Forklift Battery Charging SWMS

Forklift battery charging covers the charging of forklift and materials-handling-equipment batteries — charging the lead-acid or lithium batteries that power forklifts and warehouse plant in a charging area. The defining hazards are the hydrogen gas produced by charging lead-acid batteries, which is flammable and explosive, the corrosive sulphuric acid electrolyte, the heavy batteries and their handling, and the electrical hazards. This document is written on the basis that forklift battery charging is carried out with the hydrogen-ventilation, acid, manual-handling and electrical controls in place.

Forklift battery charging is carried out in connection with the hazardous chemicals and general WHS requirements, with the lead-acid batteries charged in a ventilated area because charging produces hydrogen gas, the corrosive electrolyte managed, the heavy batteries handled with equipment, and the electrical hazards managed. The hydrogen gas, the acid electrolyte, the manual handling, and the electrical hazards are the considerations. This document coordinates the hydrogen-ventilation, acid, manual-handling and electrical controls so the forklift battery charging is carried out safely.

Hazards identified

9 hazards covered, sorted by priority.

Control measures

Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.

1. 1Engineering: charge lead-acid batteries in a ventilated charging area because charging produces hydrogen gas, which is flammable and explosive, with no ignition sources or smoking, and manage lithium battery thermal-runaway and fire risk.
2. 2PPE: protect against the sulphuric acid electrolyte of lead-acid batteries, which is corrosive and causes chemical burns, with acid-resistant gloves and eye and face protection, an eyewash and a spill procedure.
3. 3Administrative: control ignition sources near the charging area — no smoking, no naked flames and no spark-producing work — because the hydrogen gas is flammable and explosive.
4. 4Engineering: use mechanical aids — trolleys, dollies, stair-climbers, pallet jacks and lifting equipment — and team lifting for the heavy and awkward loads, and manage the manual-handling and awkward-posture hazard with correct technique and the hierarchy of controls for hazardous manual tasks.
5. 5Administrative: have any electrical work carried out by a licensed electrician, and manage the electrical hazards of the plant, equipment and leads.
6. 6Engineering: prevent short circuits of the battery with correct handling, insulated tools and terminal protection, and manage acid spill or splash with a spill procedure and eyewash.
7. 7Engineering: ensure the charging area is adequately ventilated so hydrogen cannot build up, and manage lithium battery thermal-runaway and fire risk.
8. 8Administrative: confirm the charging is set up and carried out safely.
9. 9Administrative: all workers must hold the competencies and licences required for the work, including a High Risk Work Licence for forklift operation, a heavy vehicle driver licence for heavy vehicles, and any dangerous goods or other training required.
10. 10Administrative: conduct a pre-start toolbox talk covering the day's work, identified hazards, traffic and plant movements, required PPE and emergency procedures, and record attendance in the consultation section.
11. 11Administrative: consult workers and any health and safety representatives on the work and its risks, record the consultation, and keep this document available at the workplace.
12. 12PPE: high-visibility clothing, eye protection where required, gloves appropriate to the task, hearing protection where required, and Class I or Class II safety footwear with protective toecap to AS/NZS 2210.3.
13. 13Administrative: review and update this SWMS whenever the work scope changes, after any incident or near miss, when a worker or health and safety representative raises a concern, when new hazards are identified, or at minimum every 12 months.

Applicable Codes of Practice

Worked example

A worker is engaged to charge forklift batteries in a charging area. The lead-acid batteries are charged in a ventilated charging area because charging produces hydrogen gas, which is flammable and explosive, with no ignition sources or smoking, and any lithium battery thermal-runaway and fire risk managed. The corrosive sulphuric acid electrolyte is managed with acid-resistant gloves and eye and face protection, an eyewash and a spill procedure. Ignition sources near the charging area are controlled — no smoking, no naked flames and no spark-producing work — because the hydrogen gas is flammable. The heavy batteries are handled with mechanical aids and equipment. The electrical hazards of charging are managed, with electrical work by a licensed electrician. Short circuits are prevented with correct handling, insulated tools and terminal protection, and acid spill or splash managed with a spill procedure and eyewash. The charging area is confirmed adequately ventilated. The charging is carried out safely, and the records retained.

Related legislation

• Model Work Health and Safety Act — primary duty of care; the duty to consult workers; the reckless-conduct offence; and notifiable-incident provisions, as enacted in each jurisdiction.
• Model Work Health and Safety Regulations — the plant, hazardous manual tasks, hazardous chemicals and High Risk Work Licence provisions, and the Section 291 high risk construction work and SWMS duties where applicable, as enacted in each jurisdiction.
• The Heavy Vehicle National Law and the Chain of Responsibility, the National Transport Commission Load Restraint Guide 2018, and the Australian Dangerous Goods Code, apply to heavy vehicles and the transport of dangerous goods, alongside the model WHS framework, and are administered by the National Heavy Vehicle Regulator and the state and territory dangerous goods regulators.
• Forklift operation requires a High Risk Work Licence (LF or LO class) under each state and territory's licensing scheme, and heavy vehicle driving requires the appropriate heavy vehicle driver licence; dangerous goods drivers require dangerous goods licensing and training.
• Victoria operates under the Occupational Health and Safety Act 2004 and the Occupational Health and Safety Regulations 2017, with the plant, manual handling, hazardous chemicals and high risk construction work provisions applying in place of the model instruments, alongside the Dangerous Goods Act 1985.

Frequently asked questions