Warehouse Fire Safety
By Dave Piasecki
When
companies think about warehouse fire safety, they usually think of compliance to
fire codes and OSHA regulations. While
compliance is a good starting point (and is obviously mandatory), there is more
to warehouse fire safety than compliance. Below
are a few misconceptions about warehouse fire safety.
 |
My
warehouse just passed a fire inspection therefore it must be up to code. |
|
My
warehouse is up to code therefore it must be safe. |
|
My
warehouse was designed with a sprinkler system therefore it can’t burn
down. |
I
must admit that like many other warehouse professionals I spent many years
taking this “ignorance is bliss” approach to fire safety.
As much as we all talk about safety coming first, safety projects rarely
rate high on our prioritized project lists.
The difficulty in obtaining applicable safety and compliance information
and the fear of opening a “can-o-worms” by using outside help combined with
the fact that you may have just passed a fire inspection makes it easier to
justify perpetuating ignorance of safety issues.
And certainly most companies can operate under these conditions and never
have a serious fire. Unfortunately,
some companies will have a serious fire and the difference between a small
financial loss and a catastrophic loss with the potential for loss of life will
come down to the level of fire safety knowledge and the application of that
knowledge to warehouse design and operational practices.
Fire
inspections can vary significantly from one jurisdiction to another and from one
inspector to another. An inspector
in a primarily residential community will likely not be as knowledgeable in the
codes related to high-piled storage as an inspector in an industrial area.
An inspector that’s been involved in fighting a large warehouse fire
will likely have a higher sensitivity to certain issues than one that has not
had the same experience. Generally,
fire inspections are looking for housekeeping-type hazards such as blocked
exits, blocked aisles, damaged sprinkler systems, missing or neglected fire
extinguishers and exit lights, accumulations of flammable debris, or misuse of
electrical equipment such as extension cords.
A fire inspector can’t possibly inspect and evaluate the hazard
classifications of all the product stored and verify the engineering
specifications of a sprinkler system on a walk through inspection. If you’ve
made changes to the composition of the products being stored, the types of
packaging used, or the storage configuration, it is unlikely that the inspector
will be aware of this unless you bring it to his or her attention.
And when is the last time you volunteered to give unsolicited information
during an inspection.
Fire
codes are designed to achieve a minimum level of safety; even though the level
of detail in the codes is extensive they can’t possibly cover every hazard or
combinations of hazards. To use
traffic laws as an analogy, just because you are obeying traffic laws does not
mean that you will not get into an accident.
The same is true of fire codes; they are designed to reduce the
opportunities for fires to start, reduce the opportunities for fires to spread,
provide for evacuation of occupants, and provide access for fire fighters to
extinguish the fire.
Sprinkler
systems are engineered to cover a specific commodity classification in a
specific storage configuration. Changes
such as introducing a new product line, using a different packaging material, or
changing from wood pallets to plastic pallets can increase your hazard
classification and render your sprinkler system inadequate to control a fire.
Also, changing the size of pallets or the way product is stacked in
racking can infringe on flu space requirements, reducing the ability of the
sprinkler system to control a fire. It’s
also a common misconception that sprinkler systems are designed to extinguish
fires. Although they can be
designed to extinguish fires, systems designed to meet minimum code requirements
are only expected to help control the spread of the fire until the fire
department arrives to extinguish it. The
fact is, every year buildings with inadequate sprinkler systems burn to the
ground.
So how do you determine the level of fire protection your warehouse has/needs? I recommend a combination of a little education and employing the services of a fire protection engineer. Interpreting fire codes can get very complicated and evaluating your system’s engineering is not a do-it-yourself project. However, having someone on staff with some basic knowledge of the fire codes will help you ensure you get the best results from working with a fire protection engineer and allow you to quickly identify when operational changes may compromise the original fire protection design. Balancing safety issues with operational issues is rarely a simple task. An overly cautious fire protection design may result in significant loss of storage capacity, high costs, or create ongoing maintenance issues (such as those related to in-rack sprinklers) without necessarily reducing your exposure to hazards. While an under designed system could mean loss of life and property.
Intro
to fire codes.
The best way to become familiar with the fire codes is to read the
codebooks. If there is a fire
codebook written for amateurs, I am unaware of it, so you’re going to have to
spend some time learning to navigate the actual codebooks and interpret the
codes. To make this a little more
confusing, there are a number of organizations that publish fire codes.
Individual states and municipalities will then adopt the codes put out by
a specific organization. In
addition, the states or municipalities can also amend the codes they adopt to
include additional codes. There are
also a lot of provisions left up to the discretion of the local fire chief.
Just a note: In the event of
conflicts interpreting the fire code, the fire code is “whatever the local
fire chief says it is”.
