Assess charging and storage areas for lithium-ion battery risk, including spacing and ventilation.
Occupational Health & Safety
Lithium-Ion Battery Charging, Storage and Thermal Runaway Risks at Work
Prepares facilities and safety staff to manage lithium-ion battery charging and storage risk, recognise early signs of thermal runaway and plan an effective emergency response.
🗓️Duration5 training days
📚Content4 modules · 8 sessions
🎓On completionAccredited attendance certificate
About the programme
Course Overview
Lithium-ion batteries now power forklifts, e-bikes, power tools and backup systems in most workplaces, and a damaged or poorly charged cell can enter thermal runaway within minutes, releasing toxic gas and reigniting after it appears extinguished. This course trains facilities managers, safety advisors and warehouse supervisors to assess charging and storage risk, apply segregation and ventilation controls, recognise the early warning signs of a failing cell and plan a response that protects people before protecting the building. Through case-based scenarios covering charging areas, damaged battery returns and vehicle fires, participants learn to interpret manufacturer safety data, design charging bays with appropriate spacing and fire detection, write a damaged-battery handling procedure, and brief fire and rescue services on the specific hazards lithium-ion batteries present. The course also covers storage quantity limits and the documentation regulators and insurers now expect. Participants leave with a charging area risk assessment, a damaged battery procedure and a thermal runaway response plan for their own site.
Expected Learning Outcomes
Interpret manufacturer safety data to set safe charging currents, temperatures and durations.
Design charging bays with segregation, fire detection and suppression appropriate to battery quantity.
Recognise early warning signs of a failing cell, including swelling, heat and unusual odour.
Handle and store damaged or recalled batteries safely pending disposal or return.
Plan a thermal runaway emergency response that prioritises evacuation over firefighting.
Brief fire and rescue services and staff on the specific hazards of lithium-ion battery fires.
Who Should Attend
Facilities and warehouse managers responsible for battery charging and storage areas.
Health and safety advisors assessing risk from e-bikes, forklifts and battery-powered equipment.
Fire safety managers updating emergency plans for lithium-ion battery hazards.
Fleet and logistics managers operating electric vehicles and charging infrastructure.
Facilities staff handling returned, damaged or recalled batteries.
Insurance and risk managers assessing property risk from battery storage.
Course Modules
Select any module to see its sessions and points.
01Understanding Lithium-Ion Battery Hazards
2 sessions · 8 points
Session 1How Thermal Runaway Starts and Spreads
- Explain how internal short circuits, physical damage or overcharging trigger thermal runaway in a cell.
- Describe how thermal runaway propagates between adjacent cells and battery packs in storage.
- Identify the toxic and flammable gases released before and during a battery fire.
- Recognise why water alone may not extinguish a lithium-ion battery fire and can cause reignition.
Session 2Reading Manufacturer Data and Setting Charging Parameters
- Interpret safety data sheets and manufacturer instructions to identify approved chargers and settings.
- Set charging current, voltage and duration limits that avoid overcharging and excess heat generation.
- Identify counterfeit or incompatible chargers as a leading cause of battery failure.
- Establish temperature limits for charging and storage areas based on manufacturer guidance.
02Designing Safe Charging and Storage Areas
2 sessions · 8 points
Session 1Planning Charging Bay Layout and Segregation
- Design charging bay layouts that limit the number of batteries charged together in one area.
- Segregate charging areas from escape routes, flammable materials and occupied workspaces.
- Specify fire-resistant charging cabinets or bays for higher-risk battery types and quantities.
- Ensure charging areas have adequate ventilation to disperse gas released during failure.
Session 2Managing Storage Quantities and Fire Detection
- Set maximum storage quantities for charged and spare batteries based on building fire strategy.
- Install early-warning fire and smoke detection specific to battery storage and charging areas.
- Specify suppression systems, such as water mist or specialist agents, suited to lithium-ion fires.
- Review insurer and fire authority requirements when planning new battery storage facilities.
03Handling Damaged Batteries and Early Warning Signs
2 sessions · 8 points
Session 1Recognising and Isolating a Failing Battery
- Train staff to recognise swelling, excessive heat, unusual odour and hissing as failure warning signs.
- Isolate a suspect battery immediately, moving it to a safe outdoor location if it can be done safely.
- Avoid puncturing, crushing or continuing to charge a battery showing signs of damage or failure.
- Monitor an isolated battery for a defined period before deciding it is safe to move again.
Session 2Managing Damaged, Returned and Recalled Batteries
- Write a procedure for receiving and quarantining damaged or returned batteries from customers or staff.
- Store damaged batteries in designated fire-resistant containers away from other stock.
- Track recalled battery models across the organisation and remove them from service promptly.
- Arrange specialist disposal or transport for damaged batteries in line with hazardous waste rules.
04Planning and Testing the Emergency Response
2 sessions · 8 points
Session 1Writing the Thermal Runaway Emergency Plan
- Write an emergency plan that prioritises immediate evacuation over attempts to fight a battery fire.
- Define alarm, evacuation and muster procedures specific to areas with battery charging or storage.
- Brief on-site fire wardens on the additional risks of gas release and reignition during evacuation.
- Prepare information for attending fire and rescue services on battery types, quantities and locations.
Session 2Testing, Training and Reviewing the Plan
- Run evacuation drills specific to battery storage areas and review response times.
- Train staff who work near charging areas to recognise hazards and raise the alarm quickly.
- Review the emergency plan after any battery incident, near miss or change in storage arrangements.
- Report battery incidents and near misses to inform wider organisational and regulatory learning.
What the participant receives
4 course modules
A structured syllabus
8 training sessions
across 5 days
32 detailed points
Applied, detailed content
Accredited attendance certificate
On completing the programme
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