Battery Safety & Preparation Guide for IT Departments, Schools & Businesses

Lithium-ion batteries represent a rapidly growing fire-risk for IT departments and asset disposal programs. For example, one large U.S. city noted a 53% jump in structural fires tied to these batteries in just a year. Over one recent five-year span, federal data recorded 25,000+ events of overheating or fire involving lithium batteries. Given that many IT assets like laptops, tablets and servers use lithium-ion technology, damaged or mishandled units can present a major hazard. It’s not just about data destruction — it’s about risk-mitigation and fire prevention.

(Includes Data Recycling guidelines for customers)

Lithium-ion batteries power nearly every piece of equipment managed by IT teams: laptops, Chromebooks, tablets, phones, scanners, radios, UPS units, and more. When handled properly, they are safe and reliable. When mishandled, they can cause fires, injuries, property damage, data loss, and hazardous-material violations.

This guide provides industry-standard recommendations for battery safety, handling, and preparation in IT environments.
Sections labeled “For Data Recycling Customers” clarify how batteries should be prepared when sending equipment to Data Recycling of New England.

1. General Best Practices for IT Departments

Why Healthy Batteries May Be Removed — and Why Swollen Batteries Should Not

If a swollen battery is discovered:

• Leave the battery inside the device

• Power the device off

• Isolate the entire device using a fire-safe method

For Data Recycling customers:
We strongly recommend routing swollen or damaged batteries through The Battery Network’s damaged battery program (formerly Call2Recycle) whenever possible.
If that is not feasible, contact us before your pickup so we can determine safe handling. Data Recycling can manage these items when necessary, but they require specialized containment and advance notice.

Some devices with embedded batteries, proprietary components, or on-board storage may require additional dismantling before destruction or recycling. These items are typically processed separately to support safer handling and secure destruction procedures.

2. Identifying Swollen or Dangerous Batteries

IT personnel should be trained to identify swelling before packaging or palletizing equipment.

Common signs of swelling include:

• Bottom panel of a laptop bulging or not sitting flush

• Trackpad lifting or binding

• Screen separating from the frame

• Device rocking on a flat surface

• Clicking or cracking noises when the device is lifted

• Noticeable chemical scent

• Device running warm even while powered off

Any device displaying these symptoms should be treated as hazardous.

3. Why IT Staff Should Not Attempt to Remove a Swollen Battery

Removing a swollen battery poses significant dangers. IT departments should not attempt removal under any circumstances.
Key reasons:

Lithium-ion battery fires are extremely difficult to extinguish

Swollen batteries are at risk of thermal runaway. Once a lithium-ion battery is burning, it can keep generating its own heat, reignite after the flames go out and spread to nearby cells.

Do not be overconfident with water or a fire extinguisher. Water or a standard ABC extinguisher may knock down flames on surrounding materials, but it may not be enough to stop the battery itself. Get everyone out, close the door and call 911.

Class D extinguishers are made for lithium metal batteries, the single-use kind, not the rechargeable lithium-ion batteries in laptops, tablets and phones.

High risk of injury

Swollen lithium batteries can release:

• Toxic gases

• High temperatures

• Chemical vapors

• Sparks or flames

Attempting to pry, lift, or flex a swollen battery can cause immediate ignition.

Puncture risk

Even minor pressure on a swollen cell can puncture internal layers, instantly triggering thermal runaway.

Professional removal requires specialized tools

Professionals typically use:

• Adhesive softeners

• Anti-static pry tools

• Fire-resistant trays

• Ventilated safety cabinets

• Personal protective equipment

• Specialized containers for DDR (Damaged, Defective, Recalled) batteries

IT departments are not expected or equipped to perform safe swollen-battery removal.

4. What To Do When a Swollen Battery Is Found 

Every organization should follow these universal steps:

1. Power the device off immediately.

2. Do NOT attempt to remove the swollen battery.
Puncturing or bending a swelling cell can immediately trigger thermal runaway. Removal should only be performed by trained professionals with proper tools and PPE.

