BRITISH STANDARD AUTOMOBILE SERIES BS AU 266 1 1996 ISO 11154 1 1995 Specification for Roof load carriers — Part 1 Roof bars L ic e n s e d C o p y L o n d o n S o u th B a n k U n iv e rs it y , L o[.]
Li cen sed Copy: Lon d on Sou th Ban k U n i versi ty, Lon d on Sou th Ban k U n i versi ty, Sat Dec 09 02: 08: 52 G M T+00: 00 2006, U n trol l ed Copy, (c) BSI BRITISH STANDARD AUTOMOBILE SERIES Specification for Roof load carriers — Part : Roof bars BS AU 266-1 : 996 ISO 1 4-1 : 995 Li cen sed Copy: Lon d on Sou th Ban k U n i versi ty, Lon d on Sou th Ban k U n i versi ty, Sat Dec 09 02: 08: 52 G M T+00: 00 2006, U n trol l ed Copy, (c) BSI BS AU 266-1 :1 996 Committees responsible for this British Standard The preparation of this British Standard was entrusted to Technical Committee AUE/9, Automobile details and accessories, upon which the following bodies were represented: Automobile Association BSI Testing Services Consumer Policy Committee of BSI Department of Trade and Industry (Consumer Safety Unit, CA Division) Department of Transport Garage Equipment Association Institute of Trading Standards Administration Society of Motor Manufacturers and Traders Limited This British Standard, having been prepared under the direction of the Engineering Sector Board, was published under the authority of the Standards Board and comes into effect on Amendments issued since publication March 996 © BSI 09- 999 The following BSI references relate to the work on this standard: Committee reference AUE/9 Draft for comment 93/71 6275 DC ISBN 80 25 04 Amd No Date Comments Li cen sed Copy: Lon d on Sou th Ban k U n i versi ty, Lon d on Sou th Ban k U n i versi ty, Sat Dec 09 02: 08: 52 G M T+00: 00 2006, U n trol l ed Copy, (c) BSI BS AU 266-1 :1 996 Contents Page Committees responsible Inside front cover National foreword ii Scope Normative references Definitions Symbols and units Requirements Test methods Instructions for use and fitting Marking Annex A (normative) Approval/rej ection procedure 11 Annex B (normative) Tightening torques for fixing roof bars 12 Annex C (informative) Determination of allowable additional mass 12 Figure — Components of roof bar Figure — Components of connecting devices Figure — Test box Figure — Test box location and strapping Figure — Deflection measuring point Figure — F application point Figure — F application point Figure — F and 0, F application points l lq a List of references © BSI 09- 999 a 10 Inside back cover i Li cen sed Copy: Lon d on Sou th Ban k U n i versi ty, Lon d on Sou th Ban k U n i versi ty, Sat Dec 09 02: 08: 52 G M T+00: 00 2006, U n trol l ed Copy, (c) BSI BS AU 266-1 :1 996 National foreword This British Standard has been prepared by Technical Committee AUE/9 It is identical with ISO 1 54- : 995 Part 1: Roof bars , Road vehicles — Roof load carriers — published by the International Organization for Standardization (ISO) It is anticipated that additional parts to this standard will be published, as follows, when the corresponding ISO standards have been completed: Part 2: Accessories and attachments to roof bars for special purpose applications ; — — Part 3: Specific purpose roof devices Cross-references International Standard Corresponding British Standard ISO 9227: 990 BS 7479: 991 Method for salt spray corrosion tests in artificial atmospheres (Identical) The Technical Committee has reviewed the provisions of ISO 61 2: 978 and ISO 1 76: 990, to which reference is made in the text, and has decided that they are acceptable for use in conj unction with this standard A British Standard does not purport to include all the necessary provisions of a contract Users of British Standards are responsible for their correct application Compliance with a British Standard does not of itself confer immunity from legal obligations Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, pages to 2, an inside back cover and a back cover This standard has been updated (see copyright date) and may have had amendments incorporated This