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PROTECT YOUR FACTORY AGAINST ELECTRICAL FIRE — AND THE COST OF DOWNTIME
Why Electrical Fire Risk Is a Major Exposure in Component Manufacturing
Electrical component manufacturing environments combine high energy processes, sensitive materials and intensive testing. Burn-in rigs, power loading, high-voltage testing, SMT ovens, conformal coating, potting compounds, extraction systems, compressors and electrical panels can all become ignition sources if faults develop. Add high-value inventory (PCBs, chips, copper, connectors, resins and finished assemblies), and even a small fire can become a catastrophic loss.
The biggest cost is often not the fire damage alone—it’s the downtime. After an electrical incident, businesses face smoke contamination, electrical re-certification, machine recommissioning, requalification of processes, and customer delays. Proper insurance should protect your property and stock, fund clean-up, and provide business interruption support while production recovers.
What Electrical Fault & Fire Risk Insurance Should Include
This page focuses on the practical insurance structure electrical manufacturers use to manage electrical fault and fire exposure. It typically involves a combination of property insurance, business interruption, engineering / machinery breakdown, and liability cover. The objective is to ensure that if an electrical incident occurs, you can repair or replace what is damaged, protect cashflow during downtime, and defend any third-party claims.
Insurers will also look closely at your fire risk management, electrical testing regimes and maintenance practices. The stronger your controls, the better your terms and long-term insurability.
Core Covers Typically Involved
- Property insurance: buildings, contents, plant, stock and WIP against fire and associated perils
- Business interruption (BI): loss of gross profit and continuing expenses during downtime
- Machinery breakdown: sudden breakdown of critical plant, electrical panels, compressors and equipment
- Damage to stock: smoke/heat contamination and salvage costs (wording dependent)
- Increased cost of working: outsourcing, temporary production and expedited routes to reduce losses
- Public / product liability: third-party claims where an incident affects others
- Engineering inspections: where required for pressure/compressed air systems
Electrical & Fire Hazards in Manufacturing
- Short circuits and arcing in panels, busbars, switchgear and distribution boards
- Overheating in test rigs, burn-in systems and high-load production testing
- Faulty extraction or dust contamination impacting electrical equipment
- Battery/energy storage testing and charging infrastructure (where applicable)
- SMT ovens, reflow systems and temperature-controlled processes
- Compressed air / compressor electrical faults and overload events
- ESD controls and environmental failures causing equipment damage and downtime
Why Electrical Fault Incidents Become Large Claims
In component manufacturing, electrical incidents often cause multi-layered losses. The initial ignition might be small, but smoke and soot contamination can render stock and sensitive electronic parts unusable. A short circuit can also damage machinery control systems and trigger long lead-time replacements. Even where physical damage is contained, businesses can be forced into extended downtime while electrical systems are inspected, certified and recommissioned.
A good policy structure should address the full financial impact: physical repair, contaminated stock, debris removal, specialist cleaning, replacement of tooling and fixtures, and the gross profit loss while you recover.
Hidden Loss Drivers (Often Underestimated)
- Smoke contamination of sensitive electronic stock and WIP
- Damage to test fixtures, jigs and bespoke tooling
- Requalification time after repair (validation, audits, trial runs)
- Long lead times on specialist machines and control components
- Loss of calibration capability until test equipment is restored
- Supply chain knock-on effects and missed OEM delivery windows
- Increased cost of working to meet contracts (outsourcing/expedite)
BI & Recovery Considerations
- Gross profit calculations aligned to your real production margin
- Indemnity periods that reflect rebuild + recommission + ramp-up time
- Alternative premises / temporary production solutions (where viable)
- Overtime costs and additional shifts to catch up production
- Expedited freight and premium shipping for critical components
- Customer communication and contract management during delays
- Claims documentation readiness (stock records, WIP reporting)
Indemnity Period Tip
Many manufacturers choose an indemnity period based on how long it takes to “repair the building”. In electrical manufacturing, the real delay is often recommissioning: replacing control systems, validating processes, requalifying product, and satisfying customer audit requirements. Setting the indemnity period correctly is one of the most important decisions in BI insurance.
Fire Risk Management That Improves Terms (What Insurers Want to See)
Electrical fire risk is insurable—but underwriters want evidence of control. Many insurers now request clear information about electrical maintenance, testing, housekeeping, extraction systems, hot works controls and emergency response capability. If you can demonstrate that your business manages ignition sources properly and detects issues early, you’re more likely to secure competitive terms.
