Fire Insurance vs IAR Malaysia: Which Coverage Does Your Factory Actually Need?

Fire Insurance covers named perils only. IAR covers everything except specific exclusions. This guide compares coverage scope, premiums, eligibility thresholds, and claim outcomes for Malaysian factories. Meta Title: Fire Insurance vs IAR Malaysia | Factory Coverage Comparison Meta Description: Compare Fire Insurance vs IAR for Malaysian factories. Coverage scope, premium differences, RM50M threshold, claim scenarios, and which policy your factory needs. Published Date: 2026-01-19

Disclaimer: This article provides general guidance on insurance coverage available in the Malaysian market as of February 2026. Policy terms, conditions, and availability vary by insurer. Always review your specific policy wording or consult a qualified insurance professional before making coverage decisions.

Your factory has fire insurance. A forklift rams into your racking system and collapses three bays of finished goods. You file a claim. The insurer rejects it because "accidental impact" isn't a named peril under your fire policy.

This guide breaks down exactly what Fire Insurance covers, what Industrial All Risks (IAR) covers, where the gaps are, and which policy structure your factory actually needs based on your risk profile, asset value, and operations.

This guide covers:

  • How named perils (Fire) vs all risks (IAR) actually work
  • Extension-by-extension coverage comparison
  • The RM50 million IAR threshold and what to do if you're below it
  • Premium cost differences with actual RM ranges
  • Business interruption: Fire + FCL vs IAR Section B
  • Three claim scenarios showing how outcomes differ
  • COPE factors that affect your premiums
  • Industry-specific recommendations

Named Perils vs All Risks: The Structural Difference

This isn't just a branding difference. Fire Insurance and IAR use fundamentally different coverage structures that determine whether your claim gets paid or rejected.

Fire Insurance is a named perils policy. Only causes of loss specifically listed in the policy are covered. If the cause of your loss isn't on the list, there's no coverage. You bear the burden of proving your loss falls within a named peril.

IAR is an all risks policy. Everything is covered unless it's specifically excluded. The insurer bears the burden of proving an exclusion applies to deny your claim. This reversal of the burden of proof is the single most important difference between the two policies.

Feature Fire Insurance Industrial All Risks (IAR)
Coverage approach Named perils only All risks except exclusions
Burden of proof You prove the peril caused the loss Insurer proves an exclusion applies
Accidental damage Not covered, not available as extension Covered under all risks basis
Theft Requires separate burglary policy Included
Business interruption Separate Fire Consequential Loss (FCL) policy needed Section B integrated into same policy
Regulatory framework Revised Fire Tariff (PIAM) Special Rating Committee / LSR scheme
Premium level Lower base premium 1.5x to 2.5x Fire Insurance premium
Eligibility Any property value Minimum RM50 million total sum insured

What Fire Insurance Covers in Malaysia

Standard Fire Insurance in Malaysia follows the Revised Fire Tariff regulated by PIAM (Persatuan Insurans Am Malaysia). The base policy covers exactly three perils: fire, lightning, and explosion of domestic boilers or gas used for domestic purposes only.

That base coverage is thin. Most factories add Special Perils extensions to widen protection. But even with every available extension, Fire Insurance still can't cover accidental damage or theft because those fall outside the named perils structure entirely.

Peril Standard Fire Policy With Special Perils Extension IAR Coverage
Fire Covered Covered Covered
Lightning Covered Covered Covered
Explosion (domestic gas only) Covered Covered Covered (all explosions)
Storm, tempest, flood Not covered Covered (additional premium) Covered (subject to sub-limits)
Burst pipes / water damage Not covered Covered (additional premium) Covered
Aircraft / vehicle impact Not covered Covered (additional premium) Covered
Riot, strike, malicious damage Not covered Covered (additional premium) Covered
Subsidence and landslip Not covered Covered (additional premium) Covered (subject to sub-limits)
Accidental damage (impact, collapse) Not covered Not available Covered
Theft / burglary Not covered Not available Covered
Internal equipment transit Not covered Not available Covered
Machinery offsite for repair (60 days) Coverage ends at premises Coverage ends at premises Covered (with declaration)

The last four rows are the structural gap. No amount of extensions can add accidental damage, theft, or off-premises coverage to a Fire Insurance policy. If these risks matter to your operations, you need an all risks structure.

