Safe handling and storage of lithium batteries

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A story, the risks, and what to do

Imagine: it is Monday morning. Luca, the workshop foreman, walks among the benches and trolleys. On one trolley he notices a slightly swollen battery and detects an unusual smell. He acts calmly: he isolates the area, alerts the team and places the battery in a dedicated safety box until a specialist check. This quick action protects people, equipment and production. This experience shows how proactive prevention turns a potential incident into a well-managed event.

What lithium batteries are and who made them practical

Rechargeable lithium batteries power many everyday devices. Their operation relies on lithium ions moving between electrodes during charge and discharge. Key contributors to the modern rechargeable lithium battery include M. Stanley Whittingham, John B. Goodenough and Akira Yoshino; Yoshino developed the first commercially viable rechargeable battery that enabled today’s portable electronics. These batteries appear in smartphones, laptops, power tools, e-bikes and e-scooters, electric forklifts, stationary storage for solar systems and electric vehicles.

Fire risks: a few real cases and technical lessons

Thermal runaway can start from cell damage, internal short circuits or improper charging. Practical examples with operational value:

Investigations into Boeing 787 battery incidents prompted aviation authorities to revise design and safety approaches after battery fires affected aircraft systems. Technical findings highlight how an electrical fault can trigger a battery fire and how specific on-board safety measures protect passengers and crew.
UK reports from 2024–2025 show a rise in fires involving e-bikes and e-scooters, with frequent involvement of modified batteries, uncertain battery origins and charging practices in living spaces or near escape routes. These reports emphasize that product sourcing and charging discipline influence incident probability.

These examples highlight two operational truths: batteries store high energy density and require regular inspection, and everyday handling determines the likelihood that a defect becomes a fire.

What this means for a company

For organizations that manage facilities and people, the topic translates into practical responsibilities and operational advantages:

protection of employee safety;
continuity of production and operations;
clear handling of relationships with insurers and authorities;
control of costs related to damage, downtime and compensation claims.

A company that implements an inventory, clear procedures, staff training and emergency plans reduces financial exposure and preserves reputation.

What it means to underestimate the risk

Underestimating the risk means delaying straightforward actions that lower incident probability. Practical consequences:

higher likelihood of localized fires that damage equipment and facilities;
interruption of production and costs for recovery;
need to provide clear evidence to insurers and authorities during claims and inspections;
exposure to administrative enforcement when documentation or management fall short.

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Who can face these events

Events involving batteries can happen in many contexts and affect various roles:

warehouses and workshops using electric forklifts and battery-powered tools;
repair shops and retailers of e-bikes and e-scooters;
fleet managers and logistics teams operating electric vehicles;
maintenance staff handling battery packs or replacements;
offices and shared spaces where personal devices charge;
couriers and transporters who move batteries or devices containing batteries.

Clear, practical steps to take now

Create an operational inventory: record cell type, capacity (Wh), serial number and usage location for each battery.
Classify and zone areas: define dedicated charging zones and temporary storage zones with quantity limits.
Use appropriate containers and separation: adopt certified boxes or cabinets for used or damaged batteries; ensure ventilation and smoke detection where feasible.
Implement procedures and logs: trace each battery with dates of first charge, inspections and incident notes.
Deliver focused training: teach staff to recognize signs of anomaly (heat, swelling, unusual smell) and to follow immediate safe actions (isolate, alert, move to safety container).
Prepare an emergency plan: define isolation and evacuation steps, communication with fire services and insurers, and conduct regular drills.
Manage end of life responsibly: partner with authorized collectors and keep records of disposal and transport.

These steps move battery management from reactive to proactive.

Are there official procedures for storage and disposal?

Yes. Standards and guidance documents provide detailed instructions for installation, operation and safe handling of battery systems:

standards for large energy storage systems (ESS), such as NFPA 855, describe technical and fire-safety requirements for industrial-scale setups;
shipping and handling guidance from agencies like IATA provides air transport limits, packaging rules and prohibited categories;
ADR (UNECE) describes road transport classification (UN3480 / UN3481), packing rules and labelling for battery shipments;
Regulation (EU) 2023/1542 addresses batteries and waste batteries in the EU, including collection, traceability and safety aspects.

Integrating these references into the company HSE system strengthens compliance and simplifies interactions with inspectors.

Do the rules apply only to air transport or also to road transport?

Regulations apply to all transport modes, with mode-specific requirements:

air transport follows IATA Dangerous Goods Regulations and includes strict limits, specific packing instructions and, for some batteries, carriage only on freighter aircraft;
road transport follows ADR rules (UNECE) with UN numbers, packaging, labelling and documentation requirements for national and international road movements;
maritime transport follows IMDG rules for sea shipments.

Practical action plans should cover road, air and sea transport with tailored procedures and training for staff who move batteries.

Download here our free guideline

References: https://www.iata.org/contentassets/05e6d8742b0047259bf3a700bc9d42b9/lithium-battery-guidance-document.pdf

https://www.phmsa.dot.gov/sites/phmsa.dot.gov/files/2024-11/Lithium-Battery-Guide-2024.pdf

https://unece.org/transport/standards/transport/dangerous-goods/adr-2023-agreement-concerning-international-carriage

https://www.iata.org/en/programs/cargo/dgr/lithium-batteries/https://eur-lex.europa.eu/legal-content/EN/TXT/PDF/?uri=CELEX%3A32023R1542

https://www.nfpa.org/codes-and-standards/nfpa-855-standard/p0855code

https://www.ntsb.gov/investigations/accidentreports/reports/air1401.pdf

https://www.gov.uk/government/publications/fires-in-e-bikes-and-e-scooters/fires-in-e-bikes-and-e-scooters-2024

https://www.easa.europa.eu/en/newsroom-and-events/press-releases/easa-publishes-new-recommendations-managing-risks-lithium

https://unece.org/sites/default/files/2023-01/ADR2023_Vol2e.pdf

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