It may seem incongruous that cold storage environments could pose a fire risk. However, because of the components they rely on, these facilities do come with unique operational challenges and fire hazards.
This leads us to the question: how does cold storage work? Effective insulation is key, and combustible panels play a vital role in this insulation.
What are combustible panels?
Made from expanded polystyrene (EPS), or polyurethane foam (PUR) fitted between metal sheets, combustible panels are excellent insulators that optimise storage and preservation. However, they are highly flammable materials, which can lead to rapid combustion in a fire1. Understanding the risks involved in active usage, effective maintenance and the associated insurance challenges is critical.
Risk mitigation strategies
Cold storage warehouses using combustible panels may face higher premiums or restricted coverage because of the risks involved. Knowledge of risk mitigation options is vital for optimal premium outcomes and appropriate coverage options, as well as insurer selection and consideration of endorsements on policy schedules.
Astute material selection in construction
Fire-retardant insulation panels such as mineral wool or polyisocyanurate (PIR) foam instead of highly combustible EPS or PUR foams in construction are essential. Panels certified by the Loss Prevention Certification Board (LPCB) to standards like LPS 1181 or LPS 1208 are recommended.
Building fire-resistant compartments and properly sealed joints can also help prevent fire from spreading within the facility. Electrical and other services that penetrate panels should be fitted with non-combustible, fireproof sleeves navigating the entire thickness of the panels. Proper fire doors and barriers between sections of the cold storage warehouse can further enhance protection.
Flammable materials must not be stored within ten metres of the building. The security around the building should also be robust, with properly maintained CCTV cameras in place.
Suitable fire protection systems
The appropriate installation of active fire protection systems is equally important at the construction and process levels. Warehouses can be fully conditioned and insulated (referred to as 'big box') or have a refrigerated space inside a larger warehouse (known as 'box-in-box'). Box-in-box facilities could combine a wet sprinkler system with a specialised suppression system in the refrigerated space2.
Seal integrity is essential in box-in-box facilities to reduce condensation and ice buildup. To enhance fire resistance, additional fireproofing measures, such as fire-retardant coatings or the integration of fire barriers, may be necessary.
Fire Safety in Cold Storage: Advanced Sprinkler Systems Explained
- Dry-pipe sprinkler systems: Traditional wet-pipe sprinkler systems are not suitable for cold storage due to the risk of freezing pipes. Dry-pipe sprinkler systems are filled with pressurised air or nitrogen and only release water into the pipes when a fire is detected.
- Double interlock pre-action sprinkler systems: Like dry pipes, the piping here is filled with air or nitrogen. Before releasing water, a double interlock pre-action system requires both the fire detection system and the sprinkler heads to be activated by heat. This helps prevent accidental discharge, which can be very expensive.
Fire detection and suppression systems
Advanced fire detection and suppression systems, which are able to function effectively even at low temperatures, should be installed. These can include early smoke and heat detection systems, compliant with BS 5839, and comprehensive automatic fire detection featuring remote signalling to help detect issues and address them before they lead to a fire.
Depending on the specific conditions of the storage area, rate-of-rise or fixed-temperature heat detectors can also be used. Aspirating Smoke Detection (ASD) systems detect fire in its early stages by continuously sampling the air in an area. They can differentiate smoke from other factors, avoiding false alarms.
Regular inspections and maintenance
Regular panel inspections and proactive panel replacement should be conducted. If damage has exposed the core insulation material, metal caps or covers should be fixed to the panel3.
Fire protection systems, including alarms, sprinklers and suppression systems, must be tested regularly to ensure proper functioning even at low temperatures. Equipment and cabling should also undergo frequent electrical testing and thermographic inspections.
To prevent new fire risks, installing photovoltaic (PV) panels on flammable surfaces or placing electrical vehicle (EV) charging points close to the building needs to be avoided. The location of combustible panels must also be critically reviewed in higher-risk inception areas, such as hot cooking areas and forklift truck charging facilities.
Emergency preparedness
Employees working in cold storage facilities should be trained on fire evacuation procedures, including the use of fire extinguishers and responding to alarms. The facility should have adequate access points for firefighters. Additionally, first responders may require special protective gear or particular procedure awareness.
Compliance with standard codes and guidelines
Ensuring compliance with local fire protection codes and standards, which may have additional requirements for cold storage facilities, is non-negotiable. If a facility is found to be non-compliant, this can incur legal issues, substantial fines or mandatory modifications. The PIR and PUR materials must also meet local building codes and industry standards.
Furthermore, for workers' safety, there should be provision of personal protective equipment (PPE), sufficient ventilation and strict adherence to safety protocols in the premises, to mitigate the exposure risks during manufacturing and installation.
Insurance implications and risk management support
As the cold storage industry evolves and expands, so do the challenges to ensure proper fire protection. A specialised approach is needed; most organisations already transfer risk through insurance. Early discussions with insurers should be regarded as a priority, allowing time to consider all relevant risk features and risk mitigation tools required.
With a wealth of experience and an in-depth understanding of the operational challenges presented by composite panels in the cold chain warehousing industry, we are here to support clients in this sector in managing and mitigating risks appropriately, cost-effectively and operationally.
