BlueSafe
Battery Safety Risk Assessment

Battery Safety Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
  • • Pre-filled Content – Ready to Deploy Immediately
  • • Customisable – Easily Add Your Logo & Site Details
  • • Includes 2 Years of Free Compliance Updates

Battery Safety Risk Assessment

Product Overview

Identify and control organisational risks associated with Battery Safety through a structured, management-level Risk Assessment that focuses on governance, planning, systems, and equipment selection rather than task-by-task procedures. This document supports executive Due Diligence, aligns with WHS legislation, and helps protect your business from compliance breaches and operational liability.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • Governance, WHS Duties and Legal Compliance: Assessment of officer due diligence, PCBU obligations, consultation duties, and integration of battery safety into your WHS management system.
  • Procurement and Design of Battery Systems and Equipment: Management of supplier selection, design specifications, compatibility, and lifecycle risk considerations for batteries, chargers, cabinets, and related plant.
  • Battery Storage, Facilities and Environmental Controls: Controls for dedicated storage areas, segregation of chemistries, ventilation, temperature management, spill containment, and fire/explosion prevention.
  • Systems for Battery Handling, Changing and Extraction: Assessment of handling methods, mechanical aids, manual handling risk, traffic interfaces, and engineered systems for safe battery change-out and extraction.
  • Electrical Isolation, Connection and Battery Replacement Systems: Protocols for isolation and lockout, connection standards, prevention of short circuits and arcing, and verification systems before energisation.
  • Charging, Servicing and Maintenance Management: Controls for charging regimes, charger location and ventilation, maintenance scheduling, inspection programs, and defect management for battery systems.
  • Use of Battery Testers, Diagnostic Equipment and Monitoring Systems: Assessment of equipment selection, calibration, safe use of diagnostic tools, and integration of monitoring data into maintenance and risk controls.
  • Training, Competency and Authorisation Systems: Frameworks for competency requirements, licence/authorisation processes, refresher training, and verification of competency for battery-related roles.
  • Emergency Preparedness, Incident Management and First Aid: Planning for thermal runaway, fire, chemical exposure, off-gassing, and electrical incidents, including emergency equipment, response procedures, and first aid provisions.
  • Contractor Management and Outsourced Battery Works: Systems for prequalification, scope definition, induction, supervision, and verification of contractor controls for installation, maintenance, and disposal activities.
  • Documentation, Labelling and Information Management: Management of SDS access, labelling of batteries and storage areas, record-keeping, inspection logs, and communication of critical safety information across the organisation.

Who is this for?

This Risk Assessment is designed for Business Owners, Officers, Safety Managers and Operations Leaders responsible for planning, approving, and overseeing battery systems, storage, charging and maintenance across their organisation.

