Fire Safety of Industrial Buildings - Paint and Varnish Factories - Code of Practice

IS 9109: Scope - Key Specifications & Tables

• Scope: Covers storage requirements for paints/varnishes with flammable liquid bases, ensuring safety distances and storage limits.
• Rounding off: Values must be rounded per IS 2:1960, retaining the same significant figures as specified.
• Definitions: Refer to IS 1303 and IS 8757 for relevant terminology.
• Referenced Standards: Annex A lists related Indian Standards; users should check for latest editions.

Key Table: Outdoor Storage Limits for Paint/Varnish (Clause 15.6)

Additional Storage Clause (16.2)

• No other combustible materials allowed in storage buildings or sections.

This ensures safe storage practices for flammable paints/varnishes, minimizing fire hazards through controlled quantities and minimum separation distances.

IS 9109: Factory Layout and Roads - Key Specifications

1. Factory Location & Access (Clauses 4.2 & 5.3)

• Distance from railway siding:
  • Minimum 100 m from railway lines (preferably on windward side).
  • Can be reduced to 30 m if serviced by diesel/electric locomotives only.
• Proximity to fire brigade:
  • Factory should be within 5 km of municipal fire brigade.
• Main gate dimensions:
  • Minimum 5 m width and 5 m headroom to allow fire appliance access.

2. Storage Area Lighting & Safety (Clause 13.7 & 14)

• Lighting cables: Enclosed in screwed conduits.
• Lamps: Protected by well-glasses, fixed at least 1 m above highest stored goods.
• Cutout switch: Positioned outside storage for emergency.
• Illumination levels:

  Area	Illumination (lux)
  Open compounds	20
  Godowns (storage)	70
  Grinding/mixing/milling/heating	200

3. Compound Layout (Clause 5.1)

• Compound must be large enough for manufacturing, storage, utilities, and future expansion.
• Keep compound free from combustible materials like grass and weeds.

flowchart LR
    A[Factory Location] --> B[Distance from Railway]
    B -->|Diesel/Electric| C[30 m]
    B -->|Others| D[100 m]
    A --> E[Proximity to Fire Brigade (≤5 km)]
    A --> F[Main Gate: Width & Headroom ≥ 5m]
    G[Storage Area] --> H[Lighting: 70 lux, cables in conduits]
    G --> I[Lighting Height ≥ 1m above goods]
    G --> J[Cutout outside storage]
    K[Compound] --> L[Space for manufacturing, storage, utilities]
    K --> M[Free of combustible materials]

This summary ensures compliance with IS 9109 for safe, accessible, and well-lit factory layouts and roads.

IS 9109: Site Requirements Summary

• Compound Size & Layout (Clause 5.1):

  • Must accommodate manufacturing, storage, utility buildings.
  • Allow space for future expansion.
  • Keep free of combustible materials (grass, weeds, vegetation).

• Building Construction (Clause 6.1):

  • Buildings must comply with IS 1641 (construction standards for industrial buildings).

• Minimum Distances (Clause 5.7):

  • Residential/office buildings ≥ 20 m from manufacturing buildings.

• Referenced Standards:

  • Definitions per IS 1303 and IS 8757 apply.

Key Specifications Table

Conceptual Layout Diagram

graph LR
  A[Manufacturing Building]
  B[Storage Section]
  C[Utility Buildings]
  D[Residential/Office Buildings]
  A ---|≥20 m| D
  A --- B
  B --- C
  subgraph Compound
    A
    B
    C
    D
  end

This ensures safe distances, clean site conditions, and compliance with construction norms.

IS 9109: Key Building Construction Specifications & Tables

1. Building Location & Construction (Clauses 5.7 & 6)

• Minimum distance between residential/office buildings and manufacturing buildings: 20 m.
• Buildings within compound must comply with IS 1641 (fire safety construction).
• Roofs:
  • Directly supported on walls, no intermediate columns.
  • Roof covering: lightweight & fire-resistant.
  • Corrugated iron sheets: galvanized or aluminium painted.
  • Corrugated asbestos sheets inserted every 6 m near walls for firefighting access.
  • Roof paint: fire-retardant only.
  • Roofs must be leak-proof; no equipment supported on them.
  • Skylights must be glazed glass.

2. Storage Inside Buildings (Clause 16.2)

• No combustible contents allowed in storage sections besides the stored material.

