Sector·4 min read
Factory and Industrial Facility Fire Safety — Hazard Class and Area-Based Protection
Factories and industrial facilities cannot be protected with a single fire recipe: under one roof there may be a light assembly line, a high-rack store of flammable-packaged goods, flammable-liquid and solvent stock, processes generating combustible dust, a paint shop, and oil-filled transformers with packed switchgear rooms. This article covers factory fire safety on an area basis: hazard classification per TS EN 12845 / NFPA 13 (LH, OH1-4, HHP, HHS) and design density, ESFR sprinklers for storage and rack heights, production areas, flammable-liquid storage (NFPA 30 and — in the PFAS context — fluorine-free new-generation F3/SFFF foam), combustible-dust hazard (NFPA 652/654: dust collection, explosion venting/suppression), paint shops and spray booths (NFPA 33), electrical and switchgear rooms (clean agent + early detection), and the hydrant network with pump redundancy feeding it all.
A-Pro Engineering
Factories and industrial facilities cannot be protected with a single fire recipe. Under one roof there may be a light assembly line, a high-rack store of flammable-packaged goods, flammable-liquid and solvent stock, processes generating combustible dust, a paint shop, and oil-filled transformers with packed switchgear rooms. So protection is built not on a “same system everywhere” logic but on an area-based, scenario-driven approach. This article covers factory fire safety area by area; it is the industrial deep-dive of our which structure requires which system article.
Hazard classification: it all starts here
TS EN 12845 and NFPA 13 classify spaces by their fuel load and the speed of fire spread:
- LH (Light Hazard) — e.g. low-load assembly.
- OH1-OH4 (Ordinary Hazard) — most production/processing areas.
- HHP (High Hazard Process) — high-hazard production.
- HHS (High Hazard Storage) — high-hazard storage.
This class sets the sprinkler design density (mm/min) and the area of operation. We covered how sprinkler water demand is determined in our BYKHY and EN 12845 article.
Storage and high racks: ESFR
In high-piled storage, classic ceiling sprinklers are often insufficient; the fire grows between the racks. Two approaches:
- In-rack sprinklers for layered protection, or
- ESFR (Early Suppression Fast Response) — with high-flow, fast-response heads, it suppresses the fire within the rack and under suitable conditions can eliminate in-rack sprinklers.
The choice is made according to storage height and commodity class. We detailed ESFR in a separate article.
Flammable-liquid and solvent stock
Flammable/combustible liquids are handled within the NFPA 30 framework: limited quantities in fire-resistant safety cabinets, large stocks in separate stores with ventilation, drainage, and spill-tight thresholds. In suppression, foam stands out — and here is a critical update:
Classic fluorinated foams (AFFF, AR-AFFF, fluoroprotein) contain PFAS (“forever chemicals”) and are increasingly being banned/restricted, notably in the EU (REACH). So in new facilities fluorine-free new-generation foams (F3 / SFFF — Synthetic Fluorine-Free Foam; AR-SFFF for polar/water-miscible liquids) should be preferred.
We covered foam types and expansion ratios in our foam suppression article. Depending on the area’s hazard class, foam-water sprinklers, spill containment, and ventilation for explosive vapor are designed together.
Combustible dust
Flour, sugar, starch, wood, metal, plastic, and many food/chemical dusts are explosive when suspended in air — one of the most underestimated, most destructive risks in industry. NFPA 652 (base) and the process-based NFPA 654/61/484 first require a Dust Hazard Analysis (DHA):
- Prevent dust accumulation: enclosed process, effective dust collection, regular housekeeping.
- On enclosed equipment/silos: explosion vent panels (NFPA 68), explosion suppression/isolation (NFPA 69).
- Ignition control: bonding/grounding, ATEX equipment, spark detection.
The aim is to prevent both open flame and a dust explosion in an enclosed volume from the outset. We covered detector selection in ATEX areas in our fire detection article.
Paint shops and spray booths
Paint/coating spraying produces atomized flammable liquid and solvent vapor, making it one of the highest ignition-risk points, and it falls under NFPA 33:
- Adequate ventilation — an airflow keeping vapor safely below the LEL.
- Automatic sprinklers or suitable suppression; ATEX/explosion-protected electrical, grounding.
- Booth and exhaust ducts are paths along which fire spreads: in-duct protection and regular cleaning.
- Interlock of suppression/ventilation with process shutdown.
Electrical and switchgear rooms
Electrical distribution rooms, MCC/switchgear areas, UPS, and server rooms are areas where water damage is unwanted and continuity is critical:
- Early detection first — with very early (aspirating) smoke detection where possible.
- Clean-agent (halocarbon/inert) suppression instead of water.
- Oil-filled power transformers: secondary oil containment, separation/firewall, and water spray if needed.
- Cable galleries: compartmentation + fire-stopped penetrations.
Hydrant network and pumps
A fire water infrastructure feeds all these systems: an adequate tank, redundant pumps (electric + diesel), a ring main, and hydrants. Capacity is calculated on the worst-case simultaneous demand (e.g. the largest sprinkler area + hose flow). We covered the hydrant, hose cabinet, and fire department connection in our separate article.
