Electric vehicles (EVs) are popping up on roadways across the country and around the world with increasing frequency. Once a novelty, EVs appear to be the vehicle of the future. As prices come down, choices increase, and range improves, more and more drivers are choosing EVs in lieu of traditional gasoline-powered vehicles.
More EVs on the roads translates to a skyrocketing increase in demand for the batteries that power these vehicles. That’s why EV battery manufacturing facilities are now operating in multiple states, with additional facilities being built across the country.
With an ongoing shortage of skilled workers in the manufacturing sector, new EV battery manufacturing facilities are struggling to find enough workers to fill open positions. Moreover, these new facilities require workers with unique skills that are new to many in manufacturing.
However, worker experiences in current EV battery manufacturing facilities suggests that the training they may need most is actually some of the most basic training manufacturing workers usually receive, such as basic safety, use of personal protective equipment, and dealing with hazardous materials.
In a recent Bloomberg Law article, authors Bruce Rolfsen and Ian Kullgren note that “[w]hile the fire risks of lithium-ion batteries that power electric vehicles have made headlines around the world, the dangers from the batteries’ chemical powders, liquids, and fumes are not as well known—and the risks to American workers are increasing as more EV batteries are made in the United States.”
For example, the authors point out that there has been “a 147% boost [in OSHA] violations found [since] 2022.” Examples of violations include: “failure to train workers on turning off power to machinery; exposure to respiratory hazards, including powdered nickel, cobalt, and manganese; and failure to provide information on chemical hazards, chemical-resistant gloves, and protective clothing training.”
Safety violations in EV battery manufacturing facilities is particularly concerning, since “[m]etals used in lithium-ion EV batteries such as nickel, lithium, and cobalt are known to cause a variety of ailments, from cancer to nerve damage. And yet the extent of the risks posed by handling these materials is just beginning to come into focus.”
Unfortunately, not many regulations exist to cover the full range of potential dangers that exist in EV battery manufacturing facilities. According to the authors, “[w]hile the Centers for Disease Control and Prevention have issued exposure guidelines [for chemicals found in EV battery manufacturing facilities], most aren’t covered by specific OSHA exposure limits. For chemicals without an OSHA-set exposure limit, the agency doesn’t have specific rules for employers.”
Can manufacturers expect new regulations or guidance any time soon? Not likely. “OSHA’s time-consuming rulemaking process—a regulation to protect health-care workers from airborne diseases has been in development for 15 years—makes it unlikely the agency will directly address lithium-ion battery manufacturing hazards in the near future.”
Are regulations really necessary? Is the EV battery manufacturing process really that much more dangerous than other types of manufacturing? Let’s take a closer look at some of the dangers. As the authors note, “[w]orkers can be exposed to potentially hundreds of chemicals in building a lithium-ion battery.”
For example, in the first stage of the process, “a wet slurry is applied to” thin rolled metal to form electrodes. “The slurry can include powdered metals such as nickel, cobalt, manganese, and other ingredients mixed with a liquid solvent, often the hazardous liquid chemical N-Methylpyrrolidone. Workers need to be protected from coming in contact with the slurry by the use of respirators, protective clothing, and gloves.”
The danger doesn’t end there, however. “Once the coated metal is dried, it’s cut into pieces that fit inside battery casings. Then, a toxic liquid lithium-ion electrolyte is pumped into the casing to create the basic component of an automotive lithium-ion battery—the cell.”
Exposure to toxic chemicals and gases presents a clear danger to workers at many points during the EV battery manufacturing process. At a minimum, workers should routinely “wear gloves, respirators, and protective clothing” to stay safe.
Sadly, “workers often don’t know what chemicals are used because companies treat the recipes as trade secrets. While a manufacturer may have to share the ingredients with government regulators, the disclosure doesn’t extend to workers.”
If you’ve seen photos of EV battery manufacturing facilities, you may have seen workers wearing bright white “space suits” that look like they would be considered personal protective equipment. However, the authors notes that this “clothing doesn’t significantly protect workers from chemicals…Instead, the coverings are intended to prevent workers’ hair, sweat, and skin from contaminating unfinished batteries.” Basically, these “space suits” are meant “to protect the product from the worker, and not the other way around.”
So, what are EV battery manufacturers to do without significant regulation or guidance from OSHA? According to manufacturing consultant Dr. James Craner, “[c]ompanies need to exceed OSHA’s requirements in order to protect their workers.” According to Craner:
“OSHA simply provides the ground rules for the minimum standard of care. It doesn’t provide the methods, it doesn’t provide the tools, and it’s certainly a far cry from best practice. The industry needs to take hold of these health and safety issues as an essential business process and then show OSHA how it is done rather than the other way around.”
To take the lead on safety issues surrounding EV battery manufacturing, manufacturers must start by making workers fully aware of the hazards that exist. “Educating workers about lithium-ion battery production is a challenge the Department of Energy and Department of Labor hope to resolve by developing training curricula with the industry via the Battery Workforce Initiative, said Betony Jones, director of the Energy Department’s Office of Energy Jobs. The initiative, which is still in its early stage, is largely focused on training machine operators and machine repair technicians.”
Effective safety training for EV battery manufacturing workers must include several important areas, including lock-out/tag-out, hazardous materials, effective communication, and personal protective equipment. Rather than trying to recreate the wheel, EV battery manufacturers can collaborate with a proven training partner like Amatrol.
The experts at Amatrol have been working together with industry and educational institutions for years to design training programs featuring eLearning curriculum and hands-on experience with trainers equipped with industrial components workers will encounter on the job. For example, check out Amatrol’s variety of Safety training resources.
When it comes to EV battery manufacturing training, Amatrol is once again leading the way. In fact, Amatrol hosted the State of Ohio Electric Vehicle Workforce Strategy meeting at its headquarters in Jeffersonville, Indiana, to help chart a course for preparing the Ohio workforce for the jobs that EV battery and vehicle manufacturing facilities will soon bring. Click here to watch a video about that meeting.
Visit Amatrol online to learn more about its EV Manufacturing Program. You can also download Amatrol’s EV Manufacturing Program brochure. For more information about how Amatrol can help you upskill your current workers, contact an expert at Amatrol today!
