Op-Ed: Uncovering hidden failure points in vessel fires

Diane Spinner.

As the maritime industry evolves integrating lithium-ion batteries, hybrid propulsion systems, and increasingly complex onboard technologies vessel fires are no longer straightforward events. Yet many investigations and insurance evaluations still rely on traditional assumptions. The problem is not a lack of data, but a failure to recognize the evolving failure points that now define marine fire risk.

One of the most significant blind spots is the shift in fire behavior itself. Lithium-ion battery systems, now widely used in propulsion, auxiliary power, and cargo, introduce a fundamentally different hazard profile. These systems are prone to thermal runaway a self-sustaining chemical reaction that can produce intense heat, flammable gases, and explosive conditions once initiated (U.S. Coast Guard, 2025). Unlike conventional fuel fires, these events can re-ignite, propagate internally, and resist traditional suppression methods.

Despite this, many post-loss evaluations still approach these incidents as conventional electrical failures. The result is misclassification of origin and cause, incomplete documentation of contributing factors, and missed subrogation opportunities. Investigators who do not fully account for battery system integration, charging cycles, or management system failures risk overlooking the true ignition sequence.

Another commonly missed failure point is detection or more accurately, the absence of it. Several documented incidents show fires growing undetected due to a lack of appropriate monitoring or alarm systems in critical areas. In one case, a lithium-ion battery fire on a vessel bridge went unnoticed until secondary impacts occurred, highlighting how quickly these events can escalate without early warning systems (National Transportation Safety Board, 2023).

Detection gaps are not always regulatory violations; they are often design limitations. Many vessels were not originally engineered for high-density energy storage systems, and retrofits or incremental upgrades introduce risk pathways that are not always addressed holistically. This creates a disconnect between compliance and actual operational safety.

Cargo-related fires present an equally complex challenge. The transportation of electric vehicles and battery-powered devices has increased significantly, introducing concentrated sources of latent energy into confined environments. When thermal runaway occurs within cargo, it can rapidly spread, producing high heat release rates and toxic atmospheres that compromise firefighting efforts and crew safety (International Maritime Rescue Federation, 2025).

From an insurance perspective, these incidents often reveal another layer of missed opportunities: failure to fully evaluate system interactions. Fires rarely originate from a single point of failure. Instead, they emerge from a sequence battery degradation, mechanical damage, improper installation, or inadequate maintenance combined with delayed detection or ineffective suppression. When investigations stop at the first identifiable failure, they overlook the broader chain of contributing factors that may support subrogation.

Compounding the issue is a gap in training and understanding. Industry guidance consistently highlights that lithium-ion battery fires behave differently and require specialized response strategies, yet crews and even investigators may lack this context (Maritime Professional Council, 2026). Without this knowledge, critical evidence can be misinterpreted or lost.

The reality is that vessel fire investigations must evolve alongside vessel technology. This requires a shift from event-based analysis toward systems-based thinking examining not just what failed, but how interconnected systems allowed that failure to escalate. It also demands closer alignment between investigators, engineers, and insurers to ensure that emerging risks are properly understood and documented.

The maritime industry is not lacking in expertise; it is facing a transition. Identifying hidden failure points is no longer optional it is essential for accurate investigations, effective risk management, and informed insurance recovery strategies.

Diane Spinner, MBA, is a marine team lead and fire investigator specializing in marine incidents, complex losses, and subrogation, with over two decades of investigative and public safety experience.