NRMA Insurance required a purpose-built fitout for their LDV eD7 electric service vans. These vehicles carry heavy loads — including heavy car batteries — and needed a solution that addressed safe battery handling, organised storage, and practical field operations.
Autosafe designed and delivered a fully customised van fitout that meets the demands of electric vehicle servicing, integrating heavy-duty storage systems, ergonomic workflows, and purpose-built battery management into a single cohesive solution.
The result is a mobile service platform that improves staff safety, reduces vehicle downtime, and enables service teams to carry and manage more batteries per shift.
THE CLIENT
NRMA Insurance is one of Australia’s most recognised insurers, providing cover and roadside assistance to millions of Australians. As part of their commitment to sustainable operations, NRMA has begun transitioning their service fleet to electric vehicles.
Their LDV eD7 electric vans are deployed by field service technicians who require a vehicle capable of transporting, storing, and safely handling heavy EV batteries — all while carrying the full range of tools and equipment needed for roadside service calls.
THE CHALLENGE
The NRMA service team faced a set of complex, interconnected challenges:
- Safely lifting heavy batteries in and out of the van — requiring close collaboration with the OHS and service team to develop compliant manual handling solutions
- Batteries needed to be stored on non-corrosive surfaces to prevent damage and contamination
- The van required dedicated space for traffic cones used during roadside operations
- A hand wash station was needed within the van fit-out
- The LDV eDeliver platform offered limited floor mounting opportunities, requiring creative engineering to anchor systems securely
THE SOLUTION
- Hand wash station for field hygiene compliance
- Upper drawer — standard tool and parts storage for everyday service items
- Lower large drawer — electrically actuated, extending 1.3 metres with a 250 kg load rating. Designed specifically to store new batteries, the drawer allows service technicians to safely slide batteries out to a comfortable working height, enabling safe lift techniques without awkward reaching or bending
- A surface above the drawer system accommodates the customer’s own toolbox
- The primary engineering challenge was ensuring the actuated drawer could reliably open and close under full battery load — Autosafe engineered and validated this system to perform consistently at maximum capacity
IMPLEMENTATION
- Close collaboration with NRMA’s OHS and service teams to understand safe battery handling requirements
- Engineering assessment of the LDV eDeliver’s load capacity and available mounting points
- Design of the actuated drawer system to meet the 250 kg load requirement
- Prototype vehicle built and tested under load conditions
- Actuated drawer system tested at full battery weight to confirm reliable operation
- Feedback incorporated from NRMA service technicians for real-world usability
- Standardised fitout documentation developed for consistent fleet deployment
- Fitment teams followed defined procedures for quality and efficiency
- Ongoing aftercare support provided to keep vehicles operational
RESULTS & IMPACT
The fitout has delivered measurable improvements across safety, productivity, and operational capacity:
Improved Safety
- Electrically actuated drawer eliminates manual heavy lifting of batteries, directly reducing injury risk for service technicians
- Stainless steel battery tub prevents corrosive damage and creates a safer storage environment
- Organised storage reduces clutter and the risk of unsecured loads in transit
Increased Operational Capacity
- More batteries can be safely loaded and transported per shift, increasing service coverage
- Dedicated zones for tools, parts, cones, and batteries eliminate time lost searching for equipment
- Hand wash station supports hygiene compliance without leaving the vehicle
Reduced Downtime
- Self-sufficient vehicle setup reduces return trips to base
- Streamlined workflows allow technicians to complete more jobs per shift
- Reliable actuated drawer system minimises mechanical delays in the field
Overall, the solution enables NRMA Insurance to support the rollout of their electric service fleet with confidence — knowing their teams can operate safely, efficiently, and effectively in the field.
By combining thoughtful design, close OHS collaboration, and purpose-built engineering, Autosafe delivered a vehicle fitout that meets the unique demands of EV battery servicing.