Can you count the risks on a manufacturing floor? There are many, and some can spark, kindle, and fuel a potentially devastating fire in a blink of an eye.
In 2021, there were 39,047 total fire incidents reported in Canada, highlighting the pressing need for effective fire control measures in the manufacturing industry. The manufacturing industry is particularly vulnerable to fires due to the presence of flammable materials, electrical equipment, and various heating processes. Furthermore, these facilities often have large open spaces that can quickly spread a fire if not controlled properly.
Now think about an industrial or factory setting: with a variety of potential fire risks and a sizable workforce on site, an outdated (or non-existent) fire prevention plan can have huge consequences. To ensure the safety of employees and protect valuable assets, it is crucial for manufacturing companies to have effective fire control measures in place.
The importance of fire safety in manufacturing
Fire safety in manufacturing is not just a regulatory requirement but a critical aspect of operational efficiency and employee safety. A single fire incident can result in substantial financial losses and, more importantly, endanger the lives of workers. Implementing a robust fire safety plan can significantly reduce these risks and ensure business continuity.
Investing in fire safety measures also enhances the company’s reputation, demonstrating a commitment to employee welfare and operational excellence. A well-structured fire safety strategy can prevent workplace injuries and minimize damage to equipment and infrastructure. By prioritizing fire safety, manufacturing companies can safeguard their assets and maintain a positive work environment. Here are four tips to get you started:
Commit to good housekeeping practices
Good housekeeping is fundamental to preventing fires in a manufacturing setting. Regular cleaning of machines to remove residues of metalworking fluids (MWF), oils, and grease is essential to reduce the risk of fire. Ensuring that aisles, stairwells, and emergency exits are free from obstructions is critical for maintaining safe evacuation routes.
Implementing a system to organize tools, waste containers, and other equipment can further enhance workplace safety. Visual aids such as painted floor markings that show where things like waste containers, carts, and tools should be parked while not in use can help maintain order and prevent clutter, reducing the likelihood of fire hazards. Encouraging employees to adhere to housekeeping standards through training and regular inspections can foster a culture of safety.
Establish protective areas for hot work
With high heat and open flames, hot work like welding, brazing, and cutting poses a clear fire hazard. This is why manufacturers establish dedicated areas for these tasks, creating a protective area that stretches 50 feet in every direction around hot work operation.
In these areas, employees are required to remove flammable liquids, dust, and oil deposits; clean the floors and remove trash. Workers must also use welding pads, blankets, curtains, and fire-resistant tarpaulins to cover combustible materials or any openings in the wall or floors. For manufacturing risks where a 50-foot clearance is not feasible, production-related hot work areas are typically equipped with curtains and shields to reduce the “clear space” required.
At times, cutting and welding need to be completed in other areas, but fire safety still applies. Supervisors should sign formal Hot Work Permits before starting, and welders must ensure that sprinklers are functional and that fire hoses and fire extinguishers are readily accessible, just as they would be in a designated hot work area.
Personnel can also be assigned to “fire watches”, responsible for monitoring the work area during operations and for 60 minutes after the job is completed, ensuring no sparks or slag ignite a fire. During this time, surrounding material handling systems, such as conveyors, should be shut down to help contain any potential hazards.
There’s also an opportunity to consider alternatives that eliminate fire risks altogether. For instance, instead of using heat sources, materials could be cut with manual hydraulic shears or connections could be made with mechanical fasteners.
Maintain the efficiency of sprinkler systems
A fire in a manufacturing operation can be fueled by many sources, such as combustible hydraulic fluid from a nearby stamping press, or accumulated paper dust in a printing plant’s dust collection system. In other cases, bulk fluid supplies may pose a serious fire risk.
One of the best defenses against fire is a well-maintained fire suppression system. Sprinklers can fail for several reasons, including blockages from scale buildup in branch lines, damage caused by Microbiologically Influenced Corrosion (MIC), blocked sprinkler heads and metal racks that prevent water from reaching the source of the flames.
Inadequate design for the hazard or occupancy can also be problematic. Ensuring the sprinkler system has been properly designed for the specific risks of your manufacturing environment is essential for optimal performance.
Regular inspections are key to addressing these issues. Plan to review control valves, air pressure, and water pressure at least once a week. Also, inspect fire department connections and tamper switches at least once a month. An annual inspection by a certified fire protection contractor can help uncover deeper issues, such as blocked sprinklers or valve malfunctions, by testing open sprinklers, pre-action and deluge systems, and trip-testing dry pipe valves.
Monitor the paint booths for potential hazards
Paint booths and their surrounding areas require regular checks and preventive measures to help protect against potential fires:
- Limit flammable and combustible liquids to a single day’s supply.
- Store solvent-soaked rags, which could spontaneously combust, in ULC-listed cans.
- Any overspray should be removed to prevent the buildup of combustible residues.
- Ensure paint booths are equipped with a reliable fire suppression system.
If you want to speed up the cleanup process, you could even consider lining the booth with thin paper sheets to be replaced at least once a day.
Protect yourself and your property with insurance
No matter how well you prepare, some fire risks are inevitable in a manufacturing environment. Make sure your business is fully protected against potential fire hazards and operational disruptions. Want to learn more about securing your manufacturing operations? Learn more by visiting our manufacturing insurance page today!
