Introduction

This guide, Industrial fire risk assessment (recommended URL slug: industrial-fire-risk-assessment), explains the structured process you can use to identify, evaluate and control fire risks in factories, warehouses and other industrial buildings. In this guide you will learn practical steps to carry out a suitable and sufficient assessment, when to involve a competent specialist, which standards and legal duties apply, and how to turn findings into an effective action plan.

What is an industrial fire risk assessment and why it matters

An industrial fire risk assessment is a systematic review of the hazards, people and processes that could lead to a fire or increase its consequences. It focuses on the specific risks found in industrial settings, such as combustible dust, flammable liquids, heavy machinery, battery storage and large quantities of stored goods. A good assessment makes clear which measures will protect people, property and critical operations.

Legal duty: Under UK law the responsible person must make a suitable and sufficient fire risk assessment and keep it up to date. This duty is set out in the Regulatory Reform (Fire Safety) Order 2005 and applies to most non‑domestic premises. legislation.gov.uk

Start here: gather information and plan the assessment

Begin by collecting site drawings, process descriptions, inventory lists and records of previous incidents and maintenance. Walk the site with managers and operators. Note where hazardous materials are stored, where hot works occur, where ventilation is located and which areas are normally occupied.

Use existing documentation where available. For industrial premises the GOV.UK guide for factories and warehouses is a practical reference for the kinds of checks you need to make. It explains common hazards and the structure of a documented assessment.

Key checks at this stage

Confirm who is the responsible person and which staff are competent to assist.

Identify processes covered by DSEAR — decide whether processes use or produce dangerous substances covered by the Dangerous Substances and Explosive Atmospheres Regulations.

Decide scope and frequency of inspections and whether a specialist assessor is needed.

Identify hazards common to industrial facilities

Industrial hazards are often process specific. Typical examples include flammable liquids and solvents in storage tanks and drums; combustible dust from wood, metal, textile or food processes; batteries and energy storage systems that store significant energy; hot work operations such as welding and grinding; and electrical faults in motors, control panels and distribution equipment.

Walk every area and look for ignition sources, fuel and whether oxygen supply could accelerate a fire. Record the location, likely causes and immediate control measures that are already in place. Good housekeeping is often the first and most effective control.

HSE guidance explains how process fire precautions differ from general fire safety and why control of dangerous substances must be treated as a distinct part of your assessment. HSE guidance

Identify people at risk and critical business assets

List everyone who could be affected, including staff working in production and storage areas; visitors, contractors and temporary workers; emergency responders and neighbouring businesses.

Also identify critical assets and processes that would cause the greatest harm if lost. For example, a manufacturing line with hazardous chemicals may present both high human risk and severe business interruption. Prioritise these areas when you evaluate risk and plan controls.

Evaluate and rank the risks

Assess the likelihood of each hazard causing a fire and the potential consequences. Use a simple risk matrix to rank issues as high, medium or low. Be realistic and base judgements on evidence: records, near misses, operating temperatures and material ignition points.

Prioritise actions that remove the hazard entirely. Where removal is not practicable, reduce the risk by applying engineering controls, administrative controls and, finally, personal protective equipment. This hierarchy of control helps you focus resources on the most effective measures.

Design controls: prevention, detection and protection

Controls fall into three groups: prevent the fire starting, detect fires early and limit spread and damage. Industrial settings usually need multiple layers of protection.

Prevention

Segregate storage of flammable materials in purpose-built stores with spill containment. Use intrinsically safe or suitably rated electrical and mechanical equipment in hazardous areas. Control hot work with permit systems and use local extraction for dusty processes.

Detection

Fit automatic detection suitable for the environment (smoke, heat or aspirating detectors where appropriate). Align detection design with recognised codes such as BS 5839 for fire alarm systems. Recent BSI updates provide useful design and maintenance guidance for non‑domestic premises.

Protection

Maintain compartmentation and fire doors to limit spread between work cells and storage. Consider automatic suppression systems—sprinklers or specialised suppression for high‑risk equipment. Ensure firefighting equipment is suitable, accessible and regularly serviced.

