Battery handling safety requirements

Unsealed batteries must be kept in enclosures with outside vents or in well-ventilated rooms and arranged to prevent fumes, gases, or electrolyte spray from escaping into other areas. See the General requirement in 1926.441(a)(1).

• Practical steps: store batteries in a dedicated battery room or ventilated cabinet, keep battery tops and vents directed away from work areas, and use secondary containment (trays) to capture spills.

Ventilation must be provided that ensures diffusion of gases from the batteries and prevents accumulation of an explosive mixture. See the ventilation requirement in 1926.441(a)(2).

• Practical guidance: provide continuous mechanical or natural ventilation that removes hydrogen and other gases at the source and maintains concentrations well below explosive limits; design ventilation to avoid dead-air zones around battery cells.

Battery charging areas must be enclosed or well ventilated and arranged so fumes, gases, and electrolyte spray cannot escape into other areas. See the placement and ventilation rules in 1926.441(a)(1) and 1926.441(a)(2).

• Practical actions: locate chargers in a dedicated room with outside vents, position racks and trays to capture spray, use splash guards between batteries and adjacent spaces, and ensure exhaust vents discharge away from occupied areas.

Racks and trays must be substantial and treated to be resistant to electrolyte. See the requirement for racks and trays in 1926.441(a)(3).

• Practical materials: use acid-resistant coatings or stainless/acid-resistant metals, polyethylene or fiberglass-lined trays; inspect coatings regularly and replace damaged items to prevent corrosion and leaks.

Floors in battery handling areas must be acid-resistant unless they are protected from acid accumulations. See the floor requirement in 1926.441(a)(4).

• Practical measures: install acid-resistant concrete or chemical-resistant coatings, use curbed containment zones and trays to keep spills from contacting standard flooring, and regularly inspect floor protection for damage.

Employers must provide face shields, aprons, and rubber gloves for workers handling acids or batteries. See the PPE requirement in 1926.441(a)(5).

• Note on selecting PPE: employers should perform a hazard assessment to choose appropriate PPE (type and materials) for the tasks and exposures; see OSHA's interpretation on PPE hazard assessments at https://www.osha.gov/laws-regs/standardinterpretations/2024-03-28.

Yes. Employers must assess workplace hazards before selecting PPE and provide appropriate equipment such as face shields, aprons, and rubber gloves when handling acids or batteries. See the PPE requirement in 1926.441(a)(5) and OSHA's interpretation on PPE hazard assessments at https://www.osha.gov/laws-regs/standardinterpretations/2024-03-28.

• Make and keep a written certification of the hazard assessment when PPE is required, and choose PPE materials resistant to battery acid (e.g., neoprene or butyl gloves, acid-resistant aprons).

Facilities for quick drenching of the eyes and body must be provided within 25 feet (7.62 m) of battery handling areas. See the emergency drenching requirement in 1926.441(a)(6).

• Practical tips: ensure eyewash/stations are unobstructed, reachable within 10 seconds, regularly tested, and supplied with potable water and instructions for use.

Employers must provide facilities for flushing and neutralizing spilled electrolyte and for fire protection. See the spill and fire protection requirement in 1926.441(a)(7).

• Practical steps: keep neutralizing agents (e.g., sodium bicarbonate for acid spills), absorbents, spill kits, and class ABC or appropriate fire extinguishers nearby; train workers on spill cleanup procedures and safe disposal of neutralized waste.

Battery charging installations must be located in areas designated for that purpose. See the charging location requirement in 1926.441(b)(1).

• Practical guidance: set aside a clearly marked, dedicated charging room or space that meets ventilation, spill containment, and emergency equipment requirements.

Charging apparatus must be protected from damage by trucks. See the protection requirement in 1926.441(b)(2).

• Practical measures: install bollards, guardrails, recessed cages, raised platforms, or wheel stops to separate charging equipment from forklift or truck paths and post clear signage and traffic controls.

Yes. Vent caps must be kept in place while batteries are being charged to avoid electrolyte spray, and they must be maintained in functioning condition. See the vent cap requirement in 1926.441(b)(3).

• Practical implications: inspect vent caps before charging, replace cracked or missing caps, and do not charge batteries with defective vent covers that would allow projection of acid.

Vent caps must be kept in place during charging and maintained in functioning condition, which means they should be inspected regularly and repaired or replaced when damaged. See the maintenance requirement in 1926.441(b)(3).

• Recommended practices: include vent cap checks in daily pre-charge inspections, clean blocked vents, replace cracked or warped caps, and log maintenance actions.

No. Battery charging installations must be located in areas designated for that purpose, so charging outside those designated areas is not allowed. See the charging location rule in 1926.441(b)(1).

• Practical consequence: if temporary charging is necessary, the temporary area must still meet the same ventilation, containment, PPE, and emergency equipment requirements as a permanent charging area.

To reduce electrolyte spray, locate unsealed batteries in ventilated enclosures or rooms, use treated substantial racks and trays that resist acid, and keep vent caps in place during charging. See the placement rule in 1926.441(a)(1) and the racks and trays rule in 1926.441(a)(3).

• Specific controls: install splash guards between battery rows, use deep containment trays to catch overflow, orient batteries so vent openings face inward to the containment area, and maintain vent caps per 1926.441(b)(3).

An emergency response plan must provide prompt access to drenching facilities within 25 feet and include means to flush and neutralize spilled electrolyte as well as fire protection. See the drenching facility rule in 1926.441(a)(6) and the spill and fire rule in 1926.441(a)(7).

• Response elements: emergency eyewash/showers, neutralizing agents (e.g., sodium bicarbonate), spill kits, PPE for cleanup crews, trained personnel, written procedures, and coordination with emergency services if needed.

Employers should provide face shields, aprons, and rubber gloves as required and select additional eye protection (such as goggles) based on a hazard assessment of the specific tasks. See the PPE requirement in 1926.441(a)(5) and OSHA's interpretation on PPE hazard assessments at https://www.osha.gov/laws-regs/standardinterpretations/2024-03-28.

• Practical rule: use full face shields for splashes and combined hazards, add chemical splash goggles under a face shield if there is risk of severe splashing, and document the hazard assessment and PPE choices.

Employers should train employees on ventilation and enclosure requirements, spill response and neutralization, proper use and maintenance of PPE (face shields, aprons, rubber gloves), location and use of eyewash/showers within 25 feet, and safe charging practices including keeping vent caps in place. See the general battery requirements in 1926.441(a) and the charging rules in 1926.441(b).

• Include hands-on practice for spill cleanup, PPE donning/doffing, and daily inspection procedures (vent caps, racks, trays, and eyewash tests).