Battery Safety Risk Assessment

Activities covered include

Define battery safety responsibilities, approvals and review arrangements
Inspect, maintain, report, tag and quarantine batteries, chargers and related systems
Monitor battery inventories, storage conditions, emergency readiness and current instructions

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100% Compliant with Australian WHS Acts & Regulations
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Product Overview

This risk assessment covers battery safety arrangements across governance, consultation, procurement, competency, storage, charging, inspection, maintenance, contractor management and emergency planning. It supports planning and risk management by helping businesses identify battery-related hazards, communicate controls and review how arrangements are working.

Activities & Risks Covered

This assessment addresses activities and risks including:

Define battery safety responsibilities, approvals and review arrangements
Consult workers, representatives and contractors about battery hazards and incidents
Review batteries, chargers, leads and accessories before procurement or replacement
Provide training, supervision and awareness for battery use, charging and inspection
Plan battery storage and charging areas, including ventilation and separation needs
Inspect, maintain, report, tag and quarantine batteries, chargers and related systems
Coordinate battery-powered equipment and charging arrangements with contractors
Prepare for battery fire, thermal runaway, smoke, electrolyte exposure and evacuation events
Report, investigate and follow up overheating, damage, charging faults and near misses
Monitor battery inventories, storage conditions, emergency readiness and current instructions

Who is this for?

Suitable for contractors, workers, supervisors, managers and businesses that use, charge, store, inspect or manage batteries.

Activities & Hazards Covered

Activity	Potential Hazards
Governance	No defined battery safety standard, accountabilities or approval process across the business Battery risks not captured in enterprise risk registers, change management or management review Officers and managers do not verify that charging, storage and handling systems remain safe and compliant
Consultation	Workers, HSRs and contractors are not consulted on battery hazards, incidents or proposed controls Lessons from overheating, damage, charging faults and near misses are not shared across teams Battery controls are developed without considering how work is actually done on site
Procurement	Batteries, chargers or accessories are purchased without checking suitability, compatibility or manufacturer information Non-approved or mismatched chargers, leads and replacement batteries are introduced into service Procurement does not consider hazardous chemical information, storage limits, ventilation needs or emergency implications
Competency	Workers use, charge or inspect batteries without suitable training or supervision Supervisors cannot recognise damaged, swollen, leaking or overheating batteries or escalating failure signs Emergency response capability is weak because workers do not understand site procedures or reporting expectations
Storage and Charging Systems	Charging and storage areas are poorly designed, inadequately ventilated or exposed to ignition sources Battery systems are used for purposes outside their design limits or in unsuitable environments Incompatible materials, damaged units, excess quantities or combustible materials are not controlled in storage areas
Inspection and Maintenance	No inspection and preventive maintenance system for batteries, chargers, electrical protection or ventilation Damaged batteries remain in service because reporting, tagging and quarantine processes are unclear Testing, maintenance and repair are done by unsuitable persons or without manufacturer instructions
Contractor Management	Contractors bring battery-powered plant, chargers or temporary systems on site without review of site controls Responsibilities between the host PCBU and contractors are unclear for charging locations, emergency response and defect management Contractor work introduces ignition sources, incompatible equipment or unapproved battery storage arrangements
Emergency Planning	Emergency plans do not address battery fire, thermal runaway, toxic smoke, electrolyte exposure or evacuation triggers Emergency equipment is unavailable, unsuitable, unmaintained or workers do not know when to use it Large lithium battery quantities are stored or charged without documented escalation to emergency services planning
Incident Reporting and Investigation	Near misses such as overheating, charger faults, dropped batteries or smoke events are not reported or investigated Investigations focus on worker error instead of root causes such as poor procurement, weak supervision or inadequate systems Corrective actions are not tracked to completion or shared across the business
Monitoring and Review	Battery controls are not checked to confirm they remain effective as work changes Audits do not cover battery inventories, storage conditions, emergency readiness or contractor compliance Documents become outdated and workers rely on superseded instructions or missing SDS

Need to tailor this risk assessment?

Use the BlueSafe Portal to add site-specific activities, hazards, controls, responsibilities and review details before the assessment is put into use.

Acceptance Guaranteed: If your client or principal requests changes during document review, BlueSafe will help revise the document at no extra cost and support resubmission until it is accepted.

Legislation & References

The template records model guidance used to inform the documented controls. Applicable WHS/OHS laws and adopted Codes vary by state or territory, so confirm the current local requirements when tailoring the assessment:

Model guidance: Model Code of Practice: How to manage work health and safety risks — 5. Step 4 — How to review controls; p. 27.
Model guidance: Model Code of Practice: Managing risks of hazardous chemicals in the workplace — 2.1 How to identify which chemicals are hazardous; p. 15.
Model guidance: Model Code of Practice: First aid in the workplace — 3. First aid equipment, facilities and training; p. 12.
Model guidance: Model Code of Practice: Managing risks of plant in the workplace — Assessing plant risks — work practices and procedures; p. 20.
Model guidance: Model Code of Practice: Managing electrical risks in the workplace — 2.1 Identifying the hazards; p. 14.
Model guidance: Model Code of Practice: Work health and safety consultation, cooperation and coordination — 3. What is effective consultation?; p. 13.

Standard Risk Assessment Features (Click to Expand)

Activity-specific hazard identification and control measures
Initial and residual risk ratings
Assigned responsible persons for each activity
Risk matrix and assessment classification
Review, monitoring and sign-off fields
Site-specific customisation before use

Suitable for Industries

Building and ConstructionTransport and LogisticsManufacturing and ProductionWarehousing and DistributionElectrical and SolarAutomotive and MechanicalMining and Resources

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