3. Place the entire device in a fire-resistant container.
Suitable options:

• Steel drum or metal pail with a fire-resistant liner
  (Most common industry method)

• Fire-resistant steel battery cabinet
  (Used in schools and IT facilities)

• Bucket/bin filled with a commercial suppressant such as CellBlockEX or Veolia DefendPak

• Non-metal container filled with dry sand, clay kitty litter or vermiculite

• A ready-made damaged battery kit, such as the pails and drums sold by The Battery Network

• Ceramic container
  (Ceramic withstands high heat better than glass)

Never place a swollen battery directly into a bare metal, plastic, or cardboard container. Always use a non-conductive liner (such as a fire-resistant bag or pail liner) or fully surround the device with sand, clay kitty litter, vermiculite, or a commercial suppressant such as CellBlockEX or Veolia DefendPak to prevent shifting or accidental contact during storage or movement.

If you do not have a suppressant like CellBlockEX, cover the device with several inches of dry sand or clay kitty litter to isolate heat and sparks.
Sand does not extinguish a lithium fire, but it reduces oxygen, slows heat transfer, and prevents flame spread if venting occurs.

4. Store the container in a temperature-controlled area between 50–70°F.
Heat is one of the biggest risk factors for battery failure.

Avoid storing near:

• Sunlight

• Vehicles

• HVAC exhausts

• Boiler rooms

• Hot equipment racks

• Windows or exterior walls in summer

5. Clearly label the container:
“Swollen Lithium-Ion Battery – Do Not Charge or Open.”

6. Contact a qualified battery recycler or damaged-battery program.
Do NOT include swollen or damaged batteries with standard e-waste or cardboard-box battery pickups.

Recommended program:
The Battery Network – Damaged Battery Program
https://batterynetwork.org/battery-basics/what-to-recycle/damaged-batteries/

This program follows NFPA, DOT, and PHMSA guidelines for hazardous battery transport.

5. Handling Loose Batteries 

6. Proper Storage in IT Workrooms and Equipment Closets 

Best practices include:

• Store all batteries in a cool, dry, temperature-controlled space
  Ideal: 60–75°F (16–24°C)

• Keep swollen devices isolated from standard battery storage areas

• Use a metal container only if batteries are individually bagged or if there is a fire-resistant liner.

• Never store batteries:

  • On chargers

  • Near heat sources

  • In direct sunlight

  • On top of servers or UPS units

• Separate Lithium from Alkaline to reduce cross-reaction issues

• Avoid stacking boxes or placing batteries under heavy equipment

• Keep containment supplies nearby (dry sand, clay kitty litter, vermiculite or a commercial suppressant), and make sure staff know to leave and call 911 if a battery ignites

Heat is one of the most dangerous factors for lithium stability. Exposure to elevated temperatures significantly increases fire risk and battery failure.

7. For Data Recycling Customers: How We Prefer Batteries Prepared

Leave batteries installed in the device

This is the safest and most compliant method for equipment sent to us.

Lower the charge before pickup

A battery with less charge stored in it is far less likely to cause a serious fire, and it burns less intensely if it does. FAA fire testing found that state of charge is one of the main factors in how dangerous a lithium-ion battery fire becomes, and air shipping rules now limit lithium-ion batteries to 30% charge for the same reason.

• Do not charge devices you are retiring. Unplug charging carts and docking stations a few days before pickup if you can.

• Devices left unplugged for a long time slowly lose charge on their own, so equipment that has sat in storage is usually already lower. It happens gradually, so if pickup is soon, running a device down is faster.

• Devices at or below about 30% charge are ideal. To check:

  • Windows laptops: hover over or click the battery icon in the taskbar.

  • Mac laptops: click the battery icon in the menu bar at the top of the screen.

  • Chromebooks: look at the battery icon in the bottom right corner, or click it to see the percentage.

  • Phones and tablets: check the battery icon at the top of the screen. If it does not show a percentage, turn that on in the device's battery settings.

  A device that will not power on is usually very low, but it can still hold some charge, so handle it the same way.

How to safely run down a device

The safest way to discharge a battery is to let the device use up the power itself. For laptops, Chromebooks, tablets and phones:

• Unplug the device and turn it on.

• Turn off sleep and auto-lock, and turn the screen brightness up so it uses power faster.

