working precautions for work around battery manufacturing plant electrolyte
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Rosie's answer
Published by SALUSWorking around battery electrolyte in a battery manufacturing or charging area requires controls for corrosive sulfuric acid exposure, flammable hydrogen generation, and possible exposure to lead and other charging by-products. The core approach is to perform a task-specific hazard assessment, follow the battery manufacturer’s instructions and the SDS, train only authorized workers, and use engineering controls, PPE, spill preparedness, and emergency equipment at the point of use. [2] [2] [10]
Key hazards and exposure risks:
- Sulfuric acid electrolyte is corrosive and can severely burn skin, eyes, respiratory tissue, and the digestive tract.
- Charging lead-acid batteries generates hydrogen gas, creating fire and explosion risk if ventilation is inadequate or ignition sources are present.
- Improper charging or overcharging can generate other harmful contaminants, including hydrogen sulfide and, depending on alloy composition, arsine and stibine.
- Lead-containing materials can present inhalation or ingestion risk, especially where dust, residues, or contaminated waste are present.
- Electrical shock, short-circuit, and arc hazards exist if tools, jewelry, or conductive objects contact battery terminals.
[1] [6] [11] [11] [8] [3] PPE requirements:
- At minimum for electrolyte handling, watering, cleanup, or leak response: chemical splash goggles plus a face shield, chemical-resistant gloves, and protective clothing appropriate for acid contact.
- Use acid-resistant apron, sleeves, boots, or full chemical-protective clothing where splashing or larger-volume exposure is possible.
- Select PPE based on the SDS and task hazard assessment; only trained and authorized employees should perform electrolyte transfer, watering, neutralization, or spill cleanup.
- Use respiratory protection only under a written respiratory protection program when ventilation cannot keep exposures below applicable limits or during emergency conditions; respirator selection must match the contaminant and concentration.
[1] [3] [9] [5] Ventilation and ignition control:
- Provide adequate ventilation in all charging and electrolyte-handling areas so hydrogen does not accumulate and workers are not exposed above occupational exposure limits.
- Design ventilation to keep hydrogen below 25% of its lower explosive limit, or about 1% by volume, during worst-case charging conditions.
- Mechanical ventilation may be designed to maintain hydrogen at or below 1% by room volume, or at not less than 1 ft³/min/ft² of floor area where that design basis is used.
- Keep charging and electrolyte areas away from sparks, hot work, smoking, open flames, and other ignition sources; use explosion-proof equipment where flammable gas or vapor may be present.
- Use local exhaust or enclosed systems where mists, vapors, or dusts may be generated during manufacturing, filling, or chemical handling operations.
[1] [1] [6] [4] Handling and storage precautions:
- Handle electrolyte and batteries only according to the manufacturer’s instructions and the current SDS for the battery and electrolyte.
- Charge batteries only in approved, well-ventilated areas with eyewash, safety shower, spill kit, and suitable PPE immediately available.
- Never add sulfuric acid when watering flooded lead-acid batteries; use distilled water only, and water after the battery is fully charged and cooled.
- Keep containers tightly closed, in cool, dry, well-ventilated storage, using compatible corrosion-resistant containers; avoid metal containers where prohibited by the SDS.
- Segregate from incompatible materials and protect from heat, sparks, flames, and direct sunlight where applicable.
- Use proper battery handling equipment for large batteries, secure and restrain loads, and train workers in safe movement procedures.
[2] [9] [3] [12] [11] Spill response and hazardous materials controls:
- Treat electrolyte spills as hazardous material releases: isolate the area, keep out unprotected personnel, ventilate, and remove ignition sources.
- Wear acid-resistant PPE before approaching the spill.
- Prevent entry to drains, sewers, and the environment; cover drains and dike to stop runoff.
- For small spills, absorb with compatible non-reactive absorbent or neutralize with approved neutralizing material such as soda ash if your site procedure and SDS allow it.
- For larger spills, contain, recover with pumps or vacuum equipment if appropriate, place waste in suitable labeled corrosion-resistant containers, and dispose of as hazardous waste.
- Do not flush unneutralized or lead-contaminated acid to sewer.
- Report larger spills to internal emergency response and external authorities as required by law and site procedure.
