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ISO 11154:2023

(Main)

Road vehicles — Roof load carriers

Road vehicles — Roof load carriers

This document applies for roof racks of passenger cars and light commercial vehicles up to a permissible total weight of 3,5 t according to ISO 1176 and specifies requirements and test methods for these. It is also valid for roof racks mounted on trailers. So-called magnetic or suction foot racks, i.e. roof racks whose attachment on the vehicle is only via magnetic forces or vacuum, are excluded from this document. This document provides safety-related requirements under consideration of the weight, centre of gravity, air resistance and other safety-relevant properties for structures of roof racks for which no other technical or statutory regulations otherwise apply and which are not listed in 4.2. In individual cases, test requirements can extend beyond these requirements.

Véhicules routiers — Porte-charges de toit

General Information

Status
Published
Publication Date
01-Mar-2023
ICS
43.040.60 - Bodies and body components
Technical Committee
ISO/TC 22/SC 40 - Specific aspects for light and heavy commercial vehicles, busses and trailers
Drafting Committee
ISO/TC 22/SC 40 - Specific aspects for light and heavy commercial vehicles, busses and trailers
Current Stage
6060 - International Standard published
Start Date
02-Mar-2023
Due Date
29-Mar-2022
Completion Date
02-Mar-2023
Ref Project

Relations

Revises
ISO/PAS 11154:2006 - Road vehicles — Roof load carriers
Effective Date
08-Jul-2017

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ISO 11154:2023 - Road vehicles — Roof load carriers Released:2. 03. 2023ISO 11154:2023 - Road vehicles — Roof load carriers Released:2. 03. 2023
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ISO 11154:2023 - Road vehicles — Roof load carriers Released:2. 03. 2023
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INTERNATIONAL ISO
STANDARD 11154
First edition
2023-03
Road vehicles — Roof load carriers
Véhicules routiers — Porte-charges de toit
Reference number
ISO 11154:2023(E)
© ISO 2023
---------------------- Page: 1 ----------------------
ISO 11154:2023(E)
COPYRIGHT PROTECTED DOCUMENT
© ISO 2023

All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may

be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting on

the internet or an intranet, without prior written permission. Permission can be requested from either ISO at the address below

or ISO’s member body in the country of the requester.
ISO copyright office
CP 401 • Ch. de Blandonnet 8
CH-1214 Vernier, Geneva
Phone: +41 22 749 01 11
Email: copyright@iso.org
Website: www.iso.org
Published in Switzerland
© ISO 2023 – All rights reserved
---------------------- Page: 2 ----------------------
ISO 11154:2023(E)
Contents Page

Foreword ..........................................................................................................................................................................................................................................v

1 Scope ................................................................................................................................................................................................................................. 1

2 Normative references ..................................................................................................................................................................................... 1

3 Terms and definitions .................................................................................................................................................................................... 1

4 Symbols, types and designation .......................................................................................................................................................... 2

4.1 Symbols ......................................................................................................................................................................................................... 2

4.2 Types ............................................................................................................................................................................................................... 3

4.3 Designation ................................................................................................................................................................................................ 4

5 Attachment to the vehicle...........................................................................................................................................................................4

6 Safety requirements, tests ........................................................................................................................................................................4

6.1 Measurement uncertainties ........................................................................................................................................... ............. 4

6.2 General ........................................................................................................................................................................................................... 4

6.3 Resistance of the materials ......................................................................................................................................................... 5

6.4 Test procedure ........................................................................................................................................................................................ 5

6.5 Test conditions ........................................................................................................................................................................................ 6

6.6 Test specimens........................................................................................................................................................................................ 6

6.7 Test instruments ................................................................................................................................................................................... 6

6.7.1 Roof-box dummy for load simulation ............................................................................................................... 6

6.7.2 Test wheel ................................................................................................................................................................................. 7

6.7.3 Test skis ...................................................................................................................................................................................... 7

6.7.4 Test snowboards ................................................................................................................................................................. 7

6.7.5 Test surfboard ...................................................................................................................................................................... 7

6.7.6 Test surf mast ........................................................................................................................................................................ 8

6.7.7 Test boat ..................................................................................................................................................................................... 8

6.7.8 Test ladder ................................................................................................................................................................................ 8

6.7.9 Test roof box ........................................................................................................................................................................... 8

6.7.10 Test air deflector device .............................................................................................................................................. 8

6.7.11 Test basket ............................................................................................................................................................................... 8

6.8 External design ...................................................................................................................................................................................... 9

6.9 Functional design ................................................................................................................................................................................. 9

6.10 Attachment and type of load during the test ............................................................................................................... 9

6.11 Operational safety ............................................................................................................................................................................12

6.11.1 General .....................................................................................................................................................................................12

