Multi-Stage Vehicle Approvals Explained

The automotive industry is a dynamic and innovative sector, constantly evolving to meet new demands and regulations. One significant area of development, particularly within the commercial vehicle segment, is the practice of multi-stage vehicle manufacturing. This process involves a base vehicle, typically a chassis cab, being supplied by an Original Equipment Manufacturer (OEM) and then undergoing further modification and body construction by specialist converters. To ensure these vehicles meet stringent safety and environmental standards before they can be registered and used on public roads, a robust approval process is in place. This article delves into the world of multi-stage vehicle approvals, explaining the different routes available and the critical role they play in the modern automotive landscape.

What is Multi-Stage Vehicle Approval?

Multi-stage vehicle approval is a regulatory requirement designed to ensure that vehicles constructed in multiple phases, where different manufacturers contribute to the final product, comply with all relevant safety and environmental legislation. In the past, it was often sufficient for a vehicle to be registered based on the approval of the initial OEM base vehicle. However, as the subsequent stages of conversion can significantly impact a vehicle's compliance with safety and environmental standards – think about the added weight of a new body, altered braking systems, or different lighting configurations – a more comprehensive approval system became necessary. Multi-stage approval places the responsibility for affected approvals on the manufacturers responsible for those subsequent stages.

The Two Main Routes of Approval: Type Approval vs. IVA

There are two primary pathways for achieving multi-stage vehicle approval:

Type Approval

Type Approval is a system that approves a specification for a type of vehicle rather than an individual vehicle. This means a single approval can cover a range of vehicles with variations in specifications, such as different body sizes or wheelbases, provided they are all built to the approved type-specific design. Once a stage of the build process is completed by a manufacturer, they issue a Certificate of Conformity (COC). This COC is essentially a declaration that the vehicle, at that stage of its construction, adheres to the type-approved specification, detailing exact values for dimensions, weights, and other critical parameters. To register the final, completed vehicle, COCs from all preceding stages of its construction are required.

A crucial element of Type Approval is Conformity of Production (COP). Before a Type Approval is granted, manufacturers must demonstrate that they have adequate arrangements in place to ensure consistent quality and adherence to the type-approved specifications throughout their production process. This is a vital safeguard against variations in manufacturing that could compromise safety or environmental compliance.

Within Type Approval, there are different forms:

• ECWVTA (European Whole Vehicle Type Approval): This is the most comprehensive form, covering all aspects of a vehicle.
• ECSSTA (European Small Series Type Approval): Designed for lower volume production runs.
• NSSTA (National Small Series Type Approval): A national equivalent for small series production.

Many specialist converters utilise a combination of these, depending on the volume and complexity of the vehicles they produce.

Individual Vehicle Approval (IVA)

As the name suggests, IVA is an approval process for a single, specific vehicle. The vehicle undergoes a thorough inspection by a designated authority, such as the DVSA (Driver and Vehicle Standards Agency) in the UK, before an IVA approval is granted. Similar to Type Approval, the IVA approval, along with the First Stage COC, is required for registration. Unlike Type Approval, COP is not a requirement for IVA because the physical vehicle itself is inspected, negating the need for proof of consistent production quality.

The Multi-Stage Build Process: A Typical Example

Let's consider a common two-stage process:

1. Stage 1 (OEM): The Original Equipment Manufacturer produces a base vehicle, such as a chassis cab. They obtain a Type Approval for this incomplete vehicle and issue a corresponding COC.
2. Stage 2 (Converter): A specialist converter, like TGS, takes the chassis cab and manufactures and fits a new body – perhaps a dropside, a tipper, or a specialised unit. The converter then obtains their own approval, which might be a Type Approval or an IVA, covering the modifications and the completed vehicle. They issue a COC for this completed vehicle.

For registration, both the Stage 1 COC (for the base vehicle) and the Stage 2 COC (for the completed vehicle) are necessary.

Van Enhancement Scheme Approval

In addition to the main approval routes, there is also a Van Enhancement Scheme approval. This is specifically for minor modifications to panel vans, such as the addition of racking systems, towbars, or internal conversions. Specialist converters often hold these approvals as well, demonstrating their ability to carry out these specific types of modifications safely and compliantly.

