Product Overview

Summary: This Electric Vehicle Handling Safe Operating Procedure sets out safe, compliant methods for working with, moving and storing electric vehicles in Australian workplaces. It focuses on controlling high-voltage, fire, and manual handling risks while providing clear, step-by-step instructions that protect workers, assets and your business from emerging EV-related hazards.

Electric vehicles introduce a range of unfamiliar risks into workshops, depots and roadside environments, particularly around high-voltage systems, lithium-ion batteries and potential thermal runaway. Traditional procedures written for internal combustion engine vehicles do not adequately address these hazards, leaving businesses exposed to shocks, fires, toxic gases and uncontrolled vehicle movement. This Electric Vehicle Handling Safe Operating Procedure provides a clear, practical framework for safely receiving, isolating, moving, storing and working around EVs in line with Australian WHS expectations.

The SOP guides workers through each stage of interaction with an EV, from initial identification and visual inspection through to high-voltage isolation, use of insulated tools, safe jacking and lifting, and controlled storage of damaged or suspect vehicles. It sets out defined roles, competency requirements and PPE, and includes structured checklists for routine handling as well as incidents such as collisions, battery damage or water immersion. By implementing this procedure, organisations can demonstrate due diligence, standardise training, and confidently manage EV risks while supporting the transition to low-emissions fleets.

Developed for Australian conditions, this SOP aligns with relevant WHS legislation, electrical safety principles and emerging best practice for lithium-ion battery management. It is suitable for both small workshops and large fleet operations, providing a ready-to-use template that can be customised to site-specific layouts, equipment and local emergency arrangements.

Key Benefits

• Ensure safe, consistent handling of electric vehicles across workshops, depots and roadside operations.
• Reduce the risk of electric shock, arc flash and battery-related fires through clearly defined isolation and control steps.
• Demonstrate compliance with Australian WHS duties and electrical safety obligations for high-voltage systems.
• Standardise training for technicians, tow operators and yard staff using practical checklists and role-based instructions.
• Minimise downtime, asset damage and incident-related costs by managing EV hazards proactively and systematically.

Who is this for?

• Workshop Managers
• Fleet Managers
• Automotive Technicians and Mechanics
• Panel Beaters and Body Repair Technicians
• Tow Truck Operators and Recovery Drivers
• Vehicle Storage and Auction Yard Supervisors
• WHS Managers and Safety Advisors
• Emergency Response Coordinators
• Facilities and Operations Managers in Transport Depots
• EV Service Centre Team Leaders

Hazards Addressed

• Electric shock from high-voltage EV systems and components
• Arc flash and short-circuit events during inspection or repair
• Lithium-ion battery thermal runaway and fire
• Release of toxic or flammable gases from damaged battery packs
• Uncontrolled vehicle movement during towing, lifting or storage
• Crush injuries from improper jacking, hoisting or securing of EVs
• Exposure to hazardous substances from damaged battery casings and coolant
• Burns from hot components or battery fire residues
• Slip, trip and fall risks associated with charging cables and workshop layout
• Vehicle rollover or instability during recovery or transport

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and EV System Overview
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Guidance
• 5.0 Required PPE, Tools and Equipment for EV Handling
• 6.0 Pre-Handling Checks and Vehicle Identification
• 7.0 High-Voltage Isolation and Verification Procedure
• 8.0 Safe Workshop Handling, Jacking and Lifting of EVs
• 9.0 Towing, Recovery and Transport of Electric Vehicles
• 10.0 Storage of Damaged, Flood-Affected or Suspect EVs
• 11.0 Charging Safety and Management of Charging Areas
• 12.0 Hazard Identification and Risk Control Measures
• 13.0 Emergency Response: Fire, Thermal Runaway and Electric Shock
• 14.0 Incident Reporting, Investigation and Corrective Actions
• 15.0 Training, Induction and Competency Assessment
• 16.0 Inspection, Maintenance and Review of this SOP
• 17.0 Document Control and Recordkeeping

Legislation & References

• Model Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts
• Model Work Health and Safety Regulations 2011
• Safe Work Australia – Code of Practice: Managing electrical risks in the workplace
• Safe Work Australia – Code of Practice: Managing risks of plant in the workplace
• AS/NZS 4836: Safe working on or near low-voltage electrical installations and equipment (used as guidance for electrical safety principles)
• AS IEC 61851 series: Electric vehicle conductive charging systems
• AS/NZS 3000: Electrical installations (Wiring Rules)
• Relevant state and territory Dangerous Goods and Fire Safety requirements for lithium-ion batteries (as applicable)