After workers place
all the groups in the battery case, the straps are fused
together using a torch or high electrical power source. This
process can also be done Through The Partition (TTP), using a case that has been
punched. The connections are then welded.
The units are
tested and the posts are attached.
The major source of lead exposure in the intercell welding process comes from
Potential Sources of
Figure 1. Ventilated torch
Possible Engineering and Work Practice Controls
- Lead fumes are emitted during the manual burn
welding process. This is a minimal source of exposure for Through The Partition (TTP) welding.
- Exposure to lead may occur from manual handling of burning jigs or contaminated dams.
- High lead exposure may occur when repairing batteries.
- Contaminated air from other areas may be exhausted into the work station as a result of exhausting too much air from other workstations.
- Lead particles may become airborne if the pressure of the torch flame is too high.
Possible Engineering and Work Practice
- Use local exhaust ventilation around the torch or provide a portable welder exhaust hood on a monorail or other configuration connected
to a suitable exhaust collection system (Figure 1).
Post Tacking Portable Hood (HVLV)
Intercell Burning Backdraft Hood
- Use a plastic or glass see-through guard between the
breathing zone and the conveyer carrying the battery.
- Use canopy or slot hoods if lead pots are used.
- Use a down draft or slot hood ventilated workstation when performing
battery assembly (Figure 1).
- Install a laminar
island above workstation.
- Keep torch hose lengths to a minimum to prevent employee from working
outside the ventilated area.
- Keep burning temperatures low by substituting air-propane or air-MAP gas for oxy-acetylene
- Provide adequate PPE, a change of clothes, and shower rooms (see OSHA Lead Requirements for PPE, Housekeeping, and Hygiene Facilities).
- Ensure that local exhaust ventilation is working
- Perform battery repair
at a ventilated
- Vacuum oxide spills
immediately with a central
vacuum system or HEPA
- Avoid pointing torch flame into battery containers whenever