[15] [12] [15] [7] [7] [15] Emergency response and first aid:
- Install and maintain emergency eyewash stations and safety showers close to charging and electrolyte work areas.
- If sulfuric acid contacts eyes or skin, begin flushing immediately with clean, lukewarm, gently flowing water for at least 30 minutes and do not interrupt flushing.
- Avoid spreading contamination to unaffected skin or the other eye.
- First aid responders should wear chemical-protective gloves and eye/face protection.
- Arrange immediate medical evaluation; if safe, continue flushing during transport.
- For fire or explosion risk involving hydrogen or battery areas, evacuate nonessential personnel, control ignition sources, and use trained responders with appropriate firefighting PPE and SCBA.
[1] [1] [1] [3] [3] [13] OSHA compliance and SDS guidance:
- Maintain a written hazard communication program and ensure workers have access to SDSs for electrolyte, batteries, lead, and any other process chemicals.
- Use SDS Sections 4 through 8 as the primary operating reference for first aid, firefighting, spill response, handling/storage, exposure controls, and PPE.
- Comply with OSHA PPE requirements, including hazard assessment and documented PPE selection for each task.
- Where respirators are needed, comply with OSHA 29 CFR 1910\.134\.
- For eye and face protection, follow OSHA 29 CFR 1910\.133\.
- Control airborne lead and any acid mist exposures below applicable OSHA limits, and implement exposure monitoring, hygiene, housekeeping, medical surveillance, and regulated-area practices where required by the specific OSHA substance standards.
[10] [10] [10] [10] [14] [5] [5] [8] In practice, the safest program for electrolyte work in a battery plant is to restrict the task to trained personnel, use designated ventilated areas, eliminate ignition sources, require acid-resistant PPE, keep eyewash/shower and spill-neutralization supplies immediately available, follow the SDS and manufacturer instructions for every battery type, and treat all spills, contaminated absorbents, and lead-contaminated residues as hazardous materials requiring controlled cleanup and disposal. [9] [3] [2] [7]
Sources used for this answer
[1] Safety Data Sheet - Lead
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# SAFETY DATA SHEET (cont.) ## Classification (cont.) Lead Revision Date 09-Feb-2024 # 5. Fire-fighting measures <table><tr><th>Suitable Extinguishing Media</th><th>Water spray, carbon dioxide (CO2), dry chemical, alcohol-resistant foam.</th></tr><tr><td>Unsuitable Extinguishing Media</td><td>No information available</td></tr><tr><td>Flash Point</td><td>No information available</td></tr><tr><td>Method -</td><td>No information available</td></tr><tr><td>Autoignition Temperature</td><td>No information available</td></tr><tr><td>Explosion Limits</td><td></td></tr><tr><td>Upper</td><td>No data available</td></tr><tr><td>Lower</td><td>No data available</td></tr><tr><td colspan="2">Sensitivity to Mechanical Impact No information available</td></tr><tr><td>Sensitivity to Static Discharge</td><td>No information available</td></tr></table> Specific Hazards Arising from the Chemical Non-combustible. Do not allow run-off from fire-fighting to enter drains or water courses. Hazardous Combustion Products Lead. lead oxides. Protective Equipment and Precautions for Firefighters As in any fire, wear self-contained breathing apparatus pressure-demand, MSHA/NIOSH (approved or equivalent) and full protective gear. Thermal decomposition can lead to release of irritating gases and vapors. ## NFPA Health 2 Flammability 0 Instability 0 Physical hazards N/A <table><tr><th colspan="2">6. Accidental release measures</th></tr><tr><td>Personal Precautions</td><td>Ensure adequate ventilation. Use personal protective equipment as required. Avoid dust formation. Keep people away from and upwind of spill/leak. Evacuate personnel to safe areas.</td></tr><tr><td>Environmental Precautions</td><td>Do not flush into surface water or sanitary sewer system. Should not be released into the environment. Do not allow material to contaminate ground water system.</td></tr></table> Methods for Containment and Clean Sweep up and shovel into suitable containers for disposal. Avoid dust formation. …
[2] Safety Data Sheet - Hydrogen
