Is Your Auto Repair Shop Ready to Work on Electric Vehicle Batteries?

Text published on November 26, 2025, by Jocelyn Jargot, Prevention Advisor at Auto Prévention

In a workshop, safety around electric and hybrid vehicle (EV/HEV) batteries requires that personnel be well-trained, that specialized procedures are applied, and that the premises are properly adapted for various types of tasks and potential emergencies.

This article focuses mainly on the necessary adaptations for current workshops when working directly on high-voltage batteries.

Key Safety Measures

We have often addressed the topic of EVs in the past. This time, we will focus specifically on batteries. Here are the main safety measures regarding EV batteries:

Always treat any EV battery and its associated high-voltage circuit as energized. Electrical hazards are silent and invisible!
Establish clearly defined and appropriate high-voltage work zones. This point will be further detailed below.
Use specialized non-conductive tools (e.g., category III multimeter) for any work on or inside a battery or on external connections unless a voltage absence verification (VAV) has been performed and confirmed according to safety standards.
Ensure access to technical information to follow manufacturer instructions (database for vehicle-specific procedures). If a procedure seems unsafe, revert to basic safety principles.
Use personal protective equipment (PPE) specialized for electrical hazards, depending on the task.
Use specialized handling equipment (work tables, specific accessories) according to the task.
Train technicians specifically for EV interventions, including risks and preventive measures. Numerous tailored training programs are now available based on company needs.

For more information on managing risks related to EV batteries, consult the IRSST FAQ, developed in collaboration with Auto Prévention: vehiculeelectrique.irsst.qc.ca

Organizing the Workspace

Minimum Work Zone
If the work occurs in a general workshop, temporarily mark the work area using warning systems such as cones and non-conductive safety barriers, placed at a safe distance of at least 1 meter (3 feet) from live components (connectors, etc.). IRSST FAQ question 3.9 provides more details if needed.

Specialized Zone
A dedicated area adapted for work on and inside batteries is essential. Key considerations for this zone:

Workspace and Handling: For work inside a battery, ensure space to move around, handle components on work tables, and use handling equipment such as work tables or workshop cranes. This zone must not be located under a lifted vehicle.
Lighting: Higher lighting than in a general workshop is needed for precise battery work. PPE such as hoods, safety glasses, and tinted arc-protection visors can reduce visibility, making adequate lighting essential for small components (e.g., connectors, screws).
Ventilation (toxic fumes): Damaged batteries may crack or leak, releasing hazardous and corrosive fumes. Ventilation systems control fumes at the source, protect the rest of the building, and allow safer evacuation.
Fire Separation: A damaged high-voltage battery can short-circuit, ignite, or explode, with a risk of reignition long after the initial fire. Ensure the workshop can handle a fire. Consider a specialized area, fire-rated barriers, or fire doors.
Storage and Thermal Runaway: Damage from collisions or other events can trigger thermal runaway days or weeks later. Provide separate or remote storage and consider prolonged temperature monitoring of stored battery packs. IRSST FAQ question 5.2 covers this topic in more detail.

Conclusion

No pun intended, but stay informed of evolving standards, regulations, and safety directives around EV batteries as technology progresses. Your workshops are valuable, and adapting them is more essential than ever! The workshops of tomorrow require changes starting today.

Thanks to Damien Burlet-Vienney (IRSST) for his collaboration.

Note: A multidisciplinary research project is also underway at IRSST on handling EV batteries in garages (general mechanics, buses, dismantling, etc.), including occupational health and safety impacts. Interested in participating? Visit: irsst.qc.ca

Text Credit: Published on November 26, 2025, by Jocelyn Jargot, Prevention Advisor at Auto Prévention
Image Credit: SHUTTERSTOCK