Your Workshop, Your Liability: What the EV Revolution Means for Australian Workshop Safety Compliance

david richardson
Apr 24
4 min read

Published by AutoComply360 | Auto Workshop Safety Compliance

Mechanic in arc flash PPE working on an electric vehicle high-voltage system in an Australian automotive workshop — WorkSafe compliance automotive workshop Australia.

Electric vehicles are arriving in Australian workshops faster than most operators have planned for. Here’s what AS 5732:2022 and WorkSafe actually require — and the liability exposure if you’re not ready.

Australia crossed a milestone quietly. More than 12% of new car sales are now electric or hybrid. Industry forecasts put that figure well above 30% by 2030. That means EVs are already parking in your neighbourhood, being driven by your customers, and — if they aren’t already — rolling into your bay.

And that’s where the problem starts.

Most Australian automotive workshops are set up to service internal combustion engines (ICE). That’s what they’ve always done. But an electric or hybrid vehicle isn’t a variation on what you already know. The hazards it introduces — high-voltage systems, lithium-ion battery chemistry, thermal runaway risk, arc flash potential — are categorically different. And so are your WorkSafe obligations the moment one enters your workshop.

What the regulations actually say

Under the Work Health and Safety Act 2011, every person conducting a business or undertaking (PCBU) has a primary duty to eliminate or minimise risks to workers and others so far as is reasonably practicable. That duty doesn’t have an exception clause for ‘but we’ve always been an ICE workshop.’

The standard that sits on top of that duty for EV work is AS 5732:2022 — Electric Vehicle Operations: Maintenance and Repair. This Australian Standard defines what competent, safe EV servicing looks like. WorkSafe inspectors in every state reference it. It covers high-voltage isolation procedures, PPE requirements, safe systems of work, fire suppression provisions, battery pack handling, and more. It exists because the risks are real and the consequences of getting it wrong are severe.

WorkSafe Victoria has published specific guidance on working with hybrid and electric vehicles, reviewed as recently as December 2025. Queensland’s Electrical Safety Office has issued EV-specific compliance direction under the Electrical Safety Act 2002. This isn’t a future issue. It’s a current one.

What are the actual hazards WorkSafe is worried about?

The hazards that come with EV work are not comparable to forgetting to chock a wheel. They include:

Arc flash — a high-voltage electrical fault that produces extreme heat, pressure and molten metal ejection. Burns that can be fatal. No warning.
Thermal runaway — a chain reaction in lithium-ion battery cells that can produce fire and toxic gas hours or even days after an initial incident. A vehicle that appears fine can become a serious risk after you’ve finished work on it.
Electric shock — EV high-voltage systems operate at 400V and above. Standard ICE workshop tools are not rated for this. A worker using the wrong equipment on an energised HV circuit can be killed.
Toxic gas and fume exposure — damaged lithium-ion batteries off-gas hydrogen fluoride and other toxic compounds. Without proper ventilation separation, this reaches office areas and shared spaces.

And then there’s the one that catches operators off guard: silent operation. An EV moving under motor power gives almost no audible warning. A worker who assumes a vehicle is stationary because they can’t hear an engine is exposed to a risk that simply doesn’t exist in an ICE environment.

What does a WorkSafe inspector actually look for?

Beyond the physical hazards, there’s a question every workshop operator needs to be honest about: can you prove your preparedness?

When a WorkSafe inspector walks into a workshop where EV or hybrid servicing is being performed, they will look for evidence. Not just that the right equipment exists — but that it’s being used correctly, workers have been trained, a documented safe system of work is in place, and it’s being followed.

That means:

Written safe systems of work aligned to AS 5732:2022
Proof of staff training (AURETH101 and AURETH102 at minimum, or the full Certificate III in Automotive Electric Vehicle Technology)
High-voltage rated PPE in serviceable condition and accessible
Lockout/tagout procedures and equipment in place
Fire suppression systems meeting additional special hazard provisions
A documented vehicle intake process identifying battery chemistry and thermal risk

No documentation? That’s not just a compliance gap. Under the WHS Act, it’s personal liability for the PCBU. And if there’s an incident — a fire, an arc flash, an electric shock — and you can’t demonstrate a safe system of work was in place? That’s a prosecution waiting to happen.

The timing risk most operators haven’t calculated

Here’s what makes this urgent even for workshops that don’t actively seek EV work: you don’t choose when an EV rolls in. A customer’s BYD breaks down. A fleet vehicle comes in for a routine service. A Mitsubishi Outlander PHEV needs a tyre rotation. The moment it’s on your premises, your duty of care has been triggered.

The workshops that will be caught out are the ones that have done nothing because they think EV work is still someone else’s problem. The adoption curve has already reached your customers’ driveways.

Getting ahead of it

The framework for managing this is clear. AS 5732:2022 defines the standard. WorkSafe guidance sets out what a compliant workshop looks like. The training pathways exist and are available nationally. The equipment you need is identifiable and procurable.

The gap for most workshops isn’t knowledge — it’s action. And the longer that gap sits open, the greater the exposure.

Our next post walks through exactly what EV-ready looks like in practice: the equipment, the training, and the documented systems a WorkSafe-compliant workshop needs in place before the first EV rolls in.

AC360 is the compliance management platform built specifically for Australian automotive workshops. We’ve added EV and hybrid safety compliance checks to our curated check library, giving workshops a structured, evidence-generating process aligned to AS 5732:2022 and WorkSafe guidance. Get in touch at www.autocomply360.com.au.

This post is for general information purposes only and does not constitute legal advice. Consult a qualified legal or WHS professional for advice specific to your situation.