Electric Vehicles Introduce New Hazards for Automotive Businesses

In the last four years, automotive and battery makers have announced more than $31 billion in investments in electric vehicle manufacturing in Canada. Most recently, Honda announced a $15 billion investment to create Canada’s most comprehensive electric vehicle supply chain in Alliston, Ontario.

This is as big a transition as the shift from horse and buggy to the ICE automobile. However, there is no comparison when it comes to the pace of change in the market. Like all technology, this market opportunity is advancing rapidly, which presents unique challenges.

BEV hazards are not known or fully understood 

WSPS CEO Jody Young says, “Battery electric vehicles (BEV) are a fast-emerging form of technology. Businesses, such as auto collision centres, repair shops and auto recyclers, are beginning to see an increase in BEVs and often have a poor understanding of the health and safety hazards. This has led to apprehension about working on these vehicles.”

The lithium-ion batteries used in electric vehicles pose many serious health and safety hazards that are unknown or not fully understood. And, as many BEVs are already coming to the end of their warranty periods and even end of life, new businesses will be exposed to these hazards.  These companies will need to learn and adhere to health and safety legislation and standards that may not have applied to their work environment before. 

In March, WSPS, in collaboration with AIA Canada, I-Car, APMA, MLITSD, ATS Industrial Automation, Ontario Automotive Recyclers Association, OVIN, St. Clair College, and Ontario Tech University released Plugged Into Safety: A primer on the hazards of working with battery electric vehicles — a white paper written to assist employers and their representatives in the auto part supply, automotive dealership, autobody repair, towing and recycling industries build awareness of hazards related to battery electric vehicles in their workplaces.

Plugged Into Safety provides an overview of the growth of the BEV market, insights from subject matter experts, general information about lithium-ion batteries and the hazards of working on or around them, and existing legislation that can help mitigate these hazards. A  job aid In the form of a checklist is also available to support employers with identifying hazards associated with working on or around EV batteries in the workplace, with legislative references and recommended controls.

[See: Electric Vehicles: Safety Hazards Associated with Working On or Around the Battery]

Examples of hazards related to battery electric vehicles

Thermal Runaway Events

A thermal runaway event can be triggered by damage to a battery cell — mechanically, through a collision or damage due to an internal or external short, or as a result of electrochemical damage caused by overcharging or discharging, or external temperature.

When one of these faults elevates the cell temperature, or a portion of the cell, the materials inside begin to break down and can trigger an exothermic reaction. As the temperature increases, so does the decomposition rate, which causes rapid heating of the cell and can lead to fire or explosion.  This reaction may spread to nearby cells and modules, intensifying the event.

Electrical Hazards

The electrical system of an electric vehicle is complex and involves high-voltage components, which pose several hazards.

High voltage -- The battery pack in an EV is composed of several cells grouped into modules. The number varies depending on the vehicle. Battery packs usually operate at a high voltage between 300-800 volts, and in some cases, even higher. Contact with high-voltage parts of the battery can result in severe injury and even death.

Energy stored in the battery -- EV batteries store a large amount of energy that can be disconnected from the drivetrain and other high voltage systems, but cannot be dissipated, which can cause electrical shocks or arcing when working on or in the battery system.

Arc flash and arc blast – This occurs when there is a rapid release of electrical energy due to a short circuit or other fault and can cause severe burns and injuries.

Capacitor discharge – Capacitors can retain charge, for a period of time, even after the battery is disconnected. This stored energy can cause unexpected shocks.

Knowledge, insights and expertise to help get the conversation started in your workplace

The auto part supply, automotive dealership, autobody repair, towing and recycling industries are experiencing increased demand for BEV service and support, but they are apprehensive in the absence of reliable, comprehensive health and safety resources.

WSPS’ research and the experiences of the subject matter experts featured in this white paper highlight the need for:

• Resources to support Ontario employers in understanding and complying with provincial legislative requirements

• BEV and hybrid vehicle training standards for automotive service technicians

• Updates to CSA standards to include application to BEVs

• A requirement for individuals providing training on BEVs to have appropriate credentials

In the meantime, Plugged Into Safety is intended to assist employers in these industries build awareness and engage in critical conversations to deepen knowledge of hazards and the provincial legislation that exists to keep workers safe.

Get your copy of Plugged Into Safety: A primer on the hazards of working with battery electric vehicles here.

You may also wish to attend WSPS’ free webinar on this topic, taking place June 4, 2024.  Learn More.

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