Comment: Free resource can help with lithium-Ion battery fire safety

Lithium-ion batteries are now an essential part of modern life, powering everything from smartphones and electric vehicles to smartwatches, cameras, and household gadgets like robot vacuums.

Even if you primarily use a desktop computer, these batteries are still present in everyday devices. While they are crucial to technological advancement, they have also gained attention in the media due to fire and explosion incidents. Although relatively rare when handled properly, lithium-ion battery fires do present a growing challenge for global business resilience.

To address these concerns, FM has introduced an innovative, first-of-its-kind loss prevention data sheet specifically for lithium-ion battery manufacturing and storage. Released in October 2024, this comprehensive guide establishes much-needed fire protection standards - filling a gap that has persisted despite the rapid expansion of lithium-ion battery usage. While potential hazards exist, awareness of proper risk management remains limited, contributing to misunderstandings about their overall safety.

The FM Loss Prevention Data Sheet 7-112, Lithium-ion Battery Manufacturing and Storage is freely available and reflects extensive research, rigorous testing, and in-depth engineering analysis focused on enhancing fire safety. Collaborations with battery manufacturers, users and industry experts to gain real-world insights greatly contributed to our understanding of current practices which ultimately helped inform the development of the data sheet.

Our large-scale experiments involved deliberately igniting pallet-loads of lithium-ion batteries in controlled conditions to observe fire behaviour, heat release, and thermal runaway risks. Additionally, smaller-scale tests explored the fundamental physics of lithium-ion battery failures. These studies allowed us to identify key risk factors and develop effective fire prevention strategies.

Understanding thermal runaway: a major lithium-ion battery hazard

One of the most pressing risks associated with lithium-ion batteries is thermal runaway—a self-sustaining reaction that occurs when a battery cell short-circuits, releasing flammable gases and rapidly escalating into a fire or explosion. Once thermal runaway begins, it cannot be stopped, making prevention the best defence. The most effective way to mitigate this risk is by removing the affected battery or using water to cool it down, preventing heat from spreading to nearby cells.

What triggers thermal runaway?

Thermal runaway is often caused when batteries are “abused” by physical damage, such as a battery being dropped, punctured, or overcharged. In some cases, manufacturing defects can weaken a battery, making it more vulnerable to failure. Additionally, if one battery catches fire, the heat can spread to others, creating a chain reaction that accelerates thermal runway in another.

Despite these risks, most lithium-ion batteries in consumer electronics operate safely. Fires or explosions are uncommon unless a battery is mishandled or damaged.

Fire safety in lithium-ion battery storage

The risk of fire in lithium-ion battery storage depends on several factors, including charge levels, packaging, and storage conditions. Proper management of these variables can significantly enhance fire prevention and containment.

Imagine your warehouse is filled with power tools for example, each equipped with a lithium-ion battery charged to 30%. These batteries are housed within the power tool's plastic casing, which is then placed inside the product's packaging, and finally packed into a shipping box. Overall, this presents a relatively low risk. The 30% charge reduces the likelihood of the battery entering thermal runaway. In the event of a fire, the packaging could trigger a sprinkler system, quickly containing the blaze and preventing it from affecting nearby batteries.

On the other hand, storing large quantities of loose lithium-ion cells, modules, or battery packs poses a much greater fire hazard. Without protective casings or packaging, more batteries are exposed, increasing the risk of rapid escalation and fire spread. To minimise these dangers, our data sheet provides detailed fire protection strategies based on charge levels, storage height, and packaging materials. One key recommendation is maintaining a minimum 10-ft (3.0m) separation between lithium-ion battery storage and combustible materials. In higher-risk environments, additional safeguards, such as lower storage heights or in-rack sprinklers, may be necessary to contain potential fires.

By implementing FM’s fire safety best practices, businesses can strengthen fire protection measures, reduce risks, and create safer storage and manufacturing environments for lithium-ion batteries. However, this data sheet is just the beginning. As battery technology advances, our research and engineering teams continue refining fire safety standards to address new challenges. FM experts remain committed to providing businesses with the most up-to-date guidance on lithium-ion battery safety.