Electric vehicle ownership continues to grow across the UK and around the world. That shift brings major benefits, but it also means businesses, public sites, insurers, recovery operators and emergency responders need to plan carefully for EV fire risk.

EV fires remain relatively uncommon, but when they do occur they can be difficult to control. High-voltage lithium-ion battery packs can generate intense heat, produce toxic smoke and, in some cases, reignite after the initial fire has been managed.

As more electric and hybrid vehicles appear in car parks, workshops, charging stations, ferries, airports, depots and road tunnels, the likelihood of site teams encountering a damaged or overheating battery will naturally increase.

Why more EVs means more fire-safety planning

A video captured on CCTV in an underground car park in Shanghai shows how quickly an electric vehicle can ignite and escalate. The cause of the incident is unknown, but EV fires are often linked to battery damage, manufacturing faults, charging faults or other issues that affect the stability of the battery pack.

Video footage of the Shanghai incident was shared online:

When an EV battery cell is damaged or defective, it can enter thermal runaway. This is a chain reaction where one overheating cell causes neighbouring cells to fail, spreading heat and fire through the battery pack. Once thermal runaway begins, the fire can be extremely difficult to stop.

Vehicle recalls show why battery safety matters

Battery fire risk is not limited to fully electric vehicles. Plug-in hybrid vehicles also use high-voltage battery systems, and manufacturers continue to monitor and recall vehicles where safety concerns are identified.

Volkswagen Group previously recalled thousands of plug-in hybrid vehicles over fire risk concerns, as reported by Garage Wire. The recall affected brands including Audi, Volkswagen, Cupra, Seat and Skoda, and was linked to concerns around the insulation of high-voltage battery systems.

For site owners and operators, recalls like this are a useful reminder that EV fire planning should not only focus on obvious damage after a crash. Battery-related risks can also involve manufacturing issues, component failures or faults that are not immediately visible.

EV fires and insurance risk

The growth in electric vehicle ownership is also changing the way insurers and risk professionals think about fire safety. An article written for Insurance POST by Tim Short, a partner at Plexus Law, explored how the rise of electric vehicles could alter risk for road users and insurers, particularly in relation to fire and safety.

The full article is available here: Electric vehicles spark concerns around fire and safety – Insurance Post.

From an insurance perspective, the concern is not only the vehicle itself. EV fires can damage nearby vehicles, buildings, chargers, workshop equipment and surrounding infrastructure. In enclosed or high-density locations, the cost of collateral damage can be significant.

Battery health monitoring and early warning

Prevention and early detection are important parts of EV fire safety. A damaged lithium-ion battery can lead to thermal runaway, but it is not always easy to know whether a battery has been damaged or is beginning to fail.

Battery monitoring technology is developing quickly. Batteries News reported on Metis Engineering’s Production Battery Safety Sensor, which is designed to monitor lithium-ion battery pack health and detect cell venting, an early sign of potential battery failure.

Technology like this is a positive step because it gives manufacturers, fleet operators and safety teams more information about battery condition. Better monitoring can support earlier intervention before a damaged or failing battery becomes a fire incident.

Environmental impact from EV fires

The consequences of an EV fire can extend beyond the immediate vehicle and surrounding property. Firefighting water and residue can create environmental challenges, particularly if contaminated run-off reaches drains, sewers or watercourses.

A post from Letterkenny Fire IAFF Local highlighted one example, where crews assisted with controlling run-off from an EV fire and placed a plug in a storm drain to help protect the surrounding environment.

Reducing the amount of water needed to manage an EV fire, limiting smoke and controlling spread can all help reduce the wider impact of an incident.

Where EV fire risk needs to be considered

As EV ownership rises, fire safety planning should be considered anywhere electric vehicles are parked, charged, repaired, stored or transported. This includes:

• public and private car parks;
• EV charging stations;
• dealerships, workshops and bodyshops;
• recovery yards and roadside assistance operations;
• ferries, ports and transport hubs;
• airports, depots and fleet facilities;
• underground or enclosed parking areas;
• road tunnels and other constrained environments.

How EV fire blankets can help limit escalation

Electric vehicle fire blankets, such as the Fire Cloak EV Fire Limitation Blanket, are designed to help contain heat, smoke and flames while emergency procedures are carried out.

In many EV fire scenarios, the aim is not simply to extinguish the battery fire immediately. It is to limit escalation, protect nearby people and property, reduce smoke spread and give emergency responders a more controlled incident area.

Fire blankets can be especially useful where vehicles are parked close together or where a fire could quickly affect surrounding infrastructure. They should form part of a wider safety plan that includes staff training, emergency procedures, safe vehicle isolation and clear access for firefighters.

Planning now for a larger EV parc

Electric vehicles will continue to play a central role in the future of transport. The challenge is making sure that safety planning keeps pace with adoption.

For businesses and public sites, the practical question is not whether EVs are safe in general. It is whether the site is prepared for the specific challenges of a damaged, overheating or burning lithium-ion battery.

With suitable planning, training, monitoring and containment equipment in place, organisations can reduce the risk of one EV fire becoming a much larger incident.