Battery Manufacturing Safety Manual

Battery Manufacturing Safety Programs

The safety programs needed by a battery manufacturer depend on the battery chemistry and manufacturing processes used. A comprehensive manual may include programs covering:

• Lead Exposure
• Lithium-Ion Battery Safety
• Hazard Communication
• Chemical Safety
• Personal Protective Equipment
• Respiratory Protection
• Machine Guarding
• Lockout/Tagout
• Electrical Safety
• Fire Prevention
• Emergency Action Plan
• Spill Prevention and Response
• Forklift and Powered Industrial Truck Safety
• Hearing Conservation
• Job Safety Analysis
• Industrial Hygiene and Exposure Monitoring
• Hazardous Waste Management
• First Aid

Additional programs should be included when specific materials, equipment, or processes create additional hazards.

Battery Chemistry and Process Hazards

The first step in developing an effective Battery Manufacturing Safety Manual is identifying the battery chemistries and processes used at the facility.

Battery manufacturing may involve:

• Lead and lead compounds
• Sulfuric acid
• Lithium compounds
• Flammable electrolytes
• Organic solvents
• Nickel compounds
• Cobalt compounds
• Manganese compounds
• Graphite and carbon materials
• Other metals and metal compounds
• Acids and caustics
• Binders and coatings
• Compressed gases

The hazards, exposure controls, PPE, emergency procedures, and training requirements should be based on the substances and processes actually present.

Hazard Assessment

Each production process should be evaluated for employee safety and health hazards.

The assessment should consider:

• Chemical exposure
• Airborne contaminants
• Skin contact
• Electrical energy
• Stored battery energy
• Fire and explosion
• Thermal runaway
• Moving machinery
• Hot surfaces
• Pressure
• Material handling
• Ergonomic hazards
• Noise
• Maintenance activities
• Emergency conditions

Changes to battery chemistry, equipment, production methods, or materials should be evaluated before implementation.

Lead-Acid Battery Manufacturing

Lead-acid battery manufacturing can expose employees to lead dust, lead fumes, lead oxide, sulfuric acid, acid mist, and other hazardous materials.

Lead-related processes may include:

• Lead oxide production
• Grid production
• Casting
• Paste mixing
• Grid pasting
• Plate processing
• Plate stacking
• Assembly
• Welding or burning
• Formation
• Maintenance
• Cleaning

Facilities performing these operations should establish controls appropriate to the specific sources of lead exposure.

Lead Exposure

Lead exposure can occur when employees inhale airborne lead dust or fumes or ingest lead contamination transferred from contaminated hands, clothing, surfaces, food, or other sources.

Battery-manufacturing operations capable of generating lead exposure should be identified and evaluated.

Potential sources may include:

• Lead oxide
• Lead dust
• Molten lead
• Lead fumes
• Plate handling
• Casting
• Pasting
• Cutting
• Burning and welding
• Equipment cleaning
• Maintenance
• Contaminated surfaces

Employee exposure should be controlled according to applicable requirements.

Lead Exposure Monitoring

Employee lead exposure should be evaluated when employees may be exposed to airborne lead.

Exposure-monitoring procedures should identify:

• Employees and job classifications
• Processes
• Sampling methods
• Sampling frequency
• Results
• Employee notification
• Required corrective actions

Additional monitoring should be performed when changes in equipment, processes, materials, or controls could result in new or increased exposure.

Lead Engineering Controls

Engineering controls should be used where appropriate to reduce airborne lead exposure.

Controls may include:

• Local exhaust ventilation
• Process enclosures
• Ventilated workstations
• Automated material handling
• Isolation
• Dust collection
• Controlled material-transfer systems
• Wet methods

Ventilation and dust-control systems should be inspected and maintained so they continue to perform effectively.

Lead Work-Practice Controls

Work practices can significantly affect employee lead exposure.

Employees should:

• Minimize generation of airborne dust.
• Use designated cleaning methods.
• Keep ventilation openings unobstructed.
• Handle lead-containing materials carefully.
• Follow hygiene procedures.
• Avoid unnecessary contamination of clothing and surfaces.
• Report ventilation or process-control problems.

Compressed air should not be used for cleaning when doing so could create hazardous airborne lead exposure unless specifically permitted under applicable requirements and effective controls are provided.

