Safe charging for e-bikes and e-scooters

Electric vehicles, from cars to e-bikes, e-scooters and even forklifts, are becoming increasingly common in both personal and commercial settings. Along with their benefits come significant risks, particularly around charging and battery safety. Fires involving lithium-ion batteries can start suddenly, spread rapidly, and release toxic fumes.

This guide produced by RiskSTOP outlines comprehensive EV charging best practices for e-bikes/scooters, cars, and forklifts. By following these guidelines, users can significantly reduce fire and electrical hazards while enjoying the advantages of electric mobility.

E-bikes and e-scooters have become popular for urban transport, but their lithium-ion batteries present unique fire risks. London Fire Brigade reports that e-bikes and e-scooters were London’s fastest-growing fire trend in 2023, a trend that continued into 2024. These fires are often ferocious and can erupt without warning if a battery is faulty or damaged, quickly blocking escape routes if they occur indoors. Many incidents are caused by incompatible chargers, counterfeit batteries or DIY modifications that lead to battery failure. Modern e-bike batteries pack high energy density; when they overheat or go into thermal runaway, they can ignite and emit poisonous gases, creating a rapidly developing fire that’s very hard to extinguish.

Key safety practices for e-bike/e-scooter charging:

• Charge in a safe location: Never charge e-bikes or e-scooters in areas that could trap people if a fire starts. Avoid charging in hallways, doorways, narrow indoor spaces, or bedrooms, any place where a sudden fire could block an escape. Instead, charge in a garage, shed, or on a concrete floor away from living areas when possible. Always place the device or battery on a hard, flat surface (not on carpets or sofas) with plenty of ventilation around it. Keep the charging area clear of combustible materials such as curtains, paper, or fuels.
• Stay attentive – don’t charge unattended: Never leave batteries charging unattended for long periods, especially when you are out of the house or overnight while you’re asleep. Most e-bike fires have occurred during charging, so it’s critical to unplug chargers once the battery is fully charged. Avoid charging batteries beyond the recommended time;  overcharging can increase fire risk. If your charger doesn’t automatically shut off, set a timer as a reminder to disconnect it.
• Use the correct charger and battery: Always use the manufacturer’s original charger and battery pack designed for your e-bike or e-scooter. Do not mix and match chargers or use cheap knock-off replacements. Incompatible or counterfeit charging equipment is a known cause of fires. Lithium batteries should be charged with chargers that have proper voltage and current control; using the wrong charger can lead to overcharging and overheating. If you need a replacement battery or charger, buy from a reputable source and ensure it meets UK safety standards (look for CE or UKCA markings). Never attempt to bypass or “hot-rod” an e-bike for more speed or range; modifying the motor or battery beyond design limits greatly increases fire likelihood.
• Avoid overloading sockets and cables: Lithium battery chargers draw significant current, so plug them directly into a wall outlet that is in good condition. Do not use extension leads or multi-way adaptors if you can avoid it, an overloaded extension lead can overheat and start a fire. If an extension is absolutely necessary, use a high-quality one that fully uncoils (to prevent heat buildup) and never plug multiple chargers into one outlet.
• Temperature and damage considerations: Allow batteries to cool down before charging if they were used heavily; charging a hot battery can be hazardous. Do not charge or store e-bike batteries in extreme heat or under direct sunlight (above ~45 °C), or in freezing temperatures, as this can damage cells. Regularly inspect the battery casing for any signs of damage (cracks, bulging, leakage) and stop using any battery that is damaged or has been dropped. A damaged lithium battery can short-circuit internally and erupt into flames without warning.
• Be alert to warning signs: If you notice, during charging, that a battery is overheating (hot to the touch), emitting a strange smell, hissing, popping, or smoking, disconnect the power if it is safe to do so. Move the device away from anything flammable. These are signs the battery may be going into failure. Do NOT ignore these signs. If a fire does break out or the battery begins to vent violently, do not attempt to fight the fire yourself, as lithium battery fires are chemical in nature. Raise the alarm, evacuate the area, and call 999 immediately. Fire services are trained to handle lithium-ion fires (often requiring special extinguishing agents or large quantities of water applied for a long duration). Having a clear evacuation plan is vital because lithium fires grow very quickly.

