Unik Techno • June 24, 2025

How to Build a Battery Room for Lithium-ion, Traction, Stationary & Modular Stationary Batteries

Designing a battery room is not just about storing batteries—it’s about ensuring long-term safety, performance, and compliance. Whether you're powering forklifts with lead-acid traction batteries, running backup systems on stationary lead-acid banks, maintaining golf carts with EV or semi-traction batteries, or using lithium-ion batteries for modern applications, your battery room needs to be purpose-built and future-ready. 


In this guide, we explore the core considerations for building a multi-purpose battery room that accommodates multiple battery chemistries, improves operational safety, and simplifies ongoing maintenance. 


Plan the Layout with Functionality in Mind


A well-designed layout is the backbone of a safe battery room. Begin by allocating sufficient space for each battery system, allowing for clear access during installation, charging, or maintenance. Traction and semi-traction batteries, which are handled frequently, should be positioned near entry points or charging stations for convenience. 


Racks or trolleys can be used to allow movement of batteries, while walkways between battery stands should remain unobstructed. If your room will house both lead-acid and lithium-ion batteries, it's good practice to physically separate these systems, especially considering their different safety and environmental requirements. 


Flooring and Structural Integrity 


The floor of a battery room must be robust and resistant to chemical corrosion. For lead-acid systems, spills and leaks can occur over time, especially during maintenance. Use acid-resistant flooring materials such as epoxy coatings or ceramic tiles and ensure the floor slopes slightly towards a sump or drain to contain any accidental electrolyte discharge. 


Additionally, consider the structural load. Large stationary batteries or battery racks can be extremely heavy. Reinforcing the floor where heavy banks will sit is not only good practice but may be a compliance requirement depending on the scale of installation. 


Ventilation and Temperature Control 


Ventilation is essential, particularly for lead-acid batteries emit hydrogen gas during the charging process. Hydrogen is both odourless and explosive at relatively low concentrations, so a proper ventilation system should exchange the air in the room several times per hour. Intake vents should be located near the floor, while exhaust fans should be installed near the ceiling to remove lighter-than-air hydrogen effectively. 


For lithium-ion battery systems, thermal management is more important than gas removal. These batteries perform best in ambient temperatures between 15°C and 25°C. If your room is located in a region with high seasonal variation or inside a warehouse without climate control, consider installing dedicated air conditioning or cooling systems to maintain consistent and optimal temperature levels. 


Charging Infrastructure


With different battery types come different charging demands. Traction and semi-traction batteries often require high-current chargers, while stationary systems may need float chargers with constant voltage regulation. Ensure each charging station is matched to the battery type, voltage, and chemistry. 


Wiring should be properly insulated, labelled, and protected against overcurrent faults. Emergency disconnects and surge protectors should be installed as standard. For lithium-ion charging stations, take extra precautions by placing them in areas with enhanced thermal detection and separation from other battery chemistries. 


Safety First Equipment and Precautions


No battery room is complete without a full suite of safety equipment. Fire protection is paramount—install Class C fire extinguishers throughout the space and consider clean-agent fire suppression systems if lithium-ion batteries are present. Emergency lighting, signage, and eye wash stations should be placed near exits or high-risk areas. 


Operators working with lead-acid batteries must be provided with PPE, including acid-resistant gloves, aprons, and safety goggles. It’s also essential to train personnel in battery handling, charging safety, and emergency procedures. Even the best-designed battery room can be compromised by human error if safety practices are not enforced. 


Battery Segregation and Labelling


Wherever possible, house batteries of similar chemistry and use case together. For instance, group all stationary lead-acid banks in one section and lithium-ion systems in another. This simplifies maintenance and reduces the risk of cross-contamination or operator error. Use durable, legible labels to mark each battery rack with key information: voltage, capacity, date of installation, and battery type. 


Routine Maintenance and Monitoring


Battery rooms must be easy to inspect and maintain. Lighting should be bright and resistant to corrosion or acid vapours. Install pull-out trays or sliding racks for traction batteries, and provide room to safely top up lead-acid cells. Include cable management systems to prevent tripping hazards or strain on terminals. 


