Fire Protection Design for Production Halls and Manufacturing Plants

Fire Protection Challenges in Production Halls

Production halls and manufacturing plants are among the most demanding buildings when it comes to fire protection design. Large floor areas, diverse manufacturing processes, storage of flammable materials, and heat-generating machinery all create a complex fire risk profile.

At Oskar Sprinkler, we have extensive experience installing sprinkler systems in production halls across Belgium, the Netherlands, Norway, and Germany. Each project requires an individual approach, but common principles apply, which we discuss in this article.

Hazard Classification for Industrial Facilities

The first and most critical step is proper fire hazard classification according to EN 12845. Production halls typically fall into:

• OH2 (Ordinary Hazard 2) — metalworking, assembly plants, mechanical workshops
• OH3 (Ordinary Hazard 3) — woodworking, plastics manufacturing, printing plants
• OH4 (Ordinary Hazard 4) — chemical plants, paint and varnish production
• HHP (High Hazard Process) — processes involving flammable liquids, spray applications

Classification determines all design parameters — spray density, design area, water supply requirements, and sprinkler type.

Fire Load Analysis

Design must account for:

• Types of stored and processed materials
• Storage height and palletization method
• Production line layout and evacuation routes
• Ventilation systems and process extraction
• Ignition sources — welding, cutting, heating, chemical processes

Sprinkler System Selection

Wet vs. Dry Systems

The choice between wet and dry systems depends on environmental conditions:

• Wet system — standard for heated production halls, fastest response time
• Dry system — for unheated areas or zones exposed to freezing
• Pre-action system — for areas with sensitive equipment where accidental water discharge is unacceptable

Sprinkler Types for Production Halls

Selecting the right sprinkler type is critical:

• Standard sprinklers — for typical applications in halls up to 10 m height
• ESFR sprinklers — for high-bay storage, eliminating the need for in-rack sprinklers
• Sidewall sprinklers — for corridors, loading docks, and spaces between machines
• Corrosion-resistant sprinklers — for chemically aggressive environments

Specific Installation Challenges

High-Bay Industrial Halls

Halls with heights of 12-30 meters require special solutions:

• Use of high-output ESFR or CMSA sprinklers
• Adequate water supply — high pressure and flow rates
• Consideration of fire development dynamics at great heights
• Often requiring in-rack sprinklers in storage areas

Coordination with Other Services

In production halls, coordination of the sprinkler system with other installations is especially critical:

• Ventilation systems — overhead cranes and ductwork can obstruct sprinklers
• Electrical installations — cable trays and busbar systems
• Steel structure — mounting pipework to beams and trusses
• Cranes and suspended equipment — travel zones require special solutions

Special Zones in Production Halls

Many production halls require separate approaches for different zones:

• Production zone — main area with machinery and production lines
• Raw material storage — often higher hazard classification than the production zone
• Finished goods warehouse — parameters depending on product type and storage method
• Technical rooms — switchrooms, boiler rooms, compressor rooms
• Staff areas — changing rooms, canteens — lower requirements (LH or OH1)

Water Supply Requirements

Production halls, with their large areas and high spray densities, require powerful water supplies:

• Storage tank — typical capacities from 200 to 1,000 m3
• Fire pump set — main pump (electric or diesel) plus jockey pump
• Operating time — minimum 60-90 minutes at full demand
• Backup supply — emergency generator or diesel pump as backup

Commissioning and Certification

After installation completion, the following are required:

• Pressure test of the entire piping system
• Hydraulic test confirming design parameters
• Visual inspection by a certified inspector
• Certification by an authorized body (e.g., VdS, LPCB, CNPP)
• Training of facility personnel in system operation

Common Design Mistakes

Based on our experience from hundreds of projects, the most common mistakes include:

• Underestimated hazard classification — leads to undersized systems
• Failure to account for future changes — production expansion requires system upgrades
• Insufficient coordination — clashes with other services discovered during installation
• Undersized water supply — inadequate tank capacity or pump performance

Conclusion

Fire protection design for production halls requires experience, technical knowledge, and close collaboration between designers and installers. At Oskar Sprinkler, we combine these competencies, delivering reliable industrial sprinkler systems across Europe.

Planning a sprinkler installation in a production hall? Contact us — we will prepare the optimal solution for your facility.