S7 Paragon

Lithium-Ion Batteries

Storage, Handling, and Fire Protection Requirements

SCOPE

This White Paper covers fire protection guidelines and recommendations for the safe practices (storage, handling, charging) of Lithium-Ion Batteries. The paper does not include Lithium-Ion Battery Energy Storage Systems (ESS).

INTRODUCTION

Lithium-ion battery (LIB) power systems are a growing part of vehicular propulsion systems, and the usage extends from automobiles and buses to material handling equipment. This is in addition to the more ubiquitous usage in consumer electronics. There are several specific challenges associated with use of these systems, including the difficulty controlling fires involving LIB systems. Batteries can be wet-cell or dry-cell, with dry-cell typically being used for replaceable batteries in light consumer applications. Vehicles of all kinds use wet-cell batteries. The battery packs on vehicles are constructed of many individual cells assembled into modules, and many modules assembled into the battery pack. Each cell contributes a small amount, but together the total energy is considerable.

Fire protection criteria for lithium-ion battery storage do not currently exist in NFPA codes and standards and is currently outside the scope of NFPA 13. NFPA 855 Standard for the Installation of Stationary Energy Storage Systems (ESS) has some general criteria for storage areas and refers to NFPA 13 Automatic Sprinkler Systems for fire sprinkler protection, but again NFPA 13 currently does not address protection of LIB Storage. Factory Mutual Global (FMG) provides publicly available reports and standards developed from some LIB fire tests. FMG recommendations often exceed code requirements to further reduce risk.

The information provided here represents the current state of knowledge on this subject. The limited and current fire protection requirements for LIB storage protection apply to all LIB Chemistries (NMC, LCO, LMO, LiFePO4 – Lithium Iron Phosphate, etc.). Products containing Li-ion batteries can be treated as standard fire protection commodities if the conditions in item 2 in the Storage of Batteries, Fire Protection Requirements section below are met.

RECEIVING AND ASSEMBLY AREAS

  1. Lithium-Ion Batteries in receiving (dock/staging) areas that are temporarily stored palletized or solid piled prior to moving them to the main designated LIB storage area or stored as work-in-process in assembly/manufacturing areas of the facility can be considered INCIDENTAL Type Storage if the following conditions are met:
    • Limit storage area to no more than 200 ft2 (20 m2).
    • Limit storage height to 6 ft (1.8 m) or one pallet load high.
    • Separate multiple storage areas by aisles not less than 10 ft (3.0 m) wide.
    • Maintain a battery state of charge (SOC) of around 60%. (70% SOC considered tolerable)
  2. FMG DS 3-26 (Table 2.3.1.10, Oct 2021) only requires ceiling sprinkler protection designed for a HC-3 Hazard Category or minimum of 0.30gpm/ft2 over 2,500ft2 (wet) or 0.30gpm/ft2 over 3,500ft2 (Dry) for any LIB Manufacturing Operations and receiving/assembly areas for adequate protection of INCIDENTAL Lithium Ion Battery Storage for ceiling heights up to 30 ft. For ceiling heights of 30 to 45 ft., a minimum of 0.30 gpm/ft2 over 3,600ft2 (wet) or 0.30 gpm/ft2 over 4,600ft2 (Dry) is required. Ceiling heights over 45 ft., refer to FMG DS 3-26 (Table 2.3.1.10, Oct 2021) for HC-3 Category.
  3. If the criteria above cannot be met/maintained, the LIB storage should be protected in accordance with the Storage of Li-ion Batteries section below.

Incidental storage of lithium-ion battery protection in non-storage type occupancies (assembly, receiving staging dock areas, etc.) is based on maintaining a hazard less than or equal to that of incidental storage. This is accomplished by limiting the footprint and height of the allowable storage area and providing separation from surrounding combustibles.

The limitations for incidental storage of lithium-ion batteries are based on this knowledge to limit the fire to a known area, to promote cooling of the batteries and packaging from the sprinkler protection, and to limit the overall hazard.

STORAGE OF LI-ION BATTERIES

Fire Protection of LIBs in racks or palletized/solid pile should be per the criteria below and per Table 2.4.2.1 from FM Global Data Sheet 8-1 Commodity Classification, January 2023 revision.

