Introduction

Industrial fires represent some of the most severe hazards in the workplace. Such fires cause extensive property damage, cessation of business activities, and in numerous cases, significant loss of life. According to the US Fire Administration (USFA), thousands of non-residential buildings catch fire every year, including industrial facilities. These fires alone result in millions of dollars in damage and put countless lives at risk.

As reported by the National Fire Protection Association (NFPA), U.S. fire departments responded to approximately 36,784 industrial or manufacturing fires between 2017–2021. These incidents resulted in 16 civilian deaths, 273 injuries, and over $1.1 billion in direct property damage annually.

Beyond financial losses, industrial fires negatively impact company reputation and employee morale. Extended downtime and potential legal liabilities make fire prevention a top priority. Understanding root causes and adopting proactive strategies is essential.

Real-Life Examples Illustrating the Risks

• Glasgow Industrial Estate Fire (April 2025): A massive fire engulfed the New Albion Industrial Estate in Glasgow, prompting the deployment of eight fire engines.
• Kilwinning Battery Plant Fire (April 2025): The Fenix Battery Recycling Plant caught fire for the second time in months, raising concerns about flammable material handling and inadequate risk assessment. 
• KMCO Chemical Plant Explosion (Texas, 2019): An explosion and subsequent fire at KMCO’s Texas facility killed one person and injured several. The Chemical Safety Board (CSB) identified poor equipment maintenance and unauthorized hot work as key factors.

Identifying the Root Causes Makes a Change

An effective industrial fire safety program begins with understanding its main triggers. According to the USFA and OSHA, the most common causes of industrial fires include:

• Electrical hazards
• Hot work operations (e.g., welding, cutting)
• Flammable gases and liquids
• Combustible dust
• Poorly maintained machinery and equipment

These hazards are often the result of inadequate training, inspections, and a weak safety culture. For detailed guidance, refer to the USFA’s technical report: USFA Technical Report on Industrial Fire Prevention.

So What Happens Next?

In the following sections, we’ll analyze these fire risks further using real-world incidents. We will also highlight internationally recognized best practices to help industries establish a proactive fire safety management system. Such systems protect lives, preserve critical assets, and enhance corporate reputation.

Electrical Hazards in Industrial Settings – Causes, Cases & Controls

Operating industrial equipment, tools, and devices requires adequate electrical systems infrastructure which provides electricity, lighting, and other essential services. Nevertheless, these systems can pose enormous fire risks if they are not efficiently maintained or managed. The U.S Fire Administration (USFA) suggests that electrical failures are within the top three causes of industrial fires, especially within utility and manufacturing frameworks.

Primary Reasons for Electrical Fires

Circumstances for electrical fire risk within industrial settings include:

• Over Circuiting: When the current drawn is more than what the circuit is capable of carrying, it can lead to overheating, arcing, or burning of the conductors.
• Worn or Damaged Wiring: Degradation in insulation, fraying, or open conductors increases the risk of fire.
• Inferior Workmanship: Substandard wiring or code violations create long-term hazards.
• Aged, Unmaintained Machinery: Old transformers, control panels, and machinery without proper upkeep are high fire risks.
• Improper Grounding: Lack of proper bonding or grounding can cause electrical arcs or spark jumps.

The U.S. Department of Occupational Safety and Health (OSHA) enforces clear safety regulations under 29 CFR 1910 Subpart S for shock protection and electrical safety in general industry.

Real-World Incidents Caused by Electrical Failures

1. Arkema Chemical Plant (Texas, 2017): Backup power failed after Hurricane Harvey flooded the facility, causing multiple explosions due to heat-sensitive chemicals. Read more
2. Murray State University (2020): An old circuit breaker failed to trip, leading to overheating and fire. The incident highlighted outdated panels and lack of thermal inspections. Read more
3. Chinese Factory Fire (2019): Overloaded extension cords and DIY electrical outlets led to a deadly fire in an electronics factory in Zhejiang Province. Read more

Fire Prevention Strategies for Electrical Hazards

• Schedule Periodic Electrical Inspections: Follow NFPA 70B and local codes using certified professionals.
• Implement AFCIs: Arc-Fault Circuit Interrupters detect and prevent dangerous arcing before fires start.
• Use Thermal Imaging: Infrared cameras help detect hotspots in wiring and prevent escalation.
• Label and Isolate Panels: Ensure panels are clearly marked and away from flammable materials.
• Employee Training: Educate staff on recognizing faults, reporting hazards, and using lockout/tagout (LOTO) procedures.

