A plant has replaced all lead-acid forklift batteries with lithium packs. The old battery room still has acid-resistant floors, eyewash stations, ventilation fans and watering equipment, and the facilities manager wants to know what can change and what must stay.
Many lead-acid controls exist because of acid and hydrogen during charging. LiFePO4 packs are sealed and do not need watering, so watering equipment, acid spill kits and some ventilation may no longer be needed once no lead-acid batteries remain on site. But fire safety, electrical installation rules, charger spacing, signage and a plan for damaged packs still apply. Review the room with your safety adviser and local rules before removing anything.
Items that may change
- Watering equipment. No longer used for lithium packs.
- Acid spill kits and neutralising agents. Not needed if no lead-acid batteries remain on site.
- Ventilation for hydrogen. Lead-acid charging can release hydrogen; sealed LiFePO4 packs do not in normal use. Ask your adviser whether the existing fans can be reduced.
- Eyewash stations. Often required because of acid. Keep them until your safety review confirms they are no longer needed.
Items that still apply
- Fire safety. Detection, extinguishers suited to the area, and an emergency plan agreed with your insurer and local authority.
- Electrical installation. Correct supply, protection and cable routes for chargers.
- Charger placement. Spacing, ventilation for charger electronics, and clear access.
- Damaged pack area. A marked place to isolate a damaged or overheated pack.
- Signage and training. Updated signs and instructions for lithium charging.
Redway’s battery rooms page and safety page give background, and our changeovers article covers floor space.
Running the change
Write a short change plan: what is removed, what stays, who approves it and when. Update the risk assessment and training at the same time, and keep a record. Our training article covers operators.
Risk limits
Requirements depend on local building, fire and workplace rules, and on whether any lead-acid batteries remain. This article is general guidance; follow your safety adviser and local regulations.
Additional perspectives
Remove things in stages, starting with watering equipment. Keep safety items until the review signs them off.
Redway Tech Editorial Team – Facilities manager perspective
Update the risk assessment before changing the room. Insurers and inspectors want to see why each control was removed.
Redway Tech Editorial Team – Safety adviser perspective
Check that no lead-acid trucks or rental units will come back on site. One returning lead-acid truck brings the old requirements back.
Redway Tech Editorial Team – Fleet manager perspective
Specifications are taken from Redway product pages as of October 2026. Where a figure isn’t published, this article says so. Confirm current specifications for your model with Redway before ordering. This article is general guidance, not a site-specific engineering assessment.
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