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# SAFETY DATA SHEET (cont.) ## 5. Fire-fighting measures (cont.) Hydrogen, gas Revision Date 20-May-2024 Keep product and empty container away from heat and sources of ignition. Hazardous Combustion Products None known. Protective Equipment and Precautions for Firefighters As in any fire, wear self-contained breathing apparatus pressure-demand, MSHA/NIOSH (approved or equivalent) and full protective gear. ## NFPA <table><tr><th>Health</th><th>Flammability</th><th></th><th>Instability</th><th></th><th>Physical hazards</th></tr><tr><td>0</td><td>4</td><td></td><td>0</td><td></td><td>-</td></tr><tr><td></td><td colspan="5">6. Accidental release measures</td></tr><tr><td>Personal Precautions Environmental Precautions</td><td>Ensure adequate See Section 12</td><td>ventilation. Use for additional Ecological</td><td>personal Information.</td><td>protective equipment</td><td>as required.</td></tr></table> Methods for Containment and Clean No information available. Up ## 7. Handling and storage Handling Ensure adequate ventilation. Storage. Keep containers tightly closed in a dry, cool and well-ventilated place. ## Exposure Guidelines ## 8. Exposure controls I personal protection <table><tr><th>Component</th><th>ACGIH TLV</th><th>OSHA PEL</th><th>NIOSH</th><th>Mexico OEL (TWA)</th></tr><tr><td>Hydrogen</td><td>:</td><td></td><td></td><td></td></tr></table> ## Legend ACGIH - American Conference of Governmental Industrial Hygienists Engineering Measures Ensure adequate ventilation, especially in confined areas. ## Personal Protective Equipment <table><tr><th>Eye/face Protection</th><th>Wear appropriate protective eyeglasses or chemical safety goggles as described by OSHA's eye and face protection regulations in 29 CFR 1910.133 or European Standard EN166.</th></tr><tr><td>Skin and body protection</td><td>Wear appropriate protective gloves and clothing to prevent skin exposure.</td></tr><tr><td>Respiratory Protection</td><td>Follow the OSHA respirator regul…
[3] Hazard Communication Standard: Safety Data Sheet (OSHA Brief)
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# Section 2: Hazard(s) Identification (cont.) ## Section 4: First-Aid Measures This section describes the initial care that should be given by untrained responders to an individual who has been exposed to the chemical. The required information consists of: - Necessary first-aid instructions by relevant routes of exposure (inhalation, skin and eye contact, and ingestion). - Description of the most important symptoms or effects, and any symptoms that are acute or delayed. - Recommendations for immediate medical care and special treatment needed, when necessary. ## Section 5: Fire-Fighting Measures This section provides recommendations for fighting a fire caused by the chemical. The required information consists of: - Recommendations of suitable extinguishing equipment, and information about extinguishing equipment that is not appropriate for a particular situation. - Advice on specific hazards that develop from the chemical during the fire, such as any hazardous combustion products created when the chemical burns. - Recommendations on special protective equipment or precautions for firefighters. ## Section 6: Accidental Release Measures This section provides recommendations on the appropriate response to spills, leaks, or releases, including containment and cleanup practices to prevent or minimize exposure to people, properties, or the environment. It may also include recommendations distinguishing between responses for large and small spills where the spill volume has a significant impact on the hazard. The required information may consist of recommendations for: - Use of personal precautions (such as removal of ignition sources or providing sufficient ventilation) and protective equipment to prevent the contamination of skin, eyes, and clothing. - Emergency procedures, including instructions for evacuations, consulting experts when needed, and appropriate protective clothing. - Methods and materials used for containment (e.g., covering the drains and …
[4] Battery Charging - Industrial Lead-Acid Batteries
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# Battery Charging - Industrial Lead-Acid Batteries (cont.) ## Are there any other hazards involved? (cont.) Depending on the metal alloy composition in lead-acid batteries, a battery being charged can generate two highly toxic by-products. One is arsine (arsenic hydride, AsH3) and the other is stibine (antimony hydride, SbH3). Generally, the air levels of these metal hydrides tend to remain well below the current occupational exposure limits during battery charging operations. Overcharging a lead acid battery can also lead to the generation of hydrogen sulfide, which can cause harm to workers if exposed. Although these risks may be minimal when batteries a properly charged, their possible presence re-enforces the need for adequate ventilation systems. In addition, always follow the manufacturer's recommend charging time and only use manufacturer-approved