Traditional paint repair techniques used in vehicle bodyshops could pose a serious fire risk when applied to electric vehicles, according to insurance specialists. AXA UK Commercial has warned that standard repair processes, particularly those involving high heat, may damage sensitive EV components and increase the risk of fires or explosions.
When a car panel is repaired and repainted, it is typically cured inside specialised paint booths where temperatures can exceed 50°C. While this method is widely used for petrol and diesel vehicles without issue, the same conditions may negatively affect electric vehicles. Experts warn that excessive heat exposure can harm EV batteries or interfere with high-voltage electrical systems.
Dan Wilkins, property technical risk manager at AXA UK Commercial, said repair centres must be aware of the potential dangers and ensure procedures are adapted for electric vehicles. He explained that EV batteries are highly sensitive to temperature and damage could cause electrical faults that might lead to fires. Wilkins also noted that many garages may still lack the specialist equipment or training needed to safely carry out EV repairs.
To reduce the risks, AXA has issued new safety guidance for bodyshops working with electric vehicles. Recommendations include using low-temperature paint products, fast-drying coatings that require less heat, or infrared systems that target specific panels rather than heating the entire vehicle. The insurer also advises repairers to follow manufacturers’ guidelines and use temperature monitoring equipment to track heat levels around batteries and high-voltage components during repairs.
