From code to custom

Automated storage and retrieval systems (ASRS) are transforming fulfillment warehouses worldwide, enabling denser storage and faster operations. But with these benefits come new fire protection challenges. Traditional prescriptive codes often fall short for ASRS configurations, which feature tightly packed racks, minimal aisles, and high plastic content. It’s important to understand how performance-based design (PBD) can optimize fire suppression strategies, reduce costs, and better ensure compliance while safeguarding business continuity.

Real-world results: a major retailer’s success story

When a leading retailer sought to protect its automated storage and retrieval system (ASRS) warehouse, Johnson Controls partnered with their fire protection engineer to develop and validate a custom fire protection design through full-scale testing. The results were impressive:

• 40% reduction in total sprinklers
• Branch lines per level cut from five to three
• Vertical clearance increased by three feet per level
• Higher storage capacity and lower installation costs

This translates to giving the retailer more storage space for long-time value, while also reducing material and labor expenses to lower the initial investment without compromising fire protection. These outcomes demonstrate the power of performance-based design to deliver measurable economic and operational benefits.

Why ASRS changes the fire protection equation

Compared to conventional warehouses, ASRS facilities present unique hazards:

• Tightly packed shelving and higher racking heights
• Minimal or no longitudinal flue spaces for in-rack sprinklers
• Greater use of plastic containers and combustible materials
• Limited access for manual firefighting

These factors complicate sprinkler placement and water distribution, making prescriptive designs less effective. FM Global Data Sheet 8-34 offers guidance, but not all ASRS layouts fit the data sheet definitions or result in the most cost-effective strategy. NFPA 13 has an equivalency clause which allows alternative strategies—provided they deliver equal or superior protection. This is where performance-based design comes in.

What is performance-based design?

Performance-based design tailors fire protection to the specific ASRS configuration and worst-case ignition scenario. Instead of rigid code compliance, engineers use modeling and full-scale fire tests to validate custom solutions. Benefits include:

• Optimized sprinkler placement and type
• Reduced number of sprinklers and branch lines
• Potential elimination of costly vertical fire barriers within racks
• Greater vertical in-rack level spacing , increasing storage capacity

Beyond upfront savings, fewer sprinklers mean lower lifetime maintenance and reduced risk of accidental damage. Insurance carriers may even offer premium reductions for systems validated through full-scale testing.

The role of fire protection engineers

Fire protection engineers (FPEs) are pivotal in performance-based design projects. Their responsibilities include:

• Classifying commodities and reviewing ASRS arrangements
• Developing protection schemes and determining test criteria
• Conducting fire dynamic modeling to identify worst-case scenarios
• Coordinating with testing labs, ASRS manufacturers, and AHJs
• Documenting results and preparing performance-based design approval packages

Navigating the fire testing process

Full-scale fire tests confirm that custom designs meet or exceed prescriptive performance. A typical process includes:

1. Review ASRS and commodity arrangement, as well as commodity classification
2. Develop potential protection schemes (sprinkler type, location, water supply)
3. Define fire testing acceptance criteria, such as fire spread limits or maximum ceiling temperatures
4. Run fire modeling simulations to refine the design
5. Create and approve test plan with stakeholders
6. Schedule and build ASRS mock-up at test lab
7. Conduct full-scale fire test with technology provider on site
8. Analyze results and compile performance-based design documentation

These tests not only validate safety but also uncover opportunities to reduce material and labor costs—such as fewer sprinklers, simplified piping, and elimination of barriers.

Cold storage considerations

Performance-based design also benefits cold storage applications. The Tyco Quell methodology, for example, replaces traditional dry or pre-action systems with a double-interlock pre-action design using large-orifice CMSA sprinklers and early heat detection. Advantages include:

• Elimination of in-rack sprinklers prone to freezing
• Improved dependability and reduced maintenance
• Documented performance supported by peer-reviewed testing

Why performance-based design matters

As ASRS adoption accelerates, prescriptive codes alone can’t keep pace. Performance-based design offers a proven path to:

• Enhanced fire protection tailored to unique layouts
• Lower total cost of ownership
• Validated compliance through full-scale testing
• Greater operational flexibility and storage efficiency

Early engagement with experienced FPEs and technology partners ensures designs meet insurer and AHJ requirements while delivering measurable economic and operational benefits.

You can read more about best practices in protecting automated warehouses in this Manufacturing Automation article by Manny Silva, Chief Engineer for Water and Mechanical Products at Johnson Controls.

Bottom line: Performance-based design empowers warehouses to move beyond code minimums and embrace custom fire protection strategies that safeguard assets, optimize costs, and support uninterrupted operations.