The UK's ban on the sale of new petrol and diesel cars from 2030, reconfirmed by the Labour government in early 2026, is accelerating the shift to EVs and introducing new risk considerations for garages and repair shops.
AXA UK Commercial has flagged a specific hazard: the paint curing process used in standard body repairs.
Paint booths typically operate at temperatures exceeding 50°C, which poses no issue for petrol and diesel vehicles but can be dangerous when applied to EVs. Dan Wilkins (pictured above), property technical risk manager at AXA UK Commercial, said high heat exposure can compromise battery integrity.
"Exposing an EV battery to high temperatures can cause lasting damage and the high voltage components on the car can short, causing them to catch fire or explode," Wilkins said.
The scale of the transition underscores the urgency. Zapmap data shows there were more than 1.88 million fully electric cars on UK roads at the end of February 2026, representing about 5.5% of the national fleet.
Society of Motor Manufacturers and Traders figures show 473,348 new battery-electric cars were registered in 2025, a 23.4% market share, though that fell short of the 28% target set by the government's zero-emission vehicle mandate.
The fleet has tripled since the end of 2022, when just 664,000 EVs were on the road. Forecasts cited by industry analysts suggest the UK could see around 580,000 electric car registrations in 2026, with the mandate target rising to 33%.
The repair readiness challenge extends beyond paint booths. Research published last year by FWD Consulting found that UK businesses may be facing more than £461 million annually in EV write-off costs, with roughly one in five EVs involved in a collision being written off even after relatively minor impacts. The firm attributed this to limited national repair capacity.
Julian Green, head of research at FWD Consulting, said the situation was unsustainable. "Without rapid investment in specialist EV repair capability and clearer guidance on battery diagnostics, we risk undermining confidence in the shift to electric fleets," Green said.
Wilkins noted that many garages still lack the equipment and training needed for EV-specific work. "Even repairing a dent in a panel on an EV requires expertise to ensure the vehicle is handled correctly and isn't inadvertently damaged or catches fire during the curing process," he said.
AXA UK Commercial has issued safety risk guidance on EV paint repairs, which is being distributed to brokers and motor trade customers. Recommended measures include using low-temperature or fast-drying paints that require minimal heat exposure, as well as short-wave electric infrared systems that direct heat onto panels rather than the whole vehicle.
The insurer also advised following original equipment manufacturer instructions and using real-time dedicated temperature sensors to continuously monitor critical components, including the battery and high-voltage systems.
The 2030 petrol and diesel phase-out permits hybrid sales until 2035, when every new car and van sold must be fully zero-emission.
