Electric vehicles (EVs) continue to take center stage as the latest trend in the automotive industry. Auto recyclers are to becoming more adept at dismantling these high-voltage vehicles and rightfully so. Without proper training, the dismantling and handling of these vehicles can put recyclers and their employees at risk.
As Andy Latham, founder and chief executive officer at SalvageWire, explained, high voltage vehicles have been around since 1998 when the Toyota Prius launched, so the risks should be well known by now. However, there are three major safety concerns – chemical, electrical and incendiary.
“With chemical concerns, a damaged battery could be leaking electrolyte and this can be very harmful. Regarding the electrical realm, the biggest risk is electric shock, which could be fatal. With flammability concerns, a thermal incident could be very damaging,” Latham said. The Salvage Wire team has developed training specifically written for automotive recyclers and dismantlers on the safe handling of electric and hybrid vehicles. They are building a certified trainer network which can deliver accredited training globally to vehicle recyclers and dismantlers, vehicle technicians, engineers and first responders. The training will improve awareness, increase professional standards and help the automotive industry prepare for an electrified future.
“The most important part of any training program is personal safety, so those working on these vehicles can get home to their families at the end of the working day,” Latham said. “Every technician needs the confidence and competence to work on these vehicles along with the tools, the personal protective equipment (PPE) and the process.”
Additionally, the management team needs to know about the risks so they can complete standard operating procedures and risk assessments for every step of the process for a high voltage vehicle – this includes vehicle collection, dismantling’s safety assessment, storing high voltage parts, and selling and shipping those parts.
“Keeping themselves, their teams and their business safe is paramount – every employee needs to know that they are safe when at work. Training and development is essential to increase skills and professionalism. This investment pays for itself because staff member(s) feel valued and respected. It improves safety standards, it could improve staff retention, will allow each vehicle recycler to handle more vehicles and give new opportunities for more revenue,” Latham added.
As an expert in the electric vehicle industry and the founder of EVhype.com, Rob Dillan is well versed in the evolving standards and safety protocols for handling and dismantling EVs.
As Dillan explained, the handling and dismantling of EVs, particularly lithium-ion batteries, requires specialized training. Programs often include modules on electrical safety, high-voltage systems, battery chemistry, and emergency response procedures. For instance, the National Fire Protection Association (NFPA) offers an “EV Safety Training” program for emergency responders.
“In the U.S., the Occupational Safety and Health Administration (OSHA) has guidelines for workplace safety that apply to EV handling,” Dillan said. “These include standards for personal protective equipment (PPE), proper tools for handling high-voltage systems, and procedures for dealing with battery fires or leaks.”
Specific to lithium-ion batteries, battery handling and dismantling training covers safe handling, storage, and disposal procedures. These batteries pose risks such as thermal runaway and chemical exposure.
“Industry best practices also include using non-conductive tools and ensuring proper ventilation,” Dillan said.
Automotive technicians working with EVs often undergo certification programs. For instance, as Dillan explained, ASE (Automotive Service Excellence) offers a Light Duty Hybrid/Electric Vehicle Specialist certification, ensuring technicians are skilled in EV-specific technologies.
Latham added that the Automotive Recyclers Association (ARA) has some good training resources available from ARA University including reference manuals and online training. Training is available from other sources but a lot of recognized training is aimed at vehicle repairers and is not always relevant for vehicle dismantling and recycling.
“Salvage Wire has developed training specifically for vehicle dismantlers and recyclers that is accredited by the Chartered Institute of Wastes Management (CIWM). This training is at four levels that reflect the needs of all automotive recycling operations, from awareness for managers and HR professionals, through two levels of technician training. The latter includes vehicle assessment, dismantling, parts storage and shipping, and a level of training for battery dismantling operations that dismantle batteries for recycling or remanufacturet batteries for re-use,” Latham said.
Ahmad Ghahreman, chief executive officer, president and co-founder of Cyclic Materials, said that the global transition to EVs is reshaping the recycling landscape. For many years, catalytic converters have been one of the valuable parts of internal combustion engine (ICE) vehicles due to the valuable platinum group metals they contain. Although some hybrid vehicles still have these catalytic converters, EVs do not, which removes a valuable component for recyclers.
“While EVs don’t have catalytic converters, they do have other valuable components, including batteries containing valuable metals such as lithium, nickel and cobalt as well as traction motors and hybrid transmissions containing permanent magnets made of rare earth elements (REEs), another group of important metals.
“The global transition to EVs is changing the way recyclers handle and resell their valuables before cars make it to the shredder,” Ghahreman said. “Auto recyclers are learning how to handle and assess these new components. They are putting in place training, equipment, and procedures to safely remove batteries, which can pose a big fire hazard.”
Ghahreman also pointed to the ARA, which has developed eight EV training modules for certification of automotive dismantlers of high voltage vehicles and other personnel that manage hybrid and electric vehicles.
“Auto recyclers are also receiving training on the new valuables in an EV such as electric motors that contain REEs,” Ghahreman said. “Traction motors and hybrid transmissions are the new catalytic converter.”
Auto recyclers must be prepared to handle high voltage vehicles as they enter an automotive recycling facility. These batteries pose risk of electrocution and fire hazard and require specialized equipment and storage space for handling.
In addition to evaluating them for safety hazards, especially after an accident, batteries must also be evaluated for second life or recycling. This involves determining the health of the battery, which can be a complex process.
“It’s important to note that removing and handling traction motors and hybrid transmissions from end-of-life cars is much less labor intensive and challenging than removing and handling batteries,” Ghahreman said.
Dismantling in the Future
Like all technology, EV dismantling will continue to evolve, as will the technology required on the part of automotive recyclers to properly handle these vehicles. Latham pointed out that the automotive recycling industry has evolved over 100 years and will continue to evolve as new technologies come into production.
“Vehicle technology is changing all the time, and that change is now faster than at any previous time. The automotive recycling industry will continue to change, develop and evolve as the technology changes,” Latham said. Some of this change will be forced by legislation and regulation; new opportunities will bring more change and development but most importantly the owners and managers must look after their team, support training and development and continue to raise professional standards.
“Membership of a trade association and participation in their certification schemes will become essential if vehicle recyclers and dismantlers want to maximize their sales opportunities for recycled parts, and certification must include staff training and competence, especially in high voltage vehicles,” Latham said.
As EV adoption increases, ensuring that individuals handling these vehicles are adequately trained and aware of the safety protocols is paramount. “This not only guarantees the safety of the workers but also contributes to the overall efficacy and sustainability of the EV industry,” Dillan said.
Ghahreman advises that auto recyclers who invest in EV training and equipment will capture market share as the EV industry continues to grow. “Smaller firms must make investments to remain competitive against larger players and capture their share of the market,” he noted.
