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Battery Energy Storage Safety

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Battery Energy Storage Safety

Toolbox Talk Record

Ref: TBT-ENE-005  |  Issue: 1  |  Date: March 2026
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What?

  • Battery energy storage systems (BESS) are increasingly common on construction and renewable sites.
  • Lithium-ion batteries present risks of thermal runaway — an uncontrolled self-heating reaction.
  • Thermal runaway produces toxic gases including hydrogen fluoride, which is lethal at low levels.
  • Electrical hazards include high DC voltages that cannot be switched off — batteries are always live.
  • Fire in a BESS container can re-ignite hours or days after the initial event was controlled.
  • The Electricity at Work Regulations 1989 and DSEAR 2002 apply to battery storage installations.
  • Emergency response plans specific to BESS must be developed before commissioning.
  • Only competent persons trained in high-voltage DC should work on battery installations.
  • Ventilation systems in battery enclosures prevent accumulation of explosive hydrogen gas.
  • Installation work near BESS requires awareness of arc flash risks from DC circuits.

Why?

Toxic gas riskThermal runaway releases hydrogen fluoride and other gases that kill rapidly.
Fire dangerBattery fires are extremely difficult to extinguish and can reignite for days.
Electrical shockHigh-voltage DC systems cannot be isolated like AC — batteries remain energised.
Legal complianceDSEAR and Electricity at Work Regulations require specific controls for BESS.
Do Don't
  • Follow the site-specific BESS emergency plan and know your evacuation route.
  • Maintain a minimum safe working distance from energised battery systems.
  • Wear arc-flash rated PPE when working near DC battery circuits.
  • Ensure ventilation systems in battery enclosures are operating correctly.
  • Monitor for unusual smells, heat, or smoke from battery containers.
  • Only allow trained and authorised personnel to access battery enclosures.
  • Report any physical damage to battery modules, cables, or enclosures.
  • Keep fire service informed of BESS locations and specific hazards on site.
  • Use only approved insulated tools when working on battery connections.
  • Confirm gas detection is active before entering battery enclosures.
  • DON'T enter a battery enclosure without checking ventilation and gas levels.
  • DON'T assume a battery system is safe because it looks powered down.
  • DON'T use water on a lithium-ion battery fire without specialist guidance.
  • DON'T store flammable materials near battery energy storage containers.
  • DON'T attempt to repair damaged battery modules — isolate and report.
  • DON'T ignore warning alarms from the battery management system.
  • DON'T work on high-voltage DC circuits without specific DC safety training.
  • DON'T block ventilation openings on battery enclosures or containers.
  • DON'T re-enter a battery enclosure after a thermal event without clearance.
  • DON'T short-circuit battery terminals — the release is immediate and violent.

See also: Renewable Energy Safety Awareness | Arc Flash Awareness
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