EV Battery Fires: Addressing a Growing Public Safety Concern

//

Sultan Kiani

In August 2024, residents narrowly escaped when an apartment suddenly caught fire in Ahmedabad, India. A similar incident occurred about three years earlier in Lahore, Pakistan, where a house fire claimed two lives, including a paraplegic woman activist, and left three other family members injured.

You may also recall a viral video showing a sudden explosion right after a person entered an elevator carrying a large battery pack. It happened in China in 2021. Although the victim was rescued alive, he succumbed to severe burns and smoke inhalation injuries after four weeks. More recently, on February 18, 2025, a tragic house fire in Guildford, Australia, claimed the life of a Pakistani student. Although the above-mentioned horrific accidents occurred at different times and in different parts of the world, they share one thing in common: malfunctioning electric vehicle (EV) batteries that triggered all these fires!

EVs were introduced as a step towards eco-friendly transportation, but such incidents have raised serious safety concerns. Some critiques have even described these battery packs as "potential bombs" capable of exploding at any time. As reports of battery explosions continue to make headlines, people are becoming increasingly alarmed. This has led them to question the safety of EV batteries, viewing them as extremely dangerous. People remain uncertain about the causes of such explosions and how to minimize the risk.

Here, we took a deep dive into the matter to identify the root causes, gain a clearer understanding of the problem, and recommend effective precautionary measures to minimize the likelihood of such incidents:

Are EV batteries safe?

You might think of electric vehicles as a recent invention, but they have been around for a long time. The very first electric vehicles (EVs) were developed in the early 20th century, but they were not very practical at the time due to limited battery backup, high costs, and lack of charging infrastructure. Hence, EV batteries have undergone extensive research and development, and they are now generally considered safe. Modern electric-powered vehicles use batteries with improved cell design, a Battery Management System (BMS), reinforced shells, and fire suppression mechanisms to help prevent explosions. All renowned manufacturers test EV batteries and their charging devices through a strict quality control system before they leave the production line for the market.

Even a minor manufacturing defect in a single cell of a battery pack could increase its susceptibility to failure

Why do EV batteries catch fire or explode?

No risk can be eliminated, but it should be minimized to acceptable levels. The same applies to the batteries that store electrical charge to propel an electric vehicle. The battery should remain safe under ideal conditions, but sometimes it can suddenly overheat. This phenomenon is known as ‘thermal runaway,’ where a rechargeable battery generates uncontrollable and excessive heat, potentially leading to fire and/or violent explosion. Battery explosions can result from various causes, including manufacturing defects, accidents, improper usage, and harsh environmental conditions. For example, even a minor undetected manufacturing defect in a single cell of a battery pack could increase its susceptibility to failure. Besides manufacturing faults, user negligence can also lead to battery fires. This includes, but is not limited to, using a faulty, substandard or incorrect charger type, improper battery replacement, using a substandard or non-recommended battery type, attempting to repair a damaged battery or unauthorized electrical modifications etc. While severe mechanical damage can cause a sudden explosion, some seemingly minor damage may trigger thermal runaway later, especially when the battery is being charged. Similarly, extreme weather conditions, particularly saltwater flooding, have also been known to cause internal short circuits. Finally, the failure of safety mechanisms can also lead to such mishaps. For example, the Battery Management System (BMS), which is designed to provide overcharge protection, may fail due to various reasons, including an electronic component malfunction or a software bug.

What can manufacturers do to improve EV safety?

Electric vehicle batteries have advanced significantly, but there is always room for improvement. EV manufacturers need to investigate such mishaps, particularly those caused by battery manufacturing defects. The large corporations should invest in research and development to further improve battery design for added safety. Possible improvements, such as replacing nickel-manganese-cobalt (NMC) with lithium iron phosphate (LFP), enhancing battery cooling efficiency, developing smart protective charging mechanisms, and implementing stringent quality control checks, can make batteries safer and free of manufacturing defects.

How can state regulations make EVs safer?

While electric vehicle manufacturers can take measures to enhance EV safety, proper regulations are equally crucial in preventing battery-related accidents. An ideal regulatory framework should cover battery manufacturers, service and repair workshops, and EV charging facilities. Establishing minimum safety standards for batteries and chargers, along with standardized repair protocols, can significantly reduce the risk of battery explosions. The government should mandate licenses and certifications for all EV technicians. Such regulatory measures are necessary for ensuring manufacturers and service workshops act responsibly.

Charge your EV in an open, well-ventilated space and away from flammable materials. Avoid unsupervised or overnight charging to stay safe

What safety precautions can users take to reduce the risk of battery fires?

Nothing is truly safe if used improperly. Electric vehicle users must also be aware of the potential risks associated with batteries. Here are some important precautions to keep in mind if you own an EV or are planning to get one soon:

• Always purchase a good quality electric vehicle from an authorized dealership. If buying a used EV, conduct a thorough inspection, paying special attention to the battery pack. Avoid vehicles with damaged batteries or those repaired by unauthorized technicians.

• Carefully read the user manual and strictly follow all safety instructions before using your new electric vehicle (car, motorbike, scooter or wheelchair etc.).

• Choose well-reputed brands that offer after-sales warranties. Unfamiliar or unbranded electric two-wheelers and motorized wheelchairs imported through the gray market are often assembled with substandard batteries and low-quality electronic components, increasing the risk of battery explosions and other safety hazards.

• Always use the original charger provided by the vehicle manufacturer. If you need a replacement or borrow a charger, ensure it has the exact same specifications and is fully compatible with your electric vehicle.

• Do not attempt to repair the battery pack or sensitive electronic components by yourself. An EV should only be repaired at a well-equipped workshop.

• Only replace the battery with one that meets the company’s recommended specifications. Never modify or upgrade the battery unless approved by the manufacturer. Some EV batteries can only be replaced by qualified professionals.

• If your vehicle is involved in an accident, ensure the battery pack is not damaged before using it again. If in doubt, have it inspected by a qualified EV technician before recharging and resuming use.

  
  

Remember! Most fatal battery fires have been caused by malfunctioning EV batteries left charging overnight. Therefore, it is advisable to charge your EV in an open, well-ventilated space and away from flammable materials. Avoid unsupervised or overnight charging to stay safe. Immediately unplug the EV charger if you see smoke or detect a burning smell. It is a good idea to carry a Class D fire extinguisher which can be useful for putting out battery fires.

Electric vehicles are a promising green mode of transportation, but they have introduced a new public safety hazard in the form of battery-related fires. Although EV fires are rare, they can be extremely dangerous and life-threatening. Therefore, all stakeholders must play their part in managing risks. That is how we can make EVs one of the safest and most eco-friendly modes of transportation.