Industrial fires are among the most devastating incidents a business can face. They can cause catastrophic loss of life, destroy assets built over decades, and bring entire operations to a permanent halt. Yet the vast majority of industrial fires are preventable — with the right knowledge, culture, and systems in place.
This guide covers everything you need to know about industrial fires: why they start, the industries most at risk, and the essential precautions that save lives and protect businesses.
An industrial fire is any fire that originates within a commercial, manufacturing, warehousing, or processing environment. Unlike domestic fires, industrial fires often involve large quantities of flammable materials, complex machinery, and hazardous substances — all of which can cause fires to spread rapidly and burn with extreme intensity.
The consequences extend beyond the immediate premises. Industrial fires can trigger explosions, release toxic gases into the surrounding community, and contaminate local land and water. The financial impact — including lost stock, equipment, and downtime — can run into tens of millions of pounds.
Understanding how industrial fires start is the first step in preventing them. The most frequent causes include:
Electrical Faults Faulty wiring, overloaded circuits, damaged equipment, and poorly maintained electrical systems are leading causes of industrial fires. Arc flashes and short circuits can ignite surrounding materials in seconds.
Hot Work Welding, cutting, grinding, and soldering all generate intense heat and sparks. When carried out near flammable materials — or without adequate precautions — hot work is a significant fire risk.
Flammable Liquids and Gases Many industrial processes involve solvents, fuels, oils, and gases that are highly flammable. Improper storage, leaks, and inadequate ventilation can create volatile conditions where a single ignition source causes disaster.
Dust and Particle Accumulation Fine particles from wood, grain, sugar, coal, and metals can form explosive clouds when suspended in the air. Dust explosions and fires have caused some of the most catastrophic industrial disasters in history.
Machinery and Equipment Failure Overheating motors, friction from worn components, and mechanical failures can all generate enough heat to start a fire — particularly when machinery is not properly maintained or serviced.
Arson Unfortunately, deliberate fire-setting is a significant cause of industrial fires, particularly in storage and warehousing facilities. Security measures play an important role in fire prevention.
Human Error Careless disposal of smoking materials, improper use of equipment, failure to follow safe working procedures, and inadequate training all contribute to preventable fires.
While any industrial environment can experience a fire, certain sectors face elevated risk due to the nature of their operations:
In the United Kingdom, industrial fire safety is governed primarily by the Regulatory Reform (Fire Safety) Order 2005 (FSO). Under this legislation, the "responsible person" — typically the employer or building owner — must:
Failure to comply can result in enforcement notices, prohibition orders, unlimited fines, and even imprisonment.
The Health and Safety at Work Act 1974 and associated regulations also impose duties on employers to manage fire risk as part of their overall health and safety obligations.
Effective industrial fire prevention is built on several interconnected pillars:
A thorough, site-specific fire risk assessment is the foundation of all fire safety. It identifies hazards, evaluates risks, and determines what control measures are needed. For complex industrial sites, this should be conducted — and reviewed — by a competent fire safety professional.
Poor housekeeping is a major contributing factor in industrial fires. Waste materials, accumulated dust, and unnecessarily stored flammable substances all increase risk. Regular cleaning regimes, proper waste disposal, and strict control of combustible materials are essential.
Any hot work on site should be controlled through a formal permit-to-work system. This ensures the area is properly prepared, risks are assessed, fire watch is maintained during and after work, and appropriate extinguishing equipment is on hand.
All electrical installations should be designed, installed, and maintained by qualified electricians. Regular Electrical Installation Condition Reports (EICRs) are essential. Portable appliances should be subject to regular PAT testing, and overloading of circuits must be avoided.
Flammable liquids and gases must be stored in designated, purpose-built areas — away from ignition sources, properly ventilated, and clearly marked with appropriate hazard signage. Quantities kept in the workplace should be kept to a minimum.
