Safe Handling of Batteries

Key Hazards

• Chemical burns from acid or electrolyte
• Electrical short circuits from terminals, tools, or jewelry
• Fire or thermal runaway from damaged batteries
• Hydrogen gas buildup during charging
• Strains from lifting heavy batteries
• Leaks, corrosion, swelling, or cracked battery cases

2–3 Minute Talk Script

Batteries can create chemical, electrical, fire, and lifting hazards. Even small batteries can cause burns, sparks, heat, or fire if they are damaged or handled incorrectly.

Workers should inspect batteries before handling. Leaks, corrosion, swelling, cracked cases, heat, smoke, odor, or damaged terminals are warning signs that the battery may be unsafe.

Battery terminals should be protected from short circuits. Metal tools, jewelry, chains, and loose conductive objects can bridge terminals and create sparks, burns, or fire.

Lead-acid batteries can expose workers to acid and corrosive residue. Gloves, eye protection, face protection, aprons, and eyewash access may be needed depending on the task.

Lithium batteries should be watched for swelling, punctures, crushing, overheating, smoke, or unusual odor. Damaged lithium batteries should be reported and handled according to procedure.

Battery charging should be done in approved areas. Ventilation, fire protection, separation from ignition sources, and correct chargers are important controls.

Large batteries can be heavy and awkward. Workers should use mechanical assistance, team lifting, or proper lifting methods to avoid strains and dropped batteries.

Safe battery handling means inspecting before use, preventing shorts, using the correct PPE, charging correctly, and reporting damaged or overheating batteries immediately.

Safety Reminders

• Inspect batteries for leaks, swelling, heat, corrosion, or damage.
• Keep metal tools and jewelry away from terminals.
• Use PPE when acid or electrolyte exposure is possible.
• Charge batteries only with approved chargers and locations.
• Provide ventilation where charging can release gas.
• Use help or equipment for heavy batteries.
• Report damaged, smoking, leaking, or overheating batteries immediately.

Ask the Crew

• Is the battery leaking, swollen, hot, corroded, or damaged?
• Are terminals protected from short circuits?
• What PPE is needed for the battery type?
• Is the charging area safe and ventilated?
• Is lifting help needed to move the battery safely?