The dismantling and recycling of vehicles has always demanded technical knowledge, precision, and a strong focus on safety. With the rapid rise of electric and hybrid vehicles (EVs), the landscape is shifting dramatically. No longer are dismantlers working solely with traditional powertrains — they are increasingly faced with high-voltage systems that, if mishandled, can present serious risks to both staff and facilities.
A structured approach to competency is now essential. A health and safety competency matrix for high-voltage vehicles highlights the varying levels of skills and knowledge required across different roles in the dismantling process. This matrix not only illustrates the complexity of working with HV vehicles but also serves as a roadmap for businesses seeking to develop their teams.
The matrix divides the dismantling workforce into five key roles, each with defined expectations:
- Vehicle Dismantler – Typically the entry-level role, requiring only basic awareness of HV systems. PPE is mandatory, and there is a need for a grounding in fire safety and general isolation procedures. However, direct HV battery handling is not required.
- Level 2 HV Technician – At this stage, staff need intermediate knowledge of high-voltage systems. They should be capable of carrying out isolation procedures with confidence, have basic HV battery handling skills, and undergo training in lockout/tagout procedures.
- Level 3 HV Technician – These are advanced practitioners who not only understand but can actively manage high-voltage risks. They must be adept in risk assessment, battery handling, and isolation procedures, and they should be recommended to undergo electrical-specific first aid training.
- Level 4 HV Battery Technician – Experts at the top of the competency scale, these individuals handle the most dangerous tasks: full battery dismantling, diagnostics, and potential repair work. Their training must be at expert level, with deep knowledge of LOTO (lockout/tagout), electrical burns, first aid, and advanced risk assessments.
- Workshop Supervisor – Supervisors require advanced-to-expert knowledge across the board. Their role is not necessarily hands-on with HV systems daily, but they must understand enough to oversee safe operations, manage risk, and set standards for their teams.
The shift to EV dismantling is not optional — it is a reality already present in every treatment facility. Whether you are removing a conventional petrol engine or an 800-volt lithium-ion battery pack, the safety requirements differ greatly. The competency matrix underlines this by ensuring each role has clarity: who should do what, and to what standard.
Without such a framework, businesses risk:
- Endangering staff safety through inadequate training.
- Regulatory non-compliance, as authorities increasingly require evidence of competence.
- Damaging reputation and customer trust, particularly if unsafe practices are exposed.
- Missed commercial opportunities, since handling HV components responsibly opens up new revenue streams.
This is where Salvage Wire plays a crucial role. With years of experience in the dismantling sector and a global reputation for high-voltage training, Salvage Wire helps businesses not just meet the matrix — but thrive within it.
Our four-tiered training program is directly aligned with the competency levels outlined above:
- Level 1 Awareness Training – Designed for dismantlers, giving them the fundamental knowledge and awareness to stay safe when working around high-voltage vehicles.
- Level 2 Technician Training – Equips staff with practical skills for safe isolation and handling of HV components.
- Level 3 Technician Training – Incorporates advanced risk management, diagnostics, and best practices, ensuring technicians can lead safe dismantling procedures.
- Level 4 HV Battery Technician Training – Developed in partnership with TUV Rheinland, this advanced course certifies individuals who can handle, test and dismantle, HV batteries, placing them at the forefront of industry competence.
What sets Salvage Wire apart is not only the technical knowledge provided, but also the practical, hands-on training that mirrors real-world dismantling scenarios.
JR Car Spares, a family-run business in rural Kent, has long been known for innovation and adaptability. With Salvage Wire’s training, the company successfully upskilled its staff to manage hybrid and EV dismantling. Technicians progressed through Level 2 and Level 3 training, giving them the confidence to safely isolate and dismantle vehicles while ensuring compliance with environmental and safety standards. By adopting the competency framework, JR Car Spares not only enhanced worker safety but also diversified their business model, offering EV parts with confidence and reliability.
In the Caribbean, Salvage Wire worked with a government-backed facility preparing for the influx of hybrid and EV imports. With no prior experience in high-voltage systems, staff were trained to Level 2 and 3 standards, building capacity to safely dismantle vehicles and manage high-voltage components. The facility now acts as a regional model for safe, environmentally sound end-of-life management.
The competency matrix should be seen as more than just a checklist — it is a roadmap to a safer, more professional dismantling sector. By embedding structured training and clear role expectations, businesses can:
- Reduce accidents and downtime.
- Increase staff confidence and retention.
- Open new business opportunities in battery reuse, second-life applications, and recycling.
- Future-proof themselves in a market that is changing faster than ever.
Salvage Wire stands ready to support dismantlers, technicians, and supervisors as they navigate this journey. By working together, we can ensure that the dismantling industry is not only safe and compliant but also well-positioned to make the most of the opportunities electric vehicles bring.
The rise of EVs is reshaping the vehicle dismantling landscape. The high-voltage health and safety competency matrix offers a valuable guide for businesses to structure their workforce, ensuring every role is trained to the right level.
With Salvage Wire’s expertise, training, and international partnerships, dismantlers can move beyond compliance to excellence — protecting their staff, unlocking new opportunities, and strengthening the industry as a whole.
