Change is occurring rapidly in automotive design, materials and technology but precision and accuracy remain the cornerstones of effectively repairing today’s vehicles.
In the collision repair industry, the drive toward complete safe and quality repairs has never been more critical as vehicle construction and emerging technology continue to ramp up with each release of new vehicle models.
As technicians who’ve seen firsthand how the evolution of vehicle materials, repair techniques and equipment has reshaped our approach to structural repairs, we understand the importance of technicians entering the industry, particularly structural technicians, having the knowledge and skills needed to execute high-quality structural repairs following a collision. Today, precision and accuracy are the cornerstones of effective vehicle repair, particularly when working with high-strength and ultra-strength steels.
Traditional methods vs. precision techniques
The structural integrity of a vehicle is paramount to ensuring its safety and performance on the road. In the past, repair methods often involved excessive amounts of pulling and force, combined with heat to restore the vehicle back into alignment. While these methods were considered “the norm” then, they’re no longer sufficient for today’s vehicles. The industry has moved away from these techniques due to material constraints and an increased understanding of safety concerns.
Modern vehicles are built with advanced materials, such as high-strength steels and aluminium that are sensitive to heat and can lose their strength if not handled correctly, compromising the structural integrity of the vehicle. These exotic materials with the addition of adhesives can no longer withstand the excessive forces required to straighten their structures.
This shift in repair methodology is also driven by manufacturers who now specify areas of a vehicle that should not be straightened but instead replaced to maintain structural integrity. Vehicle build tolerances are now much tighter than in previous years with some vehicle manufacturers going as low as 0-2mm. The goal is no longer just to return a vehicle to its pre-accident appearance but to ensure that it performs as designed in the event of another collision and to restore its pre-accident structural integrity. This is where accurate measuring and pulling techniques come into play – and where the importance of continuous training with courses such as I-CAR’s new interactive measuring, anchoring and pulling courses becomes evident to keep up with current techniques and methods.
The constant change of structural repair equipment
The tooling and equipment that is used to analyse and repair collision damage has kept pace with the advancements in vehicle construction technologies.
Structural Repair Equipment has become increasingly sophisticated, offering better anchoring and pulling capabilities. These advancements have made it possible to handle a wider variety of vehicles, but they also demand a higher level of training and expertise from collision repairers.
As the complexity of using sophisticated equipment becomes more of a challenge, education can help bridge the gap between traditional practices and modern requirements. The importance of continuous learning cannot be overstated, as it provides technicians with the knowledge and skills needed to navigate the complexities of today’s structural repairs.
Understanding vehicle damage
In collision repair, accurate measurement is the foundation of a successful repair. Understanding the extent of vehicle damage is crucial to the development of an accurate repair plan.
To complete an accurate damage analysis at the estimating phase, measuring is critical as without this you cannot get a true reflection of the damage within the structure. With vehicle manufacturers now demanding tighter tolerances in the repair procedures, the precision required in both measuring and pulling has increased. Technicians must be diligent in their measurements to avoid missing hidden damage that could compromise the repairs effectiveness and ultimately the safety of the vehicle’s driver and passengers.
Collision repair facilities are also under pressure to measure vehicles more thoroughly throughout all stages of the repair process. This approach not only ensures that all damage is identified and addressed but also aligns with a culture of commitment to quality repairs that should always be reinforced throughout a shops team.
Wheel alignment and ADAS calibration
The integration of advanced driver-assistance systems (ADAS) into modern vehicles has added another layer of complexity to collision repair. Proper wheel alignment is crucial for ADAS calibration, but the two processes are often handled separately. There is a genuine need for technicians to understand how these systems interact with the structure of the vehicle and the importance of following precise procedures for both alignment and calibration.
Comprehensive training either through I-CAR or its Industry Training Alliance partners also highlights these technologies and challenges, emphasising the need for a well-rounded approach that considers both structural repair and ADAS calibration. By ensuring that all systems are correctly aligned and calibrated, technicians can help maintain the vehicle’s occupants.
Informed decisions
The industry is also witnessing a shift in repair practices, from “pull to repair” to “pull to replace”. This change reflects the growing complexity and safety requirements of modern vehicles. Technicians must make informed decisions, considering factors like material strength, safety system integration and manufacturer specifications.
Structural and safety systems
Finally, it’s important to recognise the interdependence of structural integrity and vehicle safety systems. A vehicle’s structure is the backbone that supports systems like airbags and ADAS technology. Any misalignment or structural deficiency can compromise these systems, countering the purpose of these vehicle components. Therefore, maintaining structural integrity is not just about aesthetics; it’s about ensuring the vehicle can perform as designed in critical situations.
Industry Training Updates supplied by I-CAR Australia.