Designing fire/life safety systems for industrial and manufacturing facilities involves adapting to automation trends, balancing cost-effectiveness with safety, and utilizing advanced detection and suppression technologies to ensure operational efficiency and protection.
Learning Objectives
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- Understand the unique challenges and solutions in designing fire/life safety systems for industrial and manufacturing facilities.
- Learn about the impact of changes in codes, Building Information Modeling (BIM), and wireless devices on the design and implementation of fire and life safety systems in industrial settings.
Manufacturing insights
- Trends in fire protection are moving towards advanced detection technologies and innovative suppression systems to provide early detection and minimize damage, ensuring safety while maintaining operational efficiency.
- The increasing shift towards automation in manufacturing requires fire protection systems to adapt and integrate more closely with safety and IoT technologies.
- Jarron Gass, PE, CFPS, Fire Protection Discipline Leader, CDM Smith, Pittsburgh
- Justin Milne, PE, PMP, Senior Engineer, Jensen Hughes, Allen, Texas
- Jonathan Sajdak, PE, Associate Principal / Fire Protection engineering director, Page, Houston
- Michael Whalen, PE, LEED AP BD&C, Project Manager, HDR Engineering, New York
What are some of the unique challenges regarding fire/life safety system design that you’ve encountered for such projects? How have you overcome these challenges?
Justin Milne: The primary challenge in designing fire and life safety systems for these projects lies in finding the right balance between safety and cost-effectiveness. In industrial facilities, for example, installing a break tank for fire water can enhance resilience and offer significant financial benefits to the owner. However, the costs of these systems often exceed a million dollars. The typical storage systems in industrial buildings are usually the main reason for these break tanks are required. To strike a balance between safety and cost for break tank requirements, conducting a high-piled storage engineering analysis according to IFC Standard 3204.2: Designation Based on Engineering Analysis is recommended.
Jonathan Sajdak: One unique challenge for fire protection design is providing the appropriate protection for the storage of high-piled, hazardous materials. Industrial facilities typically have large quantities of hazardous materials present, some of which are classified as flammable or combustible liquids. These liquids are critical to the manufacturing process, and quantities are kept in bulk so these facilities can operate for weeks or months should their supply chain be impacted. We have utilized fire modeling and results from full-scale fire testing to justify certain fire suppression strategies where prescriptive code requirements cannot be met. Until codes and loss prevention guidelines evolve to address certain configurations, this performance-based solution approach is one of the only ways to appropriately protect certain commodities.
Michael Whalen: The quality and housing of the fixture is an important consideration when designing lighting for these types of manufacturing facilities. The fixtures need to be treated to withstand elements like high temperatures, humidity, corrosion, oil, steam and dust. In addition, control systems are being requested in an effort to reduce electricity costs. The control systems are typically either wireless or wired and include dimming capabilities along with the ability to be adaptive based on occupancy and available daylight.
What clean agent, aerosol, chemical, oxygen reduction or other specialty fire suppression systems are typically specified? Describe a project and the system specified.
Jarron Gass: Alternative suppression systems, such as clean agents or inert gas suppression, are generally limited in larger manufacturing environments but have a place in small subset areas within these facilities. This is especially true when considering specific clean areas within, for instance, semiconductor fabrication areas or highly sensitive electronics areas within larger facilities. Additionally, foam systems are used for particular hazards, such as flammable and combustible liquid storage, or areas where these types of commodities are used in both open or closed systems as one or more steps in the manufacturing process of any particular facility. Some of the trends in these alternative suppression lines have been to develop alternatives that are less hazardous to both human health and the environment.
Justin Milne: Chemical-based fire extinguishing systems, including clean agents, aerosols and oxygen reduction systems, are tailored for specialized applications. Clean agents are commonly used in information technology and operational technology equipment areas. Aerosol systems have found applications in electrification, maritime environments and wastewater treatment/collection facilities. Oxygen reduction systems, such as those using carbon dioxide, are often implemented in normally unoccupied emergency power areas where water discharge poses concerns for owners.
