Code of practice for fire safety of chemical industries, Part 1: Rubber and plastic

IS 11457 Part 1 - Scope & Key Specifications Summary

This part covers fire safety practices for chemical industries handling rubber and plastic. It emphasizes minimizing fire/explosion hazards by:

• Proper planning of buildings and storage.
• Use of correct materials and electrical equipment.
• Provision for fire detection and suppression.

Key Points from Scope:

• Fire safety measures tailored to rubber and plastic chemical industries.
• Guidelines on signage (Clause 9.1):
  • "No smoking" signs with contrasting colors near tanks/storage.
  • Boards indicating flammable/hazardous stock visible from outside.
• Open spaces around factories to reduce fire/explosion damage (Clause 2.1).
• Use of self-contained breathing apparatus for personnel safety due to toxic fumes from polymer fires (Clause 8.4).

Units & Definitions (SI Units):

Related Codes & Specifications:

• Portable fire extinguishers (chemical, foam, dry powder types).
• Fire hose couplings, nozzles.
• Water supply for firefighting.
• Fire alarm systems.
• Breathing apparatus (IS:10245 Part 2).

flowchart TD
    A[Chemical Industry - Rubber & Plastic] --> B[Fire Hazard Identification]
    B --> C[Planning & Layout]
    B --> D[Material & Equipment Selection]
    B --> E[Fire Detection & Suppression]
    E --> F[Portable Fire Extinguishers]
    E --> G[Fire Alarm Systems]
    E --> H[Water Supply for Firefighting]
    C --> I[Open Space Around Factory]
    D --> J[Electrical Safety]
    F -->

IS 11457 Part 1: General Site and Plot Requirements - Key Points

• Plot Size & Layout (Clause 3.2):

  • Adequate size to accommodate manufacturing, storage, utility buildings.
  • Provision for future expansion without congestion.
  • Keep plot free of combustible materials (grass, weeds, scrap wood, sawdust).

• Building Separation (Clause 3.8):

  • Minimum 20 m distance between residential/office buildings and nearest manufacturing building.

• Fencing (Clause 3.1):

  • Erect a fencing or compound wall around the plot for security and demarcation.

• Open Space (Clause 2.1 & 2.3):

  • Maintain sufficient open space around factory to minimize explosion/fire damage to nearby properties and community.

Summary Table

Notes on Rounding Off (As per IS 11457 Part 1)

• Numerical values should be rounded off according to the revised rules specified in the code for accuracy and consistency.

flowchart LR
    A[Plot] --> B[Manufacturing Building]
    A --> C[Storage & Utility]
    A --> D[Residential/Office Buildings]
    B -- 20 m min --> D
    A --> E[Fencing/Compound Wall]
    A --> F[Open Space for Safety]

This ensures safe, organized, and code-compliant factory site planning.

IS 11457 Part 1 (1985) - Key Points on Building Construction and Layout

1. Building Layout

• Minimum distance: Residential/office buildings must be ≥ 20 m from nearest manufacturing units (Clause 3.8).
• Aisle marking: Multi-storeyed buildings should have 25 cm diameter yellow dots below window sills on outer walls to mark fire ladder access (Clause 4.18).

2. Construction Specifications

• Roofs:
  • Supported directly on walls, no intermediate columns/posts (Clause 4.11).
  • Roof covering must be lightweight, fire-resistant, and leak-proof.
  • Corrugated iron sheets: galvanized or aluminium painted.
  • Corrugated asbestos sheets: Inserted at 6 m intervals near walls for fire-fighting access.
  • Fire-retardant paint only on roof undersides if painted.
  • Skylights must comply with IS 1642-1986.
• Manufacturing buildings: Fire resistance equivalent to Type I construction as per IS 1642-1986 (Clause 4.4).

Summary Table

flowchart LR
    A[Building Layout] --> B[Residential/Office ≥ 20m from Manufacturing]
    A --> C[Fire Ladder Mark: 25cm Yellow Dot]
    D[Roof Construction] --> E[Directly on Walls, No Posts]
    D --> F[Light & Fire-Resistant Covering]
    D --> G[Corrugated Iron: Galvanized/Aluminium Paint]
    D --> H[Corrugated Asbestos Sheets @ 6m Intervals]
    I[Manufacturing Buildings] --> J[Fire

IS 11457 Part 1 - Fire Resistance & Compartmentation Key Points

Fire Resistance Requirements

• Compartment walls: Non-combustible, sound construction, same fire resistance as main building walls (Clause 4.2).
• Fire resistance rating: Minimum 2 hours for fire-check doors between compartments (Clause 4.1).
• Fire-check doors: As per IS 3614 (Part 1) - 1966, metal-covered or rolling type, rated for fire resistance.
• Exit enclosures (stairs, elevators): Non-combustible, fire-resisting enclosures with fire resistance equal to building walls; doors rated same as compartment doors (Clause 4.8).

Compartmentation Specifications

• Buildings for raw materials, processes, finished products should be separate and subdivided by compartment walls (Clause 4.1).
• Communication between buildings separated by ≥15 m can be via enclosed passageways of non-combustible construction, designed to release internal explosion pressure (Clause 3.6).
• Fire-check doors in passageways must have minimum 1 hour fire resistance rating (Clause 3.6).