We help you present your risk in a way insurers understand, focusing on practical measures rather than generic statements.
Electrical Safety Controls
- Documented fixed wiring inspections and remedial actions
- Thermal imaging of panels/switchgear (where used) and corrective maintenance
- Preventative maintenance for compressors, extraction and critical plant
- Load management for test rigs and burn-in systems
- PAT testing and equipment inspection regimes
- Change control for electrical modifications and contractor management
- UPS / surge protection and safe shutdown controls (where applicable)
Fire Protection & Housekeeping
- Fire alarm and detection coverage appropriate for the premises
- Extinguishers / suppression systems (and training to use them)
- Compartmentation and storage controls for flammables and resins
- Extraction maintenance (including filters) and dust control
- Clear separation of charging/testing areas from high-value stock (where possible)
- Good housekeeping and waste management to reduce fuel load
- Emergency response plans and clear incident escalation procedures
Getting the Sums Insured Right
Underinsurance is one of the most common issues we see. If your sums insured don’t reflect real replacement costs, a claim can be reduced. We’ll help you consider buildings, plant, stock and WIP realistically—especially where stock values fluctuate or where specialist machinery has long lead times and high replacement costs.
A short circuit in a distribution board caused smoke contamination across our production area. Insure24 had arranged the right mix of property and BI cover—so we could clean, replace stock and keep cashflow stable while we recovered.
Finance Director, UK Electronics ManufacturerHow to Arrange Electrical Fault & Fire Risk Insurance
The fastest route to an accurate quote is a clear summary of your premises, processes, and controls. Insurers will want to understand where ignition sources exist, how the building is protected, and what the financial exposure looks like if a serious incident occurs.
- 1. Premises details: construction, size, fire protection, security and occupancy.
- 2. Process overview: SMT, soldering, testing, burn-in, coating, potting and any high-load areas.
- 3. Electrical controls: fixed wiring inspection, maintenance, thermal imaging, contractor control.
- 4. Values: buildings, contents, plant, stock/WIP and peak stock fluctuations.
- 5. BI requirements: gross profit and realistic indemnity period for recovery + ramp-up.
Information That Speeds Underwriting
- Recent electrical inspection dates and summary of remedial actions
- Fire alarm/sprinkler details and maintenance records
- Details of extraction systems and servicing regime
- Hot works permit controls (where applicable)
- Claims history and any near-miss electrical incidents
- Largest single machine values and critical dependencies
FREQUENTLY ASKED QUESTIONS
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Does property insurance cover electrical fires and short circuits?
In many cases, yes—fire is typically an insured peril under property insurance. The scope depends on the policy wording, conditions
and compliance with risk management requirements. Insurers may also consider the cause and whether electrical maintenance and
inspection obligations were followed.
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Will business interruption cover lost income after an electrical incident?
Yes, if BI is in place and the interruption is caused by an insured event (such as a fire). BI can help protect gross profit and
continuing expenses while you recover. The indemnity period and sums insured should be set to match realistic recovery timelines.
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Does the policy cover smoke contamination of electronic stock?
Often, smoke damage is considered part of the fire claim, but the treatment of contamination can vary. Sensitive electronic stock
may need specialist cleaning or may be deemed unsalvageable. We’ll help ensure stock and WIP are considered properly in your
values and policy structure.
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What is machinery breakdown and how does it relate to electrical faults?
Machinery breakdown (engineering) cover can insure sudden and unforeseen breakdown of plant and equipment. Some electrical failures
that damage machinery may be considered under engineering cover, depending on the cause and the policy terms. It is often used
alongside property and BI to broaden protection.
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How can I reduce premiums for electrical fire risk?
Strong electrical maintenance, documented inspections, thermal imaging, good housekeeping, robust fire detection, safe storage of
flammables, extraction maintenance and clear incident response planning all help. Insurers price based on severity and control.
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How long does it take to get a quote?
Many risks can be progressed quickly, but for manufacturing fire exposure insurers often want detail. As a guide, allow around 1–2
working days once we have your premises, values and risk management information, while we approach specialist underwriters.
UNIQUE INSURANCE
TAILORED FOR YOU
Electrical faults and fire incidents can stop production overnight. Insure24 helps electrical component manufacturers protect property, stock, machinery and cashflow with the right mix of property, BI and engineering cover—supported by specialist insurer access and practical advice.
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