Coffee Sessions: Lithium Battles

Coffee Sessions: A new blog series delving into the specifics of our line of work.

If you’ve been in the fire service for more than a minute, you know that vehicle fires are our bread and butter. Pull the bumper line, knock it down, pop the hood, and wash it out. It can be that simple sometimes, but the rise of Electric Vehicles has completely flipped that script. We are no longer just fighting burning plastics and fuel; we are battling chemical chain reactions that generate their own heat, produce highly toxic gases, and can reignite days later.

To understand what we're up against, let me share a bit of what this looks like in the real world.

Let Me Paint the Picture...

Humid and cloudy, I believe it was just past mid-day. My partner and I were on our Rescue unit (Truck Co./ EMS unit) heading back from our local hospital, just about to get on the bridge that connected one city to another, when we hear that slight tone from the CAD changing to the page showing a call was coming through. Now for most of us, first thing we look for is the address, and having zone familiarity was one of the things I always harped on. Boom, saw the address, told my partner to stop real quick and throw on our turnout gear because we saw that it was a roll over, easy enough for us to figure this has a high probability to be an extensive extrication. As soon as we got our gear and jumped back in the truck, the notes started pouring in with all the calls coming through, with it saying two vehicles, a lot of damage, multiple unconscious patients, now we are feeling that sense that this is not the run of the mill roll over, but something a little more. This area has a main artery from a major highway and multiple cities so we get a lot of traffic and it only runs at 45mph, so even though we get a good amount of accidents, it's usually within the damage of two vehicles running at around that speed with the occasional fast and furious group.

Response

As we are responding on top of the bridge, dispatch came over and started saying that callers are stating that one vehicle is on fire and they are attempting to put it out. Now as soon as we get to the top of the bridge it is about a mile to get across so we don't get to see much of the other side, but knew as soon as we would start descending we may start seeing the red lights and traffic building up. Well, the wild thing was not only did we see the traffic build up between about half a mile from the bridge and almost up the bridge, the entire southern side of the bridge was empty. Not one vehicle. Just in the distance we started seeing the accident and a huge plume of smoke rolling across the  eight-lane road way. This smoke was not thick black smoke like you may see in a true vehicle fire, it was thick white smoke...

I could not make sense of that, just thought maybe there was a fire and someone on scene was able to put it out,  I couldn't tell. I told my partner to begin driving on the incoming side knowing no one was coming towards us. Because we were already on the road and not more than a mile and a half away, I knew we were going to be there first. We knew what the plan was, Life Safety, Incident Stabilization, Property Conservation and Environment Protection, right... easy. Just take the victim away from the issue. I called over to him and said, "Pack out and grab the water can", thinking to myself I just need to pack out and attempt to remove them from that environment. Well pulling up, it was not that easy.. We are a good 300 to 400 feet from the incident driving up and seeing an entire engine block sitting in the middle of the road. The amount of force to take this entire thing out of the engine compartment and sling shot it down the street had to have been insane.

Arrival

My partner and I worked so well, as everyone knows, you really don't need to have much direction from each other. Just go to work. Well as he pulls the E-brake, he jumps out to get his task done, I began my arrival report. "Rescue__, on scene of a two vehicles with heavy damage, one vehicle on its roof with smoke coming from it and one upright, [information withheld to respect privacy of victim], setting up ____ command, mobile" I believed this would be the only patient, but I was wrong. To respect the privacy and dignity of the victims and their families, that is all I will say in that regard.

The Reveal

All packed out and running over to start performing a quick triage, with my main focus of attempting to remove anyone out of the burning vehicle, as I am beginning to mask up moving from the truck to the worst vehicle, we all know the first thing to do is to analyze the entire scene not just focus solely on the worst portion, tunnel vision skews your critical decisions.

I see a large crowd standing close with their phones out and those that are attempting to help, but unable to fully get close to the car due to the smoke.

Freeze frame: now this is where the learning point came in, I thought to myself, "Why in the world is this smoke white? Why is there pressure behind it... and a lot of it."

I could not wrap my head around it, until I see my partner pulling the pin and started spraying the area that seemed to be on fire, which was the bottom of the vehicle and out the side, so I click in and see what looked like molten metal shooting out away from my partner making this popping/bubbling sounds and hissing as it cools through the air. There was fire coming from the undercarriage. He somehow keeps this fire from getting bigger and keeps it in check.

I am getting down on the ground I looked at the wheel and saw that T... a Tesla. Now it makes sense. There was so much smoke we could not see what the vehicle was until we kept that fire/smoke pushed back and away from us as the wind pushed it up and out of the scene. First thought now is, this has to be from the battery burning, but now what am I to do with this car if it was still energized and there was this much damage. I don't remember who I told, it was either my partner or a cop, but I then called for the CO2 and ABC extinguisher just to be the next mode, knowing this would not do anything, but we had to try whatever we had to keep the fire suppressed until our other unit can get to us.

Somehow with what we had we kept the fire from extending to other parts of the battery and going into thermal runaway. So I get down and try to figure out a way to get the patient out of the vehicle as the person was still buckled in, I looked up and just saw everything start to subside. The Engine crew rolling up to cool it down even more and stopping it all together. This is when someone called out that the wire has been separated from the accident and we were able to remove one of the victims from the vehicle. As I said I will not discuss the tragedy that happened, but we all tried what we could. They ended up connecting to the hydrant and flowing mass amounts of water to make sure it was cooled down.

It's wild sometimes to think there will be moments as a firefighter you will approach a scene that seems so unrealistic that your brain does not even recognize chaos, but just controls all emotions and nervous system seems to shut out in the perfect time to just fall back on training because your mind has no idea how to formulate the plan to mitigate. After the fact you just take a breath and everything rushes through your system and you are still held to a certain standard to suppress what you need to for the next call.

