Product Overview

Summary: This Electric Vehicle Towing Guidelines SOP sets out clear, practical steps for safely securing, transporting and recovering electric vehicles across Australian workplaces and roads. It helps your team manage high-voltage and battery-related risks, protect critical vehicle components, and maintain compliance with WHS obligations and manufacturer requirements.

Electric vehicles introduce new and often misunderstood risks when it comes to towing, recovery and roadside assistance. High-voltage battery systems, regenerative braking, thermal runaway potential and manufacturer-specific towing limitations mean that traditional towing methods can create serious safety hazards, permanent vehicle damage and significant liability exposure for your business. This Electric Vehicle Towing Guidelines Safe Operating Procedure provides a clear, step-by-step framework to ensure every EV is assessed, secured and transported in a way that protects workers, the public and the asset itself.

Developed for Australian conditions, this SOP aligns with WHS duties of care and incorporates current good practice for handling high-voltage vehicles. It covers pre-tow assessment, safe isolation considerations, appropriate towing methods (including when flatbed transport is mandatory), safe loading and unloading, traffic management, and emergency response if an EV battery is damaged, overheats or ignites. By implementing this SOP, organisations can standardise training, reduce the chance of serious incidents, and demonstrate a robust, defensible approach to managing the unique risks of electric vehicle towing.

Key Benefits

• Reduce the risk of electric shock, battery fire and thermal runaway during EV towing and recovery operations.
• Ensure consistent, manufacturer-aligned towing methods that minimise costly damage to high-voltage systems and drivetrains.
• Demonstrate due diligence and WHS compliance when managing high-voltage vehicles in roadside and workshop environments.
• Improve operator confidence and competence through clear, step-by-step towing and emergency response instructions.
• Streamline incident response and communication between drivers, dispatch, workshops and emergency services when an EV is involved.

Who is this for?

• Tow Truck Operators
• Roadside Assistance Technicians
• Fleet Managers
• Workshop Managers
• Panel Beaters and Smash Repair Managers
• WHS Managers and Advisors
• Emergency Response Coordinators
• Logistics and Transport Supervisors
• Automotive Service Managers
• Mining and Industrial Site Supervisors with EV Fleets

Hazards Addressed

• Electric shock from high-voltage vehicle systems
• Battery thermal runaway, fire and explosion risks
• Exposure to toxic fumes from damaged or overheating lithium-ion batteries
• Vehicle roll-away or instability during loading, transport and unloading
• Crush injuries and musculoskeletal strain during manual handling and vehicle securing
• Traffic-related risks when loading or unloading EVs on roadsides or in car parks
• Damage to high-voltage components leading to subsequent safety failures
• Environmental contamination from battery electrolyte leaks

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and EV Technology Overview
• 3.0 Roles and Responsibilities
• 4.0 Competency, Training and Licensing Requirements
• 5.0 Required Vehicles, Equipment and PPE
• 6.0 Pre-Tow Risk Assessment and Site Safety
• 7.0 Electric Vehicle Identification and Initial Checks
• 8.0 High-Voltage Safety and Isolation Considerations
• 9.0 Approved Towing Methods for Different EV Types
• 10.0 Safe Loading, Securing and Unloading Procedures
• 11.0 Traffic Management and Roadside Safety Controls
• 12.0 Managing Damaged, Submerged or Fire-Affected EVs
• 13.0 Battery Fire, Overheating and Thermal Runaway Response
• 14.0 Communication Protocols with Dispatch, Workshops and Emergency Services
• 15.0 Incident Reporting, Investigation and Corrective Actions
• 16.0 Inspection, Maintenance and Calibration of Towing Equipment
• 17.0 Recordkeeping and Document Control
• 18.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS legislation
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS regulations
• Safe Work Australia – Model Code of Practice: Managing electrical risks in the workplace
• Safe Work Australia – Model Code of Practice: Managing risks of plant in the workplace
• AS/NZS 5732: Electric vehicle safety – Operation, maintenance, repair and recovery (or successor EV safety standards, where applicable)
• AS/NZS 4836: Safe working on or near low-voltage electrical installations and equipment
• AS ISO 45001: Occupational health and safety management systems – Requirements with guidance for use
• Austroads and state-based tow truck and roadside assistance guidelines, where applicable