Navigating Lithium-Ion Battery Projects: Why You Need Expert Risk and Safety Advice from Day One

As Australia's energy storage sector expands, more businesses such as from logistics operators to solar battery installers, are entering the lithium-ion battery (LIB) space. While these batteries offer immense benefits, they also present significant fire safety, regulatory, and environmental risks. Whether you're at the concept stage of a Battery Energy Storage System (BESS) or storing smaller quantities of LIBs at a warehouse site, understanding your obligations and risk profile is essential.

At Risk and Safety Solutions Melbourne (RSSM), we assist stakeholders at every stage of their LIB project journey, helping them comply with legislative requirements and design practical, cost-effective fire safety strategies.

Below, we answer some common questions from clients new to this space.

1 Do I Need a Risk Assessment at the Planning Stage with the Department of Planning? 

Yes. Most jurisdictions in Australia require a risk-based assessment during the planning phase, especially for medium- to large-scale BESS or LIB projects. Depending on your site’s size, location, and stage of development, you may need to undertake the following studies:
- Preliminary Hazard Identification (PHA)
- Qualitative Risk Assessment
- Consequence Modelling (e.g., fire, explosion, toxic gas dispersion)
- Fire Safety Study (FSS)

These assessments inform planning approvals and demonstrate that risk controls are appropriate for the specific hazards and site conditions. At RSSM, we tailor these studies to align with jurisdictional requirements and agency expectations.

2 Can We Rely on the Manufacturer’s Fire Safety Documents or Consequence Modelling? 

No. While manufacturer supplied documentation provides helpful insights into product performance, it is not site-specific. Australian regulators such as Fire Rescue Victoria (FRV), Fire and Rescue NSW (FRNSW), and state planning departments do not accept generic or product-based consequence modelling. Your facility must demonstrate how risks apply in your unique site context.

At RSSM, we develop tailored consequence models using recognised industry software to reflect site-specific hazards and fire scenarios, not just lab test data.

3 Isn’t LIB Consequence Modelling Too Difficult Due to Data Gaps? 

Not anymore. The LIB industry has matured significantly in recent years. There is now a wealth of validated, published data available to support fire, explosion, and toxic gas release modelling.

The key is choosing a consultant with experience. RSSM has conducted risk and consequence modelling for over 100s LIB and BESS projects, ranging from residential-scale, neighbourhood to grid-level systems. We use proven software tools such as Gexcon EFFECTS, RiskCurve; DNV PHAST, and SAFETI to generate regulator-accepted outputs.

4 We are a Small-Scale LIB Logistics Operator. Do We Still Need Risk Advice or Approvals? 

Yes. Even small-scale LIB storage facilities (e.g. commercial storage or logistics hubs) may exceed threshold quantities set by dangerous goods legislation. This triggers obligations such as:
- Notifying regulators (e.g., WorkSafe Victoria, Safe Work NSW)
- Conducting a risk assessment
- Implementing fire protection systems (e.g., sprinklers, thermal barriers)
- Preparing an emergency response plan

At RSSM, we provide right-sized advice to ensure your compliance without overengineering. We help you understand what is required and what is not.

Seek assistance from the Risk and Safety Solutions Consultant – info@riskandsafetysolutions.au 

5 Does a LIB Storage Site Need Fire Water Run-Off Containment? 

Yes. Fire water runoff from an LIB fire may contain hazardous substances, including heavy metals and toxic chemicals. Australian fire authorities increasingly expect that containment measures be in place.

However, the volume you need to contain depends on your credible worst-case fire scenario. Not a one-size-fits-all number. Overdesign can cost hundreds of thousands in unnecessary infrastructure.

Our experts work closely with FRV, FRNSW, QFS, CFA, and RFS to align with agency expectations. We can help you design effective and economical containment solutions that regulators support and that suit your specific fire risk profile.

6 Where Should I Start, and How Can a Consultant Help? 

 Start by identifying your storage quantity, facility type (indoor/outdoor), and project stage (planning, operational, expansion). Then speak with an expert early— before you face planning delays or costly redesigns.

At RSSM, we:
- Interpret complex regulatory requirements
- Provide site-specific consequence modelling and risk assessments
- Prepare FSS reports that satisfy both planning and emergency services
- Engage directly with FRV, FRNSW, CFA, QFS, and RFS on your behalf

We offer scalable consulting services tailored to your business—whether you operate a multi-MWh battery storage system or a commercial warehouse with Class 9 dangerous goods.

7 What Are the Most Reliable Sources for Understanding Lithium-Ion Battery Fire Safety and Risk? 

Here are trusted national and international references we recommend:
- FRNSW (2023) – Technical Information: Large-Scale External LIB Fire Safety Study Considerations
- FRV (2024) – Fire Safety Guideline GL-55: Battery Energy Storage Systems
- AFAC (2023) – BESS Emergency Response Guidelines
- CFA (2023) – Design Guidelines for Renewable Energy Facilities (v4)
- HIPAP 2 (2011) – NSW Planning’s Fire Safety Study Guidelines
- NFPA 855 (2024) – Standard for the Installation of Stationary Energy Storage Systems
- UL 9540 – Energy Storage System Requirements
- FM Global DS 5-33 (2020) – Property Loss Prevention: Energy Storage Systems
- AS/NZS 4681 (2000) – Storage & Handling of Class 9 Dangerous Goods
- AS 3959 (2018) – Construction of Buildings in Bushfire-Prone Areas
- AS/IEC 62619 (2023) – Safety of Secondary Lithium Cells
- IEC 62897 – Stationary ESS Safety Requirements
- AS/NZS 5139 (2019) – Electrical Installations – Safety of Battery Systems
- ISO 31000:2018 – Risk Management Guidelines
- Energy Safe Victoria (2023) – High Voltage and Complex Installations Standard
- Safe Work Australia (2012) – Emergency Plans and Procedures
- NFPA 68 & NFPA 69 – Explosion Protection and Prevention Standards
- FRNSW (2024) – Position Statement: Open Yard Storage of BESS

8 What Are the Planning and Consultation Triggers with FRV for BESS Projects?

Please refer to the respective Jurisdiction Department of Planning and Fire Brigade website for more info or contact with us for more specific advice.

Reach out to us directly through our Contact Us page