Lithium-ion batteries

Information for persons conducting a business or undertaking (PCBUs) on managing the safety risks of lithium-ion batteries.

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What are lithium-ion batteries

A lithium-ion battery is an energy efficient rechargeable battery with high energy density, long cycle life and long shelf life.

Lithium-ion batteries are commonly used in:

  • motor vehicles, e-bikes and e-scooters
  • laptops, mobile phones, handheld game consoles, digital cameras, torches and toys
  • medical instruments such as hearing aids, ECG monitors and dosage dispensers
  • construction and maintenance
  • industrial equipment such as forklifts and battery powered hand tools
  • bulk energy storage facilities.

What to do in an emergency

In the event of a fire or explosion:

  • do not attempt to put out the fire
  • evacuate the area
  • call emergency Triple Zero (000) immediately.

Notify SafeWork NSW

If there is a serious injury or illness, a death or a dangerous incident caused by a lithium-ion battery, PCBUs must report it to us immediately on 13 10 50. This enables SafeWork NSW to investigate the incident and take appropriate action to identify the cause and potentially assist in the prevention of future incidents and/or injuries.

An incident involving lithium-ion batteries can lead to a number of potentially dangerous incidents that must be notified, even if no one is injured, including an uncontrolled implosion, explosion or fire.

Learn more about incident notification.

Risks of lithium-ion batteries

Lithium-ion batteries can pose health and safety risks that need to be managed effectively.

Fire and explosion hazard

Lithium-ion batteries have the potential to catch fire or explode if not handled, stored, or charged correctly. This can result in property damage, injuries, and even fatalities.

Chemical exposure

Lithium-ion batteries contain chemicals and materials that can be harmful if inhaled or exposed to skin or eyes.

Electrical hazard

Lithium-ion batteries can deliver a significant amount of electrical energy, which can pose a shock hazard if mishandled.

Storage and handling risks

Improper storage and handling of lithium-ion batteries can lead to physical damage, short circuits, and other safety hazards.

Causes of lithium-ion battery failure

If lithium-ion batteries fail, energy is rapidly released which can create fire and explosions. Failing lithium-ion batteries may release highly toxic fumes and secondary ignitions even after the flames have been extinguished.

Thermal runaway

A chain reaction that can lead to overheating, fire, and even explosion. Thermal runaway can be triggered by factors such as overcharging, physical damage, manufacturing defects, or exposure to high temperatures.

Short circuiting

When positive and negative terminals of a lithium-ion battery contact each other, short circuiting can result. This causes a rapid discharge of energy, potentially leading to overheating, fire, or explosion.

Overcharging

Overcharging causes stress on the internal components and leads to thermal runaway.

Physical damage

Physical damage includes puncturing or crushing. This can compromise the integrity of the internal battery components and lead to short circuits, thermal runaway, and other safety hazards.

Manufacturing defects

While rare, manufacturing defects can lead to internal short circuits, thermal runaway, and safety hazards. It's important to purchase batteries from reputable manufacturers to minimize the risk of defects.

How to safely use lithium-ion batteries

Managing the risk of lithium-ion battery fires is crucial. PCBUs and workers can help mitigate the risk of a lithium-ion battery fire by following these basic guidelines.

Handling and storage

Ensure you:

  • follow the manufacturer’s guidelines for handling and storage
  • store lithium-ion batteries in a cool, dry place away from direct sunlight, heat sources, and flammable materials
  • regularly check the condition of the batteries for any signs of damage or swelling and discontinue use if you notice any abnormalities.

Charging

Ensure you:

  • use chargers specifically designed for the battery type and voltage
  • do not leave batteries charging unattended or for long periods
  • never use damaged batteries
  • purchase batteries and chargers from reputable sources.

Disposal

Lithium-ion batteries cannot be placed into home garbage or recycling bins. They can cause fires during waste collection, transport, handling, and processing.

Small, undamaged batteries (not swollen, punctured, or leaking) can be safely disposed of at a battery recycling drop off point. It is recommended that battery terminals are taped over with clear adhesive tape before placing the battery carefully (without dropping it) into a battery recycling collection bin.

