Health and Safety ReportVolume 24, Issue 08

Although modern electric vehicles, or EVs, have been on Canadian roads since the early 2000s, the rechargeable lithium-ion batteries that power most electric motors are a relatively new workplace hazard for many industries.

First responders, tow truck operators, vehicle repair technicians, auto recyclers, and manufacturers are among those who may work with or around high-voltage electrical vehicle batteries, putting them at risk of injury or illness.

By identifying the hazards associated with lithium-ion batteries, and establishing safety practices to store, handle, dismantle, and transport them, employers can manage the risk to workers.

A high voltage hazard

Whereas the voltage of a hand-held power tool battery is about 18 to 20 volts, EV batteries weigh more than 450 kilograms and range from 200 to 800 volts, making them a significant handling and electrical risk to workers.

When damaged, such as in a car collision, high-voltage electrical systems have the potential to release energy. This discharge can put workers at risk of electric shock, electrical burns, and electrocution.

Damage, a crack, or a short circuit in a battery also has the potential to leak flammable electrolytes and chemical compounds. Hydrofluoric acid may be released, which is highly corrosive and toxic. Hydrofluoric acid can cause severe burns and is often lethal if inhaled.

In addition, a fire or explosion can occur when the battery overheats, causing an irreversible chemical chain reaction known as a thermal runaway.

A thermal runaway is an uncontrollable, self-heating event. This event occurs when heat generated by cells in one area of the battery spreads to other cells, resulting in extremely high temperatures. Once a thermal runaway event begins, the battery can generate heat very quickly.

Battery fires and explosions can cause burns and release toxic smoke and fumes, including hydrogen fluoride. Exposure to these chemicals can result in severe eye damage and respiratory issues, among other serious health concerns.

Plus, extinguishing lithium-ion battery blazes can be challenging because they are much more intense than fires fueled by combustible materials such as wood. Large battery fires create heat and are difficult to extinguish, and reignition is possible.

Sparking safety precautions

Workers may encounter damaged or compromised electric vehicle batteries during any stage of a vehicle’s recovery, including the repair and recycling processes. It is important for employers to identify all possible hazardous scenarios, assess the risk to their workers, and take every reasonable precaution to keep them safe under the circumstances.

Following the hierarchy of controls can help to address hazardous workplace situations. The most effective way to manage risk is to eliminate the source of exposure altogether. Developing battery technology with a lower risk of thermal runaway events would be ideal. Until then, elimination could involve removing a damaged electric vehicle from the worksite and storing it away from combustible materials. When that’s not possible, modify the worksite to store high voltage batteries in a designated storage area that manages the risk of fire and is ventilated to reduce irritating fumes from off-gassing.

It’s always good practice to make sure your workplace’s ventilation and fire protection systems comply with the legislation applicable to your jurisdiction, including occupational health and safety regulations, building codes, and fire codes. Installing barriers in your facility to suppress the spread of fire, as well as gas detection sensors to prevent the inhalation of chemical vapours also lowers risk. For smaller batteries, fire blankets and appropriate class extinguishers that are approved to put out lithium or lithium-ion fires may be used.

It’s essential to train workers on how to safely shut down energized vehicles, and how to store and dispose of their batteries. Developing an emergency response plan and first-aid measures are key to ensuring workers know what to do in the event of lithium-ion leaks, fires, explosions, and exposures.

Lastly, provide workers with the right personal protective equipment for the job, including electrical rubber insulating gloves and boots, face shields, and fit-tested respirators.

The road to ongoing battery safety

The good news is that with electric vehicle production rapidly growing, battery safety research and testing is also advancing at an accelerated pace. It’s a good idea for workplaces to stay informed and develop a comprehensive manual and training program tailored to battery safety practices.

While standard electrical safety measures can help, it’s important for workers to follow specialized protocols when working with electrical vehicles and their batteries, including manufacturer’s instructions and recommendations.

First responders, for example, should be trained on a standard response to electrical vehicle incidents. Response can include step-by-step guidance on how to safely de-energize electrical systems, and secure the vehicle, as needed. 

And because electrical vehicles are a newer technology, staying up to date on developing safety standards, regulations, and guidelines is vital to supporting the safest work environment possible. After all, the more you know about lithium-ion battery safety, the more precautions you can take as part of your overall health and safety strategy.

