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This Guide gives basic safety principles for the safe storage, use, transportation and disposal of portable batteries, though it mainly considers the safety of lithium-ion (Li-ion) rechargeable ones which, due to their high energy density, have become the most commonly used type by productions.

Those who want more detailed safety information, including of other battery types, should consult the information given via the links provided, particularly the Ö÷²¥´óÐã’s Electrical Guidance Note 18: Batteries – Safe Use, Maintenance and Disposal. 

What Can Go Wrong?

• Fire / explosion â€“ can result if the terminals are short-circuited, the battery is incorrectly charged or damaged in some way as to create internal short-circuits (leading to ‘thermal runaway’). Also, some battery contents are also corrosive / toxic.
• Electric shock â€“ though not a significant risk from low voltage batteries, it can arise from mains voltage charging equipment which is faulty or used incorrectly.
• Battery failure â€“ can lead to significant personal safety risks if they power equipment used in potentially life-critical situations (e.g. sat phones, GPS, PLBs, medical diagnostic equipment).
• Underestimation of risk â€“ due to their reliability and low voltage, batteries are often regarded as ‘safe’, which can lead to complacency in use; but the ever higher energy-density of rechargeable batteries can present significant risks should a fault occur.

Legal/Ö÷²¥´óÐã Requirements

• General legal requirement to ensure all electrical equipment provided is suitable for use, maintained in a suitable condition and properly used.
• IATA has imposed strict legal requirements for the transportation of certain battery types on all commercial passenger aircraft.

Control Measures

Storage and Disposal of Batteries

Product safety information â€“ follow manufacturer’s guidance with regard to safe battery storage, typically avoidance of conditions which could damage the battery or cause faults, including:

• avoidance of impacts, which can cause unseen internal damage (internal short-circuits)
• prevent short-circuits across their terminals – avoid storing with other metal objects (including other metal cased batteries), use non-metal containers for storage / transport
• keep within designated temperature range – keep out of direct warm sunlight
• avoid immersion
• avoid leaving batteries in equipment for prolonged periods e.g. at end of shoot – any leakage over time can damage terminals and the equipment itself, and if the battery fully discharges its cells can be irreversibly damaged.

Damaged / faulty batteries - batteries which show signs of damage or faults should be removed from service and appropriately disposed of to prevent inadvertent re-use. Signs of damage include bulging or splitting of case, signs of electrolyte leaks, corrosion on terminals, excessive heating of casing or resistance to charging.

Disposal â€“ check with the manufacturer’s instructions and Ö÷²¥´óÐã Environmental Policy. Most Ö÷²¥´óÐã buildings have collection points for the disposal or recycling of unwanted batteries (rechargeable and non-rechargeable). Many batteries contain hazardous chemicals (typically heavy metals and corrosive solutions) and have a crossed-out wheelie bin symbol to indicate that they must not enter the general waste collection. Never incinerate a battery. Where possible and safe to do so, fully discharge a battery before disposal.

Charging and Using Batteries Safely

User competence â€“ those who select and use batteries must work to the manufacturer’s safety guidelines and any relevant safe systems of work. The battery must be suitable for the equipment e.g. some rechargeable batteries may not maintain the required voltage levels for normal operation, and when connecting batteries, make sure the terminals don’t get mixed up. These requirements become particularly important where the batteries, their chargers or the equipment used are unfamiliar, or when the mains supply voltage is different to that for which the charger was designed (i.e. when overseas). It is not unknown for faulty or incorrectly charged batteries or charging leads to catch fire or explode (see Incident Lesson in Useful Documents).

Charging â€“ ensure you only use the correct charger for rechargeable batteries. Batteries vary in their required charging rates, with battery damage possible unless the charger is sophisticated enough to sense the battery type and deliver an appropriate charging routine. Never try to charge a battery which is damaged / known to be faulty. Do not try to charge Ni-Cad batteries that are very cold, as this can cause them to explode. Battery chargers can get hot – make sure they have a clear flow of air around them and do not place them on something which could catch fire on heating. Make sure the battery charger is designed for (or can be switched to) the voltage of the mains supply being used. If charging lead acid batteries, make sure this is done only in a well ventilated area to prevent build up of explosive gases.

Charger condition â€“ before use, inspect the battery charger for any signs of damage or faults – do not use if damaged / faulty. Do not use battery chargers outdoors where they could become wet. Mains powered battery chargers (and any extension leads) must have an in-date portable appliance test (PAT). Prior to connecting to location mains supplies, use a socket tester to confirm the supply has the correct polarity and effective protetective connection ('earth').

Operating life â€“ for rechargeable batteries, try to adopt a use and recharging cycle that best preserves battery condition and life – for example, Li-ion batteries are best stored with around 50% charge remaining. For potentially life-critical equipment in remote locations (e.g. GPS, Satellite phone, EPIRB, etc.), make sure the batteries are able to withstand, or are protected from, any particular environmental stresses e.g. extremes of temperature, water ingress, etc.

Fire - should a fire occur in a Li-ion battery, without putting yourself at risk of injury, you should quickly place the battery / equipment on a non-combustible surface and away from other materials which could catch fire. Foam, wet chemical or carbon dioxide extinguishers can be used and, in extremes, even water can be used to slow the spread of the fire by cooling materials around the battery.  

Safe Transportation of Batteries

Transporting spare batteries â€“ as for ‘Storage’ above, all batteries should be packed for transportation so as to minimise the risk of creating short-circuits between terminals - avoid packing with loose metal items, in metal storage containers or with charging leads connected. Also, avoid giving them heavy impacts.

Transport on airlines â€“ due to the risk of fire / explosion from accidental short-circuit of high energy-dense batteries (particularly Li-ion), the aircraft industry has imposed strict limitations on their carriage in commercial aircraft (see Recommended Links). The following rules now apply in relation to the carrying of Li-ion batteries:

• Must be carried as hand luggage (not hold luggage), though due to the bomb threat, the UK government has announced a cabin baggage ban on laptops and tablets on direct flights to the UK from Turkey, Lebanon, Jordan, Egypt, Tunisia and Saudi Arabia
• Airline prior approval required to carry any Li-ion batteries in excess of 100Wh capacity (Amp hours x voltage)
• Batteries under 100Wh capacity may be carried within electronic devices, but any batteries of greater capacity, or carried free in hand luggage, must be protected from accidental short-circuit i.e. terminals covered with insulating tape, batteries stored in a strong plastic or other suitable protective bag / case (ideally in the suppliers packaging)
• A maximum of 4 batteries per person may be carried for those under the 100Wh limit; a maximum of 2 per person for those over this limit, up to a maximum permitted capacity of 160Wh
• In-flight power supplies should not be used to charge batteries.

Division Specific Issues

• No Division specific issues.

FAQs/Did you know?

• No FAQs.