Lithium-ion batteries have become a routine part of modern workplaces. They power cordless tools, forklifts, handheld scanners, laptops, radios, mobility equipment, electric vehicles, energy storage systems, and many other devices used in warehouses, factories, construction sites, maintenance facilities, and distribution centers.
Although these batteries offer high energy capacity in a relatively compact package, they also introduce hazards that workplaces need to understand. OSHA has emphasized that lithium-ion batteries may create risks during manufacturing, use, emergency response, disposal, and recycling, including fires, explosions, and exposure to hazardous chemicals.
In 2026, OSHA also issued guidance clarifying that qualifying work-related injuries caused by lithium-ion batteries may need to be recorded on OSHA injury and illness logs. That makes battery safety an increasingly important part of overall workplace hazard awareness.
Why Lithium-Ion Batteries Can Become Hazardous
Lithium-ion batteries contain significant stored electrical energy. Under normal operating conditions, that energy is controlled within the battery cells. Problems can occur when a battery is damaged, improperly charged, exposed to excessive heat, manufactured with a defect, or used with incompatible equipment.
According to OSHA’s Lithium-ion Battery Safety Fact Sheet, workplaces that manufacture, use, install, or recycle these batteries should understand the associated safety and health hazards.
Thermal Runaway
One of the most serious concerns is thermal runaway. This is a process in which heat generated inside a battery causes additional internal reactions, leading to rapidly increasing temperatures.
Once thermal runaway begins, the affected cell may release heat, gases, smoke, or burning material. Heat can also spread to neighboring cells, potentially escalating a small battery failure into a larger incident.
Common Factors That Can Damage a Battery
Battery damage may result from crushing, puncturing, dropping, improper charging, excessive heat, electrical faults, manufacturing defects, or using a battery in equipment for which it was not designed.
Workers should not assume that a battery is safe simply because it still powers a device. Physical deformation, overheating, leaking, unusual odors, discoloration, or unusual sounds may indicate that a battery needs to be removed from normal use and evaluated under established workplace procedures.
Fire and Explosion Risks
When a lithium-ion battery fails, it may generate enough heat to ignite nearby combustible materials. Depending on the battery type and the nature of the failure, flammable gases may also be released.
The National Fire Protection Association advises that damaged or improperly used lithium-ion batteries can overheat, catch fire, or explode. Workplaces therefore need to consider not only the battery itself but also what is stored around it.
Cardboard packaging, paper products, plastics, solvents, textiles, and other combustible materials can increase the consequences of a battery fire if charging or storage areas are poorly located.
Battery Fires Can Behave Differently
Lithium-ion battery incidents may not behave exactly like ordinary fires involving paper, wood, or similar materials. For that reason, workers should follow site-specific emergency procedures rather than improvising a response.
Emergency planning should address how workers report a battery incident, when areas should be evacuated, who is authorized to respond, and what fire protection systems are available.
Readers can also review the Industrial Injury Guide workplace safety FAQ for general information on identifying unsafe conditions and responding to workplace hazards.
Chemical Exposure Is Another Concern
Fire is not the only potential hazard associated with damaged lithium-ion batteries. Battery materials and decomposition products can create chemical exposure risks.
OSHA recommends controls such as adequate ventilation, monitoring certain storage areas for flammable or toxic gases, and providing emergency washing facilities where workers may handle battery materials.
Workers involved in battery manufacturing, recycling, maintenance, or damaged-battery response may face different exposure risks than employees who simply use battery-powered tools. Controls should therefore match the actual work being performed.
Safer Charging and Storage Practices
Charging areas deserve special attention because batteries are actively receiving energy. Charging should follow manufacturer instructions and workplace procedures, using equipment that is intended for the specific battery or device.
OSHA recommends storing lithium-ion batteries in cool, dry locations. Battery storage areas should be organized so workers can detect damage and avoid unnecessary contact with combustible materials.
Keep Charging Areas Organized
Charging stations should not become cluttered with packaging, waste, tools, or other items that could interfere with inspection or emergency response. Damaged electrical cords, incompatible chargers, or poorly maintained charging equipment can introduce additional hazards.
Ventilation may also be important depending on the type and scale of the battery operation.
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Avoid Mixing Damaged Batteries With Normal Inventory
A battery showing signs of damage should not simply be returned to a shelf with normal batteries. Workplaces should have a procedure for identifying, isolating, evaluating, and disposing of damaged units.
Separating questionable batteries can help prevent unnoticed failures and reduces the chance that a damaged battery will be placed back into service.
Handling Damaged or Defective Batteries
Workers should know what signs may indicate a battery problem. The NFPA identifies warning signs such as unusual odor, excessive heat, changes in shape or color, leaking, or unusual noises.
If a battery appears damaged or unstable, employees should follow their workplace’s established procedures and avoid actions that could increase the risk. Improvised repairs, puncturing, crushing, or continued charging can make an unstable battery more dangerous.
The appropriate response may depend on the battery size, chemistry, device, workplace environment, and severity of the damage.
Training Workers Around Battery Hazards
Workers who use battery-powered equipment should receive information appropriate to the hazards they may encounter. Training can include recognizing damaged batteries, following charging instructions, knowing where approved storage areas are located, and understanding emergency procedures.
Employees involved in battery maintenance, recycling, manufacturing, or incident response may need more specialized training because their potential exposure is greater.
PPE Should Match the Task
Personal protective equipment should be selected according to the work being performed and the hazards identified. Gloves, eye protection, protective clothing, or other equipment may be appropriate in certain operations involving battery materials or damaged units.
PPE should be part of a broader hazard-control approach rather than the only safety measure.
Recycling and Disposal Require Planning
Lithium-ion batteries should not automatically be treated like ordinary trash. Improperly discarded batteries can be crushed or damaged during waste handling, creating fire hazards at collection and recycling facilities.
OSHA recommends using designated recycling facilities when disposing of lithium-ion batteries. Workplaces should establish clear procedures so workers know where used, damaged, or end-of-life batteries belong.
Battery recycling areas should also avoid unnecessary accumulation of damaged cells or packs.
Why Battery Safety Matters in 2026
OSHA’s January 2026 safety communication emphasized that lithium-ion batteries are now widely used across workplaces and may expose workers to fires, explosions, and harmful chemicals. The agency also issued a February 2026 interpretation clarifying when battery-related injuries may qualify as recordable workplace injuries.
These developments reinforce the importance of treating battery safety as part of routine workplace hazard management rather than viewing batteries as harmless accessories.
Industrial Injury Guide covers additional information on industrial hazards and workplace safety, while our About Us page explains the site’s educational focus on injury prevention and safer industrial environments.
Building a Safer Lithium-Ion Battery Program
A practical battery safety program starts with knowing where lithium-ion batteries are used, charged, stored, maintained, and discarded. Workplaces can then evaluate the specific hazards associated with those activities.
Useful measures may include inspecting batteries and chargers, keeping charging areas orderly, following manufacturer instructions, controlling heat and ventilation, separating damaged batteries, training workers to recognize warning signs, and maintaining clear emergency procedures.
As battery-powered equipment becomes more common, these practices are increasingly relevant across manufacturing plants, warehouses, maintenance shops, construction operations, and other industrial environments.
Understanding lithium-ion battery hazards at work can help workers identify problems earlier and support safer decisions involving charging, storage, use, and disposal.