OHS in Vehicle Repair and Maintenance Workshops

Garage workplace safety: the workshop’s risk map

A vehicle repair and maintenance workshop looks small but brings many separate hazards together under one roof: a lift that raises a heavy load, a pit as deep as a person is tall, vehicles with running engines, flammable fuels and solvents, batteries that produce hydrogen and, in recent years, high-voltage battery systems. The daily work of mechanics in Bursa’s industrial estates and dealer service centres requires them to stand close to several of these hazards at the same time. Garage workplace safety must therefore be planned area by area.

Area	Main hazard	Basic measure
Lift	The vehicle slipping or falling, an arm coming down on a foot	Lifting points, mechanical lock, annual periodic inspection
Pit	Falling into the pit, accumulation of heavy vapours	Cover or barrier, edge marking, ventilation
Engine tuning and testing	Exhaust fumes, rotating belts and fans	Hose exhaust extraction, guards, no loose clothing
Battery charging	Hydrogen explosion, acid splashes	Ventilated charging area, spark control, eyewash
Fuel system	Ignition of petrol and LPG vapour	Non-sparking tools, suitable draining equipment, no hot work
Bodywork and paint	Welding fumes, solvents, grinding	Local exhaust ventilation, suitable mask, hot work control
Hybrid and electric vehicles	Electric shock, arc, battery fire	Manufacturer’s service instructions, competent personnel, insulating equipment

Check your workshop’s hazard class according to your activity code; the specialist and physician times, training hours and examination frequency depend on it. The OHS obligation calculator tool draws up this picture together with your number of employees.

Vehicle lift safety and periodic inspection

Most lift-related accidents result not from lift failure but from the vehicle being lifted incorrectly. When the engine or gearbox is removed, the vehicle’s centre of gravity shifts; a vehicle resting on the end of only one arm can topple during dismantling.

For vehicle lift safety:

Lifting points: The vehicle is lifted at the lifting points specified by the manufacturer, with the pads of the lift arms fully seated. It is first raised a few centimetres and its stability is checked without shaking it.
Capacity: Under Annex I 3.2.2 of the Regulation on Health and Safety Requirements for the Use of Work Equipment, machines used for lifting loads are marked so that the maximum load that can be lifted is clearly visible. For light commercial vehicles and SUVs, always check the rated capacity on the label.
Mechanical lock: Before working under a vehicle, the lift is lowered onto its mechanical safety lock; no one goes under a vehicle held only by hydraulic pressure.
Removing heavy parts: When an engine, gearbox or rear axle is to be removed, additional support stands are used and the effect of the removal on the vehicle’s balance is considered in advance.
Lowering: Before lowering, the area under and around the lift is cleared, tools and the transmission jack are removed and people nearby are warned.

A lift is lifting equipment. In Annex III, revised on 23 December 2025, vehicle lifts are subject to periodic inspection at least once a year unless the standard specifies a shorter period. The inspection is carried out by an authorised person registered on EKİPNET (the Ministry’s register of persons authorised to inspect work equipment), and the lift is not used until the defects in the report have been remedied. For the intervals for other equipment, see our article on periodic inspection intervals for work equipment.

Working over an inspection pit

Pits carry both a fall hazard and a respiratory hazard. The basic rules for working over an inspection pit:

Falls: A pit not in use is closed with a cover or barrier. The pit edge is marked with yellow and black tape; a guide rail or wheel stop is used when a vehicle drives over the pit.
Access and exit: No one jumps into the pit; a fixed ladder is used. In long pits, exits at both ends make escape easier.
Heavy vapours: Petrol vapour and LPG are heavier than air and accumulate at the bottom of the pit. The pit is ventilated, no hot work is done in the pit, and the fuel system of an LPG vehicle is not worked on in the pit. Where necessary, the pit is assessed under confined space rules; for this, see our article on working in confined spaces.
Lighting and electricity: Lighting in the pit is selected to suit a damp environment; the cables of portable lamps are routed so that they are not crushed.

Exhaust fumes in the garage: the invisible hazard

Exhaust fumes in the garage are the most frequently underestimated hazard. The exhaust of petrol engines contains carbon monoxide, and that of diesel engines also contains nitrogen oxides and fine particulates. The International Agency for Research on Cancer (IARC) classifies diesel engine exhaust as carcinogenic to humans (Group 1).

