Garages and automotive workshops are hazardous environments. Vehicle lifts can collapse, inspection pits cause serious falls, exhaust fumes poison, and the combination of fuel vapours with ignition sources creates explosion risks. Every year, mechanics suffer serious injuries and fatalities that proper safety management could have prevented.
This guide covers the essential health and safety requirements for UK garages, MOT stations, and automotive workshops of all sizes.
Legal Duties for Garage Owners
As a garage owner or operator, you have legal duties under multiple regulations. The Health and Safety at Work Act 1974 places overall responsibility on you to ensure, so far as is reasonably practicable, the health, safety, and welfare of your employees and anyone affected by your work - including customers.
If you employ five or more people, you must have a written health and safety policy. Even with fewer employees, you need documented risk assessments covering your main activities.
Key Legal Requirements
Management of Health and Safety at Work Regulations 1999:
- Carry out suitable and sufficient risk assessments
- Implement preventive and protective measures
- Provide health surveillance where required
- Appoint competent persons to assist with health and safety
- Establish emergency procedures
Provision and Use of Work Equipment Regulations 1998 (PUWER):
- Ensure all equipment is suitable for its intended use
- Maintain equipment in safe working condition
- Provide adequate training for operators
- Guard dangerous parts of machinery
Lifting Operations and Lifting Equipment Regulations 1998 (LOLER):
- Ensure lifting equipment is thoroughly examined
- Plan lifting operations properly
- Use equipment within its safe working load
For detailed guidance on PUWER compliance, see our PUWER Regulations Guide.
Vehicle Lift Safety
Vehicle lifts are essential workshop equipment but also one of the biggest risks. Lift failures cause crushing injuries and fatalities. Under LOLER, vehicle lifts are classified as lifting equipment and must meet strict legal requirements.
LOLER Requirements for Vehicle Lifts
Thorough Examination: Vehicle lifts must be thoroughly examined by a competent person:
- Before first use (unless accompanied by a declaration of conformity and used within the parameters specified)
- At least every 6 months for lifts used to lift people
- At least every 12 months for lifts not used to lift people
- Following any substantial modification or repair
Most vehicle lifts should be examined every 6 months because mechanics routinely work beneath raised vehicles. The 12-month interval only applies where people are never under or on the lift.
Safe Working Load (SWL):
- Every lift must be clearly marked with its SWL
- Never exceed the marked capacity
- Consider the actual weight distribution of vehicles
Records:
- Keep examination records until the next examination
- Records must be available for inspection by HSE
- Insurance company examinations meet LOLER requirements
Daily Pre-Use Checks
Operators should check lifts before each use:
- Visual inspection for damage or leaks
- Check safety catches and locks engage properly
- Test emergency lowering mechanism
- Ensure lift arms/pads are secure and undamaged
- Check for unusual noises during operation
- Verify controls function correctly
Safe Operating Procedures
| Procedure | Requirement |
|---|---|
| Positioning | Centre vehicle correctly on lift arms/pads |
| Lifting points | Use manufacturer's recommended lifting points only |
| Raising | Raise slowly, checking for stability |
| Safety locks | Always engage mechanical locks before working under vehicle |
| Lowering | Ensure clear below before lowering, lower slowly |
| Capacity | Never exceed rated SWL, check vehicle weight |
Types of Vehicle Lifts
Two-post lifts: Most common in garages. Require correct positioning of arms under vehicle lifting points. Risk of vehicles falling if incorrectly positioned.
Four-post lifts: Often used for MOT testing. Vehicle drives onto platforms. Generally more stable but still require proper use and maintenance.
Scissor lifts: Compact design, often built into floor. Must have safety locks and overload protection.
Mobile column lifts: Used for HGVs and buses. Each column must be synchronised and regularly examined as a set.
Fatal Vehicle Lift Collapse
A mechanic was working beneath a car on a two-post lift when the lift failed. The vehicle fell, crushing the mechanic. Investigation found the lift had not been thoroughly examined for over 18 months, and visible damage to the lift arms had been ignored.
The garage owner was prosecuted under LOLER and HSWA. The company received a significant fine, and the director received a suspended prison sentence. The lift manufacturer issued a safety bulletin about inspection requirements.
- •Six-monthly thorough examination is essential for vehicle lifts
- •Daily pre-use checks can identify developing problems
- •Visible damage must be investigated immediately
- •The cost of proper maintenance is far less than the consequences of failure
Inspection Pit Safety
Inspection pits cause serious injuries from falls, often resulting in broken bones, head injuries, and fatalities. The risks are highest when pits are open and unattended, and when lighting is poor.
