FMVSS 216 Roof Crush Resistance Testing

At a glance

Millbrook conducts roof crush tests for vehicle manufacturers and vehicle converters for type approval sign-off and in-house development projects. Millbrook also conducts tests specific to the FMVSS 216 Roof Crush Resistance Testing standard.

Vehicle in FMVSS 216 roof crush resistance test laboratory Millbrook
Vehicle is roof crush test at Millbrook

The purpose of the FMVSS 216 Roof Crush Resistance Testing standard is to reduce deaths and injuries due to the crushing of vehicle roofs into the occupant compartment in rollover crashes.

Vehicle in FMVSS 216 roof crush resistance test laboratory Millbrook

Vehicle manufacturers can validate CAE crush predictions with a physical roof crush test during the development stage of a program, prior to committing to production tooling and manufacturing processes. Vehicle Certification Agency (VCA) witnessed roof crush tests can also be conducted on production intent vehicles at Millbrook.

Roof Crush Test Procedure

To perform a roof crush test, the vehicle or body-in-white is mounted on the rig bedplate, supported along the sills and chassis frame. The loading platen, held at the regulation requirement angles, is lowered onto the roof structure. It is then loaded to the specified force based on the unloaded mass of the vehicle.

Video recordings from inside and outside of the vehicle are made during the roof crush test, for post-test analysis of the roof structure performance. Post-test investigation of the vehicle structural performance is conducted with, or on behalf of, the customer and is supported with photographs.

“We usually conduct this type of test at an O.E.M. facility abroad, though with Millbrook being available locally and able to accommodate us within a flexible timeframe, the decision to test here was easily made.” Automotive OEM