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Preparing Your Workshop for Electric Vehicles: Australia’s Complete 2025 Guide
August 27, 2025 Brenton Thoma

Preparing Your Workshop for Electric Vehicles: Australia’s Complete 2025 Guide

Ultimate Guide to Preparing Your Workshop for EV's

Australia is on the cusp of mainstream electric vehicle (EV) adoption. This transition means more than updating your skills - it requires an overhaul of workshop infrastructure, staff training, legal compliance, and industry best practice. In this comprehensive guide, we’ll help you become truly “EV Ready” - not just compliant, but safe, efficient and competitive in a rapidly changing market.

Three pairs of EV safety gloves (yellow, red, white) on an engine bay with engine components visible - Laser Tools UK

1. Legal Foundation: Essential Laws and Standards

When preparing for EV servicing, familiarity and compliance with the right regulations is crucial.

Why AS 5732:2022 Matters

The revised AS 5732:2022 sets the benchmark for safe EV operations in Australia, mandating insulated tools, personal protective equipment (PPE), specialized workshop layouts, clear documentation practices and emergency response gear (including AEDs). It is referenced in most modern training programs and by insurers, government regulators and workplace safety auditors.


2. Preparing Your Workshop in Practical Terms

PPE and Tooling

  • Insulated Gloves (1000V rated minimum)

  • Insulated mats, boots, face shields

  • Fire extinguishers and suppression systems for lithium battery fires

  • Automated External Defibrillator (AED) within 200 meters of every EV workstation

  • Lockout/Tagout kits for high-voltage isolation

  • VDE insulated hand tools

Maintain strict inspection logs for all equipment. Assign a staff member to oversee PPE maintenance and expiration schedules.

EV and Hybrid Tool Kits and PPE Safety

EV and Hybrid Tool Kits and PPE Safety

 

Layout and Infrastructure

Car with open bonnet in EV service bay with safety barriers - lasertools.co.uk

  • Dedicated EV service bays with high-visibility floor markings and physical barriers.

  • Exclusion zones: No public access, only trained staff allowed.

  • Fireproof cabinets for tool and PPE storage.

  • Battery storage areas: Cool, ventilated, fire-retardant, and separate from major traffic routes.

  • Ventilation upgrades and emergency signage

3. Training Your Team: Essential Courses by State

Skill gaps in EV service are the biggest risk for Australian workshops - compliance and safety demand rigorous education.

State Training Providers

Each provider offers courses aligned with AS 5732:2022, including units such as AURETH101 and AURETH102 for high-voltage isolation, diagnostics and emergency management.

4. EV Emergency and Safety Systems

Australia’s standards require robust fire and electrical safety measures:

  • Lithium battery fire suppression: Install Class D extinguishers, lithium fire blankets and water mist systems.

  • AEDs: Placement and monthly checks.

  • Evacuation plans: Drill regularly; update for workshop layout changes.

  • Documentation: Lockout/tagout records, PPE inventories and hazardous materials logs must be maintained for at least seven years.

  • PPE and rescue kits: Designed to protect workers during EV emergencies.

For guidance, refer to:

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5. Handling EV Batteries and Hazardous Waste

  • Storage: Cool, ventilated, isolated from ignition sources. Use insulated, fireproof cabinets.

  • Disposal: Only via EPA-licensed hazardous waste contractors. Maintain a chain-of-custody log.

  • Do not stockpile: Exceeding legal waste thresholds risks major fines - know your state’s limits.

6. Lockout/Tagout and Documentation

Detailed procedures for high-voltage isolation, staff sign-offs, and compliance logs protect both workers and the business.
Templates, example forms and detailed best-practice procedures can be requested from your training provider or found through VETNet’s Companion Volume guides.

7. Insurance and Business Implications

Most insurers require proof of:

  • AS 5732:2022 compliance

  • Certified staff

  • Fire and emergency systems
    Notify your insurer before adding EV servicing, as audits and new premiums may apply.

8. Staff Retention, Regional Access, and Skills Shortages

Rural workshops especially struggle with access to face-to-face training.

  • Opt for blended or online courses with on-site assessment where available.

  • Apply for travel and upskilling grants via [business.gov.au].

  • Offer staff retention bonuses, career development, and partner with local workshops for group training.

9. Government Grants, Funding, and Next Steps

Federal and state funds may subsidize upskilling, infrastructure upgrades, or safety system installation.

10. Becoming “EV Ready”: Winning Trust and Standing Out

Checklist

  • Full compliance with AS 5732:2022 (display certificate in workshop)

  • Visible training records and PPE logs

  • Emergency systems operational and tested

  • Dedicated EV service bay in layout

  • Professional marketing - share your readiness online

Industry Registers

  • Register for “EV Workshop Ready” listings via your state Motor Trades Association.

11. Frequently Asked Workshop Questions (with answers!)

What does a compliant EV bay look like?
Dedicated, marked zone with barriers, PPE storage, signage, fireproof battery storage, and limited access (see sample layouts in AS 5732:2022).

How do I document lockout/tagout?
Stepwise logs, tagged pads, and sign-off sheets sourced from your training provider and VETNet guides.

Where can I access remote accredited training?
All providers listed above offer blended/distance options; check direct for assessment policies.

Do I need extra insurance for EV work?
Yes, most insurers require site audits for new cover.

How do I manage hazardous batteries?
Store in insulated, ventilated cabinets, log all movements and use EPA-licensed disposal contractors.

Conclusion:

Australia’s move to electric vehicles is fast accelerating, and workshops that are proactive, thorough and transparent will win customer loyalty and grow in a safer, smarter environment. Reference the standards, invest in the training and build your reputation as a truly “EV Ready” workshop.

For more details, consult your local training provider and check legal updates regularly. Compliance is just step one - the future is all about quality, efficiency and community trust.

Resource Links

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