Minimum RPD Standard Protects Off-Road Vehicles

Minimum Standard Rollover Protection Device (RPD)
1.0 Rollover Protection Device (RPD) Standard

This Standard applies to all light vehicles used on both graded roads and off-road. It applies
to both 2 and 4 wheel drive vehicles. Excluded from the obligatory fitting of the rollover device
are:
• Vehicles with rollover protection built in intrinsically to the vehicle specification by the
manufacturer
• Certain specialised light vehicles such as pick-ups mounted with cherry-pickers, small
tippers, minibuses and delivery vans may be exempt from the requirement to have
rollover bars fitted. Written deviation for such vehicles shall be obtained after review of
each specific case.
Vehicles which have rollover protection intrinsically built into the vehicle structure by the
manufacturer shall be exempted from this Standard if the manufacturer certifies that the
rollover protection is capable of withstanding the minimum load requirements specified below.
1.1 Minimum Load Requirements
1.1.1 The RPD must be demonstrated to withstand the following specified forces through a BP HSE
approved testing centre. This may be accomplished by means of Finite Element Analysis, or
an alternative analytical method providing this is proven to be sufficient.
1.1.2 Specific Load Requirements
The RPD must be capable of withstanding a force of:
• 7.5w applied to the ‘B’ hoop vertically.

• 5.5w applied as a single point load on the upper corner of the ‘B’ hoop longitudinally.
• 1.5w applied as a single point load on the upper corner of the ‘B’ hoop laterally.
where ‘w’ is the gross vehicles weight (as specified by the vehicle manufacturer) + 150Kg.
A gross vehicle weight rating (GVWR) is the maximum allowable total weight of a road vehicle
that is loaded, including the weight of the vehicle itself plus fuel, passengers, cargo, and
trailer tongue weight
During these tests, no part of the RPD may deform by more than 50mm.
Version 3. Date: 13/10/2008 Page 1 of 12

Owner: Transport HSE Advisor North Africa SPU, Roger Ward / Ray Bowler
2.0 Material Specifications

2.1 Tubular Members
2.1.1 All tubular members shall be of cold drawn seamless carbon steel tube and shall meet the
following minimum specifications and dimensions:
• Minimum Dimension: 0 38 mm x 2.50 mm WT or 0 40 mm x 2.00 mm WT

• Minimum Tensile Strength: 350 N/mm2
• Minimum Elongation: 22% on a 2" specimen and in accordance with ASTM A370
• Maximum Carbon Equivalent: 0.45 %
2.1.2 Each individual member within the ROP should be composed of a single piece. Their
construction shall be without unevenness, cracking or wrinkling. Minimum bending radius
should be 3 x the tube diameter used
.
2.1.3 Galvanised or plated steel shall not be used.
2.1.4 The RPD shall be protected by a minimum of a primer coat and gloss finish, or alternatively
with high quality durable powder-coat.
2.2 Plates
2.2.1 All plate material and brackets on a RPD shall meet the material property requirements
specified for tubular members.
2.2.2 For all material types the minimum thickness of all plates, brackets and tags shall be 3 mm.
2.2.3 All holes for fixing bolts shall be drilled no nearer to the edge of the full material then the
diameter of the hole drilled
2.3 Welding
2.3.1 All welding shall be continuous bead – spot welds are not permitted
2.3.2 Welding shall be performed by welders qualified to AWS D1.1 using qualified procedures.
2.4 Construction
2.4.1 General
The RPD shall be fixed to the bottom of the vehicle as near as reasonably and technically
possible to the chassis beams or any floor support/fixing brackets of the chassis.
Refer to the Design Sketches for a clear understanding of the terminology (ref Annex 1).
2.4.2 Main Hoops
Each hoop shall be built of a single piece. Their construction shall be without unevenness,
cracking or wrinkling. Minimum bending radius should be 3 x the tube diameter used

3.00 Fixing Plates

3.01 Fixing plates shall be welded or bolted to the base of the roll over bar hoops.
3.02 Reinforcement Plates
Reinforcement plates shall be fixed by welding to the chassis or substantial body members.
2
The minimum surface area of the reinforcement plates shall be 120 cm .
3.03 Doubler Plates
3.03.1 Doubler plates may be located under the reinforcement plates, or alternatively beneath the
body plate.
3.03.2 The plate shall be of one piece with at least the same surface dimensions as the fixing plate.
It is acceptable to use more than one smaller plate provided the total surface area of the
2
plates is minimally 60 cm .
3.04 Bolts/Nuts for Bottom Fixing
3.04.1 For fixing each individual leg of the main hoops to the vehicle; a minimum of 3 bolts shall be
used.
3.04.2 Minimum diameter of these bolts shall be 10 mm.
3.04.3 Minimum material specification: Grade 8-8.
3.04.4 A washer shall be used under the nut.
3.04.5 Nuts shall be of the locking type. As a alternative to locking nuts, locking washers may be
used. If nuts are tag welded to either the fixing plate or the doubler plate, a locking washer
shall be used under the fixing bolt
3.04.6 Once assembled, there shall be at least 2 threads showing once the nut has been tightened
fully.
3.05 Additional Tags
3.05.1 Tags may be welded or bolted to the main hoops of the RPD at a location convenient to
provide a combined fixing point of the hoop to the vehicle and for the upper point of the 3
point fixing (inertia reel) seat belt. The upper seat belt fixing shall be mounted to this point
and not to a separate bracket on the hoop. Refer to Design Sketch 5 (Annex 1).
3.05.2 The seat belt bracket shall still be able to rotate freely around the fixing bolt.
3.05.3 In addition to the fixing to the feet of each hoop and seat-belt upper anchorage points, the
RPD may be attached to the vehicle body using tags welded or bolted to the hoop and bolted
to the body, to provide additional rigidity to the structure.

