Fire risks, regulation, and innovation: Advancing SA battery safety

July 18, 2025

Lithium-ion batteries are embedded in modern life, from smartphones to solar storage systems and electric vehicles. With their convenience, however, comes significant risk.

Prone to overheating, fires, and even explosions under certain conditions, these powerful energy cells are officially classified as Class 9 miscellaneous dangerous goods under South Africa’s SANS 10228, which adopts the UN Recommendations on the Transport of Dangerous Goods. As their use continues to surge, so does the urgency for safe handling, robust transport systems, and forward-thinking fire protection strategies.

Regulations that set the standard

SANS 10228 aligns with global frameworks like the UN Recommendations and Europe’s ADR, ensuring that South Africa’s rules mirror international best practices. Batteries transported in bulk or those not installed in devices must comply with strict protocols including proper labelling, documentation, and most critically, UN-certified packaging. These containers undergo stringent drop, puncture, and heat tests to ensure they can contain hazardous materials even in worst-case scenarios. It’s more than just red tape; it is the foundation for nationwide battery safety.

Why lithium batteries demand extra care

When lithium-ion batteries fail, the consequences escalate fast. Factors like overheating, physical damage, or manufacturing defects can trigger “thermal runaway”, a self-sustaining reaction that rapidly releases stored chemical energy as fire or explosion. These fires burn incredibly hot (up to 2,760°C in electric vehicle incidents), require massive volumes of water to suppress, and often emit toxic gases like hydrogen fluoride, carbon monoxide, and aerosolised electrolytes that pose serious health and environmental risks. Worse, the fire’s oxidising agents originate within the battery, making conventional extinguishing methods like foam or dry powder largely ineffective. Firefighters often resort to isolating the burning battery and letting it burn out, but this reactive approach has clear limitations.

Engineering a safer path with PyroBubbles

Enter PyroBubbles, a passive fire protection innovation designed to contain and control lithium battery fires at the source. Developed by Germany’s Genius Group and distributed by Pyro Brand (Pty) Ltd in Africa, PyroBubbles are lightweight, glass-based granules that insulate heat, suppress flames, and adsorb* toxic vapours. Rated A1 for fire resistance in accordance with European and South African standards (DIN 4102, EN 13501, and SANS 11820, which harmonises with EN testing methods for non-combustibility), they don’t burn, emit smoke, or form flaming droplets.

These granules withstand temperatures of over 1,000°C, melt into a sealing crust when exposed to extreme heat, and form a thermal barrier that can stop a runaway fire from spreading. They also adsorb flammable liquid spills and trap up to 85% of harmful vapours during battery failure, creating a significantly safer containment zone. Their electrical insulation and hydrophobic properties make them particularly suitable for battery storage environments, and as a bonus, they’re reusable after fire incidents, offering a sustainable, cost-effective solution.

Passive protection meets industry standards

Rather than dousing a battery fire with water or foam, PyroBubbles let the battery “self-extinguish” inside a pre-filled bed of granules. When used in storage containers like Genius Boxes, specially engineered and UN-certified for Class 9 dangerous goods, this approach helps prevent fires from ever spreading beyond a single cell. It’s a shift from reaction to prevention, giving safety professionals a tool to stop small incidents from becoming warehouse-level disasters.

Trusted by EV giants

Automotive leaders including Volkswagen, Porsche, and Mercedes-Benz have embraced PyroBubbles as a standard in their electric vehicle (EV) programmes. During battery testing and validation, they rely on PyroBubbles to manage simulated thermal runaway events, containing fires and controlling emissions. Beyond labs, these granules are incorporated into battery logistics infrastructure – proof that PyroBubbles isn’t just a product, but a trusted engineering solution that protects high-value assets and lives.

Proactive risk management for a growing market

As demand for lithium-ion technology accelerates in South Africa and beyond, so too does the need for robust safety measures. Incidents involving fires in trucks, warehouses, and even container ships serve as stark reminders: lithium batteries can be volatile if mishandled. While regulations like SANS 10228 provide the legal framework, companies must go further by adopting best-in-class materials and practices to actively reduce risk.

That’s where solutions like PyroBubbles and Genius Boxes stand out. Fire tests and real-world deployments have shown that when a battery fails within a properly designed containment system, the result is minimal: no toxic plume, no pressure wave – just a safely contained failure and clean-up. Even so, best practices still apply: batteries must be handled carefully; staff must be trained and emergency services informed. Passive protection is no substitute for vigilance, but it gives responders vital time when seconds matter.

A national push toward safer handling

South Africa’s fire safety and logistics communities are now evaluating these innovations for wider approval. Local testing, such as the tests being conducted by Ignis Fire Testing, has validated that PyroBubbles meet South African standards, bringing the nation in line with global battery safety benchmarks. For the logistics industry, using UN-compliant packaging is not just about ticking boxes; it’s about safeguarding people, property, and brand reputation.

There’s also a need for greater public awareness. Consumers often underestimate the risk of improperly discarding damaged or swollen batteries. Tossing a defective phone battery into household waste or transporting an unsecured e-bike battery in the trunk of a car can end in disaster. Education campaigns and battery recycling initiatives with the right containment and collection protocols are vital components of a comprehensive safety strategy.

Prevention is better than cure

Lithium-ion battery fires aren’t hypothetical – they’re real, fast-moving, and dangerous. But with a combination of solid regulation, advanced engineering solutions like PyroBubbles, and smarter operational practices, South Africa is poised to lead the way in battery safety. The message is clear: we don’t have to wait for a disaster to act, we have the tools to prevent one.

* Adsorption is a surface phenomenon where atoms, ions, or molecules from a gas, liquid, or dissolved solid adhere to the surface of another substance (usually a solid). It’s common in air filters, gas masks, and fire protection materials (like PyroBubbles) that trap toxic vapours.