Document which controls are in place, which are planned and who is responsible for delivery. For practical help with implementing equipment and maintenance, Total Safe provides a range of on-site services and inspections. Total Safe fire safety services

Consider dangerous substances and DSEAR requirements

If your processes use, produce or store substances that could cause an explosion or contribute to fire, your risk assessment must address those hazards specifically. DSEAR requires employers to assess and control the risks from dangerous substances and to provide appropriate information and training to staff. Practical controls include ventilation, dust suppression, safe storage and defined exclusion zones for hot work. For further technical detail consult HSE guidance on process fire safety.

Record findings and prepare an action plan

Write a clear, proportionate report. It should list the hazards and people at risk, prioritised actions with deadlines and named owners, any temporary controls already in place, and a review date plus trigger conditions for an earlier review.

Keep records accessible. From October 2023, Building Safety Act changes emphasise recorded evidence of fire safety arrangements for many buildings, so documented assessments and action plans support compliance and demonstrate due diligence. GOV.UK

When to appoint a competent assessor

Appoint a competent person when your in‑house team lacks the technical knowledge, time or impartiality to complete a full assessment. Competent assessors will have recognised qualifications, experience of industrial hazards and the ability to advise on specialist measures such as suppression systems, compartmentation repairs and ATEX zonings for explosive atmospheres.

If you need independent advice or a full audit, contact a specialist. For example, Total Safe offers tailored industrial assessments, maintenance and follow-up support. Get in touch with Total Safe

Testing, maintenance and change management

An assessment is not a one‑off task. You must review it after any significant change: new processes, layout changes, increased storage quantities or the installation of new plant. Schedule regular testing and maintenance for alarms, suppression systems, fire doors and emergency lighting. Train staff and run evacuation drills at appropriate frequencies so everyone understands their role.

For guidance on how often to review an assessment and maintain records, refer to GOV.UK advice on workplace fire safety and the HSE factsheets on fire prevention and process precautions.

Practical examples and common industrial solutions

Example 1 — Warehouse storing solvents

Issue: bulk solvent storage increases ignition risk.

Controls: store in certified cabinets, retain spill kits, provide mechanical ventilation, fit suitable fire detection and a sprinkler or suppression system for the storage area.

Example 2 — Metalworking producing combustible dust

Issue: elevated dust concentration and hot sparks from cutting.

Controls: local extraction and filtration, regular cleaning (not by compressed air), bonding and earthing for static control, and designated hot work permits.

Example 3 — Battery room for energy storage

Issue: thermal runaway and complex fire behaviour.

Controls: specialist suppression, heat detection with early warning, segregation from other plant and a dedicated emergency response plan.

These examples illustrate a common principle: match controls to the hazard and the people at risk, then document and train.

Making the business case and managing compliance

Decision‑makers often ask about cost. Start with high‑impact, low‑cost measures such as housekeeping, clear signage, and hot work permits. Then invest where risk exposure and consequence justify it. A documented assessment helps prioritise spend and demonstrates to insurers and regulators that you have taken reasonable steps.

Bear in mind that fire safety standards and guidance change over time. For example, recent updates to BSI guidance on fire alarm systems and other British Standards refine recommendations for detection and alarm systems in non‑domestic premises. Staying aligned to recognised standards reduces regulatory risk and improves life safety.

Next steps and how Total Safe can help

If you do not have an up‑to‑date assessment, start with a gap analysis of critical areas: dangerous substances, detection, compartmentation and evacuation arrangements. Where you need detailed technical support, commission a competent assessor who understands industrial hazards and relevant British Standards. Total Safe can help with surveys, full fire risk assessments and ongoing maintenance to close actions and keep your site compliant. Explore Total Safe services and arrange a site visit via the contact page. Contact Total Safe

Industrial fire risk assessment is a practical, structured process that identifies hazards, evaluates who or what is at risk, and sets out proportionate controls. Start with thorough information gathering, evaluate hazardous processes carefully, prioritise actions by impact and cost, and ensure regular review and maintenance. When the risks are complex, involve a competent assessor to recommend technical controls aligned to recognised standards and legal duties. Acting now will protect people, reduce business interruption and help you demonstrate compliance.