As electric vehicles are reshaping industries and accelerating innovation, the growing number of EV battery manufacturing facilities remains critical to this transformation. In 2019, two EV battery factories were operating in the United States, and another two were under construction. According to a 2024 report, there are now 34 battery factories planned, under construction or already operational in the country. While this expansion marks a critical milestone, these facilities also bring fire-protection challenges inadequately addressed by current building codes.
EV lithium-ion batteries introduce risks that stem from their contents and processes. High heat-release rates, the potential for thermal runaway, and the release of flammable or toxic gases make these facilities more hazardous than traditional industrial buildings. Unfortunately, existing standards like the International Building Code and National Fire Protection Association 855 provide limited guidance on mitigating these modern fire risks.
This standards gap forces construction leaders to grapple with difficult questions. Are the EV battery manufacturing facilities they design and build equipped to handle these hazards? Are their fire protection strategies sufficient to protect people, assets and operations? Addressing these concerns requires understanding the risks, recognizing the limitations of current codes and implementing proactive solutions.
EV Battery Facilities Fire Risks
Lithium-ion technology carries inherent risks tied to its energy density and chemical composition. These risks can manifest in three ways:
- High Heat Release: Fires involving lithium-ion batteries produce intense heat, which can quickly compromise a building’s structural integrity.
- Thermal Runaway: Thermal runaway events occur when a lithium-ion cell ignites. This causes it to enter a self-sustaining reaction, igniting neighboring cells and escalating the fire’s intensity.
- Toxic and Flammable Gas Release: Lithium-ion batteries burn, emitting gases that are harmful to occupants and difficult for first responders to manage.
For example, let’s look at aviation safety: The rise in reported incidents of lithium-ion battery devices overheating on airline flights is up 28% from 2019 to 2023. However, according to a UL Standards & Engagement report, such events remain rare. E-cigarettes are the most common culprits, and 60% of thermal runaway cases occur near the seat of the passenger who brought the device, highlighting risks when these batteries are placed in checked bags or onboard.
Now, imagine this on a greater scale. Cell production, charging and storage operations increase the likelihood of fire incidents. Combined with the high volume of batteries stored in these facilities, the potential for severe outcomes rises dramatically.
The Inadequacy of Current Standards
While codes like the IBC and NFPA 855 establish baseline requirements, they fall short of addressing the risks posed by EV battery facilities. The IBC provides general fire-protection measures that apply to most industrial buildings but does not account for the specific challenges of lithium-ion technology. NFPA 855, focused on energy storage systems, offers more targeted guidance but remains insufficient for large-scale battery production and storage operations.
Compounding this issue is the reliance on outdated fire test standards. Many tests based on cellulosic fire loads assess the burning of materials like wood and paper. These standards do not reflect the modern fire loads of synthetic and hydrocarbon-rich materials in EV battery facilities.
This disconnect among codes, standards and real-world hazards makes it difficult for construction leaders to make decisions. So, what can they do?
Lessons Learned from Other Industries
First, consider what other industries have done. The oil and gas industry offers valuable insights for addressing fire risks in high-hazard environments. Over the decades, this sector has developed quantitative risk assessment methods that evaluate the likelihood, severity and consequences of fire incidents. Applying these methods to EV battery facilities can help stakeholders make informed decisions about fire-protection measures. For example, construction leaders can use risk assessments to determine whether to invest in passive fire protection, active suppression systems or a combination of both.
Proactive Strategies for Fire Protection
To address these challenges, construction professionals must adopt proactive fire-protection strategies tailored to the risks of EV battery facilities and early-stage collaboration with a trusted coating partner.
Intumescent coatings are critical in protecting structural components from extreme heat. When exposed to high temperatures, these specialized coatings expand and create an insulating barrier that helps maintain the structural integrity of steel and other building materials.
Specialized fire-protection solutions ensure that buildings remain stable during a fire, providing more time for evacuation and firefighting efforts. By integrating these protective measures into the design phase, construction teams can create more protected facilities without compromising operational efficiency.
Proactive fire protection begins with thorough risk assessments during the early design stages. Collaborating with fire protection specialists allows construction teams to identify site-specific hazards and develop tailored solutions. Early engagement reduces the likelihood of costly retrofits and ensures fire-protection measures align with the facility’s specific needs. For instance, a comprehensive assessment might reveal the need for enhanced separation between battery storage areas or additional gas detection systems.
Greater Industry Collaboration
Updating codes and standards to reflect modern fire risks requires collaboration across industries. Construction professionals, insurers and organizations such as Underwriters Laboratories, the American Society for Testing and Materials and the NFPA must work together to address gaps in existing regulations. Insurers play a key role by incentivizing better fire protection practices. Policies tied to rigorous risk assessments and enhanced fire protection measures encourage stakeholders to prioritize safety over minimum compliance.
The Cost of Inaction
The consequences of failing to address fire protection in EV battery facilities extend beyond individual projects. Fires in these facilities can result in significant human costs, financial losses, environmental damage and reputational harm. In some cases, inadequate fire protection could lead to stricter regulations imposed after catastrophic incidents.
The construction industry cannot afford to rely on reactive measures. With a proactive approach, stakeholders can reduce risks, protect assets and support the sustainable growth of the EV sector.
A Path Forward
The electrification movement depends on EV battery facilities’ safe and reliable operation. Fire protection, often treated as an afterthought, must become a central consideration in the design and construction of these high-tech buildings.
Proactive strategies—integrating advanced fire-protection coatings, conducting early risk assessments, and learning from or collaborating with other industries —offer a roadmap for addressing the challenges posed by EV battery technology.
SEE ALSO: DRIVING EFFICIENCY: OPTIMIZING VEHICLE CYCLES
