In 2021, the NFPA recorded 115,500 non-residential structure fires that led to 130 deaths, 1,100 injuries, and $3.6 billion in direct property damage and caused a staggering loss of production time for businesses. Structure fires in the manufacturing and industrial properties, among other non-residential occupancies, are included in these figures. Fire hazards are present everywhere, from manufacturing facilities to warehouses, but with proper fire prevention methods, these dangers can be significantly reduced or even eliminated altogether.
In this article, we will discuss fire hazards, how they can be prevented in factories and industrial properties, and how to promote fire safety.
What is Fire Hazard?
A fire hazard refers to any situation or material that can potentially ignite and cause a fire. This can include flammable liquids, gases, and solids, as well as electrical equipment and faulty wiring. Fire hazards are often present in industrial settings, construction sites, and homes. Some common examples of fire hazards include smoking materials near combustible materials, overheating appliances, and improper storage of chemicals.
It is vital for employers to identify potential workplace fire hazards and take appropriate measures to prevent fires from occurring and ensure fire safety. By taking proactive steps to prevent fires in the workplace, employers can protect their employees and help minimize property damage.
Common Fire Hazards in Factories
Flammable liquids and gases
Flammable or combustible liquids refer to any liquid with a flash point below 100 degrees Fahrenheit. Examples of these liquids include gasoline, oil, paint thinner, and alcohol. These types of liquids pose a significant fire hazard when they are not stored or used properly. These substances can easily ignite in the presence of open flames or electrical sparks, making them especially dangerous in factories.
According to OSHA 1910.106(a)(19), flammable or combustible liquids can be divided into four categories based on their flashpoint:
-
Category 1: Flashpoints below 73.4°F (23°C); boiling points at or below 95°F (35°C)
-
Category 2: Flashpoints below 73.4°F (23°C); boiling points at or above 95°F (35°C)
-
Category 3: Flashpoints at or above 73.4°F (23°C) and at or below 140°F (60°C); If a Category 3 liquid with a flashpoint at or above 100 °F (37.8 °C) is heated while in use within 30 °F (16.7 °C) of its flashpoint, it must be handled in compliance with the requirements noted for a Category 3 liquid that has a flashpoint below 100 °F (37.8 °C).
-
Category 4: Flashpoints above 140 °F (60 °C) and at or below 199.4 °F (93 °C); if a Category 4 liquid is heated while in use within 30 °F (16.7 °C) of its flashpoint, it must be treated in compliance with the requirements for a Category 3 liquid having a flashpoint of or above 100 °F (37.8 °C).
Flammable gases refer to any combustible gas or vapor that will ignite and cause a fire when exposed to air. Examples of these gases include methane, propane, and hydrogen sulfide; OSHA does not consider aerosols as flammable gas. These gases are highly combustible and can easily be ignited by heat, sparks, flames, or other ignition sources.
According to OSHA 1910.1200 App B., these gases have two categories:
-
Category 1: Gases, which at 20°C (68°F) and a standard pressure of 101.3 kPa (14.7 psi): (a) are flammable when combined with 13% or less by volume in the air; or (b) have a combustible range with air of at minimum 12 percentage points regardless of the lower combustible limit.
-
Category 2: Gases, other than the ones that meet Category 1, which, at 20°C (68°F) and a standard pressure of 101.3 kPa (14.7 psi), have a combustible range when mixed with air.
The NFPA (National Fire Protection Association) reported that the largest dollar loss fire or explosion in the United States in 2019 occurred in November at a petrochemical plant in Texas. The fire started due to igniting flammable liquids and gases in the processing areas. Two major explosions and a series of smaller explosions throughout the day resulted in an estimated damage of $1.1 billion. This shows how much damage flammable gases and liquids can cause.
How to prevent these hazards?
Reducing the risk of a fire or explosion through flammable liquids and gases includes training and educating employees on the dangers these materials pose and how to handle them safely. Employers should also ensure that all workers are aware of any warning signs or labels used for flammable gases and liquids. At the same time, they should ensure that all flammable materials are stored and disposed of properly.
These flammable materials should be stored in a cool, dry, and well-ventilated area away from heat sources such as flames or sparks. Flammable liquids and gases should also be kept in containers equipped with fire-resistant seals to prevent any accidental spillage or vaporization. Additionally, proper disposal of flammable gases and liquids should be done per local regulations.
Electrical Hazards
Electrical hazards refer to any potential danger that can result from the use of electricity. According to OSHA, electrical hazards include shock, electrocution, fire or explosion, and arc flash/arc blast.
Here are three examples of electrical hazards in the workplace, specifically in factories:
-
Old or faulty electrical equipment: Electrical equipment that is old or damaged can pose a significant risk to the workplace. Using outlets or appliance cords with frayed wires can generate heat that may ignite combustible surfaces such as floors, curtains, and other materials, leading to a fire outbreak. Common signs indicating faulty or outdated electrical equipment include high outlet temperature, damaged outlet cover, discoloration, and unstable power supply.
-
Inappropriate equipment usage: Improper operation of machinery poses an electrical fire hazard in the workplace. It is crucial for every worker to receive adequate training on the appropriate use, maintenance, and operation of machinery used in the workplace - particularly in high-hazard environments.
-
Human error: Neglecting safety measures is one of the primary causes of fires in factory settings. Employees must be aware of safety procedures and be trained to implement them correctly. Even minor operator errors can lead to disastrous consequences; hence it is essential to prioritize basic safety measures at all times to prevent accidents and damage from occurring.
How can electrical hazards be prevented?
