Product Overview

Summary: This Safe Operating Procedure sets out a safe, compliant and environmentally responsible process for handling, dismantling and recycling electric vehicles at end-of-life. It focuses on managing high-voltage battery systems, hazardous components and waste streams in line with Australian WHS and environmental requirements, protecting workers while maximising resource recovery.

Electric vehicles present a new set of safety, environmental and compliance challenges at end-of-life. High-voltage battery systems, complex electronics, embedded data systems and hazardous materials such as electrolytes, coolants and airbags require a structured and defensible approach to de-energising, dismantling and recycling. This SOP provides a clear, step-by-step framework for safely receiving, assessing, isolating, dismantling and processing electric vehicles in Australian workplaces, from initial triage through to final waste classification and documentation.

Developed with Australian WHS obligations and emerging circular economy expectations in mind, this document helps businesses transition from traditional internal combustion vehicle practices to best-practice EV end-of-life management. It addresses critical risk areas such as high-voltage isolation, thermal runaway and fire, manual handling of heavy battery packs, hazardous substance exposure, and environmental contamination from spills or improper disposal. By implementing this SOP, organisations can demonstrate due diligence, improve worker confidence when handling EVs, and build a consistent, auditable process that supports both safety and sustainability objectives.

Key Benefits

• Ensure safe handling, isolation and removal of high-voltage EV components, significantly reducing the risk of electric shock and fire.
• Reduce environmental and regulatory risk by standardising how batteries, hazardous fluids and e-waste are classified, stored, transported and recycled.
• Streamline end-of-life processing with clear workflows that improve throughput, reduce rework and support consistent quality of dismantling and segregation.
• Demonstrate compliance with Australian WHS and environmental legislation through documented, repeatable procedures and record-keeping.
• Support worker competence and confidence with defined roles, training requirements and step-by-step guidance tailored to electric vehicles.

Who is this for?

• WHS Managers
• Recycling Facility Managers
• Automotive Workshop Managers
• End-of-Life Vehicle (ELV) Coordinators
• Electric Vehicle Technicians
• Dismantling and Yard Supervisors
• Environmental and Sustainability Managers
• Compliance and Risk Managers
• Battery Recycling Operators
• Scrap Metal Yard Operators

Hazards Addressed

• Electric shock from high-voltage battery systems and live components
• Arc flash and short-circuit events during battery removal or handling
• Thermal runaway and battery fires, including off-gassing and explosion risk
• Chemical exposure from battery electrolytes, coolants and other hazardous fluids
• Fire and explosion from damaged lithium-ion batteries during storage or transport
• Manual handling injuries from lifting or moving heavy battery packs and components
• Crush and pinch injuries during vehicle lifting, support and dismantling operations
• Exposure to sharp edges, broken glass and metal fragments during dismantling
• Hazardous waste and environmental contamination from spills, leaks or improper disposal
• Psychosocial stress for workers unfamiliar or uncomfortable with high-voltage EV systems

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (EV, HEV, PHEV, HV battery, SoC, etc.)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Pre-Job Planning and Risk Assessment (SWMS/JSA)
• 6.0 Site Requirements, Traffic Management and Work Area Set-Up
• 7.0 Required Tools, Equipment and Personal Protective Equipment (PPE)
• 8.0 Vehicle Receipt, Identification and Initial Safety Assessment
• 9.0 High-Voltage System Isolation, Verification and Lock-Out/Tag-Out
• 10.0 Safe Dismantling Sequence for Electric Vehicles
• 11.0 Battery Pack Removal, Handling, Packaging and Labelling
• 12.0 Management of Airbags, Pyrotechnics and Other Hazardous Components
• 13.0 Hazardous Fluids and Chemical Management (Draining, Storage and Disposal)
• 14.0 Segregation, Storage and Transport of Batteries and EV Components
• 15.0 Fire Prevention, Detection and Emergency Response (Including Thermal Runaway)
• 16.0 Environmental Protection Measures and Spill Response
• 17.0 Housekeeping, Waste Minimisation and Resource Recovery
• 18.0 Training, Induction and Competency Assessment
• 19.0 Inspection, Monitoring, Auditing and Continuous Improvement
• 20.0 Record-Keeping, Reporting and Incident Management
• 21.0 Document Control and Review

Legislation & References

• Work Health and Safety Act 2011 (Cth) and model Work Health and Safety Regulations
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: Managing the Risk of Plant in the Workplace
• Safe Work Australia – Code of Practice: How to Manage Work Health and Safety Risks
• AS/NZS 3000:2018 Electrical installations (Wiring Rules)
• AS/NZS 4836:2011 Safe working on or near low-voltage electrical installations and equipment (as guidance for electrical safety principles)
• AS 5377:2013 Management of electrical and electronic equipment for re-use or recycling
• AS/NZS 5139:2019 Electrical installations – Safety of battery systems for use with power conversion equipment (as guidance for stationary battery safety concepts)
• Environment Protection legislation and waste classification guidelines as adopted in relevant Australian states and territories (e.g. POEO Act NSW, EP Act QLD/VIC/WA/SA/NT/TAS)
• Chain of Responsibility provisions in Heavy Vehicle National Law where transport of batteries and hazardous waste is involved