Lithium-ion battery storage systems are vital for energy grids but pose unique risks during emergencies. Fires, toxic gas emissions, and explosions linked to these systems demand specialized response strategies and training. Recent incidents, like the May 2024 Gateway Energy Storage fire, underscore the dangers: thermal runaway, hazardous gas exposure, and reignition risks.
Key points for responders include:
- Thermal runaway: A self-heating chain reaction that’s hard to suppress.
- Toxic gases: Emissions like hydrogen fluoride and carbon monoxide require proper respiratory protection and air monitoring.
- Explosion risks: Pressure buildup in batteries can lead to violent incidents, necessitating containment strategies.
Training programs, such as those by NFPA and IAFF, equip responders with the knowledge to identify hazards, manage fires, and use protective gear effectively. New tools, like digital workforce platforms, ensure qualified teams are deployed swiftly. As battery systems grow, updated protocols and ongoing training are critical for responder safety and community protection.
Hazards of Lithium-Ion Battery Emergencies
Thermal Runaway and Fire Risks
One of the most dangerous challenges first responders face with lithium-ion batteries is thermal runaway. This is a chain reaction of uncontrollable self-heating that traditional firefighting methods often can’t handle. The Department of Homeland Security‘s Science and Technology Directorate explains:
When a failure is triggered, these batteries can enter ‘thermal runaway’ – an uncontrollable, self-heating state marked by the release of toxic gases and rapid conflagration that can lead to explosions.
Thermal runaway can be triggered by several factors: overcharging, physical damage (like crushing or puncturing), manufacturing defects, short circuits, or exposure to high external temperatures. Once the process begins, it releases flammable gases from volatile electrolytes, and battery cells may eject from their casings, igniting surrounding materials. Flames can reach 10 feet high, and the risk of reignition means that fires can restart hours or even days later.
Warning signs of thermal runaway include cracking or bulging battery packs, popping or hissing sounds, visible gas venting, and rapidly rising temperatures. The U.S. Fire Administration advises:
Firefighters should implement thorough post-fire assessments and continued monitoring to prevent rekindling, including during post-incident transport and placement.
Beyond the immediate fire threat, toxic gases released during these events add another layer of danger.
Toxic Gas Emissions and Health Risks
The toxic gases released during lithium-ion battery fires can be even more hazardous than the flames. These include hydrogen fluoride (HF) and hydrochloric acid (HCl), along with smoke containing metals, perfluorinated compounds, and polyaromatic hydrocarbons (PAHs). In confined spaces, these emissions can quickly become life-threatening, particularly due to the risk of inhalation.
This issue is becoming more pressing. In New York City, for instance, fatalities from lithium-ion battery fires rose from zero in 2019 to 18 in 2023, largely due to the growing use of e-bikes, electric vehicles, and large-scale energy storage systems. Hazardous material response teams are increasingly tasked with decontaminating personal protective equipment and handling toxic residues that linger long after fires are extinguished.
To reduce exposure, first responders should always position themselves upwind of smoke plumes. While advanced electronic monitoring tools for detecting HF and HCl are costly and complex, colorimetric tubes provide a more affordable option for initial detection. However, firefighting efforts can create additional environmental concerns. Water runoff from extinguishing these fires often carries harmful metals and chemicals into soil and water systems, requiring careful containment planning.
In addition to the toxic risks, the buildup of internal pressure in batteries can lead to devastating explosions.
