Legal context
The Fire Safety Order 2005 applies to the premises, but on a manufacturing site it sits alongside DSEAR where flammable substances or explosive atmospheres are present, and alongside process specific duties. The assessment has to engage with the process rather than describe a building, so hot works control, dust, plant, and the fire strategy for large open floor plates all belong in the report.
Why this sector is different
- Combustible dust in extraction, above ceilings and on beams and cable trays
- Hot works, welding and grinding carried out daily as normal production
- Long travel distances across an open floor plate with racking and plant in the way
- High value single point plant that stops the whole line if it burns
- Shift working, agency staff and lone maintenance out of hours
Typical scope on a factories job
- Process led assessment covering production, stores, extraction and plant rooms
- Hot works permit system reviewed, including the post work fire watch
- Travel distances measured against the actual racking and plant layout
- Extinguisher siting matched to the process risk, including CO2 at panels and plant
- Alarm audibility over machinery noise and, where needed, visual alarm devices
- Business continuity view on what a fire in each zone would actually stop
Common findings we record on factories sites
- Dust accumulation on high level surfaces and inside extraction ductwork
- Hot works carried out without a permit or with no fire watch afterwards
- Fire exits blocked by pallets, finished goods or a forklift charging point
- Compartment walls breached by later service runs and never fire stopped
- Alarm inaudible on the shop floor when the line is running
How often to reassess
Annually as a baseline, plus a review whenever the process, layout, plant or shift pattern changes. Sites running regular hot works should review the permit system more often than the assessment itself.
What it costs
Fixed fee agreed up front and scoped from floor area, process count and number of buildings. A single unit workshop is a half day. Multi building sites with separate process risks are quoted per building, and extinguisher servicing across a large floor plate is priced per unit with in van replacement stock.