As companies with consistently high volumes of products continue to grow, storage warehouses for goods are evolving. We’re seeing more and more automated storage and retrieval systems (AS/RS), particularly for retail, warehousing and distribution companies that need to increase their storage density and efficiency. In fact, the market for AS/RS is expected to reach over $13 billion by 2030.
This popular type of warehouse system, run almost entirely by technology with very few humans on site, also comes with risks to consider. One of the biggest risks with an ASRS facility is fire.
In this article, we’ll discuss how to mitigate the risk of fire at your facility.
What are AS/RS in storage facilities?
AS/RS integrates digital, robotic and racking elements to create a custom automated warehouse that can handle a huge variety of goods, all controlled by digital automation software. Various methods are used to automatically deposit and retrieve loads to and from storage locations throughout a typically cavernous warehouse center. The management system has become an integral part of many businesses’ manufacturing and distribution processes, reducing labour costs, improving accuracy and storage capacity and increasing commercial productivity.
Fire is the number one risk factor in AS/RS storage systems
The trade-off for this storage center efficiency may be a dramatic increase in the risk of fire. Nelson Choong, vice president of consulting solutions at Marsh Advisory, warns property owners and managers to be aware of different fire risks in AS/RS warehouses vs. traditional environments.
“Components of these systems, such as robots, shuttles, batteries, cranes and charging stations, may be susceptible to fire from many causes, including overheating, electrical arcing, collisions, and electrical faults. These fires can spread to areas outside of the ASRS, quickly overwhelming a building’s sprinkler system,” he writes.
“As an example, many ASRS robots and shuttles are powered by lithium-ion batteries, which can overheat, and due to a phenomenon called thermal runaway, catch fire and emit explosive gases. Lithium-ion battery fires are extremely hot and difficult to extinguish. Doing so requires specialized training, which local fire departments may not have received.”
Other AS/RS factors that contribute to increased fire risk include:
- Due to the compact building design, access by humans, including fire fighters, could be limited
- Higher density racking systems which may not allow the installation of sprinkler systems everywhere they’re needed
- Densely packed storage aisles and shelving which may conceal fires and smouldering embers from firefighters
How to mitigate fire risks in AS/RS warehouses
Managing fire risk begins with selecting a reputable company to design and install an AS/RS in your storage building. Typically, these firms develop the plans and install the racks, robots, charging stations, cranes and automation electronics, themselves.
It’s important to ensure that the original equipment manufacturer (OEM) has proven knowledge and experience designing AS/RS with fire safety in mind. Reputable OEMs understand local fire codes and requirements and will work with contracted sprinkler designers to devise a solution for your storage building. You can ask for references and tour storage facilities they’ve worked on to see fire safety precautions for yourself.
Often, property owners will hire a separate company to perform the service and maintenance of the AS/RS. It’s recommended that they are brought in during the design stage so they can provide input into things like local codes and regulations.
Some proactive companies also invite the local fire department in to explore the facilities after the AS/RS has been installed to ensure they understand the layout, the risks and to see what kind of fire protection has been installed.
Another stakeholder to consider including is your insurance carrier to ensure they’re aware of all aspects of the building and its systems.
Fire protection and safety considerations for AS/RS design
FM Global Data Sheet 8-34: Protection for Automatic Storage and Retrieval Systems has the most recent and in-depth recommendations building owners can take to responsibly use an AS/RS.
The Canadian Fire Safety Association also advises a number of actions that can be taken to help reduce the risk of fires in the design stage. They include:
- Assess storage height. Make sure you understand the protection requirements for rack storage. NFPA 13 provides protection criteria for shelf storage up to 15 feet in height. Many AS/RS are designed to exceed this standard. Do a risk analysis to identify appropriate protection.
- Identify goods to be stored. Be aware of what type of products will be in rotation, including items such as hand sanitizer and goods with lithium-ion batteries such as cell phones, smart watches and e-scooters. Adapt fire risk mitigation practices with these considerations. (Review the electronics and batteries associated with the robotics as its own fire hazard.)
- Choose closed bins/totes. Completely enclosed bins or totes are advisable over the common open top bins for storage. This is important for sprinkler water spray pattern development.
- Analyze available water supply. If the existing infrastructure cannot provide the required flow and duration based on the protection scheme, onsite water storage may be necessary.
- Ensure firefighting access. Grid-type ASRS have no aisles to provide access into the system, so firefighting operations need to be completed from the perimeter area. If the structure prevents firefighting operations from the ground, you may need to install platforms at strategic locations around the perimeter to direct water hose spray. There may also be a need to provide remote water monitors and video/fire detection to help the fire department extinguish a fire.
Want more information about mitigating fire risk in AS/RS?
Aviva Risk Management Solutions has professional risk consultants across Canada who can provide expert advice and resources on handling fire protection at your facility. Reach out to us at arms.canada@aviva.com.
Sources:
IndustryARC - Automated Storage & Retrieval Systems Market - Forecast(2024 - 2030)
Marsh - ASRS pose new fire risks for warehouses
Marsh - Battery Energy Storage Systems and the rising risk of thermal runaway
NBC News - An exploding problem: Fires sparked by lithium batteries are confounding firefighters
Canadian Fire Safety Association