6.11.2 Vibration resistance .....................................................................................................................................................12

6.11.3 Lane change test ..............................................................................................................................................................13

6.11.4 Brake test ............................................................................................................................................................................... 14

6.11.5 Requirements and test criteria for lane change test (6.11.3) and brake test

(6.11.4) ...................................................................................................................................................................................... 14

6.12 Static load bearing capacity ..................................................................................................................................................... 14

6.12.1 General requirements ................................................................................................................................................. 14

6.12.2 General test .......................................................................................................................................................................... 16

6.12.3 Testing the forces in the direction of travel; height of the force application

point ............................................................................................................................................................................................ 16

6.12.4 Requirements for forces in the direction of travel -F ...................................................................20

6.12.5 Requirements for forces opposing the direction of travel +F ...............................................20

6.12.6 Testing the forces opposing the direction of travel +F ................................................................20

6.12.7 Requirements for forces 20° horizontal to the direction of travel (only for

Types A and B) ...................................................................................................................................................................20

6.12.8 Testing the forces 20° horizontal to the direction of travel (only for Types A

and B)......................................................................................................................................................................................... 21

6.12.9 Requirements for the stress due to vertical forces .......................................................................... 21

6.12.10 Testing the stress due to vertical forces .................................................................................................... 21

iii
© ISO 2023 – All rights reserved
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ISO 11154:2023(E)

6.12.11 Requirements for the stress due to lateral forces .............................................................................22

6.12.12 Testing the stress due to lateral forces ....................................................................................................... 22

6.13 Crash simulation stress ............................................................................................................................................................... 23

6.13.1 Requirement for the crash simulation stress ........................................................................................ 23

6.13.2 Testing the crash simulation stress ................................................................................................................ 23

6.14 Corrosion resistance ...................................................................................................................................................................... 24

6.14.1 Requirements for the corrosion resistance of components with galvanic

surface protection .......................................................................................................................................................... 24

6.14.2 Testing the corrosion resistance of components with galvanic surface

protection .............................................................................................................................................................................. 24

6.15 Weather resistance ..........................................................................................................................................................................25

6.15.1 Requirements for the weather resistance of plastic straps parts and

attachment elements exposed to UV ............................................................................................................. 25

6.15.2 Testing the weather resistance of plastic parts and means of attachment ................25

6.15.3 Cold resistance of plastic parts and attachment elements ........................................................25

6.15.4 Heat resistance of plastic parts (apart from Type G) .....................................................................26

6.16 Functional safety of roof boxes Type G .......................................................................................................................... 26

6.16.1 Requirements .....................................................................................................................................................................26

6.16.2 Test ................................... ........................................................................................................ .................................................... 27

6.17 Lock and hinge test on the roof box .................................................................................................................................. 27

6.17.1 Requirements ..................................................................................................................................................................... 27

6.17.2 Test ................................... ........................................................................................................ .................................................... 27

7 Marking ........................................................................................................................................... ............................................................................27

7.1 Requirement .......................................................................................................................................................................................... 27

7.2 Test .................................................................................................................................................................................................................28

8 Instructions for use ........................................................................................................................................... .............................................28

8.1 General ........................................................................................................................................................................................................28

8.2 Examples of safety notes in instructions for use ..................................................................................................29

8.3 Initial assembly ...................................................................................................................................................................................29

8.4 Content ........................................................................................................................................... .............................................................29

Annex A (normative) Test bicycle ........................................................................................................................................................................31

Annex B (informative) Requirements for a Belgian block test track .............................................................................33

Annex C (informative) Determination of the payload ....................................................................................................................35

Annex D (informative) Example of safety notes in instructions for use .....................................................................36

Annex E (informative) Presentation of the force application ................................................................................................37

Annex F (normative) Measuring displacement, d ...............................................................................................................................42

Bibliography .............................................................................................................................................................................................................................49

© ISO 2023 – All rights reserved
---------------------- Page: 4 ----------------------
ISO 11154:2023(E)
Foreword

ISO (the International Organization for Standardization) is a worldwide federation of national standards

bodies (ISO member bodies). The work of preparing International Standards is normally carried out

through ISO technical committees. Each member body interested in a subject for which a technical

committee has been established has the right to be represented on that committee. International

organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.

ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of

electrotechnical standardization.

The procedures used to develop this document and those intended for its further maintenance are

described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the

different types of ISO documents should be noted. This document was drafted in accordance with the

editorial rules of the ISO/IEC Directives, Part 2 (see www.iso.org/directives).

Attention is drawn to the possibility that some of the elements of this document may be the subject of

patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of

any patent rights identified during the development of the document will be in the Introduction and/or

on the ISO list of patent declarations received (see www.iso.org/patents).

Any trade name used in this document is information given for the convenience of users and does not

constitute an endorsement.

