RISK MANAGEMENT GUIDE

Freezer and Cooler Hazards

from Liberty Mutual Property

ccording to National Fire Protection Association (NFPA)

A statistics, from 1999 to 2002 an average of 100 fires occurred
annually in refrigerated storage areas. It is a common myth that
supplemental fire detection system
such as heat detectors to activate the
fires will not occur in freezers and coolers due to the cold preaction valve and allow water to enter
temperatures. However, fires do occur, and the low temperatures the piping.

typical in these environments can make it difficult to keep a Where sprinkler piping is subjected to
sprinkler system in good operating condition. freezing temperatures, it is critical that
the sprinkler system is properly
Even though some refrigerated or frozen products themselves may not be
arranged and adequately maintained.
combustible, the associated packaging and pallets make for a combustible mixture
As displayed in the picture below, poor
that can contribute to fire spread and damage. In addition, the insulated wall and
maintenance can result in ice buildup.
ceiling panels that enclose these storage spaces can be made of combustible
The weight of the ice can cause the
materials that may significantly increase the fire load.
sprinkler piping and structural members
Automatic sprinkler systems can be designed to provide adequate fire protection for to weaken or collapse. Evidence of ice
a variety of occupancies, but freezing temperatures can make using a standard wet formation on sprinkler system piping
pipe sprinkler system impractical for freezers and coolers. Instead, most freezers may be an indication that internal ice
and coolers are protected by a dry pipe or preaction sprinkler system. Although accumulation is also present. Internal
these systems do not contain water in the sprinkler piping under normal conditions, ice accumulation in the sprinkler piping
they are subject to freezing and the formation of ice plugs if not properly installed can result in severe obstructions and
and maintained. can delay water supply to the sprinkler
heads. Ice should be immediately

PROTECTING FREEZERS AND COOLERS removed from sprinklers, piping and

structural building
Because they are vital to your
members, and the
operation and often contain valuable
cause of the
inventories, freezers and coolers are
buildup should be
usually protected with a dry pipe or
investigated and
preaction sprinkler system. Piping in
resolved.
dry pipe sprinkler systems is filled
with pressurized air; water enters the
system only when a sprinkler head
activates and the pressurized air in
the piping is released. Piping in
preaction sprinkler systems is also
filled with air but differs from dry
pipe systems in that it uses a
A large freezer with ice buildup

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Ice Plugs
Ice plugs can partially or totally block sprinkler piping, preventing the release HEATED AREA
of air or stopping the flow of water into the system. Most ice plugs are
formed by moisture in the air used to fill the sprinkler piping. When air
temperature drops, water vapor in the air condenses to liquid water. As warm Two easily removed
sections of pipe
compressed air enters cold sprinkler piping, water vapor condenses and
freezes on the interior walls of the piping. Over time, this ice can build up
and partially or totally block the sprinkler piping.
Check valve
Ice plugs can also form when water enters sprinkler piping, from either
System air pressure
system testing or the accidental tripping of the dry pipe valve. After the gauge

system is drained, it might seem that all water has been removed. However,
P2
these systems will continue to drain to the low points for several hours, and
remaining water or moisture in the system can contribute to the formation of
Normally
ice plugs over time. Properly designed systems will limit moisture and allow open control
water to drain from all piping.
Shutoff
valve valves
Check valve
with 3/32 in.
Locating Ice Plugs (2.4 mm) hole
in clapper
Ice plugs are most commonly found where sprinkler piping passes through
a wall or floor into a refrigerated space. If water has entered the piping, ice Dry / preaction
plugs can also form in low spots where water accumulates. valve

Dry pipe or preaction sprinkler system piping that protects or passes through
Main control
freezers or coolers should be inspected annually in accordance with NFPA
valve
25, Inspection, Testing, and Maintenance of Water-Based Fire Protection
Systems. To inspect piping, shut down the sprinkler system and remove
Water supply
sections of pipe where the piping enters a refrigerated area, to verify that
there are no blockages. Riser, feed-main and cross-main fittings should be
designed with fittings strategically located to facilitate the inspection and
removal of any ice plugs. Using an ultrasound thickness gauge can also help
determine if ice is present in the piping. Impairment notification procedures
should be followed when a fire protection system is permanently or
temporarily shut down.

