Lithium-ion batteries: five key steps for risk professionals

Lithium-ion batteries are everywhere: powering our phones, laptops, electric vehicles and increasingly, personal light electric vehicles (PLEVs) such as e-bikes and scooters. Their popularity stems from high energy density and versatility, but these same qualities make them a source of risk.

Understanding the science – and the risks

Lithium-ion cells operate based on a self-heating phenomenon known as ‘thermal runaway’. The consequences can be severe: venting of flammable gases, ignition, ejection of cell contents and even vapour cloud explosions. Beyond the fire risk, toxic gases such as hydrogen fluoride and hydrogen cyanide, as well as the heavy metal contamination of the surrounding environment, must also be considered following an incident.

Lithium-ion battery failures can result from poor design, manufacturing defects, environmental stress, mechanical or thermal abuse, incorrect charging practices and user tampering.

Of growing concern is the rise in fires linked to PLEVs, and there have already been high-profile incidents, caused by design flaws. Fires are often exacerbated by DIY battery replacements, incompatible chargers and bypassed safety features.

The Office for Product Safety Standards (OPSS) has reported a dramatic increase in such incidents, with the London Fire Brigade responding to 178 lithium-ion battery fires in 2023, compared to just two in 2017. OPSS data also correlates cheaper, lower-quality batteries with a higher likelihood of thermal runaway.

Testing, regulation and investigation challenges

The UN 38.3 transportation testing regime is designed to ensure batteries fail safely under simulated conditions. Despite these safeguards, battery fires continue to occur, often due to substandard manufacturing or improper use.

The investigation of fires involving lithium-ion batteries can be complex because thermal runaway can occur both from internal faults and external fire exposure. Battery cells can also be projected across rooms, igniting secondary fires and complicating scene analysis. Such cases can require thorough investigation, exclusion of alternative causes and scrutiny of product history and compatibility.

Implications for risk professionals

For risk professionals, the message is clear: lithium-ion batteries present complex, evolving risks that require proactive identification and assessment. Here are my key recommendations:

1. Risk identification and assessment: Stay alert to hazards posed by lithium-ion batteries in both consumer and industrial applications. Pay particular attention to modified products or those containing poor-quality components.

2. Claims and investigation: Effective claims handling demands forensic expertise. Invest in partnerships with specialists and ensure robust protocols for thorough investigation, evidence collection and analysis.

3. Prevention and mitigation: Promote best practices for battery use, storage and charging. Advocate for quality assurance in supply chains and educate users about the dangers of DIY repairs and the importance of manufacturer-approved components.

4. Regulatory awareness: Monitor regulatory developments, product recalls and safety standards. Collaborate with industry bodies to support safer product design and usage.

5. Strategic response: Integrate battery risk into risk frameworks, scenario planning and crisis response strategies. The potential for nefarious use – whether in arson, sabotage or terrorism – adds a layer of complexity that demands vigilance and cross-sector collaboration.

Conclusion: an urgent risk

Presenting at the Island of Ireland Airmic Conference was a rewarding experience. The engagement and questions from fellow risk professionals underscored the urgency of addressing lithium-ion battery risks in our industry.

As technology evolves, so too must the approach to risk management. By combining technical expertise, investigative rigour and proactive strategies, we can help our organisations stay ahead of emerging threats and ensure safer outcomes for all.

By Lucy Pinkard, associate forensic investigator, lecturer and industry executive at Hawkins & Associates.