• Leave it running in an open, cool area, spaced out on a table, not stacked or closed inside a cart or box.

• Let it run until it shuts itself off. It stops before the battery is completely empty, which is normal and safe.

• If a device gets unusually hot, starts to swell or smells of burning, stop and follow section 4.

Do not try to drain loose or damaged batteries yourself

Shorting terminals, saltwater baths and homemade resistors can start fires and release dangerous gases. Discharging loose or damaged batteries safely takes trained staff and proper equipment. Never charge or try to drain a swollen battery. Follow section 4 instead.

Do not send swollen or leaking batteries in normal pickups

Swollen batteries must be routed through The Battery Network or a hazmat program.

Loose lithium batteries

• Tape terminals or bag individually

• Notify us in advance if you have a large quantity

• Disposal charges may vary depending on chemistry and condition

If your IT team already removed batteries

We recommend avoiding battery removal, but if already removed:

• Isolate each battery

• Tape terminals

• Store in a fire-safe metal or ceramic container

• Do not mix chemistries or include swollen cells

We are happy to help determine whether your batteries qualify for standard processing or need specialized handling.

8. Quick Reference Checklist for IT Departments

Do:

• Leave batteries installed

• Do not charge retired devices before pickup

• Tape lithium terminals

• Train staff to recognize swelling

• Use fire-safe containment

• Store devices in temperature-controlled areas

• Use The Battery Network for damaged or swollen batteries

Do Not:

• Pry or bend swollen batteries

• Mix lithium and alkaline

• Charge a bulging device

• Try to drain loose or swollen batteries yourself

• Place swollen batteries in standard e-waste pickups

• Expose battery storage to heat or direct sunlight

9. References and Authoritative Sources

FDNY – Lithium-ion battery fires rising 53% in one year: https://www.firerescue1.com/lithium-ion-battery-fires/fdny-sees-over-50-increase-in-structure-fires-due-to-li-ion-batteries/
U.S. CPSC – Over 25,000 lithium-battery overheating/fire incidents in five years: https://www.levinsimes.com/blog/lithium-ion-battery-fire-statistics/
Nationwide injury/fatality data (214 injuries, 38 deaths across 445 fires): https://www.senecainsurance.com/lithium-ion-battery-fires-on-the-rise-destroying-properties-taking-lives/
Approx. 2,000 lithium-ion battery fires per year in the U.S.; fire risk 14× higher than other chemistries: https://zipdo.co/lithium-battery-fire-statistics/
Washington State Dept. of Ecology – Guidance recommending sand for damaged battery containment: https://apps.ecology.wa.gov/publications/documents/2404043.pdf/
Irish EPA – Guidance supporting sand and vermiculite for small Li-ion battery fire control: https://www.epa.ie/publications/monitoring--assessment/waste/06792-EPA-Lithium-Ion-Battery-Guidance-Proof.pdf
Suppliers Partnership – Lithium-ion safety guidance for storage and handling: https://www.supplierspartnership.org/wp-content/uploads/2023/07/Suppliers-Partnership_EVSafetyGuidance_7.21.2023-FINAL.pdf
U.S. EPA – Lithium battery recycling & handling safety: https://www.epa.gov/recycle/used-lithium-ion-batteries/
FAA Fire Safety – State of charge and lithium-ion battery fire severity: https://www.fire.tc.faa.gov/pdf/joint/June23Meeting/keslar-0623-StateofChargeTesting.pdf
NAATBatt – Best practices for discharging damaged, defective and recalled batteries: https://assets-002.noviams.com/novi-file-uploads/naatbatt/Workshop_Materials/Lithium/2025/6_Best-Practices-for-Discharging-DDR-Batteries_Danny-Marshall.pdf
The Battery Network (formerly Call2Recycle) damaged battery program: https://batterynetwork.org/battery-basics/what-to-recycle/damaged-batteries/

Need Assistance?

If you are unsure how to classify, store, or prepare batteries or electronic devices:

Data Recycling of New England
info@datarecyclingne.com
(508) 822-2054

We are always available to help schools, businesses, and IT departments determine safe preparation procedures and proper recycling channels.