A few steps employers should take to prevent electrical hazards include performing regular safety inspections, ensuring proper maintenance of machinery, and providing adequate training and guidance for employees.
Regular safety inspections should be conducted to detect any existing or potential fire hazard. During these inspections, all electrical equipment should be checked for frayed wires, overheating outlets, discoloration, and other signs of damage. Additionally, it is important to ensure that all electrical equipment is used appropriately and in accordance with the manufacturer’s instructions.
Proper maintenance of machinery can greatly reduce the risk of electrical fire hazards. All electrical equipment should be regularly serviced and maintained in compliance with the manufacturer’s recommendations. This includes ensuring that all machines are properly lubricated and that any worn parts are replaced immediately to minimize wear and tear.
Finally, providing adequate training for employees is essential for preventing electrical fire hazards in the workplace. It is important to ensure that all employees are trained on the safety procedures that should be followed and know how to use electrical equipment correctly to prevent any errors or negligence.
Combustible Dust
Combustible dust is a fire hazard that can be found in many industrial and manufacturing settings, particularly in factories. Combustible dusts are tiny particles of combustible material such as coal, flour, sugar, wood, grain, plastic, or rubber which can be suspended in the air and become highly flammable when they accumulate in large quantities. These dusts can easily ignite when exposed to sparks, heat, or even static electricity and, once ignited, spread rapidly in all directions creating a fire hazard.
OSHA noted five primary factors that can contribute to a dust explosion:
-
Combustible Dust: Combustible dust is defined as a finely divided solid material that is capable of catching fire and burning when mixed with air in certain concentrations.
-
Dispersion: The dispersion of combustible dust into the air is critical for an explosion to occur. This can happen during material handling activities such as mixing, grinding, or conveying.
-
Oxygen: The presence of oxygen in sufficient quantities is necessary for combustion to occur. The amount of oxygen required depends on the combustibility of the dust.
-
Ignition Source: An ignition source can be any heat source, spark, or flame that is hot enough to ignite the combustible dust mixture.
-
Confinement: A confined space can increase pressure and temperature levels during an explosion, leading to more significant damage and injury potential.
How can fire hazards from combustible dust be prevented?
To minimize the risks associated with combustible dust, employers should ensure that their premises are regularly inspected for any signs of dust accumulation and take steps to prevent or reduce any potential sources of dust dispersion. Additionally, employers should ensure that their areas are well-ventilated and free from any open flames or heat sources that could act as an ignition source for combustible dust.
OSHA also has recommended some ways to control dust, such as implementing a hazardous dust inspection, testing, cleaning, and control program, and using proper dust collection systems and filters. Moreover, the regulatory body also suggested practices for ignition control which will help reduce the risks of igniting combustible dust.
Fire Prevention Plan
When it comes to workplace fire safety, prevention is better than dealing with the alternatives; injuries, fatalities, property damages, OSHA citations, and large costs. Here are the minimum requirements for a fire prevention plan found in OSHA 29 CFR 1910.39(c):
-
A detailed list of all major workplace fire hazards, proper procedures for handling and storing hazardous materials, potential ignition sources and controls, and the type of fire protection equipment required to control each hazard.
-
Methods to control accumulations of flammable and combustible materials.
-
Processes for regular maintenance of safeguards installed on heat-producing equipment to avoid accidental ignition of flammable substances.
-
Name or job title of workers responsible for maintaining equipment to prevent or control ignition sources of fire.
-
Name or job title of employees accountable for handling fuel source hazards.
Best Practices for Implementing Fire Safety Measures in the Factory Environment
Some of the best practices for implementing fire safety measures in factories include conducting regular fire drills and safety inspections, identifying potential fire hazards through fire hazard assessment, creating an emergency response plan, and providing adequate fire-fighting equipment.
Regular fire drills are an important part of any fire safety plan as they help to familiarize workers with evacuation routes and the sound of fire alarms. Safety inspections should also be carried out regularly to identify any potential fire hazards, such as blocked exits or improperly stored flammable materials. It is important to create an emergency response plan which outlines how each individual should react in the event of a fire, including evacuation instructions and contact information for emergency services.
Adequate fire-fighting equipment should also be provided throughout the factory, including fire extinguishers, alarms, and sprinkler systems. Finally, it is important to educate workers on proper safety procedures and ensure they are aware of any potential risks in the workplace.
What To Do In Case Of A Fire Emergency In The Factory Setting
In the case a fire breaks out in the factory setting, all staff members must evacuate the building immediately and follow the designated evacuation routes. All personnel should be familiar with these routes and where to gather once outside the building. Additionally, they should be aware of any safety procedures that need to be followed in order to prevent the spread of fire.
Once the building is clear, the fire brigade should be called immediately and given all necessary information, such as the exact location of the fire and what type of equipment or materials are stored inside. The fire response team should also be informed if any hazardous material on-site may require special attention from firefighters.
Finally, all personnel should remain in a safe area until the fire is extinguished and it is safe to return to the building. No one must re-enter the premises until it has been declared safe by the fire service. Following these steps can help ensure safety and minimize damage caused by a fire emergency in the factory.
Take Fire Seriously
Taking proactive steps to minimize the risk of fires in factories is essential for workplace safety. By following OSHA regulations and implementing a fire prevention plan, you can ensure that your factory meets all necessary requirements for protecting employees from fire hazards. Regular drills, inspections, emergency response plans, and adequate fire-fighting equipment and training will go a long way toward mitigating any potential risks associated with operating in an industrial setting. Don't wait until disaster strikes – take action now to protect your workers and prevent costly damages caused by fire!