OSHA: Injuries Caused by Lithium-ion Battery Malfunctions are Recordable

The Occupational Safety and Health Administration (OSHA) has issued a letter of interpretation to clarify compliance with regulations that require employers to report employee injuries caused by lithium-ion battery malfunctions in personal devices. An injury must be recorded on logs 300, 300-A, 301 or equivalent forms when a battery-related injury meets general recording criteria in Section 1904.7 of 29 CFR Part 1904 – Recording and Reporting Occupational Injuries and Illnesses.  

The Jan. 26, 2026, letter of interpretation is noteworthy because it: 

• Describes a specific workplace scenario in which employees use unprotected battery chargers and carry lithium-ion batteries in their pants pockets while at work. 
• Is the first letter to be issued so far this year, following the January release of information on OSHA’s hazard communication compliance date extension. The agency issued a batch of seven interpretation letters in December following the July 2025 launch of an opinion letter program by the U.S. Department of Labor. 
• Highlights what OSHA sees as a growing need for awareness of occupational health and safety risks associated with the personal use of devices with lithium-ion batteries, as well as in manufacturing, emergency response, waste disposal, and recycling workplace environments.  
• Explains that recordkeeping regulations do not contain a general exception for purposes of determining work-relatedness for cases involving employees engaged in purely personal activities that are not related to their employment. 
• Serves as a reminder that OSHA has the discretion to decide which questions it will answer to clarify compliance with regulations that apply to specific workplace situations or hazards without creating additional employer obligations. 

Why Battery-related Injuries are a Significant Occupational Health + Safety Concern 

Lithium-ion battery-related incidents are increasing at a rapid rate. When they fail, batteries release energy (thermal-runaway reactions) that can cause blasts, shrapnel explosions, and fires. Associated injuries include thermal burns, cuts, eye injuries, and blunt trauma. During production or when a battery fails, there is also a risk for the inhalation of toxic materials that can cause respiratory irritation, lung damage, and other potentially fatal conditions. An incident may also involve costly damage to products and property. 

Legislators are taking notice of injury exposure risks. For example, the Setting Consumer Standards for Lithium-Ion Batteries Act (HR 973) that is wending its way through Congressional committee hearings would require the U.S. Consumer Product Safety Commission (CPSC) to issue a rule requiring manufacturers and distributors of micromobility products like e-bikes and e-scooters to comply with safety standards jointly established by the American National Standards Institute, the Standards Council of Canada, and UL Solutions.  

The CPSC publishes recalls of lithium-ion powered products linked to fire and burn hazards. A 2024 CPSC report cited 586 injuries and 104 battery-related deaths in the U.S. According to UL Solutions’ battery incident reporting database, the proliferation of consumer products powered by lithium-ion batteries – including micromobility and vaping devices, smartphones, laptops, and power tools – has caused an exponential increase in incidents. Globally, by the end of 2024, 15,949 incidents, 3,126 injuries, and 194 fatalities were reported to UL, the majority of them involving fires. 

In an industry-focused report, the Environmental Protection Agency found 245 fires in 64 waste management facilities were caused by lithium metal or lithium-ion batteries between 2013 and 2020 in 28 states. Impacts included injuries, the need for community-based emergency response, service disruptions, and monetary losses.  

What’s In the Interpretation Letter? 

In the letter, OSHA addresses a scenario in which employees bring rechargeable lithium-ion batteries to the workplace for personal use of e-cigarette or vaping devices. The corresponding employer states that employees use unprotected battery terminals and carry batteries in their pants pockets. In its response, OSHA states that employers must: 

• Presume work-relatedness for injuries and illnesses resulting from events or exposures occurring in the work environment, unless an exception in Section 1904.5(b)(2) applies. 
• Determine under Section 1904.5(b)(3) whether one or more “precipitating events or exposures” caused or contributed to an injury or illness or aggravated a pre-existing condition. 

The letter clarifies that an exception to work-relatedness in Section 1904.5(b)(3) does not apply to an injury that occurs at the workplace during assigned work hours when an employee is present as a condition of employment. These principles apply:  

1. Work need only be a causal factor for an injury or illness to be work-related. The regulation does not require precise quantification of an occupational cause or assessment of the relative weight of occupational and non-occupational contributing conditions. If work is a tangible, discernible causal factor, the injury or illness is work-related.  
2. A “geographic presumption” applies to cases in which an injury or illness results from an event at work that is outside the employer’s control, such as a lightning strike, or when it involves activities that occur at work but that are not directly related to production, such as horseplay.  
3. With regard to the improper carrying of lithium-ion batteries, the nature of an activity in which an employee is engaged when an event or exposure occurs, the degree of employer control over the employee’s activity, and the preventability of the incident or the concept of fault do not affect the determination of work relationship. 

Answers to Additional Related Questions 

OSHA also answers these questions: 

Q: Do exceptions to work-relatedness in Section 1904.5(b)(2)(iv) and (v) apply because the injury is solely the result of an employee bringing something on-site for personal use? 

A:  Exceptions that relate to eating, drinking, or preparing food or drink for personal consumption and to personal grooming do not apply to this scenario. For example, a burn injury resulting from carrying a lithium-ion battery for purposes of e-cigarette use in the work environment does not fall within the exception in section 1904.5(b)(2)(vi) because it does not involve personal grooming, self-medication for a non-work-related condition, or an intentionally self-inflicted injury.  

Q: Would any exceptions apply if an injury occurs after a lithium­ion battery comes into contact with a metallic key used at work? 

A: No. It makes no difference if an employee’s injury is caused by the lithium-ion battery being co-mingled with an employer-provided item used at work. 

What Can Employers Do to Reduce Exposure Risk? 

Attorneys and occupational health and safety experts recommend that employers implement policies regarding personal use of devices powered by lithium-ion batteries, primarily due to the risk for overheating, exploding, or causing fires that can seriously injure users. Policies may include banning, restricting, or managing the charging and storage of personal devices. 

OSHA regulations apply in workplaces where there is a risk of exposure to battery-related incidents during production, shipping, or disposal. Recommended preventive measures include ventilation, isolation of toxic materials, device and battery storage in cool locations, access to safety showers and eyewash stations, training and verifying proper use of PPE, and having an emergency response plan in place. Refer to OSHA’s Lithium-ion Battery Safety fact sheet. 

Lithium-ion battery safety measures recommended by the National Fire Protection Association include: 

• Using safety-certified chargers, batteries, and cords designed for the device 
• Not overcharging or covering a device while charging 
• Storing batteries and devices in a safe place at room temperature 
• Watching for signs of deterioration such as odor, overheating, leaks, or sounds 
• Using designated recycling locations, not putting used devices and batteries in the trash   

Looking for More Guidance?  

WorkCare’s occupational health experts are here to help keep your employees safe and healthy on and off the job by providing relevant guidance on-site at the workplace and via our 24/7 telehealth Injury Care response team. For an update on the regulatory environment, tune into WorkCare’s March 11 webinar on How to Avoid the Five Most Expensive (and Frequently Cited) Types of General Industry Citations.