Warehouse Fire Risk Assessment: A Complete Guide for Responsible Persons

A warehouse fire risk assessment is one of the most important steps in protecting people, stock, equipment, and business operations within industrial environments. Warehouses and factories often present higher fire risks than standard commercial buildings due to large storage areas, combustible materials, machinery, and more complex evacuation requirements.

Whether you manage a warehouse, factory, distribution centre, or industrial unit, understanding your legal responsibilities and maintaining an up to date factory fire risk assessment is essential for compliance and business continuity.

In this blog, we explain why fire risk assessments matter for factory and warehouse environments, what regulations apply, who is responsible, and what should be included within the assessment process.

Why are fire risk assessments for warehouses and factories important?

Warehouses and factories can present unique fire safety challenges compared to other commercial premises. Large open floor areas, high stacking storage systems, machinery, packaging materials, and operational processes can all increase both the likelihood and impact of a fire.

A proper warehouse fire risk assessment helps identify these risks before they become serious safety issues. It also ensures appropriate fire safety measures are in place to protect staff, visitors, contractors, and emergency responders.

Some of the most common risks found within industrial and storage environments include:

• High fire loads from stored stock and packaging
• Combustible materials such as cardboard, plastics, and pallets
• Electrical equipment and machinery
• Charging points for forklifts or battery powered equipment
• Hot works or manufacturing processes
• Large floorplates and complex evacuation routes

The consequences of a fire within a warehouse or factory can be severe. Alongside the immediate risk to life, fires can lead to operational downtime, stock loss, insurance complications, and long term business disruption. A detailed factory fire risk assessment helps reduce these risks while supporting legal compliance and safer working environments.

What fire safety regulations apply to factories and warehouses?

Several important pieces of legislation and guidance apply to industrial and warehouse fire safety. Understanding these requirements is essential for maintaining a compliant and effective warehouse fire risk assessment.

Some key fire safety regulations to be aware of include:

The Regulatory Reform (Fire Safety) Order 2005

The Regulatory Reform (Fire Safety) Order 2005 is the main fire safety legislation for non-domestic premises in England and Wales. It places legal responsibility on the ‘Responsible Person’ to identify fire risks and ensure suitable fire precautions are in place.

This includes maintaining fire alarms, emergency lighting, fire extinguishers, escape routes, evacuation procedures, and fire risk assessments.

BS 9999 guidance

BS 9999 provides guidance on fire safety in the design, management, and use of buildings. It supports a more risk based approach to fire safety and is commonly referenced within industrial and commercial environments.

For warehouses and factories, this may include guidance around occupancy levels, escape routes, fire compartmentation, and evacuation planning.

PAS 79 methodology

PAS 79 is a recognised methodology for carrying out and documenting fire risk assessments. It provides a structured approach to identifying hazards, evaluating risks, and recording findings clearly and consistently.

Many professional fire risk assessors, including ours here at Hoyles Fire & Safety, use PAS 79 as part of their assessment process.

Building Regulations and fire compartmentation

Building Regulations also play an important role in industrial fire safety, particularly around fire resisting construction and compartmentation. Fire compartments help slow the spread of smoke and flames, protecting escape routes, and limiting damage.

In warehouses and factories, this may involve fire doors, fire stopping, protected stairwells, and separation between operational areas.

Together, these regulations and standards help ensure warehouse environments are designed and managed with fire safety in mind.

Who is responsible for warehouse fire risk assessments?

Under the Regulatory Reform (Fire Safety) Order 2005, every commercial premises must have a designated ‘Responsible Person’. In warehouse and factory environments, this may include:

• Employers
• Business owners
• Warehouse managers
• Facilities managers
• Safety officers
• Landlord or managing agents

The Responsible Person has a legal duty to ensure a suitable and sufficient warehouse fire risk assessment is carried out and regularly reviewed. Other responsibilities often include:

• Identifying fire hazards
• Implementing fire safety measures
• Maintaining fire safety systems and equipment
• Ensuring safe evacuation procedures are in place
• Providing staff training and fire drills
• Keeping records of inspections and maintenance

In some buildings, responsibilities may be shared between landlords and tenants. For example, landlords may be responsible for common areas and building infrastructure, while tenants are responsible for their own operational areas and internal processes.

Facilities managers and health and safety teams also play a key role in helping maintain compliance, particularly within larger industrial sites or multi-occupancy premises.

What should be included in a warehouse fire risk assessment?

A warehouse fire risk assessment should provide a detailed review of the building, the activities taking place within it, and the measures in place to control fire risks.

Some of the key elements that should be included in a warehouse fire risk assessment include:

Reviewing the building layout and storage areas

The assessor should review the overall layout of the premises, including storage systems, racking arrangements, production zones, loading bays, offices, and staff welfare areas. 

They should consider how people move throughout the building and whether the layout supports safe evacuation during an emergency.

Identifying fire hazards

This will typically involve identifying anything that could cause or contribute to a fire, such as:

• Electrical systems and machinery
• Flammable liquids or gases
• Packaging materials and waste build up
• Forklift charging stations
• Manufacturing equipment or hot works

The assessment will also consider housekeeping standards and how quickly fire could spread within the environment.

Evaluating fire detection and alarm systems

Fire alarm systems are a critical part of industrial fire safety. The assessor should review whether detection coverage is appropriate for the size, height, and complexity of the building.

This may include alarm auditability, detector placement, maintenance records, and system testing procedures.

Assessing fire escape routes and evacuation procedures

Escape routes, exits, and evacuation arrangements must be suitable for the number of occupants and the ways the building operates. The assessor should review:

• Travel distances to exits
• Escape route protection
• Emergency lighting
• Exit signage
• Assembly points
• Procedures for visitors and contractors

Special consideration may also be needed for shift patterns, lone workers, or higher risk operational areas.

Inspecting fire safety equipment

The assessment should also review fire extinguishers, emergency lighting, fire doors, sprinkler systems, smoke ventilation, and any other fire protection measures installed within the building.

Equipment should be suitable for the risks present and maintained in line with current standards.

How often should warehouse fire risk assessments be reviewed?

A warehouse fire risk assessment should be reviewed regularly to ensure it remains accurate and reflects the way the premises is being used.

Best practice recommends that fire risk assessments should be reviewed at least once every 12 months. However, reviews should also take place whenever significant changes occur within the building or operational processes. Some common triggers for a review include:

• Structural alterations or building extensions
• Changes to storage layouts or racking systems
• Introduction of new machinery or manufacturing processes
• Increased occupancy levels
• Changes to escape routes
• Fire incidents or near misses

Keeping the assessment up to date helps ensure fire precautions remain effective and legally compliant.

Need help with your warehouse fire risk assessment?

A well planned warehouse fire risk assessment is essential for protecting people, property, and business operations within industrial environments. From storage risks and machinery hazards, to evacuation planning and legal compliance, warehouses and factories require a fire safety approach that reflects the complexity of the site.

At Hoyles Fire & Safety, we support businesses across warehousing, manufacturing, logistics, and industrial sectors with professional, compliant fire risk assessments tailored to each premises. Our experienced team can help identify risks, improve fire safety measures, and support your ongoing compliance responsibilities.

Don’t hesitate to get in touch with us today for your factory fire risk assessment or to arrange a professional assessment for your warehouse or industrial premises.