Fire Protection Guideline for Packhouse and Fruit Cold Storage Facility

Author: Post-Harvest Innovation Programme (PHI)

Tags: Cold Storage, Fire Safety, Insurance Guidelines, Occupancy Classification, Packhouse Design, Postharvest Infrastructure, Risk Management, SANS Compliance

Publish Date: 2024-07-10

Keywords: Fire Protection, SANS 10400, SANS 10287, D3 Occupancy, J3 Storage, Fire Detection Systems, Structural Stability, Smoke Control

Introduction
Occupancy Classifications
Summary of Requirements for Fruit Store Applications
- 3.1 Packing Store
- 3.2 Cold Stores
- 3.3 Dry Material Stores
Concept Fire Protection and Insurance Guideline
- 4.1 Packing Stores
- 4.2 Cold Stores
- 4.3 Dry Material Stores

Introduction

Packhouse operators face challenges in achieving occupancy certificates. Compliance with SANS building codes and insurance requirements is necessary. Due to perceived gaps in SANS codes, insurance companies often set their own minimum standards. This guideline provides both the minimum SANS requirements and the perspective of insurance companies.

The facility is typically divided into three sections:

Packing store
Cold store
Dry material store

This document is a guideline for understanding fire requirements and concepts for fruit packhouse and cold storage facilities, based on SABS codes and insurance perspectives. Further research and surveys are documented in a separate Design Report.

Occupancy Classifications

Understanding occupancy classifications is crucial for determining fire requirements. Disagreements on classification can have significant financial impacts.

Classifications:

Code	Type	Description
D1	High risk industrial	Industrial process with materials/processes liable to cause rapid combustion, fumes, or explosions.
D2	Moderate risk industrial	Industrial process with moderate combustion risk, unlikely to cause fumes or explosions.
D3	Low risk industrial	Industrial process not falling into high or moderate risk. Most packhouses/stores are D3.
J1	High risk storage	Storage of materials liable to rapid combustion, fumes, or explosions (e.g., dry goods stores).
J2	Moderate risk storage	Storage of materials with moderate combustion risk (e.g., plastic bins).
J3	Low risk storage	Storage not falling into high or moderate risk (e.g., cold stores, freezer rooms).

Summary of Requirements for Fruit Store Applications

Requirements are based on SANS 10400, SANS 10287, and insurance company standards.

3.1 Packing Store

Insulated panels: Test per SANS 10177:5 for combustibility. If combustible, follow SANS 428.
Structural stability: Elements supporting fire walls must have tested stability for specified periods (min. 30 min).
Escape routes: Reach an emergency route or escape door within 45m to avoid required sprinklers.
Escape route width: Not less than 1m (1.5m if used by disabled persons).
Fire detection: Required for D3 occupancy if floor area > 5000 m².
Fire equipment: Hydrants, hose reels, and extinguishers required throughout.
Automatic fire systems: Required if building > 30m high or stacking heights per SANS 10287 require it.
Smoke control:
- For divisions 500–2500 m² or single storey: roof ventilators/openable windows.
- For divisions >2500 m²: mechanical/natural smoke ventilation per EN 12101.
Sprinklers: May be required depending on building size.
Audits: Yearly audits by risk surveyors.

3.2 Cold Stores

Insulated panels: Test per SANS 10177:5; follow SANS 428 if combustible.
Structural stability: Elements supporting fire walls must have tested stability (min. 30 min).
Escape routes: Reach emergency route or escape door within 45m.
Escape route width: Not less than 1m (1.5m if used by disabled persons).
Fire detection: J2 requires detection throughout; J3 requires it if floor area > 5000 m².
Fire equipment: Hydrants, hose reels, and extinguishers on external walls where practical.
Automatic fire systems: Required if building > 30m high or stacking heights per SANS 10287 require it.
Sprinklers: Required in roof voids >800 mm high and compartment area >100 m² if cold store requires sprinklers.
Sprinklers: Mostly required between roof and ceilings.
Audits: Yearly audits by risk surveyors.

3.3 Dry Material Stores

Structural stability: Elements supporting fire walls must have tested stability (J1: 60 min, J2: 30 min for single storey).
Escape routes: Reach emergency route or escape door within 45m.
Escape route width: Not less than 1m (1.5m if used by disabled persons).
Fire detection: Required throughout for J1 and J2.
Fire equipment: Hydrants, hose reels, and extinguishers required throughout.
Automatic fire systems: Required if building > 30m high or stacking heights per SANS 10287 require it.
Smoke control:
- For divisions 500–2500 m² or single storey: roof ventilators/openable windows.
- For divisions >2500 m²: mechanical/natural smoke ventilation per EN 12101.
Sprinklers: Mostly required due to high risk.
Audits: Some insurers may require monthly audits.

