Managing Lithium-Ion Battery Risks with Engineered Storage Solutions from Wickens Engineering
Wickens Engineering’s Batt-Rack provides ATFs and other operators with a safer, scalable way to store lithium-ion EV batteries. Unlike passive container storage, the engineered racking system can integrate heat, smoke and gas detection with automated suppression, helping reduce thermal runaway escalation, improve space use and strengthen operational resilience, compliance and insurer confidence.

As electric vehicle volumes rise, authorised treatment facilities and other automotive operators face growing pressure to store lithium-ion batteries safely. This case study examines how Wickens Engineering’s Batt-Rack system combines engineered racking, early detection and fire mitigation to provide a scalable alternative to conventional battery storage methods.
The rapid growth of electric vehicles has created a major challenge for manufacturers, logistics operators, recycling facilities and automotive businesses: how to safely store increasing volumes of lithium-ion EV batteries.
Damaged, defective, or end-of-life batteries can enter thermal runaway, a chain reaction in which battery cells rapidly overheat, release toxic gases, and ignite. These fires burn intensely, can re-ignite repeatedly and are significantly more difficult to suppress than conventional fires. UK fire services are reporting a sharp rise in lithium-ion battery incidents, highlighting the growing operational and safety risks associated with battery storage.
The Industry Challenge
Many current EV battery storage solutions rely on modified shipping containers or standard warehouse storage. While widely used, these systems often present limitations:
- Passive containment rather than active fire mitigation
- Limited scalability and fixed storage footprints
- Reduced accessibility for inspection and handling
- Inefficient use of vertical space
- Limited integration of early fire detection systems
As EV battery volumes continue to increase, the absence of a universally adopted UK storage framework for lithium-ion batteries is becoming a growing concern across industry and insurance sectors.
The Need for a Standardised EV Battery Storage Framework
The UK currently has no single dedicated piece of legislation governing EV battery storage facilities. Instead, organisations must comply with a combination of health and safety, fire safety and hazardous materials regulations.

- Thermal runaway prevention
- Battery segregation and spacing
- Fire detection and suppression systems
- Ventilation requirements
- Indoor versus outdoor storage controls
- Emergency response planning
- Battery handling and damaged battery quarantine procedures
The Health and Safety Executive (HSE), insurers and fire authorities are all calling for stronger controls and proactive risk management around lithium-ion battery storage.
Several UK regulations and guidance documents already influence EV battery storage design and operation, including:
- The Health and Safety Executive guidance on Battery Energy Storage Systems (BESS)
- The Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR)
- The Health and Safety at Work Act 1974
- The Management of Health and Safety at Work Regulations 1999
- The Electricity at Work Regulations 1989
- General Product Safety Regulations 2005 (GPSR)
- Fire safety guidance issued by local Fire & Rescue Services and insurers
These regulations increasingly focus on risk assessment, fire prevention, emergency planning and reducing the likelihood of thermal runaway events.
Industry momentum is also moving towards more formalised lithium-ion battery safety standards and storage guidance, particularly around high-risk environments such as recycling, warehousing and industrial storage facilities.
The Wickens Engineering Solution
Batt-Rack by Wickens Engineering was developed to provide a safer, more controlled alternative to conventional battery storage systems.
Batt-Rack combines options for:
- Integrated heat, smoke and gas detection
- Automated fire suppression response
- Heavy-duty industrial steel racking
- Modular vertical storage capability
- Space-efficient system layouts
- Scalable storage for growing operations
Unlike passive container systems, Batt-Rack actively monitors stored batteries for early warning signs of failure. When abnormal conditions are detected, integrated suppression systems can automatically intervene to help control heat escalation and slow cell-to-cell propagation.
This engineered approach supports:
- Safer indoor battery storage
- Improved operational resilience
- Reduced fire escalation risk
- Better use of warehouse space
- Enhanced compliance and insurer confidence
The Outcome
As the EV sector continues to expand, organisations require more than simple storage capacity; they need systems specifically engineered around lithium-ion battery risks.
With more than 50 years of industrial engineering expertise, Wickens Engineering has developed Batt-Rack to support the future of safe EV battery storage through integrated fire mitigation, scalable design and proactive risk management.
Batt-Rack demonstrates how engineered storage systems can help shape the future standard for safer lithium-ion battery storage across the UK industry.
Sources:
www.theguardian.com/uk-news/2026/may/11/uk-firefighters-lithium-ion-battery-fires-ebikes
www.hse.gov.uk/electricity/battery-energy-storage-systems.htm
www.hse.gov.uk/electricity/battery-energy-storage-systems.htm
www.gov.uk/guidance/statutory-guidelines-on-lithium-ion-battery-safety-for-e-bikes
Further Reading on ATF Professional
-
Best Practices for Handling Lithium-Ion Batteries
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BMRA Launches Sector-Specific Fire Prevention Plan Guidance for Metal Recyclers
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Electric Car Fires Up 133%, but Recyclers Should Keep the Risk in Context
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UK Lithium-Ion Battery Recycling: Bridging the Capability Gap Towards a Circular Future
The Industry Challenge



