Warehouses hold large amounts of stock in one place, so a fire can spread fast and cause huge losses. The risks are changing, too: modern electric forklifts and pallet trucks mean more lithium-ion batteries being charged, often without anyone watching, and more of the stock itself now contains lithium-ion batteries.

The Law

The person responsible must carry out a fire risk assessment and put suitable precautions in place:

  • England and Wales – the Regulatory Reform (Fire Safety) Order 2005
  • Scotland – the Fire (Scotland) Act 2005 and the Fire Safety (Scotland) Regulations 2006
  • Northern Ireland – the Fire and Rescue Services (Northern Ireland) Order 2006 and the Fire Safety Regulations (Northern Ireland) 2010

See Do I Need a Fire Risk Assessment?. Your insurer is likely to have its own requirements too.

Storage and Housekeeping

  • Keep aisles, exits and escape routes clear at all times.
  • If you have sprinklers, keep stock well below the sprinkler heads – insurers typically ask for at least 1 metre.
  • Keep gaps (flue spaces) between racked pallets, so heat and sprinkler water can reach the fire.
  • Store empty pallets outside and away from the building where possible – stacks of pallets burn fiercely.
  • Keep packaging waste under control, and bins and skips well away from the building. See Arson Prevention for Businesses.

Forklift Charging – Lead-Acid Batteries

Lead-acid batteries give off hydrogen when charging, and hydrogen ignites very easily. The Health and Safety Executive (HSE) advises:

  • charge in a well-ventilated area, with ventilation at high and low level,
  • no smoking, naked flames or hot work nearby,
  • keep the charging area clear of stock and anything that burns, and
  • provide eye protection and gloves – and eyewash, in case of acid splashes. See Eyewash Stations and Emergency Showers.

Lithium-Ion Batteries

Lithium-ion forklifts, power tools, e-bikes and battery stock bring their own risks. A damaged battery can overheat, give off toxic gases, explode and reignite. See Lithium-Ion Battery Fires: What You Need to Know. Insurer and industry guidance recommends:

  • A dedicated charging area – ideally a separate fire-resisting room, or a marked area with at least 2 m clear space around it.
  • No charging in bulk storage areas, and no unattended overnight charging unless the risk is properly controlled.
  • Automatic fire detection covering charging and storage areas.
  • A lithium-ion battery extinguisher at each charging point, such as a Lith-Ex. It's designed to cool a battery that's starting to overheat and slow the fire spreading from cell to cell. Staff should only tackle a small fire that's just starting – if it takes hold, get out and call 999.
  • Damaged and returned batteries – inspect returns when they arrive. Quarantine damaged or swollen batteries away from the building, or in a fire-resisting cabinet or container, and get them collected promptly by a specialist.
  • Fire limitation products, such as our Vlitex range of bags and containers, for holding a suspect battery while it's moved.

Industry guidance from RISCAuthority, the insurers' research body, covers battery charging and storage in more detail.

Extinguishers, Alarms and Sprinklers

  • Provide extinguishers to suit each area – usually water-based for general storage, with carbon dioxide (CO2) near electrical equipment. See How Many Fire Extinguishers Do I Need?.
  • A fire alarm system suited to the size of the building. See Fire Alarm Systems for Businesses.
  • There's no general law requiring sprinklers in existing warehouses, but insurers often expect them – especially for high racking and lithium-ion storage.

Official guidance: GOV.UK – factories and warehouses, gov.scot – non-residential premises, Northern Ireland Fire and Rescue Service and HSE – using electric storage batteries safely.

Worth remembering… your fire risk assessment is what decides what your premises need. This guide is general advice, not a substitute for it.

Not sure what you need? Get in touch with our team – we'll be delighted to help. No pressure. No sales patter.