EV Safety
Electric vehicles bring important environmental and operational benefits, but they also introduce specific workshop and service-centre hazards that must be understood and controlled. High-voltage systems, damaged battery packs, thermal runaway, contaminated runoff, and delayed re-ignition all require a planned and disciplined approach to risk assessment, isolation, spill response, and staff competence.[1][2][3]
In practical terms, EV safety is not just about electrical isolation. It also includes recognising damaged components, controlling access to affected vehicles, preventing liquids from entering drains, selecting the correct spill response materials, and ensuring that personnel use appropriate PPE and follow vehicle-specific manufacturer guidance.[1][4][6]
Why EV safety needs special attention
According to HSE guidance, additional skills and training are necessary for people working with electric and hybrid vehicles, and the required competence level depends on the type of work being carried out, from low-risk handling through to work on high-voltage systems.[1] HSE also notes that vehicles should be visually checked for signs of damage to high-voltage components or orange cabling, and that the high-voltage battery system should be isolated in line with manufacturer instructions where it is safe to do so.[1]
Lithium-ion battery incidents can involve overheating, chemical leakage, toxic vapours, fire, and re-ignition risk. NFCC states that thermal runaway can produce large volumes of toxic and explosive vapours, and that lithium-ion battery fires can be difficult to extinguish and may reignite even after the visible fire appears to be under control.[3] NFCC also highlights that firefighting tactics can produce contaminated fire-water runoff, which creates an environmental control issue as well as a fire issue.[2]
Main EV workshop hazards
The most common EV-related hazards in service and maintenance environments include:
- High-voltage electrical shock from damaged or improperly isolated systems.[1]
- Thermal runaway in a damaged or compromised lithium-ion battery pack.[2][3]
- Chemical leakage from battery damage or associated components.[6]
- Toxic gas generation and smoke contamination during a battery fire event.[2][3]
- Contaminated runoff entering surface water drains or internal drainage systems.[2][10]
- Unexpected vehicle movement if keys are not controlled and the vehicle is not made safe.[1]
Safe working principles for EV service areas
1. Competence and training
Staff should only carry out tasks that match their training and authority level. HSE separates work involving electric and hybrid vehicles into different activity categories, including lower-risk activities, incident response, maintenance and repair excluding high-voltage systems, and direct work on high-voltage systems.[1] This makes it essential to define who may inspect, isolate, dismantle, recover, or quarantine an affected EV.
2. Vehicle-specific information
Always refer to manufacturer guidance before carrying out servicing, dismantling, recovery, welding, body repairs, painting, or battery-related work. HSE specifically advises using reliable, vehicle-specific information and identifying the location of high-voltage cables before work such as cutting, panel replacement, or welding begins.[1]
3. Isolation and key control
Remote keys should be kept away from the vehicle to prevent accidental energisation or movement. HSE also advises isolating high-voltage systems in accordance with manufacturer instructions and proving systems dead before high-voltage work is undertaken.[1]
4. Inspection before work starts
Before moving or working on an EV, inspect it for damage to battery housings, orange high-voltage cabling, electrical components, signs of impact, heat, bulging, leaking fluids, unusual odours, or smoke residues. Government fire-risk guidance states that visibly damaged, bulging, smelly, or leaking battery packs pose an extremely high fire risk.[4]
5. Controlled access and segregation
If a vehicle is suspected of battery damage, it should be moved only if safe to do so and placed in a controlled area with restricted access. HSE notes that it may be necessary to secure an area and use warning signs so that people who may be at risk do not approach the vehicle.[1] Serpro’s guidance on EV service-centre safety also supports the use of designated quarantine spaces for damaged batteries or affected vehicles.[6]
Quarantine areas for suspect or damaged EVs
A quarantine area gives workshops a practical way to separate a suspect EV from staff, stock, ignition sources, traffic routes, and drains. This area should be clearly marked, well ventilated, easy to access for emergency response, and positioned so that any leakage or contaminated firefighting runoff can be managed more effectively.[2][6]
Where possible, quarantine arrangements should include:
- restricted access with warning signage;[1]
- clear separation from combustible materials and general workshop activity;[2]
- drain identification and immediate drain-sealing capability;[10][11]
- an agreed escalation plan for fire and rescue service attendance;[2]
- suitable spill control materials and PPE close to hand.[8][9][12]
Spill control and environmental protection
EV incidents are not only an electrical or fire problem. They may also create a spill-control problem involving battery leakage, contaminated wash-down water, and debris. Preventing liquids from entering drains is a key part of site protection, particularly in workshops, loading areas, yards, and service bays where spills could migrate quickly into surface water systems.[2][10]
For this reason, EV safety planning should include access to drain protection products and a clear procedure for deploying them without delay.[10] For wider spill response capability, workshops may also need chemical spill kits and, where applicable, battery acid spill kits as part of their broader incident preparedness arrangements.[8][9]
PPE for EV incident response
PPE requirements depend on the task, the vehicle design, and the manufacturer’s instructions. HSE states that suitable precautions, including PPE as a final measure, should be considered where live work is unavoidable and only where it is reasonable and safe to do so.[1] In spill-control terms, responders may also require gloves, eye protection, protective clothing, and other task-specific PPE to reduce contact with leaked materials or contaminated debris.[1][12]
Suitable options can be supported by a review of available work wear and PPE alongside the site’s own risk assessment and manufacturer instructions.[12]
What an EV safety response plan should cover
An effective EV safety plan should set out:
- who is trained to inspect, isolate, recover, or quarantine EVs;[1]
- how damaged vehicles are identified and reported;[1][4]
- where quarantine areas are located and how they are controlled;[1][6]
- how drains are protected and contaminated runoff is contained;[2][10]
- what spill kits, drain covers, neutralisers, and PPE are held on site;[8][9][10][12]
- when emergency services should be contacted and what information they need;[2]
- how vehicles are monitored after an incident because re-ignition remains possible.[2][3]
Recommended internal reading
For additional context, see Serpro’s guidance on Managing Lithium Battery Incidents at EV Service Centres. You may also wish to review relevant internal product and category pages for Drain Protection, Chemical Spill Kits, Battery Acid Spill Kits, and Work Wear - PPE.[6][8][9][10][12]
References
- HSE: Electric and hybrid vehicles
- NFCC: Fire Risks in Energy Technologies
- NFCC: Battery Energy Storage Systems (BESS) Position Statement
- GOV.UK: E-cycle and e-scooter batteries - managing fire risk for premises
- HSE: Grid-scale battery energy storage systems
- Serpro Blog: Managing Lithium Battery Incidents at EV Service Centres
- Serpro Blog: Managing Lithium Battery Incidents at EV Service Centres (Emergency Spill Response)
- Serpro: Chemical Spill Kits
- Serpro: Battery Acid Spill Kits
- Serpro: Drain Protection
- Serpro: Containment Products
- Serpro: Work Wear - PPE