will be indicated in the amendment table on the inside front cover ii © BSI 09- 999 Li cen sed Copy: Lon d on Sou th Ban k U n i versi ty, Lon d on Sou th Ban k U n i versi ty, Sat Dec 09 02: 08: 52 G M T+00: 00 2006, U n trol l ed Copy, (c) BSI BS AU 66-1 : 996 S cope Definitions This part of ISO 1 54 specifies the minimum For the purposes of this part of ISO 1 54, the safety requirements for roof bars intended for following definitions apply mounting on or above the roofs of passenger cars or light commercial vehicles with a maximum authorized total mass (ISO- M08) as defined in ISO 1 76 up to 3, t It applies to general- use roof bars suitable for carrying load, excluding magnetic and vacuum- fixed devices (see note ) 3.1 roof bar supporting bar with connecting devices which enables a load to be carried on the roof of a vehicle NOTE NOTE It establishes technical specifications and test methods which offer both the user of roof bars and road users a minimum level of safety when the roof Generally, roof bars are compatible with the use of additional accessories Roof bars are fixed on the roof or on original- equipment rails of the vehicle NOTE An example of components of a roof bar is given in Figure bars are being used in accordance with the 3.2 manufacturer’s instructions connecting de vice Moreover, requirements of ISO 1 54 complete the provisions of Directive 74/483/EEC 1) concerning NOTE these products NOTE set of parts connecting the supporting bar to the vehicle The other parts of ISO 1 54 are as follows: Examples of connecting device components are given in Figure and Figure — part covers additional accessories intended to be fitted on 3.3 general purpose roof bars; spe cific purpose roof device — part covers specific purpose roof devices; — part covers magnetic and vacuum- fixed devices roof device designed for a specific type of load or use 3.4 Normative references additional acce ssory The following standards contain provisions which, device used in conj unction with the roof bars to through reference in this text, constitute provisions carry a specific type of load of this part of ISO 1 54 At the time of publication, the editions indicated were valid All standards are subj ect to revision, and parties to agreements based 3.5 maximum ve hicle roof load, m d on this part of ISO 1 54 are encouraged to maximum load capacity permissible on the roof of investigate the possibility of applying the most the vehicle as defined by the vehicle manufacturer recent editions of the standards indicated below 3.6 Members of IEC and ISO maintain registers of maximum roof b ar set load, currently valid International Standards ISO 61 2: 978, Ro ad v ehicles — Dim ens ions of m o to r m b maximum load capacity permissible on roof bar set as defined by the roof bar manufacturer v ehicles and tow ed v ehicles — Term s and 3.7 definitions mass of se t of roof b ars, ISO 1 76: 990, Ro ad v ehicles — Mass es — Vocab ulary and codes ISO 9227: 990, Corrosio n tes ts in artificial atm os p heres — Salt s p ray tests European Commission Directive 79/488/EEC / / 3.8 the ore tical maximum load, m maximum vehicle roof load minus mass of set of m Directiv e 74 483 EEC on the ap p ro xim ation of the 3.9 actual maximum load, , April 979 1) European Council Directive 74/483/EEC on the p ro jections o f m o to r v ehicles © BSI 09- 999 m theoretical maximum load, bar load, m m d n e law s of the Mem b er States relating to the external p rojections of m otor v ehicles e total mass of set of roof bars roof bars adap ting to technical p rogres s Co uncil m x m n, or maximum roof b , whichever is the lowest ap p ro xim atio n o f th e law s of the Mem b er States relating to the external , September 974 Li cen sed Copy: Lon d on Sou th Ban k U n i versi ty, Lon d on Sou th Ban k U n i versi ty, Sat Dec 09 02: 08: 52 G M T+00: 00 2006, U n trol l ed Copy, (c) BSI BS AU 66-1 : 996 3.1 Slide re sistance under quasi-static force d de fle ction, app lie d at ° to ve hicle longitudinal