Chemical Risk Assessment and Hazard Communication Improvement at a Battery Manufacturing Plant in Plateau State, North Central Nigeria

Battery manufacturing facilities generate significant occupational exposures to lead, sulphuric acid, and organic solvents, creating chemical risks that require rigorous hazard communication programmes and professionally managed risk assessments to protect worker health across all production stages. This study conducts a chemical risk assessment and evaluates the adequacy of hazard communication at a lead-acid battery manufacturing plant in Plateau State, North Central Nigeria. Workplace air monitoring for lead particulate and sulphuric acid mist is performed using personal sampling pumps at six job categories across battery grid casting, paste mixing, plate assembly, and formation charging areas. Blood lead level surveillance data from 60 production workers are reviewed for the previous two years to assess biological exposure trends. Hazard communication infrastructure is evaluated against Globally Harmonised System of Classification and Labelling of Chemicals requirements for labelling, safety data sheet availability, and worker information training. A risk characterisation matrix ranks each identified chemical hazard by inhalation, dermal, and ingestion exposure routes. Engineering controls, administrative controls, and personal protective equipment adequacy are assessed against the hierarchy of controls principle. Recommendations cover ventilation upgrade specifications, blood lead monitoring protocol revision, and a practical Globally Harmonised System-compliant chemical labelling system for all production chemicals. A professionally designed hazard communication training programme is also developed for implementation by the company's occupational health and safety team. Keywords: chemical risk assessment, battery manufacturing, lead exposure, hazard communication, Plateau State