Emergency Response Guide: What to Do When Your LiPo Battery Has Suddenly Swelled Up (2025)

If a lithium‑ion polymer (LiPo) battery puffs up without warning, treat it as an imminent fire hazard. This guide gives you clear, up‑to‑date steps to stabilize the situation, protect people and property, and dispose of the battery correctly in the U.S.

Before you start: what you’ll need and what to expect

• Difficulty: Low to moderate (focus on safe isolation and disposal, not repair)
• Time: 5–15 minutes to isolate safely; 1–3 days to arrange disposal
• Personal protective equipment (PPE): safety glasses, heat‑resistant gloves, long sleeves
• Helpful items: metal container with a loose‑fitting lid and some clean, dry sand (or a LiPo‑safe bag on a noncombustible surface), nonconductive tape for terminals, masking tape/marker for labeling, thermometer (optional), ABC fire extinguisher
• Environment: ventilated, away from people/pets/flammables, ideally outdoors or in a detached area

Important: Most swollen batteries do not immediately ignite, but they can escalate without warning. If you see smoke, flames, rapid heating, or hear hissing, skip to “If it vents or catches fire.”

Step‑by‑step: Immediate actions when you notice swelling

1. Stop using it now

• Power down the device. Unplug any charger. Do not charge or try to “balance” or discharge the pack.
• If the device is hot, emitting odor, hissing, or smoking, set it down and move people away. Call 911.

2. Handle gently—no pressure

• Do not puncture, bend, crush, or tape it tightly to “flatten” the pouch. Avoid metal tools.
• If the battery is removable and cool to the touch, remove it gently. If embedded and the case is deforming, do not pry—treat the whole device as the hazard and proceed to isolation.

3. Isolate in a fire‑resistant, ventilated setup

• Place the battery (or entire device) in a vented metal container with a small layer of dry sand or other noncombustible absorbent. Do not seal airtight (venting gases need to escape).
• Set the container on a noncombustible surface (concrete, tile) in a ventilated area away from combustibles.
• If terminals are exposed, cover each with nonconductive tape.

4. Monitor calmly

• Stay nearby for the first hour. Watch for heat, odor (sweet/solvent‑like), smoke, or hissing.
• Keep a Class ABC extinguisher handy. Prepare an exit path.

Checkpoint: Isolation is complete if the item is powered down, unplugged, on a noncombustible surface, in a vented metal container with sand or in a LiPo‑safe bag, and away from people/flammables.

If it vents or catches fire

• Evacuate people and pets. Close doors behind you to limit smoke spread if safe to do so. Call 911.
• If the fire is small and you are trained and it is safe: use an ABC extinguisher to knock down visible flames, then cool the battery and surrounding materials with plenty of water from a safe distance. Expect potential re‑ignition; keep cooling and wait for firefighters.
• Why water? Fire service testing shows water effectively cools lithium‑ion batteries and reduces re‑ignition risk; Class D agents are for lithium‑metal fires, not lithium‑ion. Follow local fire department instructions.

Note: Do not delay evacuation while attempting suppression. Smoke from a lithium‑ion fire is hazardous—avoid breathing it.

What not to do (myth‑busting)

• Do not puncture to “deflate,” crush, or compress with tape or clamps.
• Do not recharge or intentionally discharge/balance a swollen LiPo.
• Do not immerse in water or saltwater (saltwater discharge is outdated and unsafe).
• Do not put it in a freezer to “fix” swelling.
• Do not mail it or ship it casually; do not put it in trash or curbside recycling.

Authoritative consumer guidance emphasizes stopping use, isolating, and seeking professional help. See iFixit’s plain‑language overview in What to do with a swollen battery (iFixit, 2023).

Temporary isolation and monitoring (until disposal)

• Preferred: Store the container outdoors or in a detached, shaded, ventilated spot (e.g., on concrete). If that’s impossible, use a well‑ventilated area indoors away from combustibles and exits.
• Use a loose‑fitting lid or vent holes—avoid airtight ammo cans; pressure buildup during venting can be dangerous.
• Label the container: “Damaged Li‑ion battery — DO NOT USE/CHARGE.”
• Minimize dwell time. Plan disposal within 1–3 days. Recheck for warmth or odors every few hours on day one.

