Battery types for aerial work platforms

Battery performance has a direct impact on the uptime, efficiency and total cost of ownership of an aerial work platform. The different battery types may serve the same purpose, but they behave very differently in practice. Understanding those differences is essential when maintaining or replacing a battery system.

This guide explains the different battery technologies used in aerial platforms and their strengths, limitations and typical applications.

This guide covers:

• Flooded lead-acid (traditional)

• AGM (Absorbent Glass Mat)

• Gel batteries

• Lithium batteries

Flooded lead-acid batteries

Flooded lead-acid batteries are a common and cost-effective battery type for aerial work platforms.

Their main advantage is the lower upfront cost. However, they require regular maintenance. The demineralised water level must be checked and topped up when necessary. If this is not done correctly, the water and electrolyte balance can be affected. Over time, this can damage the plates inside the battery and reduce its lifespan. Automatic watering systems are increasingly being used to make this maintenance easier and less time-consuming.

These batteries are best suited to standard applications and lower usage intensity. They are often a good choice when upfront cost is an important factor and regular maintenance, can be carried out correctly.

Safety notice: Lead-acid batteries can leak if they are tilted or handled incorrectly, because they contain liquid acid. This can be dangerous, so always wear the correct protective equipment when handling them.

AGM batteries

AGM stands for Absorbent Glass Mat. They batteries are a sealed, maintenance-free battery type based on lead-acid technology. Instead of liquid electrolyte, the electrolyte is held in glass fibre mats inside the battery.

This makes AGM batteries easier to maintain than flooded lead-acid batteries. They do not need water top-ups and have no leakage risk under normal use. They also offer a high discharge capacity of up to around 80% and charge faster than gel batteries. Because of this, AGM batteries are a strong option for demanding environments and frequent use.

Gel batteries

Gel batteries are a sealed, maintenance-free battery type. They are similar to lead-acid batteries, but the liquid electrolyte is replaced by gel, making them a more costly option. Because they are sealed, gel batteries do not require water top-ups and have no leakage risk under normal use.

They are safe and stable in operation, and they are best suited to steady discharge over time. This makes them suitable for lower-intensity applications. Compared with AGM batteries, they charge more slowly and offer lower peak performance. They are also sensitive to incorrect charging. As a result, they are becoming less common in aerial work platforms.

Litium batteries

Lithium batteries are becoming more common in the access industry. They charge quickly, offer more charge cycles and require little to no maintenance.

These batteries are well suited to intensive use, especially when machines need to stay available for as long as possible. Moreover, they offer high energy efficiency and consistent performance throughout the discharge cycle. However, all this is balanced by a higher upfront cost.

Lithium batteries do not charge in the same way as lead-acid, AGM or gel batteries. They require a specific charging profile and a Battery Management System (BMS) to monitor and protect the battery pack.

Safety notice: Lithium batteries must be handled with extra care, as damage or incorrect handling can increase the risk of fire. They are also subject to stricter storage and transport rules.

Warranty notice: If there is a problem with the battery pack, always check the manufacturer's instructions or warranty conditions before opening it. Opening the battery pack yourself may void the warranty.

Not sure which one to choose?

Choosing the right battery type depends on your machine, application and technical requirements. Our team can help you compare the options before you order.

Get in touch for practical advice tailored to your machine.