axis sum of permanent deformations and sliding 5.2.1 displacement of a roof bar when fixed to a vehicle deflection roof and under test conditions application of a force 0, 3.1 5.2.2 test b ox deflection When tested in accordance with d lq , the shall not exceed 50 mm under the application of a force load simulation device used during the test the F When tested in accordance with d , shall not exceed mm under the F lq Re sistance to lift 3.1 lifting force , F When used in accordance with the manufacturer’s a force applied during testing to simulate the vertical component of the aerodynamic effect of load instructions, roof bars shall be able to withstand those lifting forces which can be expected to occur When tested in accordance with 3.1 forward longitudinal force , F force l , under a F , the roof bars shall remain fixed on the roof a If front and rear connecting devices are different, force applied during testing to simulate the horizontal forward component of the force caused by the load the rear roof bar shall remain fixed to the roof under a force 0, F a when tested in accordance with Re sistance to corrosion 3.1 ° horizontal force , F When tested in accordance with lq force applied during testing to simulate the effect caused by the load during braking when cornering , no active corrosion which affects the basic function of each part shall appear after the test Re sistance of mate rials Symbols and units All materials shall allow roof bars to fulfil the For the purposes of this part of ISO 1 54, the following symbols and units apply S ymb ol requirements specified in 5.1 at outside into account ultraviolet stability and ozone ageing This shall be shown by at least one of the following Unit d Maximum vehicle roof load kg b Maximum roof bar set load kg that material property concepts are compatible e Mass of set of roof bars kg with intended use, n Theoretical maximum load kg x Actual maximum load kg Deflection mm a Lifting force N l Forward longitudinal force N limited to the width of the vehicle roof panel lq 20 ° horizontal force N (see Figure 5) However, the length of the bar shall methods a) materials certification b) tests as in clause 2) showing c) reference to applicable standards O ve rhang and e xte rnal shap e It is recommended that the bar length be not exceed the vehicle width as defined in ISO 61 2: 978, 6 The external radius of all contactable components shall conform to ap plied forward in ve hicle longitudinal axis Directive 79/488/EEC When tested in accordance with deflection d d and 6 of the F l When tested in accordance with deflection , 6 shall not exceed mm under the application of a force 0, 5.1.2 2) under the limiting S lide re sistance unde r quasi-static force 5.1 or reports conditions given above, Requirements , the shall not exceed 50 mm under the application of a force 5.3 D e signation m m m m m d F F F 2) to temperatures between – 20 ° C and + 60 °C, taking F l Reference may be made to the ISO 9000 series of International Standards for these documents © BSI 09- 999 Li cen sed Copy: Lon d on Sou th Ban k U n i versi ty, Lon d on Sou th Ban k U n i versi ty, Sat Dec 09 02: 08: 52 G M T+00: 00 2006, U n trol l ed Copy, (c) BSI BS AU 266-1 :1 996 Test methods 6.2 Slide resistance test under quasi-static forward force 6.1 General 6.1 All slide resistance and resistance to lift tests shall b e carried out on the vehicle roof in the following sequence: b) slide resistance test under a quasi- static forward force F l ; c) slide resistance test under a quasi- static force F lq The nominal value of the longitudinal forward force, F l a) resistance to lift test; at ° to the vehicle longitudinal axis Three roof b ars sets manufactured from current production tools shall be made available as test Nominal value of force 6.2.1 , is given b y the equation: F l = 40 where m m = x = x m m m x if b if n m m b b < > m m n n Test procedure 6.2.2 Mount the roof b ars on the roof of the vehicle specimens Tighten the clamps to the required torque