IIHS Crash Avoidance Tests Reveal Safety Gaps in Cargo Vans and Work Trucks

New evaluations from the Insurance Institute for Highway Safety (IIHS) show that cargo vans and Class 3 pickup trucks are falling behind passenger vehicles in front-crash prevention performance.

Initial assessments found that marginal and poor ratings were common among commercial vehicles tested for vehicle-to-vehicle and pedestrian crash avoidance.

The findings could affect commercial fleets as they evaluate vehicle safety features and make purchasing decisions, particularly as automatic emergency braking (AEB) and other driver assistance systems become more common.

Commercial Vehicles Face New Safety Evaluations

Initial testing focused on cargo vans and Class 3 pickup trucks with gross vehicle weight ratings between 10,001 and 14,000 pounds.

Unlike the Institute’s earlier commercial vehicle driver protection assessments, the new crash avoidance tests use the same protocols and four-tier rating system applied to passenger vehicles: good, acceptable, marginal, and poor.

The vehicle-to-vehicle evaluation measures the effectiveness of forward collision warning and AEB systems in scenarios involving passenger vehicles and motorcycles. IIHS also evaluates forward collision warnings using a semitrailer target.

“IIHS evaluates automatic emergency braking in unloaded conditions or, in some cases, incomplete builds. Although heavy loads and upfits may affect performance, the immediate priority is expanding availability and demand,” explained David Kidd, vice president of Vehicle Research at IIHS. “Our ratings recognize manufacturers that equip commercial vehicles with effective, high-performing crash avoidance features.”

Pedestrian crash prevention testing examines how well vehicles detect and respond to adults and children in daytime and nighttime scenarios.

Cargo Vans Show Mixed Crash Prevention Performance

Among the cargo vans evaluated, the Mercedes-Benz Sprinter 2500 was the only model to receive a good rating for vehicle-to-vehicle front crash prevention.

The Chevrolet BrightDrop 400 received an acceptable rating, while the remaining vans earned marginal or poor ratings.

The Chevrolet Express 2500 and GMC Savana 2500 received poor ratings in both categories because neither offers AEB. Both models offer optional forward collision warning systems.

“Safety is an operational requirement. An on-the-job crash costs employers more than $55,000 on average, and far more when someone is injured or killed. Our ratings show fleet managers which cargo vans and heavy-duty pickups offer the strongest protection against crashes with pedestrians and other vehicles,” added Kidd.

Motorcycle detection was a particular challenge across the vehicles tested. Several systems failed to issue warnings or reduce speed in most motorcycle test scenarios.

Other vehicles could reduce speed or avoid collisions but received lower ratings because their warning systems did not give drivers enough advance notice.

Pedestrian Detection Performance Varies

Commercial vehicles generally performed better in pedestrian crash avoidance testing, although several models struggled under specific conditions.

The Chevrolet BrightDrop 400 and Rivian RCV-Delivery 500 received good ratings for pedestrian crash prevention, while the Mercedes-Benz Sprinter 2500 earned an acceptable rating.

Among Class 3 pickups, the Ford F-350 and Ram 3500 received acceptable ratings. Both vehicles also had greater difficulty detecting and avoiding a child pedestrian during daylight conditions than an adult pedestrian at night.

Researchers indicated that the height of the vehicles’ front ends and the positioning of detection sensors near the rearview mirror may contribute to the problem.

Nighttime performance also presented challenges. Several marginal- and poor-rated systems failed to reduce speed sufficiently when approaching an adult pedestrian, with some performing worse under low-beam headlights than high beams.

How Commercial Vehicles Performed

The following ratings reflect the models and model years evaluated by IIHS.

What the Findings Mean for Commercial Fleets

The evaluations highlight differences in crash avoidance technology across commercial vehicle models, even among vehicles serving similar operational purposes.

For fleet managers, the results provide another consideration when comparing vehicles for acquisition or replacement. AEB availability alone does not necessarily indicate how effectively a system will perform across different collision scenarios.

The findings also highlight the limitations of certain systems in detecting motorcycles and pedestrians, particularly children. IIHS plans to continue evaluating Class 3 commercial vehicles through 2027, adding assessments of headlights and rear automatic emergency braking.

Testing will eventually expand to larger Class 4–6 trucks, providing additional safety performance information for commercial fleet operators managing heavier vehicles.