Electric Vehicle Batteries Make Cars Too Heavy for Safety Guardrails, Study Shows

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The rapid growth of electric vehicles (EVs) has brought significant advancements in green technology, but new research reveals a troubling downside: many EVs are too heavy for existing safety infrastructure. A study conducted by the University of Nebraska found that current guardrail systems, which are designed to protect vehicles weighing up to 5,000 pounds, are insufficient to stop the weightier electric vehicles, many of which far exceed this threshold.

Crash tests from the university demonstrated that a Rivian R1T electric pickup truck, weighing nearly 8,000 pounds, tore through a steel guardrail during a high-speed collision, barely slowing down before hitting a concrete barrier​.

This is a stark contrast to the performance of lighter, gasoline-powered vehicles, for which guardrails have traditionally been designed. The battery technology that powers these electric trucks and SUVs adds significant weight, often 20-50% more than their combustion-engine counterparts​.

The extra weight stems primarily from the massive lithium-ion batteries that are required to provide a reasonable driving range. For instance, the Ford F-150 Lightning EV is approximately 2,000 to 3,000 pounds heavier than its gasoline-powered equivalent.

This weight disparity is not just a concern for infrastructure but also raises questions about overall road safety, particularly in accidents involving lighter vehicles or roadside barriers.

Guardrails are critical safety features, meant to prevent vehicles from veering off the road in dangerous areas like cliffs or bridges. However, the study found that these guardrails fail when confronted with the immense force generated by heavier electric vehicles during collisions. In many cases, instead of slowing down, the vehicles continue through the barriers, creating a substantial safety risk​.

Moreover, while heavier vehicles offer increased protection for their occupants, they can be lethal to those in lighter cars. Studies have shown that the probability of fatalities increases significantly when heavier vehicles, such as EVs or large SUVs, collide with smaller, traditional vehicles. According to data from the National Bureau of Economic Research, the risk of death in a crash increases by 47% for every additional 1,000 pounds of vehicle weight​.

This issue becomes even more pressing as government policies push for greater EV adoption. The U.S. Department of Transportation’s National Highway Traffic Safety Administration (NHTSA) is proposing stringent new fuel economy standards that could force nearly two-thirds of new auto sales to be electric by 2032.

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