Industrial premises require robust fire detection systems tailored to the specific hazards present. Depending on the risk profile, this may include:
All systems must be regularly inspected, tested, and maintained by competent engineers.
Clear, unobstructed escape routes and emergency exits are non-negotiable. Fire doors must be kept closed (never wedged open), exit routes must be well-lit with emergency lighting, and evacuation procedures must be clearly communicated and regularly practised.
Every member of staff should understand the site's fire safety procedures: how to raise the alarm, how to evacuate, and — where appropriate — how to use fire extinguishers safely. Regular fire drills are a legal requirement and a vital part of preparedness.
Despite the best precautions, fires can still occur. Having a clear Emergency Fire Action Plan ensures that, when they do, people respond quickly and correctly.
The key steps are:
Only attempt to tackle a fire with an extinguisher if you have been trained to do so, the fire is small and contained, the exit is behind you, and you are not putting yourself at risk.
Trained fire wardens (also known as fire marshals) play a vital role in industrial fire safety. Their responsibilities include:
The number of fire wardens required depends on the size of the premises and the number of occupants. Your fire risk assessment should specify requirements.
Industrial fires cause devastating human and economic harm — but the overwhelming majority can be prevented. A robust, site-specific approach to fire safety, grounded in a thorough risk assessment and supported by trained staff, effective systems, and a strong safety culture, is the best protection any business can have.
If you need expert guidance on fire risk assessments, fire safety systems, or staff training for your industrial premises, get in touch with our team today.
Here is the link to our enquiry form Contact Us - Whale Fire or email us at info@whalefire.co.uk
Fire Safety During the COVID-19 Lockdowns: Lessons Learned from a Unique Crisis
How the pandemic both reduced and created new fire safety risks across the UK
Introduction
When the UK Government announced its first national lockdown in March 2020, the immediate focus was understandably on public health. But for fire safety professionals, building managers, and responsible persons, the sudden and dramatic change in how buildings were used — or ceased to be used — created a complex and largely unprecedented set of fire safety challenges. Some risks fell sharply. Others rose significantly. And the period as a whole exposed weaknesses in fire safety management that had previously gone unnoticed.
This article examines both sides of the picture — the ways in which lockdown genuinely reduced certain fire risks, and the new and aggravated risks that the pandemic created.
The Positives: Where Fire Risk Reduced
Fewer people, fewer ignition sources
The most obvious benefit was straightforward: empty buildings have fewer ignition sources. With offices, retail premises, restaurants, schools, and entertainment venues standing largely vacant, the day-to-day fire risks associated with human activity — cooking, electrical equipment in use, smoking, hot works, and accidental ignition — fell significantly. Fire and Rescue Service statistics for 2020-21 showed a notable reduction in accidental fires in non-domestic premises during the periods of strictest lockdown.
Reduced arson in some settings
Whilst arson remained a persistent concern, the dramatic reduction in footfall in town and city centres meant that some opportunistic arson attacks — particularly those targeting commercial bins, outbuildings, and vacant retail units — reduced during the most restricted periods when very few people were on the streets.
Heightened awareness of home fire safety
With the entire population spending far more time at home, there was a genuine increase in public awareness of domestic fire safety. The National Fire Chiefs Council (NFCC) and individual fire and rescue services ran targeted public safety campaigns encouraging people to test their smoke alarms, avoid leaving cooking unattended, and charge devices safely. Many households engaged with fire safety information for the first time.
Opportunity for building inspections
With commercial premises empty, some forward-thinking building managers and fire safety professionals used the lockdown period as an opportunity to carry out thorough fire risk assessment reviews, compartmentation surveys, fire door inspections, and remedial works that would have been far more disruptive during normal occupation. For some buildings, lockdown provided the rare opportunity of genuinely unoccupied access.
