FIRE & ELECTRICAL SAFETY TAKING CHARGE
With the UK facing a mounting stockpile of used EV batteries, the risks of unsafe storage are rising. Pete Zorgenlos, Head of Product Development (UK & Europe) at New Pig, offers his practical, expert- led guidance on how to safely manage damaged, defective or end-of-life lithium-ion batteries
The UK has been an early mover on EV adoption, with aggressive, legally binding climate targets, pioneering early incentive schemes and grants, and a rapidly expanding charging network all pushing it towards a greener future.
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For safe storage while awaiting proper disposal, the battery should be placed in a container filled with cushioning material that is non-combustible, electrically non-conductive, and absorbent.
But beneath the surface, a challenge is building – tens of thousands of used EV and energy storage batteries are piling up in the UK, with around 23,500 end-of-life batteries sitting in storage rather than being reused or recycled, according to an FT article.
For health and safety managers, recyclers, waste contractors and regulators, the challenge is clear: damaged or poorly stored batteries pose a real and growing fire and environmental risk.
Yet as battery chemistries evolve and energy densities increase, traditional approaches to storage, handling and disposal are no longer sufficient.
NAVIGATING A SHIFTING REGULATORY LANDSCAPE
The regulatory environment in the UK is tightening in response to these growing volumes. With the Lithium-Ion Battery Safety Bill and the 2025 updates to the Hazardous Waste Regulations, the ‘best practice’ of yesterday is quickly becoming the legal minimum of today.
In the UK, Li-ion batteries are classified as controlled hazardous waste, and the Environment Agency now demands rigorous tracking and separate collection. When these assets move from storage to transport, the requirements become even more stringent.
This shift places the burden of proof on the health and safety manager to ensure that every unit leaving the site is not only packaged in UN-approved containers but also chemically stabilised for the journey.
EXPERT PROTOCOLS FOR SAFE MANAGEMENT
Understanding the inherent hazards of Li-ion chemistry is essential for effective risk mitigation. Unlike traditional lead-acid batteries, Li-ion cells contain a flammable electrolyte that can fuel its own fire without the need for external oxygen. Mechanical damage, manufacturing defects, or even minor electrical faults can trigger an exothermic reaction known as thermal runaway.
In a high-density storage environment, this poses a unique threat: the ‘domino effect’, where the heat from one failing cell compromises its neighbours. This process is remarkably rapid, reaching temperatures between 700C and 1000C in seconds, often accompanied by the release of toxic hydrofluoric acid vapours.
Effective management begins with early detection. Strategic handling should focus on identifying the ‘warning signs’ of failure – such as swelling, hissing, or discolouration – before an incident occurs. Expert guidance suggests that suspect batteries should be immediately isolated.
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This ‘triple-threat’ of protection, using specialist non- combustible binders, ensures that if a cell does breach, the impact is contained. Under no circumstances should damaged batteries be placed in regular trash or recycling containers, as this introduces an unacceptable fire risk to the wider waste stream.
Where high-risk or significantly compromised units are identified, further measures may be required, including placing the battery within a specially designed, fire-rated storage case to provide an additional layer of thermal protection.
The physical environment of the storage facility also plays a critical role in battery longevity and safety. Maintaining a stable temperature profile – ideally between 4C and 27C – prevents the chemical degradation that leads to internal short circuits.
In the UK’s increasingly volatile weather patterns, climate-controlled storage is no longer a luxury for large- scale stockpiles, it is a fundamental requirement for maintaining the ‘second-life’ value of the battery while ensuring site safety.
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