Not long ago, an electric vehicle (EV) was brought into a Pennsylvania dealership following a front-end collision. After a quick inspection, the issue appeared to be battery-related. With the workday ending, the vehicle was left in a service stall overnight.
By morning, it had caught fire.
While this may sound like an isolated incident, situations like this are becoming a growing concern across the collision repair industry. As EV adoption continues to rise, so does the need for a deeper understanding of battery safety, fire risks, and proper handling procedures.
At the recent IBIS USA event, EV expert Dirk Fuchs shared critical insights into what can go wrong—and how shops can better prepare.
Understanding the Real Risk
When it comes to vehicle fires, electric vehicles often get the spotlight—but the data tells a more nuanced story.
According to research from the National Fire Protection Association (NFPA):
- EVs experience roughly 25 fires per 100,000 vehicles
- Internal combustion engine (ICE) vehicles see about 1,530 fires per 100,000
- Hybrid vehicles present the highest risk at 3,474 fires per 100,000
So while EV fires are less common, they present a different kind of challenge.
When an EV battery ignites, the fire can be more intense, longer-lasting, and significantly harder to control—especially if the battery is fully charged.
The Challenge of Thermal Runaway
Most EVs are powered by lithium-ion batteries, which introduce a unique hazard known as thermal runaway.
This occurs when damaged or defective battery cells begin to overheat uncontrollably, triggering a chain reaction that spreads from one cell to another. The result is a rapidly escalating fire that can be difficult to suppress using traditional methods.
Beyond fire risk, EVs also present additional hazards, including:
- Electrical shock
- Stranded energy (stored power remaining in damaged systems)
- Deflagration (sudden combustion events)
For collision repairers, this means a standard approach to damaged vehicles is no longer enough.
What Shops Should Be Doing Differently
Handling EVs safely starts with a shift in mindset: more caution, more control, and more preparation.
Here are a few key considerations:
1. Create a Dedicated Storage Area
EVs—especially those involved in a collision—should be stored in a designated, isolated area, ideally with access to a sprinkler system. Separation is critical in reducing risk to the rest of the facility.
2. Handle Batteries with Care
When dealing with high-voltage batteries:
- Perform proper “stable to ship” checks
- Disassemble damaged batteries when required
- Use certified packaging (such as PG1 crates)
- Ensure compliance with DOT regulations
Battery handling isn’t just best practice—it’s heavily regulated.
3. Know the Codes and Standards
Guidelines like NFPA 855 outline the minimum safety requirements for energy storage systems, including lithium-ion batteries. Understanding and following these standards is essential for compliance and safety.
Additionally, the U.S. Department of Transportation provides guidance on identifying and handling damaged, defective, or recalled (DDR) batteries—which pose even greater risks.
Transporting EVs: What’s Changed
One of the biggest misconceptions in the industry is how EVs can be transported after an accident.
Contrary to common practice, simply loading a damaged EV onto a flatbed truck may violate DOT regulations, especially if the battery is compromised.
New solutions are emerging to address this challenge.
Containment systems like the FireBox are designed specifically for EV transport and storage. These units:
- Contain and isolate potential fires
- Allow vehicles to be monitored for thermal events
- Can be filled with water to submerge battery systems if needed
- Prevent dangerous gas buildup while enabling safe drainage of contaminated water
For the first time, the industry has a more compliant and controlled way to move damaged EVs.
The Bottom Line
EVs aren’t going anywhere—and neither are the risks associated with them.
For collision repair shops, staying ahead means:
- Understanding how EV fires behave
- Adapting shop processes and layouts
- Following evolving safety standards and regulations
As technology continues to advance, so must the way we approach repair and safety.
At Colours, we’re committed to helping our customers stay informed, prepared, and equipped for what’s next in the industry.
This article was inspired by reporting from Stacey Phillips Ronak of AutoBody News.