Main Hazards
- Falls into open pits: The most common pit injury - often happening when staff take shortcuts or customers walk into workshop areas
- Trips on pit edges: Mechanics walking around pit edges while focused on the vehicle above
- Falls while entering/exiting: Using worn or damaged steps, rushing, or carrying tools
- Fume accumulation: Heavier-than-air fumes (fuel vapours, exhaust gases) can collect in pits
- Fire risk: Fuel drips and accumulated vapours create fire hazards
Control Measures
Physical barriers:
- Cover pits when not in use with secure, flush-fitting covers
- Use barriers or chains around open pits
- Mark pit edges clearly with yellow/black hazard marking
- Ensure covers can support expected loads (people, dropped tools)
Access and egress:
- Provide secure steps or ladders at both ends of the pit
- Maintain steps in good condition - replace worn treads
- Install handrails on steps
- Keep steps clear of tools and debris
Lighting:
- Pit lighting must be adequate for the work
- Use low-voltage (typically 12V or 24V) or battery-powered lighting
- Ensure light fittings are protected from damage
- Emergency lighting should cover pit areas
Ventilation:
- Provide mechanical extraction from pits where vehicles will be running
- Monitor for fuel vapour accumulation
- Never use inspection pits as storage areas
If your pit is not in use, cover it. An uncovered pit in an unattended workshop is an accident waiting to happen - particularly if customers or visitors might access the area.
Signage and Procedures
- "Inspection Pit" warning signs near pit areas
- Restrict access to pit areas to authorised persons only
- No lone working in pits without communication systems
- Clear procedures for pit use and covering
Exhaust Fume Extraction
Running vehicles in enclosed workshops creates serious risks from exhaust emissions, including carbon monoxide poisoning. Short-term exposure causes headaches, dizziness, and confusion. Prolonged exposure can be fatal. Diesel exhaust emissions are also classified as carcinogenic.
Legal Requirements
Under COSHH regulations, you must:
- Assess the risks from exhaust fumes
- Prevent exposure or, where this is not reasonably practicable, adequately control it
- Provide local exhaust ventilation (LEV) for enclosed running of engines
- Maintain and test LEV systems
Local Exhaust Ventilation (LEV)
LEV captures fumes at source before they spread into the workshop air. Effective LEV requires:
Capture devices:
- Tailpipe extraction hoses that connect directly to exhausts
- Overhead extraction arms
- Under-floor extraction systems
Design requirements:
- Sufficient airflow to capture all fumes (typically 2000 m³/hr per extraction point minimum)
- Appropriate hose/nozzle size for vehicle types serviced
- Easy connection and operation
- Coverage of all workstations where engines may run
Maintenance and testing:
- LEV systems must be examined and tested at least every 14 months
- Tests must be carried out by a competent person
- Records of examinations and tests must be kept for 5 years
- Any faults must be repaired promptly
LEV testing every 14 months is a legal requirement under COSHH. Many garages miss this requirement. Records must be kept and available for inspection.
General Ventilation
In addition to LEV:
- Ensure adequate general ventilation in workshop areas
- Open doors and windows when weather permits
- Consider mechanical general ventilation for enclosed workshops
- Never run engines without extraction in enclosed spaces
Monitoring
Consider air quality monitoring:
- Personal exposure monitoring for mechanics
- Fixed monitors in workshop areas
- Carbon monoxide alarms as backup protection
COSHH for Oils, Fuels, and Chemicals
Garages use many hazardous substances. Under the Control of Substances Hazardous to Health Regulations, you must assess and control these risks.
Common Hazardous Substances
| Substance | Hazards | Key Controls |
|---|---|---|
| Engine oils (new and used) | Skin irritation, dermatitis, used oil is carcinogenic | Gloves, barrier cream, washing facilities, no rags in pockets |
| Petrol | Highly flammable, vapours toxic, aspiration hazard | Ventilation, no ignition sources, spill containment |
| Diesel | Flammable, skin irritant, exhaust is carcinogenic | Ventilation, skin protection, avoid breathing vapours |
| Brake fluid | Eye and skin irritant | Gloves, eye protection, good hygiene |
| Battery acid | Corrosive, causes severe burns | Face shield, chemical-resistant gloves and apron, eye wash |
| Antifreeze | Toxic if swallowed, skin irritant | Good hygiene, prevent access by children/animals |
| Degreasers/solvents | Flammable, skin/respiratory irritants, some carcinogenic | LEV, gloves, minimise use, substitute where possible |
| Paints and thinners | Flammable, vapours harmful, some contain isocyanates | Spray booths, respiratory protection, substitution |
COSHH Assessment Requirements
For each hazardous substance:
- Identify the substance and its hazards (use Safety Data Sheets)
- Consider who might be exposed and how
- Evaluate the level of risk
- Decide on control measures
- Record the assessment (if you have 5+ employees)
- Implement controls and train workers
- Review regularly
For more information, see our guide on COSHH assessment requirements.