Summary
Factory and industrial facility fire safety starts with hazard classification (TS EN 12845 / NFPA 13) and gives each area protection appropriate to its risk: ESFR (or in-rack sprinklers) for high-rack storage, NFPA 30 + fluorine-free F3/SFFF foam and spill containment for flammable-liquid stock, DHA + dust collection + explosion venting/suppression (NFPA 652/68/69) for combustible-dust processes, NFPA 33 ventilation + sprinklers for paint shops, and clean agent + early detection for electrical/switchgear rooms. All are fed by a common hydrant network and redundant pump infrastructure. At A-Pro we design sprinkler/ESFR, foam, gas suppression, explosion venting, and detection systems in an area-based, integrated way for factories and industrial facilities; contact us for your project.
This content is for information purposes. Binding design must be produced project-by-project based on the facility’s actual processes and hazard analysis and the editions of TS EN 12845, NFPA 13/30/33/652/68/69 and the relevant standards and BYKHY in force.
© 2027 A-Pro Mühendislik. This is original technical content produced by A-Pro Engineering; all rights reserved. Copying, reproducing or republishing it in whole or in part without attribution and permission is prohibited.
Frequently asked questions
How is fire protection determined in a factory?+
Factory protection is determined not by a 'same system everywhere' logic but by each area's hazard class. TS EN 12845 and NFPA 13 classify spaces by their fuel load and the speed of fire spread: light hazard (LH), ordinary hazard (OH1-OH4), and high hazard — process (HHP) and storage (HHS). This class sets the sprinkler design density (mm/min or gpm/ft²) and the area of operation; for example, a high-rack store of flammable-packaged goods demands a very different water flow than a light assembly line. So the first step of design is to determine the correct hazard class and storage form (rack height, packaging type) for each zone of the facility. In Türkiye facilities are also within the scope of BYKHY and OHS legislation.
Which sprinkler is used in high-rack storage?+
In high-piled storage, classic ceiling sprinklers alone are often insufficient because the fire grows between racks before reaching the ceiling. There are two basic approaches: either protection is layered with in-rack sprinklers, or ESFR (Early Suppression Fast Response) sprinklers are used. ESFR, with its high-flow, fast-response heads, aims to suppress the fire within the rack and under suitable conditions can eliminate in-rack sprinklers; however, its high operating pressure and ceiling height must be compatible with the storage geometry and the stored material. We detailed ESFR in a separate article; the choice must be made according to storage height and commodity class.
How is flammable-liquid and solvent stock protected?+
Flammable and combustible liquids (solvent, paint, oil, chemicals) are handled within the NFPA 30 framework: limited quantities in fire-resistant safety cabinets, large stocks in separate stores with ventilation, drainage, and spill-tight thresholds. In suppression, foam stands out — but there is a critical update here: classic fluorinated foams (AFFF, AR-AFFF, fluoroprotein) contain PFAS ('forever chemicals') and are increasingly being banned/restricted, notably in the EU (REACH). So in new facilities fluorine-free new-generation foams (F3 / SFFF — Synthetic Fluorine-Free Foam; AR-SFFF for polar/water-miscible liquids) should be preferred. In addition, depending on the area's hazard class, foam-water sprinklers, spill containment, and ventilation for explosive vapor are designed together.
How is combustible-dust risk managed?+
Flour, sugar, starch, wood, metal, plastic, and many food/chemical dusts are explosive when suspended in air at a certain concentration; this is one of the most underestimated and most destructive risks in industry. NFPA 652 (the base standard) and the process-based NFPA 654/61/484 first require a Dust Hazard Analysis (DHA). The basic measure is to prevent dust accumulation: enclosed process, effective dust collection, and regular housekeeping. On top of this come explosion vent panels (NFPA 68) on enclosed equipment and silos, explosion suppression/isolation (NFPA 69), and control of ignition sources (bonding/grounding, ATEX equipment, spark detection). The aim is to prevent both open flame and a dust explosion in an enclosed volume from the outset.
What is needed in paint shops and spray booths?+
Paint and coating spraying produces atomized flammable liquid and solvent vapor, making it one of the facility's highest ignition-risk points, and it is handled under NFPA 33. Spray booths require adequate ventilation (an airflow keeping vapor safely below the LEL), automatic sprinklers or suitable suppression, ATEX/explosion-protected electrical equipment, grounding, and regular cleaning to prevent buildup. The booth and exhaust ducts are also paths along which fire spreads; so in-duct protection and regular maintenance are critical. Interlocking suppression and ventilation with process shutdown prevents the fire from growing.
How are electrical rooms and switchgear areas protected?+
Electrical distribution rooms, MCC/switchgear areas, UPS, and server rooms are areas where water damage is unwanted, continuity is critical, and there is an electrical ignition risk. There, early detection comes first — with very early (aspirating) smoke detection where possible — followed by clean-agent (halocarbon/inert) suppression instead of water. If there are oil-filled power transformers, as in other industrial facilities, secondary oil containment, separation distance or a firewall, and water spray if needed are applied. Cable galleries are separated from adjacent areas by barriers, and penetrations are sealed with fire-stops. The aim is to protect critical electrical infrastructure both from fire and from secondary damage caused by the extinguishant.
Related systems
Which Buildings Require Which Fire System? →ESFR Sprinklers — What They Are and Where Used →Foam Fire Suppression: Design and Expansion Ratios →Sprinkler Water Demand — BYKHY and EN 12845 →Fire Detection Systems, Detector Selection and ATEX →Fire Hydrant System, Hose Cabinets and Fire Department Connection →
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