If workers in your facility operate forklifts or powered industrial vehicles, you understand the importance of safety when operating forklifts. But are employees trained on proper forklift battery management and charging?
Forklift and powered industrial truck operators need to be properly trained to operate and inspect their equipment. They also need to be taught the safety requirements of forklift battery charging stations to help avoid injuries.
Like many work tasks, charging forklift batteries poses a variety of hazards. As with many routine tasks, it's easy to overlook or underestimate the hazards. That's why forklift safety training needs to be specific. It should also include information on the following hazards:
1. Moving forklift batteries is dangerous because lead-acid powered batteries are heavy. Typically, they cannot be moved or lifted into a charging station without some type of mechanical assistance. Any equipment used to move the battery should facilitate movement without manual lifting or exaggerated body movement. Double-check proper lifting techniques and the weight limits that one person should lift.
2. Potential for crushing and injury If the equipment used to move the battery does not have a failsafe or other protective device to prevent the battery from falling or moving uncontrollably, the battery could injure the employee if it falls. Requiring employees to stay away from the range of falling batteries and wearing qualified steel-toed safety work shoes and procedures can help avoid crushing and pinching injuries.
3. Battery charging causes flammable gases People often ask us, "Are the vapors from charging batteries flammable?" First, it is important to know that hydrogen gas is produced when the battery is charged. Therefore, if the battery charging area is not properly ventilated, the accumulation of hydrogen gas can cause an explosion hazard. Hydrogen monitors can help ensure that flammable gases do not reach unsafe levels in addition to providing ventilation and keeping the battery charging area clean and free of open flames or anything that could produce sparks.
4. Forklift batteries contain corrosive electrolytes Another question we often hear is, "What chemical hazards should I be concerned about when handling forklift batteries?" The electrolyte in the battery contains sulfuric acid, which is corrosive and can cause chemical burns if splashed from a rechargeable battery. Masks, goggles, gloves, and aprons help minimize injuries, especially when adding water to the battery after charging. Eyewash stations or showerheads can also help remove electrolyte quickly, preventing further injuries. Routine procedures should also include removing electrolyte and dust from battery boxes. Some facilities use sealed batteries to help minimize the chances of anyone coming into contact with electrolyte and reduce battery cleaning time.
5. Electrolyte spills can cause burns or slips Electrolyte spills can cause chemical burns and are a slip hazard. Keeping spill kits in battery stations and charging areas can help with quick response so that spills can be quickly absorbed and eliminated. Employees should know how to use personal protective equipment (PPE) and any neutralizers, tools, or equipment in the kit. Post instructions to remind you of the steps to take when cleaning up spilled battery acid.
6. Fully Charge the Battery Like all batteries, lead-acid batteries carry an electrical charge and have the potential to arc. A rule of thumb is that batteries should be charged when they reach about 30% of their capacity when they are in good condition. Employees should remove any metal jewelry that could conduct electricity and be aware of any other metal in the area that could increase the risk of explosion.
Batteries come in many shapes and varieties. While these hazards are fairly common to all types of lead-acid batteries, there may be additional hazards that are specific to the type of battery being used or other unique hazards. Forklift and powered industrial truck manufacturers often provide training and information, often free of charge, to help employees and supervisors safely and effectively operate and maintain their equipment. Be sure to take advantage of this and have your workers trained on the proper storage and charging of forklift batteries to help keep your employees safe, comply with regulations, and avoid fines.