charging devices appropriate for the voltage and amp-hours (ah) of the battery. ## How should industrial size batteries be handled? Industrial batteries (e.g., forklifts or battery powered industrial trucks) may weigh up to 900 kg (2,000 lbs) or more. Workers must be trained in how to safely move batteries using appropriate equipment (e.g., specially equipped forklift, battery cart, conveyor, overhead hoist, etc.) - Batteries must be securely placed and restrained. - Use only the appropriate tools and follow safe work procedures. Fact sheet last revised: 2023-01-26 ## Disclaimer Although every effort is made to ensure the accuracy, currency and completeness of the information, CCOHS does not guarantee, warrant, represent or undertake that the information provided is correct, accurate or current. CCOHS is not liable for any loss, claim, or demand arising directly or indirectly from any use or reliance upon the information. Battery Charging - Industrial Lead-Acid Batteries CCOHS
[5] Battery Charging - Industrial Lead-Acid Batteries
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CCOHS CCHST Canadian Centre for Occupational Health and Safety Centre canadien d'hygiène et de sécurité au travail Safety Hazards # Battery Charging - Industrial Lead-Acid Batteries ## On this page Why is it important to follow safety. procedures when charging batteries? What are the risks of charging an industrial lead-acid battery? Why is there a risk of an explosion? What are the ventilation requirements for charging areas? Why can you get a burn from acid when handling the batteries? What should I know about watering a lead-acid battery? Are there any other hazards involved? How should industrial size batteries be handled? ## Why is it important to follow safety procedures when charging batteries? The use, handling and charging of batteries in the workplace can be hazardous. It is important to identify and assess the hazards and risks, and to have the appropriate control measures in place to protect workers. The hazards and risks associated with a battery will depend on the type of battery, how it is used, how it needs to be charged and maintained, the area where it is being charged and used, among other factors. Workplaces should always make sure that procedures and practices are developed based on the battery's manufacturer's instructions and recommendations. Requirements from occupational health and safety legislation, building codes, electrical codes, and fire codes must also be followed. Always make sure the charging stations and devices have a Canadian certification mark (such as from the Canadian Standards Association (CSA) or Intertek (cETL)), indicating it meets Canadian electrical safety standards (jurisdictions may specify which certification marks are acceptable). In all cases, workers should be trained on safe work procedures, spill response, first-aid, and other related duties. Refer to the manufacturer's instructions and safety data sheets (SDS). Battery Charging - Industrial Lead-Acid Batteries CCOHS
[6] Sulfuric Acid
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# What are first aid measures for sulfuric acid? (cont.) ## What are fire hazards and extinguishing media for sulfuric acid? (cont.) Specific Hazards Arising from the Chemical: Contact with water causes violent frothing and spattering. Reacts with metals to produce highly flammable hydrogen gas. Closed containers may rupture violently when heated releasing contents. In a fire, the following hazardous materials may be generated: corrosive sulfur oxides. ## What are the stability and reactivity hazards of sulfuric acid? - Chemical Stability: Normally stable. - Conditions to Avoid: Water, moisture or humidity. - Incompatible Materials: Highly reactive. Reacts violently with: many chemicals, including, water. Corrosive to: aluminum alloys, carbon steel, and other metals. - Hazardous Decomposition Products: None known. - Possibility of Hazardous Reactions: None known. ## What are unintentional release measures for sulfuric acid? Personal Precautions: Evacuate the area immediately. Isolate the hazard area. Keep out unnecessary and unprotected personnel. Do not touch damaged containers or spilled product unless wearing appropriate protective equipment. Remove or isolate incompatible materials as well as other hazardous materials. Methods for Containment and Clean-up: Small spills or leaks: contain and soak up spill with absorbent that does not react with spilled product. Place used absorbent into suitable, covered, labelled containers for disposal. Large spills or leaks: contain and soak up spill with absorbent that does not react with spilled product. Dike spilled product to prevent runoff. Remove or recover liquid using pumps or vacuum equipment. Place used absorbent into suitable, covered, labelled containers for disposal. Store recovered product in suitable containers that are: corrosion-resistant. Contaminated absorbent poses the same hazard as the spilled product. Other Information: Large spills: contact supplier, local fire and emergency services for …