Dermatitis Prevention
Occupational skin disease is common in mechanics. Used engine oil is classified as carcinogenic and must be treated with appropriate precautions.
Prevention measures:
- Provide suitable gloves for different tasks
- Supply barrier creams and moisturisers
- Install proper washing facilities with warm water and suitable cleansers
- Never use petrol or solvents to clean skin
- Provide clean workwear and laundry arrangements
- Train workers to recognise early signs of dermatitis
Used engine oil contains carcinogenic substances. It should be treated with the same precautions as other carcinogenic materials - minimise skin contact, provide protective equipment, and ensure good hygiene.
Storage Requirements
- Store flammable substances in designated areas away from ignition sources
- Use appropriate containers with secure lids
- Provide secondary containment (bunds) for bulk storage
- Keep incompatible substances separated
- Label all containers clearly
- Maintain Safety Data Sheets for all substances
- Dispose of waste oils and chemicals through licensed contractors
Fire and Explosion Risks
Garages present significant fire risks. Fuel, solvents, and oil vapours combined with ignition sources (sparks, hot work, electrical equipment) can cause fires and explosions.
DSEAR Requirements
The Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) require you to:
- Identify dangerous substances and assess fire/explosion risks
- Eliminate or control risks
- Classify areas where explosive atmospheres may occur
- Ensure equipment in classified zones is suitable
- Establish emergency procedures
Fire Risk Assessment
Under the Regulatory Reform (Fire Safety) Order 2005, you must carry out a fire risk assessment covering:
- Sources of ignition
- Sources of fuel
- Persons at risk
- Means of detection and warning
- Means of escape
- Firefighting equipment
- Emergency procedures
For detailed guidance, see What is a fire risk assessment?.
Controlling Ignition Sources
| Source | Control |
|---|---|
| Hot work (welding, grinding) | Hot work permits, fire watch, clear area of flammables |
| Electrical equipment | Regular inspection, suitable equipment for location |
| Sparks from tools | Non-sparking tools near flammables, segregation |
| Static electricity | Bonding and earthing when dispensing fuels |
| Smoking | Strict no-smoking policy throughout premises |
| Vehicles | Keep running vehicles away from stored flammables |
| Heaters | Use suitable heating systems, maintain clearances |
Fuel and Flammable Substance Storage
- Store petrol in approved containers in well-ventilated areas
- Maximum quantities stored should be minimised
- Bulk fuel storage requires specific safety measures
- Keep storage areas clear of ignition sources
- Provide appropriate fire extinguishers nearby
- Ensure good housekeeping - no accumulation of oily rags
Emergency Procedures
- Clearly marked escape routes
- Fire detection and alarm systems appropriate to the risk
- Suitable fire extinguishers (foam or dry powder for fuel fires, not water)
- Staff trained in emergency procedures and extinguisher use
- Regular fire drills
- Evacuation procedures for vehicles in workshop
Never use water extinguishers on fuel or oil fires. Ensure your staff know which extinguishers to use and when. Foam or dry powder extinguishers are appropriate for Class B (flammable liquid) fires.
Manual Handling
Mechanics regularly handle heavy and awkward items including tyres, batteries, engine components, and toolboxes. Manual handling injuries are among the most common causes of absence in the automotive sector.
High-Risk Tasks
- Lifting and carrying wheels and tyres (especially truck tyres)
- Handling batteries (heavy and awkward shape)
- Moving engine and gearbox assemblies
- Positioning heavy body panels
- Working in cramped positions under vehicles
- Repetitive tasks (e.g., repeated wheel changes)
Control Measures
Eliminate or reduce:
- Tyre changers and handling equipment
- Battery trolleys
- Engine cranes and transmission jacks
- Adjustable ramps and lifts
- Delivery to point of use
Improve the task:
- Two-person handling for heavy items
- Rotate tasks to reduce repetition
- Schedule rest breaks
- Train workers in safe handling techniques
Environment:
- Keep floors clean and in good repair
- Ensure adequate space to manoeuvre
- Provide good lighting
- Maintain clear routes
For more information, see our Manual Handling topic page and Safe lifting techniques guide.
Manual Handling Assessment
Assess manual handling tasks using the TILE framework:
- Task: What is being done? Lifting, carrying, pushing, pulling?
