Professional fire protection in loading areas is essential to reliably protect employees, operations, and investments. When charging forklift batteries, hazards arise from hydrogen gas, electrical defects, and thermal stress. Implementing clear protection concepts reduces risks while simultaneously complying with all legal requirements.
Relevance and risks
Why is fire protection critical here?
When charging lead-acid batteries, hydrogen is released, which is highly explosive even in small quantities. Defective chargers, damaged cables, or improper handling can also cause fires.
What is the critical limit?
The lower explosion limit of hydrogen is 4 percent by volume. Therefore, charging areas must be designed to ensure that this value is never reached, even during intensive use.
Legal framework and standards
What rules apply?
The central standard for charging areas of traction batteries is DIN EN 62485-3. In addition, the Technical Rules for Workplaces regarding ventilation and the DGUV regulations for industrial trucks are relevant.
What does this mean for operators?
Operators are required to set up loading areas safely, document risk assessments, and have their measures regularly reviewed. Failure to do so risks fines and liability.
Planning of loading areas
Location and separation
Charging zones should be separate, dry, and free of flammable materials. A minimum distance of about half a meter between battery cell openings and potential ignition sources is also important.
Ventilation and gas extraction
To prevent hydrogen from accumulating, adequate ventilation is essential. It must be designed to keep the gas concentration safely below the explosion limit.
Air flow in practice
Ideally, fresh air is introduced near the floor, while exhaust air is discharged higher up. This prevents dangerous gas buildup in the immediate loading area.
Technical safety
Selecting and operating chargers
Only chargers approved for the battery type may be used. They must be checked regularly and equipped with overload and temperature monitoring to detect defects early.
Electrical installations
Cables must be mechanically protected, laid neatly, and secured with suitable protective devices. Open wires or loose cable connections must be avoided at all costs.
Fire protection technology
Extinguishing agents for loading areas
CO₂ and powder extinguishers are suitable for electrical fires. However, CO₂ should only be used with caution in small spaces, as high concentrations can displace breathable air.
Treat lithium-ion batteries differently
Different rules apply in mixed fleets with lithium-ion batteries . In the event of a fire, water or special coolants are used, as CO₂ or powder are ineffective.
Detection and automatic systems
For larger loading areas, a fire alarm system that reacts to smoke or heat buildup is recommended. Automatic extinguishing systems can ensure rapid fire extinguishing and minimize damage.
Organization and instruction
Access, marking, order
Loading areas must be clearly marked and accessible only to authorized personnel. A tidy environment reduces fire hazards and ensures safe escape routes.
Training and operating instructions
Employees should be regularly trained in the safe use of chargers, the recognition of malfunctions, and emergency procedures. Posters with clear instructions provide additional support.
Tests and documentation
Recurring inspections
Charging devices, ventilation systems, and fire protection equipment must be inspected at regular intervals. This allows for early detection and remediation of defects.
Evidence management
Complete documentation of all inspections and training sessions is mandatory. This serves as proof for authorities and insurance companies and demonstrates the effectiveness of the protective measures taken.
Practical check – core measures at a glance
- Keep hydrogen concentration below 4 percent by volume
- Maintain minimum distances between batteries and ignition sources
- Provide suitable extinguishing agents for battery types
- Clearly mark loading areas and restrict access
- Regularly document examinations and instructions
