Giving EV batteries a second life

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Electric vehicle (EV) batteries are built to last, but what happens when they no longer serve their original application?

A newly published European standard, EVS-EN 18061:2025, sets out clear rules for the safe repair, reuse, and preparation for repurposing of batteries and modules originally designed for EV applications. It aligns with Regulation (EU) 2023/1542, which governs the entire lifecycle of batteries, from production and use to recycling and circular use.

Repair and reuse with confidence

EV batteries are high-voltage systems. Improper handling during repair or refurbishment can pose serious safety risks. That is why EVS-EN 18061:2025 introduces a structured process and strict safety protocols for any operator working with these components.

Under the new framework, only certified workshops equipped with trained staff, specialised tools, and approved documentation are authorised to repair or prepare batteries for second-life use. These facilities must also follow procedures aligned with the original manufacturer’s specifications, including software testing, diagnostic checks and mechanical inspections.

Importantly, the original safety limits of the battery, such as voltage range and operating temperature, must never be exceeded unless specifically validated with technical evidence.

From diagnosis to redeployment

Before any repair or reuse operation begins, a full battery health assessment is mandatory. This includes checking for damage, assessing electrical properties like capacity and insulation, and reading error codes from the Battery Management System (BMS). A detailed checklist is included in the standard, helping workshops document each step of the process.

If a battery or module passes this screening, it may be:

• Repaired: faulty components (e.g. sensors, connectors) are replaced.
• Reused: the battery is returned to service in the same type of vehicle.
• Prepared for repurposing: the battery is made ready for a new, non-automotive application, such as energy storage.

In each case, a unique Battery Identification Number (BIN) must be applied or updated, and all traceability information must be included in the battery passport.

Safety comes first

Given the high energy content of EV batteries, risk management is a cornerstone of EVS-EN 18061. The standard incorporates safety requirements for:

• Working with voltage class B systems (>60V DC)
• Preventing unintentional reconnection
• Using Personal Protective Equipment (PPE)
• Ensuring safe storage and transport (e.g. temperature and voltage limits)

Where battery cells are replaced, workshops must consider issues such as compression force and matching the state of health between cells. Without proper precautions, durability and safety can be compromised.

Built to be repaired

Interestingly, the standard also encourages design-for-repair principles. An informative annex highlights assembly techniques that make it easier to dismantle and service battery systems in the future. These include using standardised fasteners, providing repair manuals, and ensuring that spare parts are identifiable and accessible.

A step forward for the circular economy

EVS-EN 18061:2025 represents a major milestone in Europe’s shift toward a circular economy for mobility. By supporting safe and traceable second-life applications for EV batteries, the standard helps to reduce resource extraction and waste, lower lifecycle emissions and encourage innovation in battery repurposing (e.g. for grid storage).  It also supports consumer trust by ensuring that reused or repurposed batteries meet clear technical and safety benchmarks.

As the number of EVs on Europe’s roads continues to rise, this new standard sets the groundwork for giving each battery not just one life but two, or even more.

Source: CEN-CENELEC.