The Negatives: Where Fire Risk Increased
Vacant buildings — a significant and underappreciated risk
Paradoxically, empty buildings carry their own substantial fire safety risks — and these were widely underestimated during the pandemic. Unoccupied premises are more vulnerable to arson, as reduced footfall and security means that unauthorised access goes undetected for longer. Fires in vacant buildings are also far more likely to become serious before they are discovered, precisely because there is no one present to raise the alarm or call 999 in the early stages.
Many responsible persons made the mistake of assuming that an empty building required less fire safety attention. In fact, the opposite is often true. Fire and rescue services reported a number of serious fires in temporarily vacant commercial premises during the lockdown periods.
Fire safety systems neglected
One of the most concerning trends identified by fire safety professionals during and after the lockdowns was the neglect of fire safety system maintenance. With buildings closed and budgets under severe pressure, many organisations suspended or deferred the routine servicing of fire alarm systems, emergency lighting, fire extinguishers, sprinkler systems, and dry risers. Some buildings reopened after months of closure with fire safety systems that had not been tested, serviced, or inspected since before the pandemic began.
This was not merely poor practice — in most cases it represented a breach of the Regulatory Reform (Fire Safety) Order 2005, which does not contain a pandemic exemption. The duty to maintain fire safety systems does not pause because a building is temporarily empty.
Working from home — new domestic fire risks
The mass migration to home working created a set of domestic fire risks that had rarely been considered at scale before. Millions of homes were suddenly being used as offices, with electrical equipment running for far longer periods than domestic wiring was designed to accommodate. Extension leads and multi-way adaptors were heavily used, often in living rooms and bedrooms rather than purpose-built office environments. Laptop chargers, monitors, printers, and supplementary heating devices all added to the electrical load on domestic circuits. House fires attributed to electrical faults rose during the pandemic period.
Increased cooking fires
With restaurants, cafes, and takeaways closed during the strictest lockdown periods, the nation cooked at home to an unprecedented degree. The results were predictable — cooking-related fires in domestic properties increased significantly. Fire and rescue services reported rises in chip pan fires, unattended cooking incidents, and oven fires, particularly during the earlier lockdown when people were experimenting with home cooking for the first time.
Pressure on fire doors and escape routes in residential buildings
The shift to home working placed enormous pressure on residential buildings, particularly blocks of flats and Houses in Multiple Occupation. With residents present around the clock rather than absent during working hours, fire doors were opened and closed far more frequently, accelerating wear on self-closing devices and seals. Deliveries — already rising sharply due to the closure of physical retail — led to packages being left in communal areas and corridors, obstructing escape routes in direct contravention of fire safety requirements. In many buildings, the volume of cardboard packaging accumulating in bin stores and communal areas created a significant and largely unmanaged fire load.
Reduced fire safety training and drills
With workplaces closed or operating at severely reduced capacity, annual fire safety training and fire drills were widely deferred or cancelled entirely. When buildings eventually reopened — often with significant numbers of new staff who had never set foot in the premises before — many organisations found themselves operating with workforces who had received no recent fire safety instruction and had never participated in a fire drill for that building. This gap in training took considerable time and resource to address after reopening.
Mental health and fire risk
Fire safety professionals and researchers noted with concern the potential link between the mental health crisis that accompanied the pandemic and deliberate fire-setting. The stresses of lockdown — isolation, financial hardship, domestic conflict, and anxiety — are recognised risk factors for both accidental fires (distraction, impaired judgement) and deliberate ignition. Whilst direct causal data is difficult to establish, the correlation between periods of heightened social stress and fire incidents is well documented.
What the Pandemic Taught Us
The COVID-19 lockdowns were, in fire safety terms, a stress test that exposed several important weaknesses in how fire safety is managed in the UK.
First, they demonstrated that fire safety obligations do not have an off switch. The Regulatory Reform (Fire Safety) Order 2005 applies regardless of whether a building is occupied, partially occupied, or temporarily vacant. Responsible persons who treated lockdown as a reason to suspend fire safety management found themselves with significant compliance gaps to address on reopening.
