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DISASTER RECOVERY COVER FOR ELECTRICAL MANUFACTURING
Why Disaster Recovery Risk is a Bigger Issue for Electrical Component Manufacturers
Electrical component manufacturing is rarely “plug-and-play” when disruption hits. A fire, flood or major breakdown doesn’t just damage a building — it can destroy specialist test rigs, calibration benches, jigs, tooling, stock, customer-owned items, and high-value components with long lead times. Even if the physical damage is contained, the knock-on effect can include missed deliveries, contractual penalties, emergency rework costs, customer audits, and loss of key contracts if you can’t recover quickly enough.
For businesses making switchgear, control panels, sensors and instrumentation, connectors, power supplies, chargers, cable assemblies, PCBs, enclosures, and electronic sub-assemblies, the production environment often involves: ESD-controlled areas, temperature/humidity-sensitive storage, calibration processes, incoming inspection, batch traceability and final testing. Restarting isn’t as simple as “clean the floor and turn the lights back on”.
This is where a well-structured insurance programme matters. The aim is not just to pay for damage — it’s to keep you solvent during downtime and give you the resources to recover, re-source and re-start. Insure24 helps you arrange cover that reflects the true costs of interruption and the practical steps required to get back to “shipping product” again.
What is Factory Disaster Recovery Risk Insurance?
“Factory fire, flood & disaster recovery” is not usually a single policy title. It’s a practical way of describing the bundle of covers that help a manufacturer recover after a major incident. Most programmes combine:
Core Covers that Fund Recovery
- Property insurance – buildings (if owned), tenants’ improvements, contents, plant, machinery and stock.
- Business interruption (BI) – loss of gross profit / revenue and increased cost of working during downtime.
- Equipment breakdown – sudden mechanical/electrical breakdown of key machinery (where selected).
- Goods in transit – protect stock and finished goods while being shipped to customers.
- Cyber (where relevant) – for ransomware/OT events that stop production or block shipping.
Common Extensions Manufacturers Often Need
- Stock deterioration / temperature – where components are temperature-sensitive or stored in controlled conditions.
- Customer & suppliers extension – BI triggered by loss at a key customer or supplier site (wording dependent).
- Denial of access / utilities – if you cannot access site or lose power/water due to an insured event nearby.
- Alternative premises – extra cost to move production or assembly temporarily.
- Tooling / jigs / test rigs – ensure specialist tools are declared and correctly valued.
- Motor / fleet – where logistics vehicles are critical to operations.
The most common gap we see is underestimating how long recovery takes. Electrical manufacturing often needs: replacement of specialist equipment, re-qualification of processes, re-calibration, reinstatement of ESD controls, re-ordering of long-lead components, and customer audits before production can resume. Your insurance programme must reflect this timeline — not just the cost of a contractor repairing a wall.
Factory Fire Risk in Electrical Manufacturing
Fire remains one of the highest severity risks for manufacturers because it can destroy both assets and continuity. In electrical and electronics businesses, common ignition and escalation factors include: soldering and rework areas, battery storage, charging stations, test benches, power supplies, high-current assemblies, extraction systems, dust accumulation (where fabrication is involved), and poor segregation of flammables.
Insurers will look at how your site is built, what is stored, and how fire protection is managed. Strong controls can improve premiums, deductibles and capacity.
Common Fire Exposure Points
- Battery storage/charging, damaged cells and quarantine areas
- Soldering/rework, heat tools, hot-air stations and test loads
- Extraction ducting and build-up of residues
- Flammable liquids storage (solvents, IPA, cleaners, adhesives)
- High-current testing of switchgear and panels
- Poorly segregated waste, cardboard, packaging and pallets
- Out-of-hours security and housekeeping issues
Controls Insurers Like to See
- Documented hot works controls and permits (where applicable)
- Good housekeeping, waste management and segregation
- Fire alarm maintenance, detection coverage and monitoring
- Sprinklers or suppression (where fitted) and clear impairment controls
- Battery management procedures (charging, storage limits, segregation)
- Electrical testing regimes and fixed wiring inspections
- Fire doors, compartmentation and clear escape routes
Insurance is not a substitute for risk management — but good risk management is often the key to getting the insurer terms you need. Insure24 can help you present your controls clearly to underwriters so you don’t get “blanket assumptions” applied to your risk.