The NFPA 70E Standard outlines essential safety practices, PPE guidelines, and energy control requirements for working around electrical hazards.

Hot Work Operations – Ignition Risks and Controls

Hot work refers to operations that produce heat, sparks, or flames, such as welding, cutting, grinding, soldering, and brazing. While essential in many construction and manufacturing processes, these activities present a significant ignition risk in industrial environments. According to the U.S. Chemical Safety Board (CSB) and NFPA, hot work is among the leading causes of fatal industrial fires and explosions.

Why Hot Work Is So Dangerous

Hot work is especially dangerous in environments with combustible vapors, dust, or flammable materials. Common ignition risks include:

• Igniting nearby combustibles
• Hidden sparks starting fires in concealed areas
• Flammable vapors igniting rapidly
• Explosive dust ignition in confined spaces

Reference: NFPA 51B: Standard for Fire Prevention During Welding and Cutting

Real-Life Hot Work Incidents

• DuPont Chemical Plant Fire (2010): Welding sparks ignited vapors in a tank. Read More
• Norco Refinery Explosion (1988): Seven workers died due to vapor ignition during unauthorized hot work. Details here
• Valero McKee Refinery Fire (2007): Welding near a leaking pipe caused a fire. Full Report

Fire Safety Duties During Hot Work

• Assign Trained Fire Watch: Qualified personnel must supervise hot work areas.
• Hot Work Permit System: Supervisors should approve and monitor all hot work via written permits.

Job Site Preparations

• Remove or shield combustibles within 35 feet of the work area
• Conduct gas testing for flammable vapors
• Use fire-resistant PPE including clothing, gloves, and shields
• Place functioning fire extinguishers and hoses nearby

Flammable Liquids and Gases – Storage, Handling & Safety Controls

Flammable liquids and gases are key components in the operations of machinery, cleaning equipment, and aiding in chemical processes. Nevertheless, their volatility makes them one of the most hazardous substances in an industrial area. Mishandling or poor storage and transportation can set off catastrophic fires and explosions.

According to OSHA, most fire-related injuries and deaths stem from flammable liquids and gases within the industry. In fact, in 2020, out of all industrial fire deaths, 15% were due to improper handling. Source

Understanding the Danger: Why Flammable Liquids and Gases Ignite Readily

• Gasoline: Flash point of –45 °F (-43 °C)
• Acetone: Flash point of -4 °F (-20 °C)
• Propane: Rapidly evaporates and creates volatile air mixtures

These substances can form vapor clouds that travel and ignite from external fire or heat sources. The U.S. Chemical Safety Board has reported explosions due to undetected gas leaks in poorly ventilated spaces.

Real-World Case Studies

Top Fire Prevention Practices

Storage Compliance

• Use UL-listed safety cans and flammable storage cabinets
• Install proper ventilation valves
• Keep away from ignition sources like electrical panels

Labels and Signs

• Comply with GHS labeling
• Include hazard class, flash point, and compatibility

Transfer and Handling

• Use grounding and bonding cables
• Non-sparking tools and explosion-proof equipment
• Operate in spark-free zones

Emergency Response and Training

• Train workers under Hazard Communication Standards (29 CFR 1910.1200)
• Conduct fire drills and spill response training
• Use containment pallets and absorbents

Reference Guidance and Regulations

• OSHA Flammable Liquids Standard
• NFPA 30: Flammable Liquids Code
• CSB Investigation Reports

Chemical Fires – Flammable Liquids and Gases in Industrial Settings

The rapid usage escalation of chemical substances and processes within industries results in one of the most dangerous fires globally: chemical fires. Flammable liquids and gases, such as petrol and propane, are primary sources of ignition, making these fires even more devastating. Chemical fires are widely discussed, requiring immediate attention due to the variety of chemicals involved in day-to-day operations, greatly increasing the danger of industrial fires.

According to NFPA reports, chemical fires constitute about 20% of global industrial fires every year. For further details, you can view the NFPA reports here: NFPA Fire Statistics.