FIRE PROTECTION REQUIREMENTS

  1. New li-ion cells and modules stored in open-frame rack, solid-pile or palletized storage arrangements can be protected per the guidance in Table 2.4.2.1 from FMG DS 8-1 Jan. 2023. The guidance is the same for all LIB chemistries.
  2. Finished products containing li-ion cells or modules can be protected as standard commodities (class I-IV and plastics) with packaging provided the following conditions are met:
    • Ceiling height is no greater than 40 ft (12 m)
    • Li-ion battery state of charge is ≤ 60%.
  3. When the ceiling is greater than 40 ft (12 m) OR battery state of charge is greater than 60% (SOC >60%), store finished products that contain li-ion cells or modules in open-frame racks; and protect with in-rack sprinklers per items 7-10 below.
  4. Used or refurbished li-ion cells or modules should be stored in racks and protected with in-rack sprinkler protection per items 7-10 below.
  5. Where ceiling-only protection from the table below is being used, there should be no other storage above the batteries so that sprinkler discharge can reach the batteries unimpeded.
  6. For palletized or solid-pile storage, provide a minimum of 10 ft (3.0 m) space separation between li-ion cell or module storage areas and other combustibles.
  7. When in-rack sprinklers are required by Table 2.4.2.1 from FMG DS 8-1 Jan. 2023, provide plywood (minimum 3/8 in. [10 mm]) or sheet metal (minimum 22 ga. [0.7 mm]) horizontal barriers and in-rack sprinklers installed in accordance with Figures 2.4.2.2-1 and 2.4.2.2-2 from FMG DS 8-1, depending on the rack type for storage.
    • Use a maximum vertical spacing of 12 ft (3.7 m) between barriers.
    •Do not store li-ion cells or modules above the top barrier level.
    • Design barriers without gaps in longitudinal flue spaces. A maximum gap of 3 in. (75 mm) between each barrier is permitted at the rack uprights (transverse flue) for single and double row racks.
  8. Install K8.0 (K115) or K11.2 (K160), 165°F (74°C) rated, quick-response in-rack sprinklers below each barrier.
    • Design the in-rack sprinklers to provide a minimum flow of 60 GPM (227 L/min.) out of the hydraulically most remote six (6) sprinklers (e.g., three face sprinklers and three flue sprinklers in a double-row rack) if one barrier is provided, or the most remote eight (8) sprinklers (e.g., two face sprinklers and two flue sprinklers on two levels in a double-row rack) if two or more barrier levels are provided.
    • Locate face sprinklers within 6 in. (150 mm) of the rack face.
  9. The in-rack protection is independent of the ceiling protection and the ceiling sprinkler demand does not have to be included in the hydraulic calculations for in-rack sprinklers.
  10. For areas with the in-rack sprinkler protection above, the ceiling sprinklers can be designed to protect the surrounding occupancy.
  11. Provide a water supply capable of meeting the design sprinkler discharge flow rate plus a 250 gal./min. (946 L/min.) hose stream demand for at least 120 minutes for li-ion cell and module storage. For products with li-ion batteries, the duration may be reduced to 60 minutes.
GENERAL STORAGE GUIDELINES
  1. Storage of LIB’s should be kept at a preferred SOC of <50% (nor higher than 60% at a minimum).
  2. Care should be taken to ensure batteries are not exposed to a flammable environment or are near any potential ignition sources.
  3. Lithium-Ion Batteries should be stored in a secure, cool, well ventilated, dry environment. Temperatures should be kept below 25°C (77°F).
  4. To prevent performance problems, DO NOT STORE BATTERIES IN AREAS RECEIVING DIRECT SUNLIGHT.
  5. Batteries should be kept in original shipping containers if possible. Do not store loosely.
  6. If only small quantity/storage of Li-ion Batteries, then store in UL/FMG, listed/approved Flammable Liquid Cabinets.
  7. Do not expose the batteries to excessive physical shock or vibration. Short-circuiting should be avoided; however, accidental short-circuiting for a few seconds will not seriously affect the battery. Prolonged short circuits will cause the battery to rapidly lose energy, could generate enough heat to burn skin. Sources of short circuits include jumbled batteries in bulk containers, coins, metal jewelry, metal covered tables, or metal belts used for assembly of batteries in devices. To minimize risk of short-circuiting, the protective case supplied with the battery should be used to cover the terminals when transporting or storing the battery.
