As an active light-emitting traffic guidance device within road traffic safety infrastructure, solar road studs are widely deployed on highways, urban roads, tunnels, and bridges due to their advantages of requiring no external power source, easy installation, and energy efficiency. Among the numerous performance metrics of solar road studs, crush resistance stands as a core factor determining both their service life and operational safety. This article provides an in-depth analysis of the importance of solar road stud crush resistance, its influencing factors, industry standards, and key selection criteria, helping practitioners and procurement personnel gain a comprehensive understanding of this critical metric.
solar road studs
Installed directly on road surfaces, solar road studs endure constant impact from various vehicles—passenger cars exert approximately 0.5-0.8 tons per wheel, while heavy trucks can reach 3-5 tons per wheel, with construction vehicles applying even greater pressure in extreme cases. Insufficient crush resistance leads to a series of issues:
Railroad studs with insufficient crush resistance may experience casing fractures, internal LED bulb breakage, battery detachment, or circuit failure after repeated crushing, rendering them unable to illuminate properly. This not only eliminates their role as “nighttime road markers,” but damaged components may protrude or detach, becoming road hazards that increase the risk of tire blowouts.
Rail road studs with low crush resistance have short damage cycles, requiring maintenance departments to frequently schedule personnel and equipment shutdowns for replacements. This leads to increased direct costs, including labor and procurement of new road studs. Additionally, temporary lane closures during replacements can cause traffic congestion, potentially triggering secondary traffic issues—especially on high-traffic routes like highways.
Some substandard studs become loose, warped, or even detach entirely after being run over, ending up in the middle of the lane. During nighttime with poor visibility, vehicles traveling at high speeds may fail to detect these hazards in time, potentially causing accidents such as wheel scraping or loss of control, posing a direct threat to the lives of drivers and passengers.
The outer shell and base of solar road studs directly bear the crushing force. The strength and toughness of the material directly impact crush resistance. Currently, four common materials are available on the market, each exhibiting distinct crush resistance capabilities. ABS plastic offers lower cost but inferior strength and weather resistance. Prolonged crushing can cause cracking and deformation, making it suitable only for low-traffic areas like sidewalks or residential roads, with crush resistance typically below 5 tons.
PC (polycarbonate) offers higher strength than ABS, along with superior impact resistance and weather resistance. Its crush resistance reaches 8-10 tons, making it suitable for urban main roads, secondary roads, and other medium-traffic routes.
solar road studs
Aluminum alloy solar road studs are lightweight yet highly durable, with crush resistance of 12-15 tons. They also exhibit excellent corrosion resistance, maintaining strength despite exposure to rainwater and salt. These studs are suitable for high-traffic, complex environments like highways and bridges.
Stainless steel offers the highest strength, with crush resistance exceeding 15 tons and exceptional corrosion resistance. However, its higher cost typically limits its use to special sections requiring extreme safety (e.g., tunnel entrances/exits, sharp curves).
A well-designed structure effectively disperses pressure during vehicle crushing, preventing localized stress concentration that could damage the stud. High-quality solar studs typically feature multiple structural characteristics. The stud base is usually 5-8mm thick or more, with a large contact area against the road surface. This evenly distributes pressure across the pavement, reducing the load borne by the stud itself. The housing incorporates crisscrossed internal reinforcement ribs, acting like a “skeleton” to enhance deformation resistance and prevent shell collapse under pressure. Some high-end studs also feature sealed designs, which not only provide waterproofing and dust proofing but also enhance overall structural stability, preventing internal component displacement that could compromise anti-crushing performance.
Even with superior material quality and structural design, substandard manufacturing processes can compromise the crush resistance of solar rail studs. This deficiency manifests across multiple production stages. In injection molding, road studs produced via single-piece molding feature seamless shells with enhanced overall strength. In contrast, road studs assembled from multiple parts develop weak points at the seams, making them prone to cracking under crushing forces.