U.S. transport and disposal — how to do it safely and legally

• Never place lithium‑ion batteries in household trash or curbside recycling. The U.S. Environmental Protection Agency states that “lithium‑ion batteries … should be brought to household hazardous waste collection facilities or electronics recyclers,” and explicitly says, “Do not place the waste lithium batteries in the household trash or in curbside recycling bins.” See the EPA’s 2023–2025 consumer pages: EPA Lithium‑Ion Battery Recycling FAQ and EPA Used Lithium‑Ion Batteries.
• Consumers: Hand‑carry to a local HHW site or a retailer participating in a dedicated program. Call ahead to confirm they accept damaged/swollen batteries.
• Call2Recycle: Many sites participate through Call2Recycle. For DDR (damaged/defective/recalled) Li‑ion, they provide DOT‑approved packaging solutions and program guidance; retailers and organizations can obtain specialized DDR kits. See Call2Recycle’s 55‑gallon DDR kit (DOT‑approved) and Small DDR Li‑ion pail (DDR acceptance up to 300 Wh). Call ahead—acceptance varies.
• Do not mail damaged or defective lithium batteries. U.S. Postal Service rules in Publication 52 restrict hazardous mailings; damaged/defective batteries are not accepted in consumer mail. See USPS Publication 52 — Hazardous, Restricted, and Perishable Mail. Private carriers also restrict DDR batteries; for example, FedEx notes special handling is required for “Damaged, defective or recalled batteries; Batteries for disposal or recycling” in its 2024 guide: FedEx — Shipping Lithium Batteries via FedEx Ground.
• Businesses and organizations: If you must ship DDR batteries, you are subject to U.S. DOT hazardous materials regulations (49 CFR). Work with a certified hazardous materials shipper and follow 49 CFR 173.185 lithium battery requirements.

Tip: For consumer drop‑off, transport the isolated battery in your vented metal container placed on the vehicle floor, secured to prevent tipping. Keep it cool and out of direct sun. Do not leave it in a hot car.

Device‑specific notes

• Removable RC/drone packs: If cool and stable, gently remove and isolate as above. Do not attempt to discharge or “re‑form” cells. Retire the pack permanently.
• Phones, tablets, laptops (embedded batteries): If the device is bulging, hot, or venting, do not pry it open. Power down if possible, isolate the whole device, and contact a professional repair shop or your IT/EHS department. iFixit’s repair patterns recommend plastic tools and controlled heat/isopropyl alcohol for adhesive‑backed cells when there is no active hazard; see iFixit swollen battery guidance for consumer‑level cautions.

Quick reference: Do / Don’t

Do:

• Power down, unplug, isolate in a vented metal container with some sand or in a LiPo bag on concrete
• Keep people and pets away; monitor for heat, odor, smoke, hissing
• Have an ABC extinguisher ready; know your exit path
• Arrange HHW/Call2Recycle drop‑off; call ahead; hand‑carry only

Don’t:

• Don’t puncture, crush, bend, or compress with tape/clamps
• Don’t charge, discharge, or try the “saltwater bath”
• Don’t mail it or put it in trash/curbside recycling
• Don’t use a sealed container or store near heat/flames

FAQs

• Can I keep using a slightly puffy pack if it still works? No. Swelling means internal damage. Retire it.
• Should I use a Class D extinguisher? Class D is for lithium‑metal fires. For lithium‑ion device fires, ABC can knock down flames and water is effective for cooling. When in doubt, evacuate and call 911.
• Is it safe to discharge the pack to make it less reactive? No. Any additional charging/discharging can trigger failure. Isolate and dispose.
• Why avoid airtight ammo cans? During venting, gases can rapidly increase pressure; sealed enclosures can rupture. Use vented metal with a loose lid instead.

Prevention (after the incident)

• Charge with manufacturer‑approved or certified chargers; never leave charging unattended
• Keep batteries/devices cool and ventilated; avoid heat and crushing impacts
• For storage beyond a week, keep at partial charge (roughly 30–50%) and check periodically
• Replace aging packs proactively; follow device maker’s battery care recommendations

For a plain‑language overview of consumer handling and safety warnings, see What to do with a swollen battery — iFixit (2023). For U.S. disposal rules, see the EPA’s 2023–2025 consumer pages cited above. For regulatory text on shipping DDR batteries, consult 49 CFR 173.185 on the eCFR.

Disclaimer: This guide focuses on U.S. consumer and small‑business contexts as of 2025. Always follow local regulations and your fire department’s instructions. If at any point you feel unsafe, evacuate and call 911 immediately.