Optimizing Battery Charging Areas for Safety and Efficiency

Many times, warehouse design focuses on aisles first, and battery charging areas get added as an afterthought, in whatever leftover space is available. Unfortunately, these are typically not near lift truck traffic patterns or necessary infrastructure and end up adding unnecessary travel time.

There is a better way. When designers plan designated battery areas or rooms based on projected workflow and existing infrastructure, they can keep lift trucks in the aisles longer while reducing total operational costs

Establishing a well-designed battery charging area is essential for maintaining safety and efficiency in facilities that utilize electric forklifts and other battery-powered equipment. Proper planning of these areas not only ensures compliance with safety regulations but also enhances workflow and reduces operational costs.

Strategic Location for Minimal Disruptions

One of the most critical factors in setting up a battery charging area is its location. The charging area should be strategically placed to minimize disruptions in traffic flow. Integrating it into existing lift truck routes can help reduce unnecessary travel time, keeping equipment operational for longer periods. The battery area should be located so travel between the facility’s main working areas is efficient, and the area should have appropriate electrical service from a nearby main power feed. 

Ensuring Safety Compliance

Safety compliance is another key consideration. The Occupational Safety and Health Administration (OSHA) mandates specific requirements for battery charging stations, such as adequate ventilation to disperse flammable hydrogen gas emitted during charging. Additionally, emergency equipment, including fire extinguishers, eyewash stations with a minimum 15-minute flow, and clearly marked communication devices, should be readily accessible. The area needs space to store personal protective equipment like acid resistant face shields, goggles, aprons, and gloves. You’ll also need maintenance equipment and spill kits in case of battery acid leaks. A strict no-smoking policy must also be enforced to prevent ignition of flammable gases. These measures align with OSHA standards, including 29 CFR 1910.305(j)(7) and 1926.441.

Implementing a Modular Design

A modular design approach can provide flexibility and scalability for charging areas. By using modular charging stations, facilities can more easily upgrade or adjust their setup as equipment needs change. This approach allows businesses to stay adaptable while maintaining efficiency. Build a forklift battery charging area right where you want it in your existing warehouse, build it around an existing lift-assist device, or design your charging station into an entirely new space. Because modular systems can be customized to suit a range of shapes, sizes, and capabilities, it’s easy to get exactly the area you need.

Modular systems meet battery charging area safety requirements. The components are available in a range of code-compliant options to meet fire ratings. To accommodate safety features like an eyewash or emergency shower station, you can specify water-resistant wall panel options.

There are tax benefits to going modular as well. Modular panelized wall systems are often considered tangible property so your forklift battery charging area will depreciate in just 7 years, rather than the 39 years typical for traditional construction. With modular construction, you can get the best, safest forklift battery charging station at an affordable cost.

Modular warehouse solutions from Morrison

Come to Morrison for solutions when it’s time to add a battery charging area, in-plant office space, or other modular structure to your facility. At Morrison Industrial Equipment, we provide expert, professional, warehouse design and installation of modular solutions, pallet racking, storage systems and more. Contact us to learn more!