Fire Risk Assessment for Industrial Units and Factories

Industrial units and factories present some of the most demanding fire-safety challenges faced by UK businesses. With complex machinery, hazardous substances, high electrical loads, and large workforces often operating across multiple shifts, the potential for fire ignition and rapid spread is significant. Under the Regulatory Reform (Fire Safety) Order 2005 (RRO), anyone who owns, manages, or controls a non-domestic premises is legally designated as the Responsible Person.

If you fall into this category, you are legally required to carry out a suitable and sufficient fire risk assessment of your industrial unit. This article outlines what this involves, the specific hazards you must look out for, and how to stay compliant with UK law.

Understanding Your Legal Duties

The RRO 2005 places the primary fire-safety duty on the Responsible Person. In an industrial setting, this could be the factory owner, the managing director, or an external facilities management company. The Management of Health and Safety at Work Regulations 1999 (MHSWR) further reinforce the need to identify risks and implement appropriate preventative measures.

For factories and industrial units, a fire risk assessment is not a one-off box-ticking exercise. It must be reviewed regularly and updated whenever significant changes occur, such as the installation of new manufacturing equipment, changes to the building layout, or an increase in the storage of hazardous materials. If you employ five or more people, you must record the significant findings of your assessment in writing.

Key Fire Hazards in Industrial Units

Factories and industrial units contain hazards rarely found in standard office environments. A thorough assessment must carefully evaluate the unique risks associated with your specific operations. Common hazards include:

• Combustible materials: Accumulations of packaging, wood, paper, and dust in production areas.
• Hazardous substances: Solvents, paints, chemicals, and flammable gases used in manufacturing processes.
• Electrical faults: Overloaded circuits, damaged wiring on heavy machinery, and poorly maintained equipment.
• Hot work: Welding, cutting, and grinding activities that generate sparks and heat.
• Arson and security: Unsecured perimeters allowing unauthorised access to flammable waste or storage areas.
• Machinery friction: Poorly maintained conveyor belts and moving parts generating excess heat.

The Five Steps of a Factory Fire Risk Assessment

To comply with the RRO 2005 and align with recognised guidance such as PAS 79, a fire risk assessment for an industrial unit should follow a structured methodology:

1. Identify the hazards: Walk the factory floor to locate potential sources of ignition, fuel, and oxygen. Pay close attention to storage areas, plant rooms, and production lines. 2. Identify people at risk: Consider everyone on the premises, including employees, night-shift workers, maintenance contractors, and visitors. Account for anyone who may be more vulnerable, such as individuals with mobility issues. 3. Evaluate, remove, or reduce the risks: Implement measures to eliminate hazards where practicable. If a hazard cannot be removed entirely, put controls in place to manage it safely. This might involve upgrading fire doors, installing specialist suppression systems, or enforcing strict housekeeping protocols. 4. Record, plan, and train: Document your findings and develop an emergency plan tailored to the factory layout. Ensure staff receive adequate fire safety training relevant to their roles and the specific substances they handle. 5. Review: Set a schedule to revisit the assessment, ensuring it remains accurate and effective as your industrial operations evolve.

Emergency Planning and Escape Routes

In a large industrial unit, ensuring safe evacuation is highly complex. The layout of machinery, racking systems, and goods-in-out areas can easily obstruct escape routes. The Health and Safety at Work etc. Act 1974 (HSWA) requires employers to provide and maintain safe working environments, which includes safe access and egress.

Your fire risk assessment must verify that escape routes remain unobstructed at all times. Fire doors must be kept closed and functioning correctly, and emergency lighting must be installed along all designated escape routes. Furthermore, fire detection and alarm systems must be adequate for the size and acoustic environment of the factory; a standard office alarm may not be heard over the noise of heavy manufacturing machinery.

Why Professional Assessment is Essential

While it is legally permissible for a Responsible Person to conduct their own fire risk assessment, industrial units are highly complex environments. Without a deep understanding of fire behaviour, compartmentation, and the relevant British Standards, it is easy to overlook critical risks that could endanger lives and lead to enforcement action from the fire brigade or the Health and Safety Executive (HSE).

At HawkSwift Ltd, we understand the unique challenges of industrial fire safety. Our NEBOSH-qualified assessors provide thorough, practical evaluations tailored to your specific manufacturing processes. We deliver clear, actionable 48-hour reports that highlight risks and provide sensible recommendations to keep your business compliant. With our professional fire risk assessments from £199 + VAT, achieving compliance is both straightforward and cost-effective.

To ensure your factory or industrial unit meets its legal duties and protects your workforce, book a fire risk assessment with the HawkSwift team today.