G4S develops electric vehicle assembly safety gold standard with specialised safety briefings and training

The popularity of electric vehicles is growing fast and there are a number of key safety considerations during assembly. G4S is working with the UK operations of a major European car manufacturer, at the forefront of best practice in protecting assembly teams, in what is a relatively new area, with its own specific safety challenges.

In 2021, one in ten cars bought in the United Kingdom (UK) were electric, according to the Society of Motoring Manufacturers and Traders (SMMT), which us more than in the previous five years combined. In December 2021 alone, nearly a quarter of all cars bought in the UK were electric.

Thermal Runway

The phrase ‘thermal runaway’ is not something that the average person has as part of their vocabulary. But for Steve White, the National Account Director for G4S Secure Solutions in the United Kingdom (UK), it is very much front of mind.

Electric vehicles are powered by large batteries, either fuelled by the motion of the car itself (in a hybrid model) or charged at a charging station. These lithium batteries are extremely advanced, but highly flammable, if misused or faulty.

Dangers of a thermal runway

Thermal runaway is the rapid and extreme rise in temperature passing between battery cells

Thermal runaway is the rapid and extreme rise in temperature passing between battery cells and when it happens, it can produce smoke, cause a fire or even an explosion in extreme cases.

In 2019, the G4S safety incident response team on site worked with the manufacturer’s on-site safety crew and conducted in-depth risk assessments, in order to understand the new challenges they would face with the new vehicles, and how to mitigate them.  

Growing market for electric vehicles

Steve White, the National Account Director for G4S Secure Solutions in the UK, said “More and more time on the assembly line is being devoted to electric vehicles. In terms of the risk of thermal runaway, we developed a triple-mitigation response.”

He adds, “In the unlikely event that there was a problem with the battery components, there is a small risk that the battery can catch fire, which would of course be a risk to all within the immediate vicinity.”

Triple-mitigation response

Working closely with the customer’s security team, G4S has put in place a triple-mitigation response. Firstly, the personal protective equipment (PPE) for the security team has to be fit for purpose.

Steve White said, “The safety equipment we had was far too heavy, we needed something lightweight that could be worn throughout the day and would still provide excellent protection.”

Masks and breathing apparatus fitted with P3 filters

The team invested in specific thermal runaway fire blankets, which could be thrown over the battery

In addition, masks and breathing apparatus needed to be fitted with P3 filters, specialized in filtering the toxic gases released, during a thermal runaway.

Secondly, the team invested in specific thermal runaway fire blankets, which could be thrown over the battery, in order to suffocate any potential fire.

G4S develops safety briefings and training

And lastly, G4S developed specific safety briefings and training, so all those involved would know exactly what to do, if a thermal runaway event occurred.

The training provided has four strands, which is akin to the training for Fire Brigade and emergency first responders. Firstly, the security training is accredited by the Security Industry Association (SIA). Secondly, there is fire response training, which teaches the safety incident response team how to manage a fire, within the first 15 minutes of the incident starting.

Environmental incident and medical training

The last two strands are environmental incident training and medical training, meaning that the teams are equipped to deal with the secondary impact of a thermal runaway event, be that injury to those in the area, or the structural integrity of the building around them.

As the consequences of a thermal runaway are so severe, Steve White and the team sought expert advice from 999 South and members of the British Fire Services Association (BAFSA), in order to check that the measures being implemented were the gold standard.

Security measures and risk assessment

Steve White stated, “Looking at our measures and our risk assessment, based on their experience from ex-local authority and current civil aviation firefighting, this level of PPE is highly appropriate as a control measure.”

He concludes, “We have yet to have such an event get out of hand, but I am proud of the team for the work they carried out, in identifying the risk and putting together a plan quickly, and efficiently, to mitigate against it. It will probably save someone's life.”