The repair sector’s ability to safely and cost-effectively manage electric vehicles after a collision is lagging behind rapid market take-up of EVs, according to AX.

A new report, dubbed EV Battery Longevity & Post-Accident Outcomes, from the accident aftercare specialist reveals gaps in training, diagnostics, legislation and repair processes – issues that can cause unnecessary write-offs and inflated insurance premiums while undermining sustainability goals.

Lithium-ion battery damage, even when minor, can cause significant safety concerns and costly replacements. With battery packs representing up to half of an EV’s total value, the result is higher total-loss rates compared with petrol and diesel vehicles.

While 99% of AX’s network is ‘EV-ready’, there are major gaps in EV-specific training in the UK.

According to AX’s analysis, current guidance offers baseline safety principles, but industry protocols are inconsistent, training is insufficient and a standardised post-crash diagnostic framework does not exist.

This can lead to precautionary write-offs instead of repair or reuse. However, real-world data shows that EV batteries degrade at far lower rates than often assumed. With average annual capacity losses of just 1-2%, many packs could remain viable for far longer than the vehicle itself. According to data published by Geotab in 2024, electric vehicle batteries should now last 20 years or more on average.

While EV sales are accelerating, only a small proportion of technicians currently hold advanced high-voltage qualifications. This creates a mismatch between the number of EVs on the road and the industry’s ability to assess and handle them safely.

Latest data from the Institute of the Motor Industry (IMI) shows that about 28% of the UK technician workforce holds an EV qualification, but projections suggest that demand will outpace supply by over 25,000 technicians by 2035.

AX is calling for coordinated industry action, recommending the development of national, standardised post-crash diagnostic and quarantine procedures to provide clarity for insurers, repairers and recovery operators.

Scott Hamilton-Cooper, chief commercial operator at AX, commented: “As a big advocate for EVs, we have helped our fleet and insurer partners to transition to electric vehicles. We make the process much smoother for businesses and their drivers when their car is off the road. So together with our network of expert, EV-ready repairers, we are fully prepared, but that is not the case for everyone.

“We recommend that manufacturers work closely with the sector to define clearer repair thresholds, particularly in cases where damage is cosmetic rather than structural. Scaling up high-voltage training is another priority, ensuring both technicians and emergency responders are equipped to deal with EV-specific hazards.”

The full report is available to download from the AX website.