Product Overview

Summary: This Lithium-Ion Battery Handling and Storage Safe Operating Procedure provides clear, practical guidance for managing lithium-ion batteries safely across Australian workplaces. It sets out step-by-step controls to prevent fires, thermal runaway, electric shock and environmental harm, while supporting compliance with WHS legislation and insurer expectations.

Lithium-ion batteries are now embedded in almost every workplace – from power tools, forklifts and UPS systems through to laptops, mobile devices and large-scale energy storage. While generally safe in normal use, damaged, incorrectly stored or poorly managed lithium-ion batteries can rapidly escalate into high-consequence events, including fires, explosions and toxic smoke. This SOP provides a structured, defensible approach to handling, charging, storing, transporting and disposing of lithium-ion batteries in line with Australian WHS expectations and contemporary fire safety guidance.

The procedure translates complex technical and regulatory requirements into clear actions for frontline workers, supervisors and managers. It addresses the full lifecycle of lithium-ion batteries on site: from receipt and inspection, segregation of damaged or suspect units, safe charging practices, and storage design (including fire separation and ventilation) through to emergency response and incident reporting. By implementing this SOP, businesses can demonstrate due diligence under WHS law, reduce the likelihood of catastrophic battery failures, and standardise safe practices across multiple sites, contractors and work groups.

This document is particularly valuable for organisations with high battery densities – such as warehouses, construction sites, workshops, data centres, transport depots, laboratories and retail outlets – where a single battery failure can lead to business interruption, asset loss and reputational damage. The SOP helps you embed consistent controls, support effective training and toolbox talks, and provide clear evidence of risk management for regulators, clients and insurers.

Key Benefits

• Reduce the risk of lithium-ion battery fires, thermal runaway and explosions through standardised handling and storage controls.
• Ensure alignment with Australian WHS legislation, fire safety guidance and insurer requirements for battery management.
• Protect workers, visitors and contractors from burns, electric shock, toxic fumes and smoke exposure.
• Standardise training and induction content so all staff understand how to safely handle, charge, store and dispose of lithium-ion batteries.
• Minimise costly downtime, asset damage and product loss arising from preventable battery incidents.

Who is this for?

• WHS Managers
• Operations Managers
• Warehouse and Store Supervisors
• Fleet and Asset Managers
• Electrical and Electronics Technicians
• Laboratory Managers
• Facilities and Property Managers
• EHS Coordinators
• Workshop Supervisors
• Logistics and Distribution Managers
• Battery Recycling and E‑waste Contractors
• Emergency Wardens and Fire Safety Officers

Hazards Addressed

• Thermal runaway leading to battery fire or explosion
• Ignition of nearby combustible materials from overheating batteries
• Electric shock from exposed terminals or damaged battery packs
• Short-circuiting due to improper storage or contact between terminals
• Toxic and corrosive fumes released during battery failure or fire
• Burns from hot battery surfaces, venting or ejected materials
• Mechanical damage from dropping, crushing or improper handling
• Environmental contamination from incorrect disposal or leakage
• Manual handling injuries from moving heavy battery packs or storage cabinets

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Battery Types Covered
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Guidance
• 5.0 Risk Management Overview for Lithium-Ion Batteries
• 6.0 Procurement, Receipt and Initial Inspection of Batteries
• 7.0 General Handling Requirements and Prohibited Practices
• 8.0 Safe Charging Practices and Charging Area Requirements
• 9.0 Storage Requirements (Segregation, Ventilation and Fire Protection)
• 10.0 Management of Damaged, Swollen or Suspect Batteries
• 11.0 Transport and Internal Movement of Batteries On Site
• 12.0 Housekeeping, Labelling and Inventory Control
• 13.0 Personal Protective Equipment (PPE) Requirements
• 14.0 Emergency Response: Overheating, Fire, Venting and Spills
• 15.0 Incident Reporting, Investigation and Corrective Actions
• 16.0 Training, Induction and Toolbox Talk Guidance
• 17.0 Inspection, Monitoring and Audit Checklist
• 18.0 Document Control, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant State/Territory variants)
• Work Health and Safety Regulations 2011 (Cth and relevant State/Territory variants)
• Safe Work Australia – Model Code of Practice: Managing risks of hazardous chemicals in the workplace
• Safe Work Australia – Model Code of Practice: Managing electrical risks in the workplace
• AS/NZS 3000:2018 Electrical installations (Wiring Rules)
• AS 1940:2017 The storage and handling of flammable and combustible liquids (referenced for separation distances and fire safety principles)
• AS 2419.1:2021 Fire hydrant installations (for fire protection design considerations, where applicable)
• AS 3745:2010 Planning for emergencies in facilities
• AS/NZS ISO 45001:2018 Occupational health and safety management systems – Requirements with guidance for use
• EPA and local environmental protection regulations for hazardous and e‑waste disposal (jurisdiction-specific)