Running a warehouse, workshop, or manufacturing site in Surrey — whether you’re based in Chessington, Aldershot, Redhill, or Chertsey — comes with a unique set of fire safety challenges.
These buildings are often large, complex, and filled with materials, machinery, and staff. They’re vital to the local economy — but also among the highest-risk environments Surrey Fire & Rescue Service inspects.
A fire in a warehouse doesn’t just cause damage — it can stop production, destroy stock, and threaten jobs. And when inspectors visit, they expect to see evidence that you’ve thought about every aspect of fire prevention, detection, and response.
Here’s everything you need to know about fire safety for industrial premises and warehouses in Surrey — including what the law requires, what inspectors check, and how to make sure your business stays safe and compliant.
Why Warehouses Are High-Risk
Warehouses and industrial buildings tend to combine all the ingredients for a serious fire:
🔥 Large volumes of flammable materials — packaging, pallets, paper, or stored goods.
⚙️ Electrical equipment and machinery — which can overheat or spark.
🛠️ Hot work — welding, grinding, or cutting can ignite dust or vapours.
⚡ Dust and vapours — in manufacturing sites, these can create explosive atmospheres.
🚪 Complex layouts — long travel distances and stacked racking make evacuation harder.
Because of these factors, fire safety in warehouses isn’t just about alarms and extinguishers — it’s about careful planning, risk management, and maintenance.
The Law: Your Fire Safety Dutie
The key legislation for industrial fire safety in the UK is the Regulatory Reform (Fire Safety) Order 2005.
It applies to all non-domestic premises in Surrey, including warehouses, workshops, factories, depots, and industrial estates.
Under this law, the Responsible Person (the employer, building owner, or manager) must:
✅ Carry out a Fire Risk Assessment (FRA) — and keep it up to date.
✅ Identify and control potential fire hazards.
✅ Maintain fire detection, alarm, and suppression systems.
✅ Train staff in fire prevention and evacuation.
✅ Keep accurate records of checks, tests, and maintenance.
You can find Surrey-specific information here:
👉 Surrey Fire & Rescue – Business Fire Safety.
The Fire Safety Assessment
A Fire Risk Assessment for an industrial site is more detailed than a typical office or shop report. It considers the building, processes, and materials — and how they interact.
Your assessment should cover:
1️⃣ Fire hazards – including ignition sources, storage of combustibles, machinery, and flammable liquids.
2️⃣ People at risk – employees, contractors, visitors, and lone workers.
3️⃣ Means of escape – travel distances, exit widths, and signage.
4️⃣ Fire detection and alarm systems – including zoning and automatic detection.
5️⃣ Emergency lighting – especially in large open spaces or power-dependent areas.
6️⃣ Firefighting equipment – correct types and locations for the risks present.
7️⃣ High-risk processes – such as welding, spraying, or chemical storage.
8️⃣ Maintenance, training, and drills – evidence of routine checks and staff awareness.
Your FRA must be carried out by a competent assessor familiar with industrial hazards and British Standards such as:
- BS 9999 – Fire safety in the design, management, and use of buildings.
- BS 5306 – Fire extinguisher selection and maintenance.
- BS 5839-1 – Fire alarm systems for commercial premises.
- BS 5266-1 – Emergency lighting.
Dangerous Substances and Explosive Atmospheres (DSEAR)
If your site uses or stores flammable gases, solvents, fuels, or dust-producing materials, the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) also apply.
Under DSEAR, you must:
- Identify and assess risks from explosive atmospheres.
- Classify hazardous zones.
- Control ignition sources (e.g., static electricity, hot surfaces, electrical equipment).
- Provide training and information to staff.
You can find more guidance from the HSE here:
👉 HSE – Dangerous Substances and Explosive Atmospheres Regulations (DSEAR).
Surrey Fire & Rescue collaborates with the Health and Safety Executive to enforce DSEAR regulations — so you must show evidence of compliance if inspected.
Fire Detection and Alarm Systems
For most warehouses and industrial units, a manual call point and automatic detection system is required.
Larger or more complex buildings need addressable alarm systems that identify the location of activation points — especially where multiple zones exist.
