From a regional perspective, the government has also announced the installation of 16,000 new EV chargers1. By the end of February 2025, the UK had 75,675 EV charging points across 38,350 charging locations and 110,588 connectors2.
The manufacturing sector, in particular, will benefit significantly from the greater availability of EV chargers. As businesses transition to EVs to reduce fleet operational costs, the increased number of EV chargers ensures that electric fleet vehicles are readily available for use, reducing downtime. With the UK’s plans to phase out new sales of petrol and diesel vehicles by 20303 businesses that adapt to facilitate EVs can position themselves as leaders in sustainability practices.
However, deploying EV chargers comes with its own set of challenges. This article explores these concerns for businesses in the manufacturing sector and proposes effective risk mitigation strategies.
Key risk factors for manufacturers
- Electrical and fire hazards - EV batteries can generate excessive heat, leading to potential explosions or fires. Outdated or incompatible wiring at charging stations can strain electrical systems, causing circuit overloads and fires.
- Cybersecurity risks - Cybercriminals may access sensitive information through EV data systems, impacting operational continuity and potentially causing physical infrastructure damage.
- Physical damage and vandalism - Damage can result from accidental or deliberate impacts, such as vehicle collisions or exposure to extreme weather, which can lead to costly repairs.
- Downtime and reliability issues - Inconsistent power supply and poor network infrastructure can harm charger performance and longevity.
- Insurance and liability concerns - Policies may not fully cover liability or risks associated with EV chargers, posing legal challenges for business owners.
Risk management strategies for manufacturers
- Safe installation and maintenance - Operators need to adhere to UK electrical and fire safety regulations, hire certified electricians and conduct regular safety inspections.
- Cybersecurity measures - Implement strong authentication and encryption protocols and carry out regular software updates.
- Physical protection - Install barriers to prevent unauthorised usage, use surveillance cameras to deter crime and place EV chargers in well-trafficked and well-lit areas.
- Optimal placement of EV chargers in car parks - Strategically position EV chargers near entrances or exits and ensure sufficient spacing between chargers to minimise the risk of vehicle fire spreading to neighbouring vehicles. Position EV chargers at least 7.5 metres from buildings, away from doors and windows, to ensure quick action during a fire.
- EV charger placement for fleet vehicles - Place EV chargers for forklift trucks away from critical controls to prevent fire hazards and operational downtime. Designate a separate charging area near the loading docks and conduct regular insurance surveys to identify and rectify potential risks promptly.
- Liability and user safety - Manufacturers must adhere to EV charging standards (ISO 15118n and OCPP 2.0.1), ensure compliance with the Equality Act 2010, set up clear signage and invest in staff training.
- Operational efficiency - Ensure regular maintenance, real-time diagnostics and backup solutions to maintain optimal performance and longevity.
- Adequate insurance - Coverage should include property damage, electrical fires, third-party liability, cyber incidents and business interruption.
How Gallagher can help
As the demand for electric vehicles increases, UK manufacturers should prioritise developing and installing safe, efficient and future-proof EV infrastructure. Proactive risk management is essential to safeguard users and help minimise liability concerns. By partnering with Gallagher, a risk management specialist, manufacturers can gain access to bespoke comprehensive coverage.
Contact us today to discover how Gallagher can help you navigate the risks that accompany EV chargers.