What IAR Covers That Fire Insurance Cannot

IAR operates in two sections. Section A covers material damage to property on an all risks basis. Section B covers business interruption (loss of gross profit and increased cost of working) when Section A damage interrupts your operations.

Section A: Material Damage Scenarios

Here's where the difference becomes obvious. Every scenario below would be rejected under Fire Insurance, even with all extensions purchased.

Scenario Fire Insurance Response IAR Response
Forklift collides with racking, collapses three bays Rejected: accidental impact not a named peril Covered: accidental damage to property
Overhead crane drops RM800K mould during repositioning Rejected: accidental damage Covered: accidental damage
Copper cable stolen from factory compound over weekend Rejected: theft not covered, need separate burglary policy Covered: theft included in all risks basis
Roof collapses under weight of ponding rainwater Rejected: structural collapse not a named peril Covered: accidental damage to building
CNC machine damaged during internal relocation Rejected: not covered at all Covered: damage during transit within premises
Compressor sent to workshop, workshop catches fire Rejected: coverage ends at premises boundary Covered: offsite machinery clause (up to 60 days)
Finished goods warehouse broken into, RM500K stock taken Rejected: requires separate burglary policy Covered: theft of stock

Section B: Business Interruption

Under Fire Insurance, business interruption requires a separate Fire Consequential Loss (FCL) policy. Under IAR, business interruption is Section B of the same policy, and it's compulsory for fire and allied perils.

But the real advantage of IAR Section B is that it covers business interruption from any Section A peril, not just fire. If a forklift crash shuts down your production line for three weeks, IAR Section B covers your lost gross profit. A standalone FCL policy tied to fire insurance wouldn't pay because the underlying cause (accidental impact) isn't covered by the fire policy.

Loss Type Fire + FCL Policy IAR Section B
Lost revenue after fire damage Covered Covered
Lost revenue after flood damage Covered (if flood extension added to both policies) Covered
Lost revenue after accidental equipment damage Not covered Covered
Lost revenue after theft shuts down operations Not covered Covered
Increased cost of working (temporary premises, overtime) Covered (fire perils only) Covered (all Section A perils)
Ongoing wages during shutdown Covered (fire perils only) Covered (all Section A perils)
Lost revenue from machinery breakdown Not available Available as MLOP extension

For factories where non-fire perils (accidental damage, theft, water damage) cause more frequent losses than fire itself, IAR Section B provides significantly broader interruption protection. Learn more about IAR coverage structure.

The RM50 Million Threshold: Malaysia's IAR Eligibility Rule

IAR isn't available to every factory. The Malaysian market requires a minimum RM50 million total sum insured (combining Section A material damage values and Section B business interruption values) to qualify for IAR.

This threshold creates three distinct tiers of coverage based on your factory's total insured values.

Total Sum Insured Available Coverage Pricing Structure Policy Wording
Below RM50 million Fire Insurance + extensions, or Property All Risks (PAR) Revised Fire Tariff rates Standard tariff wording
RM50 million to RM300 million Standard IAR (Tariff IAR) Special Rating Committee rates Standard IAR wording with limited flexibility
Above RM300 million Large and Specialised Risk (LSR) IAR Open market pricing Fully customisable bespoke wordings

What If You're Below RM50 Million?

Property All Risks (PAR) offers a middle ground. PAR provides all risks coverage similar to IAR's Section A but is available for smaller property values below the RM50M threshold. It covers accidental damage and theft on the same "all risks except exclusions" basis.

