Warehouse operators are being urged to strengthen controls around lithium ion battery storage as demand grows across consumer electronics, electric vehicles and energy storage systems, according to TT Club, UK P&I Club and Brooks Bell.

A joint whitepaper, published today by the three organisations, examines the operational, safety, environmental and contractual risks associated with storing and handling the batteries.

It identifies thermal runaway as the principal physical hazard. Triggered by mechanical, electrical or thermal abuse, it can cause rapidly escalating fires, toxic and flammable gas emissions, reignition and explosion. Li-ion battery fires can exceed 1,000°C and behave differently to conventional fires, making early detection, suitable suppression systems and emergency planning critical.

The whitepaper recommends a risk-based approach covering contractual responsibilities, maximum inventory levels, stagnant or abandoned stock and subcontractor liabilities. It also advises dedicated battery storage areas or separate warehouses with fire resistant materials, suitable environmental conditions and early warning systems for temperature rises, gas emissions and smoke.

Hot, damaged, dropped or otherwise impacted batteries should be promptly segregated and managed under predefined procedures covering inspection, quality control, rejection, quarantine or return.

Fire protection systems should reflect li-ion battery behaviour, with TT Club recommending early suppression fast response sprinklers. In rack systems can help contain localised incidents, while deluge systems can cool and extinguish large fires.

“Lithium-ion batteries are indispensable to the energy transition and modern commerce, but their storage demands a step change in preparedness,” said Mike Yarwood, managing director of loss prevention at TT Club. “Warehouse operators must combine clear contractual controls with purpose-designed facilities, rigorous operating procedures and close engagement with fire and rescue services. Prevention, early detection and decisive emergency response are central to reducing the potential for catastrophic loss.”

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