Jonathan Sajdak: There are certain materials used in industrial and manufacturing facilities that require special fire protection systems. One example is pyrophoric materials, which are materials that come in solid, liquid or gas form and ignite spontaneously upon exposure to oxygen (i.e., air). Additionally, many of these materials can be reactive with water. It can be very difficult to contain and suppress a pyrophoric fire. One specialty fire protection system that can used to protect these materials is an inert gas clean agent system. These systems are designed to reduce the oxygen concentration in the space to interfere with the combustion process. Other wet chemical, dry chemical and aerosol systems may be appropriate for certain materials. It is best to coordinate with the manufacturer data sheets and perform a close review of material compatibility to ensure the best means of fire protection is provided.
How have the trends in fire/life safety changed in industrial and manufacturing facility projects?
Jarron Gass: As manufacturing increasingly shifts toward automation, the fire protection industry has had to adapt and innovate to address the growing fire challenges that don’t neatly fit into standard prescriptive protection schemes. One emerging approach involves integrating safety systems more closely. For example, fire alarms and suppression systems are now designed to work collaboratively rather than independently. Additionally, with the rise of the Internet of Things (IoT), safety system responses are becoming more automated. This shift toward a performance-based design approach allows for more effective protection.
Justin Milne: There have been many trends affecting facility projects in industrial and manufacturing projects over the years. One of these is the use of fire extinguishing systems and smoke and heat vents for high-piled storage protections. The two system types approach fire safety from different perspectives. The fire suppression systems attempt to quickly knock down fires, spraying water at higher velocities and gallonage to displace combustibles, whereas the smoke and heat vent systems attempt to relieve gas and pressure build up in the space, reducing the risks of flashover occurring.
How have the trends in fire/life safety changed in industrial and manufacturing facility projects?
Michael Whalen: Identifying ways to fight fires in these facilities most effectively and efficiently, with as little damage to the assets as possible, has influenced the creation of more technologically advanced fire protection systems. These innovative systems utilize smart technology to remotely test the system, provide system diagnostics and observe pressures and water flows to maintain system functionality when needed. Early detection and advanced detection are becoming more common. We are seeing a rise in the use of high-sensitivity laser detectors or camera video analytics to sense smoke and flames very early on.
What fire, smoke control and security features might you incorporate in these facilities that you wouldn’t see on other projects?
Jarron Gass: In a specific project at a recycling facility, a performance-based approach was employed to address a challenging fire scenario where traditional prescriptive suppression methods fell short. This innovative approach integrated several different systems through automated logic to work in harmony and enhance fire and life safety measures. The strategy combined smoke and heat detection with automatic water monitors, which directed water spray at specific heat signatures identified by infrared detection. Additionally, automatic venting was activated to help control the smoke layer. While none of these measures were considered conventional, they collectively provided the level of protection required to safeguard life and property in this unique environment.
Justin Milne: Manufacturing and industrial environments with the potential for significant fires and off-gas exposures may require additional engineering evaluation for initiation devices as per NFPA 72: National Fire Alarm and Signaling Code. In industrial warehouse settings, smoke and heat removal systems are sometimes employed to prevent the accumulation of smoke and hot gases. Smoke control systems might also be utilized in windowless areas, where radiological materials are present, or when building heights necessitate such measures.
Jonathan Sajdak: Industrial and manufacturing facilities can have very large footprints and require special consideration for egress and access control. Additionally, certain areas of these buildings may have restricted access to the public and on-site workers. In these facilities, there are typically hundreds or thousands of occupants that need to be evacuated in the event of an emergency. To plan for organized emergency procedures, it is sometimes beneficial to design the fire alarm system for partial evacuation and/or relocation. Early detection, accurate occupant notification via voice communication and maintaining tenable conditions using passive fire protection features help allow for this solution. Close coordination shall be performed with the security systems for the access control interface and identifying all fail-safe and fail-secure locations, ensuring occupants have the minimum required egress options. Partial evacuation for these facilities is a reasonable, and sometimes preferred, alternative to total evacuation, but it should be noted that coordination with the authority having jurisdiction (AHJ) is typically required to get approval for this approach.
