Automated storage and retrieval systems have become standard in modern logistics and e-commerce: tall racking, narrow aisles and automated shuttles or cranes. FM Global DS 8-34 sets out the protection strategy in detail, because conventional sprinkler layouts do not work in this geometry and in-rack protection becomes essential.
ASRS Types
- Mini-load: small tote and carton systems, 4 to 12 m high, typical in e-commerce
- Top-loading: loaded from above with the robot on overhead rails
- Vertically enclosed (shuttle): very tall structures of 15 to 30 m with a shuttle at each level
- Crane-based: the classic AS/RS with a travelling crane in a narrow aisle
General Protection Principles
- FM Approved sprinklers, pipe and valves throughout
- Noncombustible construction: steel frame with concrete deck
- Commodity classified per DS 8-1, covering Class 1 to 4 and plastics
- Fire walls and zone separation, with maximum ASRS zone areas defined
In-Rack Sprinkler Arrangement
Ceiling-only protection is generally inadequate in ASRS, so in-rack sprinklers are the norm:
- Mini-load: horizontal in-rack sprinklers every two to three levels
- Shuttle ASRS: at every level, spaced according to rack depth
- Top-loading: ceiling protection plus sprinklers at the top of each zone
- K11.2 or K14 heads are typical for in-rack use
- Automatic activation coordinated with a bypass for shuttle safety
Open-Top vs Closed-Top Containers
- Open-top combustible: the hardest case, requiring in-rack sprinklers at every level
- Closed-top: contents shielded, allowing a more flexible sprinkler arrangement
- Plastic totes: Group A plastic in their own right, needing additional protection
- Cardboard totes: assessed as Class 3 or 4
Detection and Suppression
- Aspirating smoke detection: the most effective early warning in narrow ASRS aisles
- Linear heat detection: along the rack rows, monitoring temperature rise
- Robot emergency stop: shuttles and cranes moved to a safe position on detection
- Bypass: allows the fire service to move machines out of the fire zone on arrival
Quick Checklist
- ASRS type identified
- Commodity class and container type listed
- FM Approved sprinklers, pipe and valves
- In-rack arrangement verified against the DS 8-34 tables
- Aspirating and linear heat detection provided
- Robot emergency stop and bypass defined
- Fire walls and zone areas within limits
- Survey records maintained for the insurer
Frequently Asked Questions
Why does ASRS need a different protection approach from conventional racking?
Three things change: the racking is far taller, the aisles are narrow so ceiling sprinklers cannot reach into the array, and the aisles are unoccupied so nobody detects a fire early. Together these mean in-rack sprinklers and very early detection become essential rather than optional.
What determines how many in-rack levels are needed?
Storage height, commodity class and container type. Mini-load systems can often use in-rack sprinklers every two to three levels, while tall shuttle systems with open-top combustible containers require them at every level. The DS 8-34 tables give the specific combination rather than leaving it to judgement.
Why does the robot need an emergency stop tied into fire detection?
A shuttle or crane that keeps operating during a fire can spread burning material, obstruct the aisle and prevent fire service access. On detection the controller moves every machine to a defined safe position, and a bypass lets the fire service clear machines from the fire zone when they arrive.
Do plastic totes change the ASRS design?
Yes. A plastic tote is Group A plastic in its own right, adding fire load at every position in the rack, and if it is open-topped its contents are directly exposed to the flue. That combination pushes the design toward in-rack sprinklers at every level regardless of what is inside the tote.
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Download MEP Calc on the App StoreFM Global Property Loss Prevention Data Sheet DS 8-34 (Protection for Automatic Storage and Retrieval Systems), layout tables; related data sheets DS 8-1 and DS 8-9.