OSHA Fact Sheet: Lithium-ion Safety in the Workplace | Help Center

OSHA Fact Sheet: Lithium-ion Battery Safety in the Workplace

Lithium-ion batteries power everything from phones and tools to electric vehicles and energy-storage systems. As their use grows, so do the safety risks in workplaces that make, store, charge, or recycle them.

These batteries combine flammable electrolytes and high stored energy, which can lead to fires, explosions, or toxic gas releases if damaged or improperly handled. Thermal runaway—a chain reaction triggered by heat, impact, or internal short-circuit—remains a major hazard.

Chemical concerns include exposure to lithium salts, metal oxides, and organic solvents such as ethylene carbonate and dimethyl carbonate. Many of these substances are flammable, corrosive, or toxic and may not yet have established exposure limits. Employers are encouraged to review alternative occupational exposure limits and apply control banding to manage unknown risks.

Safe design and management are essential. OSHA recommends applying the Hierarchy of Controls: eliminate hazards where possible, use engineering controls such as local exhaust ventilation and automated processes, and provide training and protective equipment for workers.

Additional good practices include:
• storing batteries in cool, dry areas away from flammable materials
• following manufacturer instructions for charging and maintenance
• limiting battery quantities in storage areas
• monitoring for flammable gases in large facilities
• using proper packaging and shipping methods under 49 CFR 173.185
• disposing of spent batteries through designated recycling programs

A strong safety and health management system with worker participation helps identify and address hazards before incidents occur.

As lithium-ion technology evolves, understanding and controlling its hazards protects workers and supports safer innovation in every industry. For more details on safe handling and prevention strategies, you can check out OSHA’s Fact Sheet on Lithium-ion Battery Safety.

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