[7] Safety Data Sheet - Benzene
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# Benzene (cont.) ## 3. Composition/Information on Ingredients (cont.) Benzene Revision Date 03-Apr-2024 <table><tr><th colspan="2">6. Accidental release measures</th></tr><tr><td>Personal Precautions</td><td>Use personal protective equipment as required. Ensure adequate ventilation. Keep people away from and upwind of spill/leak. Evacuate personnel to safe areas. Remove all sources of ignition. Take precautionary measures against static discharges.</td></tr><tr><td>Environmental Precautions</td><td>Do not flush into surface water or sanitary sewer system.</td></tr><tr><td colspan="2">Methods for Containment and Clean Soak up with inert absorbent material. Keep in suitable, closed containers for disposal. Up Remove all sources of ignition. Use spark-proof tools and explosion-proof equipment.</td></tr></table> <table><tr><th colspan="2">7. Handling and storage</th></tr><tr><td>Handling</td><td>Wear personal protective equipment/face protection. Do not get in eyes, on skin, or on clothing. Use only under a chemical fume hood. Do not breathe mist/vapors/spray. Do not ingest. If swallowed then seek immediate medical assistance. Keep away from open flames, hot surfaces and sources of ignition. Use only non-sparking tools. To avoid ignition of vapors by static electricity discharge, all metal parts of the equipment must be grounded. Take precautionary measures against static discharges.</td></tr><tr><td>Storage.</td><td>Keep containers tightly closed in a dry, cool and well-ventilated place. Flammables area. Keep away from heat, sparks and flame. Incompatible Materials. Strong oxidizing agents.</td></tr></table> ## 8. Exposure controls / personal protection ## Exposure Guidelines <table><tr><th>Component</th><th>ACGIH TLV</th><th>OSHA PEL</th><th>NIOSH</th><th>Mexico OEL (TWA)</th></tr><tr><td>Benzene</td><td>TWA: 0.5 ppm STEL: 2.5 ppm Skin</td><td>(Vacated) TWA: 10 ppm Ceiling: 25 ppm (Vacated) STEL: 50 ppm (Vacated) Ceiling: 25 ppm TWA: 10 ppm TWA: 1 ppm STEL: 5…
[8] Certification of Hazard Assessment
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# Certification of Hazard Assessment (Sample Page) Work Area Assessment Conducted By. Date Personal Protective Equipment - Hazard Analysis - By Task <table><tr><th>Task</th><th>Hazard</th><th>PPE Required</th><th>Notes</th><th>Department</th></tr><tr><td>Entering high noise area</td><td>Hearing loss</td><td>Foam, cap, or earmuff type hearing protection</td><td>Both ears, all production areas, prior to exposure area</td><td>All persons</td></tr><tr><td>Chemical mixing</td><td>Caustic burns</td><td>Chemical gloves, apron, goggles and face shield, rubber boots, sleeves</td><td>Only authorized employees are to mix chemicals. Read MSDS prior to using any chemicals.</td><td>Authorized Employees</td></tr><tr><td>First aid/CPR</td><td>Bloodborne pathogens/Air borne diseases</td><td>Latex/non-latex examination gloves, safety eyewear, CPR device protective mask</td><td>Immediate notification if exposed to body fluids. See Bloodborne Pathogen Control Program</td><td>Any staff required to render first aid.</td></tr><tr><td>Grinding, sanding, chipping, abrading</td><td>Debris in eyes, burns, lacerations to face and other non-protected body parts.</td><td>Safety glasses / goggles, face shield, gloves, arm protection, Safety toed leather boots</td><td>Use point of operation area guarding when available.</td><td>Maintenance</td></tr><tr><td>Grinding, sanding, chipping, abrading</td><td>Hand lacerations, impingement</td><td>Leather or thick cloth work gloves</td><td>When using powered tools</td><td>Maintenance</td></tr><tr><td>Welding, brazing</td><td>Eye hazard, burns</td><td>Welding helmet, apron, gloves, chaps</td><td>See selection chart for proper lens shade</td><td>Maintenance</td></tr><tr><td>Work on live electrical circuits</td><td>Electrical shock</td><td>Reference NFPA 70-E</td><td>Maintenance</td><td>Must be licensed and trained.</td></tr><tr><td>Exposure to traffic</td><td>Body injuries</td><td>ANSI Class II Safety Vest</td><td>Wear near road ways or high traffic are…
[9] Battery Charging - Industrial Lead-Acid Batteries
