Safety of Automotive Batteries in a Mechanical Workshop

Automotive batteries in a mechanical workshop.

The common automotive battery presents a number of safety risks that may not be well understood or sometimes poorly managed.

Let’s take a look at some of the issues with car batteries to see how the associated risks can be managed.

The common automotive battery is what is classified as a lead acid battery, which means that it has lead plates inside it, as well as a mixture of sulfuric acid and distilled water.

Every time the battery becomes discharged from starting the vehicle, using the headlights or radio, etc., it must be recharged.

When a battery is charging it gives off a small amount of hydrogen gas and this is potentially dangerous as hydrogen gas is extremely volatile or explosive.

When this happens in a motor vehicle it is not a problem as the battery is almost always in an airflow of some kind which disperses the gas thus eliminating the problem.

When batteries are charged inside a building, and specifically in a workshop, there may be a lack of ventilation when removing them from the area, which could cause an explosion if the gas ignited.

What can be done to reduce this risk?

Make sure the battery charging area is well ventilated to outside air.

If this is not possible due to location within the building, install an exhaust fan or other type of ventilation system to remove any gas buildup in the area.

The battery charging area must be located away from a general traffic area with proper signage indicating that it is a restricted area.

A first aid kit including an eyewash module should be in close proximity and all staff trained in its use.

Make sure there is the correct type of fire extinguisher(s) mounted just outside the area with the correct signage and that all staff are trained in their use.

Make sure your battery charging equipment is in good working order and has been tested and labeled for electrical compliance, usually every 6 months.

Make sure your staff is properly trained on how to use battery charging and load test equipment.

When not in use, keep battery charger cables and clips secured to the bench or work area to reduce the risk of being caught or tripped over.

Whenever possible, remove the small water filler caps on top of the battery so the water level and specific gravity can be checked (using a hydrometer); By removing the caps, this also removes any pressure buildup within the battery due to gas production. while charging.

The area should be kept clean and tidy at all times with or storage of metal objects within the area, this eliminates the risk of a metal object falling onto the battery terminals and causing a spark and in some cases an explosion.

Always keep the battery charging area free of other chemicals, oils, greases, and any other flammable materials, including oily shop rags.

Always wash dirty batteries before charging as some acid residue and slag can cause voltage leakage.

Always wash your hands after handling batteries, as some acid residue may come into contact with the skin and cause irritation or discomfort.

Always keep a pair of gloves and safety glasses in the area for use by any staff member.

Always keep terminal cleaning equipment in the cargo area (wire brush and dedicated terminal cleaners).

If you ever perform battery terminal repairs using the carbon arc method, be very careful. For more information on this, please send a question to the email address at the bottom of this article.

When moving or lifting batteries, always use correct posture and manual handling methods: for example, use carts to move around, use two people to lift larger batteries, use benches that are at the correct height so you don’t tip over don’t get up too high.

If the battery charging area is somewhat hidden away from a clear area, you can set a warning light at the top of the area to indicate that a battery is charging. This can reduce incidents of staff leaving work during the day and leaving the battery charging overnight, as this is not recommended. The warning light is usually a 12 volt low power light (LED is best) connected to the battery being charged.

Have clear signage outside the battery charging area indicating what the battery area is and a clear set of guidelines or instructions on what to do and what not to do in this area.

Old batteries should be disposed of as soon as possible by using your local battery recycling company to collect them at their facility.

06/27/2011

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