- Individual: Who does the task? Consider age, fitness, training
- Load: What are the characteristics? Weight, shape, grip
- Environment: Where is the task done? Space, floors, lighting
Electrical Safety
Garages use extensive electrical equipment, from vehicle lifts to diagnostic equipment, power tools, and battery chargers. Electrical risks include shock, burns, and fire.
Fixed Electrical Installation
- Have the fixed installation inspected and tested at least every 5 years
- Use a competent electrician registered with a recognised scheme
- Address any defects identified promptly
- Ensure adequate socket provision to prevent overloading
Portable Appliance Testing
- Implement a PAT testing regime appropriate to your equipment
- Higher-risk equipment (power tools in harsh environments) needs more frequent inspection
- Maintain records of testing
- Visually inspect equipment before use - check leads and plugs
For more information, see our guide on PAT testing requirements and Electrical safety in the workplace.
Battery Charging
- Charge batteries in well-ventilated areas - hydrogen gas is produced
- Keep ignition sources away from charging areas
- Turn charger off before connecting/disconnecting
- Use appropriate PPE when handling batteries (eye protection, acid-resistant gloves)
- Have eye wash facilities nearby
Electric Vehicle (EV) Considerations
The growth of electric and hybrid vehicles creates new risks:
High-voltage systems:
- EVs operate at voltages up to 800V DC
- Only trained and competent technicians should work on EV systems
- Specific training is essential before working on EVs
- Follow manufacturer procedures for isolation
Battery hazards:
- Risk of electric shock from damaged batteries
- Fire risk from thermal runaway
- Battery damage may not be immediately visible after collision
Charging infrastructure:
- Installation must be by competent persons
- Regular inspection and testing required
- Consider charging point locations for fire safety
EV work requires specialist training. The high-voltage systems in electric and hybrid vehicles can cause fatal electrocution. Never work on EV electrical systems without proper training and equipment.
Asbestos in Brake Components and Clutches
Asbestos was used in brake pads, shoes, and clutch facings until relatively recently. While new parts should be asbestos-free, older vehicles and replacement parts from some sources may still contain asbestos.
Where Asbestos May Be Found
- Brake pads and shoes (particularly older vehicles)
- Brake drum linings
- Clutch facings
- Gaskets in older vehicles
- Some heat shields
Legal Position
Under the Control of Asbestos Regulations 2012:
- If you know or suspect materials contain asbestos, you must not disturb them without appropriate precautions
- Asbestos awareness training is required for workers who may encounter asbestos
- Work that disturbs asbestos may require notification and specific controls
Safe Working Practices
Assume contamination:
- Treat brake dust as potentially containing asbestos fibres
- Never use compressed air to clean brake assemblies
- Use appropriate wet methods or specialised vacuums
Control exposure:
- Use proprietary brake cleaning solutions or wet wiping
- HEPA-filtered vacuum systems designed for brake dust
- Appropriate respiratory protection if dust cannot be controlled
- Disposable overalls for heavily contaminated work
Disposal:
- Brake dust and components potentially containing asbestos must be disposed of appropriately
- Use sealed containers labelled for asbestos waste
- Licensed waste carriers for disposal
For more information on asbestos, see our Asbestos topic page and What is asbestos?.
Training Requirements
Proper training is essential for garage safety. Untrained workers operating equipment or handling hazardous substances create serious risks.
Essential Training
| Training Area | Who Needs It | Frequency |
|---|---|---|
| Health and safety induction | All new workers | On joining |
| Vehicle lift operation | Anyone using lifts | Initial + refresher |
| Manual handling | All mechanics | Initial + refresher |
| COSHH awareness | Anyone using chemicals | Initial + when substances change |
| Fire safety | All staff | Annual |
| Asbestos awareness | Anyone who may disturb ACMs | Initial + refresher |
| First aid | Appointed first aiders | Every 3 years |
| EV safety (IMI Level 2+) | Anyone working on EVs | As required by level |
Competence Requirements
Equipment operation: Operators of vehicle lifts, wheel balancers, tyre changers, and other equipment must be trained on the specific equipment they use. Manufacturer training or accredited courses may be appropriate.
MOT testing: MOT testers must be nominated by the Authorised Examiner and approved by DVSA. They must maintain their competence and complete required training.
EV technician training: The Institute of the Motor Industry (IMI) has established EV training levels:
- Level 1: EV awareness (for non-technical staff)
- Level 2: Able to work safely around EVs
- Level 3: Able to work on EV systems
- Level 4: Able to work on high-voltage systems and perform diagnostic work
Training Records
Maintain records of:
- Training provided (dates, content, provider)
- Assessment of competence
- Refresher training due dates
- Any limitations on competence (e.g., not trained on specific equipment)
Documentation and Record Keeping
Good documentation protects you, demonstrates compliance, and helps manage safety effectively.