Recently
the Building Officials and Code Administrators International, Inc
(BOCA),
International Conference of Building Officials (ICBO),
and Southern Building Code Congress international, Inc. (SBCCI)
got together forming the International
Code Council (ICC). This new organization put out the 2000 International Fire Code
(2003
International Fire Code is now available) in an effort to
standardize the fire codes . For
educational purposes I would recommend using this code.
For the most part, all of the various codes are similar and since you
should be using an expert for the detailed evaluation, I think this should be
sufficient. You will find in going
through the codes that in certain cases you may be referred to a separate
publication for additional code information such as publications put out by the
National Fire Protection Association (NFPA)
on specifications for sprinkler systems or storage of aerosols.
While
the codebooks may at first seem confusing, you can obtain a good overview of the
key requirements fairly quickly. You
will also quickly learn why you will need expert help when it comes to the
details of determining hazard classifications and code requirements.
For information relating to warehousing, the best place to start is the
section on High-Piled Combustible Storage.
Generally, high-piled combustible storage codes apply to floor or racked
storage exceeding 12 feet in height, however, at the discretion of the fire chief,
the codes may also apply to high hazard commodity storage exceeding 6 feet in
height. The codes use the
combination of commodity hazard classifications, size of storage area (square
footage), maximum storage height, material handling methods, and storage
configurations (solid-piled storage, racked storage, shelf storage, decking
type, storage height, etc.) to determine sprinkler density, flue space
requirements, aisle widths, as well as the need for building access, smoke and
heat removal systems, curtain boards, fire walls, and in-rack sprinklers.
The
following are some code requirements and recommendations that apply to many
warehouse operations. I’ll again
note that specific code requirements will vary depending upon your municipality
and storage characteristics.
|
Although
some smaller warehouses may not legally require them, automated sprinkler
should be considered as standard requirement in any warehouse. |
|
Storage
should be maintained at least 18 inches below sprinkler head deflectors. |
|
In
racked storage, transverse flue spaces of at least 3 inches should be
maintained. Transverse flue
space is the space to either side of a racked pallet. |
|
In
racked storage, longitudinal flue spaces of at least 6 inches should be
maintained. Longitudinal flue
space is the space between the rows of back-to-back rack.
It is important to note that the flue space is measured as the
distance between the loads, not the distance between the racks. In a
standard pallet rack configuration you will usually have 3 inches of pallet
overhang, calculating this into the flue space would require the rows of
rack to be at least 12 inches apart. |
|
Most
warehouses meeting the above flue space requirements do not require in-rack
sprinkler systems. Racking with
solid decking, storage configurations that prevent maintaining the flue
spaces, storage of high hazard materials, or storage greater than 40 feet in
height will probably require in-rack sprinklers. |
|
Dead
end aisles must not be more than 50 feet in length. |
|
In
solid piled floor storage there must be an aisle at least every 100 feet and
within 50 feet of walls when materials are stored against the wall.
Essentially this means that any portion of the solid piled storage
should be within 50 feet of an aisle. |
|
During
restocking operations using manual stocking methods (using stock carts,
rolling ladders, etc.) a minimum unobstructed aisle width of 24 inches or ½
the aisle width, whichever is greater, must be maintained. |
|
During
mechanical stocking operations a minimum unobstructed aisle width of 44
inches must be maintained. |
|
Automated
material handling equipment such as carousels and ASRS units will have
additional code requirements to prevent the equipment’s motion from
spreading a fire. |
|
Smoking
is prohibited in warehouses and no smoking signs are required. |
|
Battery
charging areas have specific code requirements including ventilation, acid
neutralization, eye wash stations, and spill control systems. |
|
Liquid
Propane fuel cylinders used on LP forklifts should not be stored within 20
feet of fire exits and are limited to a maximum quantity of 300 lbs per
storage location. This is the
equivalent of six 43 lb cylinders or nine 33lb cylinders.
Empty cylinders are considered full for this calculation. If
additional storage locations are required they must be separated by a
minimum of 300 feet. |
|
One
word: Plastics. Plastic content
is the single storage characteristic most likely to contribute to a class IV
or Class V high-hazard commodity classification.
The classification is based upon the type of plastic and the overall
content, measured by percent by weight for unexpanded plastics and percent
by volume and weight for expanded plastics.
This is where operational changes such as changing packaging
materials from paper based to polystyrene or changing from wooden to plastic
pallets can have a substantial impact. |
|
Another
word: Aerosols.
“Rocketing” is a term used to describe the ability of aerosol
containers to propel themselves across a warehouse, carrying a trail of fire
behind them. There is a whole series of codes dedicated to the storage
requirements for aerosol products. Depending
upon the chemical content and the amount of aerosols stored (measured by
weight), separation areas, chain-link fence enclosures, fire walls, and
additional sprinkler protection may be required. |
|
One last word: Hazardous Materials. Flammable liquids, solids, and gasses, explosives, oxidizers, and reactive materials fall under the category of Hazardous materials and have their own series of codes that apply. You’re definitely going to need some expert guidance when storing these types of materials. |
Obviously
there are a lot of other code requirements including basic fire safety
requirements such as not blocking fire exits and maintenance and placement of
portable fire extinguishers. And,
in addition to the fire codes you may also be subject to OSHA and EPA
regulations.
