Lithium-ion batteries are widely used across multiple industries due to their efficiency, portability and sustainability. They are integral to modern workplaces, powering everything from consumer electronics to industrial equipment. However, despite their advantages, they pose significant safety risks, primarily due to thermal runaway, fire hazards and toxic gas emissions. This briefing aims to equip health and safety managers with essential knowledge on lithium-ion battery risks and best practices for safe handling, storage and fire prevention.

Lithium-ion batteries can be found in:

• Consumer electronics, such as smartphones, laptops, tablets and cameras.
• Electric vehicles (EVs) – cars, bikes and scooters.
• Renewable energy systems – solar battery storage units.
• Industrial equipment – including power tools, drones and robotics.
• Medical devices such as portable monitors and ventilators.
• Household appliances, including cordless vacuums and electric toothbrushes.

Despite their potential hazards, lithium-ion batteries offer numerous benefits:

• Low maintenance: No need for constant water refilling.
• Long lifespan: Lasts for at least eight years with proper care.
• Safety: No immediate health hazards under normal operation.
• Quick charging: Technological advances allow for rapid charging.
• Superior depth of discharge: Efficient energy use.
• Eco-friendly: Reduced environmental impact compared to traditional batteries.
• Operates in extreme temperatures: Functions in diverse environments.
• Unlimited cycle life: Enhances longevity and cost-effectiveness.

There has been a lot of negative press about the dangers of lithium-ion batteries. Lithium-ion battery fires are primarily caused by thermal runaway, an uncontrollable rise in temperature. Contributing factors include:

• Overcharging - excessive voltage can overheat the battery.
• Physical damage - punctures or impacts may cause internal short circuits.
• Exposure to high temperatures - proximity to heat sources accelerates degradation.
• Electrolyte breakdown - leads to gas emissions, increasing fire risks.
• Inadequate battery management systems (BMS) - f ailure to regulate charging/discharging.
• Ageing batteries - degraded cells are more prone to failure.

Thermal runaway is a self-sustaining chain reaction leading to fires and explosions. It occurs when the battery temperature exceeds 60°C, triggering an internal reaction. Toxic and flammable gases are released, leading to swelling and rupturing. Once the gases ignite, a fire ensues, often difficult to extinguish.

Under the Regulatory Reform (Fire Safety) Order 2005 (RRO), the Responsible Person (RP) must:

• Conduct fire risk assessments, including lithium-ion battery risks.
• Implement fire safety measures, such as proper storage and fire suppression systems.
• Ensure staff training on fire response and battery handling.
• Maintain fire safety equipment and comply with legal standards.

Failure to comply can lead to fines, legal action and the workplace being closed. Lithium-ion batteries should be kept in cool, dry and well-ventilated areas (20-25°C). Facilities managers should avoid leaving flammable materials in storage locations and use fire-resistant battery storage cabinets. Damaged or swollen batteries should be stored separately for proper disposal.

Charging should be supervised, avoiding overnight charging in unoccupied areas. Manufacturer-approved chargers will prevent overcharging and overheating and designated charging zones will ensure adequate ventilation. FMs should avoid overcharging batteries and disconnect them when fully charged. They should be monitored for overheating and batteries should be inspected regularly for damage.

In order to keep occupants of workplaces safe, fire response training should be provided for managers.

Evacuation procedures:

• Activate fire alarms and evacuate immediately.
• Ensure clear communication with emergency services.

Fire suppression:

• Use Class D extinguishers.
• Avoid using water or foam-based extinguishers.

First aid considerations:

• Treat burns with cool water and sterile dressings.
• Move individuals exposed to smoke to fresh air.
• Wear PPE when handling battery-related fire incidents.

Lithium-ion batteries provide numerous benefits but also pose serious risks. By implementing proper storage, charging, handling and disposal procedures, organisations can significantly reduce fire hazards. Compliance with fire safety regulations, regular staff training and effective risk management are essential to maintaining workplace safety.