Explosion Risks and Containment Challenges
When thermal runaway occurs, the rapid release of gases and volatile electrolytes can cause internal pressure to build up, leading to violent explosions. A striking example occurred in late 2024, when a lithium-ion battery explosion involving a transport truck shut down a seven-mile stretch of highway for 48 hours.
| Indicator of Explosion Risk | Description |
|---|---|
| Mechanical Damage | Cracks or deformation caused by collisions, dropping, or physical abuse |
| Bulging | Swelling of the battery pack or casing due to internal pressure |
| Audible Signs | Popping or hissing sounds from escaping gases |
| Venting | Visible gas emissions from the battery or its enclosure |
| Thermal Instability | Rapid temperature increases that standard cooling methods can’t control |
To manage these risks, containment strategies often include specialized venting mechanisms. Modern enclosures may use rupture discs, explosion panels, or breather membranes to safely release excess pressure. First responders should familiarize themselves with Emergency Response Guides (ERGs) provided by manufacturers to understand the specific containment features and shutdown procedures for various battery systems.
sbb-itb-aa28329
Emergency Response Guide for Battery Energy Storage Systems
Training Programs for First Responders
Specialized training programs are helping first responders handle emergencies involving battery storage systems. These courses focus on the unique risks posed by lithium-ion batteries – like thermal runaway and the release of toxic or flammable gases – while teaching critical emergency protocols.
NFPA Energy Storage Systems Safety Training
The National Fire Protection Association (NFPA) offers online courses such as Energy Storage and Solar Safety for Emergency Responders and the Photovoltaic and Energy Storage Systems Online Training Series. These programs are grounded in NFPA standards, including NFPA 855, NFPA 1, and NFPA 70.
The training covers four main failure modes: mechanical, thermal, electrical, and environmental. It helps responders recognize early warning signs of thermal runaway and addresses the dangers of stranded energy – residual electrical charge that can continue to pose shock risks even after a fire is extinguished.
Fire suppression techniques are a major focus. For systems operating up to 1,000 volts DC, water serves as an effective cooling agent. The NFPA recommends applying water with an adjustable nozzle set to at least a 10-degree fog pattern from a distance of 5 feet or more to minimize electrical shock risks. The NFPA also highlights the ongoing risk of reignition:
Lithium-ion batteries have shown they can ignite, or reignite, long after they have been damaged or involved in a fire – hours, days, or even weeks later.
The program also addresses post-fire cleanup. Traditional water-based cleaning of personal protective equipment can remove about 99.2% of metallic particles left after a lithium-ion battery fire. Additionally, the NFPA provides free Emergency Response Guides from over 35 manufacturers of alternative fuel vehicles and energy storage systems.
The International Association of Fire Fighters (IAFF) offers complementary training resources to further support first responders.
IAFF Renewable Energy Emergency Response Training
The IAFF has developed its Energy Hazard Guide, released in June 2025, to help first responders manage emergencies involving renewable energy systems and battery storage. This guide provides tactical advice and protocols for addressing the risks associated with these modern energy technologies.
Response Protocols for Battery Storage Incidents
Initial Assessment and Hazard Identification
Before taking action, responders need to consult pre-incident documentation like Hazard Mitigation Analysis (HMA), UL9540A test results, and Emergency Response Plans (ERP). These documents help predict how the battery system might behave during incidents like thermal runaway. Accessing Battery Management System (BMS) data is another critical step. As the American Clean Power Association explains, this data is essential for making informed emergency decisions. Battery chemistry – such as Nickel-Manganese-Cobalt (NMC) versus Lithium Iron Phosphate (LFP) – also plays a key role in determining the right suppression techniques.
"Access to battery management system (BMS) data is also a vital part of making informed choices regarding emergency response".
The chemistry of the battery dictates its behavior in emergencies. For example, NMC cells release oxygen during thermal runaway, fueling the fire, while LFP cells do not, requiring different approaches to suppression.
Another key consideration is identifying large outdoor enclosures (600 kWh or more), which come with stricter safety standards. A thorough hazard assessment should address five main risks: fire, explosion, arc flash, electric shock, and exposure to toxic chemicals. The consequences of overlooking these risks are clear – such as the 2017 battery storage fire in Arizona that injured four firefighters.
Once the hazards are identified, the next step is to implement suppression methods tailored to the battery’s specific chemistry.
