Problems loom with structural replacement crash parts

Jan. 1, 2020
The effectiveness of controlling crash forces in a vehicle relies on collision energy transfer in the part design and how well repairs are performed.
Passwater structural repair parts aftermarket parts

Over the years the development of improved crash energy management has continued to evolve. The effectiveness of controlling crash forces in a vehicle relies on the proper collision energy absorption and collision energy transfer in the part design, as well as how repairs are performed.

Supplement restraint systems such as airbags and seat belt pre-tensioners rely on proper crash energy management and timing. Structural aftermarket parts are not new, but the "recommended usage" by insurers has opened a new concern for our industry and also for the safety of the vehicle owner.

With that in mind, let's revisit the Collision Industry Conference (CIC) last November in Las Vegas during NACE. Toby Chess, chairman of the CIC Technical Committee and a veteran I-CAR trainer, provided a short but riveting demonstration. Toby took a Sawzall tool and cut through an aftermarket bumper reinforcement from a late model Toyota Corolla. The saw blade had no problem cutting into this reinforcement; however, the same saw blade couldn't cut into the matching original equipment manufacturer (OEM) reinforcement. The OEM part has a much higher tensile strength and hardness than the aftermarket part. There were several other physical differences between these two parts as well. But unlike standard outer sheet metal parts, these parts are considered structural parts and they affect the way the crash energy is controlled.

These less expensive replacement parts have been widely "recommended" and "required" by specific insurers. Toby's follow up presentation at January's CIC meeting showed differences in both major material composition and methods of forming. Video segments showing the differences in front bumper reinforcements made it abundantly clear – we have a serious problem.

Fortunately, there have been some changes by distributors. For instance, LKQ Corp. did the right thing to pull and quarantine these parts from resell until testing is validated. Recently, the Auto Body Parts Association (ABPA) advised its entire membership base to review with their suppliers the inherent properties and testing of all structural parts including bumper reinforcements, steel bumpers, bumper brackets, radiator supports and absorbers to ensure that adequate testing is available to support that these parts perform equal to the OEM in vehicle collisions. These steps might curb the usage of unsafe parts from this date forward, but is this enough?

How many vehicles have these parts been installed on already? How can they be regarded as anything less than potential liability time bombs? Is it going to be our ethical responsibility to recall these vehicles and replace these parts for the safety of the vehicle owner, as well as any future owners of these vehicles? If so, at whose expense?

If the use of these parts was mandated or recommended by an insurer, they must bear the burden of replacing the replacement parts. The same goes for shops that used these parts, even if a customer requested or approved the alternatives. That's a big pill to swallow.

A future challenge is having a method to trace the usage of these parts proactively, rather than waiting for the possible damage and injuries they may cause. I am not saying that aftermarket structural parts will never provide the same safety as the OEM parts, but until documented independent testing can provide the validation of equivalency, and there is a tracing mechanism in place for distribution, they should not be sold for any reason. The stakes are too high.

Recently insurance companies have introduced new wording to disguise the use of alternative parts. For instance, the term "quality replacement" sounds reasonable to an unsuspecting consumer not realizing that the use of such a part could compromise the integrity of the repair, which of course, could compromise the integrity of the vehicle design. It's up to us to make sure that the consumer is never misled, or if so, be willing to face the consequences.

Contact info: [email protected]

Sponsored Recommendations

Best Body Shop and the 360-Degree-Concept

Spanesi ‘360-Degree-Concept’ Enables Kansas Body Shop to Complete High-Quality Repairs

ADAS Applications: What They Are & What They Do

Learn how ADAS utilizes sensors such as radar, sonar, lidar and cameras to perceive the world around the vehicle, and either provide critical information to the driver or take...

Banking on Bigger Profits with a Heavy-Duty Truck Paint Booth

The addition of a heavy-duty paint booth for oversized trucks & vehicles can open the door to new or expanded service opportunities.

Boosting Your Shop's Bottom Line with an Extended Height Paint Booths

Discover how the investment in an extended-height paint booth is a game-changer for most collision shops with this Free Guide.