Report: Mega Warehouse Fires Challenge Firefighters, Recommends New Strategies

Mega warehouses that are springing up across the country contain unique challenges for firefighters even though they have sprinklers and other fire protection systems.

Following a 2022 fire in a 1.2 million square-foot Walmart distribution warehouse in Plainfield, IN, subject matter experts conducted an extensive analysis reviewing every aspect of the incident. 

Officials from the National Fallen Firefighter Foundation (NFFF) organized the project at the request of fire officers across the country.

"The Foundation’s support in helping fire departments respond to mega warehouse fires is more critical than ever," Gary Krichbaum, managing director of the NFFF told Firehouse.com. "With firefighters encountering more and more of these complex incidents, we must ensure the fire service learns from past fires to reduce losses and enhance firefighter safety."

Plainfield Fire Territory Fire Chief Brent Anderson said, "Our firefighters faced extreme conditions that changed in an instant, nearly costing lives. The lessons outlined in this report are invaluable, not only for our department but for fire agencies across the country. We are committed to using this knowledge to enhance training, response strategies, and fire prevention efforts moving forward.” 

Authors explained in the report: “The incident is remarkable because of the magnitude of the property loss, the sudden change in fire conditions that occurred, and the resulting very close call to several firefighters who were inside the warehouse at that time."

“This fire, which resulted in a total loss exceeding $500 million and nearly lost firefighters, underscores the unique challenges and risks associated with mega-warehouses, which are increasingly prevalent nationwide," Indiana Fire Marshal Stephen Jones stated. Thanking the departments who took part in the investigation, Jones said, "Their transparency has provided invaluable lessons that can help us all better understand the dynamics of mega-warehouse fires and, most importantly, enhance the safety of our firefighters."

He noted that areas addressed include:

• The fire spread rapidly due to the high combustible load and the structural configuration of the warehouse, which included a multi-level Pick Module. This complexity underscores the need for specialized training and preparedness for such environments
• While the warehouse was equipped with advanced fire protection systems, the incident revealed potential limitations in their effectiveness under certain conditions. This calls for reevaluating current fire protection strategies and systems in mega warehouses
• The rapid escalation of the fire situation emphasizes the critical need for operational strategies prioritizing firefighter safety, including the potential need for defensive tactics when interior conditions become untenable.

“The insights from the Plainfield incident should serve as a catalyst for developing enhanced training programs, reviewing fire protection standards, and fostering collaboration across jurisdictions," Jones added. 

The incident

On March 15, 2022, Plainfield firefighters found the sprinkler had activated and controlled the flames, confining it to an area of shelving where goods were stored. They used a hoseline to douse the burning debris. 

“For all intent and purposes, this could be described as a routine incident up to that point. The fire originated on the second level of a four-level racking system that was loaded with combustible consumer goods,” according to the report released Thursday.

Firefighters checked and found no indication the fire had spread. Crews were told to start shutting down the sprinklers and open loading dock doors.

• Gettemeier and Frankenberg: Three Considerations for Warehouse Fires

“The situation changed very suddenly and radically…after the fire pump was shut down,” the report indicated. 

Firefighters on the roof reported smoke and flames erupted near the middle. It was the first indication that something unusual was happening.

• Podcast: Gettemeier – Tactics for the Known and Unknowns at Warehouse Fires

“Within the next 60 to 90 seconds conditions inside the building changed radically as a large fire developed and began to spread quickly in the upper part of the building. Heavy dark smoke descended to the floor level, more than 40 feet below. Most of the firefighters were able to exit quickly, but three were still close to the original fire area, within the racking structure, and totally enveloped by the dark smoke.”

The firefighters called a Mayday

“They were extremely fortunate to survive by finding the single hose line that had been extended far into the building and following it to the door where they had entered,” the report read.

“Within minutes, it was evident that the fire inside the building was uncontrollable. The fixed fire pumps were restarted, but they could not deliver enough water to control a fire of this magnitude.”

The investigators added that “the origin and cause of the fire could not be determined due to the extent of the destruction, although the location was identified by several witnesses who had observed the fire in its very early stages.

The contents of the building were known to be readily combustible and the rack storage system created the potential for an extremely challenging fire; however, the building and the rack storage systems were protected by engineered fire protection systems that were specifically designed to meet those challenges. Moreover, the sequence of events provided several indications that the fire had been successfully controlled, confined to a small area, and effectively extinguished.

During the probe, they determined “the steel roof structure and the steel structure of the Pick Module created serious communication problems with the 800 MHz trunked radio system. The firefighters who were inside the building had difficulty communicating with each other and with the Incident Commander who was outside. Many of the recorded radio communications were garbled and it appears that several attempts to communicate by radio were not registered.”

A deputy chief, one of the firefighters trapped in the structure, recounted the terrifying moments: “The noise of crashing metal was increasing in loudness and frequency and I was worried the next one would be the last one. I found the E121 Lieutenant and he told me he was missing one of his firefighters. We attempted to call a MAYDAY, but we could not get out on the radio. I told him to check the area they had been searching again to try to locate him. Just shy of complete panic was setting in - the building was collapsing and a ladder company and an engine firefighter were missing. I made another try to find L121 but was unable to locate them. I surmised they must have exited. The lieutenant had found the firefighter and we started to make our way out. Fire conditions had worsened, and visibility had decreased to a foot or less, although I never noticed any heat. We followed the line out of the building...”

Among the suggestions outlined in the report.

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

"Mega warehouse fires remain a pressing challenge for today’s fire service. The ability for us to conduct to lead this investigation, publish the report and share the findings with tactical and command actions is imperative to our mission to protect firefighters. We hope that departments take the lessons from this report and apply them to their operational plans immediately,” Krichbaum said. 

“This report provides a comprehensive examination of the factors that contributed to the fire’s rapid escalation. By understanding the response to this incident and learning more about the design of large-scale warehouse buildings and how the fire protection systems are integrated into an effective response, we aim to improve firefighting operations. At the same time, it will make it safer for the firefighters who are expected to save lives and property,” NFFF CEO Victor Stagnaro wrote in a statement.