Common Misconceptions About California Title 8 §5185: Changing and Charging Storage Batteries in Wineries

Wineries rely on powered industrial trucks for moving barrels and pallets, but battery maintenance under California Title 8 §5185 often trips up even seasoned safety managers. This regulation sets strict rules for changing and charging lead-acid storage batteries to prevent fires, explosions, and chemical hazards—critical in environments with alcohol vapors. Yet, misconceptions persist, leading to citations and close calls. Let's debunk the top ones based on our fieldwork across California facilities.

Misconception 1: 'Battery Charging Areas Don't Need Dedicated Space in Wineries'

Many assume any corner works for charging, especially in tight barrel-aging cellars. Wrong. §5185(a) mandates designated areas separated from operations to contain spills and hydrogen gas buildup. In wineries, where fermenting tanks emit flammable vapors, this isolation prevents ignition sources near Class I Division 2 hazards per NFPA 70.

We've seen facilities improvise with open bays, only to face Cal/OSHA fines after a near-miss hydrogen ignition. Designate and ventilate properly—aim for 1% max hydrogen concentration as per §5185(h).

Misconception 2: 'PPE Alone Handles Electrolyte Spill Risks'

Gloves and goggles? Not enough. §5185(i) requires emergency drench facilities for eyes and body right at the charging station. Acid splashes from sulfuric electrolyte demand immediate flushing—seconds count to avoid burns.

In one Sonoma winery audit, operators skipped drench hoses, relying on distant showers. Result: a corrosive injury during a battery swap. Install portable or plumbed units nearby; test weekly. Pair with §5185(c) neutralization kits for containment.

Misconception 3: 'Ventilation Is Optional If Batteries Aren't Overcharged'

"Our chargers are smart—no gassing," some claim. §5185(h) disagrees: continuous ventilation is non-negotiable to dilute hydrogen below explosive limits (4-15% LEL). Winery cellars amplify risks with poor airflow and ethanol vapors.

Research from the Electric Power Research Institute shows even "equalize" charges produce hydrogen. We recommend 200 CFM exhaust fans interlocked with chargers, positioned low-to-high for gas evacuation. Monitor with detectors for compliance.

Misconception 4: 'Shields and Covers Are Just for Show'

Operators shrug off §5185(b), (f), and (g) protections as overkill. Transparent shields during filling and one-piece tops during charging aren't optional—they block arcing sparks and splashes.

A Napa incident involved a battery explosion from an unattended fill, shattering shields that contained fragments. Use carboy tilters per §5185(e) for safe electrolyte handling. These aren't bells and whistles; they're engineered barriers backed by ANSI battery standards.

Misconception 5: 'This Reg Doesn't Apply to Lithium-Ion Batteries'

Wineries switching to lithium-ion for electric forklifts think §5185 is obsolete. It targets lead-acid explicitly, but Cal/OSHA interprets equivalents under General Duty Clause and §5182 for thermal runaway risks.

While ventilation differs—no hydrogen, but CO2/O2 depletion—separate charging per manufacturer specs. We've advised hybrids: follow §5185 for legacy fleets, NFPA 855 for new tech. Document variances transparently.

Steer clear of these pitfalls with annual audits and crew training. Reference Cal/OSHA's Powered Industrial Trucks guide (Title 8 §3650+) and winery-specific resources from the California Winery Safety Group. Proactive compliance saves lives—and avoids six-figure penalties.