How To Protect Workers From Forklift Battery Hazards

Forklift hazard training usually revolves around the vehicles themselves

, educating workers on how to avoid tipping the forklifts and operate them safely. However the batteries used to power these vehicles carry their own safety concerns and proper battery handling education is a key part of a safety program. There are four main dangers when handling forklift batteries.

Electrical Shock

Batteries hold a significant voltage and an accidental discharge can severely injure a worker. Workers need to be careful to avoid touching the leads during battery handling. Plus of course electricity travels easily through metal so workers should be careful when using wrenches or other tools that might fall onto terminals. Even the framework of the forklift itself can act as a conductor if it accidentally comes into contact with a terminal. Direct contact is not necessary as the electricity can arc across a small space and jump to a tool or outstretched hand.

Acid

Forklift batteries are filled with powerful acids. While these acids won't eat through steel like acid does in the movies, it can still cause painful and dangerous burns to the skin and could cause permanent blindness if a worker gets the acid into his eyes. Proper handling through the use of dedicated battery lifters and transport systems minimizes the chance a unit will be dropped or otherwise mishandled.

Hydrogen Gas

Acid gives off hydrogen gas as a normal part of its function. In an open space this is harmless because it quickly diffuses into the surrounding air space. However, if stored in confined areas for long periods of time gas can build to dangerous levels. An explosion can occur if the gas comes into contact with an ignition source that could even be the batteries themselves if a metal object drop onto a contact and causes a spark. Battery storage systems ensure good ventilation to minimize this risk.

Lifting Injuries

The other major component to batteries is lead. Lead is very dense and lead objects are much heavier than people expect. Even experienced workers can injure themselves handling these heavy objects. Improper lifting techniques can lead to back injuries or other muscle strains. Misjudging the weight can lead a worker to dropping the unit, injuring unprotected feet or hands that are in the way. Battery handling equipment such as a specialized lift is important to proper worker safety.

Remember that forklift safety is not just about driving tips and load handling techniques. When correctly handled batteries are perfectly safe but when misused they are a source of worker injury, company liability and lost resources. An investment in the proper battery handling devices will pay off by reducing worker downtime and increasing company productivity.

by: Christine Harrell

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