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Poster "Recognizing and handling defective lithium batteries"

Practical flow chart for everyday use

With this free DENIOS poster you can:

  • Identify potential damage events that could lead to damage to lithium batteries

  • Systematically check whether your lithium battery shows clear signs of a defect

  • Supplement your action plan for defective lithium batteries with practical tips from the experts



Download the PDF and use the flow chart to check whether your battery shows signs of a defect or damage. Follow the instructions for further actions to take.


  • Possible causes of damage

  • Visual checks

  • Smell test

  • In-device checks

  • Checking when charging

Technical expertise — Lithium-ion batteries


Safe solutions for active and passive storage

  • Dangerous: Unattended storing and charging of batteries.

  • All-round protection: ION-LINE safety storage cabinets for your safety.

Frequent, sometimes weekly accidents and countless damages prove: that the unattended charging and storing of batteries, for example overnight, poses great risks and dangers. People were admitted to hospitals with smoke inhalation and burns. High property damages, leading to the financial ruin of companies and other organizations.

In order to maintain the insurance cover, managing directors or their equivalent, must provide suitable storage and charging solutions for lithium-ion batteries. They are responsible for:

  • Their employees and are obliged to comply with the Occupational Health and Safety Act.
  • They are also personally liable if inadequate fire protection measures are taken. This includes damage to property, possible damage to neighbouring facilities and, if necessary, the costs for large-scale evacuation measures.


These are the sad and distressing consequences of improper storage and charging of batteries. Lithium-ion batteries pose major fire and eruption hazards.

Damaged batteries can, under certain circumstances spontaneously ignite or become unstable and explode when heated. According to the ADR, lithium-ion batteries are classified as hazardous materials and must be handled appropriately.

Regulatory requirements for storing hazardous materials by legislative bodies do not yet exist. Numerous insurance companies and associations have included clear guidelines in their contracts, showing the acute need for action.

According to insurers and associations, batteries of medium capacity must spatially or structurally (in a fire-resistant manner) be separated from other areas. Spatial separation by storing the defective batteries outdoors is only possible if there is a safety distance of 10 m surrounding the area.

In addition, you must take the manufacturer's instructions for storage into account. Take precautions with DENIOS expertise and product range.

We are happy to advise you!

Tailor-made advice, and service fulfillment. Our advisors walk the additional mile. Take advantage of our phone, mail, or on-premise service offers.

Expert advice 01952 811 991

How dangerous are lithium-ion batteries?

Lithium batteries can present a considerable safety hazard if they are incorrectly handled or stored. In addition, factory defects or contamination can pose safety risks. Deep discharge, fire, chemical reactions – each situation means a risk for workers, companies, and the environment.

Some common issues with lithium-ion batteries are:

Fire hazard due to thermal runaway

If cells overheat there is a risk of thermal runaway. Thermal runaway can be triggered by many things, from thermal loads to mechanical damage or factory defects. This is an exothermic reaction, which can ignite the stored lithium and cause an extreme fire that produces its oxygen.

High levels of heat energy vaporize the electrolyte fluid, creating additional heat and combustible gases. If the ignition temperature for a gas is exceeded, it will ignite and set fire to the battery. Thermal propagation can create a devastating chain reaction. Once set in motion, it only takes a few minutes until the battery will burn and explode.

Fire hazard due to deep discharge

If lithium-ion batteries are not used for a long period, they can completely discharge. Decomposition of the electrolyte liquid can lead to the formation of easily combustible gases. If an attempt is made to recharge the deeply discharged lithium-ion cells, the supplied energy can no longer be correctly converted due to the lack of electrolyte fluid. Deep discharge can result in a short circuit or fire.

Fire hazard due to mechanical deformation

When handling lithium-ion batteries, there is always a risk of damaging them. Collisions with operating vehicles or a fall on the hard ground are just a few examples. If cells are deformed as a result, this can lead to internal short-circuiting and fire of the battery. In rare cases, it is possible that particles that are falsely released into the cell during production can damage them from the inside over time. Here, too, internal short circuits can occur.

Measures for loss prevention

Avoid thermal stress

Avoid thermal stress

Use only suitable chargers

Caution on loading

Avoid damage

Specialized Solutions by DENIOS

We are happy to support you in selecting the best combination for your needs. For over 35 years, we have provided expert advice on the safe storage of hazardous goods and offer the highest levels of fire protection.

The new generation of storage solutions

Based on the proven technology of our hazardous substance cabinets, a powerful system was developed for the special hazard potential of storing lithium batteries. With double-sided fire protection, Lithium Ion Cabinets fulfill the increased requirements that in particular, property insurers place on the storage of lithium batteries.

Two tried and tested sizes with three to six storage levels provide tailored capacity for smaller and larger amounts of medium-power batteries. Height-adjustable heavy-duty grid floors (397 lbs load capacity) provide the necessary flexibility. A tested, liquid-tight spill tray (powder-coated sheet steel) is used to absorb any leaking sparks from burning batteries.

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