For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and

expressions related to conformity assessment, as well as information about ISO's adherence to

the World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT) see

www.iso.org/iso/foreword.html.

This document was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 40,

Specific aspects for light and heavy commercial vehicles, busses and trailers.

This first edition cancels and replaces ISO/PAS 11154:2006, which has been technically revised.

The main changes are as follows:
— update and revision of document structure, which results in renumbering;
— update and revision Clause 2;
— update and revision Clause 6;
— addition of test procedure (6.4);
— addition of lane change test (6.11.3);
— addition of brake test (6.11.4);
— revision of 6.12.2, changing application of force from 10 min to 1 min.

Any feedback or questions on this document should be directed to the user’s national standards body. A

complete listing of these bodies can be found at www.iso.org/members.html.
© ISO 2023 – All rights reserved
---------------------- Page: 5 ----------------------
INTERNATIONAL STANDARD ISO 11154:2023(E)
Road vehicles — Roof load carriers
1 Scope

This document applies for roof racks of passenger cars and light commercial vehicles up to a permissible

total weight of 3,5 t according to ISO 1176 and specifies requirements and test methods for these. It is

also valid for roof racks mounted on trailers.

So-called magnetic or suction foot racks, i.e. roof racks whose attachment on the vehicle is only via

magnetic forces or vacuum, are excluded from this document.

This document provides safety-related requirements under consideration of the weight, centre of

gravity, air resistance and other safety-relevant properties for structures of roof racks for which no

other technical or statutory regulations otherwise apply and which are not listed in 4.2. In individual

cases, test requirements can extend beyond these requirements.
2 Normative references

The following documents are referred to in the text in such a way that some or all of their content

constitutes requirements of this document. For dated references, only the edition cited applies. For

undated references, the latest edition of the referenced document (including any amendments) applies.

ISO 179-1, Plastics — Determination of Charpy-impact properties — Part 1: Non-instrumented impact test

ISO 3888-2, Passenger cars — Test track for a severe lane-change manoeuvre — Part 2: Obstacle avoidance

ISO 4210-2, Cycles — Safety requirements for bicycles — Part 2: Requirements for city and trekking, young

adult, mountain and racing bicycles

ISO 4892-2, Plastics — Methods of exposure to laboratory light sources — Part 2: Xenon-arc lamps

EN 15194, Cycles — Electrically power assisted cycles — EPAC Bicycles
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.

ISO and IEC maintain terminology databases for use in standardization at the following addresses:

— ISO Online browsing platform: available at https:// www .iso .org/ obp
— IEC Electropedia: available at https:// www .electropedia .org/
3.1
roof rack

device, which is attached directly or indirectly via other roof rack forms on the roof of passenger cars

or vehicles derived from this and which are suitable for the transportation of loads (3.2)

3.2
load

transport goods which can be transported with the roof racks (3.1) provided for this

© ISO 2023 – All rights reserved
---------------------- Page: 6 ----------------------
ISO 11154:2023(E)
4 Symbols, types and designation
4.1 Symbols
−F direction of the normal force of the load
F direction of the vertical force, acting vertically to the direction of travel
F direction of the lateral force, acting laterally to the direction of travel

−F direction of the longitudinal force, acting longitudinally to the direction of travel

F direction of the opposing longitudinal force, acting against the direction of travel

−F direction of the force in the horizontal plane, 20° to the vehicle longitudinal axis through

x20°
the centre point M
m permissible roof load in kilograms
m permissible load bearing capacity of the roof rack in kilograms

m dead weight of the roof racks and possibly the roof structural system in kilograms

s stroke path from deformation and displacement in millimetres
x-direction vehicle longitudinal axis
y-direction transverse to the vehicle longitudinal axis (horizontal)
z-direction transverse to the vehicle longitudinal axis (vertical)
M force application point
F front wheel contact force
F gravity force
F force transmitted to the ground by the rear wheel
S centre of gravity of test bicycle
RS wheelbase
h height of centre of gravity

The directions of action by the individual forces are shown correspondingly in Figure 1.

© ISO 2023 – All rights reserved
---------------------- Page: 7 ----------------------
ISO 11154:2023(E)
Key
1 cross member
2 support foot

Figure 1 — Presentation with the example of a base carrier, consisting of two carrying brackets

and four support feet for clamping attachment to a vehicle roof
4.2 Types
The following types of roof racks are differentiated:
Type A Base carrier
Type B Luggage carrier
Type C Ski carrier, snowboard carrier
Type D Windsurf carrier
Type E Bicycle carrier
Type F Boat carrier
Type G Roof box
Type H Air deflector device, advertising carriers and signal lights
Type I Luggage basket
Type J Front wheel/Rear wheel holder (bicycle)
Type K Cross-country ski carrier
Type L Surf mast carrier

