Code of practice for fire safety of industrial building: Aluminium/Magnesium powder factories
1988 Edition

Overview of Scope & Essential Requirements for Aluminium and Magnesium Powder Plants

Scope Highlights (Clauses 0.2 - 0.3)

• Pertains to fire safety measures in factories involved in the production or storage of aluminium and magnesium powders.
• Encompasses areas with potential fire and explosion hazards.
• Addresses factory layout, building design, maintenance, ventilation, and firefighting systems.
• Extended coverage to include magnesium powder facilities due to analogous risk profiles.

Principal Specifications:

• Building Design (Clause 5.8):

  • Single-storey structures without basements.
  • Construction entirely with fire-resistant materials.
  • Interior surfaces must be accessible for cleaning.
  • Masonry joints smoothed flush to prevent powder buildup.
  • Measures to prevent water penetration into powder areas.

• Lighting Standards (Clause 9.1):

• Firefighting Provisions:
  • Portable fire extinguishers compliant with relevant Indian Standards.
  • Specialized dry powder extinguishers suitable for metal fires.
  • Availability of adequate water supply for firefighting purposes.

Value Rounding

• Follow IS 2-1960 guidelines for rounding measurement and testing results to ensure uniformity.

flowchart TD
    Factory_Layout --> Single_Storey_No_Basement
    Single_Storey_No_Basement --> Fire_Resistant_Materials
    Fire_Resistant_Materials --> Accessible_Interior_Surfaces
    Accessible_Interior_Surfaces --> Flush_Masonry_Joints
    Flush_Masonry_Joints --> Prevent_Water_Ingress
    Prevent_Water_Ingress --> Housekeeping
    Housekeeping --> Fire_Fighting_Equipment
    Fire_Fighting_Equipment --> Dry_Powder_Extinguishers
    Fire_Fighting_Equipment --> Water_Supply

Summary: This standard establishes protocols for safe design, construction, and fire protection in aluminium and magnesium powder manufacturing sites by specifying layout, lighting, and firefighting requirements to reduce fire and explosion hazards.

Key Guidelines on Factory Placement and Layout According to the Standard

Minimum Distance Requirements (Clauses 3.1 - 3.3)

• Distance from railway sidings, yards, or tracks:
  • At least 150 meters, ideally located on the side from which the wind blows.
  • Can be reduced to 30 meters if served exclusively by diesel or electric locomotives.
• Separation from public buildings, residences, and warehouses:
  • Minimum 100 meters to safeguard public safety.

Fire Prevention Measures (Clause 3.1)

• Provide sufficient open space surrounding the facility to facilitate firefighting access and fire spread prevention.
• Secure the factory premises using fencing or compound walls with controlled entry.

Illumination Parameters (Clause 9.1, Table 9)

Visual Summary: Factory Distance Layout

graph LR
    Factory_Building
    Railway_Siding
    Public_Building
    Factory_Building -- "150 m (or 30 m if diesel/electric)" --> Railway_Siding
    Factory_Building -- "100 m" --> Public_Building

These provisions ensure that factory layouts comply with safety distances, accessibility, and lighting standards mandated by the code.

Essential Criteria for Site Area and Access Roads

• Site Size (Clauses 4.1 & 4.2):

  • Area should accommodate all existing buildings and allow for planned expansions.
  • Provide robust, paved roads between structures to enable unhindered movement of firefighting and rescue vehicles.
  • Keep the compound free from combustible vegetation such as dry grass and weeds.

• Access Road Specifications (Clause 4.2):

  • Roads must allow emergency vehicles clear and unobstructed access.
  • Width and layout designed for efficient traffic flow around the site.

• Explosion Venting Requirements (Clause 5.13.2):

  • Vent area should be at least 1 square meter for every 5 cubic meters of building volume.
  • Distribute vents evenly throughout the facility.

Explosion Vent Area Reference Table

Conceptual Diagram: Site Layout

flowchart LR
    Building_A ---|Paved Road| Building_B
    Building_B ---|Paved Road| Building_C
    Building_A ---|Access Road| Fire_Truck
    subgraph Factory_Compound
        direction LR
        Building_A & Building_B & Building_C
    end

Note: Roads facilitate emergency vehicle access; buildings are spaced for safety and future growth.

Refer to IS 14489 and local fire safety codes for detailed access road dimensions and clearances.

Primary Building Construction Guidelines for Fire Safety

• Fire Access Routes (Clause 4.2):

  • Provide adequate paved roads between buildings to enable firefighting and rescue access.

• Godown Construction (Clause 5.6):

  • Must comply with Type 1 fire-resistant construction as per IS 1642-1988.

• General Building Construction (Clause 5.8):

  • Structures should be single-story without basements.
  • Utilize fire-resisting materials throughout.
  • Internal surfaces must be accessible for cleaning to prevent dust buildup.
  • Masonry joints in areas with metal dust must be flush and smooth.
  • Design must prevent water penetration to avoid powder exposure.

