Forklift battery charging operations involve hydrogen gas explosion risks from lead-acid batteries, thermal runaway and fire risks from lithium-ion batteries, sulphuric acid burns during battery maintenance, and electrical hazards from high-current charging systems. The WHS Regulation 2025 introduces specific provisions for lithium-ion battery storage and charging that apply to the growing number of warehouses transitioning from lead-acid to lithium-ion powered forklift fleets. Battery changeover operations on lead-acid forklifts involve lifting batteries weighing over 1,000 kg using overhead cranes or dedicated battery handling equipment, creating significant crush and manual handling risks. This SWMS template covers lead-acid and lithium-ion battery charging, changeover, and maintenance with controls for each battery type.
WHS Regulation 2025 Part 7.1 — Hazardous Chemicals; Part 4.5 — Electrical; Li-ion provisions
Hazardous chemical exposure, electrical work, work in or near flammable atmosphere
Managing Risks of Hazardous Chemicals; Managing Electrical Risks in the Workplace (binding July 2026)
Yes — Both codes binding July 2026. Non-compliance is admissible as evidence of breach.
| Hazard | Consequence | Likelihood |
|---|---|---|
| Hydrogen gas explosion from lead-acid battery charging in poorly ventilated areas | Explosion, burns, projectile injuries, fatalities | Unlikely |
| Sulphuric acid burns from lead-acid battery electrolyte during watering and maintenance | Severe chemical burns to skin and eyes | Possible |
| Lithium-ion battery thermal runaway during charging or from damaged cells | Intense fire, toxic fume generation, explosion | Unlikely |
| Electrical shock from high-current charging connections and damaged cables | Electrocution, electrical burns | Unlikely |
| Crush injury from battery changeover using overhead handling equipment | Fatal crush injuries from dropped batteries | Unlikely |
A hydrogen gas explosion in a poorly ventilated battery charging room injured two workers. The charging area had no mechanical ventilation, no hydrogen gas detection, and batteries were being charged adjacent to a welding station providing an ignition source.
2023 — Workplace Health and Safety Queensland Prosecution Database
Our WHS consultants develop battery charging SWMS covering both lead-acid and lithium-ion systems with ventilation specifications and emergency response procedures.
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