Fire Testing Intensifies as Energy Storage Sector Pushes ‘Extreme Safety’ Standards

Growing adoption of energy storage systems is transforming how electricity is generated, stored, and consumed, but it also introduces new challenges around energy storage safety. In recent years, thermal runaway incidents in lithium-ion batteries have accelerated updates to global standards and regulations.

One of the most effective tools to address these risks is large-scale fire testing (LSFT), a rigorous evaluation method that simulates worst-case fire scenarios in energy storage products. By replicating extreme conditions at the battery, module, and system levels, LSFT provides essential scientific evidence for preventing and controlling thermal runaway. Today, LSFT is widely seen as both a compliance requirement and a critical benchmark for market acceptance.

Why Large-Scale Fire Testing Matters

With the rapid growth of renewable energy integration and battery deployment, ensuring safety has become as important as performance or cost. LSFT replicates real-world hazards—such as fully charged systems, tight installation spacing, and disabled fire suppression—to test the resilience of battery energy storage systems (BESS).

Although these trials are technically complex and can cost millions per test, an increasing number of companies are voluntarily conducting them to validate their solutions. By demonstrating strong results in battery fire testing, manufacturers build trust with regulators, utilities, and end-users, ensuring their products are ready for global markets.

Different Approaches to Battery Fire Testing

Industry experiments reveal that companies take varied approaches depending on their priorities. Some focus on fire containment at the container level, showing that flames and heat remain isolated to a single unit. Others emphasize methodologies such as smouldering combustion tests, open-door burning, or long-duration exposure, each targeting different aspects of fire performance.

These diverse strategies highlight that while the objective is universal—safer batteries and systems—the paths to achieve energy storage safety are distinct, reflecting different technology roadmaps.

Expanding to Commercial and Industrial (C&I) Storage

While LSFT has long been associated with large-scale grid-connected storage, commercial and industrial (C&I) energy storage systems are now under closer scrutiny.

C&I systems are typically smaller, cabinet-sized units deployed in populated spaces such as shopping centers, factories, and office complexes. The higher density of installations in close proximity to people makes battery safety testing even more critical.

Recent C&I fire tests have simulated extremely tight cabinet spacing (15–30 cm) and intentionally disabled active protection systems. Results showed successful thermal runaway containment within a single module or cabinet, preventing fire spread to nearby equipment. These outcomes demonstrate progress toward precision-oriented safety standards tailored for distributed energy storage.

Looking Ahead: Energy Storage and Grid Stability

As demand for renewable energy and grid stability grows, the role of safe and reliable battery technology will only expand. Utility-scale fire testing will remain essential to prove resilience under extreme, plant-level conditions, while C&I testing will refine safety for deployments in high-density urban and industrial environments.

Currently, the cost of LSFT—ranging from millions to tens of millions—means that only leading manufacturers can perform such tests regularly. Over time, however, the industry is expected to standardize more accessible approaches, making battery fire testing a norm across the entire value chain.

Ultimately, the rise of LSFT and C&I fire testing reflects a maturing industry. In the global transition to clean energy, energy storage safety has become just as important as efficiency and cost-effectiveness. Verified performance in extreme safety scenarios will be a cornerstone for accelerating the adoption of renewable energy storage systems worldwide.