Summary Table of Fire Resistance Ratings

Diagram: Compartmentation Concept

graph LR
A[Raw Material Building] -- Fire-check Door (2 hrs) --> B[Process Building]
B -- Fire-check Door (2 hrs) --> C[Finished Product Building]
A & B & C --- Enclosed Passageway (≥15m separation, 1 hr door) --- D[Other Building]
E[Exit Enclosure] -->|Fire-check Door (2 hrs)| F[Stairs/Elevators]

Note: Refer to IS 3614 (Part 1) for detailed fire-check door specifications and IS 11457 for structural design considerations related to fire resistance.

IS 11457 Part 1 - Electrical Installations: Key Points

• Clause 5.1:

  • Electrical installations must comply with IS 1646-1982 (Code of Practice for Fire Safety: Electrical Installations).
  • Separate power sources for main and ancillary connections are mandatory.

• Clause 5.2:

  • In hazardous areas, all electric motors, lighting fittings, and switches must be flameproof and dust-proof as per IS 5572 (Part 1)-1978.

• Clause 5.5:

  • Incoming feeders from the main sub-station must use underground cables to reduce fire risk.

• Clause 4.21 (Related to ventilation):

  • Exhaust fans should safely remove flammable vapors/dusts outside to prevent re-entry via air intakes.

Additional Engineering Notes:

Typical Flameproof Motor Marking (per IS 5572):

graph LR
A[Flameproof Motor] --> B[Enclosure Type: 'd']
A --> C[Ingress Protection: IP54 or higher]
A --> D[Temperature Class: T1 to T6]
A --> E[Certified for Gas Group]

Summary:
Ensure electrical installations in hazardous areas are flameproof, dust-proof, and fed through underground cables. Follow IS 1646 and IS 5572 for design and safety compliance.

IS 11457 Part 1: Storage and Handling of Materials — Key Points

Storage Location & Building Specifications

• Solid materials: Store outdoors if no hazardous reactions from moisture/sun (Clause 6.1).
• Bulk combustible materials: Store separately from manufacturing areas (Clause 6.2).
• Storage buildings:
  • Preferably single-storeyed.
  • Max height: 10 m from average ground to roof apex (Clause 4.7).
  • No wooden flooring unless on concrete/masonry without gaps.
  • Provide adequate escape routes (refer IS 1644-1986).

Safety Signage (Clause 9.1)

• Display ‘No Smoking’ signs prominently near tanks/storage.
• Indicate flammable/hazardous stock visibly from outside.
• Fire extinguisher types recommended:
  • Water type (gas pressure)
  • Foam type
  • Dry powder type
• Follow respective IS specifications and codes for fire safety equipment.

Units & Quantities (SI Units)

Summary Diagram: Storage Layout Concept

flowchart LR
    A[Manufacturing Area] -->|Separate| B[Bulk Combustible Storage]
    B --> C[Outdoor Solid Material Storage]
    C --> D[Signage & Fire Safety]
    D --> E[Escape Routes]

Use this guidance to ensure safe, code-compliant storage and handling of materials.

Dust Control & Temperature Monitoring per IS 11457 Part 1

Dust Control

• Clause 7.5: Provide dust removal/exhaust systems with hoods at all dust release points.
• Clause 6.21: Install exhaust fans if dust is visible in air (considered excessive).
• Clause 7.6: Ensure all equipment (hoppers, bins, conveyors, ducts, grinders, blenders) is dust-tight to prevent leakage.

Temperature Monitoring

• While IS 11457 Part 1 does not explicitly specify temperature monitoring formulas, standard practice involves:
  • Using thermocouples or RTDs for continuous temperature measurement.
  • Monitoring temperature to prevent ignition risks in dust-laden atmospheres.

Units & Definitions (SI Units)

Summary Diagram: Dust Control System

flowchart LR
    A[Dust Generation Point] --> B[Hood Capture]
    B --> C[Exhaust Fan]
    C --> D[Filters/Dust Collector]
    D --> E[Clean Air Discharge]

Key Points:

• Use hoods and exhaust fans to capture and remove dust.
• Maintain dust-tight equipment to avoid leaks.
• Monitor temperature continuously to detect hazardous conditions early.
• Display safety signs (e.g., No Smoking) near tank farms and storage areas (Clause 9.1).

This approach ensures compliance with IS 11457 Part 1 for dust control and temperature safety.

