Warehouse Fire Safety 101: A Guide

Developing and implementing a comprehensive fire safety plan that includes procedures for fire prevention, detection, and response can significantly reduce the risk of fire in a warehouse and ensure the safety of employees and property. This can include fire detection systems, sprinkler systems, regular safety inspections, employee training, and proper storage practices.

As a professional warehouse material handling system code compliance expert, RCS understands the importance of warehouse fire safety. Because of this, we’ve put together this guide to give you a basic understanding of what aspects are involved in fire prevention, detection, and response within warehouses.

Read below to better understand warehouse fire safety. It’s important to understand that this is a guide. Because each warehouse is unique, it’s necessary to speak to a professional to understand what fire safety regulations are specific to you and how you can best implement them. To speak with a professional at RCS regarding fire safety services for your warehouse, fill out the contact form at the bottom of this page or call us at (630) 247-6934.

Why Fire Safety is Important in Warehouses

Protection of Employees

Ensuring the safety of employees and visitors within the warehouse is the primary concern. A fire can spread rapidly, causing injuries or fatalities if proper safety measures are not in place.

In addition, it’s important to ensure that the fire safety plan is highly visible and understood by all employees so that all know their role in preventing a fire from occurring and what to do in the event of a fire. The plan should be regularly reviewed and practiced as necessary, which can include such things as fire drills.

Regulatory Compliance

It’s necessary to understand and adhere to all warehouse fire safety regulations applicable to your location, commodity classification, material handling system type, and all others. Organizations such as the National Fire Protection Association (NFPA) have developed codes aimed at fire safety for warehouses, along with specific requirements put forth at the local and state levels.

A professional company, such as RCS, can be hired to perform a life safety evaluation or high pile storage report to identify all warehouse fire safety regulations applicable to your warehouse. This will ensure that no codes are overlooked, which can lead to a delay in operations due to being shut down by the municipality. A life safety evaluation is a comprehensive analysis of codes that need to be adhered to, such as egress aisles, egress doors, fire alarm system requirements, sprinkler system criteria, fire extinguisher requirements, and exiting requirements. This is conducted by a professional who comes onsite to perform the analysis and should ideally be done during the design phase of the warehouse.

The life safety evaluation also determines what permitting documentation is required. Often, a high-piled permit is required. This permit is obtained through submitting official documentation, called a high pile storage report, to the appropriate authority. A high pile storage report is basically the life safety evaluation, but with more detailed information and compiled in the appropriate documentation.

It should be noted that regular fire safety inspections and testing by a professional is important. This helps ensure that all fire safety measures put in place will work in the event of a fire and that the warehouse remains compliant with regulations.

Prevention of Property Damage

Warehouses often store valuable inventory. A fire can result in significant financial losses due to the destruction of these assets. Additionally, fires can damage or destroy warehouse equipment, such as forklifts, conveyors, and racking systems. Replacing or repairing this equipment can be very expensive.

Beyond just replacing lost inventory and damaged equipment, there may be additional costs associated with restoring the warehouse to operational status, such as cleaning up after the fire, replacing wiring, and ensuring the building is safe to use.

While insurance can cover some losses, it often comes with deductibles, and significant claims can lead to higher premiums in the future. Some losses may not be fully covered, depending on the policy.

Business and Supply Chain Continuity

A fire can halt warehouse operations, leading to downtime and lost revenue. The longer it takes to resume operations, the greater the financial impact. Business interruption insurance can help, but it may not cover all losses. Having fire prevention and detection measures in place helps maintain continuous operations and avoid costly interruptions. Additionally, this halt in business can affect the supply chain and therefore relationships with customers and suppliers.

Warehouse Fire Safety Tips

A warehouse fire safety plan should be comprehensive and include measures to take for fire prevention, fire detection and suppression, and emergency procedures. Read below to learn more about these three aspects of fire safety planning.