Lead Housekeeping

Lead-containing dust should not be allowed to accumulate on floors, equipment, ledges, workstations, or other surfaces.

Cleaning methods should minimize airborne contamination.

Appropriate methods may include:

• HEPA-filtered vacuuming
• Wet cleaning
• Other approved dust-control methods

Dry sweeping or other practices that unnecessarily disperse lead-containing dust should be avoided where prohibited or where safer cleaning methods are feasible.

Lead Hygiene

Employees working in lead-regulated areas should follow required hygiene procedures.

Depending on exposure and applicable requirements, facilities may need to provide:

• Change rooms
• Separate storage for work and street clothing
• Washing facilities
• Showers
• Clean eating areas

Employees should wash their hands and face before eating, drinking, smoking, or applying cosmetics.

Food and beverages should not be consumed in lead-contaminated work areas.

Protective Clothing for Lead

Employees exposed to lead may require protective work clothing and equipment.

Depending on exposure, protection may include:

• Coveralls
• Gloves
• Head coverings
• Shoe coverings
• Safety footwear
• Eye protection
• Respiratory protection

Contaminated protective clothing should be handled in a manner that minimizes employee exposure and prevents contamination from being carried into clean areas.

Medical Surveillance for Lead

Employees meeting applicable exposure criteria should be included in required medical-surveillance programs.

The program may include:

• Blood lead monitoring
• Medical examinations
• Employee notification
• Physician review
• Medical removal protection when applicable
• Follow-up monitoring

Medical records should be maintained as required.

Lead Oxide Production and Handling

Lead oxide can create significant airborne lead exposure when material escapes from enclosed processes, conveyors, transfer points, mixers, or collection equipment.

Controls should address:

• Enclosed transfer
• Local exhaust ventilation
• Dust collection
• Spill cleanup
• Equipment inspection
• Maintenance
• Employee access

Lead oxide spills should be cleaned using methods that minimize airborne dust.

Paste Mixing

Lead-acid battery paste mixing can involve lead oxide, liquids, additives, and chemical exposures.

Mixing systems should be enclosed or ventilated as appropriate.

Employees should be protected during:

• Material charging
• Mixing
• Sampling
• Cleaning
• Maintenance
• Spill response

Access to operating mixers should be controlled and machine hazards appropriately guarded.

Grid Casting and Lead Pots

Molten-lead operations can expose employees to heat, burns, lead fumes, molten-metal splash, and fire hazards.

Procedures should address:

• Molten-metal handling
• Furnace operation
• Ventilation
• PPE
• Moisture control
• Dross handling
• Maintenance
• Emergency response

Employees should be trained regarding the severe hazards that can occur when moisture contacts molten metal.

Plate Processing

Battery plate processing may generate lead dust through cutting, separating, handling, stacking, brushing, or other operations.

Controls may include:

• Local exhaust ventilation
• Enclosures
• Automated handling
• Dust collection
• Wet methods
• Appropriate housekeeping

Employees should minimize unnecessary handling that can release accumulated oxide.

Battery Assembly

Battery assembly may involve manual or automated stacking, welding, burning, electrical connections, case assembly, electrolyte filling, and other operations.

Assembly areas should be evaluated for:

• Lead exposure
• Chemical exposure
• Machine hazards
• Ergonomics
• Electrical hazards
• Fire hazards
• Material handling

Automated equipment should be appropriately guarded.

Sulfuric Acid Safety

Lead-acid battery manufacturing commonly involves sulfuric acid.

Employees should be protected from:

• Skin contact
• Eye contact
• Acid splash
• Acid mist
• Chemical burns

Controls may include closed-transfer systems, ventilation, splash protection, chemical-resistant PPE, eyewashes, emergency showers, and spill-control equipment.

Acid Transfer and Filling

Acid-transfer and battery-filling systems should be designed and maintained to minimize splashing and leakage.

Employees should:

• Inspect hoses and connections.
• Use compatible equipment.
• Wear required PPE.
• Follow transfer procedures.
• Control spills promptly.
• Keep emergency washing equipment accessible.

Damaged transfer equipment should be removed from service.

Eyewashes and Emergency Showers

Where employees may be exposed to corrosive materials, suitable emergency flushing facilities should be readily available as required.

