Preventing Fire and/or Explosion Injury from Small and Wearable Lithium Battery Powered Devices

Safety and Health Information Bulletin SHIB 06-20-2019

Introduction

• Small, wearable electronic devices in workplaces rely on lithium batteries with high energy density.
• Safe when designed and used properly, but can cause injuries due to:
  • Design defects
  • Low-quality materials
  • Incorrect assembly
  • Improper use or recharge
  • Damage
• 25,000+ overheating/fire incidents reported over five years involving lithium batteries.
• Importance of using tested and certified batteries, chargers, and equipment.
• Risks for workers wearing lithium-powered devices if batteries catch fire or explode.

How Lithium Batteries Work

• Composed of lithium cells (positive/negative electrode, separator, electrolyte solution).
• Store/release power by converting chemical potential energy to electrical energy using lithium ions.
• Types:
  • Lithium-ion batteries: Rechargeable, uses ionic lithium, powers phones, laptops, cameras.
  • Lithium-metal batteries: Non-rechargeable, uses lithium metal electrodes, powers watches, calculators.

Hazards

• Safe unless defective or damaged.
• Potential for fire/explosion if:
  • Physically impacted (dropping, crushing)
  • Exposed to high temperatures
  • Charged improperly
• Thermal runaway: Chain reaction causing heat release.
• Chemical and combustion reactions possible.
• By-products can include carbon monoxide, hydrogen, and hydrocarbons.

Prevention

• Ensure testing and certification by recognized labs (e.g., UL 2054).
• Follow manufacturer’s instructions (use, storage, charging).
• Use approved batteries and chargers.
• Remove batteries from chargers once fully charged.
• Store in dry, cool places.
• Inspect for damage (bulging, leaking, smoking).
• Use fire-resistant containers for disposal.
• Follow guidelines for extinguishing small battery fires.

Training

• Workers should be trained to:
  • Verify NRTL certification.
  • Identify defective batteries.
  • Remove defective batteries/devices.
  • Respond to overheating or leaking devices.
• Emergency action plans should include lithium-related procedures.
• Communicate hazards and train workers on risks.

Resources

• OSHA provides various topic pages and guidance documents.
• Resources include NFPA assessments, Department of Energy guides on battery function.

Additional Information

• OSHA offers compliance assistance with no-cost consultations.

Workers' Rights

• Right to safe working conditions and training.
• Right to file complaints without retaliation.
• Rights under the Consumer Product Safety Improvement Act.

Contact OSHA

• OSHA sets standards and provides training for safe workplaces.
• Contact via phone or online for more information.

Legal and Compliance

• OSHA standards are advisory, not regulatory.
• Employers must comply with safety and health standards.
• Violations can result in citations based on recognized hazards.