The Volatile Reality: Navigating the Hazards of Lithium-Ion Battery Use

These little things slid into our lives almost unnoticed. They’re small and sleek and keep us moving and connected. Until the explosions and fires started happening. Yes, we’re talking about lithium-ion batteries. These increasingly common powerhouses of energy keep everything from phones to cars humming along. The downside is, without proper care, all that stored energy can cause explosions, fires, and the release of toxic gases. This has led to serious damage, injuries and has cost lives. Let’s talk about lithium battery basics and ways to stay safely powered up.

The increased use of small electronics has increased the demand for small batteries.  Battery energy density measures the amount of energy a battery can store per unit of its mass or volume. High energy density means more energy can be packed into small and lightweight batteries. Streamlined, compact batteries allow for longer run times, smaller and lighter devices and take less material so they reduce manufacturing costs.

In the U.S, there are two types of lithium batteries:  

• Single use, non-rechargeable lithium metal batteries and

• Rechargeable lithium polymer cells, commonly called “Lithium-Ion” or “Li-ion” cell batteries. 

For the remainder of the article, we’ll be talking about the rechargeable lithium-ion battery, which, when designed, manufactured and used properly, are safe to use. How do you know if your lithium-ion battery is designed, manufactured and properly used? Stay tuned, you’re about to find out!

Unsure if this risk applies to you?

Consider the following common uses:

• Electric vehicles

• Banks of chargers or centralized charging stations for two-way radios, tactical lights and flashlights, body cameras, TASERS, drones, thermal imaging cameras

• Heavy duty machinery for construction projects, such as electric excavators, wheel loaders, aerial work platforms, forklifts, pallet jacks, power tools, lawn care equipment

• Smartphones, laptops, digital cameras, energy storage such as backup systems, medical devices.

US Fire Administration recommends the following steps and acronym “CHARGE” for battery safety awareness:

Choose certified products.

Handle with care.

Always stay alert.

Recycle properly.

Get out quickly.

Educate others.

Choose Certified Products

• Only use the manufacturers’ cord and adapter made specifically for the device and follow the manufacturer instructions for charging and storage.

• Purchase certified products and look for the Underwrite Laboratories (UL) mark.  The UL mark means that the product has been tested to recognized safety standards. 

• Replacement chargers and batteries should be made by the original manufacturer of the device.

• Like any product, a small percentage of lithium-ion batteries can be defective. 

• Avoid generic and off-brand chargers, batteries, and cables.

Handle with Care

• Keep your batteries and device charged and stored at room temperature, out of direct sunlight or a heat source and away from anything flammable.

• Don’t charge devices:

  • On the path to exit a room or building, such as near exit doors, bedroom doors, or garage vehicle doors.

  • In your bedroom.

  • Overnight, especially for larger devices.

• Don’t overcharge or leave charging devices unattended or overnight.

• Plug chargers directly into a wall outlet, not an extension cord.

• Don’t charge devices on any surface that’s flammable such as bedding or a couch.

• Regularly inspect batteries for changes in shape, color, leaking, odors or odd noises such as hissing, cracking or popping. If you notice any of these conditions, discontinue use immediately.  If it can be done safely, move the device away from anything that can catch fire and call 9-1-1.

Causes of Lithium-Ion Battery Explosions:

• Physical Damage: Penetration, crushing, or exposure to water can trigger thermal runaway.

• Electrical Damage: Overcharging or using incompatible chargers can also lead to failure.

• Extreme Temperatures: Exposure to excessive heat can cause the battery to overheat and fail.

• Product Defects: In some cases, manufacturing defects can contribute to battery failures. 

 Always Stay Alert

• If there is a lithium-ion battery fire:

  • Leave the area.

  • Close the door.

  • Call 911 immediately.

• Lithium-ion batteries are known to unexpectedly re-ignite from minutes to days after a fire has been extinguished.

• Some fire extinguishers don’t work on lithium-ion battery fires. 

• White or gray, wispy smoke means there’s an immediate danger of fire.

Recycle Properly

• Responsibly dispose of old or damaged batteries at a recycling facility.

• Never discard batteries, chargers or battery powered devices into regular garbage bins.

• Two resources for finding a recycling center:

  • Earth 911

  • Call2Recycle

Get Out Quickly

• If you see, smell or hear the signs of fire, follow your fire or evacuation plan, get out quickly and call 911.

• Batteries can get blisteringly hot almost instantly and emit a flame almost as hot as a blowtorch.

• Fires can be unpredictable and escalate rapidly.

• These batteries don’t produce a lot of smoke in the early stages of failure so it might not activate a traditional smoke alarm in time to prevent a fire.

Educate Others

• Spread the word! Warn your team, family and friends of these hazards, or forward them this article. 

• Consider a policy for employees that includes requirements for purchasing and storing work devices, batteries and chargers. 

Policy, Safety, Storage

Massachusetts Institute of Technology (MIT) experienced incidents related to batteries left on chargers for extended periods of time, unattended charging, incompatible chargers and low-quality replacement batteries. MIT Lithium Ion Battery Safety Guidance and University of Washington Battery Safety both offer best practices to consider when creating your own policy.

CIS member, Josephine County, created this short video of an evolving fire on a transit bus. Quick thinking and action by the County and Grants Pass Fire Department certainly saved lives and more extensive damage. Consider that first and second responders, maintenance and mechanics that work on electric vehicles will need safety training and plans. The CIS Learning Center has classes and the Oregon State Fire Marshall has offered training on this subject.

Safety is a concern wherever lithium-ion batteries are used, both in and out of the workplace. OSHA has this information on safety basics, with a focus on small wearables such as body worn cameras. While there’s not a specific battery safety standard, many safety standards may apply. Let your teams know your expectations around buying, storing and charging equipment. 

Last, consider where you store items with lithium-ion batteries. Josephine County’s preventive efforts limited the fire damage to one bus. Consider where vehicles and e-bikes are parked. Can they be safely stored outdoors? Charging stations should not be near exits or pathways to an exit. Preplanning will keep you and your team safely powered up at home and on the job. 

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OSHA Standards

While there is not a specific OSHA standard for lithium-ion batteries, many of the OSHA general industry standards may apply, as well as the General Duty Clause (Section 5(a)(1) of the Occupational Safety and Health Act of 1970). These include, but are not limited to the following standards:

• 1910 Subpart L - Fire Protection

• 1910 Subpart S - Electrical

• 1910.39 Fire Prevention Plans

• 1910.119 Process Safety Management of Highly Hazardous Chemicals

• 1910.120 Hazardous Waste Operation and Emergency Response

• 1910.132 Personal Protective Equipment

• 1910.134 Respiratory Protection

• 1910.147 The Control of Hazardous Energy (Lockout/Tagout)

• 1910.151 Medical Services and First Aid

• 1910.178 Powered Industrial Trucks

• 1910.1000 Air Contaminants

• 1910.1020 Access to employee exposure and medical records

• 1910.1200 Hazard Communication

These standards are also representative of the types of protections that apply to the manufacture and use of other energy storage technology, whether in use now or under development.