Warehouse Fire Prevention

Fire prevention in warehouses is crucial for ensuring the safety of personnel, protecting inventory, and minimizing property damage. Warehouses can implement a variety of measures to prevent fires from occurring, including proper storage, maintenance, and employee training. Here eight effective strategies:

1. Good Housekeeping Practices
   • Clean Environment: Keep the warehouse clean and free of debris, dust, and clutter that can fuel a fire.
   • Regular Waste Disposal: Dispose of waste materials, especially flammable ones, regularly and properly.
   • Spill Management: Clean up any spills immediately, especially those involving flammable liquids.
2. Proper Storage of Materials
   • Flammable Materials: Store flammable and combustible materials in appropriate, clearly marked containers and keep them away from ignition sources.
   • Stacking and Racking: Follow proper stacking and racking procedures to avoid creating potential fire hazards. Ensure materials are stored safely and securely.
   • Separation of Hazardous Materials: Segregate hazardous materials according to their fire risk categories and store them in designated areas.
3. Electrical Safety
   • Regular Inspections: Conduct regular inspections of electrical systems, wiring, and equipment to identify and address potential fire hazards. These checks should likely be done by professionals.
   • Avoid Overloading: Ensure electrical circuits are not overloaded and use appropriate surge protectors.
   • Qualified Personnel: Ensure all electrical installations and repairs are performed by qualified electricians.
4. Maintenance and Equipment Checks
   • Regular Maintenance: Maintain machinery and equipment regularly to prevent overheating or malfunctioning, which can lead to fires.
   • Service Logs: Keep detailed service logs of all maintenance activities and ensure timely repairs of any identified issues.
   • Safety Checks: Conduct routine safety checks on fire safety equipment, such as fire extinguishers, alarms, and sprinkler systems.
5. Employee Training and Awareness
   • Fire Safety Training: Provide regular fire safety training to all employees, including the proper use of fire extinguishers, emergency procedures, and the importance of fire prevention.
   • Safety Culture: Promote a culture of safety where employees are encouraged to report potential hazards and take responsibility for maintaining a safe workplace.
6. Control of Ignition Sources
   • Smoking Policies: Enforce strict no-smoking policies within the warehouse and provide designated smoking areas away from the building.
   • Hot Work Permits: Implement a hot work permit system for activities such as welding, cutting, or grinding to ensure proper safety measures are in place.
   • Equipment Shutdown: Ensure machinery and equipment are properly shut down and cooled before performing maintenance or leaving them unattended.
7. Fire-Resistant Building Materials
   • Construction Materials: Use fire-resistant materials in the construction and maintenance of the warehouse.
   • Fire Doors and Barriers: Install fire doors and barriers to contain potential fires and prevent them from spreading.
8. Ventilation and HVAC Maintenance
   • Proper Ventilation: Ensure the warehouse is properly ventilated to prevent the buildup of heat and flammable vapors.
   • HVAC Maintenance: Regularly inspect and maintain HVAC systems to prevent them from becoming fire hazards.

Fire Detection and Suppression

Fire detection and suppression systems in warehouses are vital for early fire detection, containment, and extinguishing. Read below to learn more about these types of systems.

Fire Alarm Systems

Fire alarm systems are critical components of warehouse fire prevention and safety. They are designed to detect and alert occupants of fire hazards promptly, enabling quick evacuation and response to minimize damage and ensure safety.

When considering fire alarm systems, it’s important that they are reliable and provide adequate coverage for the entire warehouse. In addition, they must be loud and visible enough to be noticed by all occupants, including those with hearing or visual impairments. Therefore, it’s best to use both audible and visual alarms to ensure everyone in the warehouse is alerted.

Below is a detailed overview of fire alarm systems, specifically for warehouses.

Alarm Detection Types

Smoke Detectors

• Detect smoke particles in the air, which may indicate a fire.
• Types include ionization detectors (sensitive to flaming fires) and photoelectric detectors (sensitive to smoldering fires).

Heat Detectors

• Detect increases in temperature that may indicate a fire.
• Types include fixed temperature detectors (activate at a predetermined temperature) and rate-of-rise detectors (activate when temperature increases rapidly).

Manual Pull Stations

• Allows occupants to manually activate the fire alarm system in the event of a fire.
• Typically located near exits and in high-traffic areas.

Alarm Detection Ranges

Conventional Fire Alarm Systems

• Divides the building into zones.
• When an alarm is triggered, the control panel identifies the zone but not the specific device.
• Cost-effective for smaller warehouses.

Addressable Fire Alarm Systems

• Each device has a unique address.
• The control panel identifies the exact location of the triggered device.
• More suitable for larger warehouses due to precise detection and easier maintenance.

Hybrid Fire Alarm Systems

• Combine features of both conventional and addressable systems.
• Provide zone identification with some addressable capabilities.

Sprinkler Systems

Ensure the warehouse is equipped with an appropriate sprinkler system and that it is regularly inspected and maintained.

There are several types of sprinkler systems, which can be generally categorized into overhead sprinklers and in-rack sprinklers. Overhead sprinklers are fire suppression systems that are installed on the ceiling. There are many types of overhead sprinkler systems available, for example, ESFR systems (early suppression, fast response).

