Charge Up Your Workers About Battery Safety!

If your workers are involved with or around the process of changing out and charging these batteries, they should know that they are exposed to potential chemical and electrical burns and explosions, as well as the possibility of injuries from dropping heavy batteries.

Explain to your workers that batteries pose a hazard because:

• They are very heavy, weighing as much as 2,000 pounds.
• They contain corrosive sulfuric acid, which can spill when servicing or changing batteries.
• Contact with battery cells can cause electrical short circuits that can burn unprotected skin.
• When being charged, batteries can give off highly explosive hydrogen fumes.

Emphasize to your employees that if their job tasks include doing battery maintenance and inspection, they are exposed to the most severe hazards. For example, fires and explosions have occurred in battery-charging areas when undetected ventilation failures permitted the buildup of hydrogen gas. Explain to your workers what ventilation system is in place along with the inspection protocol. Also, describe the hydrogen detection alarm if your organization has one installed.

Train workers to follow these safe work practices when charging batteries:

• Batteries should be stored in specially designed and designated areas. Charge batteries only in the designated battery-charging area.
• Be especially cautious when maneuvering lift trucks in the battery-charging area. Puncturing a battery or charger with lift-truck forks could result in electrical shock or a spill of acidic electrolyte.
• Do not smoke in the charging area.
• Do not create or allow open flames, sparks, or electric arcs in battery-charging areas.
• Know where the eyewash station and safety shower are located and how to use them.

Instruct your workers that when they’re handling batteries, they must:

• Make sure equipment for flushing and neutralizing spilled electrolytic solution is in place.
• Check that protection equipment, such as fire extinguishers, is nearby and functional in case hydrogen gas becomes ignited.
• Before moving any battery, check to make sure that all the vent caps are in place to prevent electrolyte from sloshing and spilling out when the battery is moved.
• Properly position the truck and apply the brakes before attempting to change or charge batteries.
• Use a lifting beam, battery cart, or equivalent material-handling equipment when lifting and transporting the battery.

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When workers are charging batteries, they must:

• Wear safety goggles designed for working with acidic liquids in case the electrolyte bubbles or sprays up.
• Wear a face shield to protect the face from the electrolyte.
• Wear neoprene or rubber gloves that resist the acid of the electrolyte and protect hands.
• Wear a neoprene or rubber apron to protect clothing and skin from the acid.
• Remove all metallic jewelry before beginning recharging.
• Keep tools and other metallic objects away from the top of batteries. Do not lay metallic objects on top of batteries.
• Always follow the recharger manufacturer’s recommendations for attaching and removing cables and properly operating the equipment.
• Unplug and turn off the charger before connecting or disconnecting the clamp connections.
• Attach the positive clamp (+, usually colored red) to the positive terminal first, and then the negative clamp (–, usually colored black) to the negative terminal, keeping the proper polarity.
• Make sure the vent caps are functioning.
• Leave the battery (or compartment) cover(s) open to dissipate heat.
• Turn off the charger if the battery becomes hot or the electrolyte fluid comes out of the vents. Restart charging at a lower charging rate.
• Check the electrolyte level before recharging. Record the specific gravity with the hydrometer in the service log. Check the pilot cell.
• Always pour concentrated acid slowly into water. Never pour water into acid.
• Do not add water before recharging. Check the water level after charging. Add distilled water or deionized water (NOT tap water), if necessary, according to the water level indicator. Record data in service log.
• Check the voltage. If the battery has sealed vents, do not recharge with a current greater than 25 amperes.
• Check the indicator on the hour meter to see that the battery is fully charged.

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This training is best conducted in the battery-charging area itself, if possible, so that you or a volunteer can demonstrate how to do all these tasks, including donning and fitting the required personal protective equipment (PPE).

Why It Matters

• Battery changing and charging is dangerous work.
• It is vital for workers to follow safe work procedures to prevent fires and explosions and wear PPE to prevent burns, serious injuries, and even deaths.
• You must train them in the hazards and preventive measures.