Across the lithium-ion battery life cycle—from cell manufacturing and pack integration to transport, use, repurposing, recycling and disposal—multiple safety risks can arise, including fire, thermal runaway, toxic emissions and mechanical or electrical hazards. As battery deployment accelerates in mobility and stationary storage, incidents across logistics and end-of-life stages highlight the need for holistic, life-cycle-oriented safety approaches. Current safety knowledge and guidance are often siloed by sector or life-cycle stage, limiting the ability to anticipate risk transfer between stages (e.g., from use to recycling) and to define coherent prevention strategies. In addition, variability in battery designs, ageing states and handling practices increases uncertainty for risk management. This project addresses these gaps by mapping and analysing life-cycle hazards and by developing evidence to support risk assessment, modelling and guidance for safer management of lithium-ion batteries throughout their life cycle.
The project investigates which hazards and accident scenarios are most relevant at each stage of the lithium-ion battery life cycle and how these hazards are influenced by design choices, ageing and handling conditions. It examines how experimental investigations can characterise failure modes, emissions and initiating events under representative conditions and how this evidence can inform modelling of accident progression and consequences. Another research question concerns how quantitative or semi-quantitative risk assessment and modelling approaches can be developed to support preventive decision-making, including identification of hotspots and prioritisation of mitigation measures across life-cycle stages. The project also explores how results can be consolidated into practical recommendations and guidance for stakeholders involved in manufacturing, logistics, use and end-of-life management.
The project will deliver a life-cycle hazard mapping and risk assessment basis for lithium-ion batteries, supported by experimental evidence on failure modes and accident scenarios. Outputs include modelling elements to quantify risks and evaluate preventive strategies across life-cycle stages, and a set of recommendations and guidance supporting safer handling, transport and end-of-life management. Dissemination outputs will support uptake by industrial stakeholders, authorities and risk management actors.
The project workplan is organised into four main work packages. - WP1 – Life-cycle hazard identification: maps safety risks across manufacturing, use, transport and end-of-life of lithium-ion batteries. - WP2 – Experimental investigation: studies failure modes, emissions and accident scenarios under representative conditions. - WP3 – Risk assessment and modelling: develops models to quantify risks and support preventive strategies. - WP4 – Recommendations and dissemination: translates results into guidance for safer battery life-cycle management.

Amaia García
Fundación GAIKER
Spain

Leire Barruetabeña
Fundación GAIKER
Spain

Isabel Rodríguez-Llopis
Fundación GAIKER
Spain

Henriikka Kannisto
FIOH
Finland

Jarmo Vorne
FIOH
Finland

Tiina Santonen
FIOH
Finland

Anna-Kaisa Viitanen
FIOH
Finland

Arto Säämänen
FIOH
Finland

Pia Perttula
FIOH
Finland