For large or mission-critical systems, consider integrating battery monitoring systems that offer real-time data on temperature, charge levels, and potential faults. This can prevent unexpected failures and allow for predictive maintenance, which significantly extends the life of your battery assets. 



Whether you're managing a fleet of forklifts, maintaining a UPS system battery room, or operating a material handling facility, a well-planned battery room is central to operational reliability. By designing a room that accommodates multiple battery types—including traction and semi-traction lead-acid, stationary and modular setups, and lithium-ion—you protect your investment and your people. 


From layout and ventilation to charging systems and fire protection, every detail matters. Prioritise safety, plan for scalability, and ensure ease of maintenance—your battery room will reward you with years of dependable performance. 


Battery rooms are only as effective as the batteries they house. Speak to our team to find the right solution for powering your operations. 

Sulfation: The Silent Killer of Lead‑Acid Batteries & How You Can Prevent It

By Unik Techno • August 1, 2025
Sulfation is a widespread yet often overlooked issue in the world of lead-acid batteries. Frequently dubbed the “ silent killer” , it operates without obvious warning signs, quietly reducing both battery performance and service life. Whether used in industrial machinery, UPS systems, or off-grid energy storage, sulfation poses a serious risk to any application reliant on reliable battery power. What is Sulfation in Lead Acid Batteries? At its core, sulfation refers to the accumulation of lead sulphate crystals on the battery’s internal plates. This occurs naturally during discharge as the active material on the plates reacts with sulphuric acid. In a properly maintained battery, these crystals dissolve again during the charging process. However, when a battery is left undercharged, stored in a discharged state, or routinely subjected to deep discharge cycles, these sulphate crystals begin to harden. Over time, they become dense and irreversible, severely inhibiting the battery’s ability to hold and deliver electrical charge. What Causes Sulfation in Lead Acid Batteries? Understanding the root causes of battery sulfation is the first step to avoiding it. One of the most common contributors is infrequent or incomplete charging. A battery that is not brought back to a full state of charge after use may retain a residue of sulphate on the plates. This residue becomes the starting point for permanent sulfation, especially if the battery is neglected over repeated cycles. It is not just charging habits either—environmental conditions also play a significant role. High ambient temperatures accelerate the electrochemical reactions inside a battery, increasing the likelihood of crystal formation and growth. In warmer climates, or in confined battery enclosures without proper ventilation, this risk is amplified. Prevention of Sulfation in Lead Acid Batteries Prevention begins with proper charging practices. Always use a smart charger that can automatically adjust the charging voltage and current based on the battery’s state-of-charge. These chargers typically include bulk, absorption, and float stages that ensure a complete and balanced charge. Some models even include pulse or maintenance modes that help dissolve early-stage sulphate deposits, reducing the onset of crystallisation. Routine maintenance is another critical factor. For flooded lead-acid batteries, it’s important to regularly check electrolyte levels and top up with demineralised water when necessary. Low electrolyte levels expose the upper portions of the battery plates to air, causing oxidation and increasing the likelihood of sulphate build-up. In addition to fluid checks, make sure to clean terminal posts, check for corrosion, and tighten connections to ensure efficient current flow. Equalisation charging is a powerful tool in the prevention arsenal. This is a controlled overcharge applied periodically—usually once every 30 to 90 days that helps equalise the voltage between cells and reverses mild sulfation. Equalisation charges are particularly effective in larger battery banks where cell imbalance is common. However, they should only be performed according to the manufacturer’s guidelines, as excessive overcharging can damage the battery. Storage practices also matter. If a battery is left unused for extended periods, it must be stored fully charged and kept in a cool, dry environment. Batteries in storage should be recharged every 60 to 90 days to prevent the slow self-discharge that can lead to sulphate crystallisation. Even sealed lead-acid batteries are vulnerable if stored improperly. While some specialised de-sulfation chargers claim to reverse sulfation through high-frequency pulse technology, their effectiveness is generally limited to early-stage sulphate deposits. Once the crystals become hard and dense, recovery is unlikely, and battery capacity is permanently reduced. Prevention remains far more effective than any attempted cure. The consequences of ignoring sulfation can be expensive. Reduced runtime, increased charging times, and eventual failure can disrupt operations and require premature battery replacement. For businesses, this translates to higher operational costs, increased downtime, and reduced energy efficiency. At UNIK Batteries, we believe that prevention is the smartest investment. By manufacturing high-quality lead-acid batteries and state-of-the-art charging components, we help customers protect their power infrastructure from day one. Whether you operate forklifts , golf carts , maintain a solar backup system , or manage a unit of UPS batteries , we have the right solution to keep you powered and protected from sulfation. Contact us to explore our range of batteries and charging components today!
Explore the impact of Depth of Discharge (DoD) on industrial battery life.