  8. Do not disassemble or deform the battery. Should an individual cell within a battery become ruptured, do not allow contact with water. When operators handle batteries with voltage more than 50v, they must wear the insulation protection PPE.
  9. Storage areas/rooms should be clearly identified as a Lithium-Ion Battery storage area for local Fire Department Response Efforts to a LIB fire.
  10. Lithium-ion battery fires are Class B fires, due to the presence of flammable electrolyte liquids, so a standard dry chemical or ABC extinguisher can be used. Small lithium batteries contain very little lithium, so they can be doused with water and do not require Class D Metals fire extinguishers. To put out larger lithium-ion battery fires, use a foam extinguisher containing CO2, powder graphite, or specialized extinguishing agent like F-500 Encapsulator Agent.
  11. Initiate a formal housekeeping & visual inspection (damaged, etc.) program for LIB Storage Areas. Minimum frequency should be weekly unless conditions require more frequent inspections.
  12. Establish a formalized LIB storage and Handling (receiving, damaged, discarding/disposal, etc.) Program: Never discard in combustible containers with other combustibles. Discard in designated, fire rated (metal) containers with lids (example – UL Listed, oily waste rage disposal container).
    • Have a designated waste hazard disposal collection company collect discarded batteries.
    • Cover or wrap any open terminal type LIBs with electrical tape or plastic caps when discarding.
    • Place designated and fire rated disposal, collection container outside if possible until picked up.
    • If collection container is stored indoors, provide a minimum of 10 ft. space separation, or near an exit door (not designated emergency exit door or path), or in UL Flammable Liquid Cabinets until collection.
  13. Establish a specific and formalized LIB Fire Emergency Response and Post Fire Procedures Program:
    • Develop a specific pre-incident, Li-ion Battery type fire response plan including coordinating response and notifying the local Fire Department of the presence of Li-ion Battery Storage at the site.
    • The plan should include any initial manual firefighting methods to be employed (fire extinguisher use, etc.) including a plan to remove and relocate the LIB product or storage to an outside separated location.
    • Develop a post-incident recovery plan that addresses the potential for reignition of li-ion batteries (fire watch by local fire department or trained site personnel, etc.) as well as for the eventual removal and disposal of any damaged or fire impacted cells or products.
    • Do not shutoff protection prematurely due to potential for re-ignition. A LIB Fire is not OUT till all Li-ion Batteries involved have been removed from the building. There is a high re-ignition potential with many past examples or LIB fires re-starting.
    • A fire watch should be present until all potentially damaged li-ion cells, modules or products have been removed from the area following a fire event.
ADDITIONAL RECOMMENDATIONS FOR STORAGE AREAS
  1. Due to the fire hazard once a LIB fire occurs, it is strongly recommended to separate LIB storage areas from adjacent combustibles and occupied areas by a dedicated room with minimum one-hour fire walls/barriers (2 hr. rated if significant bulk storage and high state of charge) to ensure this separation is provided. Doors to the battery storage room (1 hr. rated) should be provided with a ¾ hour fire resistance rating. Side-hinged swinging doors should be automatic or self-closing. Overhead coiling doors should be provided with a 165°F fusible link for automatic closure. Adequate ventilation (in accordance with what normally would be required for human occupancy of the space) should be provided in accordance with the International Mechanical Code 2.2.
  2. If a dedicated 1 to 2 hr. rated, separated/dedicated LIB storage room cannot be provided, the LIB rack storage area(s) should be provided with a minimum 25 feet perimeter clearance or separation to any adjacent combustible storage or assembly/manufacturing areas.
  3. Install or provide area fire/smoke detection (VESDA, fast response type fire detectors, etc.) over the LIB rack battery storage area(s) for the purposes of occupant and fire department notification for a quicker response to fire fighting and evacuation, etc. The smoke detection system should be connected to the local building fire alarm panel system, which in turn should be remotely monitored a central alarm station company.
CHARGING AREAS – MATERIAL HANDLING EQUIPMENT

