By: Chad Engle, Loss Prevention Manager and Safety Specialist
Earlier this month, I attended the American Society of Safety Professionals (ASSP) Safety 2026 Conference. On my Southwest Airlines flight, I noticed a new addition to the pre-flight safety briefing: passengers were instructed to keep portable battery packs in sight rather than in overhead compartments.
While no explanation was provided, the reasoning became clear during a conference session titled “Hot Cells, High Stakes: Mitigating Lithium Battery Fire Risks in the Workplace.”
A key concept discussed was thermal runaway—a chain reaction in lithium-ion (Li-Ion) batteries where overheating leads to a rapid, violent fire that is extremely difficult to extinguish.
This may seem like a rare issue, but the presenter shared that approximately two battery-related fires occur per week on airplanes, and incidents are increasing on construction sites where the rough handling and use of Li-Ion powered tools is common.
When you think about it, Li-ion batteries are everywhere:
Electric vehicles, e-bikes, scooters, lawn equipment, laptops, tablets, phones, power tools, smartwatches, robotic vacuums, toys—the list continues to grow.
Why Li-Ion Batteries Fail
Li-Ion batteries can ignite due to:
- Mechanical damage
- High temperatures (thermal stress)
- Manufacturing defects
- Aging and repeated charging cycles
Prevention Tips
To reduce risk:
- Use only manufacturer-approved or certified chargers
- Regularly inspect batteries for swelling, dents, heat, or unusual odors
- Stop using damaged devices immediately
- Charge devices on hard, nonflammable surfaces
- Avoid charging on beds, couches, or carpets
- Do not charge overnight or near flammable materials
- Avoid extreme heat or cold exposure
- Use batteries with recognized certifications (e.g., UL Listed)
Emergency Preparedness
If a thermal runaway event occurs, preparation is critical.
- Include battery fire scenarios in your Emergency Action Plan (EAP)
- Train employees or family members on response procedures
- If a battery is smoking, bulging or damaged, move it outside and away from your home. Dial 911 and identify that you have a battery actively smoking.
- When handling a damaged battery use safety goggles and heavy nitrile or butyl gloves to prevent chemical burns from leaking lithium fluid
- Do not submerge a damaged battery in water
- Submerge the battery in a sturdy bucket filled with an inert butter like dry sand, dirt, or kitty litter
Specialized products are available, including:
- Fire-resistant battery storage containers
- Li-Ion battery fire containment kits are available through industrial and first-responder suppliers
- Fire suppression blankets for devices ranging from phones to electric vehicles
Because these fires are difficult to extinguish, property damage costs can be significantly higher than typical fires.
Proper Battery Disposal
Never dispose of Li-Ion batteries in regular trash. Improper disposal can lead to fires in garbage trucks and waste facilities.
Always use approved battery recycling or disposal programs.
Final Recommendations
Take the following steps today:
- Identify all Li-Ion batteries in your home and workplace
- Inspect and maintain them regularly
- Follow safe charging practices
- Dispose of batteries properly
- Develop and practice a thermal runaway response plan
Please don’t hesitate to reach out with any questions. I can be reached at chad@nirma.info or 402-742-9225.
