In the years we’ve been in the industry, we’ve seen a lot of things, and we know wearing of PPEs is one of the common practices neglected or (purposely) omitted by workers in the steps of charging forklift batteries because they’re tempted not to wear so during busy schedules to save time.
Charging forklift batteries must be given due importance with respect to safety, as this is a risky process. The most common hazard associated with doing this task is the acid coming into contact with the skin or entering the eye causing severe injury.
The charging station is a dangerous place to be, that’s why safety items must be provided and proper PPEs must be worn by the workers to protect them when doing this job.
It has been specified by OSHA that the provision of these safety items and PPEs is the sole responsibility of the company. It shall be given at no cost. In addition to this, the employer’s role is to train the operators in the proper use and maintenance of these PPEs.
But what are actually the complete set of safety items that must be in the charging station? Do you have those in your facility?
- Acid-resistant face shield or goggles to protect the worker’s face
- Face mask to avoid inhalation of hydrogen fumes
- Acid-resistant apron to protect the worker’s extremities from acid splashes
- Rubberized or neoprene gloves
- Hazmat boots
In addition to the five basic PPEs that must be worn by workers during battery charging, these items are also recommended to be in place in case of emergency:
- Eyewash station so that the worker can immediately wash when the acid comes into contact with his body
- Acid neutralizing solution (baking soda is OK, but the solution is better)
- Drinkable water or milk (in the event the battery water is ingested, when this happens, call a doctor immediately as this an emergency)
- Fire extinguisher for use inside the charging facility as standby firefighting equipment
- No smoking and other safety signs
We strongly advocate everyone that the practice of wearing PPEs when charging forklift batteries must be included in the steps or process in doing such a task. The objective is simple – to reduce worker exposure to hazard.
Acid-resistant Face Shield or Goggles
Face shields offer maximum protection of the eyes and exposed skin on the part of the face from chemical spray such as sulfuric acid. Never ever do the charging without this PPE on.
Most of the face shields available in the market nowadays come with ordinary visors of standard quality. What that does mean that ordinary ones would cloud up when splash with acids. What ideal for the job of battery charging is the face shields with PETG and Acetate visors to offer the best protection and clear visibility.
If you are going to ask me, I'll choose the type with headgear with browguard built into it, not only it gives protection from forehead injury but also cover the part of the head that could be exposed during chemical splash.
Here are the ANSI-compliant face shields you can buy from Amazon:
Face Masks
While others don’t use a face mask when charging the battery, it is still recommended for the operator to use a face mask to avoid inhalation of accumulated gases in the charging station. To minimize at least the inhalation of gas, operators must wear a face mask during battery charging.
If you smell rotten eggs, then that is a sign that there is hydrogen sulfide, a gas that forms when overcharging the batteries. We all know that this is a dangerous gas. Leave the charging area, report the incidence to the superior so that the station can be tested to confirm if that gas is present.
Face masks are cheap, and here are what you can buy:
Acid-resistant Apron
Acid-resistant aprons are designed to provide protection against the risk of spraying or splashing chemicals such as sulfuric acid in the battery. It should be worn when charging forklift batteries, any tears found in the apron should prompt for its replacement.
If someone is going to buy an apron, the best-recommended type is the one with long sleeves so that the worker's arms are also protected not only his extremities from acid splash when doing the task of battery charging. While those brands made of neoprene is ideal for doing the job.
Choose the design that extends to the knees and covers the torso and upper legs to fully protect workers from fluid splash.
Here are the acid-resistant aprons you can purchase:
Neoprene or Rubberized Gloves
It is ideal that the gloves are strong to withstand as charging the battery is a manual task. Having a good pair of at least 0.4mm thick of neoprene gloves will surely give not only comfort but also protection.
As the worker is doing the charging, his hand may come into contact or accidentally touch a surface contaminated with the acid battery, a good pair of neoprene gloves will surely give extra protection.
Another type of gloves suitable for handling such a task is the rubberized ones. What I also like about the rubberized gloves are that you can touch the battery terminal since your hands are insulated. But we don’t recommend doing anything with the terminals without the proper tools. Another safety point we would like stress out here is, although rubberized gloves reduce the risk of shorting the battery, we still recommend removing any ring or jewellery on your hand even if you’re using gloves when working with forklift battery.
Consider buying these neoprene and rubberized gloves on Amazon:
Consider Replacing Worn Out PPEs (It Will Come to Point It Will Worn Out)
While the PPEs use by workers in the charging station don’t actually expire, all of these gears must be kept in good condition. Hence, any worn-out items and protective gear must immediately be replaced.
We can't tell when PPEs are going to be replaced but a good tell-tale sign is, for example, if there any rips on the neoprene gloves that will make this PPE useless when handling forklift batteries. A good rule of thumb is that PPEs must be regularly checked and inspected by a qualified personnel and immediately be replaced if any damages or faults are found.