For battery recycling and safe disposal requirements and information:

Transport

Lithium-ion batteries are classified as a Class 9 Dangerous Good. When transporting lithium-ion batteries you must follow the requirements of the Australian Dangerous Goods Code (ADG Code).

Handling damaged lithium-ion batteries

Storing and transporting end of life and/or damaged lithium-ion batteries requires careful handling to minimise the risk of any safety hazards.

Ensure:

  • damaged batteries are isolated from other materials to prevent potential short circuits or further damage
  • damaged batteries are stored:
    • in suitable containers or a fire-resistant bag designed for battery storage and as per manufacturers guidelines
    • in a cool, dry place away from direct sunlight and sources of heat and in a well ventilated area to disperse any gases that may be emitted during a fire
  • containers or packaging that hold damaged lithium-ion batteries are clearly labelled to alert others to the potential risks associated when handling them
  • you follow the guidelines set forth by regulatory authorities, such as the EPA
  • you have a clear plan in place for handling emergencies involving damaged lithium-ion batteries, including procedures for containing fires or spills
  • that personnel involved in handling damaged batteries are trained in emergency response protocols.

If you are unsure about the proper procedures for handling damaged lithium-ion batteries, seek guidance from experts or regulatory authorities in your area, such as SafeWork NSW, Fire & Rescue NSW, Environmental Protection Authority (EPA), local council.

When packing damaged lithium-ion batteries for transport:

  • isolate each battery to prevent contact
  • wrap batteries in non-conductive, fire-resistant material
  • use sturdy, non-metallic packaging
  • include absorbent material for leaks
  • ensure ventilation if gases may be emitted
  • label packaging as containing damaged lithium-ion batteries
  • provide emergency response information
  • securely seal packaging to prevent movement
  • keep accurate documentation
  • follow regulations like the ADG Code.

Know your WHS duties

PCBUs that provide e-bikes for use at the workplace must ensure the device complies with current safety standards.

WHS legislation places obligation on a person conducting a business or undertaking (PCBU) to manage a known risk to health and safety of its workers and others.

PCBUs that use battery powered plant and equipment must assess the risk and must implement control measures including but not limited to the safe use, storage and handling of lithium-ion battery powered plant.

While the WHS legislation does not explicitly state provisions related to lithium-ion battery safety, it encompasses broader principles and requirements that can be applied to manage the risks associated with lithium-ion batteries.

Workplaces are responsible for identifying hazards and implementing suitable controls to ensure the health and safety of workers.

Below are general considerations that may apply in the context of lithium-ion battery safety.

Risk assessment

PCBUs must carry out risk assessments to identify hazards and evaluate risks to worker health and safety. The risk assessment applies to the use, handling, and storage of lithium-ion batteries.

Safe work procedures

PCBUs must develop safe work procedures for handling and using lithium-ion batteries. These procedures should include guidelines for storage, charging, transportation, and disposal. The procedures should also consider the specific characteristics and risks associated with lithium-ion batteries.

Training and information

PCBUs must provide appropriate training and information to workers regarding the hazards and risks associated with lithium-ion batteries. This should include control measures and safe work practices to be followed.

Personal protective equipment (PPE)

To mitigate risks associated with lithium-ion batteries, PCBUs are required to provide PPE to workers and ensure they use it. PPE includes gloves or protective clothing when undertaking maintenance and/or installation.

Emergency response

PCBUs must put appropriate emergency response plans in place, including incidents leading to the serious injury or illness of a person involving lithium-ion batteries, such as fires or leaks.

PCBUs must also ensure they are providing adequate and appropriate first aid facilities for workers and others.

Safe systems of work

PCBUs must develop and implement a system for the inspection and maintenance of lithium-ion battery powered plant, such as hand tools, buses, forklifts and bulk battery installations.

Consult with workers and others

PCBUs must consult with workers and others on the hazards and risks whilst using, handling and storing lithium-ion batteries.

It is crucial to consult with experts in fire prevention, or hazardous materials management to develop a comprehensive emergency plan tailored to your specific needs.

Further information is available at Fire & Rescue NSW or call SafeWork NSW on 13 10 50.

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