Why Depth of Discharge (DoD) Matters for Industrial Battery Lifespan

By Unik Techno • May 8, 2025
Explore the impact of Depth of Discharge (DoD) on industrial battery life. Learn best practices to extend battery lifespan and lower operational costs.

Understanding Heat-Sealed Batteries: Enhancing Safety, Reliability, and Battery Longevity

By Unik Techno • March 28, 2025
Battery safety is critical in industries relying heavily on robust, dependable power sources such as electric forklifts, golf carts, and industrial machinery. One technology significantly advancing battery safety is heat-sealed battery construction . At UNIK Batteries, we utilise advanced heat-sealing techniques to provide superior safety, reliability, and longer battery life for demanding industrial applications. What Are Heat-Sealed Lead-Acid Batteries? Heat-sealed lead-acid batteries are constructed using a specialised sealing process where battery casings are permanently bonded through heat application. Unlike traditional battery sealing methods using adhesives or mechanical seals, heat sealing creates a highly durable, airtight enclosure, ideal for demanding industrial environments. Key Benefits of UNIK's Heat-Sealed Battery Technology Electrolyte Leakage Prevention Higher resistance levels, which may impact power output. Reduced charging efficiency, resulting in longer charge times. Increased operational strain, potentially leading to faster wear and tear. Here is why winter battery maintenance is essential: Proper care reduces the risk of cell damage due to freezing temperatures. Batteries that are well-maintained offer operational efficiency. Regular maintenance extends the life of your batteries, saving on replacement costs. Taking these steps will keep your i ndustrial forklift battery in peak condition, even when temperatures plummet. Lead Acid & Lithium-ion Battery Care in Cold Weather Maintenance of Lead Acid Batteries Lead acid batteries are more sensitive to cold temperatures because their electrolyte solution can freeze, particularly when the battery is in a low-charge state. For efficient battery care in cold weather, follow these tips: Charge fully after each use as a fully charged lead-acid battery is less likely to freeze. Store batteries in a temperature-controlled environment indoors or in a heated area to protect them from the elements. Inspect the battery for cracks or leaks, as these can worsen in the cold. Lead-acid batteries need adequate water to function correctly, so check and refill water levels routinely. Clean terminals regularly to prevent corrosion and improve conductivity. Lithium-ion Battery Maintenance While lithium-ion batteries fare better than lead acid batteries in colder weather, they still require care to avoid performance drops. Follow these tips for top-notch lithium-ion battery maintenance: When starting your material handling equipment, give your battery some time to warm up just as you would allow your car battery to reach an optimum temperature before driving. Lithium-ion batteries should not be charged at sub-zero temperatures, as this can lead to permanent damage. Lithium-ion batteries are more efficient when they maintain a moderate charge level in winter between 30-80%, to reduce strain on the cells. Following these steps can help ensure that both l ead acid and lithium-ion battery maintenance routines are winter-ready. Winter can be challenging for industrial forklift batteries , but with consistent battery care in cold weather , you can protect your investment and keep your operations running smoothly. By paying attention to winter battery maintenance and adjusting your care strategies for different battery types, you can enhance battery performance and extend its life, no matter how cold it gets. Protect your operations all season long! For more tailored solutions, explore our lithium-ion battery and lead acid battery sections to find the best fit for your material handling operations. Contact us today to learn how our battery solutions can power your success.
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