3.06 Mountings
3.06.1 Existing structural anchor points may be used. In this case, doubler or reinforcement plates
may not be required. However, if not using existing structural anchor points, reinforcement or
doubler plates must be used. If there are any wiring, fuel or brake lines within the area chosen
for the installation of the reinforcement plates, then they shall be re-routed to avoid the
possibility of damage/severing in the event of a rollover.
3.06.2 Bolts used for fixing the combined fixing point of the roll cage and seatbelt shall be of the
standard type used by the vehicle manufacturer on the particular seatbelt anchorage point
and shall be fitted with a locking washer.
3.07 Method of Attaching the Two Bars
3.07.1 Where two bars have to be joined to form either a cage, or to reinforce the structure in the
case of fore and aft diagonal struts, Design Sketch 6 shall apply (ref. Annex 1). However,
other methods of joining are permitted providing they are specifically included and tested
during the Finite Element Analysis of the design
3.07.2 It shall be acceptable to weld diagonal struts to the main hoops.
3.07.3 Whenever bolts pass through the tubing for joining purposes, there shall first be an insert
welded into the tube to provide additional strength to ensure the tube cannot deform
whenever a nut and bolt is tightened.
3.08 Certificate or Proof of Compliance
3.08.1 A certificate certifying that the RPD has been designed, fabricated and installed as per this
Specification will be kept with the vehicle custodian (e.g. the vehicle owner).
3.08.2 Liability for compliance shall rest with the RPD supplier or accredited certifying agent with
respect to the design and construction of the RPD.
3.08.3 The installation of RPD must be carried out by trained personnel as specified by the
manufacturer of the RPD. Individuals operating independently will not be considered as
certified installers.
3.08.4 The fully recommended installation kit must be utilised, especially where linking the RPD to
the vehicle chassis.
3.08.5 Identification Label
Each RPD must have an identification label clearly bearing the name of the manufacturer,
and must have a unique number or code to enable manufacturer trace-ability. This
identification sticker must neither be copied nor moved (i.e. embedded, engraved or self
destroying sticker).
3.09 Roll Bar for Single Cab Pick-Up Type Vehicles
3.09.1 The design, fabrication and installation of the rollover protection bar shall comply with this
document from section 1.0 to 3.08 above.
3.09.2 For general bar configuration refer to Design Sketch 1, 4 and 6 (Annex 1).

3.09.3 There shall be a ‘B’ hoop fitted as close behind the cab as technically possible, running from
the floor area of the pick up body and following as far as is practically possible the profile of
the rear of the cab. However the centreline of the horizontal bar shall exceed the height of
the cab by a minimum of 7 cm but no more than 15 cm.
3.09.4 Each vertical member of the hoop may be braced to the upper rail of the pick up body at the
closest point of intersection using two bolts at each fixing point.
3.09.5 There shall be 2 diagonal struts (backstays) running from the outside edges of the ‘B’ hoop
onto the front half of each wheel arch.
3.09.6 To provide sufficient resistance at impact, the reinforcement plate where possible should have
dimensions so it is placed above structural members of the cargo body. Optionally, the
reinforcement plate can be extended over the full width of the pick-up body floor.
3.09.7 There shall be a front RPD assembly mounted to the internal floor area, or alternatively a
suitable external chassis location. This assembly must follow the A-pillars and roof line as far
as is practically possible and connect to both upper corners of the ‘B’ hoop. This should also
be braced across the top of the windscreen.
3.09 8 The fixing of all components to the pick up body and each other shall be in accordance with
the details described in section 3.0 to 3.05.
3.10 Roll Bar for Double-Cab Pick-Up Type Vehicles
document from section 1.0 to 3.08.
3.10.02 For general bar configuration refer to Design Sketch 2, 4, 5 and 6 (Annex 1).
3.10.03 The ‘B’ hoop shall be situated directly behind the front seats. This should follow the profile of
the ‘B’ post and roof lining as close as technically possible, running from the floor area and
following the profile of the vehicle.
3.10.04 The ‘C’ hoop may be situated directly behind the rear seats. This should follow the profile of
the ‘C’ post and roof lining as close as technically possible, running from the floor area and
Alternatively the ‘C’ hoop may be positioned in the rear buck of the vehicle as close behind
the cab as technically possible, running from the floor area of the pick up body and following
as far as is practically possible the profile of the rear of the cab. However the centreline of the
horizontal bar shall exceed the height of the cab by a minimum of 7 cm but no more than 15
cm.
3.10.05 Between the ‘B’ and ‘C’ hoops there shall be at least 1 horizontal strut at each side of the
vehicle. The horizontal struts shall follow the roof line as far as is practically possible and shall
be above the door line.
3.10.06 Each vertical member of the ‘C’ hoop may be braced to the body at the closest point of
intersection using two bolts at each fixing point
3.10.07 There shall be 2 diagonal struts (backstays) running from the outside edges of the ‘C’ hoop
onto the rear buck.