• Fire-Resistant Doors:

  • Use plate metal-covered or rolling type fire-check doors meeting relevant standards.

Construction Specification Summary

Important Considerations:

• Design layouts to minimize explosion hazards by avoiding congested spaces.
• Ensure all internal surfaces can be cleaned easily to control dust.
• Follow IS 1642 for detailed Type 1 construction norms.

flowchart LR
    Building_Layout --> Paved_Roads
    Building_Layout --> Single_Storey
    Single_Storey --> Fire_Resistant_Materials
    Fire_Resistant_Materials --> Flush_Masonry_Joints
    Flush_Masonry_Joints --> Water_Ingress_Prevention
    Water_Ingress_Prevention --> Fire_Check_Doors

For comprehensive fire safety design, consult IS 1642 and associated fire protection standards.

Storage and Safety Measures for Aluminium and Magnesium Powders

Storage Instructions:

• Powders must not be stored in open containers or gunny bags to prevent contamination and ignition risks (Clause 6.3).
• Avoid co-storage of metallic powders with other materials due to differing fire-fighting requirements and increased ignition hazards (Clause 6.4).

Precautionary Measures:

• Prevent contact of powders with iron oxide (rust) and oxidizable oils or fats to avert spontaneous combustion (Clause 12.12).
• Windows, ventilators, and skylights serving as explosion venting elements should incorporate diagonally scored glass panels to allow safe pressure release (Clause 5.13.3).

Storage Safety Summary Table

Additional Recommendations:

• Maintain clean storage zones free from ignition sources such as sparks or static discharge.
• Employ explosion-proof electrical fixtures.
• Maintain rigorous housekeeping to prevent dust accumulation.

flowchart TD
    Metallic_Powder_Storage --> Closed_Containers
    Metallic_Powder_Storage --> Material_Segregation
    Metallic_Powder_Storage --> Avoid_Rust_Oils
    Metallic_Powder_Storage --> Explosion_Venting
    Closed_Containers & Material_Segregation & Avoid_Rust_Oils & Explosion_Venting --> Safe_Storage

These stipulations ensure adherence to fire safety protocols in powder handling facilities.

Essential Machinery and Equipment Safety Measures

• Temperature Regulation (Clause 6.6):

  • Maintain ambient temperatures in machinery areas at or below 35°C to avoid overheating.

• Bearings and Sealing (Clause 7.1):

  • Employ ball or roller bearings with sealed sleeves to guard against dust ingress.

• Building Standards (Clause 5.7):

  • Facilities housing engines, transformers, or power units must conform to Type 3 construction under IS 1642:1988.

• Protection from Metallic Powders (Clause 7.2):

  • Ensure machinery design limits exposure of moving components to metallic dust to reduce wear and ignition hazards.

Machinery Compliance Summary

flowchart LR
    Machinery --> Temperature_Control(≤ 35°C)
    Machinery --> Bearings_Sealed
    Machinery --> Type_3_Building
    Machinery --> Powder_Exposure_Prevention

Adhering to these ensures enhanced equipment durability and compliance with fire safety mandates.

Key Electrical Installation Guidelines

Wiring and Equipment (Clause 8.1)

• Utilize heavy gauge screwed conduit wiring throughout.
• Enclose lighting fixtures and switchgear for protection.
• Employ flame-proof and dust-tight electric motors.
• Position remote control switches for lighting and power at least 1.25 meters outside the nearest door.
• Centralized control switches should be located at security or office posts.
• Conduct regular inspections and cleaning of electrical installations.

Building Requirements (Clause 5.7)

• Structures containing engines, transformers, or generators should be constructed as Type 3 per IS 1642-1988.

Illumination Levels (Clause 9.1, Table 9.I)

Additional Considerations

• Machines generating dust must be properly earthed and designed to minimize dust escape (Clause 7.19).

Electrical Setup Overview

flowchart TD
    Power_Source --> Conduit_Wiring
    Conduit_Wiring --> Enclosed_Fixtures
    Conduit_Wiring --> Flameproof_Motors
    Enclosed_Fixtures --> Remote_Switches
    Remote_Switches --> Central_Control
    Flameproof_Motors --> Maintenance

This framework promotes electrical safety, fire prevention, and adequate illumination in powder production environments.

Lighting Requirements as per Clause 9.1

Important Details:

• Lighting intensities are specified to maintain safe and efficient working conditions.
• Electrical installations must comply with IS 1646-1982 to ensure fire safety.
• Use heavy gauge, screwed conduit wiring.
• Lighting fixtures and switchgear should be enclosed types.
• Motors must be flameproof and dust-tight.
• Remote control switches should be located at least 1.25 meters outside dusty premises.
• Entire factory lighting should be controlled via centralized switches.
• Regular inspection and maintenance of electrical systems is mandatory.