or force The approval/rej ection procedure shall be as and record the value specified in Annex A Install the test b ox, weighted to the 6.1 Roof bars shall b e tested in pairs unless they clamp it as indicated in 6.1 m x value, and are specifically designed to b e used in sets of more Check and, if necessary, readj ust the clamps to the than two specified torque or force value 6.1 Adj ustable roof bars shall b e tested at their Install the measuring equipment as shown maximum height above the roof in Figure 6.1 Prior to each test each set of b ars shall be Progressively and continuously apply the fitted, released and retightened to the specified longitudinal force instructions required nominal value, checking the instant d F at 0, l F as shown in Figure up to the Immediately release the force, Fitting and tightening torques shall be in deflection accordance with the manufacturer’s instructions or, and measure and record the total deflection failing that, in accordance with Annex B 6.3 Slide resistance test under quasi-static 6.1 The distance b etween the roof b ars shall be as force at 20 ° to longitudinal axis specified in the instructions for fitting and use 6.1 The test box shall b e in accordance with Figure and shall not b e deformed b y the load The ballast used to adj ust the mass shall b e uniformly distrib uted in the test box The test mass of ± m x shall be adj usted to an accuracy kg The test box shall be firmly attached to the roof bars, as shown in Figure 4, using straps to preclude any movement between the bars and the test b ox For sets with more than two bars, the test b ox shall a) from the first to the second, and then b) from the second to the third bar, etc 6.1 Test forces shall be applied to achieve the maximum value within s to 30 s, to a tolerance of N 6.1 The deflection, l Nominal value of force 6.3.1 The nominal value of the ° force, F lq d , is given b y the equation: F = 40 lq where m m x = x = 6.3.2 m m m x b if n if m m b < b > m m n n Test procedure Mount the roof b ars on the roof of the vehicle Tighten the clamps to the required torque or force be attached, in turn: +1 00 and record the value Install the test b ox, weighted to the m x value, and clamp it as indicated in 6.1 Check and, if necessary, readj ust the clamps to the specified torque or force value d , shall b e measured in accordance with Figure Install the measuring equipment as shown in Figure Progressively and continuously apply the ° force F lq as shown in Figure up to the required nominal value, checking the instant deflection at 0, F lq measure and record the total deflection © BSI 09- 999 d Immediately release the force, and d Li cen sed Copy: Lon d on Sou th Ban k U n i versi ty, Lon d on Sou th Ban k U n i versi ty, Sat Dec 09 02: 08: 52 G M T+00: 00 2006, U n trol l ed Copy, (c) BSI BS AU 266-1 :1 996 6.4 Resistance to lift test 7.2 Instructions for use Test force The roof bar manufacturer shall provide instructions for use containing the following The force Fa shall be applied to the connecting minimum information: devices between roof bars and vehicle roof, up to the a) Value of actual maximum load on the roof maximum value determined by the following bars for the vehicle(s) for which it is made and, equation: a warning regarding relevant regulations m Fa = 500 + x × g (an example is given in Annex C) b) the following information: where g is the2 acceleration due to gravity 1) The load shall be as evenly distributed as (g = 9,81 m/s ) possible over the area of the carrier system, 6.4.2 Test procedure and the centre of gravity of the load kept as low Mount the roof bars on the roof of the vehicle as possible Narrow and heavy loads (for example, metal tubes) are to be carried Tighten the clamps to the required torque or force near the feet of the carrier system Loads and record the value which overhang the ends of the carrier system Install the test box, weighted to the m x value, and shall conform to any relevant laws or by-laws clamp it as indicated