Step 1 , determine applicability and record the decision. Start by mapping the vehicle to the ADR category codes and manufacture/approval dates in the Rule’s applicability table. Confirm whether the vehicle is certified to ADR 2/01 or a later ADR; if so, ADR 2/00 does not apply (Applicability). If the vehicle falls into MD, NB or NC categories, note that those categories "need not comply" after 10 May 2006. Document the manufacturer’s chosen manikin percentile (90% SAE J826 or 95% SAE J826a) because the manufacturer’s choice determines whether the door opening is captured by the Rule (Clause 2.2.0). Retain a technical memo that sets out the seating reference points used, the manikin measurements, and the door opening geometry showing whether any part of the manikin projects into the door-opening profile.
Step 2 , identify door types and check exemptions. For each door on the vehicle, identify whether it is hinged (passenger door, goods-type door), sliding, folding, roll-up, or designed to be easily removable. Folding, roll-up and easily removable doors on vehicles manufactured for operation without doors are exempt (Clause 2.2.0). For folding/piano hinges, be aware of special test-fixture instructions (Clause 2.3.1.2). Document the functional classification and the design features that might trigger exemption.
Step 3 , design latches and hinges to the specified loads. For hinged doors (except goods-type doors) ensure that each door latch and striker assembly provides two positions and is designed to resist the static loads specified: fully latched longitudinal 11.11 kN and transverse 8.89 kN; secondary latched longitudinal and transverse 4.44 kN (Clauses 2.2.1.1.1-1.2). Ensure the latch system is designed so it will not disengage from the fully latched position under inertia loads of 30g applied to the door latch system with the locking mechanism disengaged (Clause 2.2.1.1.3). Design hinges to support the door at 11.11 kN longitudinal and 8.89 kN transverse loads (Clause 2.2.1.2).
For hinged goods-type doors, design latch systems so each latch will not separate under longitudinal 11.11 kN and transverse 8.89 kN when latched; where multiple latches are used the load may be divided among them (Clause 2.2.2.1.1-1.2). For sliding doors, design track and slide or other supporting means to resist a total transverse load of 17.8 kN in the closed position (Clause 2.2.3).
Step 4 , select and execute the required tests. Use the SAE procedures referenced by the ADR for compliance demonstration:
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Latches (longitudinal and transverse loads) , perform tests in accordance with paragraph 4 of SAE J839b "Passenger Car Side Door Latch Systems" (Clause 2.3.1.1.1). If inertia loads are required under Clause 2.2.1.1.3, demonstrate compliance using paragraph 5 of the same SAE document or by an "Approved" inertia test as allowed by Clause 2.3.1.1.2.
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Hinges , perform hinge tests in accordance with paragraph 4 of SAE J934 "Vehicle Passenger Door Hinge Systems" or paragraph 5 of later SAE versions (Clauses 2.3.1.2). For piano-type hinges modify the test fixture as required so the complete hinge is loaded (Clause 2.3.1.2).
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Hinged goods-type doors , demonstrate compliance per paragraphs 4.1 and 4.3 of the SAE document(s) or by using an equivalent static bench test fixture if necessary (Clause 2.3.2.1).
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Sliding doors , demonstrate compliance by applying outward transverse loads of 8.89 kN to opposite edges of the door (17.8 kN total) either on-vehicle or in a bench fixture (Clause 2.3.3).
Ensure that the exact editions and paragraph numbers cited are the documents used. Where the ADR notes editorial updates (e.g., J839b editorial changes) follow the specific edition cited.
Step 5 , document locking functionality and child-safety features. For each door provide documentation that the locking mechanism has an operating means in the interior (Clause 2.2.1.3). For front doors, present evidence that when the locking mechanism is engaged, outside door handles or other outside latch release controls are inoperative (Clause 2.2.1.3.1). For rear doors on passenger cars (MA), provide either: evidence that both outside and inside handles are inoperative when the lock is engaged; or evidence that the outside handles are designed to remain inoperative in an impact/rollover scenario and inner handles are inoperative by engagement of Child Safety Locks (Clause 2.2.1.3.2). Testing or design substantiation for "designed to remain inoperative in event of vehicle impact or rollover" should be obtained from labs or engineering analysis and agreed with the certifying authority.
Step 6 , consider alternative conformity pathways. If the vehicle or its components have already been designed and tested to ECE Regulation R11/00-11/02, confirm that the ECE clauses relied on are within the equivalence clause of the ADR. The ADR deems ECE R11/00-11/02 equivalent to the technical requirements of certain Clauses , check the ADR's Alternative Standards clause to ensure the specific ADR clauses you intend to satisfy are covered. Where ECE R11 is accepted, include mapping documentation that demonstrates equivalence.
Step 7 , prepare certification package and retain records. Compile a certification dossier containing: applicability mapping (category, manufacture/approval date, manikin choice), technical drawings, detailed test plans, full test reports showing loads applied and results, any inertia test evidence (including the test condition that the locking mechanism is disengaged if relevant), hinge and latch test fixture description (noting any piano-hinge fixture modifications), and any equivalence mapping to ECE R11 if used. Keep reproducible records for later conformity-of-production audits and for any administrative review.
Step 8 , liaise with certifier for accepted methods. Before committing to alternate fixture arrangements or "Approved" tests (for example for inertia), consult the certifying authority or the Department’s Vehicle Safety Policy and Partnerships to confirm the experiment design is acceptable. The ADR permits certain substitutions (e.g., bench fixtures, Approved inertia tests), but administrative acceptance is necessary in practice.
Step 9 , address aftermarket modifications and conversions. If doors are modified post-manufacture (for example, conversions that change a vehicle from open to closed side doors or vice versa), re-run the manikin applicability test and the required load tests as applicable. Provide documentation to the certifier showing conformity post-modification.
Step 10 , monitor amendments and keep editions current. The ADR has been amended since 2006 (2007 Amendment 1, 2021 Amendment Instrument). Keep an eye on the Federal Register of Legislation for any future amendments, particularly those that change the manikin trigger, test methods or equivalence statements. The compilation records current operative text up to 14 May 2021; practitioners should confirm that no later instrument has altered obligations.
Following these steps aligns practical compliance activity with the Rule’s textual requirements (Clauses 2.2.x and 2.3.x) and with the ADR’s applicability matrix. Where the ADR leaves technical choices to the manufacturer (manikin percentile, use of ECE R11), document those choices and the engineering rationale to avoid disputes at certification.