Hazards & Risks Covered

Hazard Risk Description
1. Governance, WHS Duties and Legal Compliance
  • • Lack of clear organisational accountability for battery-related WHS risks, leading to gaps in oversight and decision‑making
  • • Failure to identify and comply with WHS Act 2011, WHS Regulations 2011 and relevant Codes of Practice (e.g. Hazardous Chemicals, Managing Electrical Risks, Managing Risks of Plant)
  • • Inadequate integration of battery safety (including handling, charging, storage and testing) into the PCBU’s WHS management system
  • • No formal process to identify reasonably foreseeable battery hazards across all business units (e.g. warehousing, field service, workshop, storage sites)
  • • Poor change management when introducing new battery technologies, chemistries (e.g. lithium‑ion, lead‑acid, NiMH), plant, or storage systems
  • • Inadequate consultation with workers and health and safety representatives on battery risk controls and procedures
  • • Insufficient monitoring and review of battery‑related incidents, near misses, and non‑conformances, allowing systemic issues to persist
2. Procurement and Design of Battery Systems and Equipment
  • • Selection of inappropriate battery chemistries or capacities for the application, increasing risk of thermal runaway, off‑gassing, or mechanical failure
  • • Purchase of battery chargers, battery banks, storage systems and test equipment that are non‑compliant with Australian standards or are poorly documented
  • • Lack of consideration of ergonomic and mechanical handling risks when specifying large industrial batteries (e.g. forklift, MEWP, UPS, motive power batteries)
  • • Inadequate design of battery rooms or battery storage areas (ventilation, separation distances, spill containment, fire rating, emergency access and egress)
  • • No specification of built‑in safety features (e.g. interlocks, emergency stop, insulation, polarity protection, over‑charge/over‑current protection, battery management systems)
  • • Insufficient integration between electrical design, fire systems design and WHS risk controls for large battery storage systems and battery banks
  • • Failure to specify clear documentation and labelling requirements from suppliers (SDS, technical manuals, installation instructions, emergency procedures, labelling of voltages and chemical hazards)
3. Battery Storage, Facilities and Environmental Controls
  • • Inadequate segregation of charged, discharged, damaged and waste batteries, creating risk of short‑circuit, fire or chemical exposure
  • • Poorly designed or overcrowded battery storage areas leading to blocked access, trip hazards and restricted emergency egress
  • • Insufficient ventilation in battery rooms or charging areas leading to accumulation of hydrogen gas or other hazardous vapours
  • • Inadequate control of ignition sources in areas where flammable gases may be present (e.g. open flames, non‑rated equipment, hot work)
  • • Lack of spill containment, acid‑resistant surfaces and appropriate clean‑up systems for lead‑acid or other corrosive battery types
  • • Storage of incompatible materials adjacent to batteries (e.g. flammables, LPG, oxidising agents, heat sources)
  • • Inadequate environmental protection measures leading to uncontrolled release of electrolyte or contaminated wash water to stormwater or soil
  • • Insufficient signage and delineation for high‑voltage or high‑energy battery banks and storage systems
4. Systems for Battery Handling, Changing and Extraction
  • • Manual handling of heavy batteries during change‑out, extraction or installation leading to musculoskeletal disorders or crush injuries
  • • Use of unsuitable lifting or extraction equipment for industrial batteries, causing dropped loads, impact or pinch injuries
  • • Uncontrolled movement of plant (e.g. forklifts, pallet movers) during battery change‑out due to inadequate isolation or restraint systems
  • • Lack of systematic procedures for handling damaged, leaking or swollen batteries, increasing risk of fire, chemical exposure or short‑circuit
  • • Inadequate supervision or competency verification for workers performing battery extraction, handling and replacement tasks
  • • Absence of standardised fixtures, guides or docking systems for battery trays, increasing risk of misalignment, cable damage or mechanical failure
5. Electrical Isolation, Connection and Battery Replacement Systems
  • • Inadequate isolation and lock‑out procedures when disconnecting and reconnecting industrial batteries leading to electric shock, arcing or short‑circuits
  • • Uncontrolled reconnection of high‑voltage or high‑energy battery packs resulting in arc flash, equipment damage or fire
  • • Poor management of polarity, earthing and bonding requirements in battery banks and battery storage systems
  • • Use of non‑standard, damaged or makeshift connectors and cables during battery replacement or installation
  • • Lack of formal testing and verification process after installation or replacement of battery packs and banks
  • • No clear delineation between electrical work (requiring a licensed electrician) and non‑electrical servicing tasks, causing workers to undertake tasks beyond their competency
6. Charging, Servicing and Maintenance Management
  • • Uncontrolled battery charging leading to over‑charging, overheating, thermal runaway or off‑gassing
  • • Use of incompatible or incorrectly configured chargers for specific battery types and capacities
