Body Shop Damage Assessment & Repair Estimate Checklist

This body shop damage assessment and repair estimate checklist provides a systematic process for evaluating collision damage, identifying hidden structural and mechanical damage, and documenting accurate repair estimates. Aligned with I-CAR collision repair standards, ICAR ProFirst shop certification requirements, and state insurance repair regulations. Accurate, thorough damage documentation protects shop liability and ensures complete vehicle restoration to pre-accident condition.

Industry: Automotive Body Shop
Frequency: Per Repair Order
Estimated Time: 30-60 minutes
Role: Body Shop Estimator / I-CAR Certified Technician / Insurance Appraiser
Total Items: 28
Compliance: I-CAR Professional Development Program Standards, ICAR ProFirst Certification Requirements, OEM Collision Repair Procedures, State Insurance Repair Regulations, OSHA 29 CFR 1910.94 (Spray Finishing Operations)

Initial Damage Assessment

Systematic damage documentation of all collision-affected areas. Photograph all damage before any disassembly.

Pre-repair photos taken of all damage areas (minimum 8 photos)?
All damaged panels and components mapped and recorded in estimate?
Paint depth measurements taken at impact zone and adjacent panels?
Airbag deployment status verified and documented?
Damage cause (collision direction, estimated speed, type of impact) documented?

Structural Damage Assessment

Structural damage assessment is critical - missed structural damage creates safety liability and customer risk.

Frame/unibody measuring performed to identify dimensional damage?
Subframe and engine cradle inspected for damage or misalignment?
All suspension components inspected for collision damage (bent, cracked, displaced)?
OEM collision repair procedures researched and referenced for this vehicle?
High-strength steel, ultra-high-strength steel, or aluminum noted where present in repair area?
Electronic measuring system used on any repair involving structural components?

Mechanical & Electrical Damage

Collision often damages mechanical and electrical systems beyond visible body damage. Scan all systems before estimating.

Full system diagnostic scan performed - all fault codes documented?
All ADAS components in repair area identified - calibration requirements noted in estimate?
Radiator, condenser, and cooling system components inspected for damage?
Fuel system components in damage area inspected for integrity?
Electrical harness routing in damaged area inspected for chafing, cutting, or connectors pulled?

Estimate Documentation & Compliance

Complete estimate documentation per state insurance regulations and shop liability requirements.

OEM or OEM-equivalent parts specified where structurally required?
All labor operations included in estimate (disassembly, refinish, blend, alignment)?
Likely supplement items (hidden damage, mechanical inspection after teardown) disclosed to insurer?
Customer authorization signature obtained before repair begins?
Spray refinishing operations to be completed in compliant spray booth per EPA 6H NESHAP?

Estimate Delivery & Customer Communication

Ensure customer understands scope of work, timeline, and payment before repair authorization.

Total estimated cost explained line by line to customer?
Rental or loaner vehicle arranged if customer needs transportation?
Realistic completion timeline committed in writing?
Payment responsibility (insurance vs. customer) confirmed and documented?
Customer deductible amount confirmed and payment method arranged?
Signed copy of estimate provided to customer and kept in repair file?
Total loss threshold checked against ACV - recommended if repair cost exceeds 70-75% ACV?

Related Automotive Checklists

Related Body Shop Checklists

Why Use This Body Shop Damage Assessment & Repair Estimate Checklist?

This body shop damage assessment & repair estimate checklist helps automotive body shop teams maintain compliance and operational excellence. Designed for body shop estimator / i-car certified technician / insurance appraiser professionals, this checklist covers 28 critical inspection points across 5 sections. Recommended frequency: per repair order.

Ensures compliance with I-CAR Professional Development Program Standards, ICAR ProFirst Certification Requirements, OEM Collision Repair Procedures, State Insurance Repair Regulations, OSHA 29 CFR 1910.94 (Spray Finishing Operations), EPA 40 CFR Part 63 (Auto Body Refinishing Regulations), UK ABI/BS 10125 Vehicle Repair Standard. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Body Shop Damage Assessment & Repair Estimate Checklist cover?

This checklist covers 28 inspection items across 5 sections: Initial Damage Assessment, Structural Damage Assessment, Mechanical & Electrical Damage, Estimate Documentation & Compliance, Estimate Delivery & Customer Communication. It is designed for automotive body shop operations and compliance.

How often should this checklist be completed?

This checklist should be completed per repair order. Each completion takes approximately 30-60 minutes.

Who should use this Body Shop Damage Assessment & Repair Estimate Checklist?

This checklist is designed for Body Shop Estimator / I-CAR Certified Technician / Insurance Appraiser professionals in the automotive body shop industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.