The limitation? PAR typically doesn't include the integrated business interruption section that IAR provides. You'd still need a separate FCL or loss-of-profits policy. But for material damage coverage, PAR closes the structural gap between Fire Insurance and IAR for factories that can't hit the RM50M minimum.

Calculating Your Total Sum Insured

Many factory owners underestimate their total insurable values. When you add up building replacement cost, machinery and equipment at reinstatement value, stock at maximum accumulation, and 12-24 months of gross profit for business interruption, the total often exceeds RM50M even for mid-sized operations.

Asset Category Valuation Basis Typical Range (Mid-Sized Factory)
Building and structures Reinstatement value (rebuild cost, not market value) RM8M to RM25M
Plant and machinery Replacement new (including installation and commissioning) RM10M to RM80M
Stock and raw materials Maximum accumulation value RM3M to RM20M
Office contents and furniture Replacement value RM200K to RM1M
Business interruption (12 months) Gross profit x indemnity period RM5M to RM40M
Total Combined sum insured RM26M to RM166M

A factory with RM15M in machinery, RM10M building, RM5M stock, and RM20M annual gross profit already reaches RM50M. If your combined values are close to the threshold, work with your broker to confirm whether IAR qualification is achievable.

Premium Cost Comparison: Fire Insurance vs IAR

IAR costs more than Fire Insurance. That's expected because it covers more perils and includes integrated business interruption. But how much more depends heavily on your factory's COPE profile and claims history.

Factory Profile Fire + Extensions + FCL (Annual) IAR (Annual) Premium Difference
Light manufacturing (RM50M TSI) RM35,000 to RM55,000 RM55,000 to RM90,000 +60% to +80%
Medium manufacturing (RM100M TSI) RM65,000 to RM100,000 RM100,000 to RM180,000 +55% to +80%
Heavy manufacturing (RM200M TSI) RM120,000 to RM200,000 RM200,000 to RM400,000 +65% to +100%
High-hazard (chemical, RM300M+ TSI) RM250,000 to RM450,000 RM450,000 to RM900,000 +80% to +100%

These ranges are indicative. Actual premiums depend on insurer appetite, claims history, risk survey findings, and current market conditions. The key point: the premium difference buys you accidental damage coverage, theft coverage, and integrated business interruption, which are structurally unavailable under Fire Insurance at any price.

COPE Factors That Drive Your Premium

Both Fire Insurance and IAR premiums are influenced by COPE analysis: Construction, Occupancy, Protection, and Exposure. Understanding these factors helps you reduce premiums under either policy structure.

COPE Factor What It Measures Impact on Fire Premium Impact on IAR Premium
Construction Building materials and fire resistance (Class 1A, 1B, 2, 3) Major: C1A = lowest rate, C3 = highest Moderate: assessed within overall risk profile
Occupancy What the building is used for (trade classification) Major: tariff classification directly sets base rate Major: determines risk category and rating band
Protection Fire detection, suppression, hydrants, sprinklers Tariff discounts available (up to 25%) Significant rate reductions for comprehensive systems
Exposure Proximity to other risks, flood zones, terrain Loading for adjacent hazards Loading for accumulated exposure (NatCat, adjacent risks)

Investing in fire protection systems (sprinklers, fire detection, proper hydrant systems) delivers premium savings under both policy types. A factory with a fully sprinklered facility can see 15% to 25% premium reduction versus an unsprinklered equivalent. See BOMBA fire certification requirements.

Get a P&E programme review from our specialists

The Average Clause: Why Underinsurance Hurts You Under Both Policies

Both Fire Insurance and IAR apply the condition of average (co-insurance clause). If your declared sum insured is less than the actual reinstatement value of your property, every claim payment is reduced proportionally.

Example: Your machinery is worth RM20 million at reinstatement value, but you declared RM14 million (70% of actual). A fire destroys one machine worth RM2 million. The insurer pays 70% of RM2 million = RM1.4 million. You absorb the remaining RM600,000.