Employees should know:

• Equipment locations
• How to activate equipment
• How to respond to chemical exposure
• How to obtain medical assistance

Emergency equipment should be inspected and maintained according to applicable requirements and facility procedures.

Lithium-Ion Battery Manufacturing

Lithium-ion battery manufacturing presents a different combination of hazards from traditional lead-acid manufacturing.

Depending on the process, hazards may include:

• Flammable electrolytes
• Reactive chemicals
• Toxic or irritating materials
• Stored electrical energy
• Short circuits
• Thermal runaway
• Fire
• Explosion
• Hazardous decomposition products
• Automated production machinery

Lithium-ion safety procedures should be based on the cell chemistry, materials, production stage, and state of charge.

Lithium-Ion Battery Materials

Lithium-ion battery production may involve cathode and anode materials, electrolytes, binders, solvents, separators, conductive materials, and other substances.

Employees should understand the hazards of materials used in their areas.

Safety Data Sheets and process information should be reviewed to determine:

• Flammability
• Reactivity
• Toxicity
• Exposure routes
• Incompatibilities
• PPE
• Storage requirements
• Emergency procedures

Electrolyte Safety

Lithium-ion electrolytes may contain flammable organic solvents and reactive salts.

Electrolyte operations should control:

• Ignition sources
• Static electricity
• Leaks
• Vapors
• Employee exposure
• Incompatible materials
• Moisture
• Spills

Transfer and dispensing equipment should be compatible with the materials being handled.

Flammable Liquids

Facilities using flammable electrolyte solvents or other flammable liquids should establish appropriate controls for:

• Storage
• Dispensing
• Transfer
• Ventilation
• Ignition sources
• Electrical equipment
• Grounding and bonding where applicable
• Spill response
• Fire protection

Quantities and process conditions should be evaluated to determine applicable regulatory requirements.

Dry Rooms and Controlled Environments

Some battery-manufacturing processes require low-humidity or otherwise controlled environments.

Dry-room operations should be evaluated for:

• Chemical exposure
• Ventilation
• Emergency egress
• Ergonomics
• Static electricity
• Process gases
• Fire hazards
• Employee comfort

Emergency procedures should account for the characteristics of the controlled environment.

Electrode Manufacturing

Electrode production may involve:

• Powder handling
• Mixing
• Coating
• Drying
• Calendaring
• Slitting
• Cutting

Hazards may include chemical exposure, airborne particles, moving machinery, nip points, heated surfaces, solvents, and ergonomic exposures.

Engineering controls should be incorporated into production equipment where practical.

Powder Handling

Fine powders used in battery manufacturing should be evaluated for inhalation, skin-contact, reactivity, and combustible-dust hazards as applicable.

Controls may include:

• Enclosed handling
• Local exhaust ventilation
• Dust collection
• Controlled transfer
• Appropriate cleaning methods
• PPE

Dust-collection equipment should be designed for the hazards of the material being collected.

Cell Assembly

Cell assembly operations may involve stacking, winding, welding, electrolyte filling, sealing, and automated material handling.

Employees should be protected from:

• Moving machinery
• Pinch points
• Cutting hazards
• Chemical exposure
• Electrical hazards
• Repetitive-motion hazards

Automated assembly equipment should be appropriately guarded and included in hazardous-energy-control procedures.

Battery Formation and Charging

Battery formation and charging introduce electrical energy into cells or batteries and may create additional electrical, chemical, heat, and gas hazards.

Charging areas should be evaluated for:

• Electrical energy
• Battery temperature
• Ventilation
• Gas generation
• Electrolyte leakage
• Fire
• Thermal runaway
• Equipment failure

Employees should understand abnormal conditions that require charging to be stopped.

Electrical Energy

Charged cells, modules, and battery packs can contain substantial stored electrical energy.

Employees should be protected from:

• Short circuits
• Electrical shock
• Arc hazards
• Unexpected energization
• Conductive tools or materials

Procedures should address the voltage and energy levels employees may encounter.

Appropriate insulated tools, PPE, barriers, covers, and other controls should be used when required.

Short-Circuit Prevention

Battery terminals and energized components should be protected against accidental short circuits.

