Product Overview

Summary: This Electric Vehicle Packaging and Shipping SOP sets out a clear, step-by-step process for preparing, packaging and transporting electric vehicles and high-voltage battery systems safely and compliantly within Australia. It helps your business control fire, electrical and hazardous chemical risks while meeting WHS duties and transport regulations for lithium-ion batteries and EV components.

Electric vehicles and their associated battery systems present unique risks when being packaged and shipped, particularly around high-voltage components, lithium-ion batteries, thermal runaway and hazardous chemicals. This Safe Operating Procedure provides a comprehensive, WHS-aligned framework for safely managing EVs from the moment they arrive in your facility through to dispatch and handover to the transport provider. It translates complex dangerous goods and electrical safety requirements into practical, easy-to-follow steps for Australian warehouses, dealerships, workshops and logistics operations.

The procedure covers pre-shipment inspection of vehicles and battery systems, safe de-energising and isolation, packaging requirements for complete vehicles and separate battery packs, labelling and documentation, and handover to road, sea or air carriers in line with applicable regulations. It is designed to minimise the risk of fire, electric shock, leaks and physical damage during handling and transport, while providing clear guidance for staff who may not be EV specialists. By implementing this SOP, businesses can demonstrate due diligence under WHS law, protect workers and contractors, and reduce the likelihood of costly incidents, shipment refusals and regulatory non-compliance.

This SOP is particularly valuable for organisations scaling up EV volumes or transitioning from internal combustion engine logistics to electric fleets. It standardises training, clarifies roles and responsibilities, and embeds robust risk controls into day-to-day operations. The document is written for the Australian context, referencing relevant WHS legislation, dangerous goods requirements and industry standards so your team can work confidently and consistently, regardless of site or shift.

Key Benefits

• Ensure safe handling, packaging and loading of electric vehicles and lithium-ion batteries to protect workers, contractors and transport providers.
• Reduce the risk of fires, thermal runaway events and electric shock incidents during storage, packaging and shipment.
• Streamline EV dispatch workflows with clear, repeatable steps that reduce errors, rework and shipment delays.
• Demonstrate compliance with Australian WHS duties and dangerous goods transport requirements for EV batteries and components.
• Standardise training and competency requirements across warehouses, dealerships and logistics partners handling EV consignments.

Who is this for?

• Warehouse Managers
• Logistics and Distribution Managers
• Operations Managers
• WHS Managers and Advisors
• Dangerous Goods Safety Advisors
• Freight and Dispatch Coordinators
• EV Dealership Managers
• Fleet Managers
• Import/Export Coordinators
• 3PL (Third Party Logistics) Providers

Hazards Addressed

• Electric shock from exposed or damaged high-voltage components
• Thermal runaway and fire from lithium-ion batteries
• Short-circuiting of battery terminals during packaging and transport
• Release of hazardous gases or electrolytes from damaged battery packs
• Manual handling injuries when moving heavy EVs, battery modules and crates
• Crush and pinch injuries during vehicle loading, securing and unloading
• Slips, trips and falls in packaging and dispatch areas
• Exposure to hazardous chemicals during leak or spill events
• Vehicle movement and collision risks in loading docks and yards

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (EV, HV systems, lithium-ion battery types, dangerous goods classes)
• 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 Packaging and Shipping
• 6.0 Required PPE, Tools and Equipment
• 7.0 Pre-Packaging Inspection of Electric Vehicles and Battery Systems
• 8.0 Safe De-energising, Isolation and Verification of EV High-Voltage Systems
• 9.0 Packaging Requirements for Complete EVs
• 10.0 Packaging Requirements for Loose or Replacement EV Batteries and Components
• 11.0 Labelling, Marking and Dangerous Goods Documentation
• 12.0 Storage Conditions Prior to Dispatch (segregation, temperature control, fire protection)
• 13.0 Loading, Securing and Unloading Procedures for Road, Sea and Air Transport
• 14.0 Housekeeping and Traffic Management in Packaging and Dispatch Areas
• 15.0 Emergency Procedures for Battery Damage, Fire, Leaks and Spills
• 16.0 Incident Reporting, Investigation and Corrective Actions
• 17.0 Training, Induction and Refresher Requirements
• 18.0 Monitoring, Review and Continuous Improvement of the SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth) and relevant state and territory WHS Acts and Regulations
• Safe Work Australia – Model Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Model Code of Practice: Managing the Work Environment and Facilities
• Australian Dangerous Goods (ADG) Code – Transport of Dangerous Goods by Road and Rail (Class 9 lithium batteries)
• IATA Dangerous Goods Regulations (for air freighted EV batteries, where applicable)
• AS IEC 62619: Safety requirements for secondary lithium cells and batteries, for use in industrial applications
• AS/NZS 3000: Electrical installations (Wiring Rules) – for reference to safe electrical practices around high-voltage systems
• AS ISO 45001: Occupational health and safety management systems – Requirements with guidance for use