Ensuring safety in High-Voltage bays for battery repairs

PROJECT:

High-Voltage (HV) bays for battery repair and component maintenance

INDUSTRY TYPE:

Automotive – elite vehicle dealership

CLIENT:

Confidential (global luxury vehicle brand)

LOCATION:

Australia

Initial project requirements:

Flexshield’s automotive client required purpose-built High-Voltage (HV) bays where their trained technicians could work safely on electric and hybrid vehicle systems.

These bays are unlike standard service areas. They are designed to accommodate:

High-voltage risks – modern EV platforms operate at up to 800 volts, which requires separation from other service zones and strict safety protocols.
Specialised equipment – HV servicing uses tools not required for routine vehicle repairs.
Trained expertise – only certified technicians with HV qualifications are permitted to work in the bays.
Battery repairs – the bays are specifically configured to allow for complex servicing of high-voltage battery packs.

Safety standards also require HV bays to be located close to a large water source. In rare cases where a battery ignites, the entire pack may need to be submerged in water for hours to prevent it reigniting unexpectedly.

To ensure the bays were designed to meet both our client’s technical and safety requirements, Flexshield conducted a paid site consultation. This step helped identify risks, reduced the chance of rework, and allowed us to tailor the solution with precision.

Flexshield solution:

The Flexshield team designed, manufactured, and supplied a series of sliding SonicClear PVC curtains to separate and protect the HV bays.

Key features of the solution include:

Suspended track integration – curtains glide smoothly on heavy-duty hooks and rollers, making them easy to position or move aside as required.
Curtain bunching and tie-back straps – curtains can be neatly stowed when not in use, keeping the workspace open and uncluttered.
Added fullness – each curtain was supplied with 10% extra width for improved coverage.
Strength and durability – reinforced tops, sides, and a pocketed base ensure the curtains withstand daily use.
Colour options – the client selected a combination of yellow, light grey, and clear panels to ensure visibility and safety. Additional colours are available, allowing bays to be tailored to any client’s functional and visual requirements.
UV stabilised and anti-corrosive construction – ensuring a long service life and reliable return on investment.

The SonicClear system provides a clear barrier to contain overspray and contamination, importantly while still allowing technicians full visibility. Its flexibility means that if a battery ignites, the vehicle can be quickly moved from the HV bay to a water source for safe immersion.

Colour options available — Colour options allowing bays to be tailored to any client’s functional and visual requirements.

Results achieved:

Thanks to Flexshield’s SonicClear PVC curtain solution, our client now enjoys:

Safe, compliant HV bays that meet strict high-voltage servicing standards.
Improved health and safety outcomes through controlled separation of high-risk tasks.
Support for productivity since curtains can be moved, bunched, or tied back quickly to suit changing workshop needs.
Professional presentation aligned with the dealership’s premium standards.
Durable performance from its reinforced, UV stabilised construction, ensuring long-term value.
Reduced project risk through consultation and tailored engineering advice from Flexshield.

By delivering a custom-engineered solution, Flexshield helped the dealership establish HV bays that promote health, safety, and productivity, all while supporting the demands of modern electric vehicle servicing.

For a detailed assessment and consultation, call Flexshield on 1300 799 969 or contact us online.