Flood, Storm & Escape of Water Risk
Flood and storm events can cause severe stock and machinery damage, especially where premises have basements, low-lying loading bays, or vulnerable drainage. For electronics businesses, water damage can be disproportionately costly because moisture compromises components, test equipment and finished goods — and because re-qualification and reliability assurance can be required before product can be shipped again.
Flood isn’t only river flooding. Claims can arise from surface water, blocked drains, storm damage that exposes stock, and escape of water from internal systems. Insurers will assess flood maps, building resilience, and what you have done to reduce vulnerability.
Typical Flood/Water Loss Drivers
- Stock stored at floor level without racking/pallet height protection
- Critical machinery located in basements or low points
- Blocked drains, poor site drainage and inadequate maintenance
- Roof failure, skylight damage, or storm-driven rain ingress
- Escape of water from internal pipes, heating systems or sprinklers
- Delayed detection out of hours
Resilience Measures That Help
- Raised storage / racking and defined “no stock on floor” zones
- Flood barriers, non-return valves and drain protection
- Roof inspection and maintenance programme
- Leak detection and shut-off measures (where feasible)
- Emergency response plan and contractor contacts
- Documentation of critical equipment locations and move plans
A key insurance consideration is whether you need “increased cost of working” (ICOW) and alternative premises costs. Flood events often cause longer drying and reinstatement time than businesses expect, particularly if specialist flooring, ESD areas or clean rooms are involved.
Business Interruption: The Cover That Keeps You Alive During Downtime
Property insurance pays to repair or replace physical assets. Business interruption (BI) is what protects cashflow during the recovery period. For manufacturers, BI is often the difference between surviving a disaster and closing the doors — especially if you have payroll, rent, finance agreements, key supplier commitments, and contractual delivery obligations.
The most important BI decisions are not the headline number — they are the structure: the indemnity period, how gross profit is calculated, whether ICOW is included, and whether supplier/customer extensions matter to your supply chain. Underinsuring BI is one of the most common mistakes in manufacturing insurance.
Key BI Elements to Get Right
- Indemnity period – 12, 18, 24 or 36 months depending on lead times and rebuild realities.
- Sum insured / gross profit – based on realistic turnover, variable costs and growth.
- Increased cost of working – overtime, outsourcing, temporary premises, expedited shipping, contractor costs.
- Claims preparation costs – accountants and experts to evidence the loss.
- Alternative premises – funding to temporarily relocate assembly/test operations.
- Denial of access / utilities – where you are prevented from operating due to events nearby.
Why Electrical Manufacturing BI Can Run Long
- Long-lead components (semiconductors, power devices, specialist relays, custom enclosures)
- Replacement of bespoke test rigs, calibration benches and tooling
- Re-qualification of processes and audits for OEM customers
- Regulatory or compliance steps (documentation, approvals, re-certification)
- Recruitment/training delays if skilled staff are displaced
- Backlog recovery even after physical reinstatement
If you have a strong continuity plan, BI claims can be reduced. But your insurance should still be set up to fund the plan. Insure24 can help you stress-test your recovery assumptions and select an indemnity period that reflects how your business actually works.
Supply Chain Disruption & Contingent Business Interruption
Even if your own factory survives, you can still suffer a “disaster” if a critical supplier is hit by fire, flood, cyber attack or equipment failure. Electrical component manufacturing often relies on single-source or specialist suppliers: PCB fabrication, custom magnetics, moulded housings, specialist connectors, metalwork, powder coating, cable suppliers, or calibration laboratories.
