Experts not only examine visible damage but also specifically look for hidden risks associated with damaged batteries. (Photo: © romanzaiets/123RF.com)
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May 2026
An electric car's battery can be damaged after an accident. This can lead to risks such as fires, electric shocks, or leaks. The German Association for Technical Inspection (TÃœV) has published a guideline for the safe handling of damaged high-voltage batteries.
With the increasing number of electric vehicles, it is becoming ever more important to handle high-voltage batteries damaged in accidents safely . The TÃœV Association has created a free guide for this purpose . It helps automotive workshops and experts to correctly assess such batteries in practice.
"After an accident, damaged traction batteries can cause fires, electric shocks , or leaks of toxic chemicals," says Robin Zalwert, sustainable mobility expert at the TÃœV Association . "The battery must be systematically inspected to detect even externally invisible damage."
Based on this information , workshops, experts, and vehicle owners decide whether to repair or replace the battery. "Damaged high-voltage batteries are among the most complex cases in vehicle assessment," says Zalwert. "Without clear guidelines, there is a risk of underestimating technical risks or making economically unsound decisions."
A key point in the white paper is the safety assessment of damaged batteries. Experts not only examine visible damage but also specifically search for hidden risks. These include, for example, internal short circuits or thermal instabilities that may only lead to dangerous situations later. "One challenge is reliably detecting damage inside the battery that is not visible ," says Zalwert. "A battery can appear outwardly unremarkable and still pose a significant hazard."
Operations management
Operations management
Operations management
Experts use specialized procedures for the inspection . For example, they measure insulation resistance, employ thermography, or analyze vehicle data. This allows them to detect overheating, damaged cells, or electrical faults and initiate appropriate measures. They also adhere to transport regulations and ensure proper storage conditions for accident-damaged vehicles to minimize risks to emergency responders, workshop personnel, and the environment.
Besides safety, cost-effectiveness also plays a major role. It is often significantly cheaper to repair individual battery modules than to replace the entire battery. Whether a repair is worthwhile depends on several factors: the type of repair, the battery's condition (its "state of health"), and the current value of the vehicle. "In many cases, repair is not only more economically sensible but also more sustainable than a complete replacement," says Zalwert.
From an environmental perspective , there are many arguments in favor of repairing or reusing batteries whenever technically possible. The production of lithium-ion batteries generates high CO₂ emissions. Repairs and so-called "second-life" use, on the other hand, conserve resources and prevent waste. "Every battery that is used for longer reduces the need for new raw materials and improves the climate footprint of electromobility," says Zalwert. "Therefore, a repair should always be considered – provided safety is guaranteed."
The TÃœV Association also emphasizes the importance of uniform standards and clear manufacturer specifications. Only in this way can experts safely assess and repair high-voltage batteries while simultaneously safeguarding warranty claims. "Experts play a key role in ensuring safety when dealing with damaged electric vehicles," says Zalwert. "For this, they need reliable data, clear processes, and continuous professional development."
Download tip: Here you can download the > free guide "Assessment of damaged high-voltage batteries in electric vehicles" .
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