Workplace Risk Assessment for
HV Operations
The written hazard assessment is a legal requirement for every facility that employs staff working on or around high-voltage systems. We carry out the assessment expertly, comprehensively and in full legal compliance – on-site at your premises.
Without a hazard assessment, HV work is legally impermissible
Under §5 ArbSchG (German Workplace Safety Act) every employer is required to identify workplace hazards in writing and establish appropriate protective measures. For high-voltage systems, BetrSichV §3, DGUV Vorschrift 1 §3 and DGUV Information 209-093 add specific requirements: electrical hazards, thermal runaway, arc flash and safe de-energisation procedures. A missing or inadequate hazard assessment is not a formality – it is an organisational failure with criminal liability implications.
From site inspection to legally compliant documentation
We handle the entire process – from the initial analysis to the finished, immediately deployable documentation. Everything from a single source.
Free Initial Consultation
We discuss the size of your facility, number of HV workstations, existing documentation and any special requirements. You receive a binding quote within 24 hours.
On-Site Inspection
Systematic recording of all relevant workstations, equipment, workflows and interfaces. We document hazards photographically and collect all relevant data directly at your facility.
Assessment & Action Plan
Risk assessment of all identified hazards by likelihood and severity. A prioritised action plan with concrete recommendations, responsibilities and realistic implementation deadlines.
Handover & Documentation
Complete documentation as a legally compliant PDF report. Handover meeting with your safety officer. Optional: support during implementation and follow-up inspection.
Tailored to your operation
High-voltage systems present different challenges depending on whether your staff work on production vehicles in a workshop or on assembly lines, test benches and prototypes.
Workshops & Dealerships
Every workshop working on hybrid or electric vehicles requires an HV-specific hazard assessment. We know the typical hazard scenarios in everyday workshop operations.
- De-energisation workstations and measurement areas
- Battery diagnostics and replacement
- Storage and transport of HV components
- Fire safety and emergency management
- PPE requirements and test equipment validation
Production & OEM / Tier-1
Production environments present more complex hazards: HV systems at various stages of manufacture, test benches, assembly lines and development areas with prototypes.
- Assembly and test workstations
- Pre-SOP development vehicles and prototypes
- Test benches and test facilities
- Cross-departmental interface analysis
- Qualification needs matrix by workstation
Jan Behrens is a state-certified electrical engineer with over 15 years of hands-on experience in high-voltage technology – from vehicle development to training. As an accredited instructor per DGUV 209-093, he knows the typical weak points in facilities from hundreds of training sessions and on-site visits. He carries out the hazard assessments personally.
Transparent pricing – individual quotation
The effort required for a thorough hazard assessment depends directly on the size of the facility, number of workstations and complexity of the work systems. As indicative figures:
1–3 HV workstations, manageable facility, 1–2 days on-site
- Initial consultation & needs analysis
- Inspection of all HV workstations
- Risk assessment per standard
- Full documentation (PDF)
- Action plan with deadlines
- Handover meeting
4–15 HV workstations, multiple departments, 3–4 days on-site
- Everything in small package
- Multi-day on-site inspection
- Cross-departmental analysis
- Qualification needs matrix
- Management presentation
- First follow-up inspection included
Individual quotation after initial consultation and site visit
- Everything in medium package
- On-site project coordination
- Development vehicles / test benches
- Multi-stage inspection
- Support during implementation
- Follow-up inspection schedule
All prices excl. 19% VAT and travel costs. The initial consultation is free and non-binding. A binding quote will be provided within 24 hours after the consultation.
Frequently asked questions
Yes. Under §5 ArbSchG every employer is required to identify workplace hazards in writing and specify appropriate protective measures. For high-voltage work, the written hazard assessment is a prerequisite – without it, any HV activity is legally impermissible, regardless of the qualifications of the staff involved.
The assessment must be created by qualified persons with knowledge of the relevant regulations (ArbSchG, BetrSichV, DGUV Vorschrift 1, DGUV 209-093). A master mechanic alone is not sufficient – the author must demonstrate electrical engineering expertise and familiarity with the specific hazards of HV systems.
Under §3 DGUV Vorschrift 1 the assessment must be repeated whenever working conditions change significantly – for example when new vehicle types are introduced, workflows change, after accidents or near-misses, and at least every 2–3 years as part of a general review.
This depends on the size of the facility and the number of workstations. For a small workshop with 3–5 HV workstations we estimate 1–2 days on-site plus preparation time. Medium-sized operations with 10–20 workstations require 3–4 days. OEM sites and production lines are quoted individually.
No – both are independently required. The hazard assessment under ArbSchG §5 regulates organisational protective measures. DGUV 209-093 qualification establishes the personal technical competence of each individual. Both together form the legal basis for safe HV operations.
Book a Free Initial Consultation
Tell us about your facility – industry, number of HV workstations, existing documentation. We will respond within 24 hours with a concrete proposal.