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Electric & Hybrid Vehicle Repair 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 repair risk assessment template is designed for motor‑trade workshops, dealerships and recovery operators who work on high‑voltage EV and hybrid systems. Whether you’re replacing battery packs, diagnosing high‑voltage faults, performing bodywork on EVs, or carrying out roadside recovery, this electric vehicle repair risk assessment example provides pre‑filled hazards and control measures you can customise.

The template covers all key risks for EV/hybrid repair, including high‑voltage electric shock, arc‑flash, stored energy after isolation, damaged orange high‑voltage cables, lone‑work on HV systems, battery thermal runaway, hazardous electrolyte exposure, heavy battery manual handling, unintended vehicle movement and use of non‑insulated tools. It also addresses electromagnetic field exposure, toxic coolant vapour inhalation and stray‑voltage activation of safety systems – hazards that a competent EV technician would expect to see.

Use this template for:

Workshop risk planning – quickly identify EV‑specific hazards before work starts.
Technician briefings – provide clear, actionable control measures to qualified staff.
Compliance documentation – demonstrate adherence to the Electricity at Work Regulations 1989, IET Code of Practice for Electric and Hybrid Vehicle Repair (2022) and IMI TechSafe guidance.

Each hazard includes suggested control measures covering isolation procedures, verified testing, insulated tools, PPE, safe discharge, emergency response and safe working distances, all aligned with the IET Code of Practice and IMI TechSafe standards.

Fully editable and shareable – customise hazards, add site‑specific risks, adjust control measures to match your conditions, then download as a PDF for records or share with your team.

Compliant with: Electricity at Work Regulations 1989, IET Code of Practice for Electric and Hybrid Vehicle Repair (2022), IMI TechSafe guidance, Health and Safety at Work Act 1974, Management of Health and Safety at Work Regulations 1999.

Sample PDF Document Image:

Risks covered in this Electric and Hybrid Vehicle Repair risk assessment

This Electric and Hybrid Vehicle Repair 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 electric shock during battery removal	20	10
Lone work on high‑voltage systems	20	10
Use of non‑insulated tools on HV components	20	10
Stored energy in HV system after isolation	16	8
Arc‑flash exposure when disconnecting HV cables	15	5
Damage to orange high‑voltage cables during bodywork	15	10
Battery thermal runaway during removal or charging	15	5
Fire/explosion from battery breach during crash repair	15	10
Hazardous electrolyte exposure	12	4
Manual handling of heavy battery packs	12	6
Unintended vehicle movement while HV system is active	12	4
Unexpected activation of vehicle safety systems due to stray voltage	12	4
Confined space entry during battery pack removal	12	4
High‑frequency electromagnetic field (EMF) exposure during HV diagnostics	9	3
Inhalation of toxic battery coolant vapours	6	3

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