  • • Poorly planned maintenance activities resulting in live‑work exposures or inadvertent energisation of plant connected to battery systems
  • • Lack of systematic inspection and testing of chargers, cables, connectors and battery management systems
  • • Inadequate management of electrolyte levels, vent caps and corrosion in lead‑acid batteries, increasing risk of failure and chemical exposure
  • • No standardised servicing intervals or maintenance records for critical battery banks (e.g. emergency, UPS, fire systems, BESS)
7. Use of Battery Testers, Diagnostic Equipment and Monitoring Systems
  • • Use of non‑compliant or poorly maintained battery testers leading to inaccurate results and unsafe decisions about battery condition
  • • Inadequate procedures for safe connection and disconnection of test instruments to live battery systems
  • • Insufficient training or competency in interpreting test results (e.g. capacity, internal resistance, cell balance) leading to continued use of unsafe batteries
  • • Data from monitoring systems (e.g. BMS alarms, temperature and voltage logs) not systematically reviewed or acted upon
  • • Over‑reliance on test instruments without visual inspections or consideration of manufacturer limits and environmental conditions
8. Training, Competency and Authorisation Systems
  • • Workers and contractors undertaking battery handling, replacement, charging, servicing or testing without adequate knowledge of electrical and chemical risks
  • • No formal competency framework for battery‑related roles, leading to inconsistent skills and unsafe practices between locations
  • • Insufficient training on emergency response for battery fires, electrolyte exposure, thermal runaway or gas release
  • • Inadequate induction for new workers or contractors regarding site‑specific battery storage systems and battery banks
  • • Failure to maintain current training records, licences and authorisations for persons performing high‑risk battery tasks
9. Emergency Preparedness, Incident Management and First Aid
  • • Lack of clear emergency procedures for battery fires, off‑gassing, explosions, electrolyte spills or thermal runaway events
  • • Insufficient firefighting equipment and strategies tailored to different battery chemistries and configurations
  • • Poor coordination with emergency services regarding large battery storage systems or high‑risk battery banks on site
  • • Inadequate first aid arrangements for chemical burns, inhalation exposures and electrical injuries from battery incidents
  • • Failure to systematically investigate battery‑related incidents and near misses, resulting in repeated systemic failures
10. Contractor Management and Outsourced Battery Works
  • • Contractors performing battery installation, servicing, testing or disposal without alignment to the PCBU’s WHS procedures and risk controls
  • • Insufficient verification of contractor competency, licences and insurances for high‑risk battery and electrical tasks
  • • Poor communication and coordination between multiple PCBUs working around the same battery systems or battery storage areas
  • • Inadequate supervision of contractor activities during battery extraction, installation of battery storage systems, or set‑up of battery banks
11. Documentation, Labelling and Information Management
  • • Incomplete or outdated procedures for battery handling, changing, replacement, charging, servicing and testing leading to inconsistent practices
  • • Missing or illegible labels on batteries, battery banks, isolation points and chargers causing confusion and error
  • • Workers unable to readily access SDS, technical manuals, risk assessments and emergency information relating to batteries
  • • Poor configuration control of technical drawings and documentation for installed battery storage systems and battery banks
  • • Lack of clear record‑keeping for battery inspections, maintenance, tests, failures and disposals

Need to add specific hazards for your workplace?

Don't worry if a specific hazard isn't listed above. Once you purchase, simply log in to your Client Portal and add your own custom hazards at no extra cost. We take care of the hard work—creating the risk ratings and control measures for free—to ensure your document is compliant within minutes.

Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • Model Code of Practice – How to Manage Work Health and Safety Risks: Guidance on systematic risk management processes.
  • Model Code of Practice – Managing Risks of Hazardous Chemicals in the Workplace: Relevant where batteries present hazardous chemical and off‑gassing risks.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines.
  • AS IEC 62133 (series): Safety requirements for portable sealed secondary cells and batteries containing alkaline or other non-acid electrolytes.
  • AS/NZS 3000:2018 (Wiring Rules): Electrical installations – fundamental safety principles for associated electrical equipment and charging systems.
  • AS 2676 (series): Guide to the installation, maintenance, testing and replacement of secondary batteries in buildings.
  • AS 1940:2017: The storage and handling of flammable and combustible liquids – referenced where battery systems interface with flammable liquids and fire risk controls.
  • AS 3745:2010: Planning for emergencies in facilities – emergency planning and response for battery incidents.
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

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