Managing Fire Risks in Automotive Plants: From Press Shop to EV Battery Assembly

Automotive Industry: Manufacturing Process, Fire Hazards & Industry-Specific Fire Protection Systems

The automotive industry is one of the most complex manufacturing sectors, involving extensive use of flammable liquids, gases, batteries, plastics, electrical systems, robotic automation, and high-temperature processes. From metal forming and welding to automated painting and EV battery assembly, each stage presents unique fire and explosion risks.

With increasing automation, higher production density, and the rapid growth of electric vehicles (EVs), fire safety in automotive plants has become a critical business continuity and life safety requirement.

This article explains the basic automotive manufacturing process, identifies fire safety hazards at each stage, highlights major fire incidents, and details industry-specific fire protection systems as per national and international standards, concluding with Agni Raksha Niti as a one-stop fire safety solution.

Basic Automotive Manufacturing Process

Automotive manufacturing typically consists of the following stages:

1. Press Shop (Stamping & Forming)

2. Body Shop (Welding & Fabrication)

3. Paint Shop (Surface Preparation, Painting & Curing)

4. Engine & Powertrain Manufacturing

5. Battery Assembly & EV Manufacturing Areas

6. Trim, Chassis & Final Assembly (TCF)

7. Fuel Storage, Utilities & Warehousing

Each of these areas carries distinct fire loads and ignition sources, requiring process-specific protection.

Fire Safety Hazards in Different Automotive Processes

1. Press Shop (Stamping & Forming)

Fire Hazards:

• Leakage and accumulation of hydraulic oil and lubricants

• Overheating of press motors and bearings

• Electrical faults in high-load control panels

• Oil-contaminated metal scrap and waste

2. Body Shop (Welding & Body Assembly)

Fire Hazards:

• Sparks and molten metal from robotic and manual welding

• Hot work near combustible insulation, cables, or packaging

• Accumulation of welding fumes and residues

• Electrical failures in robotic welding systems

3. Paint Shop – Highest Fire Risk Area

The paint shop is universally recognized as the most fire-prone area in an automotive plant due to extensive use of flammable liquids, vapors, electrostatic equipment, and gas-fired ovens.

Fire & Explosion Hazards:

• Flammable paints, thinners, and solvents with low flash points

• Vapor accumulation inside spray booths

• Static electricity during electrostatic spray painting

• High-temperature curing ovens

• Flame failure or overheating of burners

• Inadequate ventilation or exhaust system failure

Paint Storage Hazards:

• Bulk storage of paints, solvents, and thinners

• Leakage from drums, IBCs, and pipelines

• Improper segregation of incompatible chemicals

• Non-fire-rated paint and solvent storage rooms

Gaseous Flooding Fire Protection for Automated Paint Booths

Modern automotive plants increasingly use fully automated robotic paint booths, which demand fast-acting, damage-free fire suppression systems.

Why Gaseous Flooding Systems Are Used

Gaseous fire suppression systems are preferred because they:

• Extinguish fire within seconds

• Do not damage sensitive robotic and electrostatic equipment

• Leave no residue, preventing paint contamination

• Rapidly control fire inside enclosed spray booths

Types of Gaseous Systems Commonly Used

• Clean Agent Systems (FK-5-1-12, HFC-227ea)

• Inert Gas Systems (IG-541, IG-55, IG-100)

• CO₂ Systems (used with strict life safety controls)

Integrated Detection, Shutdown & Suppression Sequence

A properly designed system operates as a fully integrated fire protection and process shutdown system.

Typical Sequence of Operation:

1. Fire Detection
   Multi-spectrum flame detectors or IR/UV detectors detect fire instantly, often with cross-zoned confirmation.

2. Pre-Discharge Alarm
   Audible and visual alarms activate, with time delay as per design standard.

3. Automatic Process Interlocks (Critical Step)
   Upon fire confirmation:

   • Immediate shut-off of paint supply to robotic spray guns

   • Automatic closure of paint feed and solvent line valves

   • Shutdown of electrostatic spray voltage

   • Emergency stop or parking of painting robots

   • Isolation of gas burners supplying paint curing ovens

   • Controlled shutdown of ventilation to retain agent concentration

4. Gaseous Agent Discharge
   Agent floods the booth and achieves the required extinguishing concentration.

5. Post-Discharge Safety
   Booth remains isolated until inspection and system reset.

This integration ensures fuel source isolation, which is essential to prevent re-ignition.

