Product Overview

Summary: This Electric Vehicle Fire Risk Management SOP provides a clear, practical framework for preventing, responding to, and recovering from EV-related fire incidents in Australian workplaces. It helps organisations safely manage lithium-ion battery hazards, protect workers and customers, and demonstrate due diligence under WHS legislation as EV adoption accelerates.

As electric vehicles become more common across fleets, workshops, depots, car parks and public facilities, businesses must manage a new class of fire risk linked to high‑energy lithium-ion batteries. Traditional fire procedures designed for internal combustion engines are not sufficient for thermal runaway events, off‑gassing, reignition risk and the complex behaviour of damaged or unstable EV batteries. This Electric Vehicle Fire Risk Management Safe Operating Procedure gives your organisation a structured, evidence‑based approach to identifying EV fire hazards, implementing robust controls and coordinating an effective emergency response tailored to the unique characteristics of EV incidents.

The SOP sets out clear expectations for safe EV handling, storage, charging, maintenance and collision management, with specific guidance for indoor car parks, workshops, loading docks and fleet depots. It defines step‑by‑step actions for early detection and isolation of suspect vehicles, communication protocols with Fire and Rescue services, and safe evacuation and exclusion zone management. By adopting this procedure, your business can reduce the likelihood and impact of EV fire incidents, protect workers and the public, support insurers’ risk requirements, and show regulators that EV‑specific fire risks have been systematically assessed and controlled in line with Australian WHS duties.

Key Benefits

• Reduce the likelihood and severity of EV fire incidents through structured hazard identification and control measures.
• Ensure your workplace emergency response plans are aligned with current best practice for lithium-ion battery and EV fires.
• Demonstrate WHS due diligence to regulators, clients and insurers in relation to emerging electric vehicle risks.
• Standardise EV fire risk controls across multiple sites, fleets and facilities for consistent, defensible practice.
• Improve coordination with local fire services by defining clear communication, access, and handover protocols for EV incidents.

Who is this for?

• WHS Managers
• Fleet Managers
• Workshop Supervisors
• EV Service Technicians
• Facilities and Property Managers
• Emergency Wardens and Floor Wardens
• Logistics and Depot Managers
• Parking and Facilities Operations Managers
• Dealership Principals and Service Managers
• Electrical Contractors working on EV infrastructure

Hazards Addressed

• Thermal runaway and spontaneous ignition of lithium-ion traction batteries
• Reignition of EV batteries after an initial fire has been controlled
• Toxic and flammable gas release from overheating or damaged battery packs
• Electrical hazards from high-voltage EV systems during fire or post-crash recovery
• Fire spread between closely parked vehicles in car parks or depots
• Inadequate ventilation and smoke build-up in enclosed car parks and workshops
• Manual handling and collision risks when moving damaged or unstable EVs
• Exposure of workers and first responders to hot surfaces, projectiles and structural failure during EV fires
• Charging equipment faults leading to overheating or electrical fires
• Inappropriate use of extinguishing agents or equipment on high-voltage EV systems

Included Sections

• 1.0 Purpose, Scope and Application
• 2.0 Definitions and Key Concepts (EV, lithium-ion battery, thermal runaway, etc.)
• 3.0 Roles, Responsibilities and Consultation Requirements
• 4.0 Regulatory and Standards Framework for EV Fire Risk Management
• 5.0 EV Fire Hazard Identification and Risk Assessment Methodology
• 6.0 Safe Design and Layout Considerations for EV Parking, Storage and Charging Areas
• 7.0 Control Measures for EV Charging Operations (including lock-out/tag-out and supervision)
• 8.0 Procedures for Handling, Parking and Storing EVs (including damaged or suspect vehicles)
• 9.0 Workshop and Maintenance Controls for EV Servicing and Repair Activities
• 10.0 Fire Detection, Protection and Ventilation Requirements for EV Environments
• 11.0 Step-by-Step Response to Suspected EV Battery Overheating or Thermal Runaway
• 12.0 Emergency Procedures for Confirmed EV Fires (on-site and in structures)
• 13.0 Communication, Evacuation and Exclusion Zone Management
• 14.0 Coordination with Fire and Rescue Services (information, access and handover)
• 15.0 Incident Reporting, Investigation and Post-Incident Recovery of EVs
• 16.0 Training, Competency and Induction Requirements for Workers and Contractors
• 17.0 Inspection, Testing, Maintenance and Review of Controls
• 18.0 Document Control, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulations 2011 (Cth and relevant state/territory variants)
• Safe Work Australia – Managing Risks of Plant in the Workplace Code of Practice
• Safe Work Australia – Managing the Work Environment and Facilities Code of Practice
• AS 1851: Routine service of fire protection systems and equipment
• AS 2419.1: Fire hydrant installations – System design, installation and commissioning
• AS 2444: Portable fire extinguishers and fire blankets – Selection and location
• AS/NZS 3000: Electrical installations (Wiring Rules)
• AS/NZS 4825: Firefighting agencies’ equipment for fire suppression in buildings (for coordination considerations)
• AS 4083: Planning for emergencies – Health care facilities (referenced for emergency planning principles where applicable)