Michael Whalen: Facilities with clean rooms need to worry about contamination of the product and ensure no residue is left on any surface after the suppression agent has been discharged. In these manufacturing facilities, early detection is just as important as protection to ensure the fire has as little time as possible to grow. We have been specifying high-sensitivity smoke detection systems to detect the fire during its very early stages.
Do you see any future changes/requests to the structural design of these buildings regarding fire/life safety systems?
Justin Milne: With the growing interest and investment in sustainable green design options, mass timber has become a highly desirable approach for some owners. The benefits of carbon sequestration and the 2021 changes to the International Building Code to accommodate mass timber have made it a more frequently considered structural design option.
Jonathan Sajdak: Industrial and manufacturing facilities tend to have large building footprints. One requirement that has become more common in the fire protection industry is the incorporation of a firefighter air replenishment system. First added in the 2015 edition of the International Fire Code (IFC) as Appendix L, jurisdictions have begun to adopt this section of the code when buildings reach certain height or area thresholds. The routing of conduit and location of fill stations is critical, especially when projects are split into early core and shell packages with deferred fit out packages following later.
How have the cost and complexity of fire protection systems involved with industrial and manufacturing facility projects changed over the years? How did these changes impact the overall design process?
Jarron Gass: Indeed, costs continue to rise with each new advancement or technological breakthrough, whether it’s a new material or a listed approach. It’s becoming increasingly expensive to get products listed through national testing protocols like UL or approved by FM Global. Similarly, the costs associated with performance-based design approaches can be higher, as these efforts are often unique to a single challenge and cannot be repeated on other projects. This is especially true when full-scale fire testing in a laboratory is relied upon for the development of proper protection schemes.
Justin Milne: Dedicated fire water loops, hydrant yards, pump houses, backup fire pumps and dedicated fire water break tanks are all features characteristic of large-scale industrial complexes. As time has progressed, the understanding of hazards by fire protection engineering communities has evolved. A notable example is the sizing of underground lines. Many industrial process plants have 30-inch utility lines specifically designed to meet fire water demands. Over time, engineers and designers have recognized the numerous operational risks associated with having such large underground lines directly connected to fire systems. One significant risk is water hammer, where a sudden stop in water flow creates a pressure surge that rebounds through the underground lines, potentially damaging valves, fittings and other system components.
Jonathan Sajdak: Like most engineered building systems, fire suppression and fire alarm systems have seen a rise in cost over the last three to five years. Not only have materials increased in price, but the complexity of these facilities has led to longer design durations and reviews. Building information modeling (BIM) coordination has been incorporated at each milestone to help coordinate within these complex facilities and value engineering exercises have become more iterative throughout the design process. Cost is reviewed at each milestone and everything from material cost to levels of redundancy is looked at when budgets become tight.
Michael Whalen: Sophisticated fire protection and detection systems, such as clean agents and early detection systems, have increased in cost, however the upfront investment can save significantly more on the backend if there is an incident and production is affected. Owners are realizing that alternatives to their process, storage and spatial layouts can result in the fire protection system being more efficient. Examples of alternatives include reducing racking heights, creating fire barriers or increasing the fire resistance ratings of floors and walls.
How have changes to codes, BIM and wireless devices/systems impacted fire and life safety system design for these buildings?
Jarron Gass: In my experience, codes and standards have consistently lagged behind available technology, especially when considering the time it takes for a new product or process to be formally adopted into regulations. This process typically involves approval by the regulating body followed by acceptance by the AHJ. It can easily take 3-5 years for these advancements to be fully developed and accepted. The natural delay in the code adoption process has hindered the implementation of wired fire alarm devices. However, the use of wireless devices is increasing as reliability and protection from interference, whether intentional or not, are being improved.
