Technical safety in electric and hybrid vehicles: service, isolation, and incident response guidelines for independent workshops

Abstract

The growing presence of battery electric vehicles (BEVs) and hybrid electric vehicles (HEVs) in independent repair shops has shifted the focus from isolated diagnostic skills to systematic electrical risk management. This article consolidates a minimum set of regulations and best practices — combining Brazilian electrical safety rules with international standards on occupational protection, charging infrastructure and incident response — and translates these frameworks into concrete operational procedures for workshops servicing electrified vehicles. Based on this foundation, it proposes guidelines for high-voltage bay layout, signage, dedicated PPE and tool management, safe installation and use of charging equipment, as well as a standard procedure for service intake, electrical isolation and verification of absence of voltage grounded in lockout/tagout practices and the “Stop–Isolate–Test” sequence. The discussion addresses barriers for small independent shops, including training gaps, cost constraints and safety culture. It concludes that safety in servicing electric and hybrid vehicles cannot be reduced to PPE selection alone; it depends on a management system that aligns regulations, procedures, training and documented evidence, thereby improving occupational protection and the reliability of workshop operations.