The German project PPR2027 set out to develop performance‑based approval methods for road fuel tankers that would allow manufacturers to introduce innovative tank shell designs while maintaining, or improving, safety levels. The core of the work was a combination of finite‑element (FE) modelling, physical testing and accident data analysis. The FE models were calibrated against full‑scale drop and rollover tests, and the results showed a strong correlation (high coefficient of determination, R²) between impact energy and key structural response parameters for the tanker drop model. This relationship underpins the proposed subsection drop‑test and whole‑tanker topple‑test procedures, which are complemented by abrasion and penetration‑resistance requirements. Together, these tests form the basis of an outline technical code that could be adopted within the ADR framework to replace the current design‑based approval regime for novel tanker concepts.
The project also examined the risk of tank failure and flammable‑liquid spillage in frontal collisions. Analysis of the ADR collision database and the national Stats19 database (2009‑2018) revealed that 80.1 % of fuel‑tanker collisions involved a light vehicle, 9.0 % involved a heavy vehicle, 9.5 % involved a two‑wheel vehicle and 1.4 % involved other types. Impact points were distributed as 43.4 % front, 17.2 % rear and 39.4 % side. Only a single case of tank damage with spillage was identified in the dataset, suggesting that the overall risk is low but still warrants systematic assessment. The study highlighted that few tankers in the current fleet lack longitudinal frame support behind the king‑pin area or have short king‑pin assemblies, making them potentially more vulnerable to buckling. Initial FE models were found to over‑estimate loads and did not fully capture real‑world designs, indicating the need for more representative models and realistic loading scenarios.
To address these gaps, the project proposed a three‑fold approach: (1) an expanded accident analysis to identify additional relevant collisions and to compare ADR reports with Stats19 data, thereby validating the reporting coverage; (2) a fleet survey to quantify the proportion of tankers that might be prone to failure due to design features; and (3) refined FE modelling that incorporates realistic tanker geometries, attachment details and bulkhead support, as well as collision‑specific load magnitudes. These steps aim to determine whether the risk of tank rupture is generic to all designs or specific to certain configurations, and to inform targeted design improvements.
Collaboration was carried out by a consortium led by the Technical Research Laboratory (TRL) in the United Kingdom, with key contributors including Robinson B, Webb D, Hobbs J and London T. The consortium drew on expertise in vehicle dynamics, structural analysis and regulatory assessment. The project was funded under the German Federal Ministry of Transport and Digital Infrastructure’s PPR2027 programme and was completed in 2023. The final report, version 1.1, presents a comprehensive set of recommendations for performance‑based approval, a draft technical code for rollover resilience, and a roadmap for further research to refine the modelling and testing approaches.