Some insurance programmes can be extended to cover business interruption caused by damage at a key supplier or customer site (sometimes called “contingent BI” or “supplier/customer extension”). Availability and wording differ by insurer and risk profile. The key is to identify what truly constitutes “single point failure” in your operation.
Where the Single Points of Failure Often Are
- Specialist PCB fabricators or assembly houses
- Custom transformers / magnetics suppliers
- Approved component lists tied to OEM qualification
- Single approved coating/potting subcontractors
- Calibration laboratories and certification providers
- Key logistics nodes (warehouses, fulfilment centres)
Insurance & Continuity Actions
- Map and rank suppliers by impact, lead time and substitutability
- Maintain approved alternates where feasible
- Hold strategic stock for critical long-lead parts
- Review contingent BI availability and realistic limits
- Document customer commitments and prioritisation rules
- Pre-agree emergency outsourcing routes where possible
Real-World Disaster Recovery Scenarios (Electrical Manufacturing)
These examples show why “property damage” is only part of the story. The biggest cost is often time: time to replace equipment, time to rebuild stock, time to re-qualify with customers, and time to catch up on backlog.
Fire in Stores / Dispatch Area
A fire starts in a loading bay area and spreads into stored packaging and finished goods. The building is repaired relatively quickly, but the business loses weeks re-ordering long-lead components and rebuilding finished stock. Customer deliveries slip and overtime/outsourcing costs spike.
- Property: damage to stock, racking, packaging, and smoke contamination
- BI: loss of gross profit and increased cost of working to catch up
- Extra: expedited shipping and emergency sourcing of parts
Flood Damage to Test & Calibration Area
Surface water enters the factory overnight and damages test benches, calibration equipment and ESD flooring. The equipment needs replacement and re-calibration, and key customers require re-audit before product can ship.
- Property: replacement of specialist equipment and reinstatement of controlled areas
- BI: longer interruption due to re-qualification steps
- Risk: potential contract loss if customers cannot be supplied
Equipment Breakdown Stops Production
A critical CNC/busbar processing machine or automated test rig fails. Replacement parts have long lead times and the business has limited redundancy. Orders cannot be completed, and subcontracting costs increase. Without equipment breakdown and BI structure, the business absorbs the shock.
- Equipment breakdown: repair and parts (where covered)
- BI: interruption and extra expense for outsourcing
- Mitigation: redundancy planning and maintenance schedules
Supplier Fire Creates Component Shortage
A single-source supplier is hit by a fire and cannot supply a qualified component for months. Your production is constrained even though your own site is fine. You may need to re-design, re-qualify and re-test to switch components — causing delay and cost.
- Contingent BI (if arranged): potential support for lost profit
- Extra expense: engineering time, testing and qualification costs (wording dependent)
- Continuity: approved alternates and design flexibility planning
After a major water ingress event, we realised our biggest risk was downtime and re-qualification, not just repairs. Insure24 helped restructure our BI cover and recovery assumptions, and it’s now aligned with how long it would really take to restart production.
Operations Director, UK Electrical Components ManufacturerWhat Insurers Typically Ask for When Quoting Factory Disaster Risk
Property and BI underwriting is detail-driven. The better the information, the faster the quote and the more accurate the terms. Below is the practical checklist insurers usually ask for in electrical manufacturing.
Premises & Construction
- Construction type, roof details and any cladding information
- Fire protection (alarms, detection, monitoring, suppression/sprinklers if any)
- Fire compartments, fire doors and housekeeping standards
- Security (CCTV, alarms, access control, out-of-hours procedures)
- Flood risk indicators and resilience measures
Processes, Hazards & Storage
- Nature of manufacturing (assembly, fabrication, soldering, test, calibration, battery work)
- Flammables storage and handling (solvents, resins, adhesives)
- Battery storage/charging controls and segregation
- Stock values and how stock is stored (racking, floor, secure cages)
- Any customer-owned goods held at premises
Values & Business Interruption
- Buildings sum insured (if owned) and rebuild basis
- Contents/plant/machinery sums insured and valuation approach
- Stock sums insured (peak seasonal levels if relevant)
- Gross profit calculation and turnover figures
- Indemnity period selection and justification
- Any single points of failure and continuity plans
Claims History & Risk Management
- Past losses (fire, theft, flood, escape of water, machinery breakdown)
- Electrical inspection regimes and maintenance schedules
- Hot works controls and contractor management
- Emergency response and disaster recovery planning
- Photographs, site plans, and descriptions of critical areas
The aim is to avoid delays and ensure underwriters understand what you do. “Electrical manufacturing” is broad. A switchgear panel builder with high-current testing is underwritten differently to a small electronics assembly business. Insure24 helps ensure your specific risk profile is presented accurately.
How to Strengthen Your Disaster Recovery Insurance Submission
Underwriters price uncertainty. The more clearly you can demonstrate controls, maintenance and recovery planning, the more likely you are to secure competitive terms. Here are practical steps that often help in electrical manufacturing.
Operational Controls
- Maintain a documented fire risk assessment and action plan
- Demonstrate battery storage/charging segregation and limits
- Formalise hot works controls and contractor induction
- Improve housekeeping and waste removal frequency
- Keep flammables in certified cabinets or designated areas
- Schedule fixed wiring inspections and equipment maintenance
Recovery Planning
- Create a continuity plan with priority customers and products
- Identify alternate suppliers and outsource partners
- Pre-plan alternative premises options and equipment hire routes
- Back up critical production data, drawings and test configurations
- Document lead times for critical machinery and components
- Stress-test BI indemnity period assumptions realistically
If you’d like, we can also create a one-page “Insurer Risk Summary” you can use at renewal: key hazards, controls, photos and recovery assumptions. It often reduces the back-and-forth and speeds up quotations.
FREQUENTLY ASKED QUESTIONS
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Is “factory disaster recovery” a single insurance policy?
Usually not. It typically refers to a package of cover including property insurance and business interruption, often with options such as equipment breakdown,
alternative premises costs, and supplier/customer extensions depending on your risk profile.
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What is the difference between property insurance and business interruption?
Property insurance pays to repair or replace physical assets (buildings, contents, stock). Business interruption is designed to protect cashflow during downtime,
covering loss of gross profit/revenue and often increased cost of working while you recover, subject to policy terms.
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How long should the business interruption indemnity period be?
Many manufacturers choose 12 months by default, but electrical manufacturing can require longer due to specialist equipment replacement, long-lead components,
and customer re-qualification steps. 18–24 months (or more) may be appropriate depending on your situation.
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Does insurance cover flood and escape of water damage to electronics stock?
Property insurance can cover flood and escape of water damage where the peril is insured and subject to deductibles, conditions and exclusions.
Insurers may also consider stock storage practices and flood resilience measures when offering terms.
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Can I insure for supplier disruption if my own site is unaffected?
Sometimes. Some programmes offer supplier/customer extensions (contingent business interruption), but availability and wording vary by insurer and risk profile.
We can advise whether it’s realistic for your supply chain and what information underwriters will require.
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How quickly can Insure24 arrange cover?
Straightforward risks can often be quoted quickly, but manufacturing property and BI can require underwriter review — especially where there are fire loadings,
battery risks, flood exposure, high values, or complex processes. We’ll keep you updated and help gather the information needed efficiently.
UNIQUE INSURANCE
TAILORED FOR YOU
Fire, flood and major disruption can threaten any manufacturer — but electrical component businesses often face longer recovery times due to specialist equipment, controlled environments and long-lead components. Speak to Insure24 to structure property and business interruption cover that reflects your real-world recovery needs.
PROTECT YOURSELF
- Repair and replacement of buildings, contents and stock after insured events
- Business interruption protection to maintain cashflow during downtime
- Funding for increased cost of working and alternative premises (where arranged)
- Options for equipment breakdown and supply chain extensions
- Support presenting your risk controls to underwriters to secure strong terms