In case PPEs don't need to be replaced yet, it is good practice to have them available on stock so that when there's an urgent circumstance such as untimely equipment failure, the defective one can easily be replaced.
Provision of PPEs should not set aside because, at the end of the day, both the employer and their employees will benefit from wearing of PPEs.
Proper Use and Maintenance of PPE
How to Correctly Wear and Adjust Each Piece of PPE
Every piece of PPE should be worn correctly to provide the maximum level of protection.
- Protective Clothing: The acid-resistant apron should cover the front of the body from the chest to below the knees. Safety boots should fit well and be comfortable to prevent tripping or slipping.
- Hand Protection: Chemical-resistant gloves should cover the hands completely. They should fit well, not be too loose or tight, to ensure good grip and dexterity.
- Eye and Face Protection: Safety glasses or goggles should fit well around the eyes. If using a face shield, it should cover the entire face from the forehead to below the chin and across the width of the head.
- Respiratory Protection: If necessary, respirators should fit tightly around the nose and mouth to ensure no leakage.
- Electrical Safety Equipment: Insulated tools should be used whenever possible when working near the battery charger or the battery itself.
Cleaning and Storage of PPE
After use, PPE should be cleaned according to manufacturer's instructions to remove any hazardous substances. Never use harsh chemicals or cleaning methods that could degrade the protective qualities of the equipment.
Once cleaned, PPE should be stored in a dry, clean place, away from direct sunlight and extreme temperatures. They should also be stored in a manner that retains their shape and does not cause damage.
Regular Inspection and Replacement of Worn-Out PPE
PPE should be inspected regularly for signs of wear and tear, which could compromise their protective qualities. This includes checking for holes in gloves, cracks in goggles, or any signs of degradation in the material.
Any piece of PPE that is found to be damaged should be replaced immediately. Even small impairments can drastically reduce the level of protection provided. Additionally, PPE should be replaced after a certain period of usage as suggested by the manufacturer, even if no visible signs of wear are detected.
Regular inspections and prompt replacement of worn-out PPE is critical to maintain a high level of safety in the workplace.
Aside from Wearing PPEs, How to Ensure Operators’ Safety?
- Be sure to align the battery charging safety guidelines of the company to the current OSHA regulation or it must be in the same or above the level of the equipment manufacturer’s recommendation.
- A well-ventilated area dedicated for the sole purpose of battery charging. The construction of the charging area must meet the design requirements of ANSI/ISEA Z358.1 (American National Standard for Emergency Eyewash and Shower Equipment). Good ventilation so that flammable oxygen and hydrogen gasses can escape.
- Provision of training to all workers who handle forklift batteries. The main purpose of the training is to communicate to workers the proper handling, storage, and use of the batteries since they’re the ones in close contact. Manual handling training can also be included so that anyone can be educated in the proper lifting of heavy objects. While fire extinguisher training can come in handy.
Battery Charging Station Must-Have Safety Signs as Well
Safety signs in the battery charging station should also be in place to alert workers and people around of the potential hazards in entering the area. The safety signs should be attention-grabbing and placed in key locations to maximize visibility.
Here are the safety signs that must be in place in the charging station:
- Danger: Battery Charging Area
- Battery Charging Area: Strictly No smoking
- Caution: Risk of Eye Injury
- Face and Hand Protection Must Be Worn
- Disconnect Battery Charger
- Caution: Stay Back 10 Feet Away of Battery Charger
- Caution: Check Battery Acid Before Connecting Battery Charger
- Proper PPE Required When Handling Batteries or Adding Water
If you have a heavy-duty printer, you can produce these safety signs in no time. We used to print out in tabloid (ledger)-size, which is about 11x17 inches, and laminate it to make printout rigid.
However, those signs can also be purchased from Amazon, see below:
Understanding the Risks Associated with Charging Forklift Batteries
Hazardous Chemical Exposure
Most forklift batteries are lead-acid batteries which, during the charging process, can generate gases such as hydrogen and potentially sulfuric acid mist. These substances are harmful when inhaled, and sulfuric acid can cause burns upon contact with the skin or eyes.
Electrical Risks
Handling electrically-powered equipment like forklift batteries always carries a certain risk. If not properly managed, there can be dangers of electric shock, which can cause injuries ranging from minor burns to severe body harm. Faulty wiring, inappropriate handling, or lack of proper equipment can increase this risk significantly.
Physical Injury
Charging a forklift battery often involves heavy lifting and precise maneuvering, both of which can lead to physical injuries. A battery can weigh up to several hundred pounds and, if mishandled, can cause sprains, strains, crushed fingers, and even more serious injuries. Slips and falls can also occur if any battery acid is spilled onto the floor, creating a slipping hazard.