Controls may include:

• Insulated tools
• Terminal covers
• Nonconductive work surfaces
• Controlled storage
• Removal of conductive jewelry
• Appropriate spacing
• Employee training

Loose metal objects should be controlled around exposed energized battery components.

Thermal Runaway

Lithium-ion cells can experience thermal runaway, a self-heating chain reaction that can result in venting, fire, explosion, and propagation to adjacent cells.

Conditions capable of contributing to thermal runaway may include:

• Internal defects
• Short circuits
• Mechanical damage
• Excessive heat
• Improper charging
• Electrical abuse
• Process defects

Employees should understand the warning signs and facility response procedures.

Thermal-Runaway Warning Signs

Potential warning signs may include:

• Abnormal temperature increase
• Swelling
• Venting
• Unusual odor
• Vapor
• Smoke
• Hissing
• Fire

Employees should not handle a battery exhibiting abnormal conditions unless they are trained, equipped, and authorized to do so.

The area should be isolated and emergency procedures initiated when appropriate.

Thermal-Runaway Propagation

A failing lithium-ion cell can transfer heat to adjacent cells and cause additional failures.

Manufacturing, testing, charging, and storage arrangements should consider the potential for propagation.

Controls may include:

• Separation
• Detection
• Temperature monitoring
• Fire-resistant construction
• Appropriate storage arrangements
• Automatic protection systems
• Emergency isolation

The appropriate controls depend on battery chemistry, cell format, quantity, state of charge, and facility design.

Battery Fire Hazards

Battery fires may behave differently depending on the battery chemistry and materials involved.

Emergency planning should identify:

• Battery types
• Stored quantities
• State of charge
• Electrolytes
• Fire-protection systems
• Potential decomposition products
• Evacuation requirements
• Fire-department coordination

Employees should receive clear instructions regarding whether they are expected to use portable fire extinguishers or evacuate.

Hazardous Decomposition Products

Battery fires and thermal-runaway events can generate hazardous gases, vapors, smoke, and particulates.

Emergency procedures should assume that smoke from battery fires may contain hazardous substances.

Employees not trained and equipped for emergency response should remain outside affected areas.

Ventilation and reentry decisions should be made by appropriately qualified personnel.

Damaged and Defective Batteries

Damaged or defective cells and batteries should be identified, isolated, and handled according to established procedures.

Damage may include:

• Swelling
• Crushing
• Puncture
• Leakage
• Overheating
• Deformation
• Electrical damage
• Failed testing

Damaged batteries should not be placed indiscriminately with normal production materials or waste.

Battery Testing

Battery testing may involve electrical, thermal, mechanical, vibration, environmental, abuse, or performance testing.

Testing procedures should address:

• Stored energy
• Electrical isolation
• Test enclosures
• Remote monitoring
• Temperature
• Fire
• Venting
• Emergency shutdown
• Employee access

High-hazard testing should be conducted in appropriately designed areas.

Battery Storage

Cells and batteries should be stored according to their chemistry, condition, and state of charge.

Storage planning should consider:

• Temperature
• Humidity
• Ignition sources
• Physical damage
• Electrical short circuits
• Separation
• Fire protection
• Emergency access
• Damaged batteries

Storage areas should not obstruct exits, emergency equipment, or required access.

Machine Guarding

Battery manufacturing uses mixers, mills, conveyors, coating equipment, presses, slitters, cutters, winding equipment, automated assembly machinery, packaging systems, and other production equipment.

Employees should be protected from:

• Nip points
• Rotating components
• Cutting equipment
• Belts
• Chains
• Gears
• Shafts
• Automated movement

Guards and safety devices should remain in place during normal operation.

Automated Equipment and Robotics

Automated production lines may use robots, conveyors, transfer systems, and computer-controlled machinery.

Safeguarding may include:

• Physical barriers
• Interlocked gates
• Presence-sensing devices
• Light curtains
• Safety-rated controls
• Emergency stops

Employees should not bypass safeguards to clear jams, adjust equipment, or increase production speed.

Clearing Jams

Equipment jams can expose employees to unexpected movement and stored energy.

Before reaching into machinery or entering a hazardous area, employees should determine whether hazardous-energy-control procedures are required.

Normal operating controls should not be relied upon when they do not provide adequate protection from unexpected startup.

