Explosions and fires linked to the improper use, storage, or disposal of lithium-ion batteries have increasingly made headlines across the United States, raising serious workplace safety concerns
Lithium-ion batteries, prized for their ability to store large amounts of energy in compact spaces, power a wide range of devices — from rechargeable tools and wearable electronics to laptops, electric vehicles, and backup energy storage systems. Although experts, including those at the Occupational Safety and Health Administration (OSHA), stress that these batteries are generally safe under normal conditions, their potential for catastrophic fires requires heightened awareness and preparedness.
Holly Burgess, Technical Lead for Industrial and Chemical Safety at the National Fire Protection Association, and Daniel Majano, Programme Director at the Electrical Safety Foundation International, have outlined the unique dangers posed by lithium-ion battery fires. “They can emit toxic gases, burn intensely enough to overwhelm sprinkler systems, and even reignite after being extinguished,” Burgess noted.
Majano added that combustion can spread fires across multiple points in a facility, making containment a major challenge.
Best Practices To Reduce Risks
Safety experts advise several measures to reduce the risk of incidents. First, it is crucial to use lab-certified products. Burgess emphasised that manufacturing defects, such as contamination with copper particles, can cause dangerous short circuits leading to “thermal runaway” — a condition responsible for many battery fires. Users should look for certification marks such as CSA, ETL, or UL Solutions.
Monitoring battery condition is equally important. OSHA advises vigilance for warning signs like unusual heat, smell, noise, or physical changes like bulging and leaking. Defective devices should be moved to safe locations if possible and reported immediately to emergency services.
Correct charging practices are also vital. Batteries should be removed from chargers once fully charged. Burgess warned against leaving devices plugged in indefinitely, a common habit with power tools. Only manufacturer-approved chargers should be used, and charging near exits or corridors should be avoided to maintain escape routes.
Safe storage is another key consideration. Lithium-ion batteries should be kept close to room temperature, away from direct sunlight, and only used with designated products.
Finally, workplaces must develop emergency plans that account for the specific hazards posed by lithium-ion batteries. “Workers need to be trained on the signs of battery failure and evacuation procedures,” Majano stressed. Burgess recommended that site managers coordinate closely with fire protection engineers and local fire departments, conducting regular walkthroughs and updating emergency plans as necessary.
In the event of a fire, Majano advises immediate evacuation and notification of 911, with clear communication if a lithium-ion battery is involved to assist first responders in managing the incident safely.
As lithium-ion technology continues to power modern industries, experts warn that proper handling, storage, and emergency planning are crucial in preventing these increasingly common and dangerous fires.