In-rack sprinkler systems, when required, are placed strategically within a rack system. Since they’re typically placed on multiple levels of the system, it delivers water immediately to all storage areas necessary. This can help avoid extra product loss due to water being released only in the bay(s) needed.

Flue Spaces

Flue spaces are often a requirement for fire safety as dictated by NFPA 13: Standard for the Installation of Sprinkler Systems. Flue spaces are clear vertical lines that leave space from the floor to the ceiling in a rack system. These spaces mitigate fire damage that originates within a rack system by allowing heat and smoke to travel upwards faster to activate the sprinkler system as well as allow the water from the sprinkler system to travels downwards through the rack and reach the fire faster.

To learn more, read our article on flue spaces.

Fire Extinguishers

By ensuring fire extinguishers are strategically placed, easily accessible, and properly maintained, warehouses can significantly enhance their fire safety preparedness and minimize the risk of fire-related damage and injury.

Employees should be trained on the proper use of fire extinguishers, including when and how to use them effectively. In addition, fire extinguishers should be inspected regularly to ensure they are in good working condition and fully charged.

Regular Maintenance

Maintenance checks for fire alarm and sprinkler systems are essential and typically required for warehouses. Regular maintenance ensures that these critical safety systems function correctly in the event of a fire. System performance checks can include visual checks of equipment systems, battery tests, alarm tests, and tests ensuring proper communication to appropriate responders, such as the local fire department.

Emergency Procedures

Unfortunately, fires can occur in a warehouse, even for those that take the appropriate fire safety measures. Because of this, it’s best to have emergency procedures in place that enhance preparedness for fire emergencies, protect employees, and minimize property damage. Here are key procedures that warehouses should consider:

Emergency Evacuation Plan

• Clear Routes: Designate and clearly mark emergency exits and evacuation routes. Ensure they are always free from obstructions. Egress aisles, which are unenclosed aisles that lead to exits, are typically required for a warehouse to be approved for operation. Egress aisles should be part of the planning of the warehouse, including within the material handling system. A professional, such as RCS, can identify where egress aisles are required for permitting.
• Assembly Points: Identify safe assembly points outside the building where employees can gather after evacuation.
• Evacuation Procedures: Develop and communicate clear procedures for evacuating the warehouse in the event of a fire. Include steps for assisting those with disabilities.

Training and Drills

• Employee Training: Regularly train employees on fire safety procedures, including how to respond to alarms, use fire extinguishers, and follow the evacuation plan.
• Regular Drills: Conduct regular fire drills to ensure everyone is familiar with the evacuation plan and can respond quickly in an emergency.

Signage

• Signage: Clearly mark fire exits, fire extinguisher locations, and other critical safety information. Much of this will be dictated by fire codes.
• Emergency Contact Information: It may be necessary to display emergency contact information throughout the warehouse. This can help employees reach the appropriate person in the event of an emergency, streamlining response efforts.

Post-Incident Procedures

• Accounting for Personnel: Ensure that a staff roster is readily available in the event of an emergency so that after an evacuation all employees can be accounted for.
• First Aid: Maintain well-stocked first aid kits and ensure staff are trained in basic first aid.
• Incident Reporting: Have documents ready to record the incident, including the cause, response actions taken, and any injuries or damage. This information may be valuable in recalling details that may become unclear in the days after the incident. This information may be used to provide to authorities and insurance agencies, as well as be used to improve future fire safety measures.

Continuous Improvement

• Review and Update Plans: Regularly review and update the fire emergency plan to incorporate new hazards, changes in warehouse layout, or updates in fire safety regulations.
• Feedback and Training: Gather feedback from employees on drills and training sessions to identify areas for improvement and ensure ongoing training is effective.

RCS Professional Fire Safety and Code Compliance for Warehouses

If you’re in the process of building a new warehouse or moving to a new building, it’s important that you adhere to all fire codes applicable to your location, commodity class, and material handling system type. RCS is a team of professionals that specialize in making sure your material handling operation is safe and code compliant.

Through our services, our professionals can perform a life safety assessment of your planned warehouse and provide information on codes and safety regulations that should be followed. We can then help you adhere to these by providing and installing appropriate lighting, sprinkler, and fire detection systems. We are a woman owned, WBE certified company that works with end users, manufacturers, dealers, system integrators, and general contractors.

To contact RCS, fill out the form at the bottom of this page or call us at (630) 247-6934.