Lockout/Tagout

Battery-manufacturing equipment may contain electrical, mechanical, hydraulic, pneumatic, thermal, chemical, pressure, and stored energy.

Authorized employees should follow applicable energy-control procedures before servicing or maintenance where unexpected energization, startup, or energy release could cause injury.

Procedures should identify:

• Energy sources
• Isolation points
• Stored energy
• Shutdown steps
• Verification
• Restart procedures

Equipment Maintenance

Maintenance employees may have greater exposure to chemical residues, lead dust, stored energy, electrical systems, and internal machine hazards than production employees.

Maintenance planning should evaluate:

• Chemical contamination
• Electrical energy
• Stored energy
• Machine movement
• Ventilation
• Confined spaces
• Required PPE
• Decontamination

Equipment should be cleaned or otherwise prepared for maintenance when necessary to protect employees.

Electrical Safety

Battery manufacturing involves production equipment, charging systems, test equipment, electrical panels, battery modules, and energized components.

Electrical procedures should address:

• Qualified employees
• De-energization
• Electrical testing
• Stored electrical energy
• Appropriate PPE
• Tools
• Temporary electrical equipment
• Damaged equipment

Employees should understand the difference between normal battery handling and work exposing them to hazardous electrical energy.

Personal Protective Equipment

PPE should be selected based on a workplace hazard assessment.

Depending on the operation, PPE may include:

• Safety glasses
• Chemical goggles
• Face shields
• Chemical-resistant gloves
• Protective clothing
• Safety-toe footwear
• Hearing protection
• Respiratory protection
• Electrical PPE
• Heat-resistant PPE

PPE requirements may differ significantly between lead processing, electrolyte handling, lithium-ion assembly, maintenance, and testing areas.

Respiratory Protection

Respiratory protection may be necessary for exposures to lead, metal compounds, powders, fumes, vapors, gases, or other airborne contaminants.

When respirators are required, the Respiratory Protection Program should address:

• Medical evaluation
• Respirator selection
• Fit testing
• Training
• Inspection
• Cleaning
• Storage
• Cartridge and filter replacement
• Program evaluation

Engineering controls should remain the primary method of controlling airborne contaminants where required and feasible.

Hazard Communication

Battery-manufacturing employees should receive information and training concerning hazardous chemicals in their work areas.

The Hazard Communication Program should address:

• Chemical inventory
• Labels
• Safety Data Sheets
• Employee training
• Non-routine tasks
• Contractor communication

Employees should understand the hazards of the specific battery materials and chemicals they handle.

Chemical Storage and Compatibility

Chemicals should be stored according to their physical and chemical hazards.

Storage planning should address:

• Flammable liquids
• Acids
• Caustics
• Oxidizers
• Reactive materials
• Toxic materials
• Incompatible substances

Containers should be properly labeled and maintained in suitable storage locations.

Chemical Transfer

Bulk and containerized chemicals may be transferred into production systems.

Transfer procedures should address:

• Correct chemical identification
• Hose and connection compatibility
• Valve alignment
• Overfill prevention
• Grounding or bonding where applicable
• PPE
• Spill containment
• Communication

Employees should verify the receiving system before initiating transfer.

Spill Prevention and Response

Battery manufacturing facilities should prepare for chemical and electrolyte spills appropriate to the substances present.

Spill procedures should address:

• Employee notification
• Area isolation
• PPE
• Spill-control materials
• Drain protection
• Waste collection
• Emergency assistance

Employees should respond only to spills within the limits of their training and assigned responsibilities.

Ventilation

Ventilation can be critical for controlling lead dust, metal fumes, solvent vapors, acid mist, gases, and other airborne contaminants.

Ventilation systems should be:

• Designed for the process
• Operated during production
• Inspected
• Maintained
• Repaired when defective

Employees should report damaged ductwork, ineffective hoods, unusual odors, visible emissions, or other indications of ventilation problems.

Industrial Hygiene and Exposure Monitoring

Employee exposures should be evaluated according to the materials and processes present.

Monitoring may be appropriate for:

• Lead
• Metals
• Solvents
• Acid mist
• Dust
• Fumes
• Noise
• Other airborne contaminants

Results should be used to determine appropriate engineering controls, work practices, PPE, respiratory protection, medical surveillance, and employee training.

