Safe Clean Room zone in a modern service: certified protective curtains and separation of repair zones for multi-materials and EVs.

The contemporary market for accident repairs is undergoing an unprecedented material and technological revolution. In a single workshop hall, body and paint services must now reconcile traditional hot work – such as cutting, welding, or riveting – with stringent cleanliness and safety requirements when handling high-voltage (HV) installations and lithium-ion batteries in electric and hybrid vehicles. The response to these challenges is modular Clean Room workstations with certified protective curtains, produced in Germany according to the most rigorous engineering standards.

Modern car bodies are multi-material structures: real hazards in the workshop

The era of homogeneous bodies is irrevocably over. Today's vehicle structures are advanced multi-material assemblies. Even steel components are no longer pure steel – they are advanced multiphase alloys with additives of boron, manganese, silicon, or titanium, combined in hybrid structures with aluminum profiles and castings as well as composites.

During mechanical and thermal processing of such components, highly reactive metallic dust and aggressive welding fumes are emitted. These phenomena carry a dual risk:

• Fire and corrosion hazards:The mixing and accumulation of dust with different electrochemical potentials (e.g., aluminum and boron steel) can, under certain conditions, lead to a rapid ignition of a dust-air mixture and cause galvanic corrosion on components prepared for painting.

• Critical risk for EV/HV components:In the repair zone for electric vehicles, even a single metallic shaving settling on an exposed battery module or in a service socket can become the cause of an electrical short circuit, damage to the BMS electronics, and in extreme cases, initiate thermal runaway of the Li-Ion pack.

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Proven standard for dealer networks: technology implemented in the Audi network

To completely eliminate the interaction between dirty zones and clean zones, modern services emphasize physical, tight separation of repair stations. Modular protective curtains and Clean Room workstations offered by EVSolutions have already become the technical standard for leading dealer networks in Poland.

The best confirmation of uncompromising quality is the fact thatprotective workstations and certified protective curtains from the EVSolutions portfolio are now present in almost every authorized Audi service in Poland.. These solutions meet the rigorous guidelines of premium vehicle manufacturers regarding repair procedures for multi-material bodies and the organization of safe zones for electromobility.

Key properties and technical parameters of Clean Room workstations

All protective curtain systems supplied by EVSolutions are produced in specialized German manufacturing plants (100% Made in Germany), ensuring full repeatability of material parameters and compliance with European health and safety directives:

• Clean Room EV zone and charging infrastructure protection:Tight separation of diagnostic, quarantine, HV battery assembly, and electric vehicle charging stations. The system prevents the ingress of metallic contaminants and creates a professional, safe working space.

• Certified PVC inspection window (compliance with EN ISO 25980):A central, flexible viewing port with a certified optical filter effectively absorbs harmful radiation from the welding arc (UV and IR) and stops sparks. It provides constant visual monitoring of the process and battery safety without the need for personnel to enter the hazardous zone.

• Extreme thermal resistance of the base fabric:Specially woven, flame-retardant technical fibers are completely resistant to impacts from glowing sparks and metal particles generated during cutting with a grinder, welding using MIG/MAG and TIG methods, or resistance welding.

• Modular architecture and sliding rail system:The design features bearing-mounted rollers, steel mounting eyelets, and tight panel connections (using industrial Velcro or snaps) enable smooth space arrangement – from open passage to completely enclosed, dust-free workshop box.

Integrated approach: equipment + procedure + training

Implementing a Clean Room zone is not just about installing curtains. According to the principle followed by EVSolutions,equipment + procedure + training,we provide services with complete technical consulting: we assist in the optimal planning of communication flows, selection of workstation ventilation, and development of procedures for the safe movement and charging of vehicles with damaged HV batteries.

All technological implementations of EVSolutions in the workshop infrastructure area are carried out under the official patronage of the Polish Chamber of Electric Mobility Development (PIRE).