1910.178(g): Changing and Charging Forklift Batteries
Employers must charge industrial truck batteries only in designated areas with facilities for flushing and neutralizing spilled electrolyte, fire protection, damage protection and ventilation. Workers must pour acid into water, never water into acid, position and brake trucks before charging, keep vent caps working, and keep smoking, flames, sparks and metal tools away.
Key takeaways
- 1910.178(g) is part of OSHA's general industry standards (29 CFR Part 1910, Subpart N).
- OSHA cited it 69 times in the last 3 years, in 67 inspections, with $226,686 in current penalties.
- 1 death is linked to inspections that cited this rule.
- Most citations: WI (12), NJ (11), MA (10).
- Related part: 1910.178(g)(2) (57 citations).
- Free 5-minute toolbox talk for your crew below.
In this article
What this rule covers
29 CFR 1910.178(g) ("Changing and charging storage batteries") is one requirement inside 1910.178 Powered industrial trucks, an OSHA general industry standard (Part 1910, Subpart N). It includes 12 sub-paragraphs. The official text below is copied word for word from the Electronic Code of Federal Regulations (eCFR). The numbers, injury cases and training on this page show how OSHA enforces it on real job sites.
Official text
(g) Changing and charging storage batteries. 69 citations
(1) Battery charging installations shall be located in areas designated for that purpose. 5 citations
(2) Facilities shall be provided for flushing and neutralizing spilled electrolyte, for fire protection, for protecting charging apparatus from damage by trucks, and for adequate ventilation for dispersal of fumes from gassing batteries. Open (g)(2) 57 citations
(3) [Reserved]
(4) A conveyor, overhead hoist, or equivalent material handling equipment shall be provided for handling batteries.
(5) Reinstalled batteries shall be properly positioned and secured in the truck. Open (g)(5) 1 citations
(6) A carboy tilter or siphon shall be provided for handling electrolyte.
(7) When charging batteries, acid shall be poured into water; water shall not be poured into acid. 2 citations
(8) Trucks shall be properly positioned and brake applied before attempting to change or charge batteries.
(9) Care shall be taken to assure that vent caps are functioning. The battery (or compartment) cover(s) shall be open to dissipate heat.
(10) Smoking shall be prohibited in the charging area. Open (g)(10)
(11) Precautions shall be taken to prevent open flames, sparks, or electric arcs in battery charging areas. Open (g)(11) 4 citations
(12) Tools and other metallic objects shall be kept away from the top of uncovered batteries.
Source: eCFR, text current as of 2026-10-15. Read all of 1910.178.
Injuries linked to this rule
1 death is linked to inspections where OSHA cited 1910.178(g).
At 2:00 p.m. on June 6, 2024, an employee working as a laborer for a tire warehouse was operating a forklift (PIV). The employee was using the PIV to access palletized solid-core forklift tires on the third tier of a 4-tier rack storage system. While…
Where and how often it was cited
| Year | Citations |
|---|---|
| 2023 | 6 |
| 2024 | 29 |
| 2025 | 20 |
| 2026 | 14 |
Top states: WI (12), NJ (11), MA (10), MD (7), NE (6)
Largest penalties
| Employer | Location | Penalty for this rule |
|---|---|---|
| RELOGISTICS SERVICES, LLC | METHUEN, MA | $25,000 |
| HOME DEPOT USA INC | DANVERS, MA | $16,550 |
| U.S. POSTAL SERVICE | LOUISVILLE, KY | $16,131 |
| MITCHELL INDUSTRIAL TIRE CO., INC. | ELM MOTT, TX | $14,934 |
| HOME DEPOT USA INC | DANVERS, MA | $11,348 |
Free toolbox talk
A 5-minute crew talk on 1910.178(g), plus alerts when this rule changes. Free.
OSHA interpretation letters
- Batteries in powered industrial trucks must be secured horizontally and/or vertically (2003-03-18)
- Clarification of PIT requirements covering: fall protection and safety platforms, seatbelts, LP-gas storage, smoking, and eye wash stations (2002-03-08)
- Batteries in electric powered industrial trucks must be secured horizontally and vertically. (2000-09-11)
- Definition of the phrase "Adequate ventilation" as used in 1910.178. (1976-01-26)
Related parts of this rule
- 1910.178(g)(2) 57 citations
- 1910.178(g)(11) 4 citations
- 1910.178(g)(5) 1 citations
- 1910.178(g)(10)
Get your crew competent
Trainers on Black Belt Safety: Marc Harvey, Dana Reyes
Trainers and suppliers: feature your business on this rule for $25/month.
Frequently asked questions
Should acid be poured into water or water into acid?
When charging batteries, acid shall be poured into water; water shall not be poured into acid.
Is smoking allowed in the battery charging area?
No. Smoking shall be prohibited in the charging area.
What must be done to the truck before changing or charging?
The truck must be properly positioned and the brake applied.
About this page
Sources
- 29 CFR 1910.178 (eCFR), text current as of 2026-10-15
- U.S. Department of Labor enforcement data: OSHA inspections, citations and accident records, copied nightly; data as of 2026-10-22
3-year window. Federal OSHA only; state-plan rules are not counted. Plain-language text is a summary, not legal advice; the official text controls. Black Belt Safety is not part of OSHA or the Department of Labor.