EV Charger Installation — Safe Work Method Statement
Safe Work Method Statement for the installation of electric vehicle (EV) charging equipment including Level 2 AC chargers and DC fast chargers in residential, commercial, and public car park settings.
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Electric vehicle (EV) charger installation is a rapidly growing segment of the Australian electrical industry, driven by the accelerating uptake of electric vehicles and government infrastructure incentives. All EV charger electrical installation must be performed by a licensed electrician in compliance with AS/NZS 3000 (Wiring Rules) and the charger manufacturer's installation instructions. The specific technical requirements for EV charging systems are addressed in AS/NZS 62196 (plugs and sockets) and the emerging AS/NZS 61851 series (EV conductive charging systems).
DC fast chargers (50 kW and above) involve high-voltage DC output on the vehicle side of the charger — up to 1,000 V DC — and significant AC input currents at the supply side. These installations require a dedicated electrical sub-circuit, appropriate switchboard capacity, and a thorough load assessment to ensure the existing infrastructure can support the additional demand. The installation must comply with the relevant network operator's requirements, and for installations above certain capacities a network augmentation application and approval process may be required before installation commences.
The primary WHS hazards in EV charger installation are electrical — contact with live LV or HV parts during installation, and the specific risk of DC voltage exposure during commissioning and testing. The safe isolation procedure must be applied to all circuits before work commences. For car park installations, working in live traffic areas requires a traffic management plan approved by the facility owner and, where applicable, the relevant road authority.
Cable routing in existing buildings frequently requires work in ceiling spaces, car park roof decks, and plant rooms — these areas may have asbestos, existing live services, and confined space characteristics that must be assessed before entry. Civil works for underground cable routes must comply with dial before you dig requirements.
Customise this template with the charger make, model, and maximum output current; the dedicated circuit protection and cable sizing; the earthing and RCD protection strategy; and the network operator approval reference if applicable. This SWMS applies in all Australian jurisdictions.
Personal Protective Equipment
High Risk Construction Work Types
- •Work on or near energised electrical installations
Risk Assessment
1.Site survey and load capacity assessment
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Overloading existing electrical infrastructure | High | Conduct a full electrical load assessment of the existing switchboard and incoming supply before specifying charger type and quantity. Obtain a load data logger reading over a minimum 7-day period to determine peak demand. Confirm available spare capacity with the network operator (DNSP) and obtain a formal supply capacity statement. Where total new EV load exceeds available capacity, engage the DNSP for a supply augmentation application before commencing installation. Document all load assessment findings in the project technical report and have it reviewed by the supervising electrician before installation proceeds. | Low | Licensed Electrician / Electrical Engineer |
2.Switchboard modifications and circuit installation
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Electric shock during switchboard modifications | Catastrophic | Implement LOTO on the circuit being modified and any adjacent live circuits within reach inside the switchboard. Conduct Test-Prove-Test verification of isolation before opening the switchboard. Wear arc flash PPE (minimum 4 cal/cm²) while inside the switchboard enclosure even after isolation, as adjacent circuits may remain energised. Install a physically distinct labelled circuit breaker for each EV charger circuit. Verify absence of voltage on new cable before connecting to the circuit breaker. Re-install all covers and shrouds before re-energising. | Low | Licensed Electrician |
| Incorrect cable sizing causing overheating and fire | High | Select cable size per AS/NZS 3008.1 based on charger rated current, cable run length, installation method, and ambient temperature derating factors. For DC fast chargers (typically 50–350 A), engage an electrical engineer to size the cable. Ensure cable route is entirely in conduit or cable tray with no concealed direct burial in areas subject to physical damage. Thermal survey the cable terminations with a FLIR camera after commissioning under 80% load for 30 minutes. Record cable sizing calculations in the compliance documentation. | Low | Licensed Electrician / Electrical Engineer |
3.EV charger mounting and physical installation
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Charger unit struck by vehicles in car park | Moderate | Install a minimum 100 NB Schedule 40 galvanised steel bollard or engineered concrete wheel stop at each charger location to prevent vehicle collision with the charger. Bollard foundation depth minimum 500 mm in concrete-filled socket. Ensure bollard placement does not impede EV cable reach or connector access. Confirm bollard placement is compliant with the car park layout and does not obstruct fire egress. Use a charger model rated for outdoor or car park environment (IP54 minimum) where exposed to weather or vehicle splash. | Low | Installation Supervisor / Site Supervisor |
4.Cable trenching and conduit through slab or walls
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Cutting through post-tensioned concrete during core drilling | Catastrophic | Before core drilling or chasing any concrete slab or wall, obtain structural drawings and confirm the location is free of post-tensioning tendons. Where drawings are unavailable, engage a structural engineer to scan the slab using GPR (ground-penetrating radar) or cover meter before drilling. Mark the safe drilling zones on the slab surface. If a post-tensioning tendon is cut, immediately evacuate the area and contact the structural engineer — the slab may require propping. Never assume any concrete slab is conventionally reinforced only. | Low | Licensed Electrician / Structural Engineer |
| Silica dust exposure during concrete core drilling | High | Use wet core drilling for all concrete slab penetrations. Connect water supply directly to the core drill bit. Where wet drilling is not practicable, use a vacuum shroud with a HEPA-filtered vacuum on the drill. Workers must wear a fit-tested P2 respirator for all dry concrete drilling. Conduct air monitoring for RCS if drilling is conducted in poorly ventilated areas (e.g. basement car parks). Clean up slurry and drill cuttings immediately with wet methods — do not dry sweep. | Low | Licensed Electrician / All Workers |
5.Commissioning and testing of EV charger
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Fault on EVSE causing electric shock to EV owner after handover | High | Commission each EV charger per the manufacturer's commissioning checklist. Test RCD protection trip time (must not exceed 40 ms at rated current per AS/NZS 3000). Confirm earth continuity of all metal enclosures and the vehicle charging cable earth conductor. Test charger communication protocol (OCPP, if networked) and pilot signal functionality. Attach compliance plate to charger showing installation date, electrician name and licence number, and test results. Issue Certificate of Electrical Safety and provide the building owner with the charger's operation and emergency procedures. Register the charger with the relevant network operator if required. | Low | Licensed Electrician |
Relevant Codes of Practice
Worker Acknowledgement
By signing below, I confirm that I have read, understood and agree to comply with this Safe Work Method Statement.