The Role of AIS-156 in Improving EV Safety in India
How the New Safety Standard Is Protecting Riders and Pedestrians from EV-Related Accidents
Introduction
India's electric vehicle revolution is accelerating rapidly, with two-wheelers and three-wheelers leading the charge. However, rising incidents of EV fires and battery malfunctions have raised serious safety concerns among buyers, fleet operators, and policymakers. In response, the Ministry of Road Transport and Highways introduced AIS-156, a comprehensive safety standard aimed at mitigating these risks. This blog unpacks what AIS-156 entails, how it enhances EV safety for 2W and 3W vehicles in India, and why it matters to you—whether you're a daily commuter, a fleet owner, or an industry professional.
What Is AIS-156?
AIS-156, officially known as the Automotive Industry Standard for Battery Safety of Electric Vehicles, is a regulatory framework notified by the Government of India. It sets stringent technical requirements for battery packs, cell-level safety, thermal management, and electrical protection in electric two-wheelers and three-wheelers. The standard is mandatory for all new EV models launched in India and applies to both OEMs and battery suppliers. It complements existing regulations like AIS-048 and aligns with global best practices while addressing India's unique climatic and operational conditions.
Why AIS-156 Was Introduced
The Indian EV market witnessed over 300 fire incidents in 2022–2023 alone, many involving popular two-wheeler models. These incidents were traced to poor cell quality, inadequate thermal management, and insufficient protection circuits. AIS-156 was formulated to eliminate these vulnerabilities by mandating rigorous testing, high-quality components, and real-world performance validation. It also addresses the rapid proliferation of unbranded batteries and retrofitted kits, which often bypass basic safety norms.
Key Safety Requirements Under AIS-156
- Mandatory compliance with cell-level safety tests including short circuit, overcharge, and crush tests
- Stringent thermal runaway propagation prevention within the battery pack
- Real-time insulation monitoring and contactor control
- Protection against overcurrent, overvoltage, and undervoltage conditions
- Water and dust ingress protection (minimum IP67 for battery packs)
- Battery management system (BMS) with fail-safe communication
Battery Cell and Pack Level Safety
AIS-156 emphasizes safety at both cell and pack levels. Cells must pass crush, nail penetration, and thermal stability tests. At the pack level, manufacturers must ensure that even if one cell undergoes thermal runaway, the fire does not propagate to neighboring cells for at least five minutes—enough time for the rider to safely exit the vehicle. This requirement has pushed battery makers to adopt advanced materials like ceramic separators, flame-retardant electrolytes, and robust cooling systems.
Thermal Propagation and Fire Prevention
One of the most critical aspects of AIS-156 is its focus on preventing thermal runaway events. Manufacturers must demonstrate that their battery packs can withstand and contain a cell failure without catching fire. This is achieved through multiple layers of protection: cell-to-cell barriers, heat dissipation channels, and active BMS monitoring. For Indian conditions, where ambient temperatures can exceed 45°C, these measures are not just optional—they are essential.
Electrical Safety and Insulation Monitoring
Electrical safety is another cornerstone of AIS-156. The standard mandates continuous insulation monitoring and automatic disconnection of high-voltage circuits in case of a fault. This prevents electric shocks to riders and mechanics during maintenance. Additionally, the BMS must detect any abnormal current or voltage spikes and safely shut down the system. These features are particularly important for fleet operators who charge multiple vehicles simultaneously in shared infrastructure.
Impact on 2W and 3W EV Manufacturers
For OEMs, AIS-156 has been a game-changer. It has compelled them to upgrade their battery sourcing, redesign thermal management systems, and invest in in-house testing facilities. While compliance increases production costs by approximately 8–12%, it also enhances brand reputation and consumer trust. Manufacturers that fail to meet these standards risk being banned from selling in India, as seen with the recall of several models in 2023. Established players like Ola Electric, Ather Energy, and Bajaj have already achieved compliance, while smaller players are catching up through partnerships with certified battery suppliers.
What It Means for EV Buyers and Fleet Owners
For individual buyers, AIS-156 compliance translates to peace of mind. You can now choose an EV with confidence, knowing that the battery has passed rigorous safety tests. For fleet owners operating thousands of e-rickshaws or e-scooters, AIS-156 reduces the risk of catastrophic failures that can disrupt operations and lead to liability issues. It also encourages adoption of telematics and remote diagnostics, enabling proactive maintenance. Fleet owners should prioritize vehicles with AIS-156 certification and insist on battery traceability documents from their suppliers.
AIS-156 vs. Global Safety Standards
While AIS-156 shares similarities with global standards like UN ECE R100 and UL 2580, it is uniquely adapted for Indian conditions. For instance, it includes additional tests for humidity and dust ingress, given India's diverse climate. It also mandates longer thermal propagation delay times compared to some international norms, reflecting the higher population density and traffic conditions where evacuation time is critical. This makes AIS-156 one of the most comprehensive and stringent safety standards for two- and three-wheeled EVs globally.
Challenges in Implementation
Despite its benefits, AIS-156 poses several challenges. The high cost of compliance disproportionately affects smaller manufacturers and startup EV brands. There is also a shortage of accredited testing labs in India, leading to long certification queues. Additionally, the unorganized retrofit market remains largely unregulated, making it hard to enforce the standard on existing vehicles. The government is addressing these issues by establishing new testing centers and offering PLI incentives for compliant manufacturers.
The Road Ahead for EV Safety in India
AIS-156 is just the beginning. The Bureau of Indian Standards (BIS) is working on national standards for EV batteries, while the Ministry of Power is revising charging infrastructure guidelines. Future updates to AIS-156 are expected to cover second-life battery usage, recycling, and end-of-life safety. As India moves toward its target of 30% EV penetration by 2030, robust safety standards like AIS-156 will be the bedrock of consumer confidence and sustainable growth.
Conclusion
AIS-156 is a landmark regulation that transforms EV safety in India, especially for two-wheelers and three-wheelers. It addresses the root causes of battery fires, enhances electrical safety, and sets a benchmark for quality that benefits every stakeholder—from manufacturers to daily commuters. As the standard matures, it will drive innovation, improve product reliability, and accelerate the adoption of electric mobility across the country. Whether you're buying your first electric scooter or scaling a fleet, choosing AIS-156 compliant vehicles is no longer optional—it's a responsibility and a smart investment.