dimensions so it is placed above structural members of the cargo body. Optionally, the
reinforcement plate can be extended over the full width of the pick-up body floor.
3.10.10 The fixing of all components to the pick up body and each other shall be in accordance with
3.10.11 All of the internal roll cage above shoulder height shall be covered with a foam padding 15 to
20 mm thick of 50-55 shore hardness.
3.11 Roll Bar For Station Wagon Type Vehicles
document from section 1.0 to 3.08.
3.11.02 For general bar configuration refer to Design Sketch 3, 4, 5 and 6 (Annex 1).
3.11.03 The ‘B’ hoop shall be situated directly behind the front seats. This should follow the profile of
the ‘B’ post and roof lining as close as technically possible, running from the floor area and
3.11.04 The ‘C’ hoop must be situated directly behind the rear seats. This should follow the profile of
the ‘C’ post and roof lining as close as technically possible, running from the floor area and
3.11.05 Between the ‘B’ and ‘C’ hoops there shall be at least 1 horizontal strut at each side of the
vehicle, fitted as high as practically possible. The horizontal struts shall follow the roof line as
far as is practically possible and shall be above the door line.
3.11.06 There shall be 2 diagonal struts (backstays) running rearward from the outside edges of the
‘C’ hoop.
dimensions so it is placed above structural members of the body. Optionally, the
reinforcement plate can be extended over the full width of the body floor.
3.11.09 The fixing of all components to the pick up body and each other shall be in accordance with
3.11.10 All of the internal roll cage above shoulder height shall be covered with a foam padding 15 to
20 mm thick of 50-55 shore hardness.

4.0 Modifications
All modification to the RPD is forbidden and will invalidate the certification. Any alteration from
the manufacturers standard specification through machining or welding, that involved
permanent modification of the RPD may be considered as a modification. This specifically
includes drilling.

Annex 1: Design Sketches

Single Cab Pick-Up Typical RPD Layout
Double Cab Pick-Up Typical RPD Layout

Station Wagon Typical RPD Layout

Detail

Method Of Attaching Two Members
Design Sketch 6



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Minimum Standard Rollover Protection Device (RPD)

Minimum Standard Rollover Protection Device (RPD)

1.0 Rollover Protection Device (RPD) Standard

1.1 Minimum Load Requirements

1.1.2 Specific Load Requirements

The RPD must be capable of withstanding a force of:

• 7.5w applied to the ‘B’ hoop vertically.

Version 3. Date: 13/10/2008 Page 1 of 12

2.0 Material Specifications

• Minimum Dimension: 0 38 mm x 2.50 mm WT or 0 40 mm x 2.00 mm WT

2.4.2 Main Hoops

Version 3. Date: 13/10/2008 Page 2 of 12

3.00 Fixing Plates

3.02 Reinforcement Plates

3.03 Doubler Plates

3.04 Bolts/Nuts for Bottom Fixing

3.04.2 Minimum diameter of these bolts shall be 10 mm.

3.04.3 Minimum material specification: Grade 8-8.

3.04.4 A washer shall be used under the nut.

3.05 Additional Tags

Version 3. Date: 13/10/2008 Page 3 of 12

3.07 Method of Attaching the Two Bars

3.07.2 It shall be acceptable to weld diagonal struts to the main hoops.

3.08 Certificate or Proof of Compliance

3.08.5 Identification Label

3.09 Roll Bar for Single Cab Pick-Up Type Vehicles

Version 3. Date: 13/10/2008 Page 4 of 12

3.10 Roll Bar for Double-Cab Pick-Up Type Vehicles

Version 3. Date: 13/10/2008 Page 5 of 12

3.11 Roll Bar For Station Wagon Type Vehicles

Version 3. Date: 13/10/2008 Page 6 of 12

Version 3. Date: 13/10/2008 Page 7 of 12

Annex 1: Design Sketches

Double Cab Pick-Up Typical RPD Layout

Version 3. Date: 13/10/2008 Page 8 of 12

Station Wagon Typical RPD Layout

Version 3. Date: 13/10/2008 Page 9 of 12

Version 3. Date: 13/10/2008 Page 10 of 12

Method Of Attaching Two Members

Version 3. Date: 13/10/2008 Page 11 of 12

Version 3. Date: 13/10/2008 Page 12 of 12

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