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Effective Stone Chip Protection for Vehicles

Why is rockfall protection so important?

Stone chips pose a significant threat to the integrity and longevity of vehicles. This damage is not merely cosmetic; it can also cause serious structural damage. The underbody, wheel wells, and front end of vehicles are particularly vulnerable. Effective protection of these areas is crucial to ensuring the vehicle’s service life and safety. Without adequate protection, even small stone chips can lead to deep scratches and dents, which make the vehicle susceptible to corrosion. In the long term, such damage can compromise the vehicle’s structural integrity and significantly increase repair costs.

Installation of rock-fall protection on the underbody
Installation of rock-fall protection on the underbody
Stone chips caused by, for example, crushed stone
Stone chips caused by, for example, crushed stone

How does a rockfall occur?

Stone chips are typically caused by small stones and gravel kicked up by the tires of other vehicles or by your own vehicle’s tires. This happens particularly often at high speeds on highways or on unpaved roads. The impact of these particles can leave deep scratches and dents on the vehicle’s surface, which not only detract from its appearance but can also damage the bodywork. This damage promotes rust formation and compromises the vehicle’s structural integrity, which can lead to higher maintenance costs and a shorter service life.

What exactly happens?

Figure 1 illustrates how a protective coat of paint can be damaged by a stone chip. Many paints are brittle or do not adhere properly. This creates a weak spot in the protective layer where corrosion can develop. The resulting rust then penetrates the protective layer from there. Even cathodic corrosion protection, such as galvanization, cannot prevent this, since the resulting white rust can also penetrate the protective layer. The underbody is an area that is particularly vulnerable to moisture, salts, and other chemical substances.

Fig. 1: Damaged protective coating showing signs of corrosion
Fig. 1: Damaged protective coating showing signs of corrosion
Figure 1: KTL damaged by falling rocks
Figure 1: KTL damaged by falling rocks

There are standardized tests to evaluate the stone-impact resistance of a protective coating. In these tests, standardized projectiles are fired at a surface with a defined pressure and duration. Figure 1 shows what a surface coated with cathodic dip coating looks like after such a test.

Figure 2: Standardized test specimens for the stone-impact test on a test plate
Figure 2: Standardized test specimens for the stone-impact test on a test plate

What solutions are available?

Innovative protective solutions have been developed to shield vehicles from the damaging effects of stone chips. For high levels of stone chip impact, special coatings form a permanently elastic protective film that effectively seals the surface and protects it from mechanical and chemical influences. This not only preserves the vehicle’s aesthetic appearance but also strengthens its structural integrity.

Depending on the area of the vehicle underbody and the intensity of the impact, different protective measures are required.

Conclusion

The use of innovative stone chip protection products is a sustainable investment in the longevity and safety of vehicles. These modern solutions help reduce maintenance costs and preserve the vehicle’s value over the long term. These products offer not only excellent protection against stone chips but also against the resulting corrosion and chemical damage. Compliance with strict industry standards and extensive testing ensure that these products meet the highest standards. Invest in protecting your vehicle and enjoy a longer service life and increased safety on the road.

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