This applies to every claim, not just total losses. Underinsurance is one of the most common and costly mistakes in Malaysian factory insurance. It affects Fire Insurance and IAR equally.

Sum Insured vs Actual Value Claim Amount Insurer Pays You Absorb
100% (adequately insured) RM2,000,000 RM2,000,000 RM0 (deductible only)
80% RM2,000,000 RM1,600,000 RM400,000
60% RM2,000,000 RM1,200,000 RM800,000
50% RM2,000,000 RM1,000,000 RM1,000,000

Get a professional reinstatement valuation every 3-5 years. Machinery replacement costs, building construction costs, and stock values change. A policy that was adequate three years ago may be 30% underinsured today.

What IAR Still Excludes

IAR is broad, but it's not unlimited. Certain categories of loss are excluded under standard IAR wordings, and these exclusions define where you need complementary policies.

Exclusion What's Excluded Complementary Policy
Electrical/mechanical breakdown Internal failure of machinery without external cause Machinery Breakdown Insurance
Boiler explosion from internal pressure Pressure vessel failure from own steam/pressure Boiler and Pressure Vessel (BPV) Insurance
Electronic equipment internal defects Short circuits, voltage fluctuations, component failure Electronic Equipment Insurance (EEI)
Wear and tear Gradual deterioration, rust, corrosion, erosion Maintenance programmes (not insurable)
Inherent defects Faulty design, materials, or workmanship Warranty claims, product liability
Consequential losses beyond BI Contractual penalties, loss of market, fines Contract negotiation, retention
Third-party liability Injury or damage to third parties CGL Insurance
Worker injuries Employee injury, disability, death Workmen Compensation Insurance

This is why IAR alone doesn't protect your factory. It's the property and interruption foundation of a complete programme, but you still need Machinery Breakdown for internal equipment failure and BPV for pressure vessel risks. A complete property and engineering (P&E) programme layers these policies together.

Three Claim Scenarios: How Outcomes Differ

These scenarios illustrate how the same loss event produces different financial outcomes depending on whether you hold Fire Insurance or IAR.

Scenario 1: Forklift Impact in Auto Parts Warehouse

A forklift operator misjudges clearance and strikes a multi-tier racking system. Three bays collapse, destroying racking (RM400K), finished goods (RM1.2M), and damaging the concrete floor (RM150K). The warehouse section is out of service for 6 weeks while racking is rebuilt, costing RM800K in lost revenue.

Loss Component Amount Fire + Extensions IAR
Racking system RM400,000 Rejected Covered
Finished goods RM1,200,000 Rejected Covered
Floor repair RM150,000 Rejected Covered
Lost revenue (6 weeks) RM800,000 Rejected Covered (Section B)
Total loss RM2,550,000 RM0 recovery RM2,550,000 recovery

Every component of this loss is accidental damage. Fire Insurance doesn't cover any of it. The entire RM2.55 million falls on the factory owner.

Scenario 2: Weekend Break-In at Electronics Factory

Thieves break into a Penang electronics assembly plant over a long weekend. They steal copper bus bars (RM300K), testing equipment (RM450K), and finished circuit boards (RM600K). Security cameras captured the event, and a police report was filed immediately.

Loss Component Amount Fire + Extensions IAR
Copper bus bars RM300,000 Rejected: theft excluded Covered
Testing equipment RM450,000 Rejected: theft excluded Covered
Finished circuit boards RM600,000 Rejected: theft excluded Covered
Total loss RM1,350,000 RM0 recovery RM1,350,000 recovery

The factory would need a separate Burglary policy to cover this under a Fire Insurance structure. With IAR, theft is included automatically. For electronics manufacturers with high-value components, this alone can justify the IAR premium difference.

Scenario 3: Fire in Chemical Storage Area

A fire starts in the solvent storage area of a paint manufacturing plant. Fire damage destroys the storage building (RM3M), solvent stock (RM2M), and adjacent packaging machinery (RM4M). Production halts for 4 months, causing RM8M in lost gross profit. Debris removal costs RM500K.