Concept Fire Protection and Insurance Guideline

4.1 Fire Protection Guidelines for Packing Stores

4.1.1 Definitions

Access door: Entrance to an emergency route.
Common path of travel: Part of escape route leading to only one exit/access/escape door.
Emergency route: Escape route with 120 min fire protection leading to an escape door.
Escape door: Door at ground level leading directly outside or to an open space.
Escape route: Path from furthest point in any room to nearest escape door, may include emergency route.
Exit door: Door as part of an escape route from any room.
Feeder route: Part of escape route allowing travel in two directions to at least two emergency routes.
Fire rated wall: Wall that can resist fire for a specified time.
Fire retardant: Material treated to slow ignition/burning or self-extinguish.
Fire resistant: Material designed to be non-flammable and self-extinguish under heat.

4.1.2 Occupancy Classifications and Separations

Packing stores: D3 (Low Risk Industrial) if machinery/packing line present; J3 (Low Risk Storage) if only storage.
Cold store may be inside another occupancy (D2 or D3).
J2 and J3 areas may not exceed 300 m² within another occupancy.
60 min fire wall required between office (G1) and processing area (D3), and between dry material store (J2) and processing area (D3).

4.1.3 Insulated Panels

Test per SANS 10177:5 for combustibility; follow SANS 428 if combustible.
Without sprinklers/smoke control, ceiling area between insulated panels and roof must be divided:
- Combustible panels: max 250 m², fire stops every 20m.
- Non-combustible panels: max 500 m², fire stops every 30m.

4.1.4 Structural Fire Stability

Elements supporting fire walls must have tested stability.
- Single storey: D3, J2, J3 require 30 min.
- Double storey: J2 requires 60 min, J3 30 min.

4.1.5 Travel Distance and Escape Doors

If travel distance to escape door >45m, provide two or more escape routes, each with an emergency route.
Emergency route travel distance <45m (or <60m with sprinklers).
Common path of travel must not exceed 35m.
Rooms with >25 people require at least two exit doors.

4.1.6 Width of Escape Routes

Refer to SANS 10400 Part T 4.21.

4.1.7 Fire Detection

J2: Detection throughout.
J3: Detection if floor area >5000 m².
D3: Detection if floor area >5000 m².

4.1.8 Fire Hose Reels, Hydrants, and Extinguishers

Hose reels: Any building >250 m² or two+ storeys, at 1 per 500 m².
Hydrants: Any building >12m high or >1000 m², at 1 per 1000 m².
Extinguishers: J2 (1/100 m²), J3 (1/400 m²), D3 (1/200 m²), all 9kg dry chemical powder.

4.1.9 Fixed Automatic Fire-Fighting Systems

Required in buildings >30m high or basement >500 m².
D3 and J3: Not required solely by area, but may be triggered by stacking heights.
Sprinklers required if storage exceeds SANS 10287 limits or in voids >800 mm high and >100 m².
Refer to Design Report for goods category and stacking heights.

4.1.10 Smoke Control

500–2500 m² or single storey: roof ventilators/openable windows.
2500 m²: mechanical/natural smoke ventilation per EN 12101.

4.2 Fire Protection Guidelines for Cold Stores

4.2.1 Definitions

(Same as Packing Stores)

4.2.2 Occupancy Classification

J2: Moderate risk storage (material liable to moderate combustion, no fumes/explosions).
J3: Low risk storage (not high/moderate risk; ~90% of cold stores).
J2 and J3 areas may not exceed 300 m² within another occupancy.

4.2.3 Structural Fire Stability

Single storey: J2 and J3 require 30 min fire rated stability.

4.2.4 Travel Distance and Escape Doors

Same as Packing Stores.

4.2.5 Insulated Panels

Test per SANS 10177:5; follow SANS 428 if combustible.
Without sprinklers/smoke control:
- Combustible panels: max 250 m², fire stops every 20m.
- Non-combustible panels: max 500 m², fire stops every 30m.

4.2.6 Width of Escape Routes

Refer to SANS 10400 Part T 4.21.

4.2.7 Fire Detection

J2: Detection throughout.
J3: Detection if floor area >5000 m².

4.2.8 Fire Hose Reels, Hydrants, and Extinguishers

Hose reels: Any building >250 m² or two+ storeys, at 1 per 500 m².
Hydrants: Any cold store >12m high or >1000 m², at 1 per 1000 m².
Extinguishers: J2 (1/100 m²), J3 (1/400 m²), all 9kg dry chemical powder.
Do not install inside cold rooms below 5°C (risk of freezing); install outside.

4.2.9 Fixed Automatic Fire-Fighting Systems

Required in buildings >30m high or basement >500 m².
J2: Max division area 2500 m² without fixed system; above this, install system or fire wall (60 min).
J3: No limit to division area for fixed system.
Sprinklers required in voids >800 mm high and >100 m² if cold store requires sprinklers.
Sprinklers required if storage exceeds SANS 10287 limits.
Sprinkler installations in cold-storage warehouses must be dried after use.
Sprinklers exposed to damage must have metal guards.

4.3 Fire Protection Guidelines for Dry Material Stores

4.3.1 Definitions