Battery Fire Risks Across Electric Transport: How to Protect People, Property and the Planet

The transition from fossil fuels to electrified transportation is accelerating. Electric cars, buses, trucks, ferries, and even aircraft promise cleaner air, lower operating costs, and a more sustainable future. However, this shift introduces a new set of risks: lithium-ion battery fires.

An illustration showcasing the incorporation of sustainable energy solutions in transportation, featuring a car, bus, ship, and airplane linked by a battery symbol, representing the future of electric travel.

Understanding Battery Fire Risks in Electric Transport

Let's discuss the risks associated with battery fires in electric transport.

When a battery enters thermal runaway, temperatures can soar above 2,500 °C. This reaction releases flammable gases and generates intense, long-lasting fires that are far more challenging to control than gasoline blazes. Understanding these risks across the transport ecosystem is essential for fleet operators, insurers, and regulators to protect lives and assets.

Why Battery Fires Are Different

In a conventional vehicle fire, gasoline burns at around 1,500 °F (815 °C). These fires can usually be extinguished within 15–30 minutes by a small crew. Lithium-ion battery fires are fundamentally different. When cells overheat due to damage, manufacturing defects, or overcharging, the reaction propagates internally. This drives the temperature up to 2,500 °C.

These fires can burn for hours and require thousands of gallons of water—sometimes up to 40,000 gallons. They may reignite days or even weeks later. Additionally, they emit toxic gases such as hydrogen fluoride and hydrogen cyanide. For fleet operators storing vehicles indoors, the potential for severe property damage and business interruption is enormous.

Comparative Characteristics of Battery and Gasoline Fires

| Factor | Gasoline-powered vehicles | Battery-powered vehicles |

|----------------------------------|---------------------------|--------------------------------|

| Peak temperature | ~1,500 °F (815 °C) | Up to 4,500 °F (2,500 °C) due to thermal runaway |

| Typical fire duration | 15–30 minutes | 7 hours or more; may reignite days later |

| Water needed for suppression | 300–500 gallons | 3,000–40,000 gallons; Tesla fires have required 24,000 gallons |

| Re-ignition risk | Minimal | ~13% of EV fires reignite, sometimes up to 68 days later |

| Hazards | Heat, smoke, potential fuel spillage | Extreme heat, flammable gas release, toxic fumes (HF, HCN) |

Transport Sectors at Risk (Battery Fire Risks Across Electric Transport)

1. Passenger Vehicles and Fleets

The number of electric cars on the road is growing exponentially. While the per-vehicle fire rate remains relatively low, the consequences of a single event can be severe. Global data highlight the trend: Tesla documented 232 EV fire incidents with 83 fatalities, and South Korea recorded 72 EV fire events in 2023, prompting insurers to remove charging stations. Projections suggest EV fire incidents could rise from 5,194 in 2025 to 13,655 by 2030.

Fleet garages and parking structures concentrate large numbers of vehicles. In 2024, a South Korean underground parking garage fire destroyed nearly 900 vehicles and burned for more than eight hours. The combination of high temperatures, toxic gases, and re-ignition risk makes these fires a significant threat to property and business continuity.

2. Buses and Trucks

Electrification of public transit and freight offers enormous environmental benefits, but high-energy battery packs magnify fire risks. Battery electric buses often carry 300–500 kWh of energy—far more than passenger cars—so a runaway event can generate intense heat and smoke.

Long dwell times at depots and high-power charging sessions further increase thermal stress. Reports of electric school bus fires have led to fleet groundings and expensive inspections. Operators must consider fire-resistant depot design, early detection systems, and trained personnel to respond to battery incidents.

3. Maritime Shipping

Transporting electric vehicles by sea introduces compounded risk. Lithium-ion batteries on roll-on/roll-off car carriers have been linked to catastrophic fires. The Fremantle Highway and Felicity Ace cargo ship fires destroyed thousands of vehicles and cost insurers hundreds of millions of dollars.

Battery fires at sea are extremely difficult to fight because water may not reach enclosed decks, and foam systems may be ineffective against thermal runaway. Car carriers need specialized suppression systems, gas-detection sensors, and emergency procedures to isolate and cool burning EVs.

4. Aviation and New Mobility

Advanced air mobility (AAM) and long-range drones rely on high-capacity lithium-ion and lithium-polymer batteries. While strict certification reduces failure rates, the consequences of an in-flight battery fire are catastrophic.

Airlines have already seen incidents of batteries in cargo igniting mid-flight, prompting restrictions on shipping bulk batteries by air. As electric vertical take-off and landing (eVTOL) craft enter service, manufacturers and regulators must ensure that battery enclosures, thermal barriers, and suppression technologies can withstand thermal runaway without compromising flight safety.

5. Rail and Energy-Storage-Assisted Transport

Hybrid and fully electric trains, trams, and ferries use large battery modules for propulsion and energy storage. A battery fire on a moving train or ferry can lead to evacuation challenges and infrastructure damage.

Integrating fire detection, ventilation, and suppression systems into rolling stock and vessels is critical. Operators should also adopt strict charging protocols and maintenance regimes to minimize the risk of internal short circuits and mechanical damage.

Mitigation Strategies

1. Risk Assessment and Infrastructure Design: Identify locations where batteries are charged, stored, or transported in bulk. Provide adequate spacing, ventilation, and separation to limit fire spread. Incorporate containment areas and a water supply for prolonged cooling.

   
   

2. Battery Certification and Quality Control: Insist on internationally recognized safety standards (UL 2580 for EVs, UN 38.3 for shipping batteries, and other relevant standards) throughout the supply chain. Counterfeit or grey-market batteries often lack thermal management and are more prone to failure.

   
   

3. Early Detection and Monitoring: Use multi-sensor systems that detect heat, gas emissions, and smoke. Thermal cameras and gas sensors can identify off-gassing before ignition. Connected monitoring allows remote shut-down and alerts.

   
   

4. Specialized Suppression Technologies: Traditional extinguishers are ineffective once thermal runaway begins. TL-X’s patented technology neutralizes the flammable gases released during thermal runaway, converting them into non-combustible substances. Integrating such materials into battery packs or enclosures can stop fires before they start by interrupting the chain reaction.

   
   

5. Training and Emergency Planning: Equip maintenance staff, drivers, ship crews, and first responders with knowledge on handling battery incidents. Develop procedures for isolating burning vehicles, cooling battery packs, and monitoring for re-ignition over long periods.

   
   

Conclusion

Electrified transport is essential to decarbonizing our world, but stakeholders must acknowledge and address the unique fire risks posed by lithium-ion batteries. The extreme temperatures, long burn times, and toxic emissions associated with battery fires can cause significant damage, business interruption, and loss of life.

Data from recent EV fire incidents show that the problem is growing, and catastrophic examples such as the South Korean parking garage fire and cargo-ship blazes illustrate the potential scale. By adopting rigorous safety standards, investing in early detection and advanced suppression technologies like TL-X’s gas-neutralization materials, and preparing first responders, we can confidently expand electric transport while protecting people and property.

In this rapidly evolving landscape, we must remain vigilant and proactive. The future of transportation depends on our ability to innovate and mitigate risks effectively.