Two Tesla fire incidents reported in early 2023 highlighted some of the challenges emergency responders and recovery operators can face when dealing with electric vehicle battery fires.

EV fires remain relatively uncommon, but incidents involving damaged or faulty lithium-ion batteries can be difficult to manage. They may produce intense heat, create large volumes of smoke and, in some cases, reignite after the initial fire has been brought under control.

Tesla catches fire twice after Arizona crash

In Scottsdale, Arizona, a Tesla reportedly caught fire twice in one day after crashing into a building on Cactus Road.

According to Arizona’s Family, witnesses said the driver hit the accelerator rather than the brake pedal before the vehicle struck the building. Several people helped the driver out of the vehicle, and less than a minute after the crash the Tesla went up in flames.

The incident did not end there. Later the same day, fire crews were called to a second fire around two miles from the original scene. While the damaged vehicle was being towed, it reignited near a busy intersection.

The second fire caused traffic disruption for several hours, with drivers diverted away from the area and delays affecting nearby shopping centres.

California freeway Tesla fire

Another Tesla fire was reported by Batteries News after a vehicle caught fire on a freeway in California.

Fire officials reportedly said the vehicle was travelling along the freeway when sudden combustion occurred. They added that nothing unusual had happened before the fire broke out in the battery compartment. By the time firefighters arrived, the electric vehicle was engulfed in flames.

Thankfully, no-one was hurt in the incident, but it underlined the uncertainty that can still surround some EV battery fire events.

Why damaged EV batteries need careful handling

Electric vehicles use high-voltage lithium-ion battery packs. If a battery pack is damaged in a collision, affected by a fault or exposed to abnormal conditions, individual cells can overheat and enter thermal runaway.

Thermal runaway is a chain reaction where heat spreads from one battery cell to neighbouring cells. Once this process begins, the fire can be extremely difficult to stop, and the vehicle may remain a risk even after the visible flames have been controlled.

This is one reason why damaged electric vehicles need careful assessment before they are moved, stored or loaded onto a recovery vehicle.

Reignition risk for recovery operators

The Arizona incident is a useful reminder that EV fire risk does not always end at the original scene. If a damaged battery remains unstable, the vehicle can reignite during recovery, transport or storage.

That creates additional risk for recovery drivers, pedestrians, cyclists, other road users and anyone working around the damaged vehicle after the initial incident.

Recovery operators and site teams should consider how damaged EVs are isolated, monitored and transported. Where a vehicle is suspected to have battery damage, clear procedures and appropriate containment equipment can help reduce the chance of a secondary incident becoming a wider safety issue.

How EV fire blankets can help contain risk

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 recovery and roadside scenarios, an EV fire blanket can help limit escalation, reduce fire spread and provide an additional layer of protection while firefighters or trained personnel manage the incident.

The key is planning. EV fire blankets should form part of a wider response process that includes staff training, safe vehicle handling, communication with emergency services and suitable storage or isolation arrangements for damaged electric vehicles.

Planning for EV incidents before they happen

As more electric vehicles appear on the road, more workshops, recovery operators, insurers and emergency responders will encounter damaged EVs.

The incidents in Arizona and California show why EV battery fire risk needs to be understood beyond the first visible flames. Collision damage, battery faults and reignition risk all need to be part of the conversation.

With suitable training, procedures and containment equipment in place, organisations can reduce the risk of one damaged EV becoming a larger and more dangerous incident.