3. Outdoor Storage of Paint/Varnish with Flammable Liquid Base (Table 1, Clause 15.6)

Summary Diagram: Roof Support & Fire Access

graph TD
  Wall --> Roof[Roof directly supported on wall]
  Roof --> CorrugatedSheets[Corrugated iron/asbestos sheets every 6m]
  Roof --> Skylight[Glazed skylight]
  Roof -.-> FirePaint[Fire-retardant paint]

**Use IS 9109 & IS

IS 9109: Doors, Windows, and Exits Key Points

Doors (Clause 7.1, 7.2)

• Material: Non-combustible, self-closing, fireproof per IS 3614 (Part 1).
• Number: Minimum 2 doors per room, more if possible.
• Protection: Doors must be protected from vehicle impact.
• Ventilation Doors: Must open to the outside.

Windows (Clause 7.4)

• Glass: Use 3 mm wired glass where explosion risk exists.
• Operation: Hinged or pivoted to open outwards.
• Safety: Equipped with devices to prevent inward opening during explosions.

Summary Table

flowchart LR
    Room -->|At least 2| Doors
    Doors -->|Fireproof, Self-closing| IS3614
    Doors -->|Protected from vehicles| Protection
    Room --> Windows
    Windows -->|3mm wired glass| ExplosionRisk
    Windows -->|Open outwards| SafetyDevice

This ensures safety against fire, explosion, and mechanical damage as per IS 9109.

IS 9109: Process Tanks and Covers - Key Points & Specifications

1. Process Tanks (Clause 10.1 & 15.1)

• Elevation: Tanks/vats must be ≥ 15 cm above floor level to prevent water ingress during firefighting.
• Material: Must be metal, gas-tight construction.
• Venting: Provide vents to allow normal filling/emptying and to safely relieve internal pressure during fire.
• Containment: Surround tanks with bunds high enough to hold 100% of tank contents or provide drainage to a safe burn area if bunds are not feasible.
• Isolation: No bunds needed if tank is isolated and no adjacent fire risk exists.

2. Covers (Clause 10.2)

• Covers must be metal and manually closable during fire.
• Covers should overlap tank sides by ≥ 25 mm.
• Preferably, covers have a downward flange around the tank for a better seal.

3. Ventilation (Clause 9.2)

• For drying with heating, provide pre-ventilation before heating starts to avoid hazardous buildup.

Summary Table

flowchart LR
    A[Process Tank] --> B[Metal, Gas-tight]
    A --> C[Elevated ≥15cm]
    A --> D[Venting for pressure relief]
    A --> E[Bund or Drainage]
    A --> F[Metal Cover]
    F --> G[Overlap ≥25mm]
    F --> H[Downward flange preferred]
    I[Drying with Heating] --> J[Pre-ventilation before heating]

This ensures safety from fire hazards and operational reliability per IS 9109.

IS 9109 Key Points on Tank Storage and Drainage

Tank Storage (Clause 15.1)

• Tanks must be metal, gas-tight, with venting for:
  • Normal filling/emptying
  • Pressure relief during fire
• Tanks surrounded by bunds to hold entire contents if leakage occurs.
• Alternatively, adequate drainage can be provided to carry liquid to safe burning area if no bunds.
• No bunds needed if tank is isolated and no adjacent fire risk.

Overflow Pipes (Clause 11.1 & 11.2)

• Tanks ≥700 litres or ≥1 m² surface area require overflow pipes.
• Overflow pipe size must drain ≥900 litres/min (to handle sprinkler water).
• Multiple overflow pipes can be combined into one pipe with equivalent total cross-sectional area:

[ A_{total} = \sum A_i ]

Bottom Drains (Clause 12.1)

• Tanks >2200 litres must have bottom drains to empty tank during fire.
• Drains can be manual or automatic.
• Manual drains must be safe and accessible.
• If gravity drainage impractical (due to viscosity or layout), provide automatic pumps.

Summary Table:

flowchart LR
    Tank["Tank (Metal, Gas-tight)"]
    Vent["Venting for pressure relief"]
    Bund["Bund (Contain entire content)"]
    Drain["Bottom Drain (Manual/Auto)"]
    Overflow["Overflow Pipe (≥900 L/min)"]

    Tank --> Vent
    Tank --> Bund
    Tank --> Drain
    Tank --> Overflow

This ensures safe storage and emergency drainage per IS 9109.

IS 9109: Electrical Installations and Lighting – Key Points

1. Lighting Installation Requirements (Clause 13.7)

• Cables: Enclosed in heavy gauge screwed conduits in godowns/storage areas.
• Lamps: Use red pendants with well-glasses for protection.
• Height: Lighting fixed ≥ 1 m above highest stored goods.
• Cutout: Positioned outside the godown/storage area for safety.

2. Illumination Levels (Clause 14)

3. Wiring and Control (Clauses 13.1, 13.2, 13.4)

• All wiring per IS 1646.
• Use heavy gauge screwed conduit for wiring.
• Lighting fittings and switches must be enclosed type.
• Remote control switches:
  • Located 1.25 m outside nearest doorway.
  • Centralized switch points (e.g., office/watchman's cabin) allowed for total factory shutdown.