Potential for Explosions and Fires
One of the most critical risks during the battery charging process is the generation of hydrogen gas, particularly towards the end of the charge cycle. If the area is not properly ventilated, this gas can build up and potentially ignite or explode if there is a source of ignition. Moreover, faulty electrical connections or equipment can be a fire risk as well.
Understanding these risks highlights the importance of proper training and the use of Personal Protective Equipment (PPE) when charging forklift batteries. It is crucial to ensure that all safety procedures are followed to minimize these hazards.
General Overview of PPE for Forklift Battery Charging
Role of PPE in Mitigating Risks in Battery Charging
When it comes to charging forklift batteries, PPE plays a vital role in protecting employees from the risks associated with this process. Given the potential for exposure to harmful chemicals, electrical shocks, physical injuries, and the threat of fires and explosions, PPE becomes an essential layer of protection. For example, gloves and aprons can prevent chemical burns, safety glasses can guard the eyes against acid splashes, and insulated tools can minimize electrical risks.
Standard Guidelines for PPE Use in this Context
Several organizations provide standard guidelines for PPE use in the context of charging forklift batteries. Notably, the Occupational Safety and Health Administration (OSHA) in the United States has specific requirements for PPE under its general industry standards, such as the Personal Protective Equipment Standard (29 CFR 1910.132) and the Eye and Face Protection Standard (29 CFR 1910.133).
According to these guidelines, employers are required to assess the workplace to determine if hazards are present, or are likely to be present, which necessitate the use of PPE. When such hazards are identified, the employer must select and have each affected employee use the types of PPE that will protect them from the identified hazards.
Moreover, the employer is required to communicate selection decisions to each affected employee, properly fit each employee with the necessary PPE, and train them on its usage. This includes when and how they should wear it, the limitations of the equipment, and the proper care, maintenance, useful life, and disposal of the equipment.
Adherence to these guidelines is essential in ensuring the safety of employees when charging forklift batteries.
Creating a Safety Conscious Culture in the Workplace
Training on the Importance of PPE and Safety Procedures
Effective training is a cornerstone of establishing a safety-conscious culture in the workplace. Employees should be adequately trained on the hazards associated with charging forklift batteries, the importance of PPE, and the correct use of this equipment. Training should also cover emergency procedures, first aid, and the correct handling and disposal of hazardous materials. Regular refresher training is equally important to keep all employees up-to-date on safety procedures and to reinforce the importance of adhering to these protocols.
Management’s Role in Enforcing PPE Regulations
Management plays a crucial role in enforcing PPE regulations. Managers should lead by example, ensuring they wear PPE when required and adhering to all safety procedures. They should also consistently enforce these rules, taking appropriate action when regulations are not followed. This includes providing reminders and corrections, as well as more formal disciplinary action if necessary. Managers should also ensure that adequate PPE is always available and that it is properly maintained and replaced as needed.
Encouraging Employees to be Safety Conscious
Promoting a safety-conscious attitude among employees is critical to maintaining a safe working environment. This can be achieved by fostering open communication about safety, encouraging employees to report any safety concerns or incidents, and responding promptly and effectively to these reports.
Recognition and reward systems can also be put in place to acknowledge individuals or teams who demonstrate a strong commitment to safety. This not only encourages adherence to safety procedures but also promotes a sense of collective responsibility for maintaining a safe workplace.
Overall, creating a safety-conscious culture in the workplace requires ongoing effort from both management and employees. Through consistent training, enforcement of regulations, and fostering a sense of responsibility for safety, workplaces can minimize risks and create an environment where safety is a top priority.
To Make a Conclusion
Throughout this article, we have highlighted the significant role of Personal Protective Equipment (PPE) in mitigating the inherent risks associated with charging forklift batteries.
Given the potential hazards, such as exposure to hazardous chemicals, electrical shocks, physical injuries, and the risk of fires and explosions, the use of appropriate PPE is crucial. Properly utilized, PPE such as acid-resistant aprons, chemical-resistant gloves, safety glasses or goggles, respirators, and insulated tools, can substantially reduce the likelihood of workplace accidents and injuries.
Beyond the use of PPE, fostering a safety-conscious culture within the workplace is an indispensable component of risk management. The combined efforts of thorough safety training, firm management enforcement of PPE regulations, and encouraging a conscientious mindset among employees can significantly enhance the overall safety in the work environment.
In essence, while the use of PPE is vital in the immediate task of charging forklift batteries, cultivating a culture where every individual understands and prioritizes safety can have far-reaching implications in preventing accidents and injuries, thereby ensuring a healthier and safer workplace.
Image source: @ECDC
