Introduction
Advanced driver assistance systems (ADAS) have transformed vehicle safety, but they depend on precise calibration of sensors and cameras. Technicians who perform these calibrations must operate safely and adhere to legal standards. Inaccurate calibration can compromise driver safety and expose workshops to liability. This article covers essential safety practices and legal considerations for ADAS technicians.
Understanding the Risks
Calibrating ADAS systems involves handling sensitive sensors, heavy calibration equipment and sometimes accessing vehicle electronics. Improper lifting of targets can cause strains or accidents. Misaligned sensors could lead to lane‑keeping or braking systems misbehaving on the road. Technicians also work around lasers, radar and electrical systems; they must respect both mechanical and electrical hazards.
Personal Protective Equipment (PPE)
Using proper PPE is non‑negotiable. Every technician should have a kit that includes:
- Safety glasses – protect against dust, debris and accidental laser reflections.
- Cut‑resistant gloves – ensure a secure grip on tools and prevent cuts from sharp components.
- Steel‑capped footwear – protects feet when moving heavy targets or frames.
- Hearing protection – required in workshops where compressed air tools or noise levels exceed safe limits.
- High‑visibility clothing – makes technicians visible to colleagues and prevents collisions in busy bays.
Technicians should inspect PPE before every use and replace worn or damaged items.
Safe Workshop Environment
A dedicated calibration bay reduces risk and improves precision. Keep floors clean and free of oil or debris to prevent slips. Adequate lighting ensures cameras and LiDAR sensors see targets clearly. Maintain good ventilation to dissipate fumes from adhesives or solvents. Allow ample space around the vehicle so technicians can move without obstruction. Install stable stands for targets and store them in protective cases when not in use to avoid warping.
Handling Targets and Calibration Tools
Many calibration fixtures and target boards are bulky. Use proper lifting techniques—bending knees, keeping the back straight—and get assistance for large or awkward frames. Ensure stands and mounts are locked securely before measurements. Never improvise with makeshift supports; unstable fixtures can topple and damage sensors or injure colleagues.
Electrical and Software Safety
Electronic control units (ECUs) and scanning tools are sensitive. Disconnect the vehicle battery when recommended by the manufacturer. Use approved diagnostic interfaces and update scan tools regularly to avoid software compatibility problems. Do not attempt to bypass safety interlocks on ADAS components. If a fault code persists, refer to factory service information rather than guessing.
Legal Considerations and Compliance
ADAS calibration falls under product safety law in many jurisdictions. Technicians are responsible for following manufacturer procedures, documenting test results and ensuring vehicles meet roadworthiness standards. Legislation often requires that any modifications or repairs to safety systems be recorded. Using genuine parts and targets reduces legal exposure. Familiarise yourself with industry codes (such as the ADAS Industry Code of Conduct) and abide by them.
Liability and Documentation
Accurate record‑keeping protects both the workshop and customer. Before calibration, perform a pre‑repair scan to document existing faults. After calibration, run a post‑repair scan and print or store the results. Record environmental conditions (temperature, lighting) and equipment settings. Keep digital or paper copies for the period required by regulation. Proper documentation provides evidence of due diligence if an incident occurs on the road.
Continuous Training and Certification
Technology evolves quickly. New radar modules, LiDAR systems and camera arrays require updated procedures. Attend regular training sessions and maintain certifications where available. Many manufacturers offer e‑learning modules and hands‑on courses. Staying current not only improves safety but also enhances professional credibility.
Summary
Working with ADAS systems demands rigorous attention to safety and legal obligations. Wearing appropriate PPE, maintaining a clean and well‑lit workspace, handling calibration tools correctly and following manufacturer instructions all protect technicians and drivers. Compliance with industry codes and thorough documentation reduce liability. Continual training ensures that ADAS professionals deliver accurate, responsible calibrations. For more information on setting up an effective calibration workspace, see our article on Setting Up Your Calibration Station.
Hiran Alwis is an automotive lecturer and ADAS specialist with over 15 years of experience in diagnostics, advanced safety systems, and technical training. He founded ADAS Project to help everyday drivers and workshop technicians understand and safely use advanced driver assistance systems.