Hearing Conservation

Mixers, mills, presses, compressors, conveyors, ventilation systems, material-handling equipment, and other machinery may generate hazardous noise.

Employee noise exposures should be evaluated.

Engineering and administrative controls should be considered, and hearing protection and a Hearing Conservation Program should be implemented when required.

Forklift and Powered Industrial Truck Safety

Forklifts and other material-handling equipment may be used to transport raw materials, lead, chemicals, battery components, finished batteries, and waste.

Only trained and authorized employees should operate powered industrial trucks.

Operators should:

• Inspect equipment.
• Observe capacity.
• Maintain visibility.
• Control speed.
• Remain alert to pedestrians.
• Keep loads stable.

Pedestrian and forklift traffic should be separated where practical.

Material Handling

Battery materials and finished products can be dense, heavy, awkward, or hazardous.

Material-handling procedures should address:

• Mechanical assistance
• Ergonomics
• Load stability
• Chemical hazards
• Pinch points
• Sharp edges
• Storage

Employees should use suitable carts, conveyors, hoists, forklifts, or other mechanical equipment when practical.

Ergonomics

Battery manufacturing can involve repetitive assembly, lifting, material handling, awkward postures, and prolonged standing.

Ergonomic evaluations should consider:

• Workstation height
• Reaching
• Repetition
• Force
• Material weight
• Tool design
• Work positioning

Engineering improvements should be considered where repetitive or forceful tasks create musculoskeletal hazards.

Compressed Gases

Battery production, testing, laboratories, maintenance, and manufacturing processes may use compressed gases.

Cylinders should be:

• Properly identified
• Secured
• Protected from damage
• Stored appropriately
• Transported safely

Gas systems should be compatible with the materials being used.

Fire Prevention

Battery-manufacturing fire prevention should reflect the specific materials and processes at the facility.

Potential ignition and fuel sources may include:

• Flammable electrolytes
• Solvents
• Electrical equipment
• Energized batteries
• Hot work
• Combustible materials
• Process heating
• Equipment failures

Fire-protection systems should be appropriate for the facility hazards.

Hot Work

Welding, cutting, brazing, soldering, and grinding performed during maintenance or fabrication should be controlled.

Hot-work procedures should address:

• Combustible materials
• Flammable liquids
• Battery materials
• Fire watch
• Ventilation
• Fire extinguishers
• Adjacent areas

Hot work should not be performed near hazardous battery materials until the area has been appropriately evaluated.

Emergency Action Plan

The Emergency Action Plan should address foreseeable battery-manufacturing emergencies.

Potential emergencies include:

• Battery fires
• Thermal runaway
• Chemical releases
• Acid spills
• Electrical incidents
• Explosions
• Equipment fires
• Medical emergencies
• Severe weather

Employees should understand alarms, evacuation routes, assembly locations, reporting procedures, and their assigned emergency responsibilities.

Battery Fire and Thermal-Runaway Response

Facilities manufacturing or storing lithium-ion batteries should develop response procedures appropriate to their battery chemistry, quantities, state of charge, facility construction, and fire-protection systems.

Procedures should establish:

• Employee notification
• Evacuation criteria
• Isolation
• Emergency shutdown
• Fire-department notification
• Battery hazard information
• Reentry authorization

Employees who are not specifically trained and equipped for emergency response should evacuate rather than enter hazardous smoke or fire conditions.

Emergency Response Coordination

Local emergency responders should be provided appropriate information concerning significant battery and chemical hazards.

Coordination may include:

• Battery chemistries
• Chemical inventories
• Facility layout
• Battery storage
• Fire-protection systems
• Utility shutoffs
• Emergency contacts
• Hazardous decomposition products

Pre-incident planning can help emergency responders understand hazards before an emergency occurs.

First Aid

Employees should know how to obtain immediate assistance for:

• Chemical splashes
• Burns
• Electrical injuries
• Lead exposure concerns
• Eye injuries
• Cuts
• Thermal injuries
• Other workplace emergencies

Chemical exposures should be treated according to applicable first-aid procedures and Safety Data Sheet information.

Hazardous Waste Management

Battery manufacturing can generate hazardous or regulated waste, including:

• Lead-containing waste
• Contaminated dust
• Electrolytes
• Solvents
• Chemical residues
• Damaged batteries
• Off-specification cells
• Contaminated PPE and cleanup materials

Waste should be identified, accumulated, stored, handled, and disposed of according to applicable environmental and workplace requirements.

