Forklift Fueling Safety: Batteries, Gas, and Diesel Done Right
Fueling a forklift—whether charging batteries or refueling with gas, diesel, or propane—is a high-risk task that must be done with safety top-of-mind. OSHA enforces strict standards for these operations, and understanding the specific requirements for each fuel type is essential. In addition to regulatory compliance, ergonomic practices and the right PPE are vital for protecting workers from chemical exposure, fire hazards, and musculoskeletal injuries.
Battery-Powered Forklifts: Charging and Watering Safely
Electric forklifts are popular in warehouses due to their low emissions, but lead-acid batteries used in many models require careful handling. OSHA standard 29 CFR 1910.178(g) outlines specific requirements for battery charging areas, including provisions for fire protection, eye-wash stations, and ventilation.
Battery watering—adding distilled water to the cells—must be done after charging, not before, to avoid overflow of acidic electrolyte. Per 1910.178(g)(2), facilities must provide proper equipment for flushing and neutralizing spilled electrolyte. Operators must wear chemical-resistant gloves, goggles, and face shields to guard against acid splashes.
Additionally, charging areas must be free of ignition sources, as hydrogen gas can be emitted during the charging process (1910.178(g)(11)). Smoking is strictly prohibited in these zones (1910.178(g)(10)), and all battery handling must be performed using appropriate hoists or handling equipment to avoid strain injuries.
Forklifts with Compressed Gas (LPG/CNG)
Propane- and CNG-powered forklifts require operators to manage pressurized fuel cylinders. According to OSHA 29 CFR 1910.110, cylinders must be stored upright and secured against tipping. Additionally, engines should be stopped and operators dismounted during fueling.
Before connecting or disconnecting cylinders, operators should inspect them for leaks, rust, or damage. Frostbite from liquid propane is a common injury when gloves aren’t used, and sudden discharges can damage eyes. Appropriate PPE includes heavy-duty gloves, safety glasses or goggles, and long sleeves.
Ergonomically, propane tanks can weigh over 40 lbs. Training on proper lifting techniques or the use of lift-assist tools can reduce the risk of strains and sprains.
Diesel and Gasoline Forklifts: Refueling Protocols
While less common indoors due to emissions, internal combustion forklifts powered by diesel or gasoline remain common in outdoor operations. OSHA requires that refueling only occur in approved locations. The engine must be shut off during refueling, and care must be taken to prevent spills and overfilling.
Any spilled fuel must be cleaned immediately, and fuel-soaked rags must be disposed of properly to avoid fire risk. Operators should wear chemical-resistant gloves and eye protection, especially when handling gasoline, which can irritate skin and mucous membranes.
Training, Ergonomics, and Final Thoughts
Per OSHA 29 CFR 1910.178(l), only trained and certified operators may refuel or recharge powered industrial trucks. Training must cover specific fuel types, emergency procedures, PPE use, and the proper inspection of fueling components.
From an ergonomic standpoint, designing fueling areas with sufficient lighting, low lift heights, and easy access to equipment helps reduce fatigue and injury. Employers should also implement frequent inspections and clear signage to reinforce safe procedures.
By following OSHA standards and integrating ergonomic and chemical safety practices, forklift fueling becomes a safer and more efficient part of daily operations.
