Keywords: LiFePO4 handling safety, lithium battery loading guidelines, storage battery unloading, forklift handling lithium batteries, battery transport safety.
Introduction
Improper loading or unloading can cause serious damage to LiFePO₄ storage batteries. Physical impact, crushing, or dropping batteries may result in internal short circuits or BMS damage. This article provides a comprehensive guide to safe handling procedures.
1. Pre-Handling Inspection Checklist
Before moving the batteries, ensure:
✔ Packaging is intact
✔ UN labels are clearly visible
✔ No signs of swelling or leakage
✔ Pallets are stable
✔ Battery SOC is within 20–40%
Any damaged battery must be isolated immediately.
2. Forklift and Manual Handling Guidelines
Using a Forklift
- Always lift the pallet from the center
- Do not tilt the pallet during movement
- Avoid sudden braking or turns
- Never place forks directly under battery casing
- Keep batteries upright at all times
Manual Handling
- Use two-person lifting for modules
- Wear insulated gloves
- Avoid touching terminals
- Do not stack batteries manually
3. Avoiding Mechanical Shock and Vibration
Even with vibration-resistant packaging, excessive shock may:
- Crack internal cell structure
- Loosen terminals or busbars
- Damage the BMS
To minimize risk:
✔ Use shock-absorbing pads
✔ Transport pallets with slow movement
✔ Maintain clean and flat warehouse floors
4. Stacking and Storage Precautions
- Maximum stacking height: 1.5–1.8 meters depending on carton strength
- Always follow “This Side Up” arrows
- Prevent compression by heavier cargo
- Keep flammable materials away
5. Emergency Response in Case of Accidental Drop
If a battery falls or suffers severe impact:
- Isolate the area
- Do not attempt to charge or use the battery
- Monitor for 2 hours for heat or smoke
- Record the serial number
- Contact the manufacturer for further evaluation
Conclusion
Proper handling is essential to prevent mechanical damage and ensure safe transport of LiFePO₄ energy storage batteries. Following standardized procedures greatly reduces the risk of accidents during logistics operations.