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Electric and Hybrid Vehicle Recovery Risk Assessment

Free Risk Assessment template · Category: Vehicle Services and the Motor TradeView all Risk Assessment templates

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Risk Assessments

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Risk Assessment Matrix

Likelihood

5 = Certain
4 = Likely
3 = Possible
2 = Unlikely
1 = Remote

Severity

5 = Fatality
4 = Major Injury
3 = Lost Time Injury
2 = Minor injury
1 = Trivial Injury

Risk Rating [L x S]

1-5 = Low

6-12 = Medium

13-25 = High

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Risk	Initial Risk	Controlled Risk	Action
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Risk Assessment Description:

This electric and hybrid vehicle recovery risk assessment template is designed for motor trade professionals – recovery operators, breakdown crews, bodyshop technicians and MOT bay staff – who need to safely manage high‑voltage (HV) battery incidents. Whether responding to a vehicle fire, isolating a damaged battery pack, or towing an EV to a workshop, this assessment provides pre‑filled hazards and control measures that can be customised for your site. It aligns with HSE guidance on electric and hybrid vehicles (HSE, Electric and Hybrid Vehicles), the Electricity at Work Regulations 1989, PUWER 1998, and the IMI TechSafe / IET Code of Practice for Electric and Hybrid Vehicle Repair (see IMI TechSafe, IET CoP, Sec. 4‑16).

The template covers key risks identified in the motor trade context, including high‑voltage shock, thermal runaway, re‑ignition, unintended vehicle movement, chemical exposure, manual handling of heavy battery packs, slip/trip hazards from coolant leaks, and exposure to toxic gases generated during fires. Each hazard includes actionable control measures such as HV isolation procedures, insulated tooling, PPE specifications, safe lifting methods, spill containment, and post‑incident monitoring, ensuring compliance with relevant legislation and industry best practice.

Use this template to:

Roadside recovery of EVs/HEVs – assess hazards before lifting, towing or winching.
Workshop battery removal and replacement – ensure safe isolation and discharge.
Emergency response to HV battery fires – plan fire‑fighting and re‑ignition mitigation.

Each hazard includes suggested control measures covering isolation devices, insulated tools, PPE, safe discharge, fire‑extinguishing agents and post‑incident de‑briefs. The risk matrix uses a 5×5 likelihood‑severity scoring, with controlled severity always matching the initial severity as required by HSE guidance.

Fully editable and shareable – customise hazards, add site‑specific risks, adjust control measures to match your fleet and share the completed assessment with your team.

Compliant with: Electricity at Work Regulations 1989, Provision and Use of Work Equipment Regulations 1998 (PUWER), and the IMI TechSafe / IET Code of Practice for Electric and Hybrid Vehicle Repair.

Sample PDF Document Image:

Risks covered in this Recovering Electric and Hybrid Vehicles (HV/Fire) risk assessment

This Recovering Electric and Hybrid Vehicles (HV/Fire) risk assessment template covers 15 assessed hazards, each scored before and after control measures on a 5×5 HSE risk matrix.

Hazard	Initial risk	Controlled risk
High‑voltage battery fire (thermal runaway)	20	10
Accidental high‑voltage electric shock	20	10
Remote‑operation key activation causing vehicle start	16	8
Use of non‑insulated tools causing arc‑flash	16	8
Re‑ignition of extinguished HV battery fire	15	10
Mechanical damage leading to battery pack explosion	15	5
Fire spread to surrounding combustible materials	15	10
Unexpected vehicle movement due to active drive system	12	4
Incomplete isolation leaving residual voltage	12	4
Inadequate personal protective equipment (PPE)	12	6
Manual handling of heavy battery pack	12	6
Exposure to toxic gases from battery fire residues	12	4
Battery coolant leak and chemical exposure	9	3
Accidental activation of high‑voltage auxiliary systems after isolation	9	3
Slip/trip hazard from spilled coolant or electrolyte	6	2

Frequently asked questions

Are these risk assessment templates really free to download?

Yes - completely free. Over 2500 free UK risk assessment templates, free to use forever, no paywall. Customise to your workplace and download as a professional HSE-compliant PDF in minutes.

Can I download risk assessment templates in PDF or Word format?

Risk assessments download as a professional, HSE-compliant PDF - ready to print and file as-is. Word (.docx) export is not available for risk assessments, but you can fully customise every hazard, control measure, persons-at-risk entry and rating online before you download.

Are the risk assessment templates HSE-compliant?

Yes. Every template aligns with HSE guidance and the HSE 5-Step Risk Assessment process. They cover the requirements of the Management of Health and Safety at Work Regulations 1999, COSHH 2002, Manual Handling Operations Regulations 1992, Work at Height Regulations 2005, and other relevant UK regulations.

What industries do the risk assessment templates cover?

Over 2500 templates across every UK industry - painting, electrical, HVAC, plumbing, carpentry, concrete, solar panel installation, asbestos, scaffolding, working at height, manual handling, fall protection, hot works, confined space entry, lifting operations, kitchen fitting, plumbing, drywall, tiling, plastering, and many more.

What's the difference between a risk assessment form and a risk assessment template?

A risk assessment form is the blank document; a risk assessment template is a pre-filled form ready to customise. Our generator gives you both - a free interactive form you fill in plus over 2500 pre-written templates you can customise to your specific workplace.

Do I need to create an account to use the risk assessment templates?

You can build and preview a risk assessment without an account. To download the PDF you'll need a free account - it takes less than a minute, costs nothing, and also lets you save documents to your dashboard, edit them later, and share them for digital signatures.

Can I customise the risk assessment templates to my workplace?

Yes - fully. Edit hazards, control measures, persons at risk, likelihood and severity ratings, PPE requirements, and review schedules. Each template is a starting point you tailor to your specific operation.

How many risks can I add to a single risk assessment?

The number of risks (hazards) you can include in one assessment depends on your plan: guests get unlimited risks, Free accounts unlimited risks, Standard unlimited risks, Pro unlimited risks, and Enterprise unlimited risks per assessment. You can add and preview every risk in a template, then tick the ones to include up to your plan limit - upgrade any time for more. See our pricing page for the full plan comparison.

Are these risk assessment templates valid for UK construction work?

Yes. Our construction-specific risk assessment templates align with HSE construction guidance, the Construction (Design and Management) Regulations 2015 (CDM 2015), and the Work at Height Regulations 2005. Templates cover scaffolding, working at height, concrete pouring, excavation, roofing, electrical installation, and more.

How often should I update my risk assessment?

Whenever there is reason to believe the assessment is no longer valid - after workplace changes, near-misses, accidents, new equipment, new substances, or new processes. HSE guidance recommends an annual formal review at minimum.

What is the HSE 5-step risk assessment process?

Step 1: Identify the hazards. Step 2: Decide who might be harmed and how. Step 3: Evaluate the risks and decide on precautions. Step 4: Record findings and implement them. Step 5: Review the assessment and update if necessary. Our interactive generator walks you through all 5 steps.

Can I use these risk assessment templates for self-employed work?

Yes. Self-employed workers are required to assess risks to themselves and anyone affected by their work. Our templates are suitable for sole traders, contractors, and small businesses.

Do you have RIDDOR-aligned risk assessment templates?

Yes. Several templates cover RIDDOR (Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 2013) requirements - including accident reporting and investigation risk assessments. All RA templates support incident logging and review.

Risk Assessment Form Template