Report recommends new tactics for structural firefighters after a series of very large warehouse fires

A recent report analyzed the 2022 fire that destroyed a 1.2 million square-foot Walmart distribution center in Plainfield, Indiana, highlighting the unique challenges large warehouses present to firefighters. 

Warehouses this size is often referred to as "mega ware houses", and they can produce extremely large volumes of flammable fire gases. 

In metric terms, a ware house like the one analyzed, of  1,2 million square feet,  is equivalent to a warehouse of about 111,500 square meters. 

This report was recently reported on in an in-depth article on Firehouse.com, and we are also providing the original report by the US National Fallen Firefighters Foundation here below. 

In this link,Firehouse.com also reported on on the mayday calls made when two firefighters were temporarily unaccounted for in the analyzed 2022 warehouse fire.   

The incident underscored the rapid escalation of fire conditions, with significant property loss exceeding $500 million and near-miss situations for firefighters. 

The report emphasizes the need for specialized training, enhanced fire protection systems,  reevaluation of fire protection strategies, and the development of operational tactics prioritizing firefighter safety in such complex environments and more. 

The 2024 Mega-Warehouse Fire Incident Report, conducted by the National Fallen Firefighters Foundation, provides a comprehensive analysis of the fire that occurred at a mega-warehouse facility in Plainfield, Indiana, on March 15, 2022. The fire, which led to over $500 million in property loss, underscores the challenges and risks associated with mega-warehouses. 

Despite advanced fire protection systems and a robust response from the Plainfield Fire Territory (PFT), the incident resulted in the destruction of the facility. The report aims to provide critical lessons and recommendations to prevent similar occurrences in the future.

Read or download the report here

Here are some of the challenges, lessons learned and recommendations found in he complete report, as reported by FireHero.org:

Fire Response and Operational Challenges

The firefighting operations faced numerous obstacles. Upon arrival, the PFT was advised 55 employees were unaccounted for in structure. The cold smoke within the vast steel-framed structure severely limited visibility, complicating both search efforts and ventilation. 

Firefighters encountered difficulty locating and shutting down the appropriate sprinkler valves, as the building had 30 roof-level sprinkler systems and eight additional systems for the multi-level Pick Module. Communication issues further hampered coordination efforts within the large facility.

Despite the initial success of the sprinklers, the re-emergence of flames and rapid fire spread overwhelmed the fixed fire systems. Efforts to regain control by restarting the fire pumps proved ineffective. Eventually, a defensive firefighting strategy was adopted, but the fire consumed the entire facility, resulting in its total loss.

Critical Factors and Analysis

The report highlights several critical factors contributing to the fire’s escalation:

• Fire Protection Systems: While the facility was equipped with advanced fire suppression systems, including ESFR (Early Suppression Fast Response) sprinklers and CMDA (Control Mode Density Area) sprinklers, these systems failed to prevent the catastrophic fire.
• Vertical Fire Spread: Analysis suggests the fire likely smouldered undetected on upper levels for 30 to 40 minutes, potentially finding a path to ignite combustible goods above. The fire pumps were shut down just as this secondary fire began to develop, rendering the upper-level sprinklers ineffective.
• Complex Structural Configuration: The multi-level Pick Module, combined with a high combustible load, created an extremely challenging fire environment.
• Communication and Coordination: Difficulties in radio communication and challenges with fire pump operations impeded a timely and effective response.

Lessons Learned

The Plainfield incident provides several important lessons for the fire service and facility operators:

• Improved Training: Fire departments must recognize operations in large, complex warehouse environments far exceed standard training for residential and small commercial fire scenarios. The PFT frequently trained on this target hazard as their response area contains many such structures but was still overwhelmed by several factors.
• Pre-Fire Planning: Familiarity with building layouts, fire protection systems, and potential risks is essential. Fire departments should conduct regular pre-fire planning visits.
• Enhanced Fire Protection Standards: The report calls for a re-evaluation of fire suppression strategies, particularly for multi-level rack storage systems.
• Firefighting Tactics: Fire departments should be prepared to adopt a different approach to fighting fires in mega warehouses. Leaving automatic protection systems in service for longer periods than past best practice recommendations may be warranted. Consideration should be given to the weight sodden contents are placing on the module’s structural stability. The contents of the building contacted by smoke and water is most likely unsalvageable. Shifting to defensive tactics when conditions become unsafe or uncontrollable is advised.

Recommendations

The report offers several recommendations to enhance fire protection and response strategies for mega-warehouses:

1. Specialized Fire Training: Develop training programs specifically tailored to the unique dynamics of mega-warehouse fires.
2. Enhanced Fire Protection Systems: Reassess sprinkler design and fire suppression methods to better handle complex rack storage environments.
3. Communication Improvements: Invest in advanced communication technologies to overcome signal challenges within large steel structures.
4. Operational Strategies: Establish clear guidelines for when to maintain or shut down sprinkler systems during firefighting operations.
5. Prevention and Inspections: Conduct rigorous maintenance and inspections to identify and address vulnerabilities in fire protection systems.

Read or download the full report here