Failing lithium-ion batteries represent one of the fastest-growing safety risks in the workplace, according to the US trade publication ISHN. At the heart of the problem is “thermal runaway”: a self-reinforcing chemical chain reaction in which internal heat generation within a battery cell outpaces the system’s cooling capacity. This can lead to fire, explosions and the release of toxic gases.
From Cell to Battery Pack: Where It Goes Wrong
According to the article, the risks arise at multiple levels. At the cell level, internal short circuits, damaged separators, overcharging, lithium plating (the deposition of metallic lithium on the electrode) and dendrite formation all play a role. At the module and pack level, additional risks come into play, such as loose electrical connections, overheated busbars, ground faults and water ingress. When thermal runaway occurs, hazardous gases are released, including hydrogen, carbon monoxide, hydrogen fluoride, methane and propylene. These mixtures increase both the risk of explosion and the risk of toxic exposure for workers and first responders.
According to ISHN, this risk plays out across a range of work environments: large-scale battery energy storage systems (BESS) operated by utilities and commercial parties, data centers, warehouses and logistics centers, commercial fleets of electric vehicles, battery manufacturing and recycling facilities, and installations in the oil and gas sector.
Structured Risk Analysis and Standards
To manage these risks, the article points to two established methodologies from safety engineering. FMEA (Failure Modes and Effects Analysis) is a bottom-up approach in which failure modes are assessed on severity, likelihood of occurrence and detectability, in order to set priorities. FTA (Fault Tree Analysis), by contrast, works top-down, mapping how a combination of subsystem failures can lead to a catastrophic event. Battery systems are also subject to specific standards, including NFPA 855, UL 9540A, SAE J1739 and IEC 62619, which set requirements for, among other things, storage, testing and risk assessment of battery systems.
A Knowledge Gap Among Personnel
A key bottleneck, according to ISHN, is the shortage of trained personnel: many companies and emergency services lack the specific expertise needed to recognize and respond to these relatively new risks. This has prompted the US Department of Energy to develop, through targeted funding, programs for specialized safety certification and response protocols for incidents involving lithium-ion batteries.
For EHS professionals, this is relevant because lithium-ion batteries are becoming increasingly common in the workplace: in charging stations for electric equipment, in warehouses storing battery packs, and in stationary energy storage systems. Proper storage, charging procedures, ventilation and a well-considered risk analysis (FMEA/FTA) are essential to prevent or detect thermal runaway early, and to prepare first responders for the specific hazards of battery fires, such as reignition and toxic smoke.
Source: Failing Lithium-Ion Batteries are Today’s Fastest-Growing Safety Challenge, September 14, 2026