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# Battery Charging - Industrial Lead-Acid Batteries (cont.) ## Why is it important to follow safety procedures when charging batteries? (cont.) NOTE: This OSH Answers document provides general guidance for industrial lead-acid batteries used to operate forklifts and is not meant to replace the requirements from the manufacturer or legislation. ## What are the risks of charging an industrial lead-acid battery? The charging of lead-acid batteries (e.g., forklift or industrial truck batteries) can be hazardous. The two primary risks are from hydrogen gas formed when the battery is being charged and the sulfuric acid in the battery fluid, also known as the electrolyte. Hydrogen gas can lead to fires and explosions, and worker exposure to sulfuric acid can lead to chemical burns and other adverse health effects. Improper handling of batteries can also lead to shocks and electrocution, and battery charging can also result in the release of other harmful contaminants. For general safety precautions when working with batteries, please see the OSH Answers Garages - Batteries which covers automotive vehicle sized batteries and the OSH Answers on Forklift Trucks - Lead-Acid Batteries for forklift batteries. For specific guidelines regarding large industrial batteries, check with the manufacturer for recommended safe work procedures. ## Why is there a risk of an explosion? When leac-acid batteries are being recharged, they generate hydrogen gas that is explosive in certain concentrations in air (explosive limits are 4.1 to 72 percent hydrogen in air). The ventilation system needs to be able to exchange an adequate amount of fresh air for the number of batteries being charged. This is essential to prevent an explosion. Batteries should also not be charged or handled near sources of heat, flames or sparks, such as welding activities, burning cigarettes, or other source of ignition. Charging stations for battery-powered industrial trucks, per the National Fire Code of Can…
[10] Safety Data Sheet - Cresol
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# SAFETY DATA SHEET (cont.) ## SECTION 4. FIRST AID MEASURES (cont.) C0412:Cresol Version 1.1 Revision Date: 12/16/2024 ## SECTION 5. FIRE-FIGHTING MEASURES Suitable extinguishing media : Dry powder, Foam, Water spray, Carbon dioxide (CO2) Specific hazards during fire : No information available. fighting Specific extinguishing methods : Use extinguishing measures that are appropriate to local circum- stances and the surrounding environment. Immediately evacuate personnel to safe areas. Remove undamaged containers from fire area if it is safe to do so. Special protective equipment for : Use personal protective equipment. fire-fighters ## SECTION 6. ACCIDENTAL RELEASE MEASURES Personal precautions, protective : Wear suitable protective equipment.Keep people away from and up- equipment and emergency proce- wind of spill/leak. Ensure adequate ventilation.Entry to non-involved dures personnel should be controlled around the leakage area by roping off, etc. Environmental precautions : Should not be released into the environment. Methods and materials for contain- : Collect as much of the spill as possible with a suitable absorbent mate- ment and cleaning up rial. ## SECTION 7. HANDLING AND STORAGE Technical measures : Prevent generation of vapor or mist. Take precautionary measures against static discharge. Use explosion-proof equipment. Local/Total ventilation : Ensure adequate ventilation. Handle product only in closed system or provide appropriate exhaust ventilation at machinery. Use a local exhaust ventilation. Advice on safe handling : Avoid contact with skin, eyes and clothing. Wear personal protective equipment. Keep away from heat, hot surfaces, sparks, open flames and other ignition sources. No smoking. Do not subject to grinding, shock or friction. Wash hands and face thoroughly after handling. Conditions for safe storage : Keep container tightly closed. Store in a cool and shaded area. Keep in a well-ventilated place. Store locked up. ## SECTION…
[11] Forklift Trucks - Batteries