Resources 

• Electric Vehicles: Safety Hazards Associated with Working On or Around the Battery Checklist, Workplace Safety and Prevention Services
• Plugged into Safety: A Primer on the Hazards of Working with Battery Electric Vehicles, Workplace Safety and Prevention Services
• Batteries (EV), WorkSafeBC
• EV Guidelines, Automotive Retailers Association

Did you know small businesses in Canada have the same responsibilities as any other employer to protect their workers against injuries and illnesses?

That’s where our updated Health and Safety for Small Business online course can help. You will learn about your health and safety responsibilities, whether you’re a small business owner, manager, or health and safety committee member or representative.

You will also understand how to identify workplace hazards and risks, and how to develop an effective health and safety program.

Learn more about Health and Safety for Small Business.

CCOHS releases new podcasts each month to help you stay current and informed on workplace health, safety, and well-being in Canada. 

Sparking Courageous Conversations at Work

Holding courageous conversations in the workplace can help to advance equity, diversity, and inclusion. Learn how to start these discussions, and how they can foster greater understanding, connection, growth, and even healing. 

Listen to the podcast now.  

Encore Podcast: Understanding the Three Basic Rights of Workers

Every person employed in Canada has the right to a safe work environment. In this episode we discuss the three basic rights of all workers in Canada.

Listen to the podcast now. 

See the complete list of podcast topics or, better yet, subscribe to the series on iTunes or Spotify and don't miss a single episode.

We’re still accepting applications for the Chad Bradley Scholarship, but don’t wait too long, the deadline is August 31, 2024, at 11:59 p.m. EDT. 

Who can apply? Women enrolled in a post-secondary occupational health and safety program at a Canadian college or university, are eligible to win this $3,000 scholarship from CCOHS. You will need to submit a 500-800 word essay detailing why you are pursuing an education in occupational health and safety; your motivation and inspiration; what and how you expect to contribute to the field and/or safe work; and other achievements and activities that demonstrate a commitment to and involvement in your community, workplace, or school. 

Learn more about the scholarship, essay criteria, and how to apply: www.ccohs.ca/scholarships/cbradley/. 

Explore the changing world of work at CCOHS Forum, taking place May 27-28, 2025, in Calgary, Alberta. Registration is now open!  

Join us for a two-day national event designed to inspire you to take action on improving workplace health and safety. Leaders, changemakers, and subject experts representing government, labour, and workplaces will come together to share their knowledge and experience on current and emerging health and safety issues. 

Register now at the early bird rate and save. A student rate is also available. Space is limited, register early to avoid disappointment. 

Everyday tasks like turning keys can be difficult or even impossible for a person with carpal tunnel syndrome, a condition that affects the hand and wrist. Workers in some occupations may be at higher risk for the condition but there are precautions you can take to help protect them. Among the most common hand conditions affecting workers, it’s been linked to tasks like repetitive hand motions, awkward hand positions, strong gripping, mechanical stress on the palm, and vibration. These tasks are common among assembly line workers, agricultural workers, mechanics, cashiers and bakers.  

Those affected typically feel tingling, numbness, and pain in the thumb and fingers. More serious cases can cause weakness and loss of manual dexterity, resulting in difficulty with pinching and grasping. That’s why it’s important to prevent carpal tunnel syndrome.  

Tips to prevent carpal tunnel syndrome  

Redesign workstations: Set up workstations so they fit the size and proportions of the human body, accommodate most people who work in that area, and can be adjusted.  

Redesign tools: Make sure workers use tools that avoid awkward hand positions, strong gripping and other mechanical stresses. 

Redesign the job: Minimize tasks with repetitive motions and awkward wrist positions. Review the sequence of tasks to allow changes in body position and set a work-rest schedule to relieve muscles and tendons from mechanical stress. Add a variety of job duties and rotate tasks to avoid monotonous and repetitive patterns of work. Allow breaks for rest and stretching. 

Educate workers: Train workers on the risk factors that can contribute to carpal tunnel syndrome and encourage early reporting of symptoms. 

CCOHS Fact Sheets 

• Carpal Tunnel Syndrome
• Hand Tool Ergonomics – Health Hazards
• Job Design