4. Engine & Powertrain Manufacturing

Fire Hazards:

• Cutting oils, lubricants, and coolants

• Oil mist generation during high-speed machining

• Hot engine testing operations

• Use of petrol or diesel during testing

5. Battery Assembly & EV Manufacturing Areas

With the growth of electric vehicles, battery fire hazards have become one of the most critical risks.

Battery Fire Hazards:

• Thermal runaway in lithium-ion batteries

• Short circuits during assembly and testing

• Overcharging and overheating

• Mechanical damage to battery cells

• Storage of charged batteries

Battery fires are particularly dangerous due to re-ignition potential, toxic gas release, and explosion risk.

6. Trim, Chassis & Final Assembly (TCF)

Fire Hazards:

• Electrical wiring and harness installation

• Battery charging stations (hydrogen release in lead-acid batteries)

• Fuel filling and leak testing operations

• Use of adhesives, foams, and sealants

7. Fuel Storage, Gas Systems & Utilities

Fuel Storage Hazards:

• Bulk storage of petrol and diesel

• Diesel storage for DG sets

• Fuel transfer and handling operations

• Static electricity during dispensing

Gas System Hazards (Paint Shops & Utilities):

• LPG / PNG / Natural gas pipelines feeding ovens

• Gas leakage, backfire, and flame failure

• Inadequate gas detection and automatic shut-off systems

8. Warehousing & Finished Goods Storage

Fire Hazards:

• High fire load from plastics, rubber, tires, packaging materials

• Dense storage of spare parts

• Storage of EV batteries and electronic components

• Inadequate aisle spacing affecting fire-fighting access

Major Fire Incidents in the Automotive Industry

The automotive industry has experienced multiple catastrophic fires, including:

• Paint shop fires caused by solvent vapor ignition

• Warehouse fires destroying finished vehicles and spare parts

• Battery storage and EV manufacturing fires due to thermal runaway

• Fuel handling and engine testing area fires

Such incidents have resulted in production shutdowns, massive financial losses, environmental damage, and reputational impact, reinforcing the importance of strict fire safety compliance.

Industry-Specific Fire Protection Systems

(As per National & International Standards)

Applicable Indian Standards

• National Building Code (NBC) of India

• Maharashtra Fire Prevention & Life Safety Measures Act & Rules

• IS 14489 – Fire safety in industrial buildings

• PESO Regulations – Storage and handling of petrol, diesel, LPG, and gases

• OISD Guidelines – Fuel storage and handling

Applicable International Standards

• NFPA 13 – Automatic sprinkler systems

• NFPA 30 – Flammable and combustible liquids

• NFPA 33 – Spray application using flammable materials

• NFPA 86 – Ovens and furnaces

• NFPA 54 / NFPA 58 – Gas and LPG systems

• NFPA 2001 – Clean agent fire extinguishing systems

• NFPA 12 – CO₂ fire extinguishing systems

• NFPA 855 – Energy storage systems (lithium-ion batteries)

• FM Global Data Sheets – Automotive, paint shops, and storage protection

• ISO 45001 – Occupational health and safety management

Recommended Fire Protection Measures

• Automatic sprinkler, deluge, and foam systems

• Gaseous flooding systems for automated paint booths

• Fire detection and alarm systems with process interlocks

• Explosion-proof electrical installations

• Gas detection and emergency shut-off systems

• Battery fire suppression and thermal monitoring systems

• Passive fire protection and compartmentation

• Regular fire safety audits, mock drills, and training

Agni Raksha Niti – One-Stop Fire Safety Solution for the Automotive Industry

Managing fire safety in automotive manufacturing requires deep understanding of processes, automation, fuels, chemicals, and emerging EV risks.

Agni Raksha Niti provides comprehensive, end-to-end fire safety solutions, including:

🔹 Fire Risk Assessment & Process Hazard Analysis
🔹 Fire Safety Design & Engineering as per NBC, IS, NFPA & FM standards
🔹 Specialized Protection for Paint Shops, Fuel Systems & Battery Areas
🔹 Gaseous Flooding System Design with Robotic & PLC Interlocks
🔹 Fire Safety Audits, Compliance Support & Authority Liaison
🔹 Fire Safety Training, Mock Drills & Emergency Preparedness

With its industry-focused expertise, Agni Raksha Niti acts as a one-stop solution, helping automotive manufacturers protect life, assets, operations, and brand reputation through robust and compliant fire safety systems.