Summary Diagram of Lighting Setup in Godown

graph TD
    A[Power Supply] --> B[Cutout outside godown]
    B --> C[Heavy gauge screwed conduit]
    C --> D[Red pendant lamp with well-glass]
    D --> E[Light fixed ≥1m above stored goods]
    F[Remote switch 1.25m outside door] --> B

This ensures safety, adequate illumination, and easy control per IS 9109 standards.

IS 9109: Key Storage Specifications for Paints & Varnishes

1. Outdoor Storage (Clause 15.6 & Table 1)

2. Indoor Storage (Clause 16.2 & 16.4)

• No other combustible materials allowed in storage sections.
• Buildings must have adequate ventilation to prevent flammable/toxic vapor accumulation, especially for liquids with flash points < 26°C.

3. Tank Storage (Clause 15.1)

• Tanks must be metal, gas-tight, with venting for pressure relief during filling, emptying, or fire.
• Surrounded by bunds to contain full tank volume or have drainage to safe burn areas.
• No bunds needed if tanks are isolated and no adjacent fire hazard exists.

Summary Diagram

flowchart LR
    A[Outdoor Storage] --> B{Class A/B/C}
    B --> C[Max Litres & Height per Table 1]
    A --> D[Min Distances Between Piles, Property, Streets]
    E[Indoor Storage] --> F[No other combustibles]
    E --> G[Adequate Ventilation]
    H[Tank Storage] --> I[Metal, Gas-tight]
    H --> J[Venting & Bunds or Drainage]

This ensures safe storage distances, ventilation, and containment to minimize fire and health hazards.

IS 9109: Storage Inside Building – Key Points & Tables

1. Storage Inside Building (Clause 16)

• No other combustible contents allowed in the building/section used for storage (Clause 16.2).
• Manufacturing/storage buildings should be single-storeyed, max height 10 m (Clause 6.1.7).
• Wooden flooring is prohibited unless laid on concrete/masonry without space.

2. Storage of Liquid Paint/Varnish (Clause 15.6 & Table 1)

3. Tank Storage (Clause 15.1)

• Tanks: metal, gas-tight, with venting for filling, emptying, and pressure relief.
• Tanks must be surrounded by bunds to contain full contents in case of leakage.
• Alternatively, provide drainage to a safe burning area if bunds are not feasible.
• No bunds needed if tanks are isolated without exposure risk.

Summary Diagram: Storage Layout Concept

graph LR
  A[Storage Building] --> B[No other combustibles]
  A --> C[Max height 10m]
  A --> D[Concrete/Masonry floor only]
  E[Paint Storage] --> F[Containers max volume & height]
  E --> G[Portable tanks max volume & height]
  E --> H[Min distances between piles & property lines]
  I[Tanks] --> J[Metal, gas-tight]
  I --> K[Venting

IS 9109 - Drum Storage and Handling: Key Points

Drum Storage Limits & Arrangement (Clauses 17.4 & 1.5)

• Maximum stack capacity: 4,500 litres per stack.
• Aisle width between stacks: Minimum 1.5 m for safe access and separation.

Drum Positioning (Clause 17.5)

• Drums stored on their side to prevent rainwater ingress and corrosion.

Ventilation Requirements (Clause 16.4)

• Buildings must have adequate ventilation to avoid accumulation of flammable or toxic vapors.
• Special attention for liquids with flash point < 26°C and combustible dust.

Summary Table

flowchart LR
    A[Drum Stack (≤ 4500 L)] -->|Separated by| B[Aisle (≥ 1.5 m)]
    A --> C[Drums stored on side]
    D[Building] --> E{Ventilation}
    E -->|Flash point < 26°C| F[Special attention]

This ensures safe storage, handling, and minimizes risks of corrosion and fire hazards.

IS 9109 – Maintenance and Housekeeping: Key Points

1. Storage Area Safety (Clause 17.9)

• Open storage areas must be fenced and access restricted.
• No smoking or naked flames allowed near storage.

2. Storage of Liquid Paints & Varnishes (Clause 15.6)

• Follow Table 1 for safe storage quantities and conditions.
• Typically includes:
  • Maximum allowable quantity per storage unit.
  • Storage temperature limits.
  • Ventilation requirements.

3. Periodic Testing & Inspection (Clause 20.6)

• Develop periodical test schedules for:
  • Equipment.
  • Processes.
  • Safety facilities.
• Ensure documented inspections for compliance.

4. Fire Prevention & Housekeeping (Clause 25.3)

• Fire prevention measures must be:
  • Designed in consultation with local fire authorities.
  • Checked at least monthly.
• Report and rectify any irregularities immediately.

