Kiln Fire Risks in Brick Manufacturing – What Insurance Do You Need?

Introduction

Brick manufacturing is built around heat. Kilns, dryers, burners, fuel systems and dust all sit in the same environment — and when something goes wrong, the losses can be fast and severe. A kiln fire can damage buildings, plant and controls, destroy stock, and stop production for weeks or months.

This guide explains the most common kiln fire risks in brick manufacturing, practical steps to reduce the risk, and the types of UK commercial insurance that are typically used to protect a brickworks.

Why kiln fires are such a serious risk

A kiln incident rarely stays “small”. High temperatures, continuous operation, and complex mechanical and electrical systems mean a fault can escalate quickly. Even if the fire is contained, heat and smoke can:

• Damage kiln linings, burners, fans, conveyors and control panels
• Warp steelwork and compromise structural integrity
• Contaminate finished bricks and raw materials
• Trigger long shutdowns while specialist parts are sourced
• Create knock-on losses through missed delivery deadlines and contract penalties

For many brick manufacturers, the biggest cost isn’t the fire damage itself — it’s the interruption to production.

Common causes of kiln fires in brick manufacturing

Every site is different, but insurers tend to look for the same core causes.

1) Burner and fuel system faults

Gas and oil-fired systems can fail due to:

• Leaking valves, seals or pipework
• Incorrect burner settings leading to flame instability
• Blocked nozzles or poor atomisation (oil)
• Ignition failure and delayed ignition “puff backs”
• Poor maintenance of regulators and safety shut-off devices

Risk outcome: flash fires, explosions, damage to kiln internals and burner trains.

2) Electrical faults and control panel fires

Kilns rely on motors, variable speed drives, PLCs, sensors and control cabinets. Electrical fires can start from:

• Overheating cables and loose connections
• Dust ingress into panels
• Failed cooling fans or blocked filters
• Ageing components and poor thermal management

Risk outcome: localised panel fire that shuts down the whole line, plus expensive specialist repairs.

3) Overheating, refractory failure and hot spots

Refractory linings and insulation degrade over time. If they fail, heat can transfer to areas not designed for it.

• Cracked refractory allowing flame impingement
• Insulation breakdown creating external hot spots
• Misaligned burners causing uneven heating

Risk outcome: structural damage, fire spread to adjacent equipment, and extended downtime.

4) Dust, packaging and combustible materials near hot zones

Brickworks can have combustible materials on site (packaging, pallets, oils, maintenance materials). Dust and debris can accumulate in warmer areas.

• Poor housekeeping around kiln exits, conveyors and electrical rooms
• Storage too close to hot surfaces

Risk outcome: secondary fires that spread beyond the kiln.

5) Mechanical failure leading to friction and ignition

Conveyors, bearings, rollers and fans can overheat.

• Bearing failure and friction heating
• Misalignment causing rubbing and hot fragments
• Lack of lubrication or incorrect lubrication

Risk outcome: ignition of dust/debris, fire in conveyor galleries or plant rooms.

6) Human error and contractor activity

Maintenance shutdowns and repairs are high-risk periods.

• Hot works (welding, cutting, grinding)
• Bypassing safety interlocks
• Temporary wiring or poor isolation
• Inadequate supervision of contractors

Risk outcome: preventable fires that insurers often scrutinise closely.

Practical risk controls insurers like to see

Insurance is important, but it’s not a substitute for risk management. Strong controls can also improve terms and reduce premiums.

Maintenance and inspection

• Planned preventative maintenance (PPM) for burners, fans, conveyors and control systems
• Regular inspection of refractory and insulation, with documented repairs
• Thermographic surveys of electrical panels and hot spots
• Clear records of servicing for safety shut-offs, flame failure devices and gas trains

Housekeeping and segregation

• Keep combustible storage away from kiln zones and electrical rooms
• Dust control and cleaning schedules, especially around conveyors and motors
• Fire-resistant separation between kiln areas and storage where possible

Hot works management

• Permit-to-work system with clear sign-off
• Fire watch during and after hot works
• Suitable extinguishers and isolation procedures
• Contractor induction and supervision

Detection and suppression

• Appropriate fire detection in plant rooms, electrical rooms and conveyor routes
• Consider fixed suppression where risk justifies it (site-specific)
• Hydrants, hose reels and trained staff where appropriate

Business continuity planning

• Critical spares list (controls, drives, sensors, burner components)
• Alternative suppliers for key parts
• Production contingency planning and realistic restart timelines

These measures won’t eliminate risk, but they can reduce the chance of a major loss and speed up recovery.

What insurance do brick manufacturers typically need for kiln fire risks?

Insurance programmes vary by site size, turnover, and contract requirements. The covers below are the ones most commonly used to protect against kiln fire-related losses.

1) Commercial Property / Material Damage insurance

This is the core policy for physical damage to:

• Buildings (kiln halls, plant rooms, offices)
• Plant and machinery (kilns, dryers, conveyors, burners)
• Electrical installations and control panels
• Stock (raw materials, work-in-progress, finished bricks)

Key points to check:

• Sum insured accuracy: underinsurance can reduce claims payments.
• Reinstatement basis: ensure it covers replacement “new for old” where appropriate.
• Kiln and refractory: clarify how kiln linings/refractory are treated.
• Stock valuation: especially where you have large volumes of WIP.