By following these practices, e-bike and e-scooter owners can greatly reduce the chance of a devastating fire. The convenience of micromobility must be matched with respect for the electrical risks. Insurers and landlords should also communicate these safety tips to clients and residents. For example, some housing providers now issue guidance to tenants on e-bike charging safety and may designate safe charging rooms or even prohibit charging in high-risk areas. Proactive risk management in this area can save lives and property.

Safe charging for electric cars (EVs)

Charging electric cars introduces a different set of considerations. While electric vehicle (EV) fires are relatively infrequent compared to petrol car fires, they tend to attract attention due to their intensity and the challenges in extinguishing them. EV batteries contain a large amount of stored energy; if a battery cell fails or overheats, it can enter thermal runaway, an exothermic chain reaction that can cause a fire even hours or days after an initial incident, and the fire may reignite after being extinguished. For these reasons, fire safety and proper electrical installation are paramount when charging cars. The good news is that with correct equipment and precautions, EV charging is very safe.

Below are key best practices:

• Use professionally installed charging points: Do not rely on regular 3-pin wall sockets for routine EV charging. High-power EV charging draws much more current than typical appliances, so it requires purpose-built equipment. Always have charging points (whether a home wall box or commercial charge post) installed by a certified electrician or an OZEV-approved installer. Qualified installers will ensure the system meets the latest electrical wiring regulations (BS 7671 and the IET Code of Practice for EV charging), including adequate circuit capacity, proper earthing, and RCD protection to prevent electric shock. Certified charge points also have built-in safety features such as overload protection and automatic shut-off. Using an approved installer and equipment provides reassurance that legal obligations and safety standards are met.
• Follow electrical safety standards: Your EV charge point should be compliant with BS EN 61851 (the standard for EV conductive charging systems) and any relevant building regulations (e.g. Part P for electrical safety in dwellings). Ensure regular inspection and maintenance of the charging unit and cables per the manufacturer’s guidelines. Loose connections or damaged cables can lead to overheating; check periodically for wear, damage or burn marks on plugs and sockets. Never use frayed or damaged charging cables; replace them immediately to prevent short circuits or shocks. It’s also recommended to keep the charging connector and port dry and clean as moisture ingress can trip safety devices or cause corrosion.
• Avoid Improvised Charging and Extensions: Do not use domestic multi-socket extensions or simple plug adaptors to charge an EV. These are not designed to handle sustained high currents and can overheat, presenting a fire risk. If you must charge from a standard outlet (Mode 2 charging) in an emergency, use the manufacturer-supplied portable EVSE unit and plug it directly into a wall outlet that is on a dedicated circuit. Never daisy-chain extension leads to try to reach your car as this significantly increases the risk of overheating or electrical fault. The safest practice is to use a dedicated EV charging station every time.
• Location matters – charge in safe areas: Thoughtful placement of charging facilities and vehicles can mitigate fire risks. Ideally, charge your vehicle in the open or outside, away from combustible structures. Insurers like Zurich recommend that EV charging points be located at least 10 metres from combustible building materials or structures, or 7.5 metres from building openings or unprotected glazing, to reduce fire spread risk to buildings. If you are installing chargers adjacent to a building (such as a wall-mounted unit), consider fire-resistant barriers or locating the charger on a non-combustible exterior wall. Avoid charging an EV directly inside or adjacent to a building whenever feasible. In enclosed spaces (like domestic garages or underground car parks), ensure there is sufficient ventilation and ideally fire detection/suppression systems in place. Early fire detection (smoke/heat alarms) and even sprinkler protection can dramatically limit damage in the rare event an EV ignites while charging.
• Keep charging areas clear and monitored: Wherever an EV is charging, keep the surrounding area clear of flammable items (such as rubbish bins, cardboard, or fuel storage). An EV that catches fire can release extreme heat; remove any easily ignitable materials near the parked car. It’s also wise to avoid charging an EV unattended for long periods. While it’s not always practical to watch a car for the 4-8 hours it might charge, try to time charging when someone is at home or staff are on site (for commercial premises) who can notice any issues early. Many smart chargers or EVs allow you to set notifications on your phone for charging status; use these to know when charging is complete or if it stops unexpectedly. During charging, periodically check that neither the charger nor the vehicle is overheating excessively (warm is normal; scorching hot or smelling of burning is not).
• Prepare for emergencies: Ensure you have an emergency plan and the right firefighting equipment. Standard ABC fire extinguishers are largely ineffective on high-voltage lithium battery fires. For home users, the priority is evacuation and calling the fire brigade if an EV fire occurs. Commercial sites or car parks might consider keeping speciality fire extinguishing agents (such as Class Li or L2 powders, or water mist extinguishers, as recommended by fire engineers) on hand as a first response, but only if staff are trained. Fire services sometimes use large volumes of water or immersion tanks to control EV battery fires, not methods accessible to the public, which is why prevention is key. Another consideration: if you have multiple EVs charging in proximity (a fleet or car park), a single vehicle fire could spread to adjacent vehicles. Maintain separation between charging bays if space allows, and if you manage a covered car park, follow any interim guidance (such as the UK government’s guidance for EVs in covered car parks) regarding fire safety systems. Finally, remember that risk assessments are a legal requirement for workplaces, under UK fire safety legislation (Regulatory Reform (Fire Safety) Order 2005), charging an EV on commercial premises should be part of the fire risk assessment, and appropriate controls must be implemented.