Typical Table 1 Snapshot (Liquid Paint Storage):

flowchart LR
    A[Open Storage Area] -->|Fenced & Restricted| B[Safety Compliance]
    B --> C{No Smoking / Naked Lights}
    C -->|Yes| D[Allowed]
    C -->|No| E[Prohibited]
    F[Periodic Testing] --> G[Monthly Fire Checks]
    G --> H[Report & Remedial Action]

Summary: Maintain strict fencing, control ignition sources, follow storage limits (Table 1), schedule regular tests, and implement monthly fire safety reviews for effective maintenance and housekeeping per IS 9109.

IS 9109 – Fire Hazard Controls in Processes: Key Specifications & Formulas

Key Provisions:

• Fire & Accident Signage (Clause 22.2):
  Display clear signs marking hazardous process zones to warn personnel.

• Personal Protective Equipment (Clause 23):
  Provide and maintain breathing apparatus and fire suits to protect against harmful inhalation/contact.

• Waste Handling (Clause 18.2):
  Store oil/solvent-soaked waste in closed metal cans; dispose at least once per shift.

• Temperature Control & Alarm (Clause 19.16):
  Use fail-safe temperature monitoring (automatic/manual) with excess temperature alarms to prevent fire hazards.

• Fire Protection Arrangements (Clause 25):
  Design buildings, select materials, and install electrical equipment to minimize fire/explosion risks. Provide suitable firefighting facilities.

Practical Fire Safety Measures Summary:

Diagram: Fire Hazard Control Flow

flowchart LR
    A[Process Zone] --> B[Hazard Signage]
    A --> C[Temperature Monitoring]
    C --> D{Temperature > Limit?}
    D -- Yes --> E[Alarm Activation]
    D -- No --> F[Normal Operation]
    A --> G[Waste Collection]
    G --> H[Closed Metal Cans]
    H --> I[Daily Disposal]
    A --> J[PPE Provided]
    A --> K[Firefighting Equipment]

Summary: IS 9109 emphasizes clear hazard signage, strict PPE use, controlled waste management, fail-safe temperature control with alarms, and well-planned fire protection to reduce fire risks in paint/varnish factories.

IS 9109 – Oven and Heating Equipment Safety: Key Points

• Temperature Monitoring & Control (Clauses 19.16, 20.2, 20.3):

  • Oven must be constantly watched during operation.
  • Provide excess temperature alarm to alert operators.
  • Use automatic temperature control to prevent exceeding safe limits.
  • Interlock system to shut off heating medium if temperature exceeds preset limit.
  • Fail-safe methods (automatic/manual) for temperature control at each process stage.

• Flame Safety (Clause 21.3):

  • Flames under kettles must be shielded unless electric/muffled furnace is used.
  • Fire lighting should be done from opposite side of partition and behind kettles for safety.

Typical Safety Control System (Conceptual)

flowchart LR
    A[Temperature Sensor] --> B[Controller]
    B -->|Normal Temp| C[Heating Medium ON]
    B -->|Excess Temp| D[Alarm Activated]
    D --> E[Heating Medium OFF]
    E --> F[Operator Intervention]

Summary Table: Temperature Safety Features

Ensure compliance with these clauses to maintain operational safety and prevent overheating hazards.

IS 9109 Key Points on Fire Prevention, Detection, and Fighting Arrangements

Fire Prevention & Signage (Clause 22.2)

• Display dangerous process zone signs clearly to warn personnel.

Protective Equipment (Clause 23)

• Provide and maintain:
  • Breathing apparatus
  • Fire suits
• Ensure protection from inhalation/contact with harmful substances.

Fire Fighting Water Supply (Clause 25.10)

• Use fire hydrants and static water tanks.
• At least 50% of water supply must be from static tanks.
• Static tanks should be within 180 m of buildings/risks.

Fire Brigade Coordination (Clause 25.12)

• Maintain close liaison with local fire brigades.
• Conduct regular fire drills.
• Factory must provide special equipment if not available with fire brigade.

Fire Fighting & Rescue Procedure (Clause 25.15)

• Prepare, regularly practice, and update emergency procedures.

Useful Reference IS Codes (Annex A)

Summary Table: Fire Water Supply Specification

flowchart LR
    A[Fire Risk Area] -->|Within 180 m| B[Static Water Tank]
    A -->|Hydrant Network| C[Fire Hydrants]
    B & C --> D[Fire Fighting System]
    D --> E[Fire Brigade Coordination]
    E --> F[Emergency Procedures & Drills]

Note: For detailed design, consult IS 1641, IS 1646, IS 2190, and IS 3614 as referenced.