2) Business Interruption (BI) insurance

BI is often the most important cover after a kiln fire. It can help replace lost gross profit and cover increased costs of working while you recover.

What it can cover (depending on wording):

• Loss of gross profit due to reduced output
• Standing charges (wages, rent, finance costs)
• Increased cost of working (e.g., outsourcing, overtime, temporary equipment)

Key points to check:

• Indemnity period: brick manufacturing recovery can take longer than expected. Many sites consider 12–24 months depending on complexity.
• Declared gross profit: make sure it reflects current trading and growth.
• Supplier/customer extensions: if you rely on a key supplier or a single major customer.

3) Engineering insurance (Machinery Breakdown)

A kiln incident isn’t always a “fire” in the traditional sense. A mechanical or electrical breakdown can be the trigger — and some property policies have limitations for breakdown.

Engineering cover can help with:

• Sudden and unforeseen breakdown of plant
• Electrical failure of motors, drives and control systems
• Damage to boilers, compressors or pressure systems (where applicable)

Why it matters: it can bridge gaps where property policies exclude certain breakdown causes.

4) Engineering Business Interruption (Machinery Loss of Profits)

If a breakdown shuts down production but there’s limited fire damage, standard BI may not respond unless it follows insured property damage.

Engineering BI can cover loss of profit following an insured machinery breakdown.

5) Employers’ Liability (EL) and Public Liability (PL)

A kiln fire can cause injury, smoke exposure, or damage to third-party property.

• EL is a legal requirement in the UK for most employers.
• PL can cover claims from visitors, contractors, or neighbouring businesses.

Consider: your contractor management and site access procedures, as liability claims often turn on documentation.

6) Products Liability (and product recall, where relevant)

If a kiln incident affects product quality (e.g., heat damage, contamination, incorrect firing), you may face:

• Claims for defective bricks
• Costs to remove and replace installed products
• Contract disputes

Products liability can help with third-party injury/property damage arising from your products. Product recall (if purchased) can help with the cost of withdrawing products, but it’s usually optional and wording-specific.

7) Environmental liability / pollution cover (site-dependent)

Firewater run-off, fuel leaks, and contaminated debris can create clean-up costs and third-party claims.

Not every brickworks needs a standalone environmental policy, but it’s worth reviewing if you:

• Store significant fuels or chemicals
• Have sensitive drainage or nearby watercourses
• Have strict landlord or planning conditions

8) Commercial legal expenses

After a serious incident, disputes can arise with:

• Contractors (maintenance, hot works)
• Suppliers (delayed parts)
• Customers (late delivery, quality issues)

Legal expenses cover can help with certain legal costs, subject to policy terms.

Policy details that can make or break a claim

Two businesses can have “the same” cover on paper and very different outcomes after a loss. These are the details to pay attention to.

Fire protections and warranties

Some policies include conditions around:

• Hot works controls and permits
• Fire alarm maintenance
• Sprinkler or suppression systems (if installed)
• Electrical inspection intervals

If these are breached, it can complicate a claim. Make sure the policy conditions match how the site actually operates.

Average / underinsurance

If your declared sums insured are too low, insurers may apply “average” and reduce the payout. For plant-heavy sites, valuations can drift over time.

Excesses and waiting periods

• Property damage excesses can be significant for industrial risks.
• BI may have a time excess (e.g., 24/48/72 hours) before cover begins.

Claims preparation and evidence

After a kiln fire, you’ll want:

• Maintenance records and inspection logs
• Incident reports and photos
• Proof of stock levels and valuations
• Production records to evidence BI losses

Good documentation speeds up settlement.

A simple way to think about your cover

If you want a quick checklist, map your risks to your covers:

• Damage to kiln/buildings/plant: Property / Material Damage
• Lost profit during shutdown: Business Interruption
• Breakdown without a major fire: Engineering + Engineering BI
• Injury to staff/visitors: Employers’ Liability + Public Liability
• Defective output and downstream claims: Products Liability (+ optional recall)
• Clean-up and pollution issues: Environmental cover (if needed)

When should you review your insurance?

Kiln fire risk changes over time. Review your programme when:

• You install a new kiln, burner system or control upgrade
• You change fuel type (e.g., gas to oil, or alternative fuels)
• You increase throughput or add shifts
• You expand buildings, storage, or pallet/packaging volumes
• You take on larger contracts with stricter delivery penalties

A small operational change can create a big insurance gap if it isn’t declared.

Next steps: get the right cover for your brickworks

If you manufacture bricks in the UK, the right insurance should do two things:

1. Pay to repair or replace damaged buildings and plant.
2. Keep cashflow stable while production is restored.

If you want, tell me:

• Your annual turnover and rough gross profit
• Whether your kilns are gas or oil-fired
• Your biggest single site value (buildings + plant)
• How long it would realistically take to rebuild/replace a kiln

…and I’ll suggest a practical insurance checklist to discuss with your broker.

Call to action: If you’d like a quote or a review of your existing cover, Insure24 can help you assess kiln fire exposures and arrange suitable commercial insurance for brick manufacturers.