Fire Fighting Measures & Equipment per IS 11457 Part 1:

Key Specifications:

• Fire Extinguishers:

  • Water type (gas pressure) — IS: 940 (1976)
  • Foam type — IS: 933 (1976)
  • Dry chemical powder — IS: 2171 (1985)
  • Maintenance & selection per IS: 2190 (1979)

• Fire Hose & Nozzles:

  • Couplings, branch pipes, nozzles per IS: (Third revision)

• Breathing Apparatus:

  • Self-contained breathing apparatus for toxic fumes — IS: 10245 (Part 2) (1982)

Essential Fire Safety Measures:

• Earthing of all equipment to dissipate static charges (Clause 7.10)
• Signage: Large "No Smoking" signs near tank farms; stock indication boards visible from outside (Clause 9.1)
• Water Supply: Adequate provision & maintenance for firefighting water supply (Code of practice)

Units & Definitions (SI Units):

Summary Diagram:

graph LR
A[Storage Area] -->|No Smoking Sign| B[Fire Safety Signage]
B --> C[Fire Extinguishers]
C --> D[Water, Foam, Dry Powder Types]
A --> E[Fire Hose & Nozzles]
A --> F[Self-contained Breathing Apparatus]
A --> G[Equipment Earthing]

References: IS 11457 Part 1, IS 940, IS 933, IS 2171, IS 2190, IS 10245.

IS 11457 Part 1 — Safety Procedures & Personal Protection Key Points

Safety Signage (Clause 9.1)

• 'No smoking' signs must be large, with contrasting colors near tank farms and storage.
• Display boards indicating stock of flammable/hazardous materials accessible from outside tanks/storage.

Personal Protective Equipment (Clause 8.7)

• Provide and maintain PPE to prevent inhalation, ingestion, and contact with harmful substances.
• PPE includes masks, gloves, protective clothing, and eye protection.

Breathing Apparatus (Clause 8.4)

• Keep self-contained breathing apparatus (per IS: 10245 Part 2) readily available for toxic fumes from polymer fires (CO, CO2, nitro fumes, chlorinated plastics).

Fire Safety Equipment Standards

• Portable fire extinguishers: chemical (water, foam, dry powder types) as per relevant IS specifications.
• Fire hose couplings, nozzles, and spanners: per IS standards.
• Maintain water supplies for firefighting as per the code of practice.

Units & Definitions (SI Units)

Summary Diagram: Safety Setup

graph LR
A[Hazardous Area] --> B[No Smoking Sign]
A --> C[Flammable Material Board]
A --> D[Fire Extinguishers]
A --> E[Self-Contained Breathing Apparatus]
A --> F[Personal Protective Equipment]

Ensure compliance with IS 11457 Part 1 for signage, PPE, breathing apparatus, and firefighting equipment to safeguard personnel and property.

IS 11457 Part 1 (1985) – Emergency Access and Evacuation Key Points

Key Specifications:

• Clause 4.18:

  • In multi-storeyed buildings, aisle space outside walls under window sills must have a 25 cm diameter yellow dot marking ladder access points for fire fighters.

• Clause 4.8:

  • Stairs, elevators, and exits must be enclosed in non-combustible fire-resisting enclosures with fire resistance rating equal to the building.
  • Openings require fire check doors.

• Clause 4.15.1:

  • Minimum two outward-opening doors per room, opposite or widely separated.
  • Process buildings require at least three doors.
  • Doors must be protected from damage/blockage.

Fire Safety Signs (Clause 9.1):

• 'No smoking' signs must be large, contrasting, and conspicuous near hazardous zones.
• Stock boards for flammable materials must be visible from outside storage tanks.

Summary Table: Exit Door Requirements

Fire Resistance Enclosure Requirements:

• Fire resistance rating = building rating.
• Use fire check doors at all openings.

Visual Marking for Ladder Access:

graph LR
A[Wall under window sill] --> B[Yellow Dot (25 cm diameter)]
B --> C[Ladder Location for Firefighters]

Additional Notes:

• Use non-combustible materials for exit enclosures.
• Ensure clear aisle marking for emergency access.
• Follow portable fire extinguisher standards as per referenced specifications for fire safety.

This concise guidance ensures compliance with IS 11457 Part 1 for emergency access and evacuation provisions.

IS 11457 Part 1: Maintenance and Inspection Requirements - Key Points

1. Signage (Clause 9.1)

• Display 'No Smoking' signs prominently near tank farms/storage.
• Show boards indicating stock of flammable/hazardous materials visible from outside.

2. Tank Maintenance (Clause 6.12)

• Keep all tank openings securely closed except vents.
• Vents must have flame arresters or pressure-vacuum vents.
• Tanks must be clearly marked with capacity, flammability, and content nature.

3. Fire Extinguishers (Clause 8.6)

• Provide and maintain:
  • Water CO2 extinguishers (IS: 940-1976)
  • Foam extinguishers (IS: 933-1976)
  • Dry chemical powder extinguishers (IS: 2171-1985)
• Follow maintenance as per IS: 2190-1979.

4. Safety Distances (Clause 2.1)

• Maintain adequate open space around tanks to minimize explosion/fire damage.

Units & Definitions (SI Units)

Summary Diagram: Fire Safety Maintenance Flow

flowchart TD
    A[Signage Display] --> B[Tank Opening Security]
    B --> C[Vent Installation (Flame Arrester)]
    C --> D[Fire Extinguisher Provision]
    D --> E[Regular Inspection & Maintenance]
    E --> F[Maintain Open Space]

References:

• IS 2190: Maintenance of portable fire extinguishers
• IS 940, 933, 2171: Types of fire extinguishers
• IS 11457 Part 1: Fire protection & safety measures