaising with the Fire and Rescue Service.

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Fire Drills Drills should be held at least annually. They should simulate a scenario where one exit is "blocked" by fire to ensure staff can use alternative routes. Always record the results of the drill to identify and fix any weaknesses.

 

Section 8: Quality Assurance

When purchasing fire protection equipment or hiring installers, factory owners are encouraged to look for third-party certification. This provides assurance that the products and services are fit for purpose and that you are meeting your legal obligations under fire safety law.

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Checklist for routine maintenance:

• Daily: Check that fire exits are not locked or obstructed and that the fire alarm panel is normal.

• Weekly: Test a different manual call point each week and check that all staff can hear the alarm.

• Monthly: Check fire door seals and self-closing devices; test emergency lighting.

• Six-monthly: Have the fire alarm system serviced by a competent person.

• Annually: Have all extinguishers, sprinklers, and emergency lighting fully serviced and tested.

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By following this structured guidance, factory owners can create a robust fire safety strategy that protects both their personnel and their business assets from the devastating effects of fire

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Contact LESH Consulting for support

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info@LESHonline.co.uk

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01623 239705