Additional Notes:

• Avoid flat or wide flanged surfaces that can trap dust; apply sloping plaster to surfaces.
• Limit windows and openings to those strictly necessary for lighting and ventilation.

flowchart LR
    Factory_Areas --> Outdoor_Open_Areas_25lux
    Factory_Areas --> Storage_50lux
    Factory_Areas --> Operational_Zones_100lux
    Electrical_Safety --> Conduit_Wiring
    Electrical_Safety --> Enclosed_Fixtures
    Electrical_Safety --> Flameproof_Motors
    Electrical_Safety --> Remote_Switches
    Electrical_Safety --> Central_Control

These standards ensure compliance with lighting and fire safety requirements in environments handling combustible dust.

Firefighting Arrangements as per IS 4226

Personnel Requirements (Clause 10.3)

• Factories lacking their own fire brigade must appoint:
  • At least one full-time fire safety supervisor trained in firefighting.
  • Adequate number of trained firemen for equipment upkeep.
  • Sufficient trained personnel per shift to operate firefighting apparatus.

Hydrant Systems (Clause 10.3)

• Maintain operational hydrant systems equipped with hose boxes, hoses, and nozzles according to IS 9668-1980.
• Employ specialized dry powder extinguishers conforming to IS 4861-1984 for metal fires.

Fire Extinguishers

• Portable extinguishers should follow prescribed selection, installation, and maintenance codes.
• Dry powder extinguishers for metal fires must meet relevant IS standards.

Coordination with Fire Services (Clause 10.10)

• Maintain active communication with local fire brigades.
• Train them on the specific hazards of using water, CO₂, or foam on metallic powder fires.

Illumination for Fire Safety (Clause 9.1)

Firefighting Workflow

flowchart TD
    Factory_Without_Fire_Brigade --> Fire_Safety_Supervisor
    Fire_Safety_Supervisor --> Trained_Firemen
    Trained_Firemen --> Hydrant_System
    Hydrant_System --> Dry_Powder_Extinguishers
    Dry_Powder_Extinguishers --> Fire_Brigade_Liaison
    Fire_Brigade_Liaison --> Emergency_Response

References:

• IS 9668-1980: Hydrant Systems
• IS 4861-1984: Dry Powder Extinguishers for Metal Fires
• Code of Practice on Portable Fire Extinguishers

This setup ensures preparedness for fire emergencies specific to metallic powder manufacturing.

Housekeeping Standards for Dust Control and Fire Prevention

Dust Management (Clauses 11.1 & 11.3)

• Employ vacuum cleaning systems or soft push brooms to reduce dust accumulation and airborne dust.
• Remove bulk powder deposits prior to vacuuming using soft push brooms and non-sparking scoops.
• Vacuum equipment must use bonded, non-conductive, and spark-resistant hoses and nozzles.
• Avoid metallic fasteners in vacuum equipment to prevent ignition hazards.

Cleaning Frequency (Clause 11.4)

• Clean all factory areas and machinery at least once daily.
• Cleaning activities should be conducted with equipment powered off and idle.
• Increase cleaning frequency as needed based on dust levels.

Fire Safety Collaboration (Clause 10.10)

• Maintain coordination with fire brigades regarding the hazards of metallic dust fires and incompatible extinguishing agents.

Housekeeping Summary Table

flowchart TD
    Dust_Accumulation --> Remove_Bulk_Dust
    Remove_Bulk_Dust --> Vacuum_Cleaning
    Vacuum_Cleaning --> Daily_Cleaning
    Daily_Cleaning --> Fire_Brigade_Liaison

These measures significantly lower ignition risks by maintaining clean and safe environments.

Critical Safety Measures and Guidelines

Regular Cleaning and Maintenance (Clause 11.4)

• Daily cleaning is compulsory with machinery off to prevent dust build-up and associated fire and explosion hazards.

Explosion Pressure Relief (Clause 5.13.3)

• Windows, ventilators, and skylights must be fitted with diagonally scored glass designed to break safely under explosion pressures.

Fire and Explosion Causes

• Common causes include poor housekeeping, overcrowded layouts, faulty electrical installations, sparks, friction, and static electricity.
• Proper plant layout and effective firefighting provisions are vital.
• Applies specifically to aluminium and magnesium powder manufacturing facilities.

Illumination Requirements (Clause 9.1, Table 9.I)

Summary Flowchart

flowchart TD
    Daily_Cleaning --> Dust_Control
    Dust_Control --> Fire_Explosion_Risk_Reduction
    Explosion_Venting --> Scored_Glass
    Scored_Glass --> Safe_Pressure_Venting
    Fire_Safety_Layout --> Equipment_and_Housekeeping
    Equipment_and_Housekeeping --> Fire_Hazard_Minimization

Note: Detailed firefighting arrangements are outlined in Clause 10 of the standard.