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Fire Safety on Construction Sites

Fire Risk in Construction​

Construction sites present significant fire risks due to:

  • Hot work (welding, cutting, grinding)
  • Flammable and combustible materials (timber, formwork oil, solvents, LPG, acetylene)
  • Ignition sources (temporary electrical, power tools, smoking)
  • Combustible waste accumulation (packaging, off-cuts, sawdust)
  • Incomplete fire protection systems (building under construction)

[!warning] Critical Fire Risks Construction sites are particularly vulnerable because:

  • Fire detection/suppression systems not yet operational
  • Multiple ignition sources present
  • Large quantities of combustible materials
  • Hot work occurring throughout site
  • Escape routes may be incomplete

Reference: Code of Practice: Construction work

Fire Prevention​

Control Combustible Materials​

Minimize accumulation:

  • Keep only lowest quantity of combustible/flammable materials needed on site
  • Daily cleanup of combustible waste (off-cuts, packaging, sawdust)
  • Designated storage areas away from ignition sources
  • Clear exit and escape routes
  • Adequate rubbish bins and recycling bins

Separate incompatible materials:

  • Flammable liquids (solvent, petrol) stored separately from oxidizers (oxygen cylinders)
  • LPG and acetylene cylinders stored in separate, well-ventilated areas
  • Distance from hot work areas

[!example] Construction Site Housekeeping Large commercial construction site implements daily cleanup requirement:

  • Each trade cleans own work area at end of shift
  • Timber off-cuts placed in designated bin (emptied daily)
  • Cardboard/packaging collected to skip bin
  • Sawdust vacuumed from carpentry area
  • Flammable substances returned to external storage cage
  • Result: Combustible load minimized, fire risk reduced

Safe Storage of Flammable/Combustible Substances​

Flammable liquids (petrol, solvents, thinners, formwork oil):

  • External storage in ventilated, fire-rated cabinet or cage
  • Away from ignition sources, buildings, boundaries
  • Grounded containers to prevent static ignition
  • "FLAMMABLE" signage
  • Spill containment (bunding)

LPG cylinders:

  • External storage in well-ventilated, fenced compound
  • Upright, secured
  • Separated from acetylene and oxygen (5m minimum)
  • Protected from sun (temperature limits)
  • "LPG" signage

Oxygen and acetylene cylinders:

  • Separate storage (oxygen is oxidizer, acetylene is fuel gas)
  • Secured upright
  • Protected from impact
  • Flashback arrestors fitted to regulators

Fuel for plant/equipment:

  • Diesel storage in bunded area
  • Refueling in designated area (not near ignition sources)
  • Spill kits available

Control Ignition Sources​

Hot work (welding, cutting, grinding, soldering):

  • Hot work permit system for high-risk areas
  • Clear area of combustible materials (minimum 10m radius, or use fire blankets/curtains)
  • Fire extinguisher immediately available (9kg ABE minimum)
  • Fire watch during and after hot work (minimum 30 minutes after completion)
  • Check for smoldering materials, penetrations to other areas

Electrical:

  • Temporary electrical installations by licensed electrician
  • Cables positioned to avoid damage (elevated or protected)
  • RCDs on all portable equipment
  • Regular testing and tagging
  • Avoid overloading circuits

Smoking:

  • Designated smoking areas only
  • Away from flammable substances, combustible materials
  • Cigarette butt disposal bins provided

Open flames:

  • Prohibited except for authorized hot work
  • LPG heaters (if used) positioned away from combustibles, well-ventilated

Fire Fighting Equipment​

Fire Extinguishers​

Type and placement:

  • ABE (dry chemical powder): General purpose, suitable for most construction fire risks
    • Class A (ordinary combustibles - wood, paper)
    • Class B (flammable liquids - petrol, oil, paint)
    • Class E (electrical fires)
  • Minimum 9kg ABE extinguishers
  • Distribution: Maximum 15m travel distance to nearest extinguisher

Locations:

  • Near each exit/stairwell
  • At hot work areas (immediately available)
  • Near flammable substance storage
  • At site office, amenities, first aid room
  • On plant (excavators, cranes)

Maintenance:

  • Inspected monthly (pressure gauge, condition)
  • Serviced annually by technician
  • Test tag displayed
  • Not blocked or hidden

[!example] Hot Work Fire Extinguisher Requirement Welder performing cutting work on steel structure:

  • 9kg ABE extinguisher positioned within 3m of work area
  • Area cleared of combustibles (10m radius)
  • Fire blanket available
  • Fire watch assigned (checks during work and 30 min after completion)
  • No smoldering detected, area safe

Fire Hose Reels and Hydrants​

If building has fire hose reels/hydrants:

  • Ensure accessible (not blocked by materials, equipment)
  • Test functionality
  • Mark clearly

Temporary fire water supply:

  • Large sites may install temporary hydrants connected to site water
  • Hose reels at strategic locations
  • Coordinate with fire brigade (access, water supply points)

Fire Blankets​

Use:

  • Smothering small fires (particularly flammable liquid spills)
  • Protecting combustibles during hot work
  • Wrapping person whose clothing on fire

Locations:

  • Hot work areas
  • Areas with flammable liquid use (painting, thinning)

Emergency Evacuation​

Escape Routes​

Maintain clear, accessible escape routes:

  • Minimum width maintained (no materials, equipment blocking)
  • Clearly marked (signage, lighting)
  • Two means of egress from each area where practicable
  • Protected from falling objects (overhead protection if required)

Stairways:

  • Non-slip surfaces
  • Handrails installed
  • Adequate lighting (including emergency lighting)
  • Not used for storage

Exits:

  • Clearly signed ("EXIT")
  • Open outward
  • Not locked (can be opened from inside without key)

Assembly Points​

Designated assembly point(s):

  • Located safe distance from buildings (minimum 30m)
  • Clear of vehicle/plant access routes
  • Marked with signage
  • Known to all workers (site induction)

Multiple assembly points: Large sites may have multiple assembly points (different zones).

Emergency Response Procedures​

Fire Discovered​

Immediate actions:

  1. Activate alarm (air horn, siren, or verbal alert "FIRE! FIRE!")
  2. Evacuate immediate area
  3. Call 000 (Fire Brigade)
  4. Attempt to extinguish only if:
    • Fire small (less than 1m²)
    • You have appropriate extinguisher immediately available
    • You have training in extinguisher use
    • Safe to do so (escape route clear)
    • Never put yourself at risk
  5. If fire too large or spreading: Evacuate immediately

Site supervisor actions:

  • Ensure 000 called
  • Ensure all workers evacuating
  • Direct workers to assembly point
  • Conduct headcount at assembly point
  • Inform fire brigade on arrival (location of fire, hazards present, all persons accounted for)

Fire Drills​

Conduct regular fire drills:

  • At least every 6 months
  • After significant changes to site layout
  • When new workers commence (large numbers)

Drill procedure:

  1. Sound alarm (unannounced)
  2. All workers evacuate to assembly point
  3. Supervisors conduct headcount
  4. Debrief (timing, issues, improvements)

Record:

  • Date and time
  • Who participated
  • Evacuation time
  • Issues identified
  • Actions for improvement

Procedures for Managing Fire Risks​

Hot Work Permit System​

When required:

  • Hot work in areas with flammable substances, combustible materials, or confined spaces
  • Any welding, cutting, grinding, soldering near fire risks

Permit includes:

  • Description of work
  • Location
  • Hazards identified
  • Controls implemented:
    • Area cleared of combustibles
    • Fire extinguisher available
    • Fire watch assigned
    • Fire blanket/curtains if needed
  • Authorized by competent person (supervisor, WHS coordinator)
  • Fire watch sign-off after completion

Validity: Single shift or specific time period.

