When Working with Forklift Batteries, Put Safety First

Electric forklifts are often the ideal solution for moving materials inside warehouses, enclosed docks, and other indoor spaces. They are fast, strong, and unlike gas-powered forklifts, they create zero dangerous emissions.

But the batteries powering electric forklifts are not without their risks. Forklift batteries typically have to be recharged at least once per day. And while this process is generally safe, it pays to take precautions when dealing with such high-energy devices.

Four Biggest Battery Hazards

The US Occupational Safety and Health Administration, which is the Labor Department agency charged with regulating the use of forklifts in the workplace, had identified four primary hazards related to handling forklift batteries and their chargers:

• Electrocution Risk — Forklift batteries are high-powered electrical devices so the risk of electrocution should a worker accidentally touch the wrong lead or through arcing is very real.

 

• Weight — Forklift batteries tend to be very heavy, sometimes weighing hundreds of pounds. And while most usually remain on the forklift during recharging, moving or swapping out batteries runs the risk of crushing injuries and property damage.

 

• Caustic Fluids — Lead-acid battery cells contain highly acidic electrolytes, including sulfuric acid. Should these liquids splash, leak, or spill, they can cause injury to workers’ eyes and skin.

 

• Gasses — During recharging, forklift batteries can produce hydrogen gas. If the procedure takes place in an enclosed space, this can increase the risk of explosion of fire.

Forklift operators, maintenance staff, and others involved in recharging forklift batteries need to be aware of these risks and take steps to minimize or prevent them.

Minimizing Risks

Whenever possible, the space where batteries are recharged should be separated from the general workspace. A recharging area needs to be properly ventilated and feature flat, acid-resistant floors. Never recharge a forklift that is parked on an incline or ramp.

Battery charging stations should also include an eye-wash station, spill kits, and hydrogen gas detectors, as well as foam fire extinguishers.

During the recharging procedure, workers should wear Personal Protective Equipment (PPE), including safety goggles, face shields, rubber or neoprene gloves, and aprons. They also should remove anything metallic, such as jewelry, to reduce the risk of electrical arcing.

While attaching or detaching clamp connections to the battery, keep the charger turned off and unplugged. If the battery becomes hot during recharging — or starts leaking fluid — turn the charger off and begin the charging process again at a lower charge rate.

When handled properly, forklift batteries and recharging operations are extremely safe. But being aware of potential dangers and knowledgeable about the process can only improve safety.