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In this Q&A, Bryce Cornet, Senior Manager of Supply Chain Logistics at EV Battery Solutions by Cox Automotive, outlines what businesses need to know about EV battery safety—from common pitfalls to emergency planning—and how smart protocols today can support a more resilient tomorrow.
As more EV batteries enter the market, what are the biggest safety concerns to be aware of—and why are they becoming more urgent?
As EV repairs and battery replacements in dealership networks are becoming more prominent, safe handling and storage is paramount. Ensuring dealers have the proper personal protective equipment (PPE) and tools to perform repairs on EVs will ensure safer operations. In addition, there are specific storage and emergency response plans that should be considered specific to EV batteries. Both handling and storage practices should be shared with dealerships through training.
As EV battery technologies advance, so do the regulations that govern their handling, storage, and transport. It is important to know where to seek guidance to ensure regulations are met. Organizations like the Pipeline and Hazardous Materials Safety Administration (PHMSA) and the National Fire Protection Association (NFPA) offer valuable resources, and certified partners like us, EV Battery Solutions, help interpret and apply these standards effectively—ensuring safe, compliant operations at every step.
What are some of the most common mistakes you see when it comes to storing or transporting EV batteries?
- Improper Handling: The uniqueness of a battery packaging can lead to a need for different equipment like larger forklifts and lifting adapters to safely handle batteries without risking dropping or puncturing a crate or battery.
- Storage Conditions: EV batteries perform best in moderate, controlled environments, extreme temperatures can compromise their integrity and lifespan.
- Regulatory Alignment: Staying current with hazmat shipping regulations is essential for safe and efficient battery logistics. When teams are unclear on requirements or overlook key details, it can lead to safety risks, miscommunication during incidents in transport, as well as fines and shipping delays.
- Lack of Emergency Response Planning: Proper storage of battery packs includes proper fire suppression and a detailed emergency response plan that has been shared and trained for in the event of a safety incident.
- Incorrect or Inadequate Packaging: EV batteries require certain packaging that confirms their hazardous classification. It is very important to understand the safety characteristics of a battery before it is shipped, as these characteristics can further help define packaging requirements.
- Serialized Inventory Tracking: Unlike standard parts or SKUs, EV batteries benefit from serialized inventory tracking. Each battery has unique characteristics that are best managed through a distinct identifier, such as a serial number, enabling more accurate tracking and handling throughout its lifecycle.
Can you walk through what a safe, well-designed battery handling protocol looks like in practice?
One example is how we work alongside dealership networks to recover EV batteries. At EV Battery Solutions, we receive batteries in varying states of health. Before arranging transportation, we gather detailed information about each battery to determine the appropriate packaging and logistics strategy, allowing both safety and regulatory compliance based on the battery’s specific characteristics.
Once a battery arrives at our facility, it undergoes a thorough safety inspection, including both visual and electrical assessments, to confirm it’s safe to handle. If a battery is found to be unsafe, it is immediately isolated from main work areas and escalated to our safety and engineering teams for further evaluation.
How can companies best prepare for and respond to thermal events or fire risks—especially in busy facilities like auctions?
Creating an emergency response plan (ERP) for lithium-ion battery safety and thorough training on the ERP will help in preparing team members for a safety sensitive event. We have also found connecting with our local fire departments and fire officials nearby prepares those who would also be supporting a potential event. Isolated storage locations with proper fire suppression, security and monitoring will ensure that an emergency is responded to as promptly as possible.
What are some misconceptions about EV battery safety that you frequently encounter?
One common misconception is that an EV battery’s life ends after it initially fails in a vehicle. In reality, batteries that fail in vehicles can be reused or recycled as a way to extend the battery’s life. EV Battery Solutions is at the forefront of this activity throughout the US and Europe.
With regulations and safety standards evolving, what should operations teams be doing now to stay ahead?
- Stay curious and be involved with local and national committees and organizations, such as the Automotive Recyclers Association and Battery Council International, that discuss safety, regulation, and experiences
- Sign up for alerts of any changes to regulations (can be done on many of the sites where the regulations are formally published – PHMSA, NFPA, etc.)
- If you’re working within regulatory frameworks and encounter a gray area, don’t hesitate to reach out to the relevant code publisher or governing body. They can often provide formal clarification tailored to your specific scenario, helping ensure compliance and safety.
Looking ahead, how do you see the EV battery logistics space evolving—and what role will safety innovations play in that transformation?
As EV battery logistics continue to evolve, we anticipate that regulatory frameworks will become more refined to reflect the unique characteristics of lithium-ion batteries. There is growing industry discussion around whether batteries like UN3480 may eventually be classified separately from broader hazardous materials categories. Such a shift could pave the way for more tailored safety protocols and clearer compliance pathways—ultimately supporting safer, more efficient transportation and handling practices.
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