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Fire protection in the metal industry

Process‑integrated solutions to prevent sparks, smouldering nests and explosive metal dusts.

Home Industrial Fire Protection Industries Metallindustrie

Why metal production is particularly prone to fire

In metal‑processing facilities, unavoidably high temperatures, flying sparks and glowing machining residues are generated. During welding, hardening, rolling, grinding or decoring, thermal and mechanical energy meet fine, often pyrophoric metal dusts. These can accumulate in extraction systems, filters or silos and ignite spontaneously due to exothermic reactions.

At the same time, complex extraction systems transport sparks through ducts into other parts of the plant – often unnoticed and within seconds. The combination of heat, ignition sources, dust deposits and air movement makes the metal industry one of the most fire‑critical production sectors.

Metal dusts and thermally generated sparks form a dangerous interaction. Without process‑integrated monitoring, fires or explosions can occur in places where no one expects them.GreCon Engineering

A worrying trend that highlights the importance of fire prevention – extinguishing fires before they spread!

The most effective way to minimise fire and explosion risks is through high-performance spark detection and extinguishing systems, combined with tailored fire protection concepts for machinery and critical zones – developed and implemented by Fagus-GreCon.

> 1400

recorded fire incidents since 2014 – in Germany alone!

> 71 %

increase of battery-related fires from 2022

> 300

reported fires per year at UK

GreCon PROTECTOR METAL – our protection concept for the metal industry

The metal industry requires a protection system that takes into account high temperatures, intense sparking, exothermic dust reactions and complex extraction structures.

The GreCon PROTECTOR is a modular protection concept that operates preventively, is scalable and fully integrated into the process.

A comprehensive safety concept:

  • Detection of sparks, glowing particles and overheated components within milliseconds using SCOUT detection
  • Protection of thermal processing operations: hardening, welding, rolling, pressing, grinding, decoring, polishing
  • Protection of the entire extraction and conveying chain: ductwork, fans, filters, cyclones, silos, sand regeneration
  • Automatic diversion or precise low‑pressure extinguishing using HUNTER units
  • Decentralised control via RANGER modules – independent, fail‑safe, expandable
  • Transparent documentation and root‑cause analysis via MISSION CONTROL
  • Modular design – scalable from individual units to comprehensive plant‑wide solutions

How GreCon PROTECTOR works

  1. Detect – sensors identify sparks, hot particles or embers
  2. Decide – the system assesses the risk in real time
  3. Extinguish – automatically, precisely and without interrupting production
  4. Analyse – event data helps to identify and eliminate root causes
     
Worker in blue GreCon outfit with clipboard and helmet

The fu­ture of pre­ven­ti­ve in­dus­tri­al fire pro­tec­tion

For over 50 years, we have been developing tailor-made industrial fire protection concepts for every individual challenge in industrial fire protection – reliable, practical and precisely tailored to your processes.

Trust in over 50 years of experience in more than 100 industries

Benefit from 75,000 individually tailored protection concepts and experience gained from over 200,000 protected production areas. With Fagus-GreCon, you can effectively protect your company from the devastating consequences of a fire.

Consequences of a fire – more than just damage

Fires in metal‑processing facilities occur particularly frequently in areas with high temperatures, flying sparks and dust deposits. Extraction systems, filters, cyclones or silos can develop into sources of fire or explosions within a very short time.

Economic, operational and strategic consequences:

  • Injuries or loss of life
  • Damage to machinery, tools, conveying systems and storage areas
  • Production downtime and contractual delivery delays
  • Significant repair and replacement costs
  • Loss of image and trust among customers and insurers

The cost of doing nothing is high. Effective fire protection is not just a safety measure, but a strategic necessity.

Dangers in the metal industry

The metal industry is among the most process‑critical sectors, as thermal and mechanical energy come into contact with combustible or potentially explosive metal dusts. High temperatures, flying sparks and dust accumulations occur in virtually every phase of production.

Technical hazard factors:

  • Flying sparks from thermal processing: welding, hardening, casting, rolling
  • Glowing particles from grinding or polishing operations
  • Pyrophoric metal dusts in decoring, filter and sand‑reclamation systems
  • Exothermic reactions in filters and ductwork caused by dust deposits
  • Spread of sparks via extraction systems into remote production areas
  • Uncontrolled heat generation due to machine defects, friction or foreign bodies

The result? An ideal environment for fires and explosions.

These risks are not theoretical – they are real, recurring and costly. That is why effective fire protection is not an option, but a necessity.

And this is precisely where Fagus‑GreCon comes into play.

We look forward to hearing from you.

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