Electric cars are a transformative technology, and with proper charging infrastructure and habits, the risks can be managed effectively. Many insurers recognise that while EVs bring different hazards (such as battery fires and high-voltage electrical systems), these can be addressed through standards and precautions. By adhering to the above best practices, secure installations, avoiding misuse of electrical outlets, maintaining safe distances, and planning for fire safety, EV owners and businesses can significantly reduce the likelihood of accidents. This not only protects property and lives but can also be important for insurance compliance and coverage (some insurers may stipulate certain charging safety measures as part of policy conditions). In summary, treat EV charging as a critical operation that deserves the same level of safety planning as any other high-energy equipment.

Safe charging for electric forklifts and industrial vehicles

In warehouses, factories, and distribution centres, electric forklifts and pallet trucks are widely used. These heavy-duty vehicles typically use either lead-acid batteries (the traditional, very large batteries that can weigh over 500 kg) or, increasingly, lithium-ion batteries in newer models. Charging forklift batteries presents specific risks: lead-acid batteries give off hydrogen gas during charging, which is flammable and poses an explosion risk if it accumulates, while lithium-ion forklift batteries share similar fire and thermal runaway hazards as other Li-ion devices. Additionally, the charging process often involves high currents and manual handling of heavy battery units. To keep operations safe and losses low, facilities should implement the following best practices for forklift battery charging:

• Designate a safe charging area: Forklift batteries should be charged in a dedicated battery charging area or room that is well-ventilated and free of ignition sources. Good ventilation is critical because lead-acid batteries release hydrogen and oxygen gas during charging, even a small spark can ignite accumulated hydrogen with explosive force. The charging area should be open-air or equipped with forced ventilation systems to prevent gas build-up. Clearly mark the charging zone with safety signage. For example, post “No Smoking/Open Flames” signs prominently. Hot work and any open flames must be strictly prohibited in battery charging areas. The floor should be clean, dry, and ideally made of acid-resistant, non-combustible material (since lead-acid batteries can leak acid). If charging is done outdoors or in a shed, ensure the area is covered (to keep rain off electrical equipment) but still vented.
• Proper electrical setup: Just like EV cars, forklift chargers should be installed to electrical code standards. Ensure that charging units (whether wall-mounted chargers or mobile chargers) are on appropriate dedicated circuits with the correct voltage and amperage ratings for your fleet’s needs. Never use jury-rigged electrical connections or undersized wiring for charging forklifts, as the high currents can easily overheat poor connections. All charging equipment should be UL or CE certified and maintained per manufacturer’s instructions. It’s wise to include an emergency shutoff or isolation switch for the charging area’s power supply in case a battery overheats, or an electrical fault is detected, so power can be cut quickly.
• Safe charging procedures: Train staff on the correct procedure to connect and disconnect batteries from chargers. Always turn off the charger (or isolate its power) before connecting or disconnecting a battery. This prevents arcing at the terminals, which could ignite hydrogen gas. Connect the charger leads firmly and make sure the clamps or connectors are secure, as a loose connection can spark or overheat. For lead-acid batteries with removable caps, keep the vent caps open during charging to allow gas to escape (and ensure they are not clogged). After charging is complete, turn off the charger before disconnecting the leads. Have a rule that only authorised, trained personnel may perform battery charging or exchanges.
• Use proper PPE and handling gear: Charging and especially changing forklift batteries (for swap-out systems) can expose workers to electrical hazards, heavy weights, and corrosive acid. Personal protective equipment (PPE) is a must. This includes safety eyewear (goggles or face shield), insulated gloves (for electrical protection, or acid-resistant gloves if working with liquid electrolyte), and steel-toe boots. When topping up lead-acid battery electrolyte, an acid-resistant apron is recommended, and always add distilled water after charging (never before, to avoid overflow of acid). An eye-wash station and emergency shower or water source should be nearby in case of acid splashes. Use appropriate battery handling equipment – forklift batteries are extremely heavy, so use a rated hoist, lifting beam, or a purpose-built battery cart to move them. Operators should remove metal jewellery and wear non-conductive gloves when working around exposed terminals to prevent accidental short-circuits.
• No unattended charging: As a general rule, do not leave forklifts charging overnight or when the building is unattended. Charge batteries during shifts or working hours so that if a problem occurs (like smoking or a fire), someone is present to take immediate action. Many sites choose to charge during lunch breaks or between shifts and then trickle-charge or top-up as needed when staff are around. If overnight charging is unavoidable, it’s even more critical that other precautions (ventilation, alarms, good housekeeping etc.) are in place.
• Emergency response and storage: If a forklift battery shows signs of failure (e.g. smoking, bulging, or a rapid temperature rise), follow emergency protocols: disconnect it if safe, evacuate the area, and call the fire brigade if a fire is imminent. Any damaged or suspect battery should be immediately taken out of service and moved to a safe, isolated location at least 10 m away from any building or important equipment. For lithium batteries, especially, a damaged battery can ignite hours later, so isolation is crucial. Ideally, have a sand bucket or bin to dump a small burning battery if one ever goes into thermal runaway (for smaller equipment or tool batteries). As a longer-term safeguard, store spare or idle batteries in a fire-resistant enclosure. For example, keep backup forklift batteries in a cabinet or room that provides at least 60 minutes of fire resistance to contain any fire. Some sites use galvanised steel battery lockers for this purpose. Finally, ensure your facility’s fire alarm system covers the charging area and that fire extinguishers (appropriate for electrical fires at minimum) are easily accessible.

Implementing the above measures will significantly mitigate the fire and explosion hazards associated with forklift battery charging. Insurance providers will expect that businesses using fleets of electric material handling equipment have addressed these basics – indeed, following such guidance can be a condition for coverage in some cases. By treating forklift charging with the same seriousness as other industrial high-risk tasks (like welding or fuel storage), companies can protect their warehouses, employees, and goods from catastrophic battery incidents. Remember that risk management in this area is an ongoing process: review your practices whenever you add new equipment (e.g., switching to lithium forklifts) or if there are any near-miss incidents, and update your risk assessments accordingly.

 

Source: RiskSTOP