Second, the pandemic highlighted the importance of dynamic fire risk assessments. The five-step fire risk assessment process is specifically designed to respond to changes in the use, occupancy, and activities of a building. The sudden and dramatic changes brought about by lockdown — vacant premises, changed working patterns, new delivery volumes, altered occupancy — all represented material changes that should have triggered a formal review of the fire risk assessment. Many organisations failed to make that connection.
Third, the rise of home working has permanently changed the fire safety landscape. Even as offices have reopened, hybrid working patterns mean that millions of people continue to use their homes as workplaces for significant portions of the working week. Employers have a duty of care that extends to the home working environment, and domestic electrical safety, device charging, and escape arrangements all deserve attention that most homeworking policies have never addressed.
Finally, the pandemic underscored the value of professional fire safety expertise. Buildings that were managed by organisations with qualified fire safety professionals — or that had commissioned professional fire risk assessments and maintained them properly — fared significantly better in terms of compliance and safety during the pandemic than those that had treated fire safety as an administrative afterthought.
Conclusion
The COVID-19 lockdowns were an extraordinary period that tested every aspect of building management, fire safety included. Whilst the reduction in building occupancy brought some genuine reduction in day-to-day fire risk, the wider picture was one of new and aggravated hazards — vacant buildings, neglected systems, overloaded domestic electrics, blocked escape routes, deferred training, and the quiet erosion of fire safety culture during a period of crisis.
The responsible persons and organisations that emerged from the pandemic in the strongest position were those who understood that fire safety is not an activity to be suspended in difficult times — it is a continuous, legally mandated duty of care to the people who use their buildings.
For a professional fire risk assessment of your premises, contact Whale Fire Ltd at info@whalefire.co.uk or call 0800 772 0738.
Published May 2026
UK fire services are now responding to a lithium-ion battery fire once every five hours — nearly five incidents every single day. According to new research from insurer QBE, fire brigades attended 1,760 battery-related fires in 2025 alone, a staggering 147% increase compared to 2022. Five people have lost their lives to lithium-ion battery fires in the UK over the past three years.
These aren't fires confined to factories or warehouses. Almost half (46%) of all lithium-ion battery fires in 2025 started inside people's homes — in the same rooms where families sleep, eat, and live. If you own a smartphone, laptop, e-bike, e-scooter, electric toothbrush, vape, or toy, you have a lithium-ion battery in your home. This is a risk that affects almost everyone.
Lithium-ion batteries can fail through a process called thermal runaway — a self-sustaining chemical reaction triggered by impact damage, overcharging, overheating, or manufacturing defects. Once it begins, it is extremely difficult to stop.
What makes these fires uniquely hazardous:
Professor Guillermo Rein of Imperial College London has warned that lithium-ion battery fires “breach most of the layers of protection that we know,” describing the technology as an unintended new hazard that keeps him awake at night.
E-bikes were linked to 520 fires in 2025 — more than triple the 149 recorded in 2022, and close to a third of all lithium-ion battery incidents nationally. Retrofitted e-bikes with aftermarket battery kits were involved in significantly more incidents than factory-built models with original battery packs. Cheap, uncertified replacement batteries are a major risk factor.
London firefighters now respond to an e-bike or e-scooter fire every other day — a frequency that officials describe as unthinkable just a few years ago.
EV-related fires increased by 133% between 2022 and 2025, though it is worth noting that EV ownership tripled over the same period, meaning EVs are not disproportionately more dangerous per vehicle than before.
Smartphones, laptops, vapes, toys, and power banks are all potential sources of fire if the battery is damaged, counterfeit, or improperly charged.
Industry bodies estimate the financial cost of lithium-ion battery fires in the UK now exceeds £1 billion annually, not including the human cost of five deaths and many more injuries over the past three years.
Fire chiefs and safety experts are calling for stronger regulation — including restrictions on counterfeit and substandard batteries — but in the meantime, the most powerful protection available is public awareness.