GB Type Approval Scheme and Multi-Stage Applications

Following the UK's departure from the European Union, the GB Type Approval Scheme has been established to provide a framework for vehicle approvals within Great Britain. This scheme has specific considerations for multi-stage manufacturers.

Key FAQs for Multi-Stage Manufacturers under the GB Scheme:

Q: Does a multi-stage manufacturer have to wait for stage 1 manufacturers to obtain full GB approvals before starting their own application?

A: Initially, there was a derogation allowing second-stage manufacturers to obtain multi-stage approvals prior to base vehicle manufacturers obtaining full GB type approval. This provided flexibility during the transition. This derogation had specific end dates: 1st August 2026 for M and N category vehicles, and 1st August 2027 for O category vehicles. After these dates, full GB approval for all stages is generally required.

Q: In cases where the same manufacturer holds both incomplete and completed approvals, is full GB approval required for both stages?

A: Yes, the derogation mentioned above does not apply if the same manufacturer or linked manufacturer groups hold approvals for both stages, as they have the ability to coordinate their approval timelines.

Q: Can manufacturers use EU system type approvals and test reports as part of a GB WVTA application?

A: Generally, only GB or UNECE system approvals are acceptable. EU system approvals cannot be used unless specifically permitted by GB legislation. Test reports are accepted if they are from a VCA-designated Technical Service for GB Type Approval, or from any EU-designated Technical Service during an initial derogation period.

Q: What do GB type approval information documents look like?

A: Templates are based on assimilated EU legislation, either in individual regulations or the generic template in Regulation 2020/683. EU format documents can be accepted if they contain all the information required by the GB template.

Q: How long does it take to receive a type approval certificate for full GB type approval?

A: The VCA typically works to a timeline of four weeks for technical checks, followed by two weeks for administrative processes.

Conformity of Production (COP) in the GB Scheme

COP remains a critical aspect of Type Approval within the GB scheme. Manufacturers must ensure their production processes consistently meet the approved specifications. It's important to note that:

• GB COP clearance is separate from EU COP clearance.
• Testing of EU type-approved vehicles can be used for GB COP purposes if the vehicle specifications and test procedures align.
• VCA will conduct site audits regardless of whether a manufacturer has already been audited by an EU Technical Service.
• COP clearance for UK(NI) type approval is distinct from GB type approval, although VCA can assess for both schemes as a single activity.

Certificates of Conformity (CoCs) & Approval Markings

Changes to EU CoC templates are not automatically reflected in the GB scheme. However, a derogation allows the use of EU-format CoCs until 1st July 2026 for vehicles that also hold EU type approval. GB CoCs will continue to reference left/right-hand drive and metric units. Dual marking with EU approval markings is acceptable if a vehicle or component holds both EU and GB type approvals.

In-Service Conformity (ISC)

VCA will conduct Granting Type Approval Authority (GTAA) ISC testing separately from EU GTAAs. Manufacturer ISC testing of EU vehicles can be used to cover GB ISC obligations if the vehicle specifications are common to both EU and GB type approvals. Transparency tables and warranty data sharing will evolve, with a digital portal planned for the future.

Key Considerations for Converters

For specialist converters, understanding and navigating the multi-stage approval process is paramount. Key takeaways include:

• Accuracy of Documentation: Ensuring all COCs and information documents are accurate and complete is vital for registration.
• COP Compliance: Maintaining robust COP procedures is essential for Type Approval holders.
• Awareness of Regulations: Staying updated with evolving GB Type Approval regulations and derogation periods is crucial.
• Technical Services: Engaging with VCA-designated Technical Services for testing and reporting.

Manufacturer RMI Contact Information

For repair and maintenance information related to vehicles converted by TGS, you can contact them via email at [email protected] or by phone on 0117 965 9965. Please provide specific details about the vehicle in question.

Below is a list of RMI contact/dealer location information for various manufacturers:

In conclusion, multi-stage vehicle approval is a critical process that ensures the safety, environmental compliance, and roadworthiness of vehicles built through a collaborative manufacturing effort. Both Type Approval and IVA offer distinct pathways, each with its own requirements and implications. For manufacturers and converters, a thorough understanding of these processes, particularly within the evolving GB Type Approval framework, is essential for successful vehicle production and registration.

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