For aluminum alloy or stainless steel studs, welding techniques are critical. Incomplete or missed welds at joints significantly reduce structural strength, causing the stud to fracture at the weld points during crushing. Some studs undergo surface treatments like anodizing or spraying. These processes not only enhance corrosion resistance but also increase surface hardness, reducing wear during crushing and indirectly extending the anti-crushing lifespan.
solar road studs
To ensure the safe use of solar studs, explicit crush resistance standards have been established both domestically and internationally. Standards vary slightly across countries and regions, so procurement must select compliant products based on the application scenario and local regulations.
For export or international projects, focus on the requirements for solar stud crush resistance outlined in the two major international standards: ASTM and EN. The U.S. ASTM D4280 standard explicitly stipulates that after withstanding a static pressure of 13.6 tons (30,000 pounds), the stud must show no significant cracking or deformation and maintain normal illumination.
The European EN 1463 standard classifies studs into three levels (Class 1-3) based on application scenarios. The highest level, Class 3, requires a crush resistance ≥12 tons. Additionally, the stud must pass a 1000-cycle crush test (simulating repeated vehicle crushing) while maintaining normal operation, ensuring stable crush resistance performance over long-term use.
Select materials based on usage scenarios, as different environments demand varying material types and strength levels. For highways and heavy-duty roads with high traffic volume and frequent heavy vehicles, prioritize aluminum alloy or stainless steel materials to ensure crush resistance ≥12 tons. For urban main roads with moderate traffic flow, high-strength PC or aluminum alloy materials can be selected, with a crush resistance of ≥10 tons.
For residential areas or sidewalks with budget constraints, ABS + reinforced ribs material can be chosen, but the crush resistance must be ≥5 tons. To prevent suppliers from substituting inferior materials, request material test reports confirming composition compliance with relevant standards. This ensures the anti-crush performance is guaranteed from the source.
Genuine solar road studs must possess relevant certifications and test reports, which serve as key evidence of anti-crush strength compliance. Prioritize reviewing these reports during procurement. For international projects, ASTM D4280 or EN 1463 certification reports must be provided, with compliance verified against target country/region specifications. Additionally, check if the product holds ISO 9001 Quality Management System certification. This certification reflects standardized production processes, further ensuring consistent product quality and reducing instances of non-compliant crush resistance due to manufacturing issues.
Where feasible, conduct simple on-site tests to preliminarily assess a solar road stud’s crush resistance potential. If field testing is unavailable, rely on third-party inspection data. During on-site testing, lightly tap the road studs casing with a hard object (e.g., wrench) and evaluate the material quality based on the sound produced. A crisp sound typically indicates dense material and higher strength, while a dull sound may suggest inferior material quality.
Simultaneously, meticulously inspect structural details: verify base thickness compliance, examine the clarity of reinforcing ribs, and ensure smooth joints. Avoid products with loose structures or rough workmanship, as these often exhibit poor crush resistance. If on-site testing is unavailable, explicitly require suppliers to provide crush resistance test videos or detailed data from third-party testing agencies. Verify that products remain undamaged and unaffected by deformation after withstanding specified pressures, ensuring actual performance aligns with claims.
Crush resistance is a performance characteristic validated through long-term use. Therefore, choosing suppliers with strong reputations and years of industry experience is crucial. Assess supplier capabilities through multiple channels: First, review the supplier’s past projects to determine if they have experience supplying key infrastructure such as highways or large bridges. If so, proactively seek feedback from project owners regarding usage outcomes, such as “After three years of use, does the road stud’s anti-crushing performance remain stable?” This allows you to assess product reliability based on real-world application.
Secondly, focus on after-sales service. Reputable suppliers typically offer a 1-3 year warranty period. If damage occurs during this period due to insufficient anti-crushing strength, free replacement is provided. This not only reduces long-term maintenance costs but also reflects the supplier’s confidence in their product quality. Choosing such suppliers more effectively ensures the anti-crushing performance of purchased products.
The crush resistance of solar road studs not only determines the product’s lifespan but also directly impacts road traffic safety and maintenance costs. Both buyers and manufacturers should prioritize this core metric—during procurement, assess materials, verify certifications, test performance, and evaluate reputation to select compliant products tailored to specific applications. Manufacturers must continuously enhance road stud crush resistance through material upgrades, structural optimization, and process improvements. Only through joint efforts can solar road studs truly fulfill their role as “nighttime traffic guides,” safeguarding road safety.
