Battery fires are now a daily hazard in Australia’s waste and recycling industry, with damage extending far beyond the initial incident. From burned-out trucks to traumatised drivers, the impacts are stacking up and they’re becoming harder to contain.
At a recent panel at the Coffs Harbour Waste Conference, Brett Lemin, executive director of the NSW Waste Contractors and Recyclers Association (WCRA), said incidents are widespread and rising. Fires are occurring in vehicles and at waste facilities, often starting with lithium-ion batteries discarded in household bins. These batteries, when crushed or damaged, can enter a state known as thermal runaway—an uncontrollable reaction that produces extreme heat and toxic gases.
Once alight, a fire in a waste truck can be devastating. A vehicle carrying flammable plastic and general waste becomes a fast-moving furnace. The result is not just a destroyed truck, but long-term damage to essential services and worker safety.
“One of the local governments actually recently this year lost one of their trucks to a battery fire, and they couldn’t find a replacement anywhere,” Lemin said.
With supply chains already tight, replacing a side-loading collection vehicle proved impossible. This type of shortage can lead to serious service disruptions for residents, as councils might not have spare vehicles to pick up the slack.
The financial implications are equally severe. A new side-loading waste truck can cost upwards of $500,000 and can be written off in minutes if a fire takes hold. But it’s not just the vehicle loss, when collection services are suspended or reduced, residents and businesses feel the strain.
The pressure on drivers is also increasing. Some have been forced to take extended leave, including for post-traumatic stress, after experiencing multiple fires and near misses. The psychological toll of evacuating a burning truck in the middle of suburban streets, often while facing abuse from the public, is leading to a mental health crisis among waste workers.
Fire safety planning is beginning to adapt. Lemin noted that some governments are starting to designate safe areas where drivers can tip a burning load if necessary. However, in remote or densely populated areas, those options remain limited. There are growing calls for systemic change in how risks are managed, particularly in summer months and bushfire-prone regions like the Blue Mountains.
At waste processing facilities, fire suppression systems and specialised personal protective equipment (PPE) are becoming essential, but expensive. The threat isn’t just the fire – it’s the toxic gas that comes with it. Hydrogen fluoride, for example, can be fatal even in small doses and can be absorbed through the skin. Protective gear like respirators may be ineffective in some scenarios, making staff training and rapid response capabilities critical.
“You don’t need a whole lot of exposure to that gas before you have some serious health implications,” Lemin said.
The insurance sector is responding as well, with premiums skyrocketing. Some operators have seen a 600 per cent increase in recent years. As battery fires continue to mount, so too do the costs to councils, companies, and the broader economy.
Without intervention, the toll on public safety, the environment, and infrastructure will continue to rise. Manufacturers, government, and industry must act fast to design safer systems and educate the public on proper battery disposal.
For a more in-depth look at battery fires, check out the August/Sept issue of Inside Waste magazine.