Flammable Substance Management​

Procedures:

  • Minimum quantities on site
  • Storage requirements (external, ventilated, separated, bunded)
  • Handling (grounding, ventilation, no ignition sources)
  • Dispensing (designated area, spill containment)
  • Waste disposal (empty containers, contaminated materials)
  • Emergency response (spill kits, fire extinguishers)

Waste Management​

Daily removal:

  • Combustible waste (timber off-cuts, packaging, paper)
  • Regular skip bin collection
  • No accumulation in work areas, escape routes

Segregation:

  • Combustible waste separate from general waste
  • Hazardous waste (paint, solvent) separate disposal

Site-Specific Fire Safety Plan​

Included in WHS Management Plan:

  • Fire risks identified
  • Fire prevention measures
  • Fire fighting equipment locations
  • Evacuation procedures and assembly points
  • Emergency contacts (Fire Brigade, site management)
  • Hot work permit procedures
  • Flammable substance management procedures
  • Training requirements
  • Inspection and maintenance schedules

Training​

All workers must be trained in:

  • Fire risks on site
  • Fire prevention (housekeeping, hot work precautions)
  • Location of fire extinguishers and assembly points
  • Evacuation procedures
  • How to raise alarm
  • When and how to use fire extinguisher (if trained)

Site induction includes:

  • Fire safety procedures
  • Evacuation routes and assembly points
  • Smoking policy
  • Hot work requirements

Fire extinguisher training:

  • Workers performing hot work should receive hands-on extinguisher training
  • Practice using extinguisher on controlled fire

Inspection and Maintenance​

Regular inspections:

  • Daily: Supervisors check escape routes clear, extinguishers in place
  • Weekly: WHS coordinator checks fire equipment, flammable storage, waste management
  • Monthly: Detailed inspection (extinguisher pressure, signage, emergency lighting)

Maintenance:

  • Fire extinguishers serviced annually
  • Emergency lighting tested monthly (functionality)
  • Escape routes maintained
  • Signage replaced if damaged

Records:

  • Inspection checklists
  • Maintenance records
  • Fire drill records
  • Hot work permits

Practical Construction Examples​

Example 1: Multi-Storey Commercial Building Construction​

Fire risks:

  • Hot work (welding structural steel, cutting)
  • Timber formwork and scaffolding
  • Flammable substances (formwork oil, paint, solvents)
  • Incomplete fire stairs and sprinkler system

Controls implemented:

  1. Hot work permit system:

    • All hot work requires permit
    • Area cleared, fire watch assigned
    • 9kg ABE extinguisher at each hot work location

  2. Flammable storage:

    • External cage, 20m from building
    • LPG and oxygen/acetylene in separate fenced areas

  3. Fire extinguishers:

    • 9kg ABE at each stair landing
    • 9kg ABE near site office, amenities, first aid
    • 9kg ABE on each level (max 15m travel distance)

  4. Escape routes:

    • Fire stairs maintained clear
    • Temporary signage: "FIRE EXIT"
    • Emergency lighting installed

  5. Assembly point:

    • Adjacent park, 50m from building
    • Sign: "ASSEMBLY POINT - FIRE EMERGENCY"

  6. Waste management:

    • Daily timber off-cut removal
    • Skip bin emptied twice weekly

  7. Fire drills:

    • Conducted monthly
    • Evacuation time: 4 minutes (150 workers)

Result: No fire incidents during 18-month construction. Strong fire safety culture.

Example 2: Residential Housing Construction (Timber Frame)​

Fire risks:

  • Highly combustible timber framing
  • Hot work (welding, cutting roof steel)
  • Sawdust accumulation
  • LPG for heating/cooking (temp amenities)

Controls implemented:

  1. Timber off-cut management:

    • Bin on each lot
    • Collected to skip bin at end of each day
    • Sawdust vacuumed from carpentry cutting station

  2. Hot work (roof steel cutting):

    • Fire blanket placed under cutting area
    • 9kg ABE extinguisher immediately available
    • Spotter checks for smoldering timber (30 min after work)

  3. LPG storage:

    • Cylinders in external fenced compound
    • 10m from nearest building
    • Signage: "LPG - NO SMOKING"

  4. Fire extinguishers:

    • 9kg ABE at site office/amenities
    • 9kg ABE on each house under construction
    • Extinguishers moved as work progresses

  5. Smoking:

    • Designated smoking area (lunch shelter, 15m from houses)
    • Cigarette butt bin provided

  6. Assembly point:

    • Street frontage (safe distance)

Result: Minor fire ignited from grinding sparks (smoldering timber off-cut discovered by spotter 20 min after grinding). Extinguished with fire extinguisher before spread. Hot work procedures reinforced.