Introduction –

There are a lot of moving parts when working in manufacturing, which can mean a number of risks for your business. A lot of these are very common, everyday risks, which are typically well maintained, but there are a surprising number of dangerous hazards hiding in plain sight…

Specialised processes require a range of machinery and equipment to keep production high, but these can come with their own risks. A lot of manufacturing equipment can actually create risks of ignition within your workplace, seriously increasing the chance of fire and explosions.[MH1]  Ignition risks can be as common as heaters and lighting, or as obvious as naked flames and electrical equipment. As a rule of thumb, if it can create a spark or get very hot, it can cause a fire in your workplace.

However, most fires can be prevented[MH2] , and also be mitigated if they do happen, through routine safety assessments required for compliance. If you’re not sure of all the fire risks in your processes and how severe they are, it might be time to ask yourself – do I need a fire risk assessment?

What is a Fire Risk Assessment? –

Nearly every place requires a Fire Risk Assessment, but [MH3] it is important to understand what a Fire Risk Assessment is and what it aims to achieve. It is the process of assessing your workplace and processes with the sole focus of eliminating where possible, or controlling [MH4] where not possible, all the fire hazards in your business. Here are some typical stages of a Fire Risk Assessment:

Fire Hazard Identification

The first stage in any Fire Risk Assessment is to gather information. Your assessor identifies all potential fire hazards, which will allow them to understand the likelihood of a fire occurring and the consequences this could have on your business.

Risk to People

Now that all the fire hazards have been identified, it is important to consider the individuals in your business who would be at risk in the event of a fire. This can be a number of different people, from employees and customers to residents, contractors[MH5] , and firefighters, and will have a focus on vulnerable groups, such as lone workers, young persons, and persons with disabilities.

Building Evaluation[MH6] [JS7] 

Every building is different, so your building layout and structure will be analysed to better understand the areas and conditions a fire could ignite in and where and how exactly this could spread. This includes building construction materials, compartmentation, presence of voids and ducts, and means of escape.

Preventing Fires

It is important to ensure that fires are prevented as much as possible, which can be like moving designated smoking areas as far from flammable substances as possible, storing certain substances a safer distance from machinery ignition risks, inspecting your electrical equipment and systems, housekeeping and waste management, and arson prevention.

Fire Mitigation Strategies

Ensuring your teams know what to do in an emergency to reduce the risk of spreading is essential. Having the right firefighting systems in place helps mitigate and control fires. This section will include recommendations like compartmentation upgrades (if needed), emergency planning and training, and installing or upgrading firefighting and fire alarm systems.

Who needs a Fire Risk Assessment? –[MH8] 

Now you know the purpose of a Fire Risk Assessment, it’s essential to determine if you need one. This is not only a safety measure, but it is also a legal requirement. What’s more, if you employ five or more people, your assessment must be recorded. Under the Regulatory Reform (Fire Safety) Order 2005[MH9] [JS10] , a Fire Risk Assessment is required for:

• Building owners
• Employers
• Landlords
• Anyone otherwise in control of the premises

This applies to typical manufacturing facilities, like factories and warehouses, but also affects offices, retail spaces, educational institutions, and many more. Failing to meet these regulations can expose your business to serious consequences that extend far beyond the immediate risks of injury, loss of life, or operational disruption. These include enforcement notices, fines, prosecution, higher insurance premiums or invalidated policies, and reputational damage, all of which can discourage customers from returning.[MH11] 

When should a Fire Risk Assessment be done? –

It is required that a Fire Risk Assessment be completed before occupying a space, but where this is not the case, it should be completed as soon as possible. In order to ensure the safest possible workplace, a detailed knowledge and understanding of all potential fire risks is the essential first step to protecting your people and your processes.

After the initial assessment, any significant changes to the building, your operations, or fire safety arrangements, along with any fires or incidents, will trigger the need to have your workplace reassessed. If none of these occur, it is recommended that your Fire Risk Assessment is reviewed regularly. Based on previous assessment recommendations, your Fire Risk Assessor will determine and communicate to you the frequency you should think about updating or reassessing.

Who should do a Fire Risk Assessment? –

The duty to carry out a Fire Risk Assessment sits with the ‘Responsible Person’, typically an employer, owner, occupier, or anyone with control of the premises. If your focus is on protecting your people and facility, it is important to consult with a knowledgeable and experienced fire safety expert to ensure a thorough and detailed assessment. When assessing high-risk or complex environments, it is essential that every risk is assessed [MH12] and there aren’t any missed hazards putting your workplace in danger.

If you’re not sure where to start, Sigma-HSE have a team of experienced and knowledgeable fire risk assessors who will happily talk you through your Fire Risk Assessment needs, guide you through the entire process, and ensure you fully understand the results.

Do you need a Fire Risk Assessment? Email info@sigma-hse.com to protect your people and your operations with confidence.

Courtesy of Sigma-HSE

 [MH1]“and explosions?”

 [MH2]“prevented, and mitigated if they happen”

 [MH3]Nearly every place require a risk assessment, maybe this statement needs some rewording? 🙂

 [MH4]Can we change it to “controlling?”

 [MH5]“and also firefighters” as we started to seen high number of injuries and fatalities of firefighters on duty. So they are considered in fire risk assessments. There was a recent accident in May 2025 when two firefighters died during fighting a fire in Bicester. https://www.bbc.co.uk/news/articles/c39xx8edwymo

 [MH6]Do you need to add a technical touch and include examples of what we evaluate? like means of escape, compartmentation, fire doors, etc.

 [JS7]Yes please, that could add an element of knowledge to this ☺️

 [MH8]Do you need to add this “If you employ five or more people, the significant findings of your assessment must be recorded”?

 [MH9]Do we need to add references to Fire Safety Act 2021 and Fire Safety (England) Regulations 2022?

 [JS10]I haven’t found anything online about them requiring an FRA, but if it is relevant then please add this information ☺️

 [MH11]We can include loss of lives as well, and business interruptions.

 [MH12]To change to “assessed”?