Fire Suppression and Cooling Techniques
When dealing with lithium-ion battery fires, water remains the go-to resource. However, the goal isn’t just to extinguish visible flames but to cool the internal reaction driving the thermal runaway. Even after flames are out, the process can continue if the battery remains hot. This means responders must apply large amounts of water to bring down the cell temperatures and stop the exothermic reaction.
For NMC systems, which release oxygen during thermal runaway, some manufacturers recommend a controlled burn strategy. This involves allowing the fire to burn itself out once the lower flammable limit is reached, which helps prevent larger explosions. In contrast, LFP systems focus on venting gases through designated outlets or panels to avoid dangerous pressure buildup. In both cases, prioritizing responder safety through defensive tactics is essential when managing large-scale battery incidents.
After suppression, responder safety remains a top priority through proper protective measures and decontamination.
Protective Equipment and Decontamination
Responders face multiple risks during battery emergencies, including fire, explosions, arc flash, electric shock, and exposure to hazardous chemicals. Standard firefighting gear should be supplemented with equipment specifically rated for electrical and chemical hazards.
The National Fire Protection Association (NFPA) 855 requires project stakeholders to provide detailed safety documentation to local authorities. This helps ensure responders have the right protective gear. Andy Colthorpe highlighted the importance of collaboration:
"Closer engagement with local first responders would have put fire crews and authorities in a much better position to deal with a then-unfamiliar set of risks".
Response strategies also need to align with the battery type. For example, venting is more effective for LFP systems, while alternative suppression techniques may be necessary for NMC configurations. Proper protective measures and tailored tactics make all the difference in ensuring responder safety.
Battery Emergency Training Program Comparison
First Responder Training Programs for Battery Storage Emergencies Comparison
Training Program Comparison Table
Proper training is crucial to address the specific dangers associated with battery-related emergencies. Choosing the right program depends on your organization’s priorities, available budget, and the level of expertise required.
Standard HAZMAT training is structured across different levels. Level 1 (Awareness) focuses on basic containment strategies, while Level 2 (Operations) prepares responders for handling localized incidents. Level 3 (Technician) equips individuals to manage high-risk situations, and Level 5 (Incident Commander) is designed for overseeing large-scale emergencies. These levels primarily emphasize containment and mitigation of hazardous materials rather than delving into the technology behind them. Understanding these distinctions helps in comparing general HAZMAT training with battery-specific programs to make informed decisions.
Battery-specific training programs tackle the unique risks posed by lithium-ion batteries. For instance, the Fire Safety Research Institute (FSRI) provides a free 75-minute online course that analyzes the Surprise, Arizona incident, where four firefighters were injured. Steve Kerber, FSRI’s Vice President of Research and Director, highlights the importance of learning from such events:
"Firefighter line of duty injuries and near miss incidents provide a unique opportunity to interact with and collect information from the scene and the personnel involved. This can make the difference in putting all the pieces together and gaining insights that may otherwise not be possible".
FSRI’s course requires a basic understanding of fire science principles and adheres to NFPA 1001 and NFPA 1010 standards. The following table compares key training programs to help guide your decision-making process:
| Program Name | Duration | Format | Cost | Core Topics |
|---|---|---|---|---|
| FSRI: Lithium-Ion ESS Fire Service Considerations | 75 minutes | Online | Free | Tactical considerations, incident analysis (Surprise, AZ), situational awareness, NFPA 1001/1010 standards |
| Compliance Solutions: Emergency Response Level 1, 2, or 5 | Site-specific | Onsite | Quote required | Hazard identification, containment, incident command (Level 5) |
| Compliance Solutions: Emergency Response Technician (Level 3) | Duration not specified | Classroom or Online Refresher | Quote required | Containment of Class 1 explosives, NFPA 3/4 special hazards, explosion risk management, large-scale evacuation |
Additionally, many programs offer tailored options based on a thorough assessment of the specific hazards present at your site or emergency response operation.
Technology’s Role in Workforce Preparedness
Training responders is essential, but ensuring that only qualified personnel handle battery storage emergencies is even more critical. Digital platforms now bridge certification and deployment, making sure that trained professionals are the ones tackling high-risk situations.