Loss Component Amount Fire + Extensions + FCL IAR
Storage building RM3,000,000 Covered Covered
Solvent stock RM2,000,000 Covered Covered
Packaging machinery RM4,000,000 Covered Covered
Lost gross profit (4 months) RM8,000,000 Covered (FCL required) Covered (Section B)
Debris removal RM500,000 Covered (if extension added) Covered
Total loss RM17,500,000 RM17,500,000 recovery RM17,500,000 recovery

For a pure fire loss, both policies deliver the same outcome (assuming FCL and debris removal extensions are in place). The difference appears only when losses involve non-fire perils. This is why factories with primarily fire risk and limited accidental damage exposure can reasonably stay on Fire Insurance.

Industry-Specific Recommendations

Your industry determines which perils cause the most frequent and severe losses. That dictates whether Fire Insurance or IAR is the better fit.

Industry Dominant Perils Recommended Coverage Key Reason
General manufacturing Fire, accidental damage, equipment transit IAR (if eligible) Forklifts, cranes, and material handling create constant accidental damage exposure
Electronics and semiconductor Contamination, equipment sensitivity, theft IAR + EEI High-value portable components, cleanroom contamination risks
Food and beverage Fire, cold storage failure, stock deterioration IAR + stock deterioration Perishable stock exposure, cold chain dependency
Chemical and petrochemical Fire, explosion, contamination LSR IAR (above RM300M) Catastrophic loss potential requires bespoke wordings and specialist placement
Plastics and rubber Fire (combustible materials), machinery damage IAR + MB Injection moulding and extrusion equipment values push TSI above RM50M
Warehousing and logistics Fire, theft, flood Fire + extensions or PAR (if below RM50M) Lower equipment values, but consider PAR for theft coverage
Oil and gas Fire, explosion, MLOP Specialist energy policies Standard IAR typically excludes petrochemical processing risks
Commercial office / retail Fire, limited accidental damage Fire + extensions Low accidental damage exposure, unlikely to reach RM50M threshold

Not sure which coverage your factory needs? Talk to our P&E specialists

How Fire Insurance and IAR Fit Into a Complete P&E Programme

Neither Fire Insurance nor IAR is a standalone solution for a factory. Both cover property damage (buildings, machinery, stock) and, with the right structure, business interruption. But neither covers internal machinery failure, pressure vessel explosions, or electronic equipment defects.

A complete property and engineering (P&E) programme layers multiple policies to close every gap. Fire Insurance or IAR provides the property foundation. Engineering policies (Machinery Breakdown, BPV, EEI) cover internal equipment failure. Each engineering policy has its own loss-of-profits extension (MLOP, BOLOP, ILOP) to cover business interruption from its specific perils.

Risk Category Policy Loss-of-Profits Extension
Property damage (fire, flood, theft, accidental) Fire Insurance / IAR FCL (Fire) / BI Section B (IAR)
Internal machinery failure Machinery Breakdown (MB) MLOP
Pressure vessel explosion BPV BOLOP
Electronic equipment internal defects EEI ILOP
Third-party liability CGL N/A
Worker injuries Workmen Compensation N/A

Fire Insurance or IAR is just layer one. The question isn't whether you need Fire or IAR in isolation. The question is which property foundation fits your factory's risk profile, asset values, and budget, and what engineering policies need to layer on top.

Decision Framework: Choosing the Right Coverage

Use this checklist to determine which coverage structure fits your factory.

Question If Yes If No
Is total sum insured above RM50 million? IAR is available, evaluate further Consider PAR for all risks below threshold
Do operations involve forklifts, cranes, or material handling? IAR strongly recommended (accidental damage) Continue evaluation
Is theft of equipment or stock a material risk? IAR or PAR recommended (theft included) Continue evaluation
Would non-fire downtime (impact, theft, water) cause significant revenue loss? IAR Section B covers all perils BI Fire + FCL may suffice
Do you want integrated property + BI in one policy? IAR provides this structure Fire + separate FCL works
Is premium budget the primary constraint? Fire Insurance costs 40-50% less Evaluate IAR benefits vs cost
Is total sum insured above RM300 million? LSR scheme IAR with bespoke wordings Standard tariff IAR

FAQ

Can I add accidental damage coverage to Fire Insurance?