Beyond
Compliance.
As previously mentioned, compliance is only intended to provide a certain
minimum level of safety. When
working with a fire protection engineer you will likely want to incorporate
additional safety measures. When
designing a new system it is also recommended to investigate installing a design
capable of handling a higher hazard classification. Should your product line or
storage needs change in the future it can be very expensive to change your
existing system to accommodate the higher hazard classification.
There are also a lot of operational issues that relate to fire safety
that should be considered. Like everything else in your operation, the level of fire
safety will be greatly impacted by the procedures and training provided to the
employees.
|
Evacuation
Plans. It is extremely
important to make it absolutely clear to employees what they are expected to
do in the event of a fire or the sounding of the fire alarm.
The most common reaction by employees to the fire alarm sounding is
to look to their supervisor to see if they should leave the building, or
look to other employees to see what they are doing.
Employees should be informed that whenever they hear the fire alarm
they should immediately leave the building unless they have been given
previous notification of an alarm test.
It should also be made clear that they should leave through the
nearest exit. Warehouse workers
are usually not stationary so assigning a specific exit rarely applies.
I recall an employee during a drill walking across the entire
warehouse, passing several fire exits on his way to his “assigned” exit.
Now I would certainly hope that had the employee seen an actual fire,
he would not have walked into it to get to his assigned exit, but “you
never know”. Also, if
employees are required to perform certain tasks prior to leaving the
building, such as shutting down a piece of equipment, they should be given
specific instructions on the task and also under what conditions they should
perform the task and under what conditions they should immediately evacuate. |
|
Fire
Extinguisher Training. Employees
should be trained on the use and locations of fire extinguishers.
This is especially true of employees working in areas where there are
known ignition sources. |
|
Trash
Accumulation. Large
accumulations of trash and debris can be a potential fire hazard as well as
a hindrance to evacuation. Adequate
containers should be provided and specific duties assigned for removing the
trash as containers fill. There
should also be designated areas for storage of pallets, crates, etc.
It’s also a good idea to limit the stack height of loose pallets to
six feet. |
|
Designate
floor storage and staging areas. Using
tape or paint to designate floor areas approved for storage or staging of
materials will make it easier to enforce safety issues related to blocked
aisles etc. |
|
Incorporate
safety training into your regular operational procedures and training.
Safety procedures and training are often handled as a separate issue.
You’ll find it more effective to incorporate safety procedures into
your specific task procedures and training.
Issues related to clear flue spaces, sprinkler clearance, aisle
clearances, evacuation plans, battery charging and propane cylinder handling
should be part of the employee's regular training program. |
|
Maintain
open communication with your local fire department.
Make sure the fire department is aware of the additions of high
hazard materials to your warehouse or changes in storage configurations.
If you do have a fire it’s extremely important that the fire
fighters know what they are walking into. |
|
Make sure additional precautions are taken during construction and maintenance projects. If you have contractors working in or around your building, make sure additional measures such as additional fire extinguishers are used, especially if work is being done on a roof or other area where fire extinguishers are not present. Also make special plans if you have to shut down the sprinkler system for any reason. You may need to shut down certain operations, provide supplemental fire protection, or provide physical 24 hr monitoring of the building during this period. |
Maintaining an environment that provides safety to occupants and reduces the risk of property loss requires not only the initial system engineering, but also attention to safety in day-to-day operational practices and the knowledge of when operational changes may require re-evaluation of your fire protection systems.
Related Information:
|
Raymond Handling Solutions posted a nice little update on 2008 California Rack Permitting Code Changes that covers some fire safety requirements. |
|
Your Local Fire Department Needs You. Budgetary constraints often make it difficult for fire departments to acquire all the equipment they need to meet the challenges of protecting lives and property. While a lack of equipment won't stop the firefighters from fighting fires, it may make it more dangerous for them to do so as well as making it more difficult to save lives. Local companies can help by contacting their local fire chief to see what types of equipment they are in need of and donate funds towards the purchase of the equipment or actually buy the equipment and donate it to the department. |
Dave Piasecki is owner/operator of Inventory Operations Consulting LLC, a consulting firm providing services related to inventory management, material handling, and warehouse operations to manufacturers and distributors in Southeast Wisconsin. He has over 15 years experience in warehousing and inventory management and can be reached through his website (http://www.inventoryops.com), where he maintains additional relevant information and links
Copyright
© 2001-2004
Inventory Operations Consulting LLC