UKMHA and UKWA publish lithium-ion battery storage guidance for warehouses

Warehouse operators in the United Kingdom should review how they receive, store, charge and inspect lithium-ion batteries after the UK Material Handling Association (UKMHA) and the UK Warehousing Association (UKWA) published complementary guidance on 1 October 2026. The recommendations address smaller batteries kept in general warehouse areas as well as lithium-ion traction batteries used in forklifts and other materials handling equipment. ^{[1] [2]}

The guidance is relevant to fleet managers, warehouse managers, health and safety officers and anyone responsible for battery storage or charging. It covers storage conditions, segregation, inspections, monitoring, emergency response, records and staff training. The associations distinguish between battery categories rather than applying one set of controls to every lithium-ion product. ^{[1] [2]}

Two guidance notes cover different warehouse battery risks

UKWA’s note concerns smaller lithium-ion batteries stored in general warehouse environments. Its examples include batteries associated with power tools, laptops, e-bikes and consumer electronics. The note addresses receipt and inspection, segregation and labelling, returned or damaged batteries, waste batteries, charging, emergency response, record keeping, training and engagement with insurers. ^[2]

The UKWA note does not cover electric vehicle battery packs, industrial traction batteries or energy storage systems. Industrial traction batteries used in materials handling equipment are addressed separately by UKMHA. This distinction matters for operators of electric forklift trucks and pallet trucks because traction batteries require controls that reflect their size, charging arrangements, operating condition and state of charge. ^[2]

UKMHA describes its guidance as covering general precautions for lithium-ion traction batteries used in materials handling equipment. Its subject areas include the storage environment, preparation before storage, state-of-charge control, periodic checks, stock control, inspection intervals, ageing batteries, site layout, segregation, fire protection, fire detection, monitoring, escalation procedures and the management of faulty or high-risk batteries. ^[2]

Thermal runaway requires early detection and escalation

The associations do not describe lithium-ion batteries as inherently unsafe. UKMHA states that they are generally safe and reliable when properly managed, while also warning that the energy and chemicals contained in a battery create hazards that operators must understand. ^[1]

A key concern is thermal runaway. This is a chain reaction in which a battery cell generates increasing heat and may cause fire or damage to nearby batteries and materials. The UKMHA announcement warns that an unmonitored battery can enter thermal runaway. It also notes that a battery may reignite hours after an incident appears to have been brought under control. ^[1]

Consequently, a battery showing damage, abnormal heating or other high-risk behaviour should not be treated as ordinary stock. UKMHA’s guidance includes procedures for faulty or high-risk batteries, monitoring regimes and escalation. These controls are intended to help operators recognise problems, identify who must be informed and reduce the chance that an isolated fault develops into a wider warehouse emergency. ^[2]

Segregation should reflect battery condition and intended use

The joint announcement highlights cool and dry storage, limits on long-term storage and the separation of battery types. These measures require more than efficient use of warehouse space. Operators also need to consider environmental conditions, accessibility, inspection requirements and the possible consequences of an incident in each storage area. ^[1]

Segregation should distinguish normal stock from returned batteries, damaged batteries, waste batteries and traction batteries used in materials handling equipment. UKWA lists segregation and labelling alongside receipt and inspection, while UKMHA addresses site layout, stock control and ageing batteries. ^[2]

For forklift fleets, stock control therefore involves more than counting available batteries. Operators need a reliable method to identify batteries, record their condition and confirm that inspections take place at the required intervals. The published material does not prescribe one software system or one warehouse layout for every site. Its framework must be adapted to the site, the battery manufacturer’s instructions, the fire risk assessment and the insurer’s requirements. ^[2]

Charging arrangements form part of the same risk assessment

Storage and charging should be reviewed together. UKWA includes charging among the practical topics for smaller lithium-ion batteries, while UKMHA addresses storage and charging contexts for traction batteries used in materials handling equipment. ^[2]

A change in battery volumes, charging locations or storage arrangements may alter the site’s fire risk profile. UKWA recommends reviewing the site fire risk assessment when storage or charging arrangements change. It also recommends speaking with the insurer before increasing battery volumes or changing how batteries are stored or charged. ^[2]

