Fire Sprinkler Accidents: The Top 5

Causes of Discharges and Leaks

Preventative maintenance and simple tools can stop or prevent fire sprinkler accidents

Automatic fire sprinklers are a critical first line of defense if a fire breaks out. But there’s a chance
that they can be triggered when there’s no sign of a blaze—and a fire sprinkler accident can inflict
costly water damage.

In this blog, we examine the most common reasons for accidental discharges of fire sprinklers and
system leaks, from unplanned heat sources to vandalism. We also present simple ways to avoid
them, including proper maintenance and an $80 product that can prevent thousands of dollars in
property damage in impact-prone environments: heavy-duty head guards. We also highlight the
Shutgun—the fastest, easiest way of shutting accidental sprinkler trips down if they can’t be
avoided.

Feel free to browse our selection of heavy-duty head guards and Shutguns.

Minor events can cause major damage when a fire sprinkler accidentally trips

Fire sprinkler heads are automatically triggered by a buildup of heat. A liquid-filled glass bulb bursts
or a soldered metal link melts at a given temperature, allowing a plug to drop out, followed by
water. In most cases, only one or two sprinklers are needed to control a fire, helping properties
escape significant water damage from fire hoses that can spew ten times the amount of water.

But the simple activation process that makes fire sprinklers so reliable during an emergency also
makes them vulnerable to accidental discharges, a term that encompasses everything from human
carelessness to deliberate sabotage. Quick response fire sprinklers release 8 to 24 gallons per minute
or more, taking less than 20 minutes to dump hundreds of gallons of water throughout a property if
there is a persistent water supply that’s not blocked or shut off.

1. Overheating causes fire sprinkler accidents

Automatic sprinklers are triggered by high temperatures—and they can’t tell the difference between
“normal” sources of heat and a fire. That means locating them too close to heat sources such as unit
heaters, skylights, or commercial cooking equipment can inadvertently set them off. Even temporary
heat-producing sources like construction lighting or television cameras have been known to open
the floodgates.
Fortunately, there’s a simple solution for avoiding accidental sprinkler trips in places that run hotter
than normal: sprinklers calibrated so their thermal element won’t activate until higher temperatures
are reached. The 2019 edition of NFPA 13: Standard for the Installation of Sprinkler Systems lays out
specific scenarios where higher-temperature-rated sprinklers should be installed to avoid accidental
discharges:

From the 2019 edition of NFPA 13

9.4.2.5 The following practices shall be observed to provide sprinklers of other than ordinary
temperature classification unless other temperatures are determined or unless high-temperature
sprinklers are used throughout, and temperature selection shall be in accordance with Table 9.4.2.5
(a), Table 9.4.2.5 (b), Table 9.4.2.5 (c), and Figure 9.4.2.5:

(1) Sprinklers in the high-temperature zone shall be of the high-temperature classification, and
sprinklers in the intermediate-temperature zone shall be of the intermediate-temperature
classification.

(2) Sprinklers located within 12 in. (300 mm) to one side or 30 in. (750 mm) above an uncovered
steam main, heating coil, or radiator shall be of the intermediate-temperature classification.

(3) Sprinklers within 7 ft (2.1 m) of a low-pressure blowoff valve that discharges free in a large room
shall be of the high-temperature classification.

NFPA 13 Table 01

Source: the 2019 edition of NFPA 13

(4) Sprinklers under glass or plastic skylights exposed to the direct rays of the sun shall be of the
intermediate-temperature classification.

(5) Sprinklers in an unventilated, concealed space, under an uninsulated roof, or in an unventilated

attic shall be of the intermediate-temperature classification.

(6) Sprinklers in unventilated show windows having high-powered electric lights near the ceiling shall
be of the intermediate-temperature classification.

NFPA 13 Table 02
Source: the 2019 edition of NFPA 13

(7) Sprinklers protecting commercial-type cooking equipment and ventilation systems shall be of the
high- or extra-high temperature classification as determined by use of a temperature-measuring
device.

(8) Sprinklers protecting residential areas installed near specific heat sources identified in Table
9.4.2.5 (c) shall be installed in accordance with Table 9.4.2.5 (c).

(9) Ordinary-temperature sprinklers located adjacent to a heating duct that discharges air that is less
than 100° F (38° C) are not required to be separated in accordance with Table 9.4.2.5 (a) or Table
9.4.2.5 (c).

