The worrying increase in lithium-ion battery fires has seen the delivery of a new data sheet outlining fire protection strategies for their storage.
The information produced by FM Global, specifically Loss Prevention Data Sheet 7-112 (October 2024), provides detailed fire risk mitigation strategies for lithium-ion battery manufacturing and storage.
It outlines objectives such as preventing thermal runaway, minimising fire spread, and ensuring safe handling of damaged cells. The guidance becomes particularly relevant when storing large volumes of batteries (e.g., palletised bulk storage), batteries with high energy density (e.g. electric vehicle battery packs), or when the batteries are not enclosed within protective product housings. It also applies to manufacturing sites and logistics centres handling or transhipping substantial quantities of lithium-ion cells or packs.
In high risk situations additional safeguards such as lower storage heights or in-rack sprinklers may be required to limit the spread of fire.
To establish the data, FM Global conducted full-scale fire tests on palletised lithium-ion batteries to evaluate fire behaviour, thermal runaway potential, and heat release. Additional off-gas detection testing and energy release modelling contributed to the formulation of robust storage and handling measures.
Additional tests helped understand the fundamental physics behind lithium-ion battery failures and establish effective safety measures. The data also highlighted that proper management of storage situations can significantly impact fire prevention and containment.
A warehouse storing power tools with built-in lithium-ion batteries poses a relatively low risk as the batteries are encased with the tool’s protective shell within product packaging inside shipping boxes. If batteries are only partially charged to 30 per cent the chances of a thermal runaway are considerably reduced. In the event of a fire, the outer packaging would ignite first, activating the sprinkler system before flames could spread to the batteries.
However, storing large quantities of loose lithium-ion cells, modules or battery packs presents a much greater fire risk. Without the presence of a protective casing and packaging, more batteries are likely to become involved in a blaze.
On February 19, 2025, a fire broke out at an under-construction BESS project in Thurrock, Essex. The fire, which lasted three days and took over 200 firefighters to put out, highlighted the potential risks associated with large-scale battery storage facilities and the need for stringent safety measures during the construction and operation of these sites.
The rise in lithium and lithium-ion battery usage has coincided with a worrying spike in fire incidents across the UK. Data, compiled from Freedom of Information requests to fire services in March 2025, showed a 93% increase in such fires between 2022 and 2024.
Lithium-ion batteries, which power a wide range of consumer products including e-bikes, e-scooters, electric vehicles, smartphones, and power tools, were linked to 1,330 fires in 2024, up from 690 in 2022. Between 2022 and 2024, electric car fires rose from 131 to 232, marking a 77% increase.
According to the National Fire Chiefs Council (NFCC), lithium batteries are responsible for 48% of waste fires, costing the UK economy over £158 million annually.
A survey of more than 500 organisations carried out between September 2023 and February 2024 revealed that 71 per cent of respondents had not updated their fire risk assessments to cover the risk of Lithium-ion battery fires, with just 15 per cent having done so and a further 14 per cent unsure.
To mitigate the risks presented by Li-ion batteries it is vital to take steps to mitigate against all associated risks, including overheating, fire, explosions and intoxication. A suitable and sufficient fire risk assessment should be undertaken and be subject to regular review. This should cover handling, storage, use and charging, where appropriate, with consideration also given to the requirements of the Dangerous Substances and Explosive Atmospheres Regulation (DSEAR) recognising the potential risk to people from energy-releasing events such as fires, explosions and thermal runaway.
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