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Loss Prevention Bulletins

Wet cell batteries

What your employees don’t know can hurt them

Every year common, ordinary automotive batteries are responsible for minor mishaps such as peeling paint and electrical shocks. They are also to blame for more serious problems like severe eye injuries, acid burns, and catastrophic fires. Battery accidents happen, perhaps, because so many people handle batteries in a casual manner.

Wet-cell batteries are everywhere in your business – in vehicles, forklift trucks, inventory, charging areas, “car pushers” and other equipment or just sitting on the floor on the way to recycling. You can’t walk through many automotive businesses without literally tripping over them. Yet, they are very dangerous and demand your respect. It would be difficult to find a technician who hasn’t seen a battery explode. The purpose of this bulletin is to remind you of these dangers and provide information on how to protect your business from loss.

Batteries hooked up to chargers present the greatest hazard for one reason; they produce explosive, hydrogen gas. Extreme caution must be used when charging wet-cell batteries of any size: from small motorcycle batteries up to the larger ones used to power forklift trucks. Many of our customers have found out the hard way that this gas can be easily ignited, and then start a catastrophic fire.

Here’s how to protect your business and employees:

Provide adequate ventilation in charging areas for disposal of hydrogen gas fumes from gassing batteries. Appropriate mechanical ventilation includes an explosion-proof electrical fan vented to the outside.

At the very least, the charging room should be well-ventilated (passive outside vents) so that gas cannot build up inside the room. Never charge batteries in a small, tightly sealed room.

Eliminate all ignition sources from the charging area. The hydrogen gas can’t explode without an ignition source, so remove or eliminate as many as possible. Post “No Smoking” signs in and outside the room. Any electrical wiring, light fixtures and switches inside the room must be explosion-proof. If they are not, remove the equipment from the room. Perform cutting, welding and other hot work far away from the battery charging area. Keep the charging area clear of all combustible materials such as cardboard, wood, paper, etc.

Follow the manufacturer’s recommended procedures for using battery chargers. Employees working in the battery-charging area should be aware of the hazards involved and properly trained in the correct procedures for charging batteries. Ensure that all cells are filled to the recommended level (if not maintenance free) with water and that all battery caps are in place prior to charging. Attach clips securely to batteries before turning the charger on to reduce the chance of a spark. Do not overcharge batteries; avoid overnight or extended charging times.

Employ good electrical practices. Plug battery chargers directly into grounded electrical outlets; avoid using extension cords that can overheat. Don’t alter or modify the charger itself, the power cord or clips.

Fire and explosion are not the only hazards associated with batteries. They also contain very dangerous sulfuric acid that can burn, maim and blind employees and customers. Technicians and Parts Department employees work around batteries constantly. They tend to forget how dangerous batteries are and treat them in a careless manner. Remind employees of the dangers of handling wet-cell batteries and follow these common-sense precautions:

Wear proper PPE (Personal Protective Equipment) when handling, and most importantly, whenever working around charging batteries. Proper eye protection is most important. Eye protection means more than ordinary safety glasses; employees should wear PPE that protects the eyes from all angles. Goggles worn in conjunction with full-face shields provide the best protection. Acid-resistant gloves and aprons should also be provided and worn.

Provide an emergency eyewash. The eyewash must meet Occupational Safety and Health Administration (OSHA) standards by being readily accessible to employees and provide a 15-minute “flushing” supply of water. The once-popular hand-held squeeze bottles of eyewash are not adequate (by themselves) due to the requirement of a 15-minute water supply.

Use extreme caution when jumpstarting or charging vehicle batteries. A battery being charged while it is still in a vehicle is more dangerous than one charged elsewhere. Technicians should stand clear of the battery and never allow customers in the area during charging operations. Technicians should also remove all jewelry before working around batteries. Remember to keep tools and other metallic objects away from the top of uncovered batteries, and remove all ignition sources from the area. Attach the charger to the battery prior to turning it on. Ensure that the clips are secured to the posts and have a strong electrical connection. For proper linkage, connect the positive charger clip/jumper cable to the positive (+) terminal on the battery and the negative (-) charger clip/ jumper cable to the engine block, frame or other grounded part of the vehicle. These procedures vary if the car has a positive ground – most cars do not.

Neutralizing agents should be provided for electrolyte spills. Bicarbonate soda, lime or other commercially available neutralizing chemicals should be kept on hand to treat acid or electrolyte spills. Store all batteries on wood pallets, preferably inside in a segregated area. Leaking or damaged batteries must be placed in an acid-resistant leak-proof container. Avoid storing used batteries outside because they may pollute the ground water. Keep the number of used batteries on hand to a minimum; have them removed from your business (by an approved recycler) in a timely manner.

Using common sense when charging or handling batteries will help protect your business from unnecessary loss. Train supervisors and employees on safe procedures and then make sure they are followed. Your customers, employees, and your business depends on it.

This bulletin in pdf format:

LC-110 ASM 12-07 Š2007 Zurich American Insurance Company

If you have any questions or comments, contact your Zurich account executive or the Loss Prevention Department at 800-821-7803.

This Loss Prevention Bulletin is provided for informational purposes only. Please consult with qualified legal counsel to address your particular circumstances and needs. Zurich is not providing legal advice and assumes no liability concerning the information set forth above.

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