Essential Records
Risk assessments:
- General workplace risk assessment
- Manual handling assessments
- COSHH assessments for each hazardous substance
- Fire risk assessment
- DSEAR assessment if applicable
Equipment records:
- Vehicle lift thorough examination reports (LOLER)
- LEV testing records (every 14 months)
- Electrical installation test certificates
- PAT testing records
- Equipment maintenance records
Training records:
- Induction records
- Equipment training
- First aid certification
- Other competency records
Incident records:
- Accident book entries
- RIDDOR reports
- Near-miss reports
- Investigation findings
For comprehensive guidance, see our article on Health and safety record keeping.
Common Questions
Frequently Asked Questions
Vehicle lifts must be thoroughly examined at least every 6 months if mechanics work beneath raised vehicles (which covers most garage situations). The examination must be carried out by a competent person - typically your insurance company's engineer. Records must be kept until the next examination.
If you have LEV installed, it must be tested at least every 14 months regardless of other ventilation. Opening doors provides general ventilation but doesn't eliminate the need for local exhaust ventilation or its testing. Natural ventilation alone is rarely adequate for workshops where engines are run.
You need extinguishers suitable for the fire risks present. For garages, this typically means foam or dry powder extinguishers for flammable liquid fires (Class B), plus CO2 for electrical fires. Never use water extinguishers on fuel fires. The number and size depends on your fire risk assessment. Staff must be trained in their use.
No. EVs contain high-voltage systems that can cause fatal electrocution. Only technicians trained to appropriate IMI levels (or equivalent) should work on EV electrical systems. Level 2 training is needed for safe working around EVs; Level 3 or higher for working on the systems themselves. This is a rapidly developing area - ensure training is current.
Yes. While new UK-sold brake components should be asbestos-free, older vehicles and some imported parts may contain asbestos. Treat brake dust as potentially hazardous - never use compressed air, use wet cleaning methods or HEPA vacuums, and dispose of waste appropriately. Asbestos awareness training is required for mechanics.
You're responsible for ensuring your work activities don't create risks for others, including vehicle owners. Ensure vehicles are secure when on lifts, protect interiors from damage and contamination, and ensure vehicles are safe before return (e.g., handbrake engaged, not left in gear). Your public liability insurance should cover damage to customers' property.
MOT bays have specific safety requirements. Ensure inspection pits are properly protected, lighting is adequate, emissions extraction is in place, and lifting equipment is examined. The area should be clearly segregated from general repairs during testing. DVSA requirements and general health and safety law both apply.
This depends on your first aid needs assessment considering your workforce size, hazards present, and location. As a minimum, you need a first aid kit and an appointed person. For most garages, having at least one trained first aider is advisable given the hazards present (burns, cuts, chemical exposure). An eye wash station is essential where chemicals are used.
Summary
Automotive workshop safety requires managing multiple significant hazards:
- Vehicle lifts - proper examination, daily checks, correct use, and training
- Inspection pits - covering when not in use, barriers, safe access, and ventilation
- Exhaust fumes - effective LEV with regular testing, general ventilation
- Hazardous substances - COSHH assessments, proper controls, dermatitis prevention
- Fire risks - controlling ignition sources, safe storage, emergency procedures
- Manual handling - mechanical aids, training, task assessment
- Electrical safety - installation testing, PAT, EV-specific training
- Asbestos - awareness training, safe working practices for brake dust
The combination of these hazards makes garages challenging environments to manage safely. However, with proper systems, equipment maintenance, training, and supervision, the risks can be effectively controlled.
Related Content
Topics:
- Workplace Safety - General workplace safety guidance
- Fire Safety - Fire prevention and emergency procedures
- COSHH - Control of hazardous substances
- Manual Handling - Safe lifting and carrying
- Electrical Safety - Electrical hazard management
- Asbestos - Asbestos awareness and control
Regulations and ACOPs:
- L22 - PUWER ACOP - Provision and Use of Work Equipment
- PUWER Regulations Guide - Work equipment compliance
Articles:
- What is a fire risk assessment?
- COSHH assessment requirements
- Safe lifting techniques
- Health and safety record keeping
- Electrical safety in the workplace
- What is asbestos?
Related Sectors:
- Manufacturing - Industrial safety management
- Construction - Site safety requirements
Tools:
- Responsibility Checker - Find out what applies to you
This guidance covers key health and safety requirements for UK garages and automotive workshops. It is not exhaustive and does not constitute legal advice.