Commercial Vehicles Face High Fail Rates, According to TÜV Report - For the First Time, Heavy Trucks Lag Behind - Commercial vehicles have a high failure rate, with one out of every five failing inspections, according to the TÜV report. Particularly, heavy trucks struggle the most during their initial checking.
In a recent analysis conducted by the TÜV Association, it was found that a concerning number of heavy trucks on the road have significant or dangerous defects. The biennial report, which analysed 2.31 million commercial vehicle inspections from 2023 and 2024, revealed an increase of 0.8 percentage points in the defect rate compared to the last report in 2023.
The Federal Motor Transport Authority (KBA) was mentioned in the context of the analysis. However, the report highlighted a challenge in comprehensively integrating driver assistance systems like non-braking or lane-change assistants and fatigue warning systems into the main inspection (HU). This is due to manufacturers and vehicle system suppliers restricting access to safety-relevant vehicle data.
The increased usage of heavy trucks, particularly those over 7.5 tons, has been identified as a contributing factor to the rise in age-related defects. Since 2015, the number of trucks in this category has increased by 22 percent. In 2024, these heavy trucks averaged 43,309 kilometers, while tractor units reached 86,585 kilometers.
Vehicles between 3.5 and 7.5 tons had a defect rate of 20.0 percent, while those between 7.5 and 18 tons saw a defect rate of 16.5 percent. Surprisingly, vehicles up to 3.5 tons had the highest defect rate of 21.5 percent.
Richard Goebelt, head of the vehicle & mobility department at the TÜV Association, expressed his surprise at the increase in defects for heavy trucks, given their frequent inspections and typical maintenance. He emphasised the importance of keeping heavy trucks in a reliable technical condition throughout their entire lifespan.
Goebelt also pointed out that any technical defect in large vehicles poses a higher danger. He noted that many companies are keeping older vehicles in operation, which could be a factor in the rising defect rate.
The demand for a main inspection that can reliably cover digital and automated systems has been made, given the current trend towards more complex vehicles. As our roads become more congested with heavy trucks, it is crucial that these vehicles are in a safe and reliable condition to ensure the safety of all road users.
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