Product Overview

Summary: This SOP provides a clear, step-by-step framework for safely managing hazardous materials associated with electric vehicles (EVs), including high-voltage batteries, coolants, and other dangerous goods. It helps Australian workplaces control EV-specific risks, meet WHS and environmental obligations, and protect workers, customers, and the public throughout servicing, storage, transport, and end-of-life handling.

As electric vehicles become commonplace across Australian fleets and workshops, they introduce a new class of hazardous materials that must be managed with precision and care. High‑voltage lithium‑ion batteries, thermal management fluids, refrigerants, and associated electronic components all present unique fire, chemical, electrical, and environmental risks if mishandled. This Safe Operating Procedure provides a comprehensive, practical system for identifying, storing, handling, transporting, and disposing of hazardous materials linked to EVs in line with Australian WHS and dangerous goods requirements.

The document translates complex regulatory expectations into clear, workshop-ready instructions that can be followed by technicians, supervisors, and managers alike. It covers the full lifecycle of hazardous materials in EV operations—from intake inspection and isolation of damaged vehicles, through maintenance and repair, to end‑of‑life battery removal and transfer to licensed recyclers. By implementing this SOP, businesses can significantly reduce the likelihood of thermal runaway events, chemical exposures, environmental releases, and non‑compliance with dangerous goods and waste regulations, while demonstrating due diligence to regulators, insurers, and clients.

Key Benefits

• Ensure safe handling, storage, and transport of EV batteries and associated hazardous materials in line with Australian WHS and dangerous goods requirements.
• Reduce the risk of fires, explosions, chemical spills, and electric shock incidents in workshops, depots, and recovery operations.
• Standardise EV hazardous material practices across sites and shifts, improving training quality and operational consistency.
• Demonstrate due diligence to regulators, insurers, and clients through documented, defensible procedures.
• Minimise environmental harm and waste management costs by directing hazardous EV components into compliant recycling and disposal pathways.

Who is this for?

• Workshop Managers
• Electric Vehicle Technicians
• Automotive Service Managers
• Fleet Managers
• WHS Managers and Advisors
• Dealership Service Directors
• Auto Electricians
• Vehicle Recovery and Tow Operators
• Recycling and Salvage Yard Managers
• Emergency Response Coordinators

Hazards Addressed

• Thermal runaway and fire involving lithium-ion traction batteries
• Electric shock and arc flash from high-voltage EV systems
• Chemical burns and inhalation from battery electrolyte and coolants
• Release of refrigerants and other regulated gases from EV systems
• Toxic fume generation during damaged battery handling or fire events
• Manual handling injuries from lifting or moving heavy EV batteries and components
• Environmental contamination from spills, leaks, or improper disposal of hazardous EV materials
• Explosion risks from off-gassing batteries in confined or poorly ventilated spaces

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and EV Hazardous Material Types
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification and Risk Assessment for EV Operations
• 6.0 EV Intake, Assessment and Isolation of Damaged or High-Risk Vehicles
• 7.0 Handling and Storage of High-Voltage Batteries and Modules
• 8.0 Management of EV-Related Hazardous Chemicals (Coolants, Electrolytes, Refrigerants)
• 9.0 Labelling, Segregation and Dangerous Goods Storage Requirements
• 10.0 Manual Handling and Mechanical Aids for EV Battery Movement
• 11.0 Spill, Leak and Contamination Control Procedures
• 12.0 Fire Prevention, Thermal Runaway Response and Isolation Zones
• 13.0 Personal Protective Equipment (PPE) Selection, Use and Maintenance
• 14.0 Transport, Transfer and Handover to Licensed Waste and Recycling Providers
• 15.0 Emergency Response, First Aid and Incident Reporting
• 16.0 Training, Induction and Competency Verification for EV Work
• 17.0 Inspection, Monitoring, Recordkeeping and Continuous Improvement
• 18.0 Document Control and Review

Legislation & References

• Work Health and Safety Act 2011 (Cth) and model Work Health and Safety Regulations
• Safe Work Australia – Managing Risks of Hazardous Chemicals in the Workplace Code of Practice
• Safe Work Australia – Managing the Risks of Plant in the Workplace Code of Practice
• Safe Work Australia – Managing the Work Environment and Facilities Code of Practice
• AS/NZS 3000:2018 Electrical installations (Wiring Rules) – relevant principles for high-voltage safety
• AS IEC 62660 series – Secondary lithium-ion cells for the propulsion of electric road vehicles (reference for battery safety characteristics)
• AS/NZS 3760: In-service safety inspection and testing of electrical equipment (as applicable to workshop equipment)
• Australian Dangerous Goods (ADG) Code – Transport of dangerous goods by road and rail
• National Environment Protection (Movement of Controlled Waste between States and Territories) Measure – for interstate movement of hazardous waste
• Relevant state and territory environmental protection regulations for hazardous waste and battery disposal