By Greg Aguilera, International Automotive Consulting Ltd / greg@intautoconsulting.com
Not long ago, the mere sight of an electric vehicle (EV) on a tow truck was enough to cause anxiety in most recycling yards. Teams rushed to mount rescue hooks on walls, ordered Class 0 gloves in bulk, and downloaded OEM battery disconnect procedures. Some even installed fire blankets and spill kits—just in case.
That initial fear was justified. EVs were new, complex, and posed risks that many weren’t prepared to handle. But in hindsight, much of the industry’s response was more symbolic than strategic. Safety gear was purchased, but rarely used. Rescue hooks hung unused. Rubber gloves sat in drawers—uninspected, untested, and often forgotten.
Today, the fear is gone—but it may have been replaced by something more dangerous: complacency.
EVs have become a routine part of the flow. Battery electrics, plug-in hybrids, and mild hybrids are arriving at yards in growing numbers. Their presence no longer sparks the same concern. In many operations, the default attitude is now: “We’ve seen these before. We know what to do.”
But do we?
In the past year, team from International Automotive Consulting, based in Toronto, Canada, have visited recycling operations across the country and spoken to dozens of yard owners and operators. They’ve conducted EV safety training sessions tailored to real-world workflows. And what they’ve found is revealing—and concerning.
Over 90% of the shops they assessed had at least one pair of defective or expired Class 0 gloves in active use. Fire safety zones were mislabeled or missing. Many staff couldn’t confidently identify high-voltage components under the hood. Disconnect procedures were either outdated or based on guesswork. In some cases, EVs were being dismantled without verifying whether the battery was even isolated.
This isn’t about blaming hardworking recyclers. It’s about recognizing that the industry has quietly slipped from panic into a false sense of security. And as volumes rise, so do the risks—especially if those early habits haven’t evolved.
The real issue isn’t the tools. It’s the culture.
EVs require a new kind of safety thinking—one that is proactive, situational, and woven into daily operations. It’s not just about gloves and signage. It’s about whether every team member, from the buyer to the dismantler to the sales desk, understands how to handle electrified vehicles confidently and safely.
That starts with tailored training—right there in your own yard.
International Automotive Consulting specialize in this kind of hands-on learning. Their training is not classroom-based or hypothetical. It’s conducted onsite, using your tools, your people, and your vehicles. That matters. Because every operation is different. The layout of your yard, the flow of your inventory, the tools you have on hand—all of it shapes how safety needs to work for you.
Their approach focuses on three core outcomes:
- Practical Safety Knowledge: Training staff to identify high-voltage systems, use testing equipment properly, and follow consistent deactivation procedures that are up-to-date with OEM guidance.
- Customized SOPs: Developing site-specific Standard Operating Procedures (SOPs) that make sense for your facility, ensuring that safety isn’t theoretical—it’s part of the daily routine.
- Cultural Shift: Helping owners and managers build a culture of awareness and accountability, so that EV safety isn’t dependent on one or two “experts”—but a shared responsibility.
This isn’t a one-and-done topic. EV technology is evolving fast. New battery chemistries, voltages, and thermal management systems are already hitting the market. Keeping up means regular refreshers and ongoing dialogue—not just a binder that gets filed away.
But here’s the upside: with the right approach, EVs can be handled just as safely—and profitably—as traditional vehicles. The tools exist. The knowledge exists. The support exists. What’s needed now is the will to step back, reassess, and reset the standard.
The EV conversation in auto recycling shouldn’t be driven by panic—or by apathy. It should be driven by confidence. That confidence comes from knowing your team is prepared, your facility is aligned, and your risk is being managed, not assumed.
So, ask yourself:
- Do we actually inspect our gloves before use?
- Which is more dangerous, a Hybrid or BEV?
- Do our staff know the difference between a Hybrid a PHEV and a BEV under the hood?
- Are our disconnect procedures current?
- If someone got hurt tomorrow, would we know exactly what went wrong—and why?
If the answer to any of those is “I’m not sure,” then maybe it’s time for a reset.
Because when it comes to high-voltage safety, guessing is not a strategy.