Is Your Electric Vehicle Safe to Drive? Why EVs catch fire and how India fixed it?

You might have seen different videos of electric vehicles going up in flames on social media. Such videos, often featuring electric scooters, often hinder or breed suspicion in the minds of users who were thinking about buying an electric vehicle themselves. This raises one important question: Are electric vehicles safe? The short answer is yes! So what is the deal with those videos we keep getting on our feed? Let’s find out!

Instances of Electric Vehicles Catching Fire

Recently, a video of Mahindra’s BE6 went viral, where the car was seen catching fire on a busy highway. Although the brand came up with a clear statement clarifying that the fire was not a result of any battery related issue, the incident once again pushed electric vehicles into the spotlight for being vulnerable to fire. The fact that the fire was not a result of any battery related issue implicitly meant that this could have happened with any vehicle, internal combustion or electric. It was further known that the fire was the result of the vehicle being driven for an extended period with a completely deflated rear right tyre. (Know more)

The first reaction to an EV catching fire is generally one of chaos. People tend to believe battery failure is the most probable cause. Well, they aren’t completely wrong!

In 2022, a video of an Ola S1 Pro catching fire in Pune made the company infamous for its production quality, compelling the company to recall 1,441 electric scooters. It was earlier that year when Pure EV also recalled its 2,000 electric scooters from the market.

Why do EVs catch fire?

An EV battery pack is made up of many lithium-ion cells, either hundreds of large cells or a few thousand smaller ones, depending on the design.

Now, the problem usually begins with just one single cell. That first cell may fail due to reasons such as a battery management system (BMS) malfunction, an internal short circuit, improper or faulty charging, a manufacturing defect, or severe external damage to the battery pack. When that one cell fails, it starts generating excessive heat. If the heat is not controlled, it spreads to the neighbouring cells. This triggers a chain reaction known as thermal runaway, where one overheated cell causes the next one to overheat and ignite.

As this process continues from cell to cell, the fire grows stronger and spreads through the battery pack. That is why, although EV fires are uncommon, they can appear intense and are relatively more difficult to extinguish once the chain reaction begins.

Can you put out an EV fire?

Yes, EV fires can be put out. However, traditional tools and ways of fire extinguishing might fail in this case. Due to the chemical nature of the battery, the fire is generally self sustained and doesn’t need any external oxygen support; hence, it rules out using any CO2 based fire extinguishers, foams, chemicals, or fire blankets.

The solution is very basic: water. A lot of it. The most effective readily available way to put out an EV fire is to cool down the battery heated due to thermal runaway. However, firefighters may also use other cooling agents to relieve the EV fire.

Additionally, there is a chance that the fire might reignite after some time, so it's necessary to remain vigilant for a few hours after putting out the EV fire.

How does the government step in?

Taking cognisance of the initial cases of EV fires, the Government of India seriously considered the issue and conducted various technical inquiries. The Ministry of Road Transport and Highways asked the Centre for Fire, Explosive, and Environment Safety (CFEES), a laboratory under the Defence Research and Development Organisation (DRDO), to investigate the causes of frequent EV fires.

CFEES conducted its analysis and concluded that the use of low grade battery materials, weaknesses in thermal and battery management systems, and deficiencies in the testing and certification procedures were the main causes of EV fires.

Unsatisfied with the report, the government called for further technical inputs directly from the Defence Research and Development Organisation. However, DRDO also identified similar challenges, including poor battery quality, inadequate battery management systems, inadequate ventilation, and poor safety standards.

Based on these investigations, India strengthened its regulatory framework. By 2024, the country established stricter indigenous safety standards for EV batteries through bodies such as the Bureau of Indian Standards (BIS), Automotive Industry Standards (AIS), and the Automotive Research Association of India (ARAI).

Under the updated norms, manufacturers must now conduct rigorous tests such as the thermal propagation test, which ensures that if one cell undergoes a short circuit, the adjacent cell remains safe, preventing chain reactions. Additional mandatory evaluations include BMS validation, free fall tests, fire exposure tests, vibration and shock tests, and other safety assessments. Only after successfully clearing these enhanced checks can an EV battery receive certification.

These regulatory interventions played a crucial role in enhancing battery quality, improving accountability, and substantially reducing the risk of EV fire incidents in India."