(10) Sprinklers in walk-in type coolers and freezers with automatic defrosting shall be of the
intermediate-temperature classification or higher.

(11) Sprinklers in closets containing ventless clothes dryers shall be of the intermediate-temperature
classification or higher.

NFPA 13 Table 03

Source: the 2019 edition of NFPA 13

Keep this in mind as well: If new heat sources are added to a property, fire sprinklers may also need
to be adjusted.

2. Freezing temperatures cause leaks

This one doesn’t always involve an accidental sprinkler head activation, per se. But it will certainly
put a lot of water on the floor. Most sprinkler systems are wet pipe systems, meaning water
constantly fills their pipes. And if even a small portion of the system is exposed to freezing
temperatures during an unexpected cold snap or a power outage that leaves a building without
heat, ice can quickly form in the piping.

Frozen water expands by about 10 percent, exerting thousands of pounds of pressure that can break
fittings, crack pipes, and force valve caps open. When the temperature finally warms and the ice
melts, leaks or even full-blown system trips can result.
Adding a listed anti-freeze solution to the pipes, using electric heat tracing, or increasing insulation
can help avoid damage. But if heating is interrupted to a wet sprinkler system for more than a few
hours and the ambient temperature plummets toward 40° F—the temperature when ice crystals
begin to form—draining the water from the sprinkler pipes might become necessary.

It’s wise for property owners to familiarize themselves with their system’s drainage procedures, as
sprinkler contractors may not be able to respond quickly enough when emergencies occur. It’s also a
good idea to check the area that houses the sprinkler system for improperly sealed doors and
windows, cracks, loose siding, or other defects that could lead to frozen pipes.

Frozen pipes

Ice crystals start to form in fire sprinkler pipes at 40° F, long before obvious freezing like this occurs.

Dry sprinkler systems are installed to maintain reliable automatic fire protection in places regularly
prone to freezing temperatures. They avoid the frozen pipes that render wet systems useless in cold
weather by relying on pressurized air or nitrogen to hold back the water supply at a dry pipe valve
located in a heated space.

But even dry sprinkler systems risk damage caused by freezing if water pools in their pipes from
condensation or someone fails to adequately drain the system after annual testing. If the ice causes
the pipes to crack, the change in air pressure can trip the dry pipe valve.

NFPA 13 mandates precautions to ensure that dry sprinkler systems are drained of water before cold
weather starts. These range from using sprinkler heads listed for dry applications to requiring
installers to slope dry sprinkler piping at a specific pitch.

Preaction fire sprinkler systems have similarities with dry systems, but go even further to prevent
accidental discharges. They typically require two separate events before releasing water, such as the
activation of the sprinkler head and separate detection of flame, heat, or smoke.

Interested in learning more about dry sprinkler systems? Read part one in our dry sprinkler series.

3. Fire sprinkler manufacturing defects and mechanical damage

The odds of a manufacturing defect leading to unwanted discharges are astronomically low: about 1
in 16 million. But that doesn’t mean they don’t occur.
After the failure of a dynamic O-ring water seal was linked to a deadly nursing home fire, more than
35 million sprinkler heads were recalled between 2001 and 2007—one of the largest replacement
programs in the history of the Consumer Product Safety Commission.

Fire sprinkler manufacturers regularly test sprinklers before they are sold, usually at two or three
times expected operating pressures. An acceptance test is also performed right after systems are
installed to ensure that they work as expected.

But unfortunately, damaged or defective fire sprinklers do occasionally make their way into service,
and it’s usually because of damage that occurs after they are manufactured. Quick response
sprinklers are especially vulnerable to damage during shipping and installation, as the components
that heighten their sensitivity also make them more fragile.

Regular inspection and testing is key to catching damage to your sprinkler system that could cause it
to malfunction. But if all other potential reasons for a fire sprinkler accident have been ruled out, it
may be time to contact your sprinkler’s manufacturer for professional analysis.

Mechanical damage is a leading cause of accidental sprinkler discharges, and something as simple as
over-tightening a sprinkler head can wreak havoc. The components of a fire sprinkler system are
joined together like a tightly coiled spring, and the impact from something like an errant basketball
can knock them apart and instantly pop open the sprinkler. If the entire sprinkler head is ripped off
—say, by a forklift—water will gush even faster, potentially dumping hundreds of gallons in minutes.

But smaller, unseen impacts can be just as serious, setting the stage for the sprinkler to
unexpectedly release weeks or even months after the damage is done. Careful handling is essential
during installation and the importance of using the proper fire sprinkler wrenches can’t be
emphasized enough. Manufacturers often specify the use of special wrenches to reduce the
possibility of slippage damaging the sprinkler’s operating mechanism, or causing parts to loosen over
time.

Heavy-duty fire sprinkler head guards can prevent accidental damage in impact-prone environments,
such as gymnasiums, warehouses, construction sites, and recreational centers. NFPA 13 requires
listed head guards for impact-prone sprinklers. But while standard sprinkler cages can defend
against small or slow-moving objects, they are no match for hard hits.

Heavy duty sprinkler head guard

Heavy-duty head guards completely repel hard impacts or slow even-harder ones by creating a
“crush zone.” They can be installed over existing fire sprinklers and cages via two jig-assembled
clamps that attach directly to the sprinkler system’s piping, further boosting their strength vs.
standard head guards, which attach to the head. These head guards come in bright colors that make
the sprinklers hard to miss, as well as standard choices like white and black.

Since they are not “listed,” they typically shouldn’t protect NFPA-compliant fire sprinkler systems
alone without approval from the authority having jurisdiction (AHJ). But as a complement to smaller,
existing cages or a temporary solution on a job site, they save property owners from the incredibly
costly water damage of a fire sprinkler accident.

4. Corrosion will cause leaking pipes

Corrosion has long kept the fire protection industry up at night with the potential to cause extensive
damage. While dry sprinklers suffer the highest risk, any system that mixes iron, water, and oxygen
creates the perfect scenario for electrochemical corrosion to occur. And when it does, its orangey-
red rust eats away at the metal pipes from the inside, boring holes the size of pins or even pennies.

At the right temperatures, this “corrosion triangle” also creates an ideal breeding ground for
microbiologically influenced corrosion (MIC), obstructing pipes with a crust of tubercules, creating
holes, and degrading flow characteristics if loose scale or rust plugs sprinklers and valves.

A Potter Corrosion Solutions report promoted by the NFPA asserts that 73 percent of dry sprinkler
systems suffer significant corrosion issues after 12.5 years. If discovered in time, it’s possible to fix
the failing pieces of pipe. But often, pinhole leaks that are discovered in a section of pipe are just a
minor symptom of a rotting system hidden behind walls or within the ceiling. Left untreated,
corrosion will weaken sprinkler system parts enough to cause leaks and unintentional activations of
dry systems.

Regular inspection and testing of sprinkler systems are critical to catching corrosion at its earliest
stages and preventing costly damage—or worse, system failure during a fire. A growing trend toward
stripping the pressurized air from dry sprinklers and replacing it with nitrogen is also dramatically
increasing the lifespan of dry piping.

Nitrogen is an inert gas, meaning it doesn’t undergo the chemical reactions that lead to
electrochemical corrosion. Creating an oxygen-free environment in sprinkler pipes enables them to
last an average of 5.3 times longer regardless of whether water is present, according to Potter
Corrosion Solutions research.

A prison hallway

Ongoing vandalism to sprinkler heads is a primary reason prisons delay installing fire protection
systems.
5. Deliberate sabotage of fire sprinklers

From insurance fraud to vandalism to not-so-funny pranks, deliberate sabotage is the final leading
cause of accidental sprinkler discharges. Headlines are filled with tales of sprinklers that caused
mayhem after they were intentionally set off, and some environments such as prisons and mental
health facilities are especially prone to deliberate sabotage.

A 15-year-old student was charged with first-degree criminal mischief and falsely reporting an
incident in connection with the activation of a fire sprinkler in a bathroom at his Danbury, CT high
school. A Minnesota Security Hospital patient faced felony property damage charges after breaking
off two fire sprinkler heads and causing $2,800 in water damage. And at least 21 inmates over 16
months at the Vanderburgh County Jail in Indiana were accused of vandalizing fire sprinklers in their
cells, flooding floors and forcing evacuations.

In fact, the risk of ongoing vandalism to sprinkler heads is a significant reason prisons delay installing
fire protection systems, fearing the substantial costs of clean-up. But choosing to go without creates
an even bigger risk in an environment where inmates trapped behind bars would be unable to
escape a raging fire. About 600 fires occur in prisons and jails every year, and one out of four is
intentionally set.

Placing fire sprinklers in hard-to-reach spots and using institutional sprinkler heads can prevent acts
of sabotage by reducing access to fragile parts.