in 6.1 in force, and shall be adequately secured Check and, if necessary, readjust the clamps to the 2) Loads shall be adequately secured using specified torque or force value suitable straps or similar tightening devices Progressively and continuously apply a vertical After loading, recheck the security of the load lifting force Fa across the test box as shown and roof bars regularly throughout the in Figure 8, up to the nominal value journey Elastic straps with securing hooks Maintain this force for 10 shall not be used Release the force 3) Where surfboards are carried (or similar items which may produce lifting forces), they If front and rear connecting devices are different, shall not be carried side-by-side, but stacked apply a vertical lifting force at the rear of the test one upon the other All surfboards and similar box equal to 0,5Fa, with the same test method, as items shall be secured independently to the shown in Figure front and rear of the vehicle using straps or 6.5 Resistance to corrosion test other methods which are capable of Expose the roof bars to the neutral salt spray test with-standing the lifting forces (NSS) with % of sodium chloride for 192 h Expose 4) Where specialized accessories are available the functional parts to this salt spray for 400 h to carry or secure loads, for example cycle These tests shall be performed in accordance with carriers, it is recommended that they are used ISO 9227 5) The handling characteristics of a vehicle will change when a carrier system is fitted and Instructions for use and fitting especially when it is loaded (in particular, 7.1 Fitting instructions crosswind sensitivity, handling on bends, and braking) Driving techniques should be altered The roof bar manufacturer shall give the following to allow for these changes, reducing speed, information in the assembly instructions: especially on bends, and allowing for longer a) detailed fitting instructions with figures or braking distances illustrations; 6) To reduce fuel consumption, it is b) the value of the torque or force where it is recommended that the roof bars be removed necessary to apply a specified torque or force to a after use fastening device in order to fix the roof bars to a c) a warning explaining: vehicle; 1) the importance of correctly following the c) a recommendation to have approximate instructions for fitting and use; spacing between bars of 700 mm or that specified by the vehicle manufacturer; 2) the need for the fixing devices to be tightened correctly and checked regularly d) mounting points on the type(s) of vehicle(s) for during the journey; which the roof bars are intended and a warning that roof bars must not be used on vehicles other 3) that loads are carried within the limitations than those specified by the manufacturer of 7.2 a) and 7.2 b) 1); 6.4.1 © BSI 09-1999 Li cen sed Copy: Lon d on Sou th Ban k U n i versi ty, Lon d on Sou th Ban k U n i versi ty, Sat Dec 09 02: 08: 52 G M T+00: 00 2006, U n trol l ed Copy, (c) BSI BS AU 266-1 :1 996 4) that loads are secured correctly and safely; 5) that equipment must b e maintained in good working order Marking Roof bars shall have the following marking: a) name or trademark of the manufacturer, importer or distrib utor; b ) type of bar; c) maximum roof b ar load defined in accordance with this part of ISO 1 54; d) a reference to ensure traceab ility ) See Figure Figure — Components of roof bar Figure — C omponents of connecting devices © BSI 09- 999 Li cen sed Copy: Lon d on Sou th Ban k U n i versi ty, Lon d on Sou th Ban k U n i versi ty, Sat Dec 09 02: 08: 52 G M T+00: 00 2006, U n trol l ed Copy, (c) BSI BS AU 266-1 :1 996 ) If the distance b etween outside roof bars is more than 900 mm, the test box length shall be equal to this distance plus 00 mm Figure — Test box © BSI 09- 999 Li cen sed Copy: Lon d on Sou th Ban k U n i versi ty, Lon d on Sou th Ban k U n i versi ty, Sat Dec 09 02: 08: 52 G M T+00: 00 2006, U n trol l ed Copy, (c) BSI BS AU 266-1 :1 996 ) In accordance