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# Forklift Trucks - Batteries (cont.) ## Why is it important to follow safety procedures when charging batteries? (cont.) NOTE: This OSH Answers document provides general guidance for industrial lead-acid batteries used to operate forklifts and is not meant to replace the requirements from the manufacturer or legislation. ## Why should you follow safety precautions when charging batteries? Lead-acid batteries contain sulfuric acid. Only trained and authorized personnel should handle them. When talking about lead-acid batteries, people usually call sulfuric acid "battery acid" or the "electrolyte". An electrolyte is a general term used to describe a non-metallic substance like sulfuric acid or salts that can conduct electricity when dissolved in water. Lead-acid batteries can produce explosive mixtures of hydrogen and oxygen gases when they are being charged. Note that in some cases, hydrogen gas has been found to interfere with carbon monoxide detectors. Check with your detector manufacturer(s) for more information. - Charge batteries only in approved, well-ventilated battery-charging areas. - Install a safety shower and an eyewash station in a battery-charging area. - Always follow the manufacturer's instructions for safely charging the battery. ## What are some precautions to use when watering a battery? During the normal operation of a forklift with a flooded lead acid battery, the water in the electrolyte evaporates and needs to be refilled (watered) to keep the battery operating effectively and safely. - Develop procedures based on the manufacturer's instructions on how and when to water the battery. - In general, a battery should be watered after it has been fully charged and cooled down. - Do not water a battery before or during charging, as the water may boil over and cause acid to leak. - Use distilled water (not tap water) to refill the electrolyte. - Never add sulfuric acid to the electrolyte. - Wear appropriate personal protective equipme…
[12] Battery Charging - Industrial Lead-Acid Batteries
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# Battery Charging - Industrial Lead-Acid Batteries (cont.) ## Why can you get a burn from acid when handling the batteries? (cont.) - Take care not to rinse contaminated water into the unaffected eye, or onto the face or skin. - First aiders should avoid direct contact. Wear chemical protective gloves, eye and face protection and other PPE, as necessary. - Quickly transport the victim to an emergency care facility or call 911. If safe to do so, continue flushing during transport. - Safely dispose of contaminated clothing, equipment, and materials. ## What should I know about watering a lead-acid battery? Flooded lead-acid batteries (e.g., used in some electric forklifts) contain an electrolyte solution of sulfuric acid and distilled water. During normal operation, the water evaporates and needs to be refilled (watered) to keep the battery operating effectively and safely. Use distilled water. Do not add sulfuric acid to the electrolyte. Batteries should be watered after it has been fully charged and has cooled down. Do not water a battery before or during charging, as the water may boil over and cause acid to leak from the battery. Develop procedures on how to safely water a battery, based on the manufacturer's instructions, and train workers. Appropriate personal protective equipment (PPE) should be worn, including eye and face protection (e.g., chemical safety goggles and face shield); chemical-resistant gloves, aprons, and boots; or other protective clothing as needed. Make sure to water the batteries in the designated charging area where there is access to spill response equipment, PPE, and emergency eyewash stations or showers. There are also sealed batteries, such as absorbed glass mat batteries, which have the electrolyte fluid sealed into the battery, and do not require distilled water to be added. Always use the type of battery that is compatible with the equipment and recommended by the manufacturer. ## Are there any other hazards involved? It…
[13] TB60 OPERATOR'S MANUAL - ANSI (Identifier: 0082168)
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# 13. FIRE FIGHTING & HAZARDOUS CHEMICAL CONTAINMENT A TB 60 contains the following materials and objects that potentially could become significant fire or environmental hazards during the lifetime of a TB 60: Anti-freeze (ethylene glycol) Battery, lead/acid Diesel fuel Foam in tires Gasoline Hydraulic oil Liquefied petroleum gas Motor oil The rest of this chapter lists manufacturers' information you will need if you ever have to control any of the above items during an upset or emergency. ## ANTIFREEZE (UN 1993) Fire extinguishing media: Dry Chemical, foam, or CO2. Special fire fighting procedures: Water spray may be ineffective on fire but can protect fire fighters and cool closed containers. Use fog nozzles if water is used. Do not enter confined fire-space without full bunker gear. (Helmet with face shield, bunker coats, gloves & rubber boots). Use a NIOSH approved positive pressure self-contained breathing apparatus. Keep container tightly closed. Isolate from oxidizers, heat & open flame. Spill or leak: Small - mop up with absorbent material & transfer to hood. Waste disposal method: Small - evaporate until