What is this document?
INDG139 provides safety guidance for workplaces that use, charge, or store electrical storage batteries. This includes lead-acid batteries commonly found in forklift trucks, backup power systems, and other industrial applications.
The leaflet explains the hazards associated with batteries and the precautions needed to protect workers. Battery charging in particular creates risks that many workplaces underestimate.
Who needs to read this?
- Warehouse and logistics managers with forklift truck fleets
- Maintenance engineers responsible for battery charging areas
- Facilities managers overseeing backup power systems
- Small business owners with battery-powered equipment
- Health and safety advisors assessing battery-related risks
- Anyone who charges, handles, or maintains industrial batteries
- Employers with battery charging rooms or designated charging areas
Key points covered
The guidance addresses four main hazard categories:
Chemical hazards
- Batteries contain sulphuric acid which is poisonous and corrosive
- Acid causes burns and irritation on contact with skin or eyes
- Spillages require proper cleanup and disposal procedures
Electrical hazards
- Short circuits cause extensive arcing, burning, and metal melting
- Electric shocks can occur from batteries and charging equipment
- Metal objects across terminals create serious risks
Explosion hazards
- Hydrogen gas is released during battery charging
- Flammable hydrogen-air mixtures can accumulate in poorly ventilated areas
- Ignition sources near charging batteries can cause explosions
Manual handling hazards
- Batteries are heavy and awkward to move
- Improper handling causes injuries and battery damage
How this applies to you
Battery charging areas
Designate a specific area for battery charging with:
- Adequate ventilation to disperse hydrogen gas safely
- No ignition sources including smoking, sparks, or naked flames
- Clear access for emergency response
- Appropriate fire extinguishing equipment
- Spill containment measures for acid leaks
Personal protective equipment
Provide and ensure use of:
- Eye protection (goggles or face shield)
- Acid-resistant gloves
- Protective clothing including apron where appropriate
- Emergency eyewash facilities nearby
Safe working practices
- Train all personnel who work with batteries
- Never place metal objects on top of batteries
- Use insulated tools when working on battery terminals
- Check charging equipment before use
- Follow manufacturer instructions for charging procedures
- Consider valve-regulated batteries which release less hydrogen
Ventilation requirements
INDG139 provides guidance on ventilation for battery rooms to prevent dangerous accumulation of hydrogen. For larger installations or more detailed technical requirements, refer to IEC 62485-2.
Related Safety Clarity content
- Electrical Safety Requirements - General guidance on workplace electrical hazards
Source: This page summarises HSE guidance document INDG139. For the full official guidance, visit the HSE website.