Lithium-ion batteries are a remarkable technology that power our modern lives. Used carefully and responsibly, they are safe. The dramatic rise in fires is driven not by the technology itself, but by damaged batteries, poor-quality chargers, unsafe charging habits, and uncertified products entering the market.
A few simple changes to how you charge, store, and dispose of batteries could genuinely save your life.
Email Whale Fire today @ info@whalefire.co.uk or call us on 0800 772 0738
As a large fire has broken out across residential flats in West London, it is worth reiterating the importance of fire risk assessment for these types of buildings.
Communal areas — corridors, stairwells, lobbies, entrance halls, meter cupboards and shared storage spaces — are critical parts of a residential building’s fire-safety strategy. These are the routes residents rely on to escape and the areas firefighters depend on to access the building. A thorough fire risk assessment ensures these spaces remain safe, compliant, and fit for purpose.
Under the Regulatory Reform (Fire Safety) Order 2005, responsible persons must assess and manage fire risks in the common parts of residential buildings. Updated guidance from the Home Office confirms that this includes the building’s structure, external walls, and flat entrance doors.
The Fire Safety (England) Regulations 2022 introduced further duties, especially for buildings over 11m and high-rise blocks, including checks on fire doors, firefighting equipment, signage, and information sharing with fire and rescue services.
Failing to carry out a suitable and sufficient fire risk assessment can lead to enforcement action, prosecution, and significant financial penalties.
Communal areas must remain clear, protected, and smoke-free for as long as possible during a fire. Government guidance for small blocks of flats emphasises that responsible persons must ensure these areas are assessed and maintained to support safe evacuation.
A proper assessment identifies:
Obstructions in escape routes
Combustible items stored in corridors
Faulty or missing fire doors
Damaged compartmentation
Even small fires in communal areas can spread rapidly, endangering residents and blocking escape routes. London Fire Brigade data shows 281 fires in communal areas in 2022 alone, highlighting the ongoing risk.
Fire risk assessments help prevent the most common causes of fires in shared spaces, including:
Charging or storing e-bikes and scooters
Accumulation of rubbish or furniture
Faulty lighting or electrical installations
Arson risks in unsecured areas
The London Fire Brigade warns that even small fires in communal areas can cause major damage, mass displacement, and high financial costs for landlords and insurers.
Communal areas are used by everyone, including children, elderly residents, and people with mobility issues. Updated government guidance for purpose-built flats stresses the need for responsible persons to identify risks specific to their building and occupants.
A good fire risk assessment ensures:
Escape routes are accessible
Fire doors close and latch properly
Signage is clear and visible
Lighting supports safe evacuation
High-rise and multi-occupied buildings now require:
Floor plans
External wall information
Wayfinding signage
Checks on firefighting lifts and equipment
These measures, introduced through the Fire Safety (England) Regulations 2022, help firefighters navigate the building quickly and safely.
A fire risk assessment ensures these requirements are met and maintained.
The economic impact of a communal-area fire can be severe. The average cost of a domestic fire in London was estimated at over £48,000 — and this figure is likely conservative when factoring in inflation, displacement, and repairs.
A proactive assessment reduces the likelihood of:
Major structural damage
Insurance claims and premium increases
Rehousing costs
Legal action from residents
For landlords, managing agents, and housing providers, a well-documented fire risk assessment shows:
Compliance with UK fire-safety law
Commitment to resident safety
Proper management of communal areas
A proactive approach to risk reduction
This is essential for reputation, accountability, and long-term building safety.
A fire risk assessment in the communal areas of flats is not just a legal obligation — it is a vital safeguard that protects lives, property, and the integrity of the building. With updated legislation and increasing risks such as e-bike fires, regular assessments are more important than ever.
Please email Whale Fire @ info@whalefire.co.uk or use our enquiry form here Contact Us - Whale Fire