all vapors are gone. Dispose of remainder by legally applicable methods. ## BATTERY, LEAD/ACID (UN 2794) Extinguishing media: Dry chemical, foam, or CO2. Special fire fighting procedures: Use positive pressure, self-contained breathing apparatus. Unusual fire and explosion hazards: Hydrogen and oxygen gases are produced in the cells during normal battery operation (hydrogen is flammable and oxygen supports combustion). These gases enter the air through the vent caps. To avoid the chance of a fire or explosion, keep sparks and other sources of ignition away from the battery. Spill or leak: Remove combustible materials and all sources of ignition. Contain spill by diking with soda ash (sodium carbonate) or quicklime (calcium oxide). Cover spill with either chemical. Mix well. Make certain mixture is neutral then collect residue and place in a…
[14] Battery Charging - Industrial Lead-Acid Batteries
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Open source documentSource excerpt
# Battery Charging - Industrial Lead-Acid Batteries (cont.) ## What are the ventilation requirements for charging areas? (cont.) Many standards and codes recommend a ventilation system that prevents the accumulation of hydrogen to above 25% of its lower explosive limit (LEL), or above 1% by volume. Guidelines for ventilation in battery charging areas, based on the National Fire Protection Agency Standards (NFPA 855), are provided below: Natural exhaust ventilation: designed to limit the concentration of flammable gas to 25% of the lower explosive limit (LEL) during the worst-case scenario of charging all batteries at the same time. Mechanical Ventilation: an exhaust ventilation rate that is effective at limiting the maximum concentration of hydrogen to 1% of the total volume of the room or area during a worst-case scenario when all batteries are being charged at the same time. Alternatively, having a ventilation rate based on the area of not less than 1ft3 / min / ft2 of the floor area of the room. ## Why can you get a burn from acid when handling the batteries? You can get a skin burn when handling lead-acid batteries. Sulfuric acid is the acid used in lead-acid batteries (electrolyte) and it is corrosive. Note: workers should never pour sulfuric acid into flooded lead acid batteries (included in new watering a battery section). If a worker comes in contact with sulfuric acid when watering a battery or when handling a leaky battery, it can burn and destroy the skin. It is corrosive to all other body tissues. For example, the eyes, respiratory tract, or digestive system can be harmed severely if a worker gets a splash in the eyes, inhales sulfuric acid mist or unintentionally ingests sulfuric acid. As with any corrosive chemical, appropriate handling procedures must be followed to prevent contact with the liquid. These procedures include the wearing of face and eye protection, and protective chemical- resistant clothing such as aprons and gloves that are suita…
[15] Safety Data Sheet - Sulfuric Acid
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Open source documentSource excerpt
# SAFETY DATA SHEET (cont.) ## SECTION 6: Accidental release measures - 6.1 Personal precautions, protective equipment and emergency procedures Advice for non-emergency personnel: Do not breathe vapors, aerosols. Avoid substance contact. Ensure adequate ventilation. Evacuate the danger area, observe emergency procedures, consult an expert. For personal protection see section 8. - 6.2 Environmental precautions - Do not let product enter drains. - 6.3 Methods and materials for containment and cleaning up Cover drains. Collect, bind, and pump off spills. Observe possible material restrictions (see sections 7 and 10). Take up with liquid-absorbent and neutralising material (e.g. Chemizorb® H+, Merck Art. No. 101595). Dispose of properly. Clean up affected area. - 6.4 Reference to other sections - For disposal see section 13. ## SECTION 7: Handling and storage - 7.1 Precautions for safe handling For precautions see section 2.2. - 7.2 Conditions for safe storage, including any incompatibilities - Storage conditions - No metal containers. - Tightly closed. - Storage class - Storage class (TRGS 510): 8B: Non-combustible, corrosive hazardous materials - 7.3 Specific end use(s) - Apart from the uses mentioned in section 1.2 no other specific uses are stipulated ## SECTION 8: Exposure controls/personal protection 8.1 Control parameters Ingredients with workplace control parameters Aldrich 339741 The life science business of Merck KGaA, Darmstadt, Germany operates as MilliporeSigma in the US and Canada Page 4 of 11 lillipoRe SiGMa
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