Damaged Battery Waste

Damaged lithium-ion cells and batteries may retain substantial energy and can present fire hazards during storage and disposal.

Procedures should address:

• Identification
• Isolation
• Terminal protection
• Physical damage
• Temperature
• Storage
• Transportation
• Disposal or recycling

Employees should not assume a rejected or discarded battery is electrically or chemically inert.

Housekeeping

Battery-manufacturing housekeeping is an important exposure and fire-prevention control.

Employees should keep:

• Floors clean
• Aisles clear
• Emergency equipment accessible
• Electrical equipment accessible
• Chemical areas orderly
• Battery storage organized

Cleaning methods should be appropriate to the contaminants present.

Job Safety Analysis

A Job Safety Analysis (JSA) can help identify hazards associated with battery-manufacturing tasks.

JSAs may be appropriate for:

• Lead handling
• Paste mixing
• Grid casting
• Plate processing
• Electrolyte filling
• Chemical transfer
• Cell assembly
• Formation and charging
• Battery testing
• Damaged battery handling
• Equipment maintenance
• Lockout/tagout
• Spill response
• Non-routine operations

The JSA should identify the task steps, associated hazards, and controls required to perform the work safely.

Management of Process and Equipment Changes

Changes in battery chemistry, materials, production equipment, process parameters, automation, or facility layout should be evaluated for new hazards before implementation.

The review should consider:

• Chemical hazards
• Fire hazards
• Electrical energy
• Exposure controls
• Machine guarding
• Ventilation
• PPE
• Emergency response
• Employee training

Affected procedures and training should be updated before or as the change is implemented.

Contractor Safety

Contractors performing maintenance, construction, electrical, ventilation, or equipment work should receive information concerning hazards that could affect their employees.

Contractor coordination may address:

• Lead-regulated areas
• Chemical hazards
• Energized batteries
• Flammable materials
• Lockout/tagout
• Hot work
• Emergency procedures
• Required PPE
• Restricted areas

Contractors should comply with applicable facility safety procedures.

Battery Manufacturing Safety Training

Employees should receive training appropriate to their assigned work, battery chemistry, and exposures.

Training may include:

• Lead safety
• Lithium-ion battery safety
• Chemical hazards
• Electrolyte handling
• Thermal runaway
• Fire prevention
• Electrical safety
• Machine guarding
• Lockout/tagout
• PPE
• Respiratory protection
• Forklift safety
• Spill response
• Emergency procedures

Training should be documented as applicable and updated when materials, processes, equipment, hazards, or employee responsibilities change.

Building a Battery Manufacturing Safety Manual

A Battery Manufacturing Safety Manual should be customized to the battery technologies and manufacturing processes used at the facility rather than relying solely on a generic manufacturing safety manual.

A lead-acid battery manufacturer may require extensive programs for lead exposure, sulfuric acid, industrial hygiene, medical surveillance, hygiene facilities, respiratory protection, ventilation, casting, plate processing, and battery formation.

A lithium-ion cell manufacturer may instead place greater emphasis on flammable electrolytes, chemical exposure, electrode materials, controlled environments, automated cell assembly, stored electrical energy, formation and charging, battery testing, thermal runaway, and fire protection.

A facility assembling battery modules or packs from purchased cells may have another combination of hazards and may not perform many of the chemical-production processes associated with cell manufacturing.

The manual should reflect the facility’s battery chemistry, raw materials, production processes, machinery, employees, maintenance operations, battery storage, fire hazards, emergency procedures, and regulatory requirements.

The completed safety manual should provide practical procedures employees and supervisors can use while supporting OSHA compliance, employee training, exposure control, industrial hygiene, JSAs, equipment inspections, emergency planning, incident investigation, and the company’s overall safety-management system.

Customized Battery Manufacturing Safety Manuals

Get a Battery Manufacturing Safety Manual customized for your lead-acid, lithium-ion, cell, module, or battery-pack manufacturing operations, including lead exposure, electrolytes, chemicals, formation and charging, battery testing, thermal runaway, fire hazards, automated equipment, material handling, maintenance, and other battery-manufacturing hazards.