Battery Maintenance

Many organisations rely on lead-acid batteries to power their day-to-day operations.

Lead-acid batteries need to be maintained, and that requires specialist knowledge and time that a lot of organisations don’t always have.

If your batteries aren’t maintained correctly, they begin to degrade and lose capacity, which means they have to work harder to keep up with the demands placed on them. This can result in a failure that harms operational performance, increases cost as batteries and components need to be replaced prematurely, all whilst increasing the potential risk for safety issues.

Through our Battery Maintenance service, we’re able to solve these problems and keep you focussed on what you do best.

What our Battery Maintenance service includes

We offer a tiered range of services that work together to ensure the health, performance and safety of your battery fleet.

What our Battery Maintenance service includes

In a busy working environment, battery components will inevitably succumb to incidental damage, neglect, misuse and/or failure through fair wear and tear.

Whilst replacement battery components are cost-effective and readily available, even the smallest components can be disruptive to an operation if they aren’t in working order, and they can lead to bigger, more serious, issues if they aren’t fixed.

We perform a detailed visual inspection of all batteries to proactively identify problems before they happen. The Inspection covers:

  • Cables

  • Plugs

  • Bolts

  • Battery cells

  • Battery Trays

The findings of the inspection are reported after each visit. We identify components that need to be replaced, and establish the cause of faults and recommend corrective and preventative actions where possible.

Battery Topping

The fluid in your lead-acid battery is extremely important, and it needs to be monitored and kept at a safe working level.

Known as ‘electrolyte’, the fluid is a mixture of sulphuric acid and water. When a battery charges, the electrolyte heats up, which causes some of the water to evaporate – known as ‘gassing’. This results in electrolyte levels lowering over time.

Conversely, when a battery is overwatered before charging, the electrolyte will expand and overflow. This can damage the battery, has the potential to cause injury and alters the concentration of electrolyte which results in reduced battery performance

​We check the levels of de-ionised water in your batteries and refill them, where necessary, following the battery manufacturers recommendations to ensure each battery cell is in optimal operating condition.

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Maintenance Tracking & Reporting

Battery maintenance is essential to the smooth running of your operation, and battery operators must keep a detailed record of all maintenance activity for each asset they own.

This can often be difficult to manage as paper-based systems are often time-consuming and not well suited to recording large amounts of data accurately and reliably, which results in operational inefficiencies relating to performance and cost.

We solve this problem using a digital asset management or iTAG to record and report on the health and status of each of your batteries, and all maintenance activity.

With reliable data at your fingertips, you can manage your battery fleet more effectively, comply with manufacturers conditions of service and product warranty, and schedule services only when they're needed.

Here’s how it works

1. We apply a unique and scannable barcode to each battery that we maintain.


2. Our Engineer will scan the barcode and will record when they visited the site, inspection data and the work they carried out. The data collected includes, but is not limited to:

  • Asset ID

  • Install Date

  • Manufacturer

  • Manufacture Date

  • Description

  • Voltage

  • Battery Capacity

  • Filling

  • System Type

  • Photo Records


3. The data is stored using cloud storage and can be viewed by authorised personnel via a web portal. The portal offers the added benefit of being able to track the progress of jobs, gain access to a full history of works with 24-hour web-based access. Full training will be given and will form part of any implementation process at no cost.

Battery Cleaning

Industrial working environments are inherently dirty, and batteries are no exception.

Batteries pick up dirt from the ordinary day-to-day operation, but during charging, they give off gasses that can cause a build-up of moisture on surfaces that attract more dirt. Whilst much of the moisture evaporates, it leaves behind a corrosive layer of grime that, if left untreated, can:

  • Damage the battery and its components

  • Cause uneven power output between cells and premature failure

  • Hide other unrelated issues such as damage or wear and tear

  • Pose a safety hazard to operators

Battery cleaning includes a chemical clean of all surfaces, electrical connectors and the filling cap to keep batteries in good, clean, working order.

Battery Health Check

When you use a battery, it goes through a ‘charge cycle’, which is the terminology used by manufacturers that represents the number of complete charges and discharge cycles the battery can perform before its capacity diminishes.


All batteries have a limited number of charge cycles, and once the cycle count has been reached a battery may need to be replaced to maintain performance.


Knowing how many charge cycles a battery has completed, and how many are left, can help you determine when to replace the battery, but other factors will contribute to battery health such as how it has been used and maintained.


Whilst the importance and benefits of maintaining a healthy battery fleet are well-understood, it’s not possible to determine the health and longevity of a battery with a visual inspection alone. We perform an internal Health Check to determine the condition of the individual cells in your batteries. This includes:

  • Voltage check to measure the strength of each battery cell to identify if cells are below their minimum operating value. If a cell is found to be operating outside of the normal range it could indicate a fault, which we validate through further testing.

  • Specific Gravity (SG) check to indicate the state of charge of battery cells.

This more in-depth Health Check will help you to proactively manage your battery fleet by identifying battery cells that might be close to their end-of-life before they become a problem for you.

Component Replacement

Following our Visual Check, we replace essential components that are in poor condition or pose a safety risk. This includes:

  • Intercell Connectors

  • Connector Bolts

  • Battery Harness Sleeving

  • Battery Filling Watering system components

For more information or to book an appointment to discuss how ‘Juice’ can support your company, please contact your account manager or email or