My Takeaways

1. White pressurized smoke coming from the vehicle with no known hazardous markers.

2. Always expect a car to be hot until we de-energize the vehicle

3. Batteries are individual and small so it can start burning battery by battery until multiple batteries start going off as it is extending through the pack

4. Batteries burning spew out what looks like a molten metal.

5. Need to keep everything extending to cool down to stop the thermal runaway

6. It takes either letting it burn out or mass amounts of water.

7. Use whatever you got, especially if there is a possible victim.

8. Stay vigilant!

As those points highlight, EV fires require a total mental shift. Let’s break down the hazards we are actually facing, how to lock down the scene, and strategies that actually work.

Knowing the Enemy: EV Fire Hazards

You can usually tell you're dealing with an EV by the badging, a charging port, or fire emanating directly from the undercarriage. If you hear a hissing or popping sound, the battery is already involved. Here is what is happening beneath the floorboards:

• Thermal Runaway: This is the nightmare scenario. It’s an uncontrollable, self-sustaining chain reaction within the lithium-ion cells. The battery is rapidly increasing in temperature and pressure, leading to explosions and fire.

• Toxic Off-Gassing: When these batteries fail, they release heavy smoke packed with carbon monoxide, hydrogen cyanide, and hydrogen fluoride. Inhaling this plume is a critical health hazard. * High Voltage: The propulsion system and battery pack are always considered energized. Look out for the orange cables—they carry massive voltage and pose a severe electrocution risk.

• Re-Ignition Risk (The Zombie Fire): Just because the fire is out doesn't mean it's over. Stranded energy and latent heat in undamaged cells can push the battery back into thermal runaway hours or even days later.

Your Initial Response

Always remember the fire growth timeline of an EV often outpaces our arrival. By the time dispatch is initiated (2–4 minutes) and we arrive on scene (6–8 minutes), the vehicle is likely already heavily involved. Rapid size-up is your best tool.

Securing the Scene and Protecting Yourself

• PPE is Non-Negotiable: Full PPE is required anywhere near the Warm Zone. If you are in the Hot Zone (within 75 feet), you must be on air.

• Immobilize the Threat: EVs can move silently. Put the vehicle in Park, set the brake, and chock the wheels immediately. If possible, get the proximity key at least 16 feet away.

• Kill the Power: Consult the Emergency Response Guide (ERG) for the specific make/model. The standard move is disconnecting the 12-volt battery to deactivate the high-voltage contactors.

Now Dealing with Charging Stations

If the car is plugged in, do not just yank the cable.

1. Hit the E-Stop: Look for the large red mushroom switch on the pedestal. This is your fastest, safest option.

2. Kill the Breaker: If the E-Stop is melted or inaccessible, find the electrical panel and shut off the main breaker to the unit. Visually verify it's off.

3. Manual Disconnect (Last Resort): Only remove the cable after power is verifiably dead. Pulling a live, locked plug creates a massive arc flash hazard.

Cool It or Let It Burn?

Our primary goal isn't just to extinguish flames; it's to stop the cell-to-cell spread of heat by cooling the battery casing.

• Water, Water, Water: Be prepared for an extended operation. You may need anywhere from 3,000 to 8,000+ gallons of water to fully suppress an EV thermal event. Secure a sustainable water supply immediately.

• Application: Direct multiple large-volume handlines (2.5-inch or master streams) directly at the vehicle's underside.

• The Defensive Tactic: Sometimes, the best offense is a good defense. If there is no immediate life safety issue or severe exposure risk, it is entirely valid to protect your exposures and let the battery burn itself out while monitoring it with a Thermal Imaging Camera (TIC).

Overhaul and Aftermath

Keep flowing water until your TIC shows the battery area has cooled below 200°F. Because of the toxic byproducts, perform a gross decon of all personnel in the Warm/Hot zones before anyone drops their gear.

When it's time to clear the scene, your job isn't quite done. You must inform the tow operator about the re-ignition risk. The EV needs to be stored in an open area, at least 50 feet away from buildings or other cars, and monitored for at least 72 hours. Also, keep an eye on your water run-off—it's likely full of heavy metals and toxins, so get Hazmat on the line if containment is an issue.

Community Outreach & Tools

The public is buying lithium-ion powered devices—from Teslas down to e-bikes and scooters—at record rates. We need to be proactive. Share the Take C.H.A.R.G.E. safety model with your community:

• Choose certified products.

• Handle devices with care.

• Always look for warning signs (swelling, heat, hissing).

• Recycle batteries properly.

• Get out quickly if things go south.

• Educate others.

Tech Tools for the Job

Make sure your crews have the right apps downloaded on their devices. EV Rescue is a great free app showing lifting points and battery cooling info, while the digital ERG (Emergency Response Guidebook) is a must-have for initial incident response for all alternative fuel vehicles.

The Bottom Line: Staying Ahead of the Current

EV fires are not "standard" car fires—they are complex chemical events that require a tactical shift in response. For the modern firefighter, success depends on aggressive cooling, persistent monitoring, and strict scene control.

Key Takeaways for the Crew:

• Water is King: Prepare for an extended operation using 3,000+ gallons to cool the battery casing, not just the flames.

• Trust the TIC: Never consider the fire "out" until temperatures drop below 200°F and stay there.

• Safety First: Because of toxic off-gassing and re-ignition risks, full PPE and post-incident decon are life-saving requirements.

At Firefighter.com, we’ve spent 27 years providing the gear that keeps you safe on every call. Stay informed, stay equipped, and stay safe on the line.

A Note on Tactics: This guide is for educational discussion only. Firefighting tactics vary by region, staffing, and equipment. Always prioritize your department’s specific SOPs and consult your training officer before implementing new strategies on the fireground.