By building on traditional emergency response training, these platforms help ensure that the right people are deployed quickly and efficiently.
Certification and Compliance Tracking
Today’s workforce platforms play a key role in verifying responders’ qualifications. They track compliance with NFPA 1001/1010 standards, classroom training, and simulation completions. For example, ABLEMKR’s platform uses this data to match pre-vetted workers to emergency sites based on their certifications, training, availability, and location – making rapid deployment of crews possible.
Recognizing the importance of streamlined training management, NFPA and Vector Solutions introduced a Distributed Energy Resources (DER) Custom Activity in March 2025. This feature, available within the TargetSolutions training management platform, allows fire departments to assign and monitor training specific to solar farms and battery storage sites. Andrew Klock, NFPA Senior Manager, emphasized the importance of this initiative:
"As more distributed energy resources are deployed nationwide, the fire service needs to be properly prepared to respond to them safely and effectively".
This integration of technology ensures that responders remain consistently prepared, complementing their hands-on training.
Faster Response Through Workforce Matching
Speed is crucial when dealing with battery storage emergencies like thermal runaway. Tools such as ABLEMKR’s mobile-first platform use geo-location and job-matching features to provide real-time updates on worker availability, enabling the deployment of certified teams within hours.
Additionally, TargetSolutions equips firefighters with virtual hazard scenarios accessible on smart devices during walkthroughs of DER facilities. As Klock explained:
"firefighters can now face virtual hazard scenarios as a team on their smart devices while performing field familiarization".
Conclusion
Battery storage systems are becoming more common across the United States, and first responders need specific training to handle the unique risks associated with these installations. Standard firefighting techniques often fall short when dealing with challenges like thermal runaway events, toxic gas emissions, or lithium-ion battery fires.
Field-based training plays a vital role in improving responder readiness. In March 2025, the NFPA and the U.S. Department of Energy introduced the Distributed Energy Resources Safety Training (DERST) Field Familiarization Evolution Program. This program allows firefighters to participate in on-site walkthroughs at "target hazard" locations and tackle virtual hazard scenarios as a team using smart devices. This practical experience is now enhanced by advanced deployment technologies.
Tools like ABLEMKR help by verifying certifications, tracking compliance, and quickly deploying pre-qualified workers to emergency sites based on their training, availability, and location.
Charles Strickland, Fire Marshal at the University of California at San Diego, emphasized the urgency of this training:
"Energy storage systems and new battery technology has far-outpaced our abilities to provide well-informed fire protection to these systems. There is a need for these resources and national standardized training".
As battery installations continue to grow, ongoing investment in specialized training and digital workforce management will be crucial. These efforts create a comprehensive safety framework to protect both responders and communities during the rapid shift toward renewable energy.
FAQs
What should be the first action at a battery storage fire scene?
The initial priority at a battery storage fire scene is setting up a secure perimeter. This allows responders to control access and keep bystanders safe. Before any firefighting efforts begin, it’s essential to evaluate potential dangers like fire intensity, explosion risks, or the release of toxic gases. Taking the time to assess these hazards ensures that the response is both safe and effective.
How do responders detect and protect against toxic gases like HF?
Responders rely on specialized training, hazard mitigation techniques, and personal protective equipment (PPE), such as self-contained breathing apparatus (SCBA), to identify and handle toxic gases like hydrogen fluoride (HF). These gases, which may be released during events like venting or thermal runaway, demand precise and cautious management. Mitigation efforts often include suppression methods, such as using water or sand, to address the dangers associated with highly toxic and flammable gases like HF, hydrogen cyanide, and hydrogen.
How long can lithium-ion batteries reignite after a fire?
Lithium-ion batteries carry the risk of reigniting after a fire because of residual heat and stranded energy in neighboring cells. These conditions can lead to thermal runaway, even after the fire seems to be under control. This underscores the need for careful monitoring of the affected areas to reduce the chance of re-ignition.
