SunCast 872: The Landfill Explosion That Changed Tesla’s Fire Strategy
Nov 11, 2025
Kathleen McCaffery, a retired battalion chief and Tesla's former Global Fire Liaison, shares her unique insights into fire safety for battery storage. She recounts the explosive consequences of a Powerwall truck incident that reshaped Tesla's fire strategy. Kathleen discusses the phenomenon of delayed thermal runaway and debunks the 'big fire, big water' myth. Her innovative misting techniques minimize risks and cleanup efforts. She emphasizes the need for collaboration between developers and fire departments to ensure safety in renewable energy projects.
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Landfill Blast That Sparked Change
- A delivery truck flipped and responders tossed damaged Powerwalls into a landfill, then a fire erupted days later.
- That event prompted Tesla to create a Global Fire Liaison role and recruit Kathleen McCaffery to bridge the knowledge gap.
Cold Call That Became A Mission
- Kathleen retired and then received a cold call from Tesla that she assumed was a prank, but the company persisted.
- She eventually accepted a non-frontline operations role to manage fire response and training programs.
Learning From Cell To Pack
- Immersing in R&D gave Kathleen hands-on understanding from cell chemistry to aging processes.
- That deep technical foundation enabled credible training for firefighters and effective cross-team collaboration.