Annual partial trip tests of dry pipe valves, preaction systems, refrigerated
area systems and other associated equipment following NFPA 25 can also be Shutoff
valves
performed as a method of ice plug investigation. A longer-than-average trip
Pressure Air pressure
time may indicate the presence of ice plugs. During such tests, piping in gauge
regulator
heated areas should be arranged to keep water from entering the cold P1
portion of the system. Refer to Dry Pipe System Test Records (Form Air
PE1013B) for more guidance on trip testing. dryer

Coalescer Check valve

filter
Figure A.7.9.2.4 from NFPA 13 (2007 edition).
Arrangement of refrigerator area sprinkler Air
piping to minimize the chances of developing compressor
ice plugs. Note the freezer air intake and the and tank
two easily removed sections of pipe.

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 Preventing Ice Plugs
Ice plugs can be prevented by using air with a low moisture content to
REFRIGERATED SPACE pressurize the sprinkler piping. This can be accomplished by drawing the air
from the coldest freezer, since cold air does not hold as much moisture as
warm air. This is displayed in the diagram on the left. Alternatively, air can be
30 in. artificially dried to lower its moisture content by using an adequately sized
(762 mm)
dehydrator, regenerative air dryer or approved dry air package system for
these refrigerated storage areas.

Removing Ice Plugs

To remove ice plugs, piping should be disassembled and moved to a warm
area to thaw. If ice plugs are small, they can be broken with a hammer and
removed from the piping. Some sprinkler contractors have successfully used
steam or hot water to remove ice without removing the piping. Be sure to
remove all ice so that the pipes are clear of blockages.

Do not use torches, welders or other electrical resistance heating methods on

installed piping, as they create an ignition source.

Insulated Panels
Wall panels with combustible insulation are often used in the construction
6 ft. (1.8 m) minimum

of freezers and coolers. These present a more significant fire hazard than
noncombustible construction materials do, because their combustible
Two easily removed insulation could increase the fire load. In all new construction, Liberty Mutual
air supply lines Property recommends Underwriters Laboratories (UL)–listed panels with a
flame-spread rating of less than 25. A flame-spread rating is the relative rate
at which a flame could spread over the surface of a material as compared to
over a controlled material (asbestos-cement board – rated 0; red oak board –
rated 100). When panels are used in walk-in freezers and coolers, it is
important to have appropriately designed sprinklers located above and inside
the refrigerated space to ensure proper protection of both the contents and
the building structure.

If the UL–listing and flame-spread-rating information is not available for an

existing freezer or cooler constructed with insulated panels, contact your
Liberty Mutual Property loss prevention consultant to discuss the arrange-
ment. He or she will evaluate the existing arrangement and, if warranted,
provide practical recommendations to help safeguard your facility based on
the severity of the exposure.

Freezer air intake

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smart & responsive
For more Risk Management Guides, go to
www.libertymutualproperty.com/resources.

PE1003 ■ Hurricane & Tropical Storm

References:
Catastrophe Action Plan &
Checklists
NFPA 13. Installation of Sprinkler Systems.
PE1004 ■ Minimizing Hot Work Fires
NFPA 25. Inspection, Testing, and Maintenance of Water-Based Fire Protection PE1005 ■ Human Element Programs
Systems.
PE1012 ■ Wet Pipe Systems

PE1013 ■ Dry Pipe Sprinkler Systems

PE1015 ■ Fire Pumps

Responsibility. What’s your policy?TM PE1021 ■ Keeping Sprinklers in Service

PE1022 ■ Sprinkler Plan Reviews

PE1023 ■ Transverse Flue Space

PE1025 ■ Flammable and Combustible

Liquids
PE1026 ■ Flood Exposures

PE1027 ■ Maintaining Fire Doors

PE1028 ■ Avoiding Sprinkler Damage

for the Hospitality Industry
PE1029 ■ Winter Threats

PE1030 ■ Protection for Large Dip Tanks

PE1031 ■ Idle Pallet Storage

PE1032 ■ HID Lighting

PE1033 ■ Spiral Coolers

PE1034 ■ Ammonia Refrigeration

PE1035 ■ Specification and Review Process

PE1036 ■ Industrial Oil Cookers

PE1037 ■ Freezer and Cooler Hazards

PE1038 ■ Minimizing Damage from Hail

PE3001 ■ Impairment Procedures

20 Riverside Road
Weston, MA 02493
While following the procedures and information outlined in this guide may aid in minimizing hazards associat-
TEL: 781-891-0230
ed with freezers and coolers, the procedures and information do not contemplate every potential for loss or
EMAIL: propertyengineering@libertymutual.com
damage. Therefore, every situation should be reviewed by the appropriate safety manager in an effort to take
all appropriate steps and precautions to minimize freezer and cooler hazards. No duty or undertaking is www.libertymutualproperty.com
intended or assumed by Liberty Mutual by this publication, as it is informational in purpose.

© Copyright 2007, Liberty Mutual. This brochure is for informational purposes only. PE1037 07/07