No. Accidental damage is structurally excluded under the named perils approach. No extension exists because Fire Insurance can only cover specifically listed perils. You need an all risks policy (IAR or PAR) for accidental damage coverage.

What's the minimum sum insured for IAR in Malaysia?

RM50 million total sum insured, combining Section A (material damage: building, machinery, stock) and Section B (business interruption: gross profit). If your combined values fall below RM50M, consider Property All Risks (PAR) as an alternative.

Does IAR cover machinery breakdown?

No. IAR covers damage from external causes like fire, impact, or theft. Internal mechanical or electrical breakdown (a motor burning out, bearings seizing, gearbox failing) is excluded. You need separate Machinery Breakdown Insurance, which integrates with IAR through the MLOP extension for loss-of-profits coverage.

Is IAR always more expensive than Fire Insurance?

Yes. IAR typically costs 1.5x to 2.5x the equivalent Fire Insurance premium because it covers accidental damage, theft, and integrated business interruption. But comparing like-for-like, you'd need Fire Insurance + separate burglary policy + separate FCL policy to approximate IAR coverage, and the total cost of those separate policies often approaches the IAR premium anyway.

What happens if I'm underinsured on either policy?

Both Fire Insurance and IAR apply the average clause. If your sum insured is 70% of actual reinstatement value, every claim payment is reduced to 70%. This applies to partial losses too, not just total losses. Regular reinstatement valuations (every 3-5 years) are the only protection against this.

Does IAR cover flood damage automatically?

Most IAR policies include flood as part of the all risks base coverage, but with sub-limits or higher deductibles for flood-prone locations. Always verify the flood sub-limit in your policy schedule. Some policies in high-risk flood zones may exclude flood entirely or impose very high deductibles.

Can small factories get all risks coverage below RM50 million?

Yes. Property All Risks (PAR) provides similar all risks coverage for smaller properties below the RM50M IAR threshold. PAR covers accidental damage and theft on the same structural basis as IAR's Section A. Business interruption typically requires a separate policy attachment.

How long does a Fire Insurance or IAR claim take to settle?

Simple property damage claims (clear cause, documented values) typically settle in 4-8 weeks under either policy. Business interruption claims take longer because the insurer must verify the actual loss of gross profit over the interruption period. Complex manufacturing BI claims can take 3-6 months to finalise.

What's the difference between standard IAR and LSR scheme IAR?

Standard tariff IAR (RM50M to RM300M) uses Special Rating Committee pricing and standardised policy wordings with limited flexibility. LSR scheme IAR (above RM300M) offers open market pricing and fully customisable bespoke wordings. LSR wordings can integrate machinery breakdown, expand territorial limits, and include broader business interruption triggers.

Does my factory need both Fire/IAR and Machinery Breakdown?

Almost always yes. Fire Insurance and IAR cover property damage from external causes (fire, flood, impact, theft). Machinery Breakdown covers internal failure (electrical burnout, mechanical seizure, material fatigue). These are completely different causes of loss with no overlap. A complete P&E programme needs both layers.

Foundation Conclusion

Fire Insurance covers named perils. IAR covers everything except specific exclusions. For Malaysian factories with material handling operations, theft exposure, or complex risk profiles, IAR provides structural coverage that no combination of Fire Insurance extensions can match.

But the real question isn't Fire vs IAR in isolation. It's how your property foundation (Fire or IAR) integrates with Machinery Breakdown, BPV, EEI, and loss-of-profits extensions to create a complete P&E programme with no gaps.

Talk to our P&E specialists about your factory's coverage structure

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