The 4 Biggest Hazards of Forklift Batteries, Part 1

Forklift batteries are different than other types of batteries. Unlike the A, AA, or AAA batteries that power your TV remote, radio-controlled car, or flashlights, forklift batteries are big, heavy, and powerful.

They also are long-lasting, create zero emissions, and are completely rechargeable, allowing you to run your forklift efficiently and affordably. Working with battery-powered forklifts is often the best option for warehouse and dock operations that are mostly indoors because these convenient vehicles keep workers safe while providing versatility and mobility for a variety of uses.

Electric Forklift Safety

When handled properly, forklift batteries and the chargers used to power them are completely safe. But they do have inherent dangers so workers need to be cautious when working with or around them.

Electric forklift batteries and their chargers are generally extremely safe as long as workers are properly trained and use caution when recharging their vehicles. Training and preparation are critical for ensuring optimal safety of people and property.

But when workers are not properly trained or shortcuts are taken that sidestep recognized safety procedures, risks of working with electric forklifts can include burns, electrocutions, accidental fires, and even explosions.

Specifically, there are four primary concerns when working with forklift batteries and charging stations: Weight, caustic fluids, gasses, and potential exposure to electricity.

Forklift Battery Hazard No. 1 — Weight

Unlike the tiny batteries that power household devices, forklift batteries are very heavy, sometimes weighing hundreds of pounds. Generally, the battery will stay inside the vehicle during recharging.

But when the battery is being serviced or replaced, it usually is necessary to remove it from its housing by means of a suspension cable. Any time a heavy weight is suspended above a work area, there are inherent dangers to the people underneath. Should the cable snap or the heavy battery somehow break free from its truss, it could cause crushing injuries.

Forklift Battery Hazard No. 2 — Caustic Fluids

Like most batteries, forklift batteries work by having high levels of electrolytes surrounding lead. While this is what creates the electric charge, it also potentially puts workers at risk of exposure to highly caustic sulfuric acid should the battery be mishandled or spring a leak.

Exposure can result in burns to the skin, inhalation of toxic fumes, and dangerous spills.

Forklift Battery Hazard No. 3 — Gasses

When forklift batteries are being recharged in the charging station, a byproduct of this process is hydrogen gas. If high levels of this gas are allowed to build up in an enclosed, unventilated space, there is the potential for the hydrogen to burst into flames or even explode.

Forklift Battery Hazard No. 4 — Exposure to Electricity

Finally, forklift batteries are charged with electricity. Anytime there is an electrical charge, there is always the possibility of electrocution or burns. When not handled with care, forklift batteries also have the potential to arc, which could cause electrical burns or, in the presence of gasses, create a fire or explosion.

These are the four biggest hazards associated with working with forklift batteries. In the next blog, we will take a look at steps you can take to reduce risks and create a safe and productive work environment for your employees.