How to Strengthen Your Facility's Fire Protection and Monitoring Strategy for Warehouse Fires

Warehouses and distribution centers play an important role in supply chains across every industry. However, they also pose some of the most complex fire safety risks in the “built environment” (any human construction).

New research from the National Fire Protection Association (NFPA) reveals that U.S. fire departments responded to an average of 1,508 warehouse fires each year between 2018 and 2022. These fires resulted in approximately three civilian deaths, 19 injuries, and $323 million in property losses annually.

While sprinkler systems are required in many facilities, the raw data tells us that compliance alone isn't enough. Many warehouse fires occur not because there was no fire suppression, but because the systems in place weren't configured, maintained, or monitored properly for the specific hazards involved.

The problem isn't just outdated technology. It's an outdated understanding of how fast-moving and high-risk warehouse environments have become.

Today, we'll explore the top fire protection challenges that warehouse operators face today, how legacy systems can be insufficient in 2025, and how the right fire alarm monitoring solutions close the gaps in real-time visibility, code compliance, and emergency readiness.

What Makes Warehouses So Risk-Prone?

The NFPA's findings are a wake-up call: warehouse fires are not rare, and their financial impact is massive. But why do they keep happening - even in facilities that meet code?

The answer? It's the complex nature of warehouse operations. These are not static environments. Inventory changes weekly, packaging materials vary in combustibility, and floor layouts are routinely reconfigured to accommodate seasonal or contract-based shifts.

The result is a perfect storm for fire hazards:

1. High fuel load from stored goods and packaging
2. Limited prewetting effectiveness due to shrink-wrapped or encapsulated products
3. Obstructed water flow from tall racking systems and dense storage
4. Complexity in zoning and sprinkler coverage
5. Inconsistent inspection, testing, and maintenance (ITM)

Each of these problems represents a weak point in the fire protection strategy of even well-run warehouses.

1. Understanding Fire Loads and Commodity Classifications

Not all storage presents the same level of risk. That's why NFPA 13, the standard for sprinkler system design, includes a system for classifying stored commodities based on combustibility. These range from Class I (noncombustibles) to Group A Plastics (highly flammable, fast-burning materials).

In many warehouses - especially third-party logistics (3PL) hubs - different commodity types are stored side by side. Some facilities attempt to design sprinkler coverage to the “worst-case” classification.

Others try to zone storage areas based on hazard levels. But when products are swapped, relocated, or introduced without consulting fire protection engineers, the risk level can easily exceed what the sprinkler system was designed to handle.

If your sprinkler system no longer matches your inventory's hazard classification, you will very likely see fires spread faster than expected. That can exceed suppression capacity.

2. Prewetting Challenges with Encapsulated Goods

Most sprinkler systems rely on prewetting (spraying water in the fire's projected path to limit spread). However, this tactic doesn't work well when goods are encapsulated in plastic wrap or sealed packaging.

Products stored in shrink wrap, heavy polyethylene, or multi-layer cartons don't absorb water the way exposed materials do. That reduces the system's effectiveness and allows flames to reach higher temperatures before containment begins.

If you have encapsulated goods that make water-based suppression less effective, fires will gain momentum - even with sprinklers activated ahead of the fire's spread.

3. Obstructions Can Disable ESFR Sprinkler Systems

Early Suppression Fast Response (ESFR) sprinklers are widely used in warehouses because they discharge water at high velocity and activate earlier than standard sprinklers. Their effectiveness depends heavily on clear spray paths, though.

Tall pallet stacks, banners, signs, ductwork, and overhead lighting can all block water distribution, rendering even the most advanced systems ineffective.

Any obstructed discharge patterns compromise ESFR performance, meaning water never reaches the seat of the fire in time.

4. Inventory Changes Create Fire Design Mismatches

Warehouse storage configurations evolve frequently. A facility that was originally designed to store paper goods may now hold plastic toys, batteries, or flammable cleaning products.

Unfortunately, many warehouse operators fail to reevaluate fire protection systems after major changes in inventory or racking layout. This leads to compliance gaps, as the sprinkler system may not have sufficient density, zoning, or water supply to protect new hazards.

If inventory turnover is not matched by fire system reassessment, code violations, and high-risk zones go unnoticed.

5. Flammable Liquids and Gases: Beyond NFPA 13

When warehouses store flammable liquids or compressed gases, the fire risk increases dramatically - and so does the complexity of compliance.

These substances fall under different NFPA codes:

• NFPA 30 for flammable and combustible liquids
• NFPA 55 for compressed gases
• NFPA 400 for hazardous materials
• NFPA 58 for LP gas

Many facility managers mistakenly assume that meeting NFPA 13 is sufficient. In reality, storing these materials requires a multidisciplinary design that includes special ventilation, containment, and suppression methods.