with mounting instructions or 700 mm b y default Figure — Test box location and strapping © BSI 09- 999 Li cen sed Copy: Lon d on Sou th Ban k U n i versi ty, Lon d on Sou th Ban k U n i versi ty, Sat Dec 09 02: 08: 52 G M T+00: 00 2006, U n trol l ed Copy, (c) BSI BS AU 266-1 :1 996 Figure — Deflection measuring point © BSI 09- 999 Li cen sed Copy: Lon d on Sou th Ban k U n i versi ty, Lon d on Sou th Ban k U n i versi ty, Sat Dec 09 02: 08: 52 G M T+00: 00 2006, U n trol l ed Copy, (c) BSI BS AU 266-1 :1 996 NO TE The force is ap p lied in the direction of vehicle movem ent, at the centre of the tes t b ox front face Figure — Figure — © BS I 9- 99 F l F lq application point application point Li cen sed Copy: Lon d on Sou th Ban k U n i versi ty, Lon d on Sou th Ban k U n i versi ty, Sat Dec 09 02: 08: 52 G M T+00: 00 2006, U n trol l ed Copy, (c) BSI BS AU 266-1 :1 996 Figure — 10 F a and 0, F a application points © BS I - 99 Li cen sed Copy: Lon d on Sou th Ban k U n i versi ty, Lon d on Sou th Ban k U n i versi ty, Sat Dec 09 02: 08: 52 G M T+00: 00 2006, U n trol l ed Copy, (c) BSI BS AU 266-1 :1 996 Annex A (normative) Approval/rej ection procedure © BSI 09- 999 11 Li cen sed Copy: Lon d on Sou th Ban k U n i versi ty, Lon d on Sou th Ban k U n i versi ty, Sat Dec 09 02: 08: 52 G M T+00: 00 2006, U n trol l ed Copy, (c) BSI BS AU 266-1 :1 996 Annex B (normative) Tightening torques for fixing roof bars Torque Type of fixing N·m Hand nut/screw diameter less than 35 mm Hand nut/screw diameter 35 mm to less than 45 mm Hand nut/screw diameter 45 mm to less than 55 mm Hand nut/screw diameter 55 mm to less than 65 mm Slotted head screw M6 Slotted head screw M8 a CHC, VH, TORX M6 screw CHC, VH, TORXa M8 screw Hexagon nut M6 Hexagon nut M8 Butterfly nut M6 Butterfly nut M8 a TORX is a trade- name This information is given for the convenience of users of this International Standard and does not constitute an endorsement by ISO of the product named Equivalent products may be used if they can be shown to lead to the same results Annex C (informative) Determination of allowable additional mass The maximum load to be carried on roof bars shall be limited such that — the maximum allowable mass on the vehicle roof, — the maximum allowable mass on the set of roof bars, and — the maximum total mass of the vehicle, are not exceeded Calculation examples are given below Values in kilograms Ref a Items to be considered Maximum allowable mass on the vehicle roof defined Example No Example No Example No 60 75 00 350 500 650 75 50 00 300 380 450 10 20 50 75 a – e 50 70 80 c 75 50 00 b – (d + e + f) 40 65 05 40 50 80 by the vehicle manufacturer b Payload (as defined by vehicle manufacturer) c Maximum load which carrier system can accept d Assumed interior load (75 kg/passenger + luggage) e Mass of carrier system f Maximum allowable load on towing hook g Maximum allowable load on roof carrier system — the lowest of the following calculated values: that is 12 © BSI 09- 999 Li cen sed Copy: Lon d on Sou th Ban k U n i versi ty, Lon d on Sou th Ban k U n i versi ty, Sat Dec 09 02: 08: 52 G M T+00: 00 2006, U n trol l ed Copy, (c) BSI BS AU 266-1 :1 996 List of references See national foreword © BSI 09- 999 Li cen sed Copy: Lon d on Sou th Ban k U n i versi ty, Lon d on Sou th Ban k U n i versi ty, Sat Dec 09 02: 08: 52 G M T+00: 00 2006, U n trol l ed Copy, (c) BSI BS AU 266-1 : 996 ISO 1 4-1 : BSI — British Standards Institution 995 BS I is the indep endent national b ody res p ons ib le for p rep aring Britis h S tandards It p res ents the UK view on s tandards in E urop e and at the international level It is incorp orated b y Royal C harter Revisions Britis h S tandards are up dated b y amendment or revis ion Us ers of Britis h S tandards should make s ure that they p oss es s the latest amendments or editions It is the constant aim of BS I to imp rove the quality of our p roducts and services We would b e grateful if 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