Electric vehicle (EV) battery fires are rare—but they’re a real and evolving risk for fleet operators. Understanding how and why they occur, and how to reduce the chance of an incident, is critical as more fleets introduce EVs into their operations.
At the 2025 EROAD Fleet Day in Hamilton, EV FireSafe Director Emma Sutcliffe delivered a powerful and myth-busting presentation to help fleet professionals understand what actually causes EV battery fires—and what doesn’t. Her message was clear: with the right processes, training, and infrastructure, the risk is manageable.
EV Fires Are Rare, But Real
Since 2010, EV FireSafe has verified 712 plug-in electric vehicle battery fires globally. With over 14 million EVs on the road, this represents a tiny fraction—showing that EVs are not inherently fire-prone. However, EV battery fires are complex, hard to extinguish, and present new risks to drivers, first responders, and infrastructure.
What Causes EV Battery Fires?
Sutcliffe, whose work is funded by the Australian Department of Defence, explained the most common causes:
- Traffic collisions – Often with another vehicle or roadside object.
- Road debris – Impact from large objects like scrap metal tearing open battery packs.
- Salt water submersion – Especially in storm or flood conditions.
- External fires – Arson, bushfires, or nearby building fires.
- Battery faults – Like the Hyundai Kona recall, due to manufacturing defects.
- Poor charging practices – Often the fault of DIY installations or unsafe use of adapters.
In New Zealand, EV FireSafe has verified eight EV battery fires, with similar patterns to Australia.
Don’t Buy Into EV Fire “Solutions” That Don’t Work
One of the biggest risks to fleet safety? False confidence in ineffective products.
Sutcliffe warned fleet managers against buying fire blankets, underbody sprays, or EV-specific extinguishers. “They do not work,” she said. “We’ve tested them. In fact, using these products can increase the risk to your drivers.”
During joint testing with U.S. agencies, some fire blankets even exploded under pressure—creating more danger, not less.
What Fleets Should Do
While there’s no magic extinguisher, there are smart, simple actions fleets can take:
1. Install Charging Infrastructure Correctly
A normally operating EV that’s connected to a compliant charger cannot cause a battery fire.
- Use AS/NZS 3000 compliant wiring.
- Employ licensed electricians.
- Ensure regular inspection and maintenance of equipment.
Sutcliffe explained that EVs and chargers perform a handshake safety check before current flows. If the car repeatedly refuses to charge, don’t ignore it—it may indicate a fault.
2. Avoid DIY or Unsafe Home Charging
Poor charging at home is a growing risk. Sutcliffe shared jaw-dropping examples:
- A council worker rewired his own shed and caused a fire.
- A driver used a travel adapter from a phone charger to connect a Japanese-import EV to an Aussie socket.
- Another wired a Tesla directly into mains power lines.
Fleet drivers must be trained and equipped for safe home charging.
3. Use Free and Trusted Resources
EV FireSafe offers two resources that every fleet should use:
- Free 15-Point Safety Plan (Australian Building Codes Board): A cost-neutral checklist to reduce charging site risk.
- Charging Site Toolkit: A low-cost online guide for installing and maintaining EV chargers, developed with insurers and fire engineers in mind.
These tools help manage fire risk while keeping your insurers and safety teams satisfied.
4. Train Drivers and Fleet Teams
EV FireSafe provides training tailored to fleet operators and emergency responders. Topics include:
- How battery fires behave (e.g., jets of flame, popping and hissing sounds).
- Safe charging habits.
- How to respond to suspected faults or post-collision risks.
Sutcliffe noted, “Confidence in technology is badly impacted after a fire. You don’t want your team turning against EVs because of one bad incident.”
Managing Driver Perception and Clickbait
Another challenge is misinformation. Sutcliffe highlighted how clickbait videos and AI-generated EV explosions create fear and confusion.
Fleet managers need to proactively address misconceptions, using verified data and trusted experts like EV FireSafe to reassure drivers and stakeholders.
Key Takeaways for Fleet Managers
- Don’t panic—EV fires are rare but must be taken seriously.
- Use qualified installers for all EV charging—never DIY.
- Avoid gimmick products—blankets and sprays won’t help in a real battery fire.
- Access the EV FireSafe tools to design and maintain safe charging sites.
- Train your team so they understand the risks and don’t fall for misinformation.
Resources
Emma Sutcliffe’s presentation at the 2025 EROAD Fleet Day served as a timely reminder: you don’t manage risk with products—you manage it with planning, training, and compliance. EV battery fires may be rare, but fleet safety should never be left to chance.
Want help reviewing your fleet’s charging setup or policies? Reach out for guidance or training opportunities with EV FireSafe.
