⚡️The Hidden Dangers of Lithium Power in the Workplace

Lithium-ion batteries are widely used in everything from smartphones and laptops to electric vehicles (EVs), e-scooters, and industrial tools. While generally safe when used correctly, they can pose serious fire and explosion risks under certain conditions.

At COHIBL, we’re seeing a growing need for awareness and risk management around lithium battery hazards.  Whether you’re a business owner, facilities manager, or simply charging devices at home, here’s what you need to know.

🔥 Key Risk Factors

Lithium batteries can become dangerous when defective, damaged, or improperly charged. Energised cells have the potential to explode or ignite, especially in high-voltage applications like EVs or industrial equipment.

Thermal runaway is when batteries overheat uncontrollably.  A self-sustaining chain reaction causes heat to build up inside the battery, faster than it can dissipate.  Thermal runaway can be triggered by overcharging of the battery, internal short circuits, physical damage, or exposure to high temperatures.

Puncturing, crushing, or dropping a battery can mean that the internal structure of the battery is compromised and lead to failure, whilst poor quality cells or errors in assembly can make the battery more vulnerable and increase the risk of fire.

It is also important to ensure that you are not using incompatible chargers or charging through incorrect ports, as this can bypass internal safety mechanisms.

If a battery system is faulty, damaged, or improperly maintained, it may cause a vehicle or equipment to move suddenly or uncontrollably – known as kinetic force.  This is especially dangerous in confined spaces like warehouses or workshops, as it can result in serious injury or equipment damage.

Worryingly, even after a fire is extinguished, lithium-ion batteries can reignite hours or even days later, especially in the case of EVs or larger battery packs.  This means it is essential to ensure there is a post incident monitoring process in place.

Workplace Incidents: A Growing Concern

Recent UK data paints a worrying picture:

• In 2023, UK fire services responded to 921 lithium-ion battery fires, with e-bikes accounting for nearly a third
• Electric scooters were linked to 125 fires, and electric cars to 118.
• Electric trucks saw a 300% increase in fire incidents year-on-year

A survey by Aviva published in January this year found that 54% of UK businesses had experienced lithium battery-related incidents – including sparking (19%) and smoking (17%).  The most frightening statistics being that:

“Around one in eight respondents had experienced fires (13%) or explosions (12%) in the workplace.”

These incidents often stem from improper charging, damaged cells, or lack of staff training – and they’re happening in offices, warehouses, and industrial sites across the country.

Why Training and Awareness Are Critical

Employers must ensure that staff are properly trained and informed about the hazards of lithium batteries.  Many of the lithium-ion battery related incidents stem from human error, including using the wrong charger, overcharging, or not storing batteries properly.

Clear information, instruction, and training on battery risks is important, including the chemical, electrical, and kinetic risks associated with battery powered equipment.

Thorough training will ensure that staff not only understand how to safely operate and store batteries, but also how to respond to emergency situations if things go wrong.

Core topics for training should include: –

• Battery basics
• Hazards
• Thermal runaway
• Safe charging
• Storage protocols
• Emergency response
• Maintenance & inspection

Practical elements like the use of fire extinguishers (like Class D or CO2) and discussion of real-life case studies and incident simulations can be of real benefit.

Role specific modules should be included for the facilities team, and managers responsible for risk assessment and policy enforcement.

Safe Storage

Risk can be significantly reduced with proper handling and storage:

✅ Do:

• Store in a cool, dry, and well-ventilated area away from direct sunlight and heat sources.
• Use fire-resistant storage cabinets (preferably metal) for batteries not in use.
• Keep batteries away from flammable materials and out of escape routes.
• Separate damaged or suspect batteries in a designated, clearly marked container.
• Ensure storage areas are clearly labelled and access is restricted to trained personnel.
• Consider restricting lithium-powered devices from hazardous sites like chemical plants.

 ❌ Avoid:

• Storing batteries in high humidity or extreme temperatures.
• Piling batteries on top of each other or storing them loosely.
• Keeping batteries near combustible materials like paper, cardboard, or fuel.

Safe Charging Procedures

✅ Do:

• Use only manufacturer-approved chargers and follow the device’s charging instructions.
• Charge batteries on non-combustible surfaces, away from flammable materials.
• Supervise charging – avoid leaving batteries charging overnight or unattended.
• Install smoke detectors and, where appropriate, automatic fire suppression systems in charging areas.
• Ensure charging stations are well-ventilated and not overloaded with multiple devices.

❌ Avoid:

• Charging modified or damaged devices, including batteries that are damaged, swollen, or leaking.
• Using extension leads or daisy-chained sockets for multiple chargers.
• Charging in escape routes, stairwells, or communal areas.

• Avoid charging e-scooters and e-bikes on commercial premises where fire risk is elevated.

Fire Detection and Emergency Planning

Fire detection and emergency planning are critical components of managing lithium-ion battery risks, whether in a commercial or residential setting.

You can:

• Protect your business by installing automatic fire detection and suppression systems.
• Develop effective emergency response plans including battery-specific fire response protocols in liaison with local fire brigades.
• Ensure charging is never left unattended without a management system in place.

After any incident you should conduct a thorough investigation, updating your emergency plans and risk assessments accordingly.

Insurance and Risk Management

Insurers are increasingly scrutinising lithium battery risks. It’s vital that all processes and protections are regularly reviewed, ensuring that risks are clearly communicated to underwriters.

Your policy must reflect the reality of your operations and exposures.  At Caunce O’Hara, we help businesses and individuals navigate these emerging risks with tailored insurance solutions and expert advice.

If you fail to provide a valid fire risk assessment document or demonstrate proper fire safety precautions at your property or workplace, your building insurance may become invalid in the event of a fire and face prosecution under fire safety legislation.

A lithium battery fire will quickly escalate in the wrong set of circumstances and seriously endanger life.  It is therefore essential to have a suitable and sufficient fire risk assessment, evaluated annually and when: –

• the use of the building has changed
• there has been a change of occupancy
• there has been a fire, evacuation, or near miss

Need Support?

Under the Regulatory Reform (Fire Safety) Order 2005, you must arrange the undertaking of a thorough inspection and prepare a comprehensive fire risk assessment document, alongside actioning any significant findings.

At Caunce O’Hara, our in-house Risk Manager, Steve Haines, can support you with your Fire Safety Risk Assessments, even if you are not an existing client.