Common Chemical Fire Hazards

1. Liquids – Many industrial facilities deal with paints, petrol, oils, and even gasoline. All of these pose a greater danger due to their flammability. Any small spark can set them on fire or result in an explosion.
2. Gases – A group of gases including acetylene, propane, hydrogen, and even methane put industrial facilities at greater risk. Static discharge can put the gas into an ignited state along with open flames.
3. Chemical Reactions – Applying adequate amounts of chemical substances during chemical reactions could result in igniting the fire, especially if the reaction is exothermic in nature.
4. Improper Storage – Incorrectly storing flammable liquids or gases increases the risk of fire. Chemicals that are not properly contained and ventilated can evaporate or leak, creating a dangerous atmosphere.

Surgical Strikes on Chemical Fires in Industrial Settings

Texas City Refinery Explosion (USA, 2005)

The United States experienced one of the most devastating industrial explosions when a chemical plant vented hydrogen and other flammable gases. Ignition occurred as the plant poured fuel into its uncontained safety systems. An explosion decimated the facility, resulting in the death of 15 workers and injuring over 170 people.

Source: Texas City Refinery Explosion

Bhopal Gas Tragedy (India, 1984)

Methyl isocyanate gas was carelessly released in excess from the storage tank of a chemical plant, giving rise to a savage inferno, along with the already dire consequences of thousands of casualties. The incident stemmed from one of the most horrific industrial incidences due to insufficient safety protocols and lack of adequate training for the workforce.

Source: Bhopal Gas Tragedy

Chevron Richmond Refinery Fire (USA, 2012)

A fire began at the Chevron Richmond Refinery in California when flammable liquids gushed from a pipeline. Toxic smoke was emitted, and the refinery was considerably damaged. The company was blamed for this incident as they did not maintain essential equipment, which led to the leak in the first place.

Source: Chevron Richmond Refinery Fire

Fire Prevention Measures for Chemical Fires

Proper Storage of Chemicals

• Ensure good airflow so vapors do not collect, and store easily flammable chemicals in the defined areas.
• Chemicals need to be stored in accordance with their specific instructions, accompanied by dosing out harmful gases.
• Check the chemical containers regularly for tight sealing and leaks. It is recommended to close them in advance.

Implementing Hazardous Materials Safety Plans

• Develop plans for responding to emergencies arising from the possibility of fire or release of dangerous chemicals.
• Train employees on proper chemical management. Teach them to control MSDS (Material Safety Data Sheet).

Use of Flame Arresters and Venting Systems

• Equip inflow pipes of flammable gases with feelers that ward away ignition from outside inflows.
• Provide vessels that release flammable gases actively, able to redirect emissions away from self-ignition locations.

Preventative Maintenance

• Carry out periodic maintenance on apparatus that manages flammable liquids and gases for leak detection and mechanical failure.
• Put chemical flow interruption systems, leak detection systems, and automated shut-off valves in place that can stop the chemicals from flowing when there is a malfunction.

Control of Static Electricity

• Flammable chemicals can explode due to static electrical discharge. To prevent this, static control measures should be employed by grounding tanks, vessels, and piping systems.

Other Required Guidelines and Regulations

• NFPA 30 - Flammable and Combustible Liquids Code: This code outlines precautionary procedures for the storing, handling, and using flammable liquids.
• OSHA's Process Safety Management (PSM) Standard: The purpose of OSHA's PSM regulations is to avert chemical disasters. It requires firms to control, assess, and manage defined risks from highly hazardous chemicals.
• API Recommended Practice 500 - Classification of Locations for Electrical Installations at Petroleum Facilities: This standard helps define boundaries for areas where combustible vapors and liquids would pose risks to personnel and equipment.

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• Safety in operation of flame arrestors in chemical works

Inadequate Fire Prevention and Protection Systems – Prevention and Protection Measures

The lack of fire prevention and protection systems in industrial settings remains one of the biggest threats to the safety of workers, infrastructure, and the ecosystem. Despite developments in safety technology and equipment, fire safety infrastructure at many industrial sites remains critically lacking. Inability to effectively control fires or properly service fire protection equipment can result in fires of unimaginable magnitude, which can be disastrous for people’s health and business operations.

The Effects of Inadequately Managing Fire Protection Systems

The absence of fire safety measures or failure to maintain available equipment is, unfortunately, quite common at many industrial sites. The consequences of this negligence can include:

• Sprinklers that either do not function or go unattended during a fire.
• Absence of fire extinguishers or incorrect placement of available extinguishers that hinder workers from controlling the fire during its early stages.
• Fire alarms that are maintained inoperative, rendering staff defenseless to the lethal risks lurking in their immediate environment.
• Insufficient fire escapes or unobstructed places of exit that permit injury and even death during an escape.

