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
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Standards Content (Sample)
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
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ISO 11154:2023(E)
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© ISO 2023
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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
x
6.12.5 Requirements for forces opposing the direction of travel +F .20
x
6.12.6 Testing the forces opposing the direction of travel +F .20
x
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
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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
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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.
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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
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ISO 11154:2023(E)
4 Symbols, types and designation
4.1 Symbols
−F direction of the normal force of the load
Z
F direction of the vertical force, acting vertically to the direction of travel
z
F direction of the lateral force, acting laterally to the direction of travel
Y
−F direction of the longitudinal force, acting longitudinally to the direction of travel
x
F direction of the opposing longitudinal force, acting against the direction of travel
x
−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
D
m permissible load bearing capacity of the roof rack in kilograms
N
m dead weight of the roof racks and possibly the roof structural system in kilograms
E
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
Vr
F gravity force
g
F force transmitted to the ground by the rear wheel
Hr
S centre of gravity of test bicycle
m
RS wheelbase
h height of centre of gravity
Sm
The directions of action by the individual forces are shown correspondingly in Figure 1.
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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).
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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.
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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:
1)
— 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.
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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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