NOTE Only types A and B can be mounted directly on the vehicle. Type A contains a base carrier, which

is mounted directly on the vehicle or on special devices on the vehicle. Type B (luggage carrier) is a luggage

basket with integrated carrier function. Types C to L can only be mounted on the base carrier (Type A). Special

versions are possible insofar as these correspond to the safety requirements of this document (see Introduction

and Clause 1).
© ISO 2023 – All rights reserved
---------------------- Page: 8 ----------------------
ISO 11154:2023(E)
The following essential elements characterize the base carrier:

— carrying bracket or cross member for holding and attaching roof rack types C to L;

— device (for example, supporting foot with retaining claws) for positive and non-positive attachment

of the carrying bracket or cross member to the vehicle or to special devices on the vehicle (screwed

or clamped connection or railing or similar).
4.3 Designation

Roof racks according to this document can be marked via the designation of the document and the

designation of the type.
EXAMPLE Designation of a roof rack type A:
Roof rack ISO 11154 – A
5 Attachment to the vehicle

The attachment of the roof racks to be tested according to this document with the vehicle shall be

realized by a mechanical non-positive locking. Combinations of non-positive with positive locking are

thus not excluded.

If a manufacturer brings a special roof rack into circulation, which only requires a carrying bracket or

cross member of type A (e.g. single wheel carrier or wind deflector) for attachment to the vehicle, the

manufacturer shall test this special roof rack completely with the entire intended structure and the

intended vehicle according to this document.
6 Safety requirements, tests
6.1 Measurement uncertainties

Unless otherwise stated, the measurement uncertainties based on the Newton values shall correspond

to the following:
Forces and torques ±5 %
Masses and weights ±2 %
Dimensions ±2 %
Angles ±2°
Time (e.g. test duration) ±5 s
Temperatures ±5 %
Pressure ±5 %
Speed ±5 %
6.2 General

The test requirements described in the following clauses are minimum requirements. Tests with

increased requirements are permissible.

The following requirements and associated tests apply for components whose failure would also entail

a failure of the overall system or detachment/loss of the load or which would render safe driving of the

vehicle impossible.
© ISO 2023 – All rights reserved
---------------------- Page: 9 ----------------------
ISO 11154:2023(E)
6.3 Resistance of the materials

The roof rack including accessories shall fulfil requirements 6.11 to 6.13 in the temperature range from

−20 °C to +60 °C.

This is to be demonstrated for plastic parts in the force flow by one of the following methods:

— material test certificates and test reports show the suitability of the design for the intended

purpose;
— performing tests under the above extreme conditions;
— reference to corresponding material standards.
6.4 Test procedure

Five test samples shall be used for the tests. The sequence of the tests shall follow Figure 2.

Figure 2 — Test sequence

1) For example, technical specifications for the material or test sample of the manufacturer or manufacturer

certificate.
© ISO 2023 – All rights reserved
---------------------- Page: 10 ----------------------
ISO 11154:2023(E)
6.5 Test conditions

The strength and functional safety are determined both by dynamic test bench tests as well as in drive

tests and static-load tests.
The screws are tightened with the torques indicated in the instructions for use.

The roof racks shall be tested in the installation situation approved as least favourable for the user (e.g.

height-adjustable roof racks are tested in the highest position).

For types A to L, the distance in the x-direction of the middle plane of the base carrier, which the

roof racks to be tested assume, shall be (700 ± 2) mm. Roof racks for which the distance is already

specified by regulations or design, shall be tested with the specified distance. In case of roof racks that

are fastened to rain gutters, the following rain gutter distances shall serve as a basis: during drive

test ≥ 1 250 mm; during the tests for the static load bearing capacity = 1 250 mm. If the intended use is

limited by the manufacturer of the roof rack, the maximum permissible distance of rain gutters shall be

applied.

The detailed mounting conditions that shall be followed for the test are oriented to the specifications of

the manufacturers of the roof racks or vehicle manufacturers. These specifications shall be included in

the user information.
6.6 Test specimens

Roof racks which correspond to the series state shall be presented as test specimens for the operational

safety (see 6.11), the brake test (see 6.11.4), the static-load bearing capacity (see 6.12) and the crash

simulation stress (see 6.13). A new test specimen can be used, if required, for testing the operational

safety. If one of these tests is negative, this test may only be repeated to pass these requirements if an

improvement has been made to the roof rack or the attachment to the vehicle. The other tests shall be

repeated with this new technical status if their result is affected by the modification.

6.7 Test instruments
6.7.1 Roof-box dummy for load simulation

The test crate shall be designed according to Figure 3 and shall not be deformed by the load. The mass

of the test crate shall correspond to Table 1. The mass of the load weights shall be evenly distributed.

The centre of gravity heig
...

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