Measures:

Hose exhaust extraction: An extraction hose is fitted to the exhaust of every engine running inside the workshop. The hose is connected before the vehicle is started.
Closed-door risk: In winter, work is done with the doors closed and exposure increases. A vehicle with its engine running is not left in a closed workshop without extraction.
Carbon monoxide detector: Especially in small, enclosed workshops, an ambient CO detector provides an early warning; the detector does not replace extraction.
Symptoms: Headache, dizziness and nausea may be the first signs of carbon monoxide exposure. An employee with these complaints is taken out into fresh air and reported to the workplace physician. For symptoms and first aid, see our article on carbon monoxide poisoning.

If gas and particulate levels in the environment need to be measured, we plan the measurements with authorised laboratories and enter the results into the risk assessment.

Explosions during battery charging and the fuel system

When a lead-acid battery is being charged, hydrogen is released, especially towards the end of the charge. Hydrogen forms an explosive mixture with air, and a single spark can blow the battery’s cover and acid into the face. To guard against the battery charging explosion risk:

Charging is done in a well-ventilated place away from spark sources such as smoking, welding and grinding.
The charger is switched on after the clamps have been connected to the battery and switched off before they are removed.
When removing a battery from a vehicle, the terminal connected to the chassis is disconnected first and, when fitting, connected last; this prevents a short circuit if the spanner touches the body.
Eye protection is used against acid splashes; eyewash facilities are available near the charging area.
When jump-starting with booster cables, the connection points specified by the manufacturer are used.

When working on the fuel system, the ignition of petrol vapour is the most serious hazard. The fuel tank and lines are drained with draining equipment made for this purpose, without pouring into open containers. While the fuel system is open, welding, grinding and heaters are not used in that part of the workshop. For the safe use of brake fluid, antifreeze, cleaning solvents and paints, refer to the products’ safety data sheets; how to read them is explained in our article on the safety data sheet. For work such as exhaust and chassis welding, applying a hot work permit is the most effective way of preventing fire in workshops containing fuel and oil.

High voltage in hybrid and electric vehicles

The traction batteries and cables of hybrid and electric vehicles carry voltages that can be fatal in the event of electric shock. High-voltage cables in these vehicles are usually identified by their orange colour. Working on these systems requires a different competence from ordinary auto-electrical work:

The manufacturer’s instructions are fundamental. Disabling the high-voltage system, the waiting time and checking for the absence of voltage are done in the order set out in the vehicle’s service instructions.
Competent personnel: Only employees who have received the relevant training do this work. The high-voltage procedure is demonstrated in practice in the job-specific risks part of the training.
Equipment: Insulating gloves of a suitable class and insulated tools are used; gloves are checked before each use.
Separating the area: A vehicle with its high-voltage system open is separated with barriers and marked. No one else works on the vehicle until the work is finished.
Damaged battery: A vehicle that has been in an accident or has a damaged battery is kept in a separate area away from the building in case of fire and handled according to the manufacturer’s instructions.

Not working without verifying the absence of voltage is the common rule of all electrical work; we explained the general principles in our article on the five safety rules in electrical work.

In a typical workshop, the annual inspection calendar includes at least the following: vehicle lifts, the compressor air receiver, the electrical installation and earthing, and fire extinguishers. Bringing these inspections together in a single calendar and following up the defects in the reports is the subject of our periodic inspection service. At Bursa Sistemer OSGB, we prepare the site arrangements and instructions for the lift, pit, exhaust extraction and battery charging area together with the risk assessment under our occupational safety specialist service.

Frequently Asked Questions

How often is the periodic inspection of a vehicle lift carried out?

Under Annex III of the Work Equipment Regulation, vehicle lifts are inspected at least once a year unless the standard specifies a shorter period. The inspection is carried out by an authorised person registered on EKİPNET; the contract is set up via ISG-KATİP (the Ministry’s online OHS registration system) at least one day before the inspection.

Is a mask enough against exhaust fumes in the garage?

No. Carbon monoxide is not stopped by ordinary dust masks. The real measure is to fit an exhaust extraction hose to every vehicle with its engine running and not to run engines without extraction in a closed workshop. PPE is only used for the risk that remains after collective measures.

Why do explosions happen when charging a battery?

The hydrogen released during charging forms an explosive mixture with air. Connecting or disconnecting the clamps while the charger is on, or a spark nearby, can ignite this mixture. Ventilation and the correct connection sequence significantly reduce the risk.

Is separate training required for electric vehicle repair?

Employees who will work on the high-voltage system should be trained separately according to the vehicle manufacturer’s instructions and the job-specific risks. This training is covered in practice in the job- and workplace-specific risks section of the basic OHS training.