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Lithium-Ion Battery Safety: Practical Steps to Reduce Risk in the Workplace

Lithium-ion batteries have become part of everyday life in modern workplaces. From cordless tools and handheld scanners to laptops, mobile devices, forklifts, and personal equipment carried by employees, these batteries help keep operations running efficiently. But alongside convenience, there are real risks that every employer should understand and manage. When lithium-ion batteries are damaged, improperly charged, exposed to heat, or used with incompatible chargers, they can fail in a dangerous way — and quickly.

The goal of this guide is to break lithium-ion battery safety down into clear, practical steps that any workplace can follow. You don’t need to be a battery expert — just aware, prepared, and consistent.

Understanding the Risk

Lithium-ion batteries store energy in a compact space. If the internal structure is damaged or overheated, the battery can experience what’s known as thermal runaway — a rapid, uncontrollable increase in temperature that can lead to:

• Fire or flame

• Toxic smoke

• Pressure build-up and explosion

• Rapid spread to nearby batteries or stored materials

Most workplace incidents start from:

• Physical damage (dropping, crushing, puncturing)

• Using unapproved or off-brand chargers

• Charging batteries in hot or confined spaces

• Aging or visibly swollen batteries remaining in circulation

• Improper storage during transport or disposal

These risks are manageable — but only when understood and addressed consistently.

Recognizing Warning Signs

Train employees to stop using a battery immediately if they notice:

• Bulging, swelling, or unusual shape

• Hissing, popping, or clicking sounds

• Unusual heat during charging or use

• Discoloration, odor, or melting casing

• Past exposure to being crushed, dropped, or soaked

One of the most helpful safeguards is simply empowering workers to report and replace early, before damage escalates.

Safe Charging Practices

Charging is one of the most common points of failure, but also one of the easiest areas to control. Implement these guidelines in all work areas:

• Use only manufacturer-approved chargers

• Charge batteries in dry, ventilated areas, away from direct heat

• Avoid charging near flammable materials (paper, chemicals, packaging)

• Do not charge overnight unless safeguards are in place

• Designate a charging station, not scattered outlets across the facility

• Post clear signage reminding employees to unplug chargers once full

Charging areas should be treated like a controlled space — simple, visible, and easy to keep safe.

Safe Storage and Handling

For everyday handling:

• Avoid dropping or striking battery-powered equipment

• Do not leave batteries in vehicles, near heaters, or in direct sunlight

• Keep terminals away from metal tools and other conductive materials

For storage:

• Store batteries in a cool, dry area

• Keep them in original casing or insulated containers

• Separate damaged or questionable batteries in a clearly labeled “Battery Quarantine” container

This prevents damaged batteries from mixing with safe ones and allows for quick removal if heat or smoke begins.

Emergency Response

In the event of smoking or flaming batteries:

• Do not use a standard water or ABC fire extinguisher as the first response.

• A Class D (metal fire) extinguisher is recommended where large-format batteries exist.

• For hand-held tool batteries, water can be used to cool and prevent spread.

Ensure employees:

• Know the location of extinguishers

• Know when to call 911

• Understand that evacuation may be appropriate if multiple batteries are stored or charging together

Quick awareness is more important than complex procedures — keep instructions simple and visible.

How Simple Safety Coach Helps

Creating safe practices is one step — maintaining them is another.

Organizations use Simple Safety Coach (SSC) to:

• Training Management: Deliver and track lithium-ion battery safety courses.

• Inspection Forms: Import the Battery Safety Inspection Form in our Form Repository, or build and use your own checklists for storage, charging stations, and equipment.

• Incident & Near Miss Tracking: Document battery-related hazards in real time.

• Asset Management: Track battery-powered tools and ensure inspections are scheduled.

• Mobile App: Employees can document unsafe conditions and access training, even offline.

SSC supports continuous improvement by making the safety process repeatable and trackable — without adding administrative burden.

Conclusion

Lithium-ion battery safety is not about eliminating batteries — it’s about building awareness, consistency, and quick response habits. With clear training, proper storage, thoughtful charging practices, and simple reporting, workplaces can continue using battery-powered tools and devices confidently and safely.

If your organization is building or refining its battery safety practices, SSC is here to help you make those efforts easier to maintain and scale.