For material handling equipment, such as forklifts or pallet jacks, interior charging areas should be arranged to limit the exposure to the rest of the facility should a fire erupt. The area should be:

  1. Located along an exterior wall, with access from the outside to facilitate fire department operations and allow for removal of the equipment if necessary. This will require an exterior door of adequate size based on the equipment being charged.
  2. Enclose the area with a one-hour rated wall assembly, if possible. Doors to the charging room should be provided with a ¾ hour fire resistance rating. Side-hinged swinging doors should be automatic or self-closing. Overhead coiling doors should be provided with a 165°F fusible link for automatic closure. Adequate ventilation (in accordance with what normally would be required for human occupancy of the space) should be provided in accordance with the International Mechanical Code 2.2. Provide automatic sprinkler protection (0.20@2500) within the room or enclosure.
  3. Locate multiple-panel battery charging installations, including LIB installations for batteries smaller than 50 kWH, serving more than two trucks in a dedicated cutoff room.
  4. If the separation wall can’t be provided, a clear space of at least 10 feet should be provided in all directions from the chargers if the building is sprinklered. For non-sprinklered buildings, 25 feet should be provided.
  5. The charging area should not be used for any other purpose. All combustible materials should be removed and kept away from the chargers and equipment. For example, do not place LIB electrical chargers within storage racking.
  6. Charging equipment should be securely mounted to the wall or other permanent element of the building. The mounting point should not be a combustible element. Charging equipment should be provided with physical protection around the battery chargers to prevent any possible mechanical damage.
  7. Install or provide area smoke detection (VESDA, fast response type fire detectors, etc.) over the charging area for the purposes of occupant and fire department notification for a quicker response to fire fighting and evacuation, etc. The smoke detection system should be connected to the local building fire alarm panel system, which in turn should be remotely monitored a central alarm station company.
  8. LIB Electrical Vehicles (EV’s) – If practical/possible, charge EV’s outdoors with a minimum of 10 ft. between EV’s. Arrange (rig) vehicle so that it can be moved quickly if a fire starts with the vehicle. If stored/charged indoors –

Lithium-Ion Batteries | 6

  1. moved outside quickly in case of a fire.

CHARGING OPERATIONS – SMALLER EQUIPMENT USING LITHIUM-ION BATTERIES

  1. For typical tools/appliances, etc. – battery charging area should be on or in metal shelving or designated fire rated metal cabinets/units and not on wooden desktops.
  2. Keep batteries at room temperature when possible. Do not charge them at temperatures below 32°F (0°C) or above 105°F (40°C).
  3. Separate smaller charging equipment from other combustibles (3ft. minimum) and larger format batteries and chargers by at least 10 ft.
  4. Always use the designated, specific, manufactured, charging equipment for the battery.
  5. Inspect batteries for damage – cracking, bulging, leaking, – discard properly.

CONCLUSION

Lithium-ion batteries are becoming more common and are anticipated to continue to increase their market share. While there are additional hazards associated with these batteries, proper handling, charging, fire protection, and storage practices can mitigate the exposure.

Sigma 7 Paragon Risk Engineering can provide risk analysis and loss prevention services (Li-ion Battery focused visits or desktop review analysis for new Li-ion battery projects or operations, etc.) for owners and operators of sites that manufacture, handle, or store lithium-ion batteries.

Sigma7 Paragon Risk Engineering is a worldwide risk engineering provider with over 200 engineers in 35 countries with extensive industry experience and technical expertise. We are fully independent of any insurance company or broking entity and are part of the Sigma7 group of companies, with colleagues working in other specialized areas such as forensic post loss accounting, Business Interruption pre-loss assessments, worldwide /security threat monitoring, online e-training for site personnel and financial/risk due diligence.

For more information about how Sigma 7 \ Paragon Risk Engineering Consultants can help protect your facility from the risks of lithium-ion battery usage and storage, contact us at today to learn more.

REFERENCES

FM Global Data Sheet 8-1 Commodity Classification, January 2023 revision

FM Global Data Sheet 3-26 Fire Protection for Non-storage Occupancies October 2021 revision

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