Flammable liquids require more than just water-based suppression. If you don't follow the right procedures and meet the right codes, fires involving hazardous materials escalate even faster than normal.

6. The ITM Breakdown: When Systems Fail Quietly

Perhaps the most preventable source of fire suppression failure is inspection, testing, and maintenance (ITM). According to NFPA data, 79% of sprinkler system failures were due to maintenance lapses.

Common ITM problems include:

• Control valves left closed
• Corrosion in piping
• Undetected leaks
• Failing supervisory switches
• Outdated panel programming

NFPA 25 outlines strict requirements for weekly, monthly, and annual inspections. But even in well-staffed facilities, ITM records are often inconsistent - and system faults go unnoticed until it's too late.

Local-Only Fire Alarms Aren't Enough

Many warehouse fires are detected too late because the fire alarm panel only sounds locally. If no one is present to hear the alarm - or if the alarm is misunderstood - precious minutes are lost.

This is especially dangerous for facilities that:

• Operate at reduced capacity during off-hours
• Lack on-site fire watch personnel
• Rely on janitorial or non-technical staff overnight

Without centralized alarm reporting and supervisory monitoring, a building could be on fire for minutes - or even hours - before anyone responds.

These are the moments where remote fire alarm monitoring becomes indispensable.

Build a Complete Fire Protection System

A modern warehouse needs more than sprinklers and pull stations. It needs a fire monitoring and supervisory platform that offers:

• Zone-specific detection and alerting
• Remote visibility of system faults and alarms
• Real-time supervisory alerts (e.g., closed valves, pressure drops)
• Automated event logging for NFPA 25 compliance
• Multi-panel integration for large or multi-building facilities
• Redundant communication paths (fiber, cellular, IP, radio)

Together, these capabilities form the foundation of a resilient and proactive fire safety strategy. This is especially useful in facilities where inventory, hazards, and layouts are in flux.

Digitize Closes the Fire Protection Gaps in Warehouses

Digitize offers fire alarm monitoring systems that are purpose-built for large, complex facilities - like warehouses, logistics hubs, municipal storage centers, defense installations, and even decommissioned warships.

Prism LX Head-End Monitoring Platform

• UL/ETL 864-listed for life safety compliance
• Compatible with legacy and modern fire panels
• Supports zoning, color-coded alerting, and custom event labeling
• Real-time dashboard with data logs, system maps, and remote notifications
• Works with municipal radio networks and IP-based central stations

The Prism LX allows warehouse managers to see every alarm, fault, or supervisory signal as it happens - even across multiple buildings or alarm panel models.

Integration Without System Replacement

Digitize's hardware bridges legacy equipment with modern monitoring platforms. You don't need to replace your entire alarm system to get smarter monitoring. Just connect existing panels to Digitize mediation equipment.

This is particularly valuable for older warehouses where equipment works but lacks connectivity.

Supervisory Monitoring

Prism LX supports detailed supervisory alerts, including:

• Tamper switch activation
• Flow switch triggers
• Air pressure monitoring in dry systems
• Low water supply pressure alerts
• Main valve status

These are the silent failures that typically go unnoticed. When you work with Digitize, they won't be able to hide.

Inspection, Testing, and Maintenance (ITM) Support

Digitize systems automatically log:

• Alarm events
• Trouble conditions
• Reset acknowledgments
• Manual tests and drills

All data is timestamped and stored. This simplifies compliance with NFPA 25 and makes audits more straightforward for fire marshals and insurers.

Don't Wait for a Fire to Reveal Your System's Weaknesses

Fires move fast - faster than most warehouse operators expect. The difference between a contained incident and a catastrophic loss often comes down to detection, response, and communication.

Digitize helps make sure that:

• Fires are detected quickly
• Alarms reach the right people in real time
• Supervisory failures are addressed before they escalate
• System performance is always visible and logged

Ready to Modernize Your Warehouse Fire Monitoring?

If you're operating a warehouse, distribution center, or storage-heavy facility, the next fire safety upgrade you make shouldn't just be about more sprinklers or bigger panels. It should be about visibility, response, and control.

Digitize gives you the tools to:

• Upgrade monitoring without replacing your existing panels
• Support compliance with NFPA 13, 25, and 72
• Get alerts for trouble, supervisory, and alarm conditions
• Build a data-driven inspection and maintenance plan

Call us at 1-800-523-7232
Email info@digitize-inc.com

Your warehouse is a critical asset. Protect it with the visibility and reliability that it deserves.