NFPA research has demonstrated that frail fire prevention and protection systems are a huge factor in over half of industrial fire accidents. From unscheduled business halts to expensive damages, these incidents can even lead to legal complications and business penalties.

Source: NFPA

Common Problems in Fire Protection Systems

1. Subpar Sprinkler Systems: Fire controlling sprinklers are a must in stem stage fires, but unfortunately, almost every industrial setting is plagued with poorly managed sprinkler systems. A study showed that around 30% of industrial fires lack required basic maintenance and use outdated systems. This means sprinklers bursting into flames are failing around the world.
2. Fire Alarm System Failure: Exiting flames in the workplace are not uncommon. It is critical to notify all personnel to evacuate a fire to stay alive; otherwise, they may never leave. Day-to-day enforcement of testing the units is required to avoid false warnings and to keep the devices working. According to The National Fire Alarm and Signaling Code, more than 15% of fire incidents in industrial plants have been directly tied to malfunctioning devices.
3. Obstructed Fire Escape Routes: In case of a fire, emergency exits should always be accessible and clear of any obstructions. Unfortunately, many workplaces do not maintain proper signage and guidance on exit areas. As highlighted by the U.S Fire Administration, close to 40% of workplace fire-related fatalities can be traced back to inaccessible escape routes.
4. Missing or Misplaced Fire Safety Equipment: Fire extinguishers serve a vital role in preventing small fires from escalating into uncontrollable blazes. However, too much time can be lost trying to locate extinguishers, especially if they are misplaced or if staff are not trained in their location. OSHA has strict guidelines on the placement of fire extinguishers, stating that they should be within 75 feet of any working area. But this is often overlooked in remote and hazardous locations.

Source: OSHA Fire Extinguisher Guidelines

Case Studies on Subpar Fire Prevention Systems

Grenfell Tower Fire Incident (UK, 2017)

The Grenfell Tower fire stands out as one of the most tragic examples of insufficient fire safety measures. The fire spread rapidly because of the combustible cladding, and the building's sprinkler system was only partially functional. The presence of fire alarms was inadequate, and poor fire safety measures resulted in the destruction of 72 lives and significant property loss.

Source: UK Government Report on Grenfell Tower Fire

Kissimmee Fire Incident (Florida, 2018)

Kissimmee, Florida, was the site of a chemical fire in a storage unit that gained notoriety for subpar fire safety measures. The facility possessed a fire suppression system, but the sprinklers failed to turn on, allowing an uncontrolled fire to spread. The absence of maintenance and no routine checking of the devices were leading factors.

The Triangle Shirtwaist Factory Fire (New York, 1911)

The Triangle Shirtwaist Factory Fire is an infamous event in history that showcases the results of poor fire exits and insufficient safety measures. There were inadequate fire exits, and workers were prevented from escaping early due to locked doors. Around 146 people died, marking a turning point in modern fire safety regulations in the United States of America.

Source: NFPA Report on Triangle Shirtwaist Fire

Measures to Ensure Effective Fire Prevention Systems

Regular Maintenance and Inspection of Fire Protection Equipment

• Perform periodic checks on the sprinkler systems, alarms, and fire extinguishers to ensure all equipment functions reliably.
• Develop a comprehensive fire protection plan detailing regular readiness checks to verify equipment operability prior to emergencies.

Establish Fire Safety Training Programs

• Educate staff on the protocols for operating fire protection devices and outline evacuation strategies.
• Include routine fire drills to train staff on navigating emergency exits and protocols.

Maintaining Clear and Precisely Defined Emergency Routes

• Ensure exit routes are clear, well-defined, and accessible at all times.
• Regularly verify the visibility and operational status of fire exit signs and lighting.

Install and Test Fire Suppressing Systems

• Regular testing and installation of fire suppression systems in high-risk zones.
• Upgrade older fire protective systems to meet current standards.

Important Fire Safety Regulations and Policies

• NFPA 13 – Standard for the Installation of Sprinkler Systems
• NFPA 72 – National Fire Alarm and Signaling Code
• OSHA Fire Safety Standards

If fires in industrial environments are not managed adequately, they may result in catastrophic damages and losses. Every business can mitigate risks through proper understanding of fire causation and application of appropriate fire preventive measures. Fire prevention starts from cultivating a safety preparedness culture within the organization, rather than mere possession of physical equipment.

Visit us at Phoenix Safety and Consulting for other tips on safety procedures and expert fire protection services.

Stay safe and protected!