Standards to follow:
- BS 5839-1:2025 for design, installation, and maintenance.
- Weekly tests (rotating call points).
- Quarterly and annual servicing by a competent engineer.
ESI tip: For noisy environments, visual alarms (beacons) or vibrating pagers for staff may be required.
Fire Extinguishers and Suppression Systems
The right extinguishers depend on your specific risks:
| Fire Class | Common Cause | Recommended Extinguishers |
|---|---|---|
| Class A | Paper, wood, cardboard | Water, foam |
| Class B | Flammable liquids (oil, paint, fuel) | Foam, CO₂, dry powder |
| Class C | Gases | Dry powder |
| Electrical | Machinery, panels | CO₂ or dry powder |
| Metal | Magnesium, aluminium | Specialist powder |
Extinguishers should be:
- Positioned on escape routes and near hazards.
- Serviced annually (BS 5306-3).
- Checked monthly for pressure and tampering.
For large sites, automatic sprinkler systems or water mist systems may be needed — especially in storage areas with high fire load.
Storage and Housekeeping
One of the biggest causes of warehouse fires isn’t equipment — it’s poor housekeeping.
To stay compliant and safe:
✅ Keep aisles and exits clear.
✅ Maintain safe separation between stored goods and heaters or lights.
✅ Avoid stacking stock up to ceilings or blocking sprinklers.
✅ Use fire-resistant storage for flammable materials.
✅ Implement a “no smoking” policy throughout the site.
Simple housekeeping is one of the cheapest, most effective fire prevention measures you can take.
Electrical Safety
Old wiring, overloaded sockets, and poorly maintained machinery are frequent ignition sources in warehouses.
Ensure you have:
- Fixed wiring tests (EICR) every 5 years.
- PAT testing for portable tools and equipment annually.
- Daily or shift-based visual checks by supervisors.
- Clearly labelled isolation points for machinery.
ESI tip: Keep a record of all electrical inspections and maintenance — Surrey Fire & Rescue will want to see it during audits.
Staff Training and Fire Drills
Even the best systems fail if people don’t know what to do.
Your staff must:
- Know how to raise the alarm.
- Understand evacuation routes and assembly points.
- Be trained in extinguisher use (if appropriate).
- Receive refresher training annually.
- Take part in at least one fire drill per year — ideally more for larger teams.
Training records should be kept and updated — inspectors may ask for them.
What Surrey Fire & Rescue Inspectors Check
When Surrey Fire & Rescue Service visit an industrial site, they typically check:
✅ A current, competent Fire Risk Assessment.
✅ Maintenance records for alarms, lighting, and extinguishers.
✅ Safe storage and housekeeping practices.
✅ Fire doors, exits, and signage in good condition.
✅ DSEAR risk assessments (if applicable).
✅ Staff training and emergency plans.
If they find deficiencies, you may receive:
- Advice or informal notice (for minor issues).
- Enforcement notice (with deadlines for action).
- Prohibition notice (if life is at immediate risk).
You can find examples of enforcement activity here:
👉 GOV.UK – Fire Safety Enforcement Notices and Prosecutions.
How ESI Helps Surrey Industrial Businesses Stay Compliant
At ESI: Electrical and Fire Safety Specialists, we’ve been supporting industrial and commercial sites across Surrey for over 20 years — helping businesses protect their people, their property, and their productivity.
Our services include:
- BS 9999-compliant Fire Risk Assessments.
- Fire alarm design, testing, and maintenance (BS 5839-1).
- Emergency lighting installation and inspection (BS 5266-1).
- Fire extinguisher servicing (BS 5306-3).
- DSEAR risk assessments for hazardous materials.
- Electrical testing and compliance (BS 7671:2018).
We work with manufacturers, logistics firms, and warehouses across Chessington, Redhill, Aldershot, and Chertsey — keeping them compliant with both national standards and Surrey Fire & Rescue expectations.
If your Fire Risk Assessment is due for renewal, or you want a professional review before your next inspection, we can help.
Book your Fire Risk Assessment in Surrey and let ESI make sure your warehouse or industrial site meets every fire safety requirement — safely, efficiently, and affordably.