This point is especially relevant when a warehouse converts part of its forklift fleet from internal combustion equipment to electric trucks. Electrification can change the way batteries are moved, inspected and charged, as well as the responsibilities assigned to staff. The guidance supports an assessment of charging areas, emergency access, inspection duties and staff competence; it does not replace that assessment. ^[2]

Inspection and records turn policy into operational control

Written procedures are only effective when staff can apply them consistently. The UKWA guidance covers receipt and inspection, records and training, while UKMHA includes periodic checks, inspection intervals, stock control and monitoring for traction batteries. ^[2]

A practical warehouse process should make clear which batteries may enter normal storage, which conditions require isolation or escalation and who is responsible for recording the decision. The associations’ material does not establish a universal inspection form or a single interval that applies to every battery. Operators should therefore align their process with the relevant guidance, manufacturer information, equipment condition and site risk assessment. ^[2]

Ageing batteries also require attention. UKMHA specifically includes ageing batteries among its topics, indicating that battery condition and service history should be considered alongside location and type. For forklift operators and maintenance teams, consistent identification and records can support decisions about inspection, continued use and escalation of concerns. ^[2]

Emergency planning must include staff training and post-incident monitoring

Both associations identify emergency planning and staff training as important parts of battery management. UKWA’s note includes emergency response, records and training, while UKMHA highlights emergency plans and staff training within its wider guidance package. ^{[1] [2]}

Staff should know how batteries are classified on the site, where normal and high-risk batteries are stored, who is responsible for escalation and which actions are prohibited. Training should distinguish a routine inspection from an incident involving a damaged, overheating or otherwise suspect battery. The published guidance does not provide one training syllabus for every operator, so businesses must align instruction with their equipment, procedures, manufacturer information and fire risk assessment. ^[2]

Emergency planning should also account for possible reignition after visible flames have been extinguished. UKMHA’s warning reinforces the need for clear handover arrangements, communication with emergency responders and a defined process for monitoring an affected area after an incident. ^[1]

Industry guidance supports, but does not replace, site duties

UKWA states that its notes are industry guidance only. They are not legal or professional advice and do not replace applicable legislation, a site fire risk assessment, manufacturer instructions or insurer requirements. UKWA also makes clear that following the guidance does not guarantee legal compliance or prevent incidents. ^[2]

Warehouse managers should therefore use the documents as a structured starting point for reviewing battery storage, charging, inspection and emergency arrangements. Manufacturer instructions should take precedence where they differ from the guidance. Operators should also assess whether changes to the site require a further fire risk assessment and should consult their insurer when battery volumes or storage and charging arrangements change. ^[2]

Sites handling both smaller lithium-ion batteries and forklift traction batteries need to map the applicable controls across receiving, storage, charging, inspection, damage handling, emergency response and staff training. The separate UKWA and UKMHA scopes provide a basis for making that distinction without treating all lithium-ion batteries as one category. ^[2]

Frequently asked questions about UK lithium-ion battery guidance

Which UK guidance should a forklift operator or warehouse manager use for traction batteries?

Use the UKMHA guidance for lithium-ion traction batteries used in materials handling equipment, including forklift trucks and other MHE. The separate UKWA note is intended for smaller batteries stored in general warehouse environments. ^[2]

Does the guidance apply to electric vehicle batteries or energy storage systems?

The UKWA guidance for smaller lithium-ion batteries does not cover electric vehicle battery packs, industrial traction batteries or energy storage systems. Industrial traction batteries used in materials handling equipment are addressed separately by the UKMHA guidance. ^[2]

What should take precedence if the guidance differs from a battery manufacturer’s instructions?

Manufacturer instructions should take precedence. UKWA also says operators should review their site fire risk assessment and consult their insurer before increasing battery volumes or changing storage or charging arrangements. ^[2]

Why are damaged or unmonitored lithium-ion batteries treated as a higher risk?

The associations warn that an unmonitored battery may enter thermal runaway and cause a fire. UKMHA also notes that batteries can sometimes reignite hours after an incident appears to be under control, which is why monitoring and escalation procedures are included in the guidance. ^[1]