Fire safety design and planning approach for a Lithium battery storage warehouse - By Karel Roodt

By Karel Roodt, managing director, The Fire Engineer

With the rise of renewable energy and electric mobility, Lithium-ion battery storage warehouses are becoming increasingly common in South Africa. However, these facilities present unique fire safety challenges due to the flammable nature of Lithium-ion batteries and the potential for thermal runaway.

As a fire engineer, a comprehensive fire safety design and planning approach should be adopted to mitigate these risks, ensuring compliance with South African National Building Regulations (NBR), SANS codes and international best practices.

This article outlines a conceptual fire safety strategy for a Lithium battery storage warehouse, considering local and international codes, decisionmaking in fire code selection and the importance of hazardous chemical containment and fire water runoff management.

Understanding fire risks in Lithium-ion battery storage

1. Thermal runaway and fire hazards

Lithium-ion batteries can selfignite under fault conditions, overheating or mechanical damage. Once ignited, the fire spreads rapidly due to:

• Exothermic reactions within the cells• Production of flammable gases such as Hydrogen and Methane• Challenges in extinguishing, as the fire can reignite even after suppression

Fire safety planning approach

Step 1: Regulatory and fire code selection

The selection of fire safety codes and guidelines depends on factors such as storage method, warehouse classification and operational risks. A comparison of the relevant fire codes are shown in the table on the previous page.

The fire engineer approach should typically integrate SANS 10400-T and SANS 10263, with elements of NFPA 855 and FM Global Data Sheet 5-33 for a hybrid best-practice approach.

Step 2: Fire protection strategies

1. Active fire suppression

Considering the challenges of extinguishing Lithium battery fires, a combination of fire suppression technologies is required:

✓ Water mist suppression (SANS 10287, NFPA 750): Effective at cooling and preventing fire spread

✓ Gaseous suppression (FM200, Novec 1230) (NFPA 2001, SANS 14520): Suitable for enclosed battery rooms

✓ Dry chemical suppression (NFPA 17, ISO 7202): Immediate fire knockdown in isolated battery racks

✓ High-expansion foam suppression (NFPA 11, SANS 10287): Used in large open storage areas

🚫 Avoid standard sprinkler systems: Water alone is ineffective on Lithium-ion battery fires and can lead to electrical hazards. Currently we are aware of only one supplier with a listed deluge sprinkler system.

2. Passive fire protection

✓ Fire-rated battery storage compartments (EN 14470, SANS 1253)

✓ Fire barriers and fire-resistant doors (SANS 10400-T, NFPA 221)

✓ Smoke ventilation and gas extraction (SANS 10400-O, NFPA 92)

✓ Explosion venting in case of gas release (NFPA 68, ATEX Directives)

Step 3: Warehousing of dangerous goods and containment

Why dangerous goods classification matters

Lithium-ion batteries are classified as Dangerous Goods (DG) Class 9 under SANS 10263 and UN 3480/3481, requiring special segregation, containment and environmental protection measures.

Key warehouse safety considerations

✓ Primary containment: Battery storage compartments with firerated separation

✓ Secondary containment: Spill trays, bunded areas for electrolyte leaks

✓ Tertiary containment: Drainage design for hazardous fire water runoff

Why fire water runoff containment is critical

During a fire event, contaminated runoff containing heavy metals and toxic electrolytes can infiltrate stormwater systems, causing severe environmental damage.

The design of a Lithium battery storage warehouse demands a multi-layered approach to fire safety

Solutions

• Polluted water holding tanks (SANS 10263)• Oil-Water separators and chemical treatment systems (ISO 14001, NFPA 30)• Spill response procedures and absorbent deployment

Conclusion

The design of a Lithium battery storage warehouse demands a multi-layered approach to fire safety, integrating:

✓ Code-driven decision making: Balancing SANS 10400-T, NFPA 855 and FM data sheets

✓ Advanced fire suppression technologies: Water mist, gas suppression and foam systems

✓ Passive fire containment: fire-rated compartments and explosion venting

✓ Dangerous goods handling and fire water runoff management: Preventing environmental contamination

By applying Fire Engineer’s structured fire safety approach, warehouse operators can mitigate risks, protect assets

and ensure